Service Manual - Street Triple RS

Introduction

Introduction

This manual is designed primarily for use by trained technicians in a properly equipped workshop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools to complete the job.

A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessary in order to carry out maintenance and repair work satisfactorily. Whenever the owner has insufficient experience or doubts regarding his ability to do the work, an authorised Triumph dealer must undertake all adjustments, maintenance, and repair work.

In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work.

All work should be performed with great care and in a clean working area with adequate lighting.

Always use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of substitutes may adversely affect safe operation.

Where accurate measurements are required, they can only be made using calibrated, precision instruments.

For the duration of the warranty period, an authorised Triumph dealer must perform all repairs and scheduled maintenance.

To maximise the life of your motorcycle:

How to use this manual

To assist in the use of this manual, the section title is given at the top.

Each major section starts with a contents page, listing the information contained in the section.

The individual steps comprising repair operations are to be followed in the sequence in which they appear.

Adjustment and repair operations include reference to service tool numbers and the associated illustration depicts the tool.

Where usage is not obvious, the tool is shown in use.

Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, specialist information and useful assembly details.

Warnings, Cautions and Notes

Particularly important information is presented in the following form:

warning

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

caution

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

note
  • This note symbol indicates points of particular interest for more efficient and convenient operation.

Tampering with Noise Control System Prohibited

Owners are warned that the law may prohibit:

References

References to the left hand or right hand side given in this manual are made when viewing the motorcycle from the rear.

Operations covered in this manual do not always include reference to testing the motorcycle after repair. It is essential that work is inspected and tested after completion and, if necessary, a road test of the motorcycle is carried out particularly where safety related items are concerned.

Dimensions

The dimensions quoted are to design engineering specification with service limits where applicable.

During the period of running-in from new, certain adjustments may vary from the specification figures given in this manual. These will be reset by the dealer at the 500 mile/800 km service, and thereafter should be maintained at the figures specified in this manual.

Repairs and Replacements

Before removal and disassembly, thoroughly clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. Particular attention should be paid when installing a new part, that any dust or metal filings are cleared from the immediate area.

Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Never lever a component as this will cause damage both to the component itself and to the surface being levered against.

Whenever tapping to aid removal of an item is necessary, tap lightly using a hide or plastic faced mallet.

Edges

Watch for sharp edges, especially during engine disassembly and assembly. Protect the hands with industrial quality gloves.

When replacement parts are required, it is essential that only genuine Triumph parts are used.

Safety features and corrosion prevention treatments embodied in the motorcycle may be impaired if parts other than genuine Triumph parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification.

Tightening procedure

Generally, when installing a part with several bolts, nuts or screws, they should all be started in their holes and tightened to a snug fit, evenly and in a cross pattern. This is to avoid distortion of the part and/or gas or oil leakage. Conversely, bolts, nuts, or screws, should all be loosened (in sequence if specified) by about a quarter of a turn and then removed.

Where there is a tightening sequence specified in this Service Manual, the bolts, nuts, or screws must be tightened in the order and by the method indicated.

Torque wrench setting figures given in this manual must be observed. The torque tools used must be of accurate calibration.

Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. This applies particularly to micro-encapsulated fixings which must always be replaced if disturbed. Where necessary, the text in this manual will indicate where such a fixing is used.

Use of Crow Foot Spanner Adapters with Torque Wrenches

The use of a crow foot spanner adapter will effectively lengthen the lever arm of a torque wrench. The amount of torque applied to a fastener is increased as the torque wrench lever arm is extended, therefore the torque wrench setting must be adjusted in order to achieve the correct tightening torque.

Before tightening a fixing using a crow foot spanner adapter, measure the normal length of the torque wrench from the centre of the drive square to the centre of the handle (dimension L1). Fit the crow foot spanner adapter to the torque wrench as shown below. Measure the extended length of the torque wrench from the centre of the crow foot spanner head to the centre of the handle (dimension L2).

Use the following formula to calculate the correct torque wrench setting to achieve the required tightening torque.

note
  • The example shown below is calculated using a crow foot spanner measuring 25 mm from the centre of the spanner head to the centre of the drive square.

M1 = M2 x L1 / L2

Example

M2 is the required tightening torque to be applied

90 Nm

L1 is the normal length of the torque wrench, measured from the centre of the drive square to the centre of the handle

300 mm

L2 is the extended length of the torque wrench, measured from the centre of the crow foot spanner head to the centre of the handle

325 mm

M1 is the calculated torque wrench setting

83 Nm

General Information

Ignition System Safety Precautions

warning

The ignition system produces extremely high voltages. Do not touch any part of the ignition system or any cables while the engine is running.

An electric shock caused by contact with the ignition system may lead to illness, injury or death.

warning

Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and or diagnostic equipment.

The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death.

Dangerous Substances

warning

Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far as possible, be kept from contact with the skin. These substances among others include acid, antifreeze, asbestos, brake fluid, fuel, lubricants, and various adhesives. Always pay close attention to the instructions printed on labels and obey the instructions contained within. These instructions are included for your safety and well-being.

NEVER DISREGARD THESE INSTRUCTIONS!

Third Party Products

warning

Many proprietary products, such as chemicals, solvents and cleaning agents, will cause damage to components if used incorrectly or inappropriately. Always follow the manufacturer’s instructions printed on the product container’s labels and obey the instructions given. These instructions are included for your safety and well-being.

Damage to the motorcycle components caused by the incorrect or inappropriate use of chemicals, solvents and cleaning agents may reduce the components efficiency, resulting in loss of motorcycle control and an accident.

Fluoroelastomers

warning

Fluoroelastomer material is used in the manufacture of various seals in Triumph motorcycles.

In fire conditions involving temperatures greater than 315°C this material will decompose and can then be potentially hazardous. Highly toxic and corrosive decomposition products, including hydrogen fluoride, carbonyl fluoride, fluorinated olefins and carbon monoxide can be generated and will be present in fumes from fires.

In the presence of any water or humidity, hydrogen fluoride may dissolve to form extremely corrosive liquid hydrofluoric acid.

If such conditions exist, do not touch the material and avoid all skin contact. Skin contact with liquid or decomposition residues can cause painful and penetrating burns leading to permanent, irreversible skin and tissue damage.

Oils

warning

The engine oil may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned.

warning

Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which can cause cancer. Wear suitable clothing and avoid skin contact.

Health Protection Precautions

warning

Any risk of eye injury must be avoided. Always wear eye protection when using a hammer, air line, cleaning agent or where there is ANY risk of flying debris or chemical splashing.

Environmental Protection Precautions

caution

Do not pour oil on the ground, down sewers or drains, or into water courses. To prevent pollution of water courses etc., dispose of used oil sensibly. If in doubt contact your local authority.

Burning of used engine oil in small space heaters or boilers can be recommended only for units of approved design. If in doubt, check with the appropriate local authority and/or manufacturer of the approved appliance.

Dispose of used oil and used filters through authorised waste disposal contractors, to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact your local authority for advice on disposal facilities.

Brakes

warning

Brake fluid is hygroscopic which means it will absorb moisture from the air. Any absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction in braking efficiency.

Replace brake fluid in line with the routine maintenance schedule. A dangerous riding condition could result if this important maintenance item is neglected!

Do not spill brake fluid onto any area of the bodywork as this will damage any painted or plastic surface.

Always use new brake fluid from a sealed container and never use fluid from an unsealed container or from one that has been previously opened.

Do not mix different brands of fluid. Check for fluid leakage around brake fittings, seals and joints.

Check regularly for brake hose damage.

FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING EFFICIENCY LEADING TO AN ACCIDENT.

warning

If there has been an appreciable drop in the level of the fluid in either brake fluid reservoir, consult your authorised Triumph dealer for advice before riding.

If the brake lever or pedal feels soft when it is applied, or if the lever/pedal travel becomes excessive, there may be air in the brake lines or the brake may be defective.

It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph dealer before riding the motorcycle.

Failure to take remedial action may reduce braking efficiency leading to an accident.

warning

Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to an accident.

Failure to change the brake fluid at the interval specified in the routine maintenance schedule may reduce braking efficiency resulting in an accident.

warning

Never use mineral-based grease in any part of the braking system or in any area where contact with the braking system is possible. Mineral-based grease will damage the hydraulic seals in the calipers and master cylinders.

Damage caused by contact with mineral-based grease may reduce braking efficiency resulting in an accident.

warning

Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid.

Never use solvents, petrol (gasoline), engine oil or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders.

A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.

Safety Instructions

Jacking and Lifting

warning

Always ensure that any lifting apparatus has adequate load and safety capacity for the weight to be lifted. Ensure the motorcycle is well supported to prevent any possibility of the machine falling prior to lifting or jacking or while repairs and servicing are carried out.

Never rely on a single means of support when working with the motorcycle. Use additional safety supports and straps to prevent toppling.

Do not leave tools, lifting equipment, spilt oil, etc. in a place where they could become a hazard to health. Always work in a clean, tidy area and put all tools away when the work is finished.

Precautions Against Damage

Avoid spilling brake fluid or battery acid on any part of the bodywork. Wash spillages off with water immediately.

Disconnect the battery earth lead before starting work, see ELECTRICAL PRECAUTIONS.

Always use the recommended service tool where specified.

Protect exposed bearing and sealing surfaces, and screw threads from damage.

Coolant

warning

Coolant mixture, which is blended with antifreeze and corrosion inhibitors contains toxic chemicals which are harmful to the human body. Never swallow antifreeze, corrosion inhibitors or any of the motorcycle coolant.

warning

Do not remove the radiator cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.

caution

The coolant antifreeze contains a corrosion inhibitor which helps prevent damage to the metal surfaces inside the cooling system. Without this inhibitor, the coolant would 'attack' the metals and the resulting corrosion would cause blockages in the cooling system leading to engine overheating and damage. Always use the correct antifreeze as specified in the Owner's Handbook. Never use a methanol based antifreeze as this does not contain the required corrosion inhibition properties.

caution

Distilled water must be used with the antifreeze (see specification for antifreeze) in the cooling system.

If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Reduced cooling system efficiency may lead to the engine overheating and engine damage.

Cleaning Components

A high flashpoint solvent is recommended to reduce fire hazard.

Always follow container directions regarding the use of any solvent.

Always use the recommended cleaning agent or equivalent.

Do not use degreasing equipment for components containing items which could be damaged by the use of this process. Whenever possible, clean components and the area surrounding them before removal. Always observe scrupulous cleanliness when cleaning dismantled components.

Lubrication

The majority of engine wear occurs while the engine is warming up and before all the rubbing surfaces have an adequate lubrication film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface, which has lost its lubrication film. Old grease and dirty oil should be cleaned off. This is because used lubricants will have lost some lubrication qualities and may contain abrasive foreign particles.

Use recommended lubricants. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulphide grease in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants.

Joints and Joint Faces

Assemble joints dry unless otherwise specified in this manual.

If gaskets and/or jointing compound is recommended for use; remove all traces of old jointing material prior to reassembly. Do not use a tool which will damage the joint faces and smooth out any scratches or burrs on the joint faces using an oil stone. Do not allow dirt or jointing material to enter any tapped holes.

Gaskets, O-rings

Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.

Liquid Gasket, Non-permanent Locking Agent

Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly as excessive amounts of sealer may block engine oil passages and cause serious damage.

Prior to reassembly, blow through any pipes, channels or crevices with compressed air.

warning

To prevent injury, always use eye, face and ear protection when using compressed air. Always wear protective gloves if the compressed air is to be directed in proximity to the skin.

Screw Threads

Metric threads to ISO standard are used.

Damaged nuts, bolts and screws must always be discarded.

Castellated nuts must not be loosened back to accept a split pin, except in those recommended cases when this forms part of an adjustment.

Do not allow oil or grease to enter blind threaded holes. The hydraulic action on screwing in the bolt or stud could split the housing.

Always tighten a nut or bolt to the recommended torque figure. Damaged or corroded threads can affect the torque reading.

Unless specified, threaded fixings must always be fitted dry (no lubrication).

warning

Never lubricate a thread unless instructed to do so.

When a thread of a fixing is lubricated, the thread friction is reduced. When the fixing is tightened, reduced friction will cause over tightening and possible fixing failure.

A fixing which fails in service could cause component detachment leading to loss of control and an accident.

Locking Devices

Always release locking tabs and fit new locking washers. Do not reuse locking tabs.

Fitting a Split Pin

Always fit new split pins of the correct size for the hole in the bolt or stud. Do not loosen back castle nuts when fitting a split pin, except in those recommended cases when this forms part of an adjustment.

Always fit new roll pins of an interference fit in the hole.

Circlips, Retaining Rings

Replace any circlips and retaining rings that are removed. Removal weakens and deforms circlips causing looseness in the circlip groove. When installing circlips and retaining rings, take care to compress or expand them only enough to install them.

Always use the correct replacement circlip as recommended in the Triumph parts catalogue.

Self-Locking Nuts

Self-locking nuts can be reused, provided resistance can be felt when the locking portion passes over the thread of the bolt or stud.

DO NOT reuse self-locking nuts in critical locations, e.g. suspension components. Always use the correct replacement self-locking nut.

Encapsulated Bolts

An encapsulated bolt can be identified by a coloured section of thread which is treated with a locking agent.

Unless a specified repair procedure states otherwise, encapsulated bolts cannot be reused and MUST be replaced if disturbed or removed.

warning

Failure to replace an encapsulated bolt could lead to a dangerous riding condition. Always replace encapsulated bolts.

Oil and Grease Seals

Replace any oil or grease seals that are removed. Removal will cause damage to an oil seal which, if reused, would cause an oil leak.

Ensure the surface on which the new seal is to run is free of burrs or scratches. Renew the component if the original sealing surface cannot be completely restored.

Protect the seal from any surface which could cause damage over which it has to pass when being fitted. Use a protective sleeve or tape to cover the relevant surface and avoid touching the sealing lip.

Lubricate the sealing lips with a recommended lubricant. This will help to prevent damage in initial use. On dual lipped seals, smear the area between the lips with appropriate grease.

When pressing in a seal which has manufacturer's marks, press in with the marks facing out.

Seals must be pressed into place using a suitable driver. Use of improper tools will damage the seal.

Press

A part installed using a press or driver, such as a wheel bearing, should first be coated with oil or grease on its outer or inner circumference so that it will locate smoothly.

Ball Bearing

When installing a ball bearing, the bearing race which is an interference fit should be pushed by a suitable driver. This prevents severe stress or damage to the load carrying components. Press a ball bearing until it touches the shoulder in the bore or on the shaft.

With the sealing lip facing the lubricant, press or drift a seal to the depth of its housing, if the housing is shouldered, or flush with the face of the housing where no shoulder is provided.

Chassis Bearing Lubrication

note
  • This information relates only to bearing lubrication. For the procedures necessary to replace a bearing, always refer to the relevant section of this Service Manual.
  • Bearings installed in engine and transmission applications are not covered by this information. Refer to the Lubrication chapter or the relevant engine chapter for additional information.

General

For a bearing to be serviceable for its anticipated life span it must be checked, adjusted and lubricated at regular intervals, as specified in the service schedules given in the Owner’s Handbook and this Service Manual.

A correctly lubricated bearing will have a film of lubrication that separates the moving parts, disperses heat and protects the bearing surfaces from corrosion.

note
  • In all cases, use the lubricant recommended.
  • Grease the bearing, not the cavity where it is located.
  • A bearing that is not regularly checked and lubricated will have a reduced life span.

New Bearings

New bearings are typically protected with an oil preservative to prevent corrosion etc. during storage. This is NOT the lubrication for the bearing but DOES NOT need to be washed off prior to assembly and in-service lubrication.

When lubricating a new bearing with grease the following steps should be taken:

  1. Do not clean off the oil preservative.
  2. Grease must be forced between the roller elements and the roller cage.
  3. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts.
  4. Any excess grease should be smeared on the outside of the rollers.

Lubrication and Checks While Servicing a Bearing

  1. Disassemble parts as necessary to access the bearing.
  2. Inspect the old grease covering the bearing, looking for signs of bearing damage, i.e. flakes or specks of metal.
  3. Remove the old grease.
  4. Check the bearing for smooth operation and visually check for corrosion, dents and flaking in the bearing race, rollers or cage. Replace if necessary.

Below/overleaf several common bearing types and the lubrication procedures for each are identified:

Sealed Bearings

note
  • Sealed bearings can be identified by their integrated seals.
  • Sealed bearings are lubricated for life by the manufacturer.
  • Any attempt to change the grease in a sealed bearing will damage the integrated seals. If the seals are damaged, dirt and water will ingress and the life of the bearing will be greatly reduced.

Taper Bearings
  1. Grease must be forced between the inner race and the roller carrier.
  2. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts.
  3. Any excess grease should be smeared on the outside of the rollers.

Angular Contact and Ball Bearing
  1. Grease the bearing races and the ball bearing carrier.
  2. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts.

Needle Roller Bearings
  1. Coat the needle rollers with grease.
  2. Ensure the needle rollers turn so that the grease is distributed over the entire circumference of the internal parts.
  3. Assemble the parts, adjust and check as necessary.

Metal Bushes

  1. Disassemble the parts as necessary to access the bush.
  2. Remove the old grease.
  3. Apply fresh grease to the metal bush.

Fuel Handling Precautions

General

The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled safely. It also outlines other areas of risk which must not be ignored. This information is issued for basic guidance only and, if in doubt, appropriate enquiries should be made to your local Fire Officer.

Petrol – Gasoline

When petrol (gasoline) evaporates it produces 150 times its own volume in vapour which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout any indoor environment by air currents, consequently, even a small spillage of petrol (gasoline) is potentially very dangerous.

warning

Petrol (gasoline) is highly flammable and can be explosive under certain conditions. When opening the fuel tank cap always observe all the following items:

Turn the motorcycle ignition switch OFF.

Do not smoke.

Always have a fire extinguisher containing FOAM, CO2, HALON or POWDER close at hand when handling or draining fuel or fuel systems. Fire extinguishers must also be present in areas where fuel is stored.

Always disconnect the vehicle battery, negative (black) lead first, before carrying out, dismantling or draining work on a fuel system.

Whenever petrol (gasoline) is being handled, drained, stored or when fuel systems are being dismantled, make sure the area is well ventilated. All potential forms of ignition must be extinguished or removed (this includes any appliance with a pilot light). Any lead-lamps must be flame-proof and kept clear of any fuel spillage.

Warning notices must be posted at a safe distance from the site of the work to warn others that petrol (gasoline) is being openly handled. The notice must instruct the reader of the precautions which must be taken.

Failure to observe any of the above warnings may lead to a fire hazard which could result in personal injury.

warning

No one should be permitted to repair components associated with petrol (gasoline) without first having specialist training on the fire hazards which may be created by incorrect installation and repair of items associated with petrol (gasoline).

Repairs carried out by untrained personnel could bring about a safety hazard leading to a risk of personal injury.

warning

Draining or extraction of petrol (gasoline) from a vehicle fuel tank must be carried out in a well ventilated area.

The receptacle used to contain the petrol (gasoline) must be more than adequate for the full amount of fuel to be extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storage area which meets the requirements of local authority regulations.

When petrol (gasoline) has been extracted or drained from a fuel tank, the precautions governing naked lights and ignition sources should be maintained.

Failure to observe any of the above warnings could bring about a safety hazard leading to a risk of personal injury.

Fuel Tank Removal

Fuel tanks should have a 'PETROL (GASOLINE) VAPOUR' warning label attached to them as soon as they are removed from the vehicle. In all cases, they must be stored in a secured, marked area.

Chassis Repairs

warning

If the motorcycle is involved in an accident or collision it must be taken to an authorised Triumph dealer for repair or inspection. Any accident can cause damage to the motorcycle, which if not correctly repaired, may cause a second accident which may result in injury or death.

The frame must not be modified as any modification to the frame such as welding or drilling may weaken the frame resulting in an accident.

Electrical Precautions

The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and electronic components fitted to the motorcycle. Where necessary, specific precautions are detailed in the relevant sections of this manual which should be referred to prior to commencing repair operations.

Equipment - Prior to commencing any test procedure on the motorcycle ensure that the relevant test equipment is working correctly and any harness or connectors are in good condition, in particular mains leads and plugs.

warning

The ignition system produces extremely high voltages. Do not touch any part of the ignition system or any cables while the engine is running.

An electric shock caused by contact with the ignition system may lead to illness, injury or death.

warning

Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and/or diagnostic equipment.

The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death.

warning

The battery contains harmful materials. Always keep children away from the battery whether or not it is fitted in the motorcycle.

Do not jump start the battery, touch the battery cables together or reverse the polarity of the cables as any of these actions may cause a spark which would ignite battery gases causing a risk of personal injury.

High Voltage Circuits - Whenever disconnecting live H.T. circuits always use insulated pliers. Exercise caution when measuring the voltage on the coil terminals while the engine is running. High voltage spikes can occur on these terminals.

Connectors and Harness - The engine of a motorcycle is a particularly hostile environment for electrical components and connectors. Always ensure these items are dry and oil-free before disconnecting and connecting test equipment. Never force connectors apart either by using tools or by pulling on the wiring itself. Always ensure locking mechanisms are disengaged before removal and note the orientation to enable correct reconnection. Ensure that any protective covers and substances are replaced if disturbed.

Having confirmed a component to be faulty, switch off the ignition and disconnect the battery negative (black) lead first. Remove the component and support the disconnected harness. When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking mechanism becomes fully engaged.

Battery Disconnecting

Before disconnecting the battery, switch off all electrical equipment.

warning

To prevent the risk of a battery exploding and to prevent damage to electrical components ALWAYS disconnect the battery negative (black) lead first. When reconnecting the battery, always connect the positive (red) lead first, then the negative (black) lead. Always disconnect the battery when working on any part of the electrical system.

Failure to observe the above warnings may lead to electrical damage and a fire hazard which could cause personal injury.

Always ensure that battery leads are routed correctly and are not close to any potential chafing points.

Disciplines

Switch off the ignition prior to making any connection or disconnection in the system. An electrical surge can be caused by disconnecting 'live' connections which can damage electronic components.

Ensure hands and work surfaces are clean and free of grease, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts.

Prior to commencing any test, and periodically during any test, touch a good earth to discharge body static. This is because some electronic components are vulnerable to static electricity.

Electrical Wires

All the electrical wires are either single-colour or two-colour and, with only a few exceptions, must be connected to wires of the same colour. On any of the two-colour wires there is a greater amount of one colour and a lesser amount of a second colour. A two-colour wire is identified by first the primary colour and then the secondary colour. For example, a yellow wire with thin red stripes is referred to as a 'yellow/red' wire; it would be a 'red/yellow' wire if the colours were reversed to make red the main colour.

Glossary of Circuit Diagram Symbols

The following is a description of the symbols found in the circuit diagrams used in all Triumph Service Manuals.

Connector

This illustration is used to show all multiplug type electrical connectors on Triumph circuit diagrams. The numbers in the box relate to the terminal numbers of the connector pins. On ECMs with two connectors, the number would be prefixed with the letters 'A' or 'B' to identify each connector. An additional number outside the box will identify the component.

Diode

An electrical one-way valve. Diodes allow current to flow in one direction but will not allow it to return. The arrow, which forms part of the diode symbol, indicates the direction of current flow.

Electromagnetic Winding (solenoid)

An electromagnetic winding (or solenoid) is used to convert an electrical current into a lateral movement. This can then be used to operate switches (as used in relays) or other components such as fuel injectors or secondary air injection solenoids.

Fuse

A fuse is a device which protects a circuit in the event of a fault. The fuse will 'blow' should a short circuit occur, protecting that circuit from further damage. The number next to the fuse on the circuit diagram indicates the position of the fuse in the fuse box.

Ground Point

This symbol is used to show ground points. This is the negative connection to either the frame or engine, and is a common cause of intermittent faults due to loose or corroded connections.

Lamp or Bulb

This symbol is used to show all types of light bulbs. The numbers in the box relate to the terminal numbers of the connector pins. An additional number outside the box will identify the component.

LED (Light Emitting Diode)

Triumph use LEDs for the alarm warning light, instrument illumination and warning lights, gear change lights and rear light/brake lights on various models.

Motor

An electric motor. This could be the starter motor or a motor within an actuator, for example within the ABS modulator.

Relay

A relay is effectively an electromagnetic switch. To close the relay contacts and complete the circuit, an electromagnet in the relay is energised which causes the relay contacts to close, making the circuit complete.

Relays are used when the electrical current is too great for a mechanical switch, usually when the switching must be done quickly to prevent arcing across the switch contacts. If a mechanical switch were used, the mechanical switch contacts would quickly burn away.

Resistor

A device placed in a cable to reduce a voltage or restrict the maximum current a device can draw.

Splice

A hard cable joint where two or more cables are joined in the wiring harness. A potential source of both open and short circuits.

Switches

A mechanical device for completing or breaking a circuit. There are three common types of switch: normally open, normally closed and changeover.

Electrical Testing

For any electrical system to work, electricity must be able to flow in a complete circuit from the power source (the battery) via the components and back to the battery. No circuit means no electrical flow. Once the power has left the positive side of the battery and run through the component it must then return to the battery on its negative side (this is called earth or ground). To save on wiring, connections and space, the negative side of the battery is connected directly to the frame or engine. Around the frame and engine will be various other ground points to which the wiring coming from components will be connected. In the case of the starter motor it bolts directly to the engine, which is bolted to the frame. Therefore the frame and engine also form part of the earth return path.

Ohm’s Law

The relationship between voltage, current and resistance is defined by Ohm’s Law.

Ohm’s law, for practical work can be described as -

Power is calculated by multiplying Volts x Amps -

By transposing either of these formulae, the value of any unit can be calculated if the other two values are known.

For example, if a battery of 12 V is connected to a bulb of 60 W:

To use either of the following triangles, put your finger over the value you want to find. Multiply the remaining values if side by side, or divide if one is over the other.

Basic Electrical Circuits

Basic Circuit Diagram

In the above circuit an electrical reservoir (the battery) is connected via a cable to a terminal on the controlling device (the switch) whose contacts are either open or closed. The other terminal on the switch is connected via a cable to the consumer (the bulb), and the other side of the bulb filament is connected to ground (earth) by another cable. The ground point is usually a part of the frame or engine, to which the battery negative terminal is also connected.

When the switch contacts are open (as shown in the diagram), the circuit is broken and no current flows. When the switch contacts are closed, the circuit is made and current flows from the battery positive terminal through the switch contacts and bulb filament to ground. The frame completes the circuit to the battery negative terminal and the bulb illuminates.

Although some circuits on the circuit diagram may at first seem more complicated, it will generally be found that they can be broken down into sections which do not differ greatly from the basic circuit above.

Circuit Diagrams

Circuit diagrams are created to provide a 'picture' of the electrical system and to identify the route taken by each individual wire through the system, in order to identify which components it feeds and which connectors the wire runs through. Circuit diagrams are an essential tool for fault finding, as it is possible to locate start and finish points for a circuit without having to manually trace the wire through the motorcycle itself. Circuits diagrams may look confusing at first but when they are studied closely they soon become logical.

Due to the complex circuits and the number of individual wires, Triumph uses two types of circuit diagram in its Service Manuals.

Both of these circuit diagrams use similar symbols to illustrate the various system components and will be accompanied by a key indicating circuit diagram components and wiring colour codes.

Circuit diagrams also depict the inner workings of a switch housing (i.e. which wire connects to which when a switch is turned from one position to another) so that a test of that switch can be made using the wire terminals in the connector instead of disassembling the switch itself.

Tracing Circuits

The following is a description of two types of common electrical failures, and some of the methods which may be used to find them.

Open Circuit

A break in an electrical circuit - current cannot flow. Usually caused by a break in a wire or cable or by a loose connection. Open circuits can often be intermittent, making diagnosis difficult.

Short Circuit

A 'short cut' in an electrical circuit - current bypasses the intended circuit, either to ground or to another, different circuit. Often caused by failure of the cable insulation due to chafing or trapping of the wire. There are two different types of short circuit - short to ground and short to battery Voltage.

A short to ground means that the current is going to ground before it reaches the component it is supposed to feed. These are often caused by chafing of the harness to the frame or wires trapped between a bolted component, and will often blow the fuse on that circuit.

A short to battery voltage (12 Volts) is caused by a live power supply wire contacting an adjacent cable. Note that it is also possible for a 5 Volt sensor reference voltage to short to an adjacent circuit, which can also cause electrical failures and DTCs (Diagnostic Trouble Code) to be stored.

When tracing a wire that is suspect, carefully check the circuit diagram before starting. Remember:

To Check Continuity:

caution

Ensure the circuit being tested is switched off before measuring continuity. Damage to the Digital Multi Meter (DMM) may result from testing a 'live' circuit with the meter set to resistance (Ω).

In the example below, the ground circuit continuity is being tested from the battery to the frame.

To Measure Voltage:

In the example below, the circuit voltage is being measured at the bulb positive (+) terminal.

Splices

Splices are probably the most common cause of wiring faults after connectors. Splices are made where two or more wires come together and diverge in different directions, usually to feed a different circuit.

To locate a splice, it is necessary to peel back the insulation and examine the splice for its integrity. The most common fault is where one of the wires at the joint has come adrift usually causing the circuit it feeds or grounds to become 'dead'.

Switches

To check a switch, set the multimeter to resistance/continuity and probe the two pins that form a closed circuit when the switch is pushed. If the switch is working correctly, the resistance should register or the meter will bleep.

Relays

All relay cases have a circuit path engraved on them showing the circuit path across the electromagnet and the switch. Before making any checks, first note the pin designations, current paths, and whether or not there is a diode in either circuit path.

Make continuity checks across the electromagnet first, usually from pin 86 (positive) to pin 85 (negative). If a diode appears in the circuit use the diode check on the multimeter (Volts scale) in the direction of current flow. If there is no diode, use the resistance check facility. An open circuit or unusually high resistance value indicates a faulty relay.

To check the switch side, apply a 12 Volt supply between pins 86 and 85. With the supply connected, the relay should be heard to click and there should be continuity between pins 30 and 87. An open circuit indicates a faulty relay.

CAN (Controller Area Networking)

CAN (sometimes called CANbus) is a protocol for data communication between Electronic Control Modules (ECMs). Each ECM on the network is connected by a single pair of twisted wires (or bus) which are used for the transmission of vehicle sensor data. By using CAN, the overall number of system sensors, and the amount of cabling required to allow ECMs to communicate with each other is greatly reduced.

This saves cost, weight and space, and makes the system more reliable, as the physical number of wires and connections is reduced.

CAN works by each ECM sending out 'packets' of information (such as engine speed or fuel consumption information) on to the network bus (note that the network must be free of data before any ECM is allowed to transmit). This data is given a priority according to its importance (for example 'engine speed' may have a higher priority than 'low fuel level'), so that even if two ECMs send data at the same time, high priority information is always sent first. Lower priority data is then resent after the high priority data has been received by all ECMs on the network.

The receiving ECM confirms the data has been received correctly and that the data is valid, and this information is then used by the ECM as necessary. Specific data not required by an ECM will still be received and acknowledged as correct but then disregarded (for example if an ECM does not require 'clutch switch position' information, this data packet would be ignored).

This allows for a very high speed system of communication, which is also very reliable. Should one ECM fail or transmit corrupted or otherwise incorrect messages, none of the other ECMs on the network will be affected, and after a certain time that ECM will be prevented from transmitting further messages until the fault is rectified. This stops the ECM from clogging the network with incorrect data and preventing other messages from getting through. The fault would then be reported by a DTC (Diagnostic Trouble Code).

Triumph currently uses CAN for communication between the following ECMs:

Service Tools

Service Tools and Garage Equipment

Special service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical components in a practical manner without causing damage. Some operations in this service manual cannot be carried out without the aid of the relevant service tools. Where this is the case, the tools required will be described during the procedure.

Special Service Tools

T3880001 - Fuel Pressure Gauge

T3880003 - Front fork Seal Installer

T3880023 - 50 mm Socket

T3880027 - Chain Link Tool Kit

T3880053 - Wheel Bearing Extraction Kit

3880065-T0301 - Bearing Installer

T3880067 - Fork Spring Compressor

3880070-T0301 - Bearing Installer

3880085-T0301 - Fork Piston Holder

T3880103 - Engine Mounting Adjuster

T3880104 - Swinging Arm Adjuster Wrench

T3880105 - Torque Angle Gauge

T3880106 - Balancer Gear Holder

T3880123 - Extension Cable

T3880147 - Radiator and Cap Tester Kit

3880160 -T0301 - Fork Oil Filler/Evacuator

T3880171 - Fork Holding Tool

T3880181 - Wrench Frame Adjuster

T3880186 - 45 mm Octagonal Socket

T3880207 - Hose Clip Pliers

T3880307 - Clutch Anti-rotation Jig

T3880308 - Cylinder Barrel Clamps

T3880365 - Alternator Housing Puller

T3880367 - Wrench, Damper Cylinder, 33mm

T3880368 - Bearing Installer

T3880369 - Switch Housing Removal Tool

T3880375 - Alternator Rotor Holder

T3880601 - Camshaft Timing Pin

T3880607 - Camshaft Timing Tensioner

T3880609 - Timing Torque Limiter

T3880636 - Kit, Brake Lever Pivot Sleeve

T3880640 - Camshaft Timing Plate

T3880642 - Fork Seal Guide/Protector

BatteryMate Battery Charger - See Latest Parts Catalogue for Part Number Information

Specifications

Specification

Dimensions, Weights, and Performance

A list of model specific dimensions, weights and performance figures is available from your authorised Triumph dealer, or on the Internet at www.triumph.co.uk.

Engine

Engine Configuration

3 Cylinder 12 valve DOHC

Arrangement

Transverse in-line

Displacement

765 cc

Bore x Stroke

78 x 53.38

Compression Ratio

12.65:1

Cylinder numbering

Left to Right (No.3 adjacent to camshaft drive chain)

Cylinder Sequence

Number 1 at left

Firing order

1 2 3

Cylinder Head

Valve Head Diameter

Inlet

30.50 mm

Exhaust

25.50 mm

Valve Lift

Inlet

9.40 mm

Exhaust

8.70 mm

Valve Stem Diameter

Inlet

3.975 - 3.990 mm

Service Limit

3.965 mm

Valve Stem Diameter

Exhaust

3.955 - 3.970 mm

Service Limit

3.945 mm

Valve Guide Bore Diameter

Inlet

4.000 - 4.015 mm

Service Limit

4.043 mm

Valve Guide Bore Diameter

Exhaust

4.000 - 4.015 mm

Service Limit

4.043 mm

Valve Stem to Guide Clearance

Inlet

0.010 - 0.040 mm

Service Limit

0.078 mm

Valve Stem to Guide Clearance

Exhaust

0.030 - 0.060 mm

Service Limit

0.098 mm

Valve Seat Width (in head)

Inlet

0.80 - 1.20 mm

Service Limit

1.50 mm

Valve Seat Width (in head)

Exhaust

1.00 - 1.40 mm

Service Limit

1.70 mm

Valve Seat Width (valve)

Inlet

1.27 - 1.57 mm

Exhaust

1.06 - 1.93 mm

Valve Seat Angle

45°

Inlet/Exhaust Valve Spring Load at Length

513 N +/- 25 N at 27.5 mm

Valve Clearance

Inlet

0.10 - 0.20 mm

Exhaust

0.275 - 0.325 mm

Valve Bucket Diameter

Inlet

25.385 - 25.399 mm

Service Limit

25.375 mm

Valve Bucket Diameter

Exhaust

25.385 - 25.399 mm

Service Limit

25.375 mm

Valve Bucket Bore Diameter

Inlet

25.414 - 25.435 mm

Service Limit

25.449 mm

Valve Bucket Bore Diameter

Exhaust

25.415 25.435 mm

Service Limit

25.449 mm

Camshafts

Camshaft Timing

Inlet

Open 21° BTDC

Close 57° ABDC

Duration

259°

Exhaust

Open 50° BBDC

Close 24° ATDC

Duration

254°

Camshaft Journal Diameter

23.940 - 23.960 mm

Camshaft Journal Clearance

0.040 - 0.081 mm

Service Limit

0.17 mm

Camshaft Journal Bore Diameter

24.000 - 24.021 mm

Camshaft End Float

0.23 - 0.33 mm

Service Limit

0.40 mm

Camshaft Run-out

0.15 mm maximum

Clutch and Primary Drive

Primary Drive Type

Gear

Reduction Ratio

1.848:1 (46/85)

Clutch Type

Wet multiplate

Number of Friction Plates

9

Plate Flatness

Within 0.2 mm

Friction Plate Thickness

3.00 mm

Service Limit

2.90 mm

Clutch Pack Height

43 mm =0.34/-0.66 mm

Clutch Actuation Method

Cable

Cable Free Play (at lever)

2.0 - 3.0 mm

Pistons

Cylinder Bore Diameter

77.985 - 78.003 mm

Service Limit

78.053 mm

Piston Diameter (at 90° to gudgeon pin)

77.970 - 77.980 mm

Service Limit

77.920 mm

Piston Ring to Groove Clearances

Top

0.02 - 0.06 mm

Service Limit

0.075 mm

Second

0.35 - 0.50 mm

Service Limit

0.075 mm

Piston Ring End Gaps

Top

0.15 - 0.3 mm

Service Limit

0.52 mm

Second

0.35 - 0.50 mm

Service Limit

0.52 mm

Oil

0.20 - 0.70 mm

Service Limit

0.84 mm

Gudgeon Pin Bore Diameter in Piston

16.994 - 17.001 mm

Service Limit

17.029 mm

Gudgeon Pin Diameter

16.984 - 16.989 mm

Service Limit

16.974 mm

Connecting Rods

Connecting Rod Small End Diameter

17.005 - 17.018 mm

Service Limit

17.028 mm

Connecting Rod Big End Side Clearance

0.15 - 0.30 mm

Service Limit

0.50 mm

Crankshaft

Crankshaft Big End Journal Diameter

33.010 - 33.026 mm

Service Limit

32.970 mm

Crankshaft Big End Bearing Clearance

0.035 - 0.065 mm

Service Limit

0.070 mm

Crankshaft Main Bearing Journal Diameter

34.984 - 35.000 mm

Service Limit

34.960 mm

Crankshaft Main Bearing Clearance

0.014 - 0.038 mm

Service Limit

0.070 mm

Crankshaft End Float

0.15 - 0.30 mm

Crankshaft Run-out

0.02 mm or less

Service Limit

0.05 mm

Transmission

Type

6 Speed, Constant Mesh

Gear Ratios

1st

2.62:1 (34/13)

2nd

1.95:1 (39/20)

3rd

1.57:1 (36/23)

4th

1.35:1 (27/20)

5th

1.24:1 (26/21)

6th

1.14:1 (25/22)

Gear Selector Fork Thickness

5.9 - 6.0 mm

Service Limit

5.80 mm

Gear Selector Groove Width

6.1 - 6.17 mm

Service Limit

6.27 mm

Gear Selector Fork to Groove Clearance

0.47 mm maximum

Final Drive

Final Drive

Chain

Final Drive Ratio

2.88:1 (46/16)

Chain Type

RK XW-ring

Number of Links

118

20 Link Length

319 mm

Drive Chain Play

20-30 mm

Chain Lubrication

Chain spray suitable for XW-ring chains

Lubrication

Type

Pressure Lubrication, Wet sump

Oil Capacity (dry fill)

3.5 litres

Oil Capacity (wet fill including filter)

3.1 litres

Oil Capacity (wet fill excluding filter)

2.9 litres

Recommended Oil Approval Rating

API SH (or higher) and JASO MA

Viscosity

10W/40 or 10W/50

Type

Semi or fully synthetic

Oil pressure (in main gallery)

2.07 bar (30.0 lb/in²) Minimum oil temperature at 80° engine at 5,000 rpm

Oil Pump Rotor Tip Clearance

0.15 mm

Service Limit

0.20 mm

Oil Pump Body Clearance

0.15 - 0.22 mm

Service Limit

0.35 mm

Oil Pump Rotor End Float

0.04 - 0.09 mm

Service Limit

0.17 mm

Ignition System

Type

Digital Inductive

Electronic Rev Limiter

12,650 rpm

Pick-up Coil Resistance

0.21Kilo Ohms +/- 10% at 20° C

Ignition Coil Type

Plug-top

Spark Plug Type

NGK CR9EIA-9

Spark Plug Gap

0.9 mm

Fuel System

Fuel Type

Unleaded, 91 RON (U.S. 87 CLC/AKI)

Fuel Tank Capacity (motorcycle upright)

17.4 litres

Low Level Warning Lamp

4 litres remaining

Fuel Pump Type

Submerged

Fuel Pressure (nominal)

3.5 bar (50.8 lb/in²)

Purge Control System

Electronic, via fuel system ECM

Fuel Injection System

Type

Electronic, sequential

Idle Speed

1,200 rpm

Injector Type

Multi hole, solenoid operated plate valve

Throttle

Electronically controlled throttle bodies

Control Sensors

Atmospheric air pressure, throttle position, twist grip position, coolant temperature, crankshaft position, oxygen sensor, intake air temperature, gear position, MAP, vehicle speed (from ABS)

Emissions Controls

Catalytic converter

One cataltic converter between headers and silencer

Oxygen sensor

One oxygen sensor between headers and catalytic converter

Evaporative Control

Activated carbon canister (certain markets only)

Secondary Air Injection

Solenoid controlled, reed valve

Coolant System

Anti-Freeze Type

Triumph HD4X Hybrid OAT Coolant

Freezing point

Minus 35° C

Cooling System Capacity

2.1 litres

Radiator Cap Opening Pressure

1.1 bar (15.95 lb/in²)

Thermostat Opening Temperature

71° C (nominal)

Cooling Fan Switch On Temperature

103° C

Temperature Gauge Sensor Resistance

2.9 - 33 Kilo Ohms at 15° C

Suspension

Front Fork Travel

115 mm

Recommended Fork Oil Grade

Showa SS47

Fork Oil Level (fork fully compressed)

65 mm

Fork Oil Volume (dry fill)

515 cc

Fork Pull Through (measured from the flat/machined surface on the underside of the upper yoke to the top of the fork outer tube)

28 mm

Rear Wheel Travel

131mm

Brakes

Front Type

Two hydraulically actuated four piston radial calipers acting on twin discs

Caliper Piston Diameter

30mm

Disc Diameter

310 mm

Disc Thickness

4.5 mm

Service Limit

4.0 mm

Disc Run-out

0.3 mm

Master Cylinder Diameter

18mm

Recommended Fluid

DOT 4

Rear Type

Hydraulically actuated single piston caliper, single disc

Caliper Piston Diameter

34 mm

Disc Diameter

220 mm

Disc Thickness

5.0 mm

Service Limit

4.5 mm

Disc Run-out

0.3 mm

Master Cylinder Diameter

12.7 mm

Recommended Fluid

DOT 4

Wheels and Tyres

Front Wheel Size

MT 3.5 x 17

Front Tyre Size

Front Tyre Pressure

2.34 bar (34 lb/in²)

Recommended Front Tyre

Visit www.triumphmotorcycles.co.uk

Front Wheel Rim Axial Run-out

0.5 mm

Front Wheel Rim Radial Run-out

0.5 mm

Rear Wheel Size

MT 5..5 x 17

Rear Tyre Size

Rear Tyre Pressure

2.90 bar (42 lb/in²)

Recommended Rear Tyres

Visit www.triumphmotorcycles.co.uk

Rear Wheel Rim Axial Run-out

0.5 mm

Rear Wheel Rim Radial Run-out

0.5 mm

Electrical Equipment

Battery Type

YTX-9BS

Battery Rating

12 Volt - 8 Ah

Alternator Rating

14 Volt, 34 Amp at 5,000 rpm

Fuses

See Fuse Identification

Torque Wrench Settings

Cylinder Head

Application

Torque (Nm)

Notes

Camshaft cover to cylinder head

12 Nm

See Camshaft Cover - Installation

Apply clean engine oil to the seal(s)

Camshaft drive chain tensioner to cylinder barrel

9 Nm

Secondary air injection valve covers to camshaft cover

9 Nm

Camshaft ladder to cylinder head

*

See Camshaft - Installation and Timing

Camshaft sprocket to camshaft

16 Nm

Fit new fixing(s) if loosened or removed

Cylinder head nuts

*

See Cylinder Head - Installation

Cylinder head M6 x 88 mm fixings

10 Nm

Spark plugs

12 Nm

Exhaust stud to cylinder head

10 Nm

Fit new fixing(s) if loosened or removed

Timing torque limiter

0.6 Nm

Cylinder head bypass spigot

15 Nm

Fit new fixing(s) if loosened or removed

Cylinder head blanking plug

25 Nm

Fit new fixing(s) if loosened or removed

Sound suppression bolt

12 Nm

Clutch

Application

Torque (Nm)

Notes

Clutch centre nut

98 Nm

Fit new fixing(s) if loosened or removed

Fit new Belleville washer

Clutch pressure plate to centre

10 Nm

Clutch lever nut

3.5 Nm

Clutch lever clamp bolts

12 Nm

Clutch switch to switch housing

2 Nm

Clutch cable bracket

9 Nm

Balancer, Crankshaft and Crankcase

Application

Torque (Nm)

Notes

Crankcase to crankcase fixings

*

See Crankcases - Assembly

Crankcase dry seal plug

25 Nm

Fit new fixing(s) if loosened or removed

Crankcase face seal plug

8 Nm

Fit new fixing(s) if loosened or removed

Connecting rod big end bolts

*

See Connecting Rods - Installation

Sprag clutch to crankshaft

*

See Starter Drive/Sprag Clutch - Installation

Camshaft drive sprocket to crankshaft

27 Nm

Fit new fixing(s) if loosened or removed

Engine Covers

Application

Torque (Nm)

Notes

Clutch cover to crankcase

11 Nm

See Clutch Cover - Installation

Alternator cover to crankcase

10 Nm

See Alternator Cover - Installation

Front sprocket cover to crankcase

9 Nm

See Front Sprocket Cover - Installation

Sump to crankcase

10 Nm

See Sump - Installation

Sump plug

25 Nm

Fit new sealing washer(s)

Engine breather cover to crankcase

9 Nm

See Engine Breather Cover - Installation

Transmission

Application

Torque (Nm)

Notes

Front sprocket to output shaft nut

85 Nm

Fit new fixing(s) if loosened or removed

Input shaft bearing retainer

12 Nm

Fit new fixing(s) if loosened or removed

Input selector fork plug

22 Nm

Input selector shaft retainer

12 Nm

Fit new fixing(s) if loosened or removed

Detent wheel to selector drum

12 Nm

Fit new fixing(s) if loosened or removed

Detent arm fixing

15 Nm

Fit new fixing(s) if loosened or removed

Detent arm spring fixing

12 Nm

Fit new fixing(s) if loosened or removed

Selector drum bearing retaining screw

12 Nm

Fit new fixing(s) if loosened or removed

Output selector shaft retainer

12 Nm

Fit new fixing(s) if loosened or removed

Gear change pedal bolt

22 Nm

Fit new fixing(s) if loosened or removed

Gear change rod front lock nut

6 Nm

Gear change rod rear lock nut

4 Nm

Lubrication System

Application

Torque (Nm)

Notes

Oil pressure relief valve

15 Nm

Apply ThreeBond 1305 to the threads

Oil pressure switch

13 Nm

Fit new sealing washer(s)

Oil filter adapter

16 Nm

Fit new fixing(s) if loosened or removed

Oil filter

10 Nm

Apply clean engine oil to the seal(s)

Oil pump to crankcase

12 Nm

Fit new fixing(s) if loosened or removed

Oil cooling jet (pistons)

10 Nm

Fit new fixing(s) if loosened or removed

Oil pump drive chain guide fixings

12 Nm

Fit new fixing(s) if loosened or removed

Oil pump drive chain retainer plate

10 Nm

Fit new fixing(s) if loosened or removed

Oil pump drive sprocket to oil pump

12 Nm

Fit new fixing(s) if loosened or removed

Oil transfer pipe

10 Nm

Fit new fixing(s) if loosened or removed

Oil pick up pipe

12 Nm

Fit new fixing(s) if loosened or removed

Oil level dipstick

1.2 Nm

Final Drive

Application

Torque (Nm)

Notes

Rear sprocket to sprocket carrier

55 Nm

See Rear Sprocket - Installation

Rear sprocket studs to sprocket carrier

30 Nm

See Rear Sprocket - Installation

Rear hugger and chain guard moulding to swinging arm

4 Nm

Chain rubbing strip to swinging arm

4 Nm

Cooling System

Application

Torque (Nm)

Notes

Radiator to frame upper

6 Nm

Radiator lower mounting bracket to frame

6 Nm

Radiator to lower bracket

6 Nm

Thermostat housing

9 Nm

Coolant expansion tank

6 Nm

Coolant expansion tank stud

6 Nm

Fit new fixing(s) if loosened or removed

Coolant temperature sensor

18 Nm

Apply ThreeBond 1374 to the threads

Coolant return elbow to crankcase

12 Nm

Fit new fixing(s) if loosened or removed

Coolant inlet to crankcase

8 Nm

Coolant T-piece to crankcase

6 Nm

Fuel System, Exhaust System and Airbox

Application

Torque (Nm)

Notes

Fuel tank to frame (pivot nut)

8 Nm

Fuel tank front mounting to fuel tank

9 Nm

Fuel tank front mounting to frame

9 Nm

Fuel pump mounting plate to fuel tank

9 Nm

Throttle body transition piece to cylinder head

8 Nm

Fit new fixing(s) if loosened or removed

Throttle body adaptor clip

1.5 Nm

Fuel rail to throttle body

3.5 Nm

Throttle position sensor

2 Nm

Exhaust header to cylinder head

15 Nm

See Exhaust Header Pipe - Installation

Exhaust silencer to frame front fixings

28 Nm

Exhaust silencer to frame rear fixing

28 Nm

Exhaust silencer bracket

8 Nm

Exhaust silence clamp

5 Nm

Catalytic converter heat shield

5 Nm

Silencer rear finisher

5 Nm

Oxygen sensor

25 Nm

Airbox Upper to Lower

1.5 Nm

Airbox lower housing to engine

8 Nm

Air intake trumpet

6 Nm

Secondary air injection reed cover

9 Nm

Secondary air injection valve bracket

9 Nm

Crankshaft position sensor

6 Nm

Fit new fixing(s) if loosened or removed

Ambient air pressure sensor

1.5 Nm

Air temperature sensor (airbox)

2.5 Nm

Air temperature sensor (in cockpit)

1.5 Nm

Gear position sensor

5 Nm

Fit new fixing(s) if loosened or removed

Road speed sensor blanking plug

4 Nm

Fit new fixing(s) if loosened or removed

Immobiliser module

1.5 Nm

MAP sensor

2.5 Nm

Fit new fixing(s) if loosened or removed

Fall detection switch

3 Nm

Fit new fixing(s) if loosened or removed

Front Suspension

Application

Torque (Nm)

Notes

Upper yoke centre nut

90 Nm

Upper yoke pinch bolt

26 Nm

Lower yoke pinch bolt

22 Nm

Damping cylinder assembly

90 Nm

Handlebar clamp bolt

26 Nm

Handlebar end weights

8 Nm

Fit new fixing(s) if loosened or removed

Headstock bearing adjuster and lock nut

*

See Steering Head Bearing - Adjustment

Handlebar risers

38 Nm

Fork top cap

35 Nm

Wire guide to upper yoke

20 Nm

Twist grip housing

2.5 Nm

Left hand grip

3 Nm

Damping rod to top cap lock nut

27.5 Nm

Rear Suspension

Application

Torque (Nm)

Notes

Swinging arm pivot nut

110 Nm

See Swinging Arm - Installation

Swinging arm pivot bolt adjuster

6 Nm

See Swinging Arm - Installation

Drive chain slack adjuster lock nut

20 Nm

Drive chain rubbing strip

4 Nm

Rear suspension unit upper mounting clevis to frame

52 Nm

Rear suspension unit to upper mounting clevis

48 Nm

See Rear Suspension Unit - Installation

Rear suspension unit lower mounting nut

48 Nm

See Rear Suspension Unit - Installation

Rear suspension unit drop link to swinging arm

48 Nm

See Drag and Drop Links - Installation

Drag link to drop link

48 Nm

See Drag and Drop Links - Installation

Drag link to frame

48 Nm

See Drag and Drop Links - Installation

Rear hugger and drive chain guard moulding to swinging arm

4 Nm

swinging arm spindle finisher

1 Nm

Wheels

Application

Torque (Nm)

Notes

Front wheel spindle/axle bolt

65 Nm

Fork to wheel spindle pinch bolts

22 Nm

Rear wheel spindle lock nut

110 Nm

Rear sprocket to sprocket carrier

55 Nm

Fit new fixing(s) if loosened or removed

Sprocket carrier stud

30 Nm

See Rear Sprocket - Installation

Front Brakes

Application

Torque (Nm)

Notes

Brake caliper to front fork

45 Nm

Front brake master cylinder to handlebar

8 Nm

Brake hose to master cylinder

25 Nm

Fit new sealing washer(s)

Brake hose to front caliper

25 Nm

Fit new sealing washer(s)

Brake disc to wheel

22 Nm

Fit new fixing(s) if loosened or removed

Brake lever pivot bolt

1 Nm

Brake lever pivot bolt lock nut

6 Nm

Front brake fluid reservoir bracket

6 Nm

Front brake fluid reservoir to bracket

6 Nm

Brake master cylinder reservoir cap fixings

0.7 Nm

Caliper bleed screw

8 Nm

Master cylinder bleed screw

14 Nm

Rear Brakes

Application

Torque (Nm)

Notes

Brake hose to rear caliper

25 Nm

Fit new sealing washer(s)

Brake master cylinder to control plate

16 Nm

Brake master cylinder reservoir to frame

6 Nm

Fit new fixing(s) if loosened or removed

Brake hose to master cylinder

25 Nm

Fit new sealing washer(s)

Brake light switch bracket to control plate

6 Nm

Brake hose P-clip

6 Nm

Brake disc to wheel

22 Nm

Fit new fixing(s) if loosened or removed

Brake line bracket

15 Nm

Brake pedal pivot pin

22 Nm

Fit new fixing(s) if loosened or removed

Brake caliper bleed screw

14 Nm

ABS System

Application

Torque (Nm)

Notes

ABS wheel speed sensors

9 Nm

ABS modulator bracket to frame

9 Nm

Fit new fixing(s) if loosened or removed

ABS modulator to bracket

9 Nm

Fit new fixing(s) if loosened or removed

Brake line union block to headstock

9 Nm

Anti-rotation moulding to ABS modulator

3 Nm

Rear brake line to modulator P-clip

6 Nm

Hose routing bracket

15 Nm

Brake line union to modulator

25 Nm

Fit new sealing washer(s)

Front brake hose to hard line union

25 Nm

Fit new sealing washer(s)

Front ABS sensor wire conduit

2 Nm

Fit new fixing(s) if loosened or removed

Frame, Footrests, Control Plates and Engine Mountings

Application

Torque (Nm)

Notes

Bank angle indicator

9 Nm

Fit new fixing(s) if loosened or removed

Front control plate

24 Nm

Heel guard

16 Nm

Rear footrest hanger

27 Nm

Side stand bracket

45 Nm

Side stand switch

7 Nm

Fit new fixing(s) if loosened or removed

Side stand heat shield

1.5 Nm

Side stand spring peg

7 Nm

Side stand bolt

20 Nm

Side stand lock nut

9 Nm

Frame cylinder head adjuster ring

3 Nm

See Engine - Installation

Frame gearbox upper and lower adjuster rings

10 Nm

See Engine - Installation

Engine mounting bolts

48 Nm

See Engine - Installation

Swinging arm height adjuster

6 Nm

Rear subframe to main frame

48 Nm

Fit new fixing(s) if loosened or removed

Rear subframe cross member fixing

30 Nm

Rear bridge to subframe

12 Nm

Front mudguard moulding to front fork

6 Nm

Front mudguard to mudguard moulding

1.5 Nm

Rear mudguard to frame

4 Nm

Fit new fixing(s) if loosened or removed

Fall detect switch bracket

4 Nm

Evaporative hose wire guide

7 Nm

Licence plate upper hanger

8 Nm

Licence plate lower hanger

3 Nm

Rear body work

3 Nm

Rear body work under tray

3 Nm

Seat bridge

5 Nm

Rider seat rear fixing

9 Nm

Seat cowl base

1.5 Nm

Flyscreen facia to front subframe

3 Nm

Flyscreen to front subframe

3 Nm

Air intake finisher to flyscreen

1.5 Nm

Radiator cowl finisher

4 Nm

Radiator cowl bracket to radiator lower fixing

8 Nm

Radiator cowl outer to radiator cowl inner

1.5 Nm

Headstock infill panels

4 Nm

Belly pan mounting brackets to sump

7 Nm

Belly pan to rear mounting brackets

4 Nm

Centre belly pan panel to outer panels

1.5 Nm

Grab handle bolts

20 Nm

Front subframe mounting bolts

13 Nm

Fit new fixing(s) if loosened or removed

Mirror pinch bolt

1 Nm

Fuel tank infill panel

3 Nm

Seat lock mechanism to seat bridge

5 Nm

Fit new fixing(s) if loosened or removed

Seat lock barrel housing to bracket

9 Nm

Fit new fixing(s) if loosened or removed

Electrical

Application

Torque (Nm)

Notes

Alternator rotor to crankshaft

*

see Alternator Rotor - Installation

Alternator rotor to crankshaft, stage 1

85 Nm

Alternator rotor to crankshaft stage 2

120 Nm

Alternator stator to cover

12 Nm

Fit new fixing(s) if loosened or removed

Alternator cable brackets to cover

6 Nm

Fit new fixing(s) if loosened or removed

Alternator regulator/rectifier to bracket

9 Nm

Alternator regulator/rectifier bracket to frame

12 Nm

Alternator cover

10 Nm

Battery terminal fixings

4.5 Nm

Starter motor to crankcase

10 Nm

Starter motor power lead connection

3 Nm

Starter motor solenoid lead connection

5 Nm

Horn

15 Nm

Immobiliser ECM

1.5 Nm

Ignition switch

16 Nm

Fit new fixing(s) if loosened or removed

Instrument assembly

3.5 Nm

Instrument mounting to hinge assembly

5 Nm

Instrument hinge assembly

5 Nm

Headlight to headlight bracket

3 Nm

Headlight bracket to front subframe

7 Nm

Headstock gasket

9 Nm

Licence plate light

1 Nm

Rear light

4 Nm

Front and rear direction indicator

3 Nm

Direction Indicator Lens

0.3 Nm

Negative battery lead to ground stud

4 Nm

Negative battery lead to ground lock nut

10 Nm

ECU conduit fixing

1.5 Nm

Main harness conduit front fixing

3 Nm

Ambient air temperature sensor (instruments display)

1.5 Nm

Routings

Main Wiring Harness Routing

Clutch Cable Routing

ABS Brake Hose Routing

Fuel Tank Breather and Evaporative Hose Routing

Routine Maintenance

Routine Maintenance Introduction

To maintain the motorcycle in a safe and reliable condition, the maintenance and adjustments outlined in this section must be carried out as specified in the schedule of daily checks, and also in line with the Scheduled Maintenance chart.

Weather, terrain and geographical location affects maintenance. The maintenance schedule should be adjusted to match the particular environment in which the vehicle is used and the demands of the individual owner. For advice on adjusting the service schedule, consult your authorised Triumph dealer.

warning

In order to correctly carry out the maintenance items listed in the Scheduled Maintenance chart, special tools and specialist knowledge will be required. As only an authorised Triumph dealer will have this knowledge and equipment, Triumph strongly recommends that your authorised Triumph dealer carries out all scheduled maintenance.

A dangerous riding condition could result from incorrect maintenance leading to loss of motorcycle control and an accident.

warning

All maintenance is vitally important and must not be neglected. Incorrect maintenance or adjustment may cause one or more parts of the motorcycle to malfunction. A malfunctioning motorcycle is dangerous and may lead to an accident.

Scheduled maintenance may be carried out by your dealer in three ways; annual maintenance, mileage based maintenance or a combination of both, depending on the mileage the motorcycle travels each year.

In all cases maintenance must be carried out at or before the specified maintenance intervals shown. Consult an authorised Triumph dealer for advice on which maintenance schedule is most suitable for your motorcycle.

warning

Triumph Motorcycles cannot accept any responsibility for damage or injury resulting from incorrect maintenance or improper adjustment carried out by the owner.

Since incorrect or neglected maintenance can lead to a dangerous riding condition, always have an authorised Triumph dealer carry out the scheduled maintenance of this motorcycle.

Scheduled Maintenance Chart

Operation Description

Odometer Reading in Miles (Km) or time period,whichever comes first

First Service

Annual Service

Mileage Based Service

Every

500

(800) one month

Year

6,000 and 18,000 (10,000and 30,000)

12,000

(20,000)

24,000

(40,000)

Lubrication

Engine oil cooler - check for leaks

Day

•

•

•

•

•

Engine oil - renew

-

•

•

•

•

•

Engine oil filter - renew

-

•

•

•

•

•

Fuel System and Engine Management

Fuel system - check for leaks, chafing etc.

Day

•

•

•

•

•

Throttle body plate (butterfly) - check/clean

-

•

•

•

AutoScan - carry out a full AutoScan using the Triumph diagnostic tool (print a customer copy)

-

•

•

•

•

•

Exhaust clamp bolts - check/adjust

-

•

•

•

•

•

Secondary air injection system - check/clean

-

•

•

Air cleaner - renew

-

•

•

Throttle bodies - balance

-

•

•

•

Fuel hoses - renew

Every four years, regardless of mileage

Evaporative loss hoses* - renew

Every four years, regardless of mileage

Ignition System

Spark plugs - check

-

•

Spark plugs - renew

-

•

•

Cooling System

Cooling system - check for leaks

Day

•

•

•

•

•

Coolant level - check/adjust

Day

•

•

•

•

•

Coolant - renew

Every 3 years, regardless of mileage

Engine

Clutch cable - check/adjust

Day

•

•

•

•

•

Valve clearances - check/adjust

-

•

•

Camshaft timing - adjust

First 12,000 mile (20,000 km) service only

Wheels and Tyres

Wheels - inspect for damage

Day

•

•

•

•

•

Wheel bearings - check for wear/smooth operation

-

•

•

•

•

•

Tyre wear/tyre damage - check

Day

•

•

•

•

•

Tyre pressures - check/adjust

Day

•

•

•

•

•

Electrical

Lights, instruments and electrical systems - check

Day

•

•

•

•

•

Steering and Suspension

Steering - check for free operation

Day

•

•

•

•

•

Forks - check for leaks/smooth operation

Day

•

•

•

•

•

Fork oil - renew

-

•

Headstock bearings - check/adjust

-

•

•

•

•

Headstock bearings - lubricate

-

•

•

Rear suspension linkage - check/lubricate

-

•

•

Brakes

Brake pad wear - check

Day

•

•

•

•

•

Brake master cylinders - check for fluid leaks

Day

•

•

•

•

•

Brake calipers - check for leaks and seized pistons

Day

•

•

•

•

•

Brake fluid levels - check

Day

•

•

•

•

•

Brake fluid - renew

Every 2 years, regardless of mileage

Drive Chain

Drive chain slack - check/adjust

Day

•

•

•

•

•

Drive chain - wear check

Every 500 miles (800 km)

Drive chain - lubricate

Every 200 miles (300 km)

Drive rubbing strip - check

-

•

•

•

•

•

Drive rubbing strip - renew

-

•

•

•

General

Fasteners - inspect visually for security

Day

•

•

•

•

•

Bank angle indicators - inspect visually for wear

Day

•

•

•

•

•

Stand - check operation

Day

•

•

•

•

•

* Evaporative system fitted to models for certain markets only.

Engine Covers

Exploded View – Sump

Exploded View – Clutch Cover

Exploded View – Alternator Cover

Exploded View – Camshaft Cover

Exploded View – Front Sprocket and Breather Covers

Sump - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

warning

If the engine has recently been running, the engine oil will be hot to the touch. Contact with the hot oils may cause damage to exposed skin. To avoid skin damage, do not touch hot oil.

warning

Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contamination which can cause cancer. Wear suitable clothing and avoid skin contact.

The engine oil and filter must be replaced in accordance with scheduled maintenance requirements.

warning

If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid skin damage, always allow the hot parts to cool before working on the exhaust system.

  1. Release the bolts securing the sump to the lower crankcase.

    2. Sump Fixings Release Sequence
  2. Detach the sump and collect the water pump drain tube. Remove and discard the four drain tube O-rings.

    3. note
    • The water pump drain tube may remain attached to the water pump or become detached with the sump.

    1. Water pump drain tube

    2. O-rings
  3. Remove and discard the sump gasket.
  4. If necessary, remove the oil transfer pipe and oil pick up pipe. Discard the fixings and the three O-rings.

    1. Oil transfer pipe

    2. Oil pick up pipe

    3. Fixings

Sump - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. If removed, fit the oil transfer pipe incorporating new O-rings. Fit new fixings and tighten to 10 Nm.
  2. Refit the oil pick up pipe incorporating new O-rings. Fit new fixings and tighten to 12 Nm

    1. Oil transfer pipe

    2. Oil pick up pipe

    3. Fixings
  3. Incorporating new O-rings, position the water pump drain tube to the oil pump.

    1. Water pump drain tube

    2. O-rings
  4. Incorporating a new sump gasket, position the sump to the lower crankcase.
  5. Tighten the sump fixings to 10 Nm in the sequence shown below.
  6. Re-tighten the fixings one and two to 10 Nm.

    7. Sump Fixings Tightening Sequence

Perform the following operations:

Camshaft Cover - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Disconnect the electrical connections to the ignition coils and remove the coils.
  2. Progressively release the camshaft cover fixings in the sequence shown below.

    3. note
    • Two shorter bolts are fitted at the end adjacent to the camshaft drive chain.

    Camshaft Cover Fixings Release Sequence
  3. Remove the camshaft cover from the motorcycle.

    4. caution

    Never use a lever to remove the camshaft cover from the head.

    Using a lever will cause damage to the head and camshaft cover which could lead to an oil leak.

  4. Remove the camshaft cover gasket. If necessary, recover the three dowels from the secondary air injection holes in the camshaft ladder (these may come away in the camshaft cover or gasket).
  5. Discard the camshaft cover gasket and bolt seals.
  6. Remove any residual oil from the front of the head using a syringe or lint free cloth.

Camshaft Cover - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Refit the three dowels to the camshaft ladder.

    1. Dowels
  2. Fit a new camshaft cover seal to the cylinder head. Ensure the groove in the gasket is correctly seated to the head. Ensure the plug tower seals and the dowels are correctly located.

    1. Camshaft cover seal

    2. Dowels

    3. Plug tower seals
  3. Fit the camshaft cover, ensuring that the gasket remains in the correct position.
  4. Lubricate the new camshaft cover screw seals with clean engine oil. Fit the camshaft cover screws and screw seals and tighten until finger tight.
  5. Finally, tighten the camshaft cover fixings, in the sequence shown below, to 12 Nm.

    6. Camshaft Cover Fixings Tightening Sequence
  6. Inspect the ignition coils seal for damage and replace if necessary.
  7. Fit the ignition coils and reconnect the electrical connectors.

Perform the following operations:

Engine Breather Cover - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. If fitted, cut the cable tie and detach the purge control valve from its bracket.

    2. note
    • Note that the grey connector on the fuel hose connects to the fuel rail for installation.
  2. Ease the latch away from the connector until the release buttons are exposed.

    1. Locked position

    2. Unlocked position
  3. Disconnect the fuel hose by squeezing the sides of the connector and pulling the hose free from its spigot on the fuel rail.
  4. Release the retaining clip and detach the engine breather hose from the engine breather cover.

    5. note
    • Note the positions of the two harness brackets mounted to the engine breather cover for installation.
  5. Release the six fixings and remove the engine breather cover, harness shown removed for clarity.

    1. Engine breather cover

    2. Harness brackets

    3. Fixings
  6. Discard the gasket.

Engine Breather Cover - Installation

  1. Fit a new engine breather cover seal to the crankcase.
  2. Fit the engine breather cover, ensuring that the gasket remains in the correct position.
  3. Position the harness brackets as noted for removal, fit the fixings and tighten to 9 Nm in the sequence shown below.
  4. Re-tighten the fixings one and two to 9 Nm.

    5. Engine Breather Cover fixings Tightening Sequence
  5. Reconnect the grey connector of the fuel hose to the fuel rail by gently pushing inwards until the hose engages with a click.
  6. Slide the double check latch to the locked position until the release buttons are covered. If the latch will not slide into position, then the fuel hose is not fully home on its spigot and must therefore be refitted correctly.

    1. Locked Position

    2. Unlocked Position
  7. If removed, secure the purge control vale to its bracket with a cable tie.

Perform the following operations:

Clutch Cover - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the clutch cable from the actuating arm (see Clutch Cable - Removal).
  2. Place an oil catch tray beneath the clutch cover to collect any oil that may spill out on removal.
  3. Release the fixings securing the clutch cover to the crankcases. Note the position of the copper washer for installation.

    1. Clutch cover

    2. Copper washer position
  4. Carefully withdraw the cover.
  5. Remove the gasket and clean the surfaces of the crankcase and the clutch cover using a lint free cloth.

Clutch Cover - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • The pull-rod should be free to move in and out and also it should be free to turn.
  1. Incorporating a new clutch cover gasket, position the clutch cover to the crankcase.
  2. Tighten the clutch cover fixings to 11 Nm in the sequence shown below.
  3. Re-tighten the fixings one and two to 11 Nm.

    4. Clutch Cover Fixings Tightening Sequence
  4. Refit the clutch cable to the actuating arm (see Clutch Cable - Installation).
  5. Set the clutch adjustment (see Clutch Cable - Installation).

Perform the following operations:

Alternator Cover - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

The rotor magnets are very strong. When handling the alternator cover the magnets may 'grab' the stator, causing injury to the hands or fingers. When handling the alternator cover wear suitable gloves and only grip the alternator cover by the outside surfaces; always keep hands and fingers clear when handling the alternator cover.

Perform the following operations:

  1. If fitted, cut the cable tie and detach the purge control valve from its bracket.
  2. Release the fixings and detach the two harness brackets from the engine breather cover.
  3. Ease the rubber boot from the battery ground cable, Release the fixing and detach the ground cables from the frame.

    1. Harness brackets

    2. Fixings

    3. Rubber boot

    4. Ground cable fixing

    note
    • Note the routing of the crankshaft position sensor harness for installation.
  4. Disconnect the crankshaft position sensor from the main harness. Route the harness back to the alternator cover.

    1. Crankshaft position sensor connector

    note
    • Note the routing of the alternator harness for installation.
  5. Disconnect the grey connector from the regulator/rectifier. Route the harness back to the alternator cover.

    1. Grey connector

    2. Regulator/rectifier
  6. Place an oil catch tray beneath the alternator cover to collect any oil that may spill out on removal.
  7. Release the fixings securing the alternator cover to the crankcases.

    1. Alternator cover

    2. Fixings
  8. Withdraw the cover from the crankcase and discard the gasket.

Alternator Cover - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Position a new gasket to the crankcase dowels then refit the alternator cover.
  2. Tighten the cover bolts to 10 Nm in the sequence shown below.
  3. Re-tighten the fixings one and two to 10 Nm.

    4. Alternator Cover Fixings Tightening Sequence
  4. Route the alternator harness to the regulator/rectifier as noted for removal.
  5. Connect the grey connector to the regulator/rectifier.
  6. Route the crankshaft position sensor harness to the main harness as noted for removal.
  7. Connect the crankshaft position sensor the main harness.

    1. Crankshaft position sensor connector
  8. Connect the ground cables to the frame and tighten the fixing to 10 Nm. Refit the rubber boot over the battery ground cable.
  9. Attach the two harness brackets to the engine breather cover and tighten the fixings to 9 Nm.

    1. Harness brackets

    2. Fixings

    3. Rubber boot

    4. Ground cable fixing
  10. If removed, secure the purge control vale to its bracket with a cable tie.

Perform the following operations:

Front Sprocket Cover - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

Rotating the rear wheel will cause the drive chain to rotate on the sprockets. To prevent injury, never place loose clothing, fingers or hands near the drive chain or sprockets. Loose clothing, fingers or the hands could become trapped as the drive chain rotates on the sprockets causing a crushing injury to the fingers, hands or other parts of the anatomy.

Perform the following operations:

    note
    • Note the routing of the breather hoses and harnesses in front of the sprocket cover for installation.
  1. Remove the fixings securing the sprocket cover to the crankcase.

    1. Front sprocket cover

    2. Fixings

    3. Breather hoses and harnesses

Front Sprocket Cover - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

Rotating the rear wheel will cause the drive chain to rotate on the sprockets. To prevent injury, never place loose clothing, fingers or hands near the drive chain or sprockets. Loose clothing, fingers or the hands could become trapped as the drive chain rotates on the sprockets causing a crushing injury to the fingers, hands or other parts of the anatomy.

  1. Fit the sprocket cover, ensuring that the breather hoses and harnesses are routed as noted for removal.
  2. Fit the sprocket cover fixings and evenly tighten to 9 Nm.

    1. Front sprocket cover

    2. Fixings

    3. Breather hoses and harnesses

Perform the following operations:

Crankcase Right Hand Cover - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

If the engine has recently been running, the engine oil will be hot to the touch. Contact with the hot oils may cause damage to exposed skin. To avoid skin damage, do not touch hot oil.

warning

Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contamination which can cause cancer. Wear suitable clothing and avoid skin contact.

The engine oil and filter must be replaced in accordance with scheduled maintenance requirements.

  1. Place an oil catch tray beneath the crankcase right hand cover to collect any oil that may spill out on removal.
  2. Release the seven fixings and remove the right hand crankcase cover. Discard the gasket.

    1. Fixings

Crankcase Right Hand Cover - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit a new gasket to the crankcase right hand cover.
  2. Fit the crankcase right hand cover and tighten its fixings to 10 Nm in the sequence shown below.
  3. Re-tighten the fixings one and two to 10 Nm.

    4. Crankcase Right Hand Cover Fixings Tightening Sequence

Cylinder Head

Camshaft Drive Chain Tensioner - Inspection

  1. Inspect the camshaft drive chain tensioner spring for damage and deformation. Renew as necessary.
  2. Inspect the tip of the camshaft drive chain tensioner plunger for wear and damage. Renew as necessary.

Exploded View - Cylinder Head

Exploded View - Camshaft, Camshaft Drive and Valves

Cylinder Head Description

The engine is fitted with an aluminium alloy cylinder head, which carries the camshafts, valves and spark plugs. The cylinder head is cast as a single entity and various components are permanently added after machining.

The camshafts run directly in the head without separate bearings. Valve clearances are adjusted by changing variable thickness shims which sit between the valve tappet bucket and the valves.

The camshafts are driven by a silent-type drive chain, via a sprocket bolted to each of the camshafts, using slotted holes. The use of slotted holes allows the camshaft timing to be adjusted very accurately, to compensate for manufacturing tolerances in the camshaft drive system.

The chain is guided by two blades and is tensioned by a hydraulic tensioner.

The hydraulic tensioner is fed oil via a gallery in the cylinder head. The combination of oil pressure and spring pressure pushes the plunger against the tensioner blade which tensions the camshaft drive chain. The hydraulic tensioner has an oil pressure relief valve located in the plunger that is set to open between 12-16 bar and when open sprays oil through a drilling in the tensioner blade onto the camshaft drive chain.

Oil is supplied to the head by a gallery in the crankcase. Once supplied to the head, the oil is distributed along internal drillings within the head casting and camshaft.

Single valve springs are used to close both the inlet valves and exhaust valves. These valve springs have close wound coils at one end to assist in the prevention of valve bounce at high engine speed and to give a smooth valve actuation. When assembling the cylinder head it is important that the close wound, colour coded ends of the springs are fitted downwards (towards the piston). Both the tip and seating face of the valves are hardened to give a long service life.

Due to the methods used to assemble the valve seat and valve guides to the head, these parts cannot be replaced.

caution

In any of the following operations which necessitate the removal or disconnection of the camshaft drive chain, NEVER turn the engine without the camshaft drive chain and tensioner correctly fitted and adjusted. In the disassembled condition, the pistons will contact the valves if the crankshaft is turned, causing severe engine damage.

Valve Clearances

Camshaft, valve, valve shim and valve seat wear affects the valve clearances. The effect of this wear is to change the gap between the camshaft and tappet bucket, causing engine noise and improper running. If the valve clearances become too small, permanent damage to the valve and valve seat will take place. If the valve clearance becomes too great, the engine will become noisy and will not run correctly.

Camshaft Drive Chain Tensioner - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the seven fixings and remove the right hand crankcase cover. Discard the gasket.

    1. Fixings
  2. Rotate the crankshaft clockwise (the normal direction of rotation), using the bolt fitted to the end of the crankshaft. Stop rotation when number 1 cylinder is at Top Dead Centre (TDC), that is when the dot mark on the primary gear aligns with the line on the crankcase.

    3. note
    • While rotating the crankshaft, ensure that the front camshaft drive chain rubbing blade remains in its mounting.
    • Before inserting the timing pin, ensure the dot on the primary gear is aligned with the line on the crankcase.
  3. Insert T3880601 - Camshaft Timing Pin into the timing holes in the crankcase and crankshaft.

    1. DOT alignment mark

    2. Marker line

    3. T3880601 - Camshaft Timing Pin

    4. Timing hole in crankcase
  4. In addition to the dot mark alignment, at TDC, the alignment marks on the camshaft bosses will point inwards.

    1. Camshaft alignment marks
  5. Place a suitable wedge between the camshaft drive chain tensioner blade and crankcase, to hold the camshaft drive chain taut during removal of the tensioner.

    6. warning

    The hydraulic tensioner is under spring tension. Always wear hand, eye, and face protection when withdrawing the tensioner mounting bolts and take great care to minimise the risk of injury and loss of components.

    note
    • Note the orientation of the hydraulic tensioner.
  6. Evenly release the hydraulic tensioner mounting bolts until the plunger spring tension has been released.
  7. Remove the hydraulic tensioner and discard the O-ring and gasket.

Camshaft Drive Chain Tensioner - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Check that the dot mark on the primary gear is still aligned with the line on the crankcase and the T3880601 - Camshaft Timing Pin is installed. Ensure the crankshaft cannot rotate.
  2. Ensure that the wedge fitted earlier is still holding the camshaft drive chain tensioner blade in contact with the camshaft drive chain.
  3. Check that the camshaft alignment marks point inwards.
  4. To set the hydraulic tensioner onto the first tooth of the ratchet (minimum extension) carry out the following:

    5. note
    • If installing a new hydraulic tensioner, do not release the plunger before fitting.
    • If installing the original hydraulic tensioner, the engine oil must be drained out of the tensioner to enable the plunger to be set onto the first tooth of the ratchet.
  5. Hold the resister ring ends together and pull out the plunger.

    1. Resister ring ends

    2. Plunger
  6. Remove the spring.

    1. Spring
  7. While holding the resister ring in place, pour out the engine oil into a suitable container.
  8. Ensure the resister ring is correctly located as shown in the illustration below.

    1. Resister ring
  9. Refit the spring.

    10. caution

    When resetting the tensioner, care must be taken to avoid activating the tensioner when there is no resistance on the plunger.

    Activating the tensioner when there is no resistance on the plunger may cause internal damage to the tensioner housing.

    It is recommended that the plunger is pushed into the tensioner housing in a controlled manner using a suitable soft jawed vice. Once the snap ring is located into it’s groove, the vice should be released slowly to ensure that the plunger is held in place.

  10. Hold the resister ends together and insert the plunger into the tensioner housing.
  11. Place the tensioner in a soft jawed vice.
  12. While holding the resister ends together, use the vice to push the plunger through the resister ring until the groove for the snap ring aligns with the snap ring.

    1. Resister ring

    2. Plunger

    3. Groove for snap ring

    4. Snap ring
  13. When the groove aligns with the snap ring, release the resister ring and move one end of the snap ring into the groove. Slowly release the vice to ensure that the plunger is held in place.

    1. Groove for snap ring

    2. Snap ring
  14. Fit a new O-ring and gasket to the hydraulic tensioner.
  15. Fit the tensioner to the cylinder head as noted for removal. Tighten the bolts to 9 Nm.
  16. Remove the wedge, taking care not to move or damage the tensioner blade.
  17. Remove the T3880601 - Camshaft Timing Pin.
  18. To release the hydraulic tensioner, rotate the crankshaft 1/4 of a turn anticlockwise using the bolt fitted to the end of the crankshaft. Then rotate the crankshaft clockwise two revolutions until the 'dot' mark on the primary gear aligns with the line on the crankcase.
  19. Check that there is tension in the camshaft drive chain and the timing marks at the camshaft sprockets are correctly aligned.

    20. note
    • After fitting to the engine, the hydraulic tensioner will be empty of engine oil. After starting the engine, the camshaft drive chain and tensioner blade will be noisy until full pressure is felt at the tensioner plunger. This could take up to 5 seconds.
  20. Check that the tensioner plunger is correctly located in the middle of the camshaft drive chain tensioner blade when viewed from above.
  21. Rotate the engine through 4 full revolutions, and reset number 1 cylinder to TDC. Ensure that the dot mark on the primary gear aligns with the line on the crankcase.

    1. Dot mark

    2. Marker line

    note
    • The alignment marks do not need to be perfectly in line to each other, they only need to be pointing to each other.
  22. Check that the camshaft timing marks point as illustrated below.

    23. Camshaft Alignment Marks
  23. Re-check the tensioner plunger location against the camshaft drive chain tensioner blade.
  24. Refit the camshaft cover (see Camshaft Cover - Installation).
  25. Fit a new gasket to the crankcase right hand cover.
  26. Fit the crankcase right hand cover and tighten its fixings to 10 Nm in the sequence shown below.
  27. Re-tighten the fixings one and two to 10 Nm.

    28. Crankcase Right Hand Cover Fixings Tightening Sequence

Camshaft Drive Chain Tensioner Blade - Disassembly

note
  • For the purpose of this instruction, the top of the tensioner blade is where the pad is located.
  1. Release the clips and remove the pad.

    1. Pad

    2. Clip (one side shown)
  2. Detach the top hook from the tensioner blade.

    1. Top hook

    2. Tensioner blade
  3. Release the three side locating devices.

    1. Locating devices

    2. Facing blade
  4. Release the three hooks and remove the facing blade.

    1. Hooks

Camshaft Drive Chain Tensioner Blade - Assembly

  1. Assembly is the reverse of disassembly.

Camshaft - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the seven fixings and remove the right hand crankcase cover. Discard the gasket.

    1. Fixings
  2. Remove the spark plugs to reduce compression resistance when turning the engine.

    3. note
    • The camshaft sprocket fixings need only be loosened sufficiently to allow the sprockets to rotate on the camshafts.
    • The camshaft sprocket fixings are patch locked and must never be reused if loosened or removed; however new fixings should only be installed during final tightening after the timing procedure has been completed.
    • If the sprockets are to be removed from the camshafts, temporarily refit the sprockets for timing adjustment using the old fixings, and only install new fixings during final tightening.
  3. Loosen the two camshaft sprocket fixings. Do not remove the fixings at this stage.

    1. Fixings

    note
    • While rotating the crankshaft, ensure that the front camshaft drive chain rubbing blade remains in its mounting.
  4. Rotate crankshaft until the remaining two fixings are accessible.

    5. caution

    Do not rotate the engine further once the four camshaft sprocket bolts have been loosened. Rotation of the engine with the four sprocket bolts loose will result in valve to piston contact and serious engine damage.

  5. Loosen the two remaining camshaft sprocket fixings. Do not remove the fixings at this stage.

    6. note
    • Note the orientation of the tensioner before removal.
  6. Evenly release the camshaft drive chain tensioner mounting bolts until the plunger spring tension has been released.
  7. Remove the tensioner and discard the O-ring and gasket.
  8. Note the orientation of the camshaft ladder in relation to the head.
  9. Progressively release the bolts securing the camshaft ladder to the head in the sequence shown below.

    10. Camshaft Ladder Bolt Release Sequence
  10. Remove the camshaft ladder and top pad, and collect the dowels (if loose) and spark plug tower O-rings.

    11. note
    • Each camshaft and sprocket is removed as an assembly.
  11. Lift the camshaft drive chain from the inlet camshaft sprocket and remove the inlet camshaft.
  12. Lift the camshaft drive chain from the exhaust camshaft sprocket and remove the exhaust camshaft.

    1. Camshaft drive chain

    2. Inlet camshaft
  13. For the removal of the camshaft drive chain (see Camshaft Drive Chain - Removal).
  14. Rotate the crankshaft clockwise (the normal direction of rotation), using the bolt fitted to the end of the crankshaft. Stop rotation when number 1 cylinder is at Top Dead Centre (TDC), that is when the dot mark on the primary gear aligns with the line on the crankcase.

    15. note
    • Before inserting the timing pin, ensure the dot on the primary gear is aligned with the line on the crankcase.
  15. Insert the T3880601 - Camshaft Timing Pin into the timing holes in the crankcase and crankshaft.

    1. Dot mark

    2. Marker line

    3. T3880601 - Camshaft Timing Pin

    4. Timing hole in crankcase
  16. At this stage the camshafts and sprockets can be separated if required.

Camshaft and Sprocket Identification

note
  • The inlet and exhaust camshafts are different. They can be identified by a raised feature in the centre of the exhaust camshaft, which is machined off on the inlet camshaft. The camshafts can be further identified by a letter I for inlet or E for exhaust stamped on the end of the sprocket boss.

  1. Inlet camshaft

  2. Machined section

  3. Exhaust camshaft

  4. Raised section

caution

Never fit a camshaft sprocket to a camshaft using incorrectly identified bolt holes. Severe engine damage will result from incorrect attachment.

The same sprocket is used for both inlet and exhaust camshafts, and is attached to the camshaft using slotted bolt holes. The same holes are used when fitting the sprocket to either camshaft.

Note that the mark on the camshaft boss is not a timing mark, it is used as a visual aid during the timing adjustment procedure.

Accurate camshaft timing can only be obtained using the correct timing method and service tools as described on Camshaft - Installation and Timing in this chapter.

Camshaft and Bearing Cap Inspection

  1. Inspect the camshaft sprockets for damaged and worn teeth. Replace as necessary.
  2. Measure the camshaft journals with a micrometer. If any journal is outside the specified tolerance, replace the camshaft. For specifications refer toCamshafts.

    1. Camshaft journal
  3. Examine all camshaft and camshaft bearing caps for excessive wear and damage.
  4. Check the journal-to-head clearances, using Plastigauge (Triumph part number 3880150-T0301) as follows:

    5. Measuring the Compressed Plastigauge

    note
    • The camshaft ladder is unique to each cylinder head and is, therefore, not available separately. If the camshaft ladder is worn or damaged, the complete cylinder head must be replaced.
  5. Calculate the journal clearance using the Plastigauge chart supplied with the Plastigauge kit.
  6. For specifications refer toCamshafts.
  7. If the clearance measured is within the specified tolerance, remove the cap/ladder and clean off all traces of Plastigauge. Assemble the camshafts (see Camshaft - Installation and Timing).

    8. caution

    Although Plastigauge is oil soluble, all traces of the material must be removed to prevent blockage of the oil drillings and resultant engine damage.

Camshaft - Installation and Timing

caution

The camshaft sprockets are attached to the camshafts using slotted bolt holes. This allows for very accurate valve timing and therefore improved performance and fuel economy.

Never fit the camshaft sprockets without correctly setting the camshaft timing using the service tools and timing procedure described below. Severe engine damage will result from incorrect valve timing adjustment.

  1. Check that the dot mark on the primary gear is still aligned with the line on the crankcase and the T3880601 - Camshaft Timing Pin is installed. Ensure the crankshaft cannot rotate.
  2. Thoroughly clean the camshafts and journals. Inspect the ends of the camshafts for correct fitment of the sealing plugs. Lubricate the camshafts with clean engine oil before fitting to the head.
  3. If removed, refit the camshaft sprockets noting their orientation, and secure using the original bolts. DO NOT tighten the fixings at this stage; the sprockets must be free to rotate.
  4. Refit the camshaft drive chain and, if removed, the tensioner blade and rubbing strip (see Camshaft Drive Chain - Installation).

    5. note
    • Locate each camshaft to the head ensuring the camshafts are correctly identified (inlet and exhaust) and are also correctly located over their respective valve banks.
  5. Refit the exhaust camshaft to the cylinder head, hooking the camshaft drive chain over the sprocket as you do so.
  6. Ensure there is no slack between the crankshaft and exhaust sprocket when the sprocket fixings are centrally located within the slotted holes. Ensure alignment marks on the end of the camshaft journals are pointing inwards.
  7. Refit the inlet camshaft to the cylinder head, hooking the chain over the sprocket as you do so.
  8. Ensure the fixings on the inlet sprocket are also centrally located within the slotted holes when there is no slack between the exhaust and inlet sprockets. Ensure alignment marks on the end of the camshaft journals are pointing inwards.
  9. Check that the chain is correctly located around the crankshaft, and both camshaft sprockets.
  10. Rotate the camshafts until the alignment marks on the end of the camshaft journals are pointing inwards.

    11. Camshaft Alignment Marks

    caution

    The T3880640 - Camshaft Timing Plate must be located centrally between the camshafts. Incorrect positioning of the tool may prevent the camshaft ladder locating correctly to the cylinder head during fixing tightening, resulting in incorrect valve timing being set. Severe engine damage will result from incorrect valve timing adjustment.

  11. Insert the T3880640 - Camshaft Timing Plate into the camshaft slots, ensuring the removal screw is unscrewed fully, as shown below.Ensure that the tool is centrally located between the camshafts.

    1. T3880640 - Camshaft Timing Plate

    2. Camshaft slots

    3. Removal screw
  12. Assemble the dowels, spark plug tower O-rings, camshaft ladder and top pad in the same location and orientation as prior to removal.

    13. note
    • The bolts for the camshaft cap ladder are tightened in two stages.

Stage 1

  1. Fit and evenly tighten the fixings to 5 Nm, in the sequence shown below.

    2. Camshaft Cover Fixings Tightening Sequence

Stage 2

  1. In the sequence shown above, tighten the bolts to 10 Nm.
  2. Fit the T3880607 - Camshaft Timing Tensioner using the original fixings and tighten to 9 Nm.

    1. T3880607 - Camshaft Timing Tensioner

    caution

    The torque value stated is very important to accurate timing. Always use the correct value of 0.6 Nm, as set using the T3880609 - Timing Torque Limiter. Using an incorrect torque value will result in incorrect valve timing being set, or damage to the tensioner blade or other valve train components. Either condition may result in serious damage to the engine, reduced engine performance, or reduced fuel economy.

  3. Using the T3880609 - Timing Torque Limiter and a 6 mm Ball Ended Allen Key, tighten the T3880607 - Camshaft Timing Tensioner to 0.6 Nm preset by the T3880609 - Timing Torque Limiter.

    1. T3880607 - Camshaft Timing Tensioner

    2. T3880609 - Timing Torque Limiter

    3. 6 mm Ball Ended Allen Key
  4. Remove and discard the two accessible (uppermost) camshaft sprocket fixings, and replace with new fixings. Tighten to 16 Nm.

    1. Uppermost fixings
  5. Remove the T3880601 - Camshaft Timing Pin by rotating the removal screw clockwise as shown below.

    1. T3880640 - Camshaft Timing Plate

    2. Removal screw
  6. Remove the T3880601 - Camshaft Timing Pin.

    7. caution

    Always check that the T3880640 - Camshaft Timing Plate has been removed before rotating the engine. Severe damage will result to the camshafts or T3880640 - Camshaft Timing Plate if engine rotation is attempted with the tool installed.

  7. Rotate the engine until the remaining two sprocket fixings are accessible.
  8. Remove and discard the two remaining camshaft sprocket fixings, and replace with new fixings. Tighten to 16 Nm.
  9. Place a suitable wedge between the camshaft drive chain tensioner blade and crankcase, to hold the camshaft drive chain taut during removal of the T3880607 - Camshaft Timing Tensioner.
  10. Release the tension on Camshaft Timing Tensioner T3880607 and remove it.
  11. Refit the timing chain tensioner, incorporating a new gasket and O-ring (see Camshaft Drive Chain Tensioner - Installation).
  12. Rotate the crankshaft clockwise 2 complete turns, using the bolt fitted to the end of the crankshaft. Stop rotation when number 1 cylinder is at Top Dead Centre (TDC), that is when the dot mark on the primary gear aligns with the line on the crankcase.

    13. note
    • Before inserting the timing pin, ensure the 'dot' on the primary gear is aligned with the line on the crankcase.
  13. Insert the T3880601 - Camshaft Timing Pin into the timing holes in the crankcase and crankshaft.

    1. Dot mark

    2. Marker line

    3. T3880601 - Camshaft Timing Pin

    4. Timing hole in crankcase
  14. Check that the timing marks are still approximately aligned (to check that the camshaft timing has not moved during T3880607 - Camshaft Timing Tensioner removal).
  15. Remove the T3880601 - Camshaft Timing Pin.
  16. Check the valve clearances. Adjust as necessary (see Valve Clearance Measurement).
  17. Fit the crankcase cover and tighten its bolts to .
  18. Refit the camshaft cover (see Camshaft Cover - Installation).
  19. Fit the crankcase right hand cover and tighten its fixings to 10 Nm in the sequence shown below.
  20. Re-tighten the fixings one and two to 10 Nm.

    21. Crankcase Right Hand Cover Fixings Tightening Sequence

Valve Clearance Measurement

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • Valve clearance measurement must be carried out with the engine cold.
  • When replacing a valve shim, always refer to the EPC.
  • For valve clearance specifications (see Cylinder Head).
  1. Remove the camshaft cover (see Camshaft Cover - Removal).
  2. Remove the spark plugs to reduce compression resistance when turning the engine.
  3. Select a high gear and, using the rear wheel, turn the engine until a pair of camshaft lobes are positioned pointing away from the valves.
  4. Using feeler gauges, measure and record the clearances for this pair of valves only.
  5. Repeat the process until the valve clearances for all valves have been checked.

    6. note
    • If the measurement does not fall within the specified range, adjustment must be made.

    caution

    If the valve clearances are not checked and corrected, wear could cause the valves to remain partly open, which lowers performance, burns the valves and valve seats and may cause serious engine damage.

  6. Record the measured valve clearances on a chart similar to the example shown.

Typical Valve Clearance Chart

Inlet Valve No.

Gap Measured

1

as measured (mm)

2

as measured (mm)

3

as measured (mm)

4

as measured (mm)

5

as measured (mm)

6

as measured (mm)

Exhaust Valve No.

Gap Measured

1

as measured (mm)

2

as measured (mm)

3

as measured (mm)

4

as measured (mm)

5

as measured (mm)

6

as measured (mm)

Valve Clearance Adjustment

note
  • To adjust the valve clearances the camshafts must be removed. Follow the camshaft removal procedure.
  1. Remove the camshafts (see Camshaft - Removal).
  2. Remove the tappet bucket from the cylinder head.
  3. Remove the shim from the valve head.

    1. Tappet bucket

    2. Shim

    note
    • The shim may withdraw with the tappet bucket.
  4. Measure the original shim, using a micrometer and select the appropriate new shim as required.

    5. note
    • Shims are available ranging from 1.70 mm to 3.00 mm in increments of 0.025 mm.
  5. Fit the new shim to the valve head.
  6. Lubricate the tappet bucket(s) with a 50/50 solution of engine oil and molybdenum disulphide grease.
  7. Refit the tappet bucket.
  8. Refit the camshafts (see Camshaft - Installation and Timing).
  9. Re-check all valve clearances.
  10. Repeat the procedure if the valves require further adjustment.
  11. Fit the camshaft cover (see Camshaft Cover - Installation).

Camshaft Drive Chain - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Remove the bolt from the centre of the camshaft drive chain housing in the cylinder head.

    1. Centre bolt
  2. Raise the front camshaft drive chain rubbing blade and detach the camshaft drive chain from the crankshaft gear.
  3. The camshaft drive chain is removed from inside the head-space.

Camshaft Drive Chain - Inspection

Visual in-situ checks can also be made as follows:

  1. Check for significant blue discolouration of the drive chain plates indicating excessive heat build-up.
  2. Examine all pins for signs of rotation.
  3. Check for cracking or deep scratching of the drive chain plates.
  4. Check for severe wear of the inner plates as indicated in the diagram below.

For a more thorough check, proceed as follows:

  1. Remove the drive chain from the engine.
  2. Suspend the drive chain from a pin or hook with a 13 kg weight attached at the lower end.
  3. Measure across 23 links as shown in the diagram below. If the drive chain is within limits, the measurement should be no longer than 149.48 mm. Measurements beyond 149.48 mm indicate that the drive chain must be replaced.
  4. Check for severe wear of the inner surface of the outer plates at the side-contact points with the sprocket teeth.
  5. Check for signs of stiffness or kinking.
  6. Check for severe wear of the plates in the area shown below.
  7. If any of these symptoms are evident, the camshaft drive chain must be replaced.

Camshaft Drive Chain - Installation

  1. Fit the camshaft drive chain and locate the lower end around the crankshaft gear.
  2. Incorporating a new seal, refit the bolt to the centre of the camshaft drive chain housing in the cylinder head, tightening to 12 Nm.

Perform the following operations:

Cylinder Head - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • Removal of the cylinder head is not possible with the engine in the frame.

Perform the following operations:

  1. Remove the camshaft drive chain tensioner blades.
  2. Note the position of all tappet buckets and shims such that they can be refitted in the same positions. Remove all the tappet buckets and shims.

    1. Tappet bucket

    2. Shim

    note
    • To prevent the tappet buckets and shims from becoming mixed, place the shim and tappet together in a marked container. The components must be refitted in their original positions.
  3. Disconnect the coolant bypass hose from the rear of the cylinder head.
  4. Release the screws securing the outside of the cylinder head to the upper crankcase.

    1. Cylinder head to upper crankcase screws
  5. Progressively release the cylinder head nuts in the order shown below.

    6. Cylinder Head Release Sequence
  6. Lightly tap the cylinder head with a rubber mallet to break the seal of the gasket.

    7. note
    • Retain two of the cylinder head nuts for the installation of the barrel.
  7. Remove the cylinder head. Discard the cylinder head gasket and the nuts and washers.

    8. caution

    The gasket between the barrel and the crankcase must also be replaced if the cylinder head has been removed.

    Failure to replace the gasket may result in an engine oil leak between the barrel and crankcase.

  8. Remove the barrel (see Barrels - Removal) and discard the gasket.

Cylinder Head - Inspection

  1. Thoroughly clean the surface of the cylinder head and check for damage and/or pitting of the combustion chambers.
  2. Using a straight edge and feeler gauges, check the cylinder head face for warp, which could lead to gasket failure. Replace the cylinder head if warped beyond the flatness limit.

    1. Cylinder head

    2. Straight edge
  3. For specifications refer toCylinder Head.
  4. Inspect the valve guides for damage or wear.
  5. If a valve guide is found to be worn beyond the service limit, the complete cylinder head must be renewed.
  6. For specifications refer toCylinder Head.
  7. Check the camshaft drive chain rubbing blades. Renew if worn or damaged.

caution

Ensure all traces of fluid (coolant, oil etc.) are removed from the threaded holes in the crankcase. Should any fluid remain in any of the threaded holes, severe crankcase damage could result from hydraulic locking of head bolts on assembly of the engine.

Cylinder Head - Installation

  1. Fit a new gasket to the barrel and refit it to the crankcase (see Barrels - Installation).
  2. Thoroughly clean the upper faces of the barrel, taking care not to damage the mating surfaces.
  3. Fit a new cylinder head gasket ensuring that the head to crankcase location dowels are correctly in place.

    1. Cylinder head gasket
  4. Ensure that the cylinder head face is completely clean.
  5. Carefully lower the cylinder head over the camshaft drive chain and locate the head onto the dowels.

    6. caution

    Using the correct procedure to fit and tighten the cylinder head nuts will ensure the long term reliability of the cylinder head gasket.

    Clean each stud, paying particular attention to the threads. If any of the threads are damaged, replace the stud(s).

    Lubricate the threads at the upper end of the studs with engine oil, and then wipe clean with a lint-free cloth leaving minimal oil on the threads (that is, almost dry to touch).

    Tighten the nuts using the three-stage procedure given below.

    Failure to observe these important items may lead to engine damage through a damaged head gasket.

    note
    • New cylinder head nuts and washers must be fitted.
  6. Lubricate the threads on the studs and the top surface of the hardened washer with clean engine oil.
  7. Fit new nuts and washers to the cylinder head and tighten until finger tight.
  8. The cylinder head nuts are tightened in three stages, in the sequence shown below. This is to ensure that the cylinder head gasket seals correctly to the head and barrel.

    9. note
    • For stages one and two of the cylinder head tightening operation, a torque wrench of known, accurate calibration must be used.
    • For stage 3 of the cylinder head tightening operation, the nuts must be turned through a set number of degrees to reach the final setting. To accurately gauge the turn, T3880105 - Torque Angle Gauge must be used.

Stage 1

Cylinder Head Tightening Sequence

Stage 2

Stage 3

Fit the T3880105 - Torque Angle Gauge between the Torx socket and the drive handle and locate the Torx drive to the nut. Pick an increment point on the torque turn gauge which aligns with a suitable reference point on the head.

  1. Fit the screws securing the side of the cylinder head to the crankcase and tighten to 10 Nm.

    2. Cylinder head to upper crankcase screws
  2. Install the camshaft drive chain tensioner blades.
  3. Clean and lubricate the tappet buckets with a 50/50 solution of engine oil and molybdenum disulphide grease and refit the buckets and shims in the same locations from which they were removed.

Perform the following operations:

Valves and Valve Stem Seals - Removal

  1. Remove each valve from the head using a valve spring compressor. The compressor must act on the valve spring retainer to allow removal of the valve collets.

    2. Valve removal
  2. Once the collets are released, remove the following items:

    1. Valve stem seal

    note
    • Ensure the inlet and exhaust valve components do not become mixed.

    1. Collets

    2. Valve spring retainer

    3. Valve spring

    4. Valve spring base

    5. Valve stem oil seal

    6. Valve

Valves and Valve Stem Seals - Installation

  1. Lubricate the valve stems with new engine oil which meets specification API SH (or higher) and JASO MA.
  2. Install the valve into the valve guide and refit the spring base to the valve spring recess in the head.
  3. Fit the valve stem seal over the valve stem and, using a suitable tool, press down fully until the seal is correctly seated over the valve guide.

    4. note
    • During fitment of the valve stem seal, two distinctly different degrees of resistance will be noted when the seal is correctly fitted.
    • Firstly, press the seal down the valve stem until the lower side of the seal comes into contact with the valve guide. Greater resistance is felt at this contact point and further gentle pressure is then required to locate the seal over the top end of the valve guide.
    • On application of this pressure, the seal can be felt to positively locate over the top face of the valve guide. Once correctly positioned, the seal cannot be pushed down any further.

    caution

    Incorrect fitment of the valve stem oil seals could lead to high oil consumption and blue smoke emissions from the exhaust system. Do not use excessive force in fitting the seal as this may break the seal ring.

  4. Install the valve spring over the valve stem. Ensure the close wound, colour coded ends of the springs are fitted downwards (towards the piston).
  5. Fit the valve spring retainer.
  6. Compress the valve spring ensuring that the spring is compressed squarely to prevent damage to the valve stem and cylinder head.
  7. Fit the valve collets ensuring correct collet location in the spring retainer and valve as the spring compressor is released.

    8. caution

    Always check for correct location of the valve collets during and after assembly. If not fitted correctly, the collets may become dislodged when the engine is running allowing the valves to contact the pistons. Any such valve to piston contact will cause severe engine damage.

Barrels and Pistons

Exploded View - Barrel and Pistons

Barrels - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Clean the area around the barrel base gasket joint to prevent dirt falling into the crankcase when the barrels are removed.

    2. note
    • Note the position of the piston alignment mark on the pistons for installation.

    1. Piston alignment mark

    2. Barrel

    caution

    Support the pistons as the barrels are removed to prevent piston damage.
  2. Mark each piston and cylinder bore with a number to ensure the pistons are fitted into their original cylinders on installation..
  3. Carefully remove the barrel. Take care to ensure that the piston/connecting rod is not allowed to fall against the inside of the crankcase.
  4. Discard the gasket.

Barrels - Inspection

  1. Measure the diameter of each cylinder bore using an internal micrometer or similar accurate measuring equipment.

    2. Cylinder Bore Diameter Measurement Points
  2. Measure the inside diameter 10 mm from the top of the bore as shown above.
  3. If the reading is outside the specified limits, replace the barrel and pistons as an assembly.
  4. When measuring the cylinder barrels internal diameter always refer to the specification table (see Pistons).

Barrels - Installation

  1. Thoroughly clean the mating surfaces of the crankcase and barrels taking care not to damage the mating surfaces.

    2. note
    • To ensure the piston rings do not get damaged, the piston/connecting rod assemblies must be fitted into the barrel before fitting the barrel to the engine.
    • Damaged piston rings may result in engine failure.
  2. Remove the piston and connecting rod assemblies from the engine (see Connecting Rods - Removal).
  3. Fit the three piston and connecting rod assemblies into the barrel from the bottom as noted for removal. Ensure that the piston alignment mark on the piston faces forward.
  4. Invert the engine and fit a new base gasket and refit the locating dowels as noted during removal.

    5. note
    • While fitting the barrel and pistons assembly, ensure that the connecting rods do not contact and damage any of the three oil jets on the crankcase.
    • A damaged oil jet will reduce the amount of oil delivered to the underside of the piston which may result in severe engine damage.

    caution

    Do not allow the full weight of the barrels to rest unsupported on the pistons. Failure to support the barrels is likely to result in piston ring breakage.

    caution

    Do not force the pistons into their bores. The base of each bore is chamfered to ease installation and excess force should not be needed. If either piston jams, lift the barrels slightly and check the rings are correctly located into their grooves before continuing. The use of force is likely to result in piston ring breakage.

  5. With the aid of an assistant, carefully fit the barrel to the crankcase ensuring that:

    1. Connecting rods

    2. Oil jets
  6. To hold the barrel in position, fit the T3880308 - Cylinder Barrel Clamps to two of the cylinder head studs and secure using two of the original retaining nuts for the cylinder head.
  7. Invert the engine and connect the connecting rods to the crankshaft (see Connecting Rods - Installation).
  8. Assemble the crankcase halves (see Crankcases - Assembly).
  9. Invert the engine, remove the two cylinder head nuts and the T3880308 - Cylinder Barrel Clamps. Discard the two nuts.

Perform the following operations:

Piston - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Remove and discard the gudgeon pin circlip from one side of the piston.

    2. caution

    If a circlip is dropped into the crankcase, it must be recovered before the crankshaft is rotated. Failure to do so will result in serious engine damage.

    Removing the Gudgeon Pin Circlip
  2. Remove the gudgeon pin by pushing the pin through the piston and connecting rod toward the side from which the circlip was removed.

    3. caution

    Never force the gudgeon pin through the piston. This may cause damage to the piston which may also damage the cylinder barrel when assembled.

    note
    • If the gudgeon pin is found to be tight in the piston, check the piston for a witness mark caused by the circlip. Carefully remove the mark to allow the pin to be removed.
  3. Remove the remaining circlip from the piston and discard it.

    4. note
    • The rings may be removed using a proprietary piston ring expander tool or, if a tool is not available, carefully spread the ring opening using thumb pressure then push up on the opposite side of the ring to remove it from the piston.
  4. Remove the piston rings.

    5. note
    • If the piston rings are to be reused, note the orientation of the oil control rings prior to removal.

Piston - Wear Check

  1. Remove any carbon build-up from the piston crown. Inspect the piston crown for signs of pitting and check the piston skirt and ring grooves for signs of wear or scuffing. If any sign of damage is found, renew the piston.
  2. Measure the piston outside diameter 9 mm from the bottom of the piston and at 90° to the direction of the gudgeon pin.

    1. Piston outside diameter

    2. Measurement point

    3. Gudgeon pin
  3. Always refer to the specifications table (see Pistons).
  4. Replace the piston and rings if outside the specified limit.

Piston Ring to Groove - Clearance

note
  • Prior to removing the rings, check the ring-to- groove clearance of each compression ring.
  1. With the piston rings correctly installed on the piston, check the ring-to-groove clearance of each compression ring, using a feeler gauge.

    2. Piston Ring-to-Groove Clearance Check
  2. When checking the piston ring to groove clearance, always refer to the specifications table (see Pistons).

    3. note
    • If the ring-to-groove clearance is too large, replace the piston rings with a new set.
    • If the gap remains too large with new piston rings, the piston must also be replaced.
    • If the gap is too small, check the piston ring grooves closely for distortion, replacing the piston as necessary. Do not file the ring grooves.

Piston Rings - Removal

    caution

    Do not expand the piston rings any more than is necessary to allow them to be removed from the piston. The rings are brittle and will break if expanded too much.

    note
    • The top and second compression rings are different and are not interchangeable (see Piston - Assembly).
    • Piston rings must be removed from the piston using hand pressure only. Do not overextend the piston rings during removal.
    • If the piston rings are to be reused, note the orientation of the oil control rings prior to removal.
    • If the piston rings are to be re-used, keep them with their respective piston to ensure they are refitted in their original locations.
  1. Ease the top compression ring out of its groove and remove it from the top of the piston.
  2. Remove the second compression ring in the same way.
  3. Remove the oil control rings and expanders.

Piston Ring - End Gap

  1. Check each piston ring end gap as follows.

    2. note
    • The piston ring end gap must be measured in the cylinder bore to which the piston ring will be fitted to on installation.
    • Ensure all piston rings are fitted in their original locations (if original rings are being reused) or to the piston/bore which the end gaps were checked (if new rings are being installed).

    Checking Piston Ring End Gap
  2. When checking the piston ring end gap, always refer to the specifications table (see Pistons).

    3. note
    • If the end gap is too large, replace the piston rings with a new set.
    • If the gap remains too large with new piston rings, both the pistons and barrels must be replaced.
    • If the gap is too small, check the cylinder bore for distortion, replacing as necessary.
    • Do not file the piston rings.
  3. Repeat the procedure for the remaining piston rings.

Piston - Assembly

  1. Ensure the piston ring grooves are clean.

    2. note
    • Ensure all piston rings are fitted in their original locations (if original rings are being reused) or to the piston/bore which the end gaps were checked (if new rings are being fitted).

    caution

    Do not expand the piston rings any more than is necessary to allow them to be installed on the piston. The rings are brittle and will break if expanded too much.

  2. Fit the oil control ring expander to the piston then install the upper and lower control rings (the oil control rings are both the same and can be fitted either way up).

    3. note
    • Ensure the second and top compression rings are correctly installed.
    • The second and top compression rings are different and are not interchangeable.
  3. Fit the second compression ring carefully to the piston, ensuring its 2T mark is facing upwards.
  4. Fit the top compression ring to the piston ensuring its 1T mark is facing upwards.

    5. Piston Ring Identification
  5. Ensure all piston rings move freely in their grooves.
  6. Fit the piston onto the connecting rod.

    7. note
    • connecting rods may be fitted either way round. However, ensure all three are fitted the same way.
  7. Lubricate the piston, small end and gudgeon pin with a 50/50 solution of engine oil and molybdenum disulphide grease.
  8. Align the small end in the connecting rod with the gudgeon pin hole in the piston and fit the gudgeon pin.
  9. Fit new circlips on both sides of the gudgeon pin ensuring the circlips are correctly fitted in the grooves.

    10. warning

    Failure to use new gudgeon pin circlips could allow the pin to detach from the piston. This could seize the engine leading to loss of motorcycle control and an accident.

  10. Position the piston ring end gaps as follows (piston viewed from above, triangular mark facing forwards).

    11. Piston Ring End Gap Locations

    1. Top ring

    2. Second ring

    3. First steel oil control ring

    4. Oil control ring expander

    5. Second steel oil control ring

    note
    • The top compression ring gap should be in the 12 o'clock position.
    • The second compression ring gap should be in the 6 o'clock position.
    • The first oil control ring gap should be in the 12 o'clock position.
    • The second oil control ring gap should be in the 6 o'clock position.
    • The oil control ring expander gap should be in the 7 o'clock position.
  11. Fit the piston and connecting rods to the barrel then to the crankcase (see Barrels - Installation).

Clutch

Exploded View - Clutch Controls

Exploded View - Clutch Assembly

Clutch Cable - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the routing of the clutch cable and the position of the retaining clips/grommets for installation.
  1. Detach the clutch cable retaining clip from its bracket.
  2. Loosen the cable lock nut and release the adjuster at the clutch cover end to give maximum play in the cable.

    1. Clutch cable

    2. Adjuster

    3. Clip

    4. Bracket
  3. Release the clutch cable from the actuating arm by pushing the inner cable nipple through the arm and sliding the cable out of the slot. Detach the cable from the bracket.

    1. Actuating arm

    2. Inner cable nipple
  4. Align the cable adjuster and lever bracket slots.
  5. Pull in the clutch lever and turn the inner cable, anticlockwise through the slots in the adjuster and lock nut, until the cable can be detached from the lever by pushing downwards.

    1. Cable adjuster/lever bracket slots

    2. Cable release point
  6. Detach the clutch cable retaining clip from the top of the radiator.

    1. Hose clip

    2. Bypass hose

    3. Retaining clip

    4. Clutch cable
  7. Remove and discard one of the fixings for the headstock cable guide and remove the clutch cable.

    1. Fixings

    2. Cable guide

    3. Clutch cable

Clutch Cable - Inspection

  1. Check the inner cable for free movement through the outer cable.
  2. Examine the inner cable for frayed strands.
  3. Examine the two inner cable nipples for signs of looseness and damage. Replace the cable if necessary.

Clutch Cable - Installation

  1. Position the cable to the motorcycle using the same routing as noted during removal.
  2. Attach the inner cable to the clutch lever and actuating arm using a reversal of the removal process.
  3. Refit the outer cable to the adjuster bracket at the clutch end.
  4. Attach the clutch cable retaining clip to its bracket.
  5. Secure the clutch cable retaining clip to the top of the radiator.
  6. Route the clutch cable behind the headstock cable guide. Secure the cable guide with a new fixing and tighten to 13 Nm.

    7. note
    • Ensure that the two adjuster nuts are positioned one either side of the bracket.
  7. Set the lever adjuster to a point where an equal adjustment is possible in both directions.
  8. Set the adjuster at the clutch end to give a preliminary setting of 2 - 3 mm of free play as measured at the lever. Tighten the lock nut.
  9. Operate the clutch lever several times and recheck the amount of free play present.
  10. Set the final adjustment of the cable to give 2 - 3 mm of free play at the lever by turning the adjuster nut and lock nut at the lever end.

    1. Clutch lever

    2. Correct setting, 2 - 3 mm

Perform the following operations:

Clutch - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note that the stopper plate has an OUT mark. This must face outwards when fitted.
    • There are spring seats located in the pressure plate. Ensure the seats are in the pressure plate prior to fitting the springs.
  1. Release the 3 bolts, remove the stopper plate, springs, pressure plate and spring seats.

    1. Bolts

    2. Stopper plate

    3. Springs

    4. Spring seats

    5. Pressure Plate
  2. Remove the clutch pull-rod.

    1. Clutch pull-rod

    2. Clutch pressure plate
  3. Remove the clutch friction plates and steel plates together with the anti-judder spring and anti-judder seat washer.

    4. note
    • Record the orientation of all components as they are removed. The plates must be assembled in the same order.

    note
    • The inner and the two outermost friction plates are different to the other friction plates. They must be fitted in their noted positions.
    • The outer steel plate is different to the other plates. It must be fitted in its noted position.

    1. Outer friction plate

    2. Steel plate

    3. Anti-judder spring

    4. Anti-judder seat washer

    5. Clutch inner drum

    note
    • Store all plates in their correct fitted order to avoid confusion on installation.
    • Refer to the following page of this section for details of clutch friction plate checking.
    • It is not normally necessary to disassemble the clutch further, but if the clutch inner and outer drums are to be removed, proceed as follows:
  4. Engage second gear and lock the inner and outer clutch drums together using T3880307 - Clutch Anti-rotation Jig.

    1. T3880307 - Clutch Anti-rotation Jig
  5. Depress the rear brake pedal to prevent the engine from turning, then release the clutch centre nut.
  6. Remove the centre nut, Belleville washer, flat washer, clutch inner drum and thrust washer. Discard the nut and Belleville washer.

    1. Centre nut

    2. Belleville washer

    3. Flat washer

    4. Inner drum

    5. Thrust washer
  7. Slide the clutch outer drum assembly gently backwards and forwards to dislodge the inner bearing sleeve. Carefully remove the bearing sleeve while supporting the clutch outer drum.

    1. Outer drum

    2. Bearing sleeve
  8. Remove the clutch outer drum leaving the oil pump drive sprocket, bearing and sleeve in place on the input shaft.

Friction Plate Inspection

Thickness

    note
    • If any friction plate thickness is outside the service limit, replace the friction plates as a set.
  1. Measure the thickness of the friction plate.

    1. Clutch friction plate
  2. For the clutch friction plate thickness, refer to Clutch and Primary Drive.

Steel Plate Inspection

Bend/warp

Check all plates for bend and warp as follows:

  1. Place the plate being checked on a clean surface plate and attempt to pass a feeler gauge of the maximum service limit thickness between the steel plate and surface plate. If the feeler gauge can be passed beneath the steel plate at any point, renew the plates as a set.

    1. Steel plate

    2. Feeler gauge

    3. Surface plate
  2. For specifications refer toClutch and Primary Drive.

Clutch Pack Height

The clutch pack height should only be measured if the friction plates and the steel plates have been replaced.

The clutch pack height is critical for a smooth operation of the gear change and needs to be measured prior to installation.

If used steel plates are being fitted, the clutch pack height measurement is not necessary, as the plates may not be worn to the service limit (and are therefore still serviceable), but could fall outside the clutch pack height tolerance when measured.

If building a new clutch pack, its height must be correct. To achieve this, build the new clutch pack with the following:

Friction plate and steel plate arrangement

  1. Arrange the new friction and new steel plates in a stack as shown below.

    1. Outer friction plates

    2. Friction plates

    3. Inner friction plate

    4. Steel plate, 2.0 mm thickness

    5. Outer steel plate, 2.0 mm thickness
  2. Place the assembled clutch pack on a flat surface and measure its height as shown below.

    1. Clutch pack height
  3. For the correct clutch pack height for this clutch assembly see Clutch and Primary Drive.
  4. If the clutch pack is too high, continue from step 5, omit step 6 then continue from step 7.If the clutch pack is too low, continue from step 6.

    5. note
    • 1.6 mm and 2.3 mm steel plates are available, refer to the Parts Catalogue for part numbers.
    • No more than one 1.6 mm thick steel plate is to be used in the clutch pack.
  5. If the clutch pack height is too high, replace the 2.0 mm steel plate indicated below with a new 1.6 mm steel plate.

    1. 2.0 mm steel plate to be replaced

    note
    • No more than one 2.3 mm thick steel plate is to be used in the clutch pack.
  6. If the clutch pack height is too low, replace the 2.0 mm steel plate indicated below with a new 2.3 mm steel plate.

    1. 2.0 mm steel plate to be replaced
  7. Re-check the clutch pack height as described earlier.

Clutch - Installation

  1. To fully engage the outer drum, insert a suitable tool to preload and align the primary gear and backlash eliminator gear through the hole shown in the illustration below.

    1. Alignment hole

    2. Outer drum
  2. Position the clutch outer drum assembly to the input shaft and align the oil pump drive pegs with the corresponding holes in the rear of the clutch outer drum.

    1. Clutch outer drum

    2. Oil pump sprocket drive pegs

    3. Oil pump drive holes
  3. While holding the clutch outer drum in position and ensuring correct engagement with the oil pump drive, refit the bearing sleeve and bearing.

    1. Outer drum

    2. Bearing sleeve

    note
    • When the bearing sleeve is correctly fitted, it will be a flush fit with the clutch drum face.
  4. Fit the thrust washer to the shaft.
  5. Fit the clutch inner drum.
  6. Fit the flat washer, a new Belleville washer (OUT mark facing outwards), and fit a new centre nut.

    1. Centre nut

    2. Belleville washer

    3. Flat washer

    4. Inner drum

    5. Thrust washer
  7. Lock the inner and outer drums together using T3880307 - Clutch Anti-rotation Jig. Depress the rear brake pedal to prevent the engine turning, and tighten the centre nut to 98 Nm. Remove the clutch anti-rotation tool.

    1. T3880307 - Clutch Anti-rotation Jig
  8. Disengage second gear and check for free rotation of the clutch inner drum.
  9. Using a suitable pin punch, stake the nut to the shaft.
  10. Coat all clutch friction plates in clean engine oil before fitting the friction plates, steel plates, anti-judder spring and anti-judder seat washer to the clutch basket in the same order and orientation as noted during removal.

    11. note
    • The inner and the two outermost friction plates are different to the other friction plates. They must be fitted in their noted positions.
    • The outer steel plate is different to the other plates. It must be fitted in its noted position.

    1. Outer friction plate

    2. Steel plate

    3. Anti-judder spring

    4. Anti-judder seat washer

    5. Clutch inner drum
  11. Refit the clutch pull-rod.
  12. Fit the pressure plate. Ensure that the spring seats are fitted into the pressure plate as noted for removal.
  13. Fit the springs and stopper plate, ensure that the OUT mark on the stopper plate is facing outwards. Secure with the bolts and tighten to 10 Nm.

    1. Bolts

    2. Stopper plate

    3. Springs

    4. Spring seats

    5. Pressure plate

    note
    • The pull-rod should be free to move in and out and also it should be free to turn.

Perform the following operations:

Crankshaft, Connecting Rods and Pistons

Exploded View – Crankshaft and Connecting Rod

Exploded View – Crankcase

Crankcases - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

caution

The upper and lower crankcases are machined as a matched set and must never be assembled to non-matching halves. Doing so may cause seizure of the engine.

Perform the following operations:

  1. Invert the engine to give access to the lower crankcase bolts.

    2. caution

    Failure to follow the correct screw release sequence may result in permanent crankcase damage.

  2. Release the lower crankcase bolts in the sequence shown in the diagram below. Note the position of the hardened washers under bolts 19 to 26.

    3. Crankcase Bolt Release Sequence
  3. Separate the lower and upper crankcases ensuring that the 3 locating dowels remain in the upper crankcase.

    4. caution

    Do not use levers to separate the upper and lower sections of the crankcase or damage to the crankcases could result.

Perform the following operations:

Crankcases - Assembly

Perform the following operations:

  1. Use high flash-point solvent to clean the crankcase mating faces. Wipe the surfaces clean with a lint-free cloth.
  2. Ensure that the transmission is in neutral.
  3. Ensure that the three locating dowels are in position in the upper crankcase.

    1. Locating dowels
  4. Apply a thin bead of silicone sealant (at the factory, ThreeBond 1216E is used) to the lower crankcase mating faces.

    5. Sealer Areas

    caution

    Do not use excessive amounts of sealer. The extra sealer may become dislodged and could block the oil passages in the crankcases causing severe engine damage.

  5. If removed, refit the three piston cooling jets into the upper crankcase and tighten their fixings to 10 Nm.

    1. Piston cooling jets

    2. Fixings

    caution

    Ensure the three piston cooling jets are installed. If the piston cooling jets are omitted, oil pressure will be reduced. Running the engine with low oil pressure will cause severe engine damage.

  6. Install and lubricate the crankshaft bearing shells with a 50/50 solution of engine oil and molybdenum disulphide grease (see Connecting Rod Big End Journal Checking, Measuring and Bearing Selection before proceeding).
  7. Lubricate the crankshaft journals with clean engine oil.
  8. Fit the crankshaft (see Crankshaft - Installation).
  9. If removed, refit the balancer (see Balancer - Installation).
  10. Position the lower crankcase to the upper. An assistant may be required to support the crankcase during alignment.
  11. Fit the bolts into the lower crankcase and hand tighten until the bolt heads are near contact with the crankcase. Note the position of the hardened washers under bolts 1 to 8.

    12. note
    • The crankcase screws are tightened in stages.
    • Two different sizes of crankcase bolts are used. All bolts must be tightened in the two stages as follows:

    caution

    Failure to follow the correct bolt tightening sequence may result in permanent crankcase damage.

Stage 1

  1. In the sequence shown below, tighten crankcase bolts 1 to 8 to 10 Nm.

    2. Crankcase Bolt 1 to 8 Tightening Sequence
  2. In the sequence shown above:

    3. T3880105 - Torque Angle Gauge

Stage 2

  1. In the sequence shown below, tighten only the M8 size crankcase bolts (number 9 to 26) to 12 Nm.

    2. Crankcase Bolt 9 to 26 Tightening Sequence
  2. In the sequence shown below, tighten only the M8 size crankcase bolts (number 14 to 19) to 32 Nm.

    3. Crankcase Bolt 14 to 19 Tightening Sequence

Perform the following operations:

Crankshaft - Removal

Perform the following operations:

  1. Release and remove the crankshaft from the upper crankcase.

    2. note
    • Identify the location of each bearing shell.
    • Remove all bearings and inspect for damage, wear, overheating (blue discolouration) and any other signs of deterioration. Replace the bearings as a set if necessary (see Connecting Rod Big End Journal Checking, Measuring and Bearing Selection).
    • If the camshaft drive chain sprocket is removed from the crankshaft for any reason, always install a new fixing. Tighten to 27 Nm.
  2. Remove the balancer (see Balancer - Removal).

Crankshaft - Installation

caution

Always check the bearing journal clearance (see Connecting Rod Big End Journal Checking, Measuring and Bearing Selection and Crankshaft Main Bearing/Journal Checking, Measuring and Bearing Selection), before final assembly of the crankshaft. Failure to correctly select crankshaft bearings will result in severe engine damage.

    caution

    Ensure the three piston cooling jets are installed. If the piston cooling jets are omitted, oil pressure will be reduced. Running the engine with low oil pressure will cause severe engine damage.

  1. Select and fit new main and big end bearing shells using the selection processes (see Crankshaft Main Bearing/Journal Checking, Measuring and Bearing Selection).

    1. Big end shells
  2. Lubricate all bearings with a 50/50 solution of engine oil and molybdenum disulphide grease.
  3. Ensure that the crankshaft is clean, and that the oil ways within the crankshaft are clean and free from blockages and debris.
  4. Refit the balancer (see Balancer - Installation).
  5. Install the crankshaft ensuring that the crankshaft journals align with the big ends and that the crankshaft and balancer gear markings align as shown in the next illustration.

    1. Balancer backlash and drive gear markings

    2. Crankshaft markings

Perform the following operations:

Connecting Rods - Removal

Perform the following operations:

  1. Mark each big end cap and connecting rod to identify both items as a matched pair and to identify the correct orientation of the bearing cap to the connecting rod.
  2. Release the connecting rod bolts and remove the big end cap. Ensure that the bearing shell remains in place in the cap.

    1. Big end cap

    2. Connecting rod bolt

    note
    • It may be necessary to gently tap the big end cap with a rubber mallet to release the cap.
  3. Push the connecting rod up through the crankcase and collect the piston and connecting rod from the top.
  4. Label the assembly to identify the cylinder from which it was removed.

    5. caution

    Never reuse connecting rod bolts. If the connecting rod cap is disturbed, always renew the bolts. Using the original bolts may lead to severe engine damage.

  5. Detach the piston from the connecting rod (see Piston - Removal).

Connecting Rods - Installation

note
  • Connecting rod bolts are treated with an anti-rust solution which must not be removed.
  • Clean the connecting rod with high flash-point solvent.
  • Remove all bearings and inspect for damage, wear and any signs of deterioration and replace as necessary.

warning

Connecting rod bolts MUST only be used once. If the bolts are removed or undone for any reason, new bolts MUST always be used.

Re-using bolts can cause connecting rods and their caps to detach from the crankshaft causing severe engine damage, loss of motorcycle control and an accident.

note
  • Ensure the piston is fitted correctly to the connecting rod.
  • If a previously run engine is being rebuilt, always ensure that the piston and connecting rod are assembled in the same orientation, and to the same cylinder, as prior to strip-down.
  1. Fit the piston onto the connecting rod (see Piston - Assembly).
  2. Fit the three piston and connecting rod assemblies into the barrel and then fit the assembly to the crankcase (see Barrels - Installation).
  3. Select the big end bearing shells (see Connecting Rod Big End Journal Checking, Measuring and Bearing Selection).
  4. Fit the bearing shells to the connecting rod and the big end cap, lubricate with a 50/50 solution of engine oil and molybdenum disulphide grease.
  5. Align the connecting rod to the crankshaft and fit the big end cap.

    1. Big end cap

    2. Connecting rod bolt

    caution

    The torque characteristics of the connecting rod bolts are sensitive to the correct lubrication being applied. If the threads and under head areas are not lubricated with molybdenum disulphide grease, the bolts may be stretched and may become loose when in service resulting in an engine failure.

  6. Lubricate the threads and under-head area of the new bolts with molybdenum disulphide grease. Tighten the bolts evenly and progressively as follows:

    7. caution

    The torque characteristics of the connecting rod bolts are sensitive to the rate at which they are tightened. If all the torque is applied in one action, the bolt may be stretched and may become loose when in service resulting in an expensive engine failure.

    T3880105 - Torque Angle Gauge

Perform the following operations:

Connecting Rod Big End Journal Checking, Measuring and Bearing Selection

Using selective bearings compensates for minor differences in crankshaft main bearing journal and crankcase dimensions. For further information on bearing part number to colour cross-references, refer to the electronic parts catalogue EPC.

  1. Measure the bearing and crankshaft journal clearance as follows.

    2. note
    • Do not turn the connecting rod and crankshaft during the clearance measurement as this will damage the Plastigauge. The crankshaft journal clearances are measured using Plastigauge (Triumph part number 3880150-T0301).
  2. Remove the big end cap from the journal to be checked.
  3. Wipe the exposed areas of the crankshaft journal, and the bearing face inside the cap.
  4. Apply a thin smear of grease to the journal and a small quantity of silicone release agent to the bearing.
  5. Trim a length of the Plastigauge to fit across the journal. Fit the strip to the journal using the grease to hold the Plastigauge in place.

    6. note
    • The original fixings may be reused for bearing selection. Do not use new fixings as they may only be used once, even if the single use is related to bearing selection.
  6. Lubricate the threads and under-head area of the bolt with molybdenum disulphide grease. Refit the bearing and cap and tighten the big end bolts (see Connecting Rods - Installation).
  7. Release the bolts and remove the cap being measured. Using the gauge provided with the Plastigauge kit, measure the width of the compressed Plastigauge.

    8. Checking the Measured Clearance
  8. For specifications refer toCrankshaft.
  9. If the clearance exceeds the service limit, measure the diameter of the crankshaft bearing journal.

    10. note
    • If any journal has worn beyond the service limit, the crankshaft must be replaced. Due to the advanced techniques used during manufacture, the crankshaft cannot be reground and no oversize bearings are available.

Connecting Rod Bearing Selection

note
  • If the measured clearance exceeds the service limit, measure the crankshaft journal diameter.

Crankshaft journal diameter

    note
    • Minor differences in dimensions are compensated for by using selective bearings. For further information on bearing part number to colour cross-references, see the latest parts information.
  1. Select the correct bearing shell as follows:
  2. Measure and record the diameter of each crankshaft bearing journal.
  3. Measure and record each bearing bore diameter (bearings removed, journal caps fitted and all fixings torqued see Connecting Rods - Installation).
  4. Select the correct bearings by matching the information found in the bearing selection chart.
  5. Install the new bearings.

Big End Bearing Selection Chart

Shell Colour

Connecting rod bore diameter

Big end bearing journal diameter

WHITE

38.009 to 38.000 mm

35.018 to 35.010 mm

RED

38.009 to 38.000 mm

35.009 to 35.002 mm

For instance:

Connecting rod Big End Diameter

38.003

Crankshaft Journal Diameter

35.007

Required Bearing

Red

note
  • Repeat the measurements for all respective journals.
  • It is normal for the bearings selected to differ from one journal to another.
  • It is also normal for there to be two options of bearing shell colour. In such cases, pick the shell size that gives the greater running clearance.

warning

Always confirm, using the Plastigauge method, that the running clearance is correct before final assembly. Severe engine damage could result from incorrect clearance resulting in loss of motorcycle control and an accident.

Crankshaft Main Bearing/Journal Checking, Measuring and Bearing Selection

Using selective bearings compensates for minor differences in crankshaft main bearing journal and crankcase dimensions. For further information on bearing part number to colour cross-references, refer to the EPC.

  1. Measure the bearing to crankshaft journal clearance as follows:

    2. note
    • Do not turn the connecting rods and crankshaft during the clearance measurement as this will damage the Plastigauge. The crankshaft journal clearances are measured using Plastigauge (Triumph part number 3880150-T0301).
  2. Separate the crankcase halves (see Crankcases - Removal).
  3. Wipe the exposed areas of the crankshaft journals, and the bearing face inside the cap.
  4. Apply a thin smear of grease to the journals and a small quantity of silicone release agent to the bearings.
  5. Trim a length of the Plastigauge to fit across each journal. Fit the strip to the journal using the grease to hold the Plastigauge in position.

    6. note
    • The original fixings may be reused for bearing selection. Do not use new fixings as they may only be used once, even if the single use is related to bearing selection.
  6. Lubricate the threads and the face of the fixings with molybdenum disulphide grease. Refit the crankcase and tighten the original fixings (see Crankcases - Assembly).
  7. Release the fixings and remove the crankcase.
  8. Using the Plastigauge kit, measure the width of the compressed Plastigauge.

    9. Checking the Measured Clearance
  9. For specifications refer toCrankshaft.
  10. If the clearance exceeds the service limit, measure the diameter of the crankshaft bearing journal.

    11. note
    • If any journal has worn beyond the service limit, the crankshaft must be replaced. Due to the techniques used during manufacture, the crankshaft cannot be reground and oversize bearings are not available.

Main Bearing Selection

    note
    • Minor differences in dimensions are compensated for by using selective bearings. For further information on bearing part number to colour cross-references, see the latest parts information.
  1. Select the correct bearings as follows:
  2. Measure and record the diameter of each crankshaft bearing journal.
  3. Measure and record each bearing bore diameter in the crankcase (bearings removed, journal caps fitted and all fixings fully torqued).
  4. Select and install the correct bearings by matching the information found in the main bearing selection chart.
  5. Install the new bearings.

Main Bearing Selection Chart

Shell Colour

Crankcase Bore

Crankshaft Journal Diameter

Running Clearance

White

37.984 to 37.975

35.000 to 34.993

0.033 to 0.011

Red

37.984 to 37.975

34.992 to 34.984

0.034 to 0.011

Red

37.993 to 37.985

35.000 to 34.993

0.035 to 0.013

Blue

37.984 to 37.975

34.992 to 34.984

0.035 to 0.013

For instance:

Crankcase Bore

37.978 mm

Crankshaft Journal Diameter

34.988 mm

Required Bearing

Blue

warning

Always confirm, using the Plastigauge method, that the running clearance is correct before final assembly. Severe engine damage could result from incorrect clearance resulting in loss of motorcycle control and an accident.

note
  • Repeat the measurements for all respective journals.
  • It is normal for the bearings selected to differ from one journal to another.
  • It is also normal for there to be two options of bearing shell colour. In such cases, pick the shell size that gives the greater running clearance.

Crankshaft End Float

  1. For specifications refer toCrankshaft.

note
  • Crankshaft end float is controlled by the tolerances in crankshaft and crankcase machining. No thrust washers are used. If the crankshaft end float is outside the specified limit, the crankshaft and/or the crankcases must be replaced.

Balancer

Exploded View - Balancer Shaft

Balancer

The balancer is fitted to control pulsing within the engine. Without any form of balancer, the engine would pulse each time the crankshaft rotated. This pulsing would be felt as a vibration which would amplify as the engine speed was increased.

The balancer has the effect of a pair of counterbalance weights which create an equal amount of energy in the opposite direction, and at the same time as that produced by the crankshaft, pistons and connecting rods. Because the opposing pulses occur at the same point of crankshaft rotation, and are of an equal magnitude, a state of equilibrium or balance is reached.

Balancer - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. With the crankcase halves separated, lift out the balancer shaft complete with the shaft bearings/circlips.

    2. note
    • As the shaft is released from the crankcase, the backlash eliminator gear will spring out of alignment with the crankshaft.
  2. To remove the left hand bearing, slide the bearing, circlip and bearing sleeve from the balancer shaft. Note the orientation of the bearing prior to removal.
  3. To remove the right hand bearing, remove the circlip and washer, and, using a press and press bars remove the bearing race from the shaft, ensuring the inner bearing race is supported. Note the orientation of the bearing prior to removal. DO NOT remove the drive gear from the shaft.

    4. warning

    When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.

    Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.

    caution

    Do not remove the drive gear from the balancer shaft. The drive gear is aligned to the shaft. If the balancer and drive gear are not correctly aligned, severe engine vibration will occur leading to damage to components.

  4. To strip the backlash eliminator from the drive gear, release the circlip and remove the wave-washer, backlash gear and spring.

    1. Balancer shaft

    2. Wave washer

    3. Circlip

Balancer - Inspection

  1. Inspect all gears for chipped or missing teeth.
  2. Inspect all bearings for signs of overheating (blue discolouration), seized or damaged rollers, and any other damage.
  3. Inspect the backlash spring for deformities, damage etc.
  4. Inspect the gear teeth for overheating (blue discolouration).

Balancer - Installation

note
  • Before assembling the backlash gear to the balancer shaft, lubricate all contact surfaces of the balancer drive gear, backlash spring and backlash gear with new engine oil which meets specification API SH (or higher) and JASO MA.
  1. If the backlash gear was disassembled, fit the backlash spring over the shaft and position to the balancer drive gear, positioning the spring ends on either side of the peg.
  2. Fit the backlash gear, ensuring its peg is located anticlockwise (viewed from the left hand bearing end of the shaft) of the balancer gear peg and also between the spring ends.

    1. Balancer shaft

    2. Backlash gear

    3. Backlash spring
  3. Fit the wave washer and secure all components in position with the circlip.

    1. Balancer shaft

    2. Wave washer

    3. Circlip
  4. Using a press and press bars, fit the right hand bearing to the shaft, with the circlip positioned nearest to the drive gear. Ensure the inner race of the bearing is supported when installing the bearing.

    5. warning

    When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.

    Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.

  5. Refit the washer and a new circlip to the shaft.
  6. Lubricate and fit the left hand bearing and install a new circlip in the same orientation as noted prior to removal.

    7. note
    • Prior to installation in the crankcase, it is essential that the markings on the backlash eliminator and drive gears are brought into alignment against the tension of the spring. This will facilitate correct positioning of the balancer in relation to the crankshaft when both are installed in the crankcase.

    1. Drive gear dot

    2. Backlash gear line
  7. Using T3880106 - Balancer Gear Holder, bring the backlash and drive gear marks into alignment against the backlash spring as follows:

    8. note
    • When in alignment, the line on the backlash gear must be located directly above the drive gear tooth marked with a dot.
    • Since the drive gear dot cannot be seen when the backlash gear is in alignment, always mark the dot-marked gear tooth with a paint mark in order that it can always be identified.
  8. Secure the backlash gear in position with the fixture supplied with T3880106 - Balancer Gear Holder by placing the fixture pegs across two gear teeth (ensure that the fixture will not be in the way when assembling the balancer to the crankshaft).

    1. T3880106 - Balancer Gear Holder

    2. Securing fixture

    3. Balancer backlash gear marking

    caution

    If the balancer and crankshaft are not correctly aligned, severe engine vibration will occur leading to damage to components.

  9. With the drive and backlash eliminator gear still correctly aligned, locate the balancer to the crankcase. Align the balancer gears and crankshaft as shown in the illustration below.

    1. Balancer gear marking

    2. Crankshaft marking
  10. Ensure that the right hand bearing circlip and dowel locate correctly in the corresponding groove in the crankcase.

    1. Balancer shaft

    2. Securing fixture

    3. Balancer backlash gear marking
  11. Ensure that the left hand bearing circlip and dowel locate correctly in the corresponding groove in the crankcase.

    1. Balancer shaft

    2. Left hand bearing

    3. Circlip

    4. Dowel
  12. Remove the securing fixture.
  13. Check that the balancer and crankshaft are correctly aligned before continuing to assemble the crankcase halves.

Perform the following operations:

Transmission

Exploded View – Input and Output Shafts

Exploded View – Gear Selectors and Drum

Exploded View – Gear Change Lever

Gear Change Linkage - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the routing and cable tie securing locations of the quickshifter cable for installation.
  1. Disconnect the quickshifter multiplug from the main harness.

    1. Quickshifter multiplug
  2. Cut the cable tie securing the quickshifter cable to the main harness.
  3. Route the cable down to the quickshifter.

    4. note
    • Note the position of the quickshifter sensor for installation.
  4. Remove the wire clips retaining the quickshifter linkage front and rear ball joints, as shown below.

    1. Wire clip

    2. Front ball joint
  5. Remove the quickshifter linkage.

Gear Change Linkage - Installation

  1. Locate the quickshifter linkage through the frame as noted for removal.
  2. Attach the front ball joint to the transmission linkage.
  3. Attach the rear ball joint to the foot control.
  4. Refit the wire clips to retain the ball joints. Ensure the wire clips locate correctly in the ball joints before rotating the clips to lock in place.

    1. Ball joint

    2. Wire clip
  5. Route the quickshifter cable as noted for removal and connect the multiplug to the main harness. Secure the cable to the main harness with a cable tie as noted for removal.

    1. Quickshifter multiplug

Perform the following operations:

Gear Change Shaft - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Note the position and orientation of the gear pedal crank in relation to the shaft, then remove the crank.
  2. Remove the E-clip and washer from the gear pedal end of the gear change shaft.

    1. Gear change shaft

    2. E-clip

    3. Washer
  3. Un-hook the spring from the detent arm.

    4. caution

    Take care to ensure that the washer fitted to the inner end of the selector shaft remains in position during removal of the shaft. Should the washer become dislodged during removal, it is possible for it to drop into the engine. Should this happen, it will be necessary to disassemble the crankcase to recover the washer.

  4. Carefully withdraw the gear change shaft and detent arm from the clutch end of the crankcase. Ensure the washer fitted to the inner end of the shaft remains on the shaft.

    1. Detent arm spring

    2. Detent arm

    3. Gear change shaft
  5. Collect the detent arm spring.

Gear Change Shaft - Installation

  1. Rotate the selector drum to the neutral position.

    1. Detent wheel

    2. Neutral position
  2. Using grease to NLGI 2 specification, lubricate the lip of the seal for the gear change shaft.

    1. Gear change shaft seal

    2. Gear change shaft bearing

    caution

    Take care to avoid damaging the lip of the seal when inserting the gear change shaft into the crankcase. A damaged seal will lead to oil loss and could result in engine damage.

  3. Ensure that the inner washer is fitted to the shaft and carefully insert the gear pedal end of the shaft through the bearings and lip seal in the crankcase.

    1. Washer

    2. Gear change shaft
  4. Support the detent arm bearing clear of the selector drum as the selector shaft is fully installed, and ensure the selector shaft spring fits either side of the abutment bolt.

    1. Gear change shaft

    2. Spring

    3. Abutment bolt
  5. Fit the washer and E-clip to the gear pedal end of the gear change shaft.

    1. Gear change shaft

    2. E-clip

    3. Washer
  6. Fit the gear pedal crank to the shaft in the same orientation as noted for removal. Ensure the dot mark on the shaft aligns with the split line on the gear pedal crank. Tighten the fixing to 9 Nm.
  7. Refit the detent arm spring.

Perform the following operations:

Selector Forks and Drum - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Remove and discard the fixings for the selector drum, input and output keeper plates/washer. Note the position of the washer and keeper plates for installation.

    1. Fixings

    2. Selector drum keeper plate

    3. Input selector shaft washer

    4. Output selector shaft keeper plate

    caution

    The two output shaft selector forks can be fitted incorrectly. Ensure the position and orientation of the selector forks are marked prior to removal. Incorrect fitting of the selector forks will cause gearbox damage.

    note
    • There are identification markings on one side of the fork. These markings must face the alternator side of the engine when installed.
    • Note the orientation of the selector forks for installation.
  2. Slide the output selector shaft from the crankcase in the direction of the clutch. Collect the two selector forks as they are released by the selector shaft.

    1. Output selector shaft

    2. Sixth gear selector fork

    3. Fifth gear selector fork
  3. Noting the position of the selector fork, remove the input selector shaft, leaving the selector fork in the gearbox.

    1. Input selector shaft

    2. Selector fork
  4. Withdraw the selector drum from within the crankcase.

    1. Selector drum removal
  5. Collect the input shaft selector fork from the crankcase.

Selector Forks and Drum - Inspection

Inspect all bearings for damage or wear. Renew as necessary.

Inspect the selector forks and selector grooves for wear beyond the service limits. Renew the components as necessary.

  1. Examine the gear change shaft seal for damage and/or wear. Replace the seal if damaged and/or worn.

Selector Forks and Drum - Installation

  1. Position the input shaft selector fork into the crankcase, locating the fork into the selector groove on the input shaft. Ensure the fork is fitted in the position noted during removal.

    1. Input shaft selector fork

    2. Input shaft
  2. Using clean engine oil, lubricate the selector drum bearings. Lubricate the selector drum tracks with new engine oil which meets specification API SH (or higher) and JASO MA.
  3. Position the selector drum into the crankcase.

    1. Selector drum
  4. Rotate the selector drum and ensure a smooth movement. Rectify as necessary.

    5. caution

    The selector forks can be fitted incorrectly. Ensure the position and orientation of the selector forks are the same as noted during removal. Incorrect fitting of the selector forks will cause gearbox damage.

  5. Push the input selector shaft into the crankcase from the clutch end. As the shaft is inserted, locate the selector fork onto the shaft. Ensure the fork is fitted in the position noted during removal.

    1. Input selector shaft

    2. Selector fork
  6. Push the output selector shaft into the crankcase from the clutch end. As the shaft is inserted, locate the selector forks. Ensure the selector forks are fitted in the positions and orientation as noted during removal.

    1. Output selector shaft

    2. Sixth gear selector fork

    3. Fifth gear selector fork
  7. Fit new fixings for the selector drum, input and output keeper plates/washer, ensuring the washer and the keeper plates are fitted in the positions noted during removal. Tighten the fixings to 12 Nm.

    1. Fixings

    2. Selector drum keeper plate

    3. Input selector shaft washer

    4. Output selector shaft keeper plate

Perform the following operations:

Input and Output Shaft Assemblies - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • The input and output shafts may be removed from the upper crankcase after first separating the lower crankcase from the upper.
  • The rear needle roller bearing on the input shaft remains in the crankcase on removal of the shaft.

Perform the following operations:

  1. Lift the output shaft from the upper crankcase, noting the orientation of each bearing, their circlips and dowels.
  2. Remove the selector shafts, forks and selector drum (see Selector Forks and Drum - Removal).

    3. note
    • The input shaft bearing housing fixings may not be reused but should be retained for use during installation of the input shaft.
  3. Release the three fixings securing the input shaft bearing housing to the upper crankcase.

    1. Fixings

    2. Bearing housing

    note
    • Note the orientation of the bearing housing for installation.
  4. Insert two M6 bolts into the two threaded holes at the periphery of the bearing housing. Evenly and progressively tighten both bolts to draw the bearing housing and input shaft from the crankcase.

    1. Bearing housing

    2. M6 threaded holes

    3. Transmission oil tube
  5. If required, the transmission oil tube can now be removed. Remove and discard the three oil tube O-rings.

Input and Output Shaft Assemblies - Installation

  1. If removed, check the transmission oil tube for blockages and contamination. Carefully fit new O-rings to the transmission oil tube and insert the tube into the crankcase, ensuring the tag on the tube locates in the slot in the crankcase.
  2. Locate the input shaft to the upper crankcase, installing it through the aperture for the bearing housing.
  3. Align the fixing holes to the threaded holes in their crankcase and fit the bearing housing into the aperture, by hand, as deeply as possible.
  4. Using the old fixings, evenly and progressively tighten them to draw the bearing housing into the upper crankcase until fully home as noted for removal. Remove and discard the fixings.

    1. Bearing housing

    2. Fixings

    3. M6 threaded holes

    4. Transmission oil tube
  5. Install new fixings to the bearing housing and tighten to 12 Nm.
  6. Refit the selectors and shafts (see Selector Forks and Drum - Installation).
  7. Refit the output shaft to the crankcase ensuring the snap-ring locates in the corresponding groove in the crankcase, and the dowel locates in the slot in the upper crankcase.
  8. Ensure the output shaft seal aligns with its recess in the crankcase.

    1. Groove in crankcase

    2. Snap ring

    3. Dowel

    4. Seal
  9. Ensure the hole in the output shaft needle roller bearing outer race is positioned to locate onto the dowel provided in the upper crankcase.

    1. Roller bearing

    2. Dowel

Perform the following operations:

Exploded View - Input Shaft

  1. Thrust washer

  2. Second gear

  3. Lock washer

  4. Splined washer

  5. Splined bush

  6. Sixth gear

  7. Splined thrust washer

  8. Circlip

  9. Third/fourth gear

  10. Circlip

  11. Splined thrust washer

  12. Fifth gear

  13. Plain bush

  14. Input shaft

  15. Bearing

  16. Bearing housing

  17. Bearing retainer

Input Shaft - Disassembly

note
  • The numbers in brackets in the following text refer to the exploded view on Exploded View - Input Shaft.

Working from the opposite end to where the clutch assembly is fitted, dismantle the input shaft as follows:

  1. Slide off the plain thrust washer (1).
  2. Mark one side of second gear to denote its correct orientation. Remove second gear (2).
  3. Remove the splined lock washers (3 and 4).
  4. Mark one side of sixth gear to denote its correct orientation. Remove sixth gear (6), complete with the splined bush (5) which runs inside the gear.
  5. Note their orientation and remove the splined thrust washer (7) from in front of the circlip between sixth and third/fourth gear.
  6. Remove the circlip (8) from the shaft.
  7. Mark one side of the combined third/fourth gear to denote its correct orientation. Remove the combined third/fourth gear (9).
  8. Remove the circlip (10) from in front of fifth gear.
  9. Remove the splined thrust washer (11) adjacent to fifth gear.
  10. Mark one side of fifth gear to denote its correct orientation. Remove fifth gear (12), complete with the plain bush (13) which runs inside the gear.

    11. note
    • Unless the bearing at the clutch end of the input shaft is damaged or worn, it is not normally necessary to remove it from the shaft. The bearing is pressed onto the shaft and is also pressed into its housing. The bearing and housing are removed from the shaft together and are then separated.

    warning

    When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.

    Never wear loose clothing, which could become trapped in the press and cause crushing injuries to the hand, arms or other parts of the anatomy.

  11. Support the bearing and housing (15 and 16) on press bars, then press the shaft (14) through the bearing and housing as shown below.

    1. Press bars

    2. Bearing/housing
  12. Support the outer circumference of the bearing housing on press bars, then press the bearing through the housing.

    13. Pressing out the Bearing

Input Shaft - Inspection

  1. Examine all gears, bearings and bushes and thrust washers for damage, distortion, chipped teeth and wear beyond the service limits. Replace all defective components and always use new circlips to assemble the shaft.
  2. Thoroughly clean the bearing housing and inspect for damage, scoring and cracks. Replace the housing if necessary.

Input Shaft - Assembly

note
  • The numbers in brackets in the following text refer to the exploded view on Exploded View - Input Shaft.
  • Lubricate each gear, thrust washer and bush with clean engine oil during assembly.

warning

When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.

Never wear loose clothing, which could become trapped in the press and cause crushing injuries to the hand, arms or other parts of the anatomy.

caution

Bushes and gears with oil holes must always be MISALIGNED with the corresponding oil holes in the input shaft. Reduced oil pressure and gear lubrication may result from alignment of the oil holes, which would cause premature wear of engine and transmission components.

caution

Removing the input shaft bearing from the shaft and its housing will damage the bearing and snap ring. Never reuse removed bearings or snap rings as use of damaged or weakened components could lead to engine and transmission damage. Also, check for damage to the housing itself.

caution

Press only on the bearing outer race to prevent bearing damage.
  1. Support the housing on press bars as shown below and press the bearing fully into the housing in the direction of the arrow.

    1. Bearing housing

    2. Bearing

    caution

    Press only on the bearing inner race to prevent bearing damage.
  2. Locate the bearing and housing to the input shaft. Carefully support the shaft on the press bed, and using a suitable sleeve over the input shaft to ensure the bearing is pressed only on the inner race, press the bearing onto the shaft.

    1. Sleeve

    2. Bearing/housing

    3. Press bars

    4. Input shaft
  3. Fit the plain bush (13) to the shaft.
  4. Fit fifth gear (12) to the input shaft as noted during disassembly, with the dog teeth pointing away from the input shaft bearing.
  5. Slide on the splined thrust washer (11).
  6. Fit a new circlip (10) to the input shaft ensuring that the clip is located in the circlip groove as shown below.

    1. Fifth gear

    2. Thrust washer

    3. Circlip
  7. Fit the combined third/fourth gear (9) as noted during disassembly, with the larger gear facing toward fifth gear. Ensure that the oil hole in the input shaft DOES NOT align with the oil hole in the gear.

    8. warning

    If the oil hole in the third/fourth gear is aligned with the corresponding hole in the input shaft, engine oil pressure and gear lubrication will be reduced.

    Reduced oil pressure and gear lubrication will cause engine damage and could also lead to engine seizure resulting in loss of motorcycle control and an accident.

  8. Fit a new circlip (8) to the input shaft ensuring that the circlip is located in the circlip groove as shown below.

    1. Sixth gear

    2. Thrust washer

    3. Circlip
  9. Fit the splined thrust washer (7) to the input shaft and slide up the shaft until in contact with the circlip.
  10. Fit the splined bush (5) from sixth gear. Ensure that the oil hole in the input shaft DOES NOT align with the oil hole on the shaft.
  11. Fit sixth gear (6) as noted during disassembly, with the dog teeth facing third/fourth gear.
  12. Fit the splined and lock washers (4 and 3), ensuring the tabs in the smaller washer (3) locate in the slots in the larger (4) washer.

    1. Second gear

    2. Large splined lock washer

    3. Small splined lock washer
  13. Fit second gear (2) to the shaft as noted during disassembly.
  14. Fit the plain thrust washer (1) adjacent to second gear.

Exploded View - Output Shaft

  1. Bearing

  2. Thrust washer

  3. First gear

  4. Plain bush

  5. Thrust washer

  6. Fifth gear

  7. Circlip

  8. Splined thrust washer

  9. Fourth gear

  10. Splined bush

  11. Lock washer

  12. Splined washer

  13. Splined bush

  14. Third gear

  15. Splined washer

  16. Circlip

  17. Sixth gear

  18. Circlip

  19. Splined thrust washer

  20. Plain bush

  21. Second gear

  22. Output shaft

  23. Snap ring

  24. Bearing

  25. Sprocket spacer

  26. Output shaft seal

  27. Output sprocket

  28. Tab washer

  29. Output sprocket nut

Output Shaft - Disassembly

note
  • The numbers in brackets in the following text refer to the exploded view on Exploded View - Output Shaft.

Working from the opposite end to the drive sprocket, dismantle the output shaft as follows.

  1. Remove the output shaft bearing (1) and plain thrust washer (2).
  2. Mark one side of first gear to denote its correct orientation. Remove first gear (3) from the shaft, complete with the plain bush (4) which runs inside the gear.
  3. Remove the plain thrust washer (5).
  4. Mark one side of fifth gear to denote its correct orientation. Remove fifth gear (6) from the shaft.
  5. Remove the circlip (7) and splined thrust washer (8) from in front of fourth gear.
  6. Mark one side of fourth gear to denote its correct orientation. Remove fourth gear (9) complete with the splined bush which runs inside the gear (10).
  7. Note their orientation and remove the splined lock washers (11 and 12).
  8. Mark one side of third gear to denote its correct orientation. Remove third gear (14) off the shaft complete with the splined bush (13) which runs inside the gear.
  9. Remove the splined thrust washer (15).
  10. Remove the circlip (16) from in front of sixth gear.
  11. Mark one side of sixth gear to denote its correct orientation. Remove sixth gear (17) from the shaft.
  12. Remove the circlip (18) from in front of second gear.
  13. Remove the splined thrust washer (19).
  14. Mark one side of second gear to denote its correct orientation. Remove second gear (21) from the shaft, complete with the plain bush (20) which runs inside the gear.
  15. Position the output shaft (22) in a vice with soft jaws fitted. Tighten the vice to prevent the shaft from turning and release the tab washer (28) from the output sprocket nut (29), then release the nut.
  16. Remove the output sprocket nut (29), tab washer (28) and sprocket (27).
  17. Collect the output shaft seal (26).
  18. If it is found necessary to replace the large bearing (24) at the end of the shaft, use a press to remove both the bearing and output shaft sprocket spacer (25) together.

warning

When removing the output shaft bearing, always wear overalls, eye, face and hand protection. The bearing races are hardened and are liable to splinter if broken. Debris from broken bearings could cause injury to eyes, face and any unprotected parts of the body.

Output Shaft - Inspection

  1. Examine all gears, bearings, bushes and thrust washers for damage, distortion, chipped teeth and wear beyond the service limits. Replace all suspect components and always use a new circlip to assemble the shaft.

Output Shaft - Assembly

note
  • The numbers in brackets in the following text refer to the exploded view on Exploded View - Output Shaft.
  • Lubricate each gear and bush with clean engine oil during assembly.
  • Examine all gears, bearings and sleeves for damage, chipped teeth and wear beyond the service limits. Replace all suspect components and always use new circlips, a new output shaft seal and a new sprocket tab washer to assemble the shaft.

warning

When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.

Never wear loose clothing, which could become trapped in the press and cause crushing injuries to the hand, arms or other parts of the anatomy.

caution

Bushes and gears with oil holes must always be MISALIGNED with the corresponding oil holes in the output shaft. Reduced oil pressure and gear lubrication may result from alignment of the oil holes, which would cause premature wear of engine and transmission components.

caution

Removing the output shaft bearing from the shaft will damage the bearing and snap ring. Never reuse removed bearings or snap rings as use of damaged or weakened components could lead to engine and transmission damage.

caution

Press only on the bearing inner race to prevent bearing damage.
  1. Working from the output sprocket end of the shaft, fit a new bearing (24) and a new sprocket spacer (25) to the shaft using a press and press bars. Fit the sleeve with the large chamfer facing outwards.

    1. Output shaft

    2. Bearing

    3. Press bars
  2. Lubricate and fit a new output shaft seal (26).
  3. Transfer the shaft to the vice and secure between soft jaws. Fit the output sprocket (27), new tab washer (28) and nut (29). Tighten the nut to 85 Nm. Close the tab washer.
  4. Withdraw the shaft from the vice and continue to assemble from the opposite end to the output sprocket.
  5. Fit the plain bush (20) to the shaft.
  6. Locate second gear (21) to the shaft as noted during disassembly, with the large step side facing towards the output sprocket end. Fit the splined thrust washer (19) and retain with a new circlip (18) as shown below.

    1. Second gear

    2. Thrust washer

    3. Circlip
  7. Fit sixth gear (17) as noted during disassembly, with the selector fork groove facing away from the output sprocket end. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft.
  8. Fit a new circlip (16) to retain sixth gear. Fit the splined thrust washer (15) to the rear of third gear as shown below.

    1. Third gear

    2. Splined thrust washer

    3. Circlip
  9. Fit the splined bush (13) for third gear. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft. Fit third gear (14) to the shaft with the large step side facing away from the output sprocket.
  10. Fit the splined lock washers (12 and 11), ensuring the tabs in the smaller washer (11) locate in the slots in the larger washer (12) as shown below.

    1. Third gear

    2. Large splined lock washer

    3. Small splined lock washer
  11. Fit the splined bush (10) from fourth gear. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft.
  12. Fit fourth gear (9) as noted during disassembly, with the larger step side facing towards the output sprocket.
  13. Fit the splined thrust washer (8) and retain with a new circlip (7) as shown below.

    1. Fourth gear

    2. Splined thrust washer

    3. Circlip
  14. Fit the fifth gear (6) to the shaft with the groove facing towards the output sprocket. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft.
  15. Fit the first gear thrust washer (5) and plain bush (4).

    16. note
    • When fitting first gear, ensure the solid side of the gear faces the clutch.
  16. Fit first gear (3) to the shaft as marked during disassembly as shown below.

    1. First gear

    2. Thrust washer

    3. Thrust washer

    4. Needle roller bearing
  17. Finally fit the thrust washer (2) and needle roller bearing (1) to the end of the shaft.

Starter Drive and Sprag Clutch

Exploded View – Flywheel, Sprag Clutch and Starter Gears

Starter Drive/Sprag Clutch - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Withdraw the starter idler gear and shaft, noting the fitted position of the components.

    1. Idler gear

    2. Idler shaft
  2. Remove the alternator rotor (see Alternator Rotor - Removal).
  3. Withdraw the starter drive gear from the sprag clutch.

    1. Starter drive gear

    2. Sprag clutch/housing

    3. Alternator rotor
  4. Remove and discard the fixings securing the sprag clutch housing to the alternator rotor. Withdraw the sprag clutch housing.
  5. Remove the sprag clutch from the housing.

    1. Sprag clutch housing

    2. Sprag clutch assembly

Starter Drive/Sprag Clutch - Inspection

  1. Check the sprag clutch bearings for overheating, wear and/or non-smooth operation. Replace the sprag clutch if overheating, wear and/or non-smooth operation is found.
  2. Examine all gears for chipped teeth and for any other damage.
  3. With the sprag clutch mounted in the housing, check the sprag clutch for smooth, free movement in one direction only (as indicated by the arrow marked on the sprag clutch body).

Starter Drive/Sprag Clutch - Installation

  1. Locate the sprag clutch to the sprag clutch housing as shown below. Push firmly until the lip seats in the recess provided in the housing.

    1. Sprag clutch housing

    2. Sprag clutch assembly
  2. Fit the housing to the alternator rotor.
  3. Ensure that the housing is squarely seated and is not on the rotor. Install new fixings.
  4. Tighten the cover bolts to in the sequence shown below to 16 Nm.

    5. Tightening Sequence
  5. Once all six bolts have been tightened, go around again in sequence and recheck each bolt is correctly torqued, if any bolt moves, go around again. Repeatedly check the bolts in sequence until all are correctly torqued and do not move when checked, this will ensure the sprag clutch housing is correctly seated on the rotor.
  6. Fit the starter drive gear to the sprag clutch.

    1. Starter drive gear

    2. Sprag clutch/housing

    3. Alternator rotor
  7. Refit the alternator rotor (see Alternator Rotor - Installation).
  8. Lubricate the idler gear shaft with new engine oil which meets specification API SH (or higher) and JASO MA.
  9. Fit the starter idler gear and shaft to the crankcase.

    1. Idler gear

    2. Idler shaft

Perform the following operations:

Lubrication

Exploded View - Oil Pump/Water Pump, Gears and Heat Exchanger

Engine Oil - Specification

Use semi or fully synthetic 10W/40 or 10W/50 motorcycle engine oil which meets specification API SH (or higher) and JASO MA, such as Castrol Power 1 Racing 4T, sold as Castrol Power RS Racing 4T in some countries.

Triumph recommends the fully synthetic 10W/40 motorcycle engine oil for most conditions. The oil viscosity may need to be changed to accommodate the ambient temperatures in your riding area.

Refer to the chart below for the correct oil viscosity (10W/40 or 10W/50) to be used in your riding area.

Oil Viscosity Temperature Range

caution

Triumph high performance fuel injected engines are designed to use semi or fully synthetic motorcycle engine oil which meets specification API SH (or higher) and JASO MA.

Do not add any chemical additives to the engine oil. The engine oil also lubricates the clutch and any additives could cause the clutch to slip.

Do not use mineral, vegetable, non-detergent oil, castor based oils or any oil not conforming to the required specification. The use of these oils may cause instant, severe engine damage.

Ensure no foreign matter enters the crankcase during an oil change or top up.

Triumph Engine Oil

Your Triumph motorcycle is a quality engineered product which has been carefully built and tested to exacting standards. Triumph Motorcycles are keen to ensure that you enjoy optimum performance from your machine and with this objective in mind have tested many of the engine lubricants currently available to the limits of their performance.

Disposal of Used Engine Oil and Oil Filters

To protect the environment, do not pour oil on the ground, down sewers or drains, or into watercourses. Do not place used oil filters in with general waste. If in doubt contact your local authority.

Oil Circuit Diagram

Oil Circuit

Oil is collected from the sump and is drawn through a mesh strainer into the oil pump rotor. The oil pump is fitted with a single pumping rotor which supplies pressurised oil to the lubrication circuit via the oil pressure relief valve. The relief valve is set to open at 5.1 bar (75 lb/in 2) and when open, returns high pressure oil direct to the sump.

The pressurised oil is delivered to the outside rim of the oil filter, where it is filtered by passing through the filter membrane. Filtered oil is then fed into the water heat exchanger (mounted on the front of the engine), where it is cooled.

After the oil has passed through the oil filter and oil cooler, it is distributed around the engine:

Heat Exchanger

The heat exchanger is used to transfer heat from the engine oil into the coolant.

Filtered oil is delivered to the heat exchanger via an opening (1) where it is circulated through the heat exchanger core. Coolant is pumped through a similar opening (3) into the heat exchanger core to cool the oil. The cooled oil then exits the heat exchanger (2) and flows to the main oil gallery. The coolant then flows out of the heat exchanger (4) and through the rest of the cooling system.

  1. Oil in

  2. Coolant in

  3. Oil out

  4. Coolant out

An additional benefit of the heat exchanger is that, as the engine coolant reaches its operating temperature more quickly than the engine oil, the oil is heated by the engine coolant at lower engine temperatures; this allows the engine oil to reach its optimum operating temperature more quickly, thereby helping to improve engine oil life, reduce exhaust emissions and reduce engine wear.

Oil Level Inspection

In order for the engine, transmission, and clutch to function correctly, maintain the engine oil at the correct level, and change the oil and oil filter in accordance with scheduled maintenance requirements.

warning

Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated engine wear resulting in engine or transmission seizure. Seizure of the engine or transmission may lead to loss of motorcycle control and an accident.

  1. Start the engine and run at idle for approximately five minutes.
  2. Stop the engine, then wait for at least three minutes to allow the oil to settle.
  3. Remove the dipstick, wipe clean and screw fully home in the crankcase.

    1. Filler

    2. Dipstick location in crankcase

    3. Dipstick

    4. Upper marking

    5. Lower marking

    note
    • The actual level is indicated when the motorcycle is level and upright, not on the side stand, and when the dipstick has been screwed fully home.
    • Do not add oil through the dipstick hole in the crankcase.
  4. Remove the dipstick.
  5. The oil level is indicated by lines on the dipstick. When full, the indicated oil level must be level with the upper marking on the dipstick.
  6. If the oil level is too low, remove the filler plug and add oil a little at a time through the filler plug hole in the clutch cover, until the correct level is reached.
  7. Once the correct level is reached, fit the dipstick and the filler plug.

Oil and Oil Filter Change

warning

Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contamination which can cause cancer. Wear suitable clothing and avoid skin contact.

The engine oil and filter must be replaced in accordance with scheduled maintenance requirements.

warning

If the engine has recently been running, the engine oil will be hot to the touch. Contact with the hot oils may cause damage to exposed skin. To avoid skin damage, do not touch hot oil.

  1. Warm up the engine thoroughly, and then stop the engine and secure the motorcycle in an upright position on level ground.
  2. Place an oil pan beneath the engine.
  3. Remove the oil drain plug.

    1. Oil drain plug

    2. Oil filter
  4. Unscrew and remove the oil filter using service tool T3880313 - Oil Filter Wrench. Dispose of the old oil filter in an environmentally friendly way.
  5. Apply a smear of clean engine oil to the sealing ring of the new oil filter.
  6. Fit the oil filter and tighten to 10 Nm usingT3880313 - Oil Filter Wrench.
  7. After the oil has completely drained out, fit a new sealing washer to the drain plug. Fit and tighten the plug to 25 Nm.
  8. Fill the engine with a 10W/40 or 10W/50 semi or fully synthetic motorcycle engine oil that meets specification API SH (or higher) and JASO MA, such as Castrol Power 1 Racing 4T 10W-40 (fully synthetic).
  9. Start the engine and allow it to idle for a minimum of 30 seconds.

    10. caution

    Raising the engine speed above idle before the oil reaches all parts of the engine can cause engine damage or seizure. Only raise engine speed after running the engine for 30 seconds to allow the oil to circulate fully.

    caution

    If the engine oil pressure is too low, the low oil pressure warning light will illuminate. If this light stays on when the engine is running, stop the engine immediately and investigate the cause. Running the engine with low oil pressure will cause engine damage.

  10. Ensure that the low oil pressure warning light remains off and the oil pressure message is not visible in the instrument display screen.
  11. Stop the engine and check the oil level. Adjust if necessary.

Oil Pump - Removal

warning

If the engine has recently been running, the engine oil will be hot to the touch. Contact with the hot oils may cause damage to exposed skin. To avoid skin damage, do not touch hot oil.

warning

Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contamination which can cause cancer. Wear suitable clothing and avoid skin contact.

The engine oil and filter must be replaced in accordance with scheduled maintenance requirements.

note
  • The oil pump and water pump are supplied as an assembly and cannot be separated. This procedure covers the removal of the oil and water pump assembly.

Perform the following operations:

    note
    • The oil pressure relief valve is fitted to the oil transfer pipe.
    • One of the fixings for the transfer pipe also secures the pick up pipe.
  1. Release and discard the five fixings and remove the oil transfer pipe. Remove and discard the two O-ring seals.

    1. Oil transfer pipe

    2. Oil pick up pipe

    3. Fixings
  2. Release and discard the remaining fixing and remove the oil pick-up. Remove and discard the O-ring seal.

    1. Oil pick up pipe

    2. Fixing
  3. Using a suitable punch, carefully tap the raised ring on the coolant pipe to detach it from the water pump.

    1. Coolant pipe

    2. Raised ring

    3. Water pump
  4. Remove and discard the two inner O-rings and remove the coolant pipe from the crankcase.

    1. O-rings

    2. Coolant pipe
  5. Remove and discard the four remaining O-rings from the coolant pipe.

    1. O-rings

    2. Coolant pipe
  6. Remove and discard the bolt securing the coolant inlet elbow to the crankcase and withdraw the elbow. Remove and discard the O-ring from the elbow.

    1. Coolant inlet elbow

    2. Fixing
  7. Release the fixings securing the drive chain guide to the crankcase and remove the guide.

    1. Oil pump drive chain guide

    2. Fixings
  8. Slide the oil pump drive sprocket gently backwards and forwards to dislodge the inner needle roller bearing.

    1. Oil pump drive sprocket

    2. Needle roller bearing
  9. Carefully remove the bearing while supporting the oil pump drive sprocket.

    1. Needle roller bearing

    2. Oil pump drive sprocket
  10. Release the fixings securing the drive chain cover to the oil pump. Remove the drive chain cover.

    1. Oil pump

    2. Fixings

    3. Drive chain cover
  11. Using a suitable tool, slide the dowel upwards to release the oil pump from the crankcase. It is not necessary to remove the dowel completely from the oil pump.

    1. Oil pump

    2. Dowel
  12. Detach the drive chain from the oil pump.

    1. Oil pump

    2. Drive chain
  13. Carefully withdraw the oil pump from the crankcase.
  14. Remove and discard the O-ring from the inlet sleeve on the water pump body.

Oil Pump - Disassembly

  1. Release the fixing and remove the drive sprocket and spacer washer.

    1. Oil pump

    2. Spacer washer

    3. Drive sprocket

    4. Fixing
  2. Release the three fixings and withdraw the oil pump cover.

    1. Oil pump cover

    2. Fixings

Oil Pump - Inspection

caution

If any part of the oil pump is found to be outside the service limit, the complete pump must be replaced. Severe engine damage may result from the continued use of a faulty oil pump.

Rotor Tip Clearance

  1. Measure the rotor tip clearance using feeler gauges.
  2. For specifications refer toLubrication.

    3. Rotor Tip Clearance

Pump Body Clearance

  1. Measure the pump body clearance using feeler gauges.
  2. For specifications refer toLubrication.

    3. Pump Body Clearance

Pump End Clearance

  1. Check the pump end clearance, using Plastigauge (Triumph part number 3880150-T0301) as follows:

    1. Outer rotor

    2. Plastigauge

    1. Outer rotor

    2. Plastigauge

    3. Gauge, in millimetres
  2. For specifications refer toLubrication.

Oil Pump - Assembly

  1. If all clearances are within service limits, liberally apply clean engine oil to all internal components and refit the oil pump cover. Refit the fixings and tighten to 12 Nm.
  2. If any clearance measured is outside the service limits, renew the complete pump.
  3. Inspect the sprockets and chain for wear and/or damage. Replace the sprockets and chain if wear and/or damage is found.
  4. Check the water pump shaft and shaft bearings for side and end float. Renew if necessary.
  5. Check for corrosion and scale build-up around the impeller and in the pump body. Renew if necessary.
  6. Check the oil pump location dowel for damage. Renew if necessary.
  7. Refit the spacer washer and drive sprocket. Ensure that the OUT mark is facing outwards. Apply ThreeBond 1374 to the threads and tighten to 12 Nm.

    1. Oil pump

    2. Spacer washer

    3. Drive sprocket

    4. Fixing

    5. OUT mark

Oil Pump - Installation

caution

Before fitting the oil pump to the crankcase ensure the pump internal surfaces have been wetted with clean engine oil. The pump may fail to pick-up oil from the sump if the surfaces have not been wetted. This will cause the engine to run without engine oil pressure and will lead to severe engine damage.

  1. Install a new O-ring to the inlet sleeve on the water pump body.
  2. Fill the oil pump with new engine oil, turning the pump rotor as the oil is poured in to ensure all surfaces are coated with oil.
  3. Position the oil pump to the crankcase and insert the water pump inlet sleeve into the opening in the crankcase.
  4. Fit the oil pump to the crankcase, ensuring the oil pump dowel correctly locates into the bolt hole in the crankcase.

    5. caution

    Do not use excessive force to insert the dowel into the crankcase. Severe dowel or crankcase damage may result from the use of excessive force.

  5. Using a suitable pin punch, gently tap the dowel downwards into the crankcase until it seats.
  6. Feed the drive chain over the transmission input shaft and fit to the sprocket.
  7. Fit the drive chain to the sprocket on the oil pump.
  8. Support the oil pump drive sprocket and carefully refit the needle roller bearing.

    1. Needle roller bearing

    2. Oil pump drive sprocket
  9. Refit the oil pump drive chain cover to the oil pump and fit new fixings. Tighten the fixings to 12 Nm.

    1. Oil pump

    2. Fixings

    3. Drive chain cover
  10. Refit the oil pump drive chain guide. Install new fixings and tighten to 10 Nm.
  11. Install a new O-ring to the coolant inlet elbow and position the elbow to the water pump inlet. Fit a new bolt and tighten to 12 Nm.

    1. Coolant inlet elbow

    2. Fixing
  12. Install four new O-rings to the coolant outlet pipe as shown in the illustration below.

    1. O-rings

    2. Coolant pipe
  13. Position the coolant pipe through the crankcase and fit two new O-rings to the pipe.

    1. O-rings

    2. Coolant pipe
  14. Align the pipe to the water pump and using a suitable punch, carefully tap the raised ring on the pipe to engage it fully into the water pump.

    1. Coolant pipe

    2. Raised ring

    3. Water pump
  15. Install a new O-ring to the oil pick-up and refit the oil pick-up. Fit new bolts and tighten to 12 Nm.
  16. Install two new O-rings to the oil transfer pipe and refit the oil transfer pipe. Fit new bolts and tighten to 10 Nm.

Perform the following operations:

Heat Exchanger - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

If the engine has recently been running, the engine oil will be hot to the touch. Contact with the hot oils may cause damage to exposed skin. To avoid skin damage, do not touch hot oil.

warning

Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contamination which can cause cancer. Wear suitable clothing and avoid skin contact.

The engine oil and filter must be replaced in accordance with scheduled maintenance requirements.

note
  • Prior to disassembly of the coolant hose, note the orientation and position of the hose clip to help ensure that it is returned to the same position and orientation on assembly.

Perform the following operations:

  1. Disconnect the coolant hose from the heat exchanger.
  2. Release the fixings and remove the heat exchanger.

    1. Heat exchanger

    2. Fixings

    3. Coolant hose clip

Heat Exchanger - Inspection

  1. Check the heat exchanger body for corrosion and/or damage.

Heat Exchanger - Installation

  1. Fit a new seal for the heat exchanger to the lower crankcase.

    1. seal

    2. Lower crankcase
  2. Fit the heat exchanger to the crankcase and tighten its fixings to 10 Nm.
  3. Fit the coolant hose to the heat exchanger and secure with the coolant hose clip.

    1. Heat exchanger

    2. Fixings

    3. Coolant hose clip

Perform the following operations:

Low Oil Pressure Warning Light Switch - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

The low oil pressure warning light switch is located in the upper crankcase, behind the cylinder head.

Perform the following operations:

  1. Disconnect the electrical connection to the switch.
  2. Remove the switch and collect the copper washer.

    1. Low oil pressure warning light switch

    2. Electrical connection

Low Oil Pressure Warning Light Switch - Installation

  1. Incorporating a new copper washer, fit the switch and tighten to 13 Nm.
  2. Refit the electrical connection.

Perform the following operations:

Engine Remove and Install

Engine - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    caution

    To prevent chain damage, do not allow the chain to come into contact with dirt, road grit etc.

  1. If required, drain the engine oil (see Oil and Oil Filter Change).
  2. Set the drive chain adjustment to allow maximum free play in the chain (see Final Drive Chain Free-Movement Adjustment).
  3. Disconnect the gear position sensor from the main harness.
  4. Release the pinch bolt and remove the gear change linkage from the gearbox shaft.

    1. Pinch bolt

    2. Gear pedal crank

    3. Gear position sensor connector
  5. Release the fixings and detach the two harness brackets from the engine breather cover.
  6. Ease the rubber boot from the battery ground cable, Release the fixing and detach the ground cables from the frame.

    1. Harness brackets

    2. Fixings

    3. Rubber boot

    4. Ground cable fixing

    note
    • Note the routing of the crankshaft position sensor harness for installation.
  7. Disconnect the crankshaft position sensor from the main harness.

    1. Crankshaft position sensor connector

    note
    • Note the routing of the alternator harness for installation.
  8. Disconnect the grey connector from the regulator/rectifier. Route the harness back to the top of the engine.

    1. Grey connector

    2. Regulator/rectifier
  9. Disconnect all the remaining electrical connections from the main harness to the engine.
  10. Disconnect the clutch cable from the clutch (see Clutch Cable - Removal).
  11. Place a support beneath the engine and ensure that the frame is still adequately and securely supported.

    12. note
    • Note the position of the spacer installed to the lower gearbox bolt, left hand side of the engine.
  12. Remove the cover for the gearbox upper mounting on the left hand side of the frame.

    1. Cover

    2. Gearbox upper mounting
  13. Release the nuts securing the gearbox mounting bolts and remove the two bolts. Collect the washers and collect the spacer from the lower bolt.

    1. Nut

    2. Washer

    3. Spacer
  14. Release the nut securing the left hand front engine mounting bolt and remove the bolt.
  15. Remove the left hand centre engine mounting bolt.

    16. note
    • The frame is fitted with four frame adjuster sleeves, located on the left hand side of the frame, as shown below.

    1. Front frame adjuster position

    2. Centre frame adjuster position

    3. Rear upper frame adjuster position

    4. Rear lower frame adjuster position
  16. Using T3880103 - Engine Mounting Adjuster, loosen the rear upper frame adjuster sleeve.
  17. Using T3880181 - Wrench Frame Adjuster, loosen the rear lower frame adjuster sleeve.

    1. T3880103 - Engine Mounting Adjuster

    2. Rear upper frame adjuster

    3. T3880181 - Wrench Frame Adjuster

    4. Rear lower frame adjuster
  18. Using T3880103 - Engine Mounting Adjuster, loosen the centre and front frame adjuster sleeves.

    1. T3880103 - Engine Mounting Adjuster

    2. Front frame adjuster

    3. Centre frame adjuster
  19. Remove the two remaining (right hand) engine mounting bolts and lower the engine sufficiently to allow the drive chain to be detached from the output sprocket.
  20. Remove the engine from the frame.

caution

To prevent damage to components, lower the engine very carefully.

Engine - Installation

  1. Position the engine beneath the frame.
  2. Raise the engine, looping the drive chain over the output sprocket as it is raised.

    3. caution

    Unless the following engine mounting bolt installation/tightening sequence is precisely followed, severe frame damage can occur.

  3. Align the engine to the frame.
  4. Lubricate the threads of the mounting bolts for the cylinder head rear mountings only with a smear of proprietary high temperature copper based grease.
  5. Fit the right hand centre engine mounting bolt (located at the rear of the cylinder head) ensuring the engine is still adequately and securely supported. Do not tighten the bolt at this stage.

    6. note
    • The frame is fitted with four frame adjuster sleeves, located on the left hand side of the frame, as shown below.

    1. Front frame adjuster position

    2. Centre frame adjuster position

    3. Rear upper frame adjuster position

    4. Rear lower frame adjuster position
  6. Align the left hand centre engine mounting and using T3880103 - Engine Mounting Adjuster, tighten the frame adjuster to 3 Nm.

    1. T3880103 - Engine Mounting Adjuster

    2. Centre frame adjuster
  7. Fit the left hand centre engine mounting bolt but do not fully tighten at this stage.
  8. Insert the lower and upper rear (gearbox) bolts from the right hand side, ensuring the spacer is installed as noted during removal.

    1. Nut

    2. Washer

    3. Spacer
  9. Using T3880103 - Engine Mounting Adjuster, tighten the rear upper frame adjuster sleeve to 10 Nm.
  10. Using T3880181 - Wrench Frame Adjuster, tighten the rear lower frame adjuster sleeve to 10 Nm.

    1. T3880103 - Engine Mounting Adjuster

    2. Rear upper frame adjuster

    3. T3880181 - Wrench Frame Adjuster

    4. Rear lower frame adjuster
  11. Fit the right hand front engine mounting bolt (located at the front of the cylinder head), fit a new nut and tighten the bolt to 48 Nm.
  12. Tighten the right hand centre engine mounting bolt to 48 Nm.
  13. Tighten the left hand centre engine mounting bolt to 48 Nm.
  14. Fit the washer and a new nut to the lower rear (gearbox) bolt and tighten the bolt to 48 Nm.
  15. Using T3880103 - Engine Mounting Adjuster, tighten the front frame adjuster to 3 Nm.

    1. T3880103 - Engine Mounting Adjuster

    2. Front frame adjuster
  16. Fit the washer and a new nut to the upper rear (gearbox) bolt and tighten the bolt to 48 Nm.
  17. Fit the left hand front engine mounting bolt and fit a new nut. Tighten the bolt to 48 Nm.
  18. Remove the support from beneath the engine.
  19. Refit the cover to the gearbox upper mounting on the left hand side of the frame.

    1. Cover

    2. Gearbox upper mounting
  20. Connect the clutch cable to the clutch (see Clutch Cable - Installation).
  21. Connect the crankshaft position sensor to the main harness.

    1. Crankshaft position sensor connector
  22. Route the alternator harness as noted for removal and connect it to the regulator/rectifier.

    1. Grey connector

    2. Regulator/rectifier
  23. Attach the ground cables to the engine and tighten the fixing to 10 Nm. Refit the rubber boot over the ground cables.
  24. Attach the two harness brackets to the engine breather cover and tighten the fixings to 9 Nm.

    1. Harness brackets

    2. Fixings

    3. Rubber boot

    4. Ground cable fixing
  25. Connect the gear position sensor to the main harness.
  26. Reconnect all electrical connections to the engine.
  27. Align the split line on the gear pedal crank to the dot mark on gear change shaft. Tighten the pinch bolt to 9 Nm.

    1. Dot mark

    2. Split line

    3. Pinch bolt
  28. Set the drive chain adjustment (see Final Drive Chain Free-Movement Adjustment).
  29. Route the side stand switch down to the side stand as noted for removal.
  30. If drained, refill the engine oil (see Oil and Oil Filter Change).

Perform the following operations:

Fuel System and Engine Management

Exploded Views

Exploded View – Fuel Tank and Fuel Pump

Exploded View – Fuel Rail, Throttles and Injectors

Exploded View - Airbox

Exploded View - Exhaust System

Exploded View - Secondary Air Injection

Exploded View – Evaporative System

Exploded View - Immobiliser Control Module

Engine Management

Fuel Requirements

Fuel Requirements - all countries except USA

This model must be run on 91 RON or higher unleaded fuel.

Fuel Requirements - USA

In the United States of America where the octane rating of fuel is measured in a different way, the following information may be applied:

This model is designed to run on unleaded gasoline with a CLC or AKI octane rating (R+M)/2 of 87 or higher.

note
  • If 'Knocking' or 'Pinking' occurs at a steady engine speed under normal load, use a different brand of gasoline or a higher octane rating.

caution

The use of leaded gasoline is illegal in some countries, states or territories and will invalidate the vehicle and emissions control warranties. Additionally, leaded gasoline will cause damage to emissions control components.

Oxygenated Gasoline

To help in meeting clean air standards, some areas of the U.S. use oxygenated gasoline to help reduce harmful emissions. This model will give best performance when using unleaded gasoline. However, the following should be used as a guide to the use of oxygenated fuels.

caution

Because of the generally higher volatility of oxygenated fuels, starting, engine response and fuel consumption may be adversely affected by their use. Should any of these difficulties be experienced, run the motorcycle on normal unleaded gasoline.

Ethanol

Ethanol fuel is a mixture of 10% ethanol and 90% gasoline and is often described under the names 'gasohol', 'ethanol enhanced', or 'contains ethanol'. This fuel may be used in Triumph motorcycles.

Methanol

caution

Fuels containing methanol should not be used in Triumph motorcycles as damage to components in the fuel system can be caused by contact with methanol.

MTBE (Methyl Tertiary Butyl Ether)

The use of gasolines containing up to 15% MTBE (Methyl Tertiary Butyl Ether) is permitted in Triumph motorcycles.

Glossary of Terms

The following terms and abbreviations will be found in this section. A brief explanation is given below of what some of the more common terms and abbreviations mean.

Air temperature

The air temperature in the airbox and intake system.

Air temperature sensor

A sensor located in the airbox to detect the temperature of the incoming air.

ATDC

After Top Dead Centre (TDC).

Ambient air pressure

Pressure of the air in the airbox.

Battery Voltage

The voltage at the input to the Engine Electronic Control Module (ECM).

BTDC

Before Top Dead Centre (TDC).

Catalytic converter

A device placed in the exhaust system which reduces exhaust emissions by stimulating secondary combustion of the exhaust gases.

Closed throttle position

Throttle position at idle (i.e. against end stop), measured as a voltage and expressed as a percentage.

Coolant temperature

The coolant temperature in the cylinder head.

Coolant temperature sensor

Sensor which detects coolant temperature.

Cooling fan status

The ON or OFF condition of the cooling fan.

DTC

Diagnostic Trouble Code.

Engine ECM

Engine Electronic Control Module

Engine speed

The crankshaft revolutions per minute.

Fall detection

The fall detection switch will detect if the motorcycle is on its side and will cut power to the engine ECM immediately.

Freeze frame

A data set captured at the time a Diagnostic Trouble Code (DTC) is set.

Gear position sensor

Gearbox mounted sensor which delivers information to the engine ECM. This is converted to the gear position value that is displayed on the instrument’s gear position indicator and/or neutral lamp.

Idle fuel trim

The percentage above or below the nominal fuel requirement for the volume of air entering at idle.

Idle fueling

Adjustment of fueling at idle to suit the actual air inducted.

Idle reference speed

The target idle speed as determined by the engine ECM. (It should be the same as the actual idle speed if the motorcycle is operating correctly.)

Ignition advance

The timing of ignition at the spark plug relative to top dead centre (TDC).

Ignition switch position

The ON or OFF position of either or both the ignition switch and the engine stop switch.

Ignition timing

Same as ignition advance.

Immobiliser and Tyre Pressure Monitoring System (TPMS) control module

The control module for the Immobiliser and TPMS system.

Injector pulse time

The time during which an injector remains open (i.e. delivering fuel).

Long term fuel trim

Fuelling after adapting to the engine's long term fuelling requirements (closed loop only). See also short term fuel trim.

MAP sensor

Manifold Absolute Pressure (the air pressure in the intake system). Measured after the throttle valves. This reading is compared to the ambient air pressure reading to allow the engine ECM to calculate engine load.

MIL

Malfunction Indicator Lamp.

Illuminates when most Diagnostic Trouble Codes (DTCs) are set.

Open circuit

A break in an electrical circuit - current cannot flow.

Over temperature

High temperature within the Engine Control Module (ECM) caused by an internal or external failure.

Oxygen Sensor

The Oxygen sensor measures the oxygen levels in the exhaust gases and feeds this information to the ECM. Based on this information, adjustments to air/fuel ratio are made.

Primary throttle position sensor

Sensor for the primary (lower) throttle position.

Throttle actuator motor

Motor used to open/close the throttle.

Twist grip position sensor

The twist grip position sensor is used to relay twist grip position information to the engine ECM. The engine ECM uses this information to drive the throttle actuator motor to the correct position.

Purge valve duty cycle

The time the purge valve is open in an open/close cycle, expressed as a percentage of the cycle time.

Road speed sensor

Non ABS models use a gearbox mounted sensor which delivers information to the engine ECM that is converted to the road speed value that is displayed on the speedometer.

ABS models use the rear wheel speed sensor to supply road speed data to the engine ECM.

Secondary air injection

A small amount of air injected into the exhaust port to reduce the levels of pollutants in the exhaust gases.

Sensor supply Voltage

Supply voltage to the system sensors (nominally 5 Volts).

Short circuit

A 'short cut' in an electrical circuit - current by-passes the intended circuit (usually to earth).

Short term fuel trim

A correction applied to the fuel mixture during closed loop catalyst operation. This, in turn has an effect on the long term fuel trim in that, if an engine constantly requires mixture correction, the long term fuel trim will adapt to this requirement thus reducing the need for constant short term adjustment.

Side stand status

The up or down position of the side stand.

Target dwell time

The actual time from coil on to coil off.

Throttle position

The position of the throttle butterfly given as a percentage of the movement range. When the data is displayed on the tool, fully open need not be 100% nor fully closed 0%.

Throttle Voltage

Voltage at the throttle potentiometer.

TDC

Top Dead Centre.

TPMS

Tyre Pressure Monitoring System.

Transponder

A transmitter-responder chip located in the ignition key. The transponder is activated by a radio signal sent out by the immobiliser and TPMS control module, via an antenna located around the ignition switch. If the immobiliser and TPMS control module does not receive the correct code signal from the transponder, the immobiliser will remain active and the engine will not start.

Engine Management System

System Description

This model is fitted with an electronic engine management system which encompasses control of both ignition and fuel delivery. The engine electronic control module (ECM) draws information from sensors positioned around the engine, cooling and air intake systems and precisely calculates ignition advance and fueling requirements for all engine speeds and loads.

In addition, the system has an on-board diagnostic function. For additional information, see System Diagnostics.

System Sensors

Sensor Locations

Actuators

System Actuators

In response to signals received from the sensors, the engine ECM controls and directs messages to a series of electronic and electro-mechanical actuators. The function and location of the actuators is given below.

note
  • In this system, the starter lockout system (clutch switch, gear position sensor, side stand switch) all operate through the engine ECM.

Actuator Locations

Immobiliser System

System Description

This model is fitted with an electronic immobiliser system to help protect it against theft. This system has to be paired with the engine ECM and the ignition key which contains a transponder chip. If all the components are correctly paired, the immobiliser will allow the engine to start. The Triumph diagnostic tool is the only way these components can be paired.

In addition, the system has an on-board diagnostic function. This ensures that, should a malfunction occur in the immobiliser system, a malfunction code is stored in the chassis ECM memory. This stored data can then be recovered using the Triumph diagnostic tool (see System Diagnostics).

System Components and Operation
Keys

When the motorcycle is delivered from the factory it is supplied with two keys. Keys can be deleted or added to the immobiliser system using the Triumph diagnostic tool. A maximum of four keys can be added to the system.

To ensure the immobiliser system functions correctly note the following:

Diagnostics

To fully diagnose the immobiliser system it is necessary to check for fault codes in the immobiliser control module using the Triumph diagnostic tool (see System Diagnostics).

Further Diagnosis

The diagnostic trouble code tables, if used correctly, help to pinpoint a fault in the system once a diagnostic trouble code has been stored (see System Diagnostics).

Immobiliser System Components Location

Engine Management Circuit Tables

Key to Circuit Diagram

Key

Item Description

1

Engine Electronic Control Module

2

Diagnostic Connector

3

Bluetooth Module

4

Instruments

5

ABS Module

6

Immobiliser

7

Clutch Switch

8

Side Stand Switch

9

Ignition Switch

10

Fuel Level Sender

11

Gear Position Sensor

12

Fall Detection Switch

13

Ambient Pressure Sensor

14

Manifold Absolute Pressure (MAP) Sensor

15

Intake Air Temperature Sensor

16

Quickshifter

17

Twist Grip Position Sensor

18

Throttle Position Sensor

19

Throttle Actuator Motor

20

Fuel Pump Relay

21

Fuel Pump

22

Cooling Fan Relay

23

Cooling Fan

24

Brake Lamp

25

Front Brake Switch

26

Rear Brake Switch

27

Ignition Coil 3

28

Ignition Coil 2

29

Ignition Coil 1

30

Oxygen Sensor

31

Secondary Air Injection Solenoid

32

Fuel Injector 3

33

Fuel Injector 2

34

Fuel Injector 1

35

Purge Valve

36

Engine Management System Relay

37

Fuse Box

38

Crankshaft Position Sensor

39

Coolant Temperature Sensor

40

Engine Sub-harness

41

Ignition Switch
Key To Wiring Colour Codes

Code

Wiring Colour

B

Black

U

Blue

N

Brown

G

Green

S

Slate/Grey

O

Orange

K

Pink

R

Red

P

Purple

W

White

Y

Yellow

LG

Light Green

LU

Light Blue

Engine Management Circuit Diagram

Engine Management Adaption

General Information

The engine management system fitted to this model is adaptive. This means that the system is able to learn about new or changing operating conditions and continuously adapt itself without needing to constantly make major adjustments from a fixed baseline setting.

Adaptive changes can become necessary because of changing rider behaviour, changes in the region in which the bike is operated (i.e. operation at high altitude where it was previously used at sea level) or because a new part may have been fitted which has slightly different characteristics to the old part. All adaptive changes are automatic and require no intervention by rider or dealer.

Adaption Status

To see if a motorcycle has fully adapted, a facility named 'ADAPTION STATUS' is provided on the diagnostic tool. The following adaption details can be examined:

Function Examined

Report Method

Closed throttle position reference status

Adapted/not adapted

Idle speed control adaption status

%

Oxygen sensor adaption status (off idle)

%

Oxygen sensor adaption range (off idle)

%

Oxygen sensor adaption status (idle)

%

Oxygen sensor adaption range (idle)

%
Terminology

Where the term 'status' is used, this indicates how far the present operating parameter is from the stored (baseline) value. The nearer these figures are to zero the better as it indicates the motorcycle has adapted to its current operating conditions.

The term 'range' indicates how much (in percentage terms) of the adjustment range has been used to reach the current operating status.

Typical Values

In a correctly adapted motorcycle, the following will be typical:

Function Examined

Read Out

Closed throttle position reference status

Adapted

Idle speed control adaption status

Between +100 and -100%

Oxygen sensor adaption status (off idle)

0% +/- 10%

Oxygen sensor adaption range (off idle)

Between +100 and -100%

Oxygen sensor adaption status (idle)

0% +/- 10%

Oxygen sensor adaption range (idle)

Between +100 and -100%
Forcing Adaption to Take Place

If the read out indicates that the motorcycle is not adapted, the following will force the system to make adaptions:

warning

Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate the motorcycle in the open-air or in an area with adequate ventilation.

note
  • Resetting adaptions with the motorcycle connected to an exhaust extraction system may cause incorrect values to be set, causing poor engine running. Always reset the adaptions with the engine disconnected from any exhaust extraction system whilst ensuring the motorcycle is positioned in a well ventilated area.
  1. Ensure the engine is cold.
  2. WITHOUT TOUCHING THE THROTTLE, start the engine and allow it to warm up until the cooling fan comes on.
  3. Leave the engine to idle for a further 12 minutes.

note
  • As an alternative to the above process, connect the diagnostic tool, select ADJUST TUNE (see the Triumph Diagnostic Tool User Guide) and select RESET ADAPTIONS. This will force a fast adaption routine to take place in around five seconds. For this to happen, the engine MUST be running, it must be at normal operating temperature and in closed loop control mode. Under any other conditions fast adaption will not take place and may cause default values to be loaded, which may then require a normal 12 minute adaption routine to be run.
Fault Indications

If 'range' figures at 100% are seen, then the adjustment has reached maximum indicating a mechanical fault exists on the motorcycle. This can be due to a number of faults but the most likely causes will be low/high fuel pressure, faulty injectors or air leaks at the throttle bodies or airbox.

In these circumstances, locate and rectify the fault, and reset the adaptions as described above.

Diagnostics and Testing

Electrical Connectors

Before beginning any diagnosis, the following connector related information should be noted:

note
  • A major cause of hidden electrical faults can be traced to faulty electrical connectors. For example:
  • Dirty/corroded terminals
  • Damp terminals

For example, the engine electronic control module (engine ECM) relies on the supply of accurate information to enable it to plan the correct fuelling and ignition timing. One dirty terminal will cause an excessive voltage drop resulting in an incorrect signal to the engine ECM.

If, when carrying out fault diagnosis, a fault appears to clear by simply disconnecting and reconnecting an electrical plug, examine each disconnected plug for the following.

When Disconnecting a Connector:
When Inspecting a Connector:
When Connecting a Connector:
Disconnection of the Engine ECM Connectors

caution

When disconnecting a connector, never pull directly on the wires as this may result in cable and connector damage.

caution

Never disconnect an ECM when the ignition switch is in the ON position as this may cause multiple fault codes to be logged in the ECM memory.

Always disconnect an ECM after disconnecting the battery negative (black) lead first.
  1. Turn the ignition to the OFF position and wait at least 1 minute for the engine ECM to complete its power down sequence.
  2. Detach the engine ECM and its bracket and the airbox (see Engine Electrical Control Module (ECM) - Removal).

note
  • Two different sized connectors are used in the engine ECM, which ensures correct connection is always made. The connectors are coloured black and correspond with identical connectors on the main harness.
  1. Press down on the locking device and gently pull back on the connector to release it from the engine ECM.

    1. Locking device

    2. Locking lever
Reconnection of the engine ECM Connectors

caution

Damage to the connector pins may result if an attempt to fit the connectors incorrectly is made.

  1. Fit the connector into its socket. When the locking lever starts to move, stop pushing the connector and use the locking lever to fully insert the connector home and lock it.

    1. Connector B (large)

    2. Connector A (small)
  1. Refit the engine ECM and its bracket to the frame under the seat (see Engine Electronic Control Module (ECM) - Installation).

System Diagnostics

The engine management system has an on-board diagnostics feature which allows service technicians to retrieve stored data from the ECM using Triumph diagnostic software. Full details of the Triumph diagnostic software operation and how to interpret the results are given in the Triumph Diagnostic Tool User Guide.

The software allows the user to retrieve data associated with the system sensors and actuators, test various component functions, read build data and make minor adjustments to the set-up of the system. The data and tests available are described on the following pages.

On-board Fault Detection System

The on-board diagnostic system has two stages to fault detection. When a fault is detected, the DSM (Diagnostic Status Manager) raises a flag to indicate that a fault is present and increments a counter. The counter checks the number of instances that the fault is noted. For example, if there is a fault in the crankshaft position sensor, the counter will increment its count each time the crankshaft turns through 360°, provided the fault is still present.

When the count begins, the fault is detected but not confirmed. If the fault continues to be detected and the count reaches a predetermined threshold, the fault becomes confirmed. If the fault is an emissions related fault or a serious malfunction affecting engine performance, a DTC (Diagnostic Trouble Code) and freeze-frame data will be logged in the ECM's memory and the MIL (Malfunction Indicator Lamp) on the motorcycle instrument panel is illuminated. Once a fault is confirmed, the number of warm-up cycles made by the engine is counted. If the fault clears, the warm-up cycle counter will extinguish the MIL (Malfunction Indicator Lamp) at a predetermined count, and erase the DTC and freeze-frame data from the ECM memory at another (higher) count.

A single warm-up cycle is deemed to have taken place when the following criteria have been met:

note
  • When a fault has been rectified, the MIL will remain illuminated until sufficient non-fault warm-up cycles have taken place to turn it off. The MIL will be immediately extinguished if, after first rectifying the fault, the DTC (diagnostic trouble code) that caused the MIL illumination is erased from the ECM memory using the Triumph diagnostic software.

note
  • In some cases, when a fault is detected, the engine management system will revert to a limp-home mode. In this mode, the engine will still function though the performance and fuel economy may be marginally affected. In some cases, the rider may not notice any appreciable difference from normal operation.

ECM Connector Pin Numbering

The above illustration shows the pin numbering system used in the engine management circuit diagram.

The smaller connector's pins are prefixed A and the larger connector pins B. As viewed on the mating face with the ECM (as per the illustration), pins are numbered from right to left with number one in the top right corner.

Tool Connection

Diagnostic Tool Connection
  1. To connect the Triumph diagnostic interface to the motorcycle, remove the seat (see Seat - Removal) and release the diagnostic connector from its location on the airbox.

    1. Diagnostic connector
  2. Plug the Triumph diagnostic interface directly into the diagnostic connector.

    3. T3880057 - Triumph Diagnostic Interface
  3. When the diagnostic session is completed, disconnect the Triumph diagnostic interface.
  4. Refit the diagnostic connector to its location and refit the seat (see Seat - Installation).

Triumph Diagnostic software

Described on the following pages is the range of information which can be retrieved from the ECM’s memory and the adjustments which can be performed using the Triumph diagnostic software.

The tables indicate which tests are performed by the on-board system and what information can be retrieved by the Triumph diagnostic software.

note
  • Full details of how to operate the software can be found in the Triumph Diagnostic Tool User Guide, which can be downloaded by authorised Triumph dealers from www.triumphonline.net.
Build Data

The Build Data screen will display the following information:

Current Data

The data available under Current Data is:

Function Examined

Result Reported (Scale)

Fuel system status

open or closed loop operation

Calculated load value

%

Engine coolant temperature

°C

Short term fuel trim

%

Intake manifold absolute pressure

mmHg

Engine speed

rpm

Vehicle speed

km/h

Ignition timing advance

degrees

Intake air temperature

°C

Absolute throttle position

%

Oxygen sensor

Volts
Sensor Data

When using this function it is possible to check the status of various sensors and actuators.

The data sets are divided into seven groups - Sensor Voltages; Sensor Readings; Injector Data; Ignition Data; Idle Speed, Throttle Data and Inputs and Adaption Status. Each of these screens is described on the following pages.

Sensor Voltages

The data available under Sensor Voltages is:

Item Checked

Result Unit

Battery voltage

Volts

Voltage from ignition switch to ECU

Volts

Air temperature sensor voltage

Volts

Coolant temperature sensor voltage

Volts

Atmospheric pressure sensor voltage

Volts

Manifold absolute pressure sensor voltage

Volts

Throttle position sensor voltage

Volts

Twist grip sensor voltage

Volts

Fuel level sensor voltage

Volts

Oxygen sensor output voltage

Volts
Sensor Readings

The data available under Sensor Readings is:

Item Checked

Result Unit

Air temperature

°C

Coolant temperature

°C

Atmospheric (barometric) pressure

mmHg

Manifold absolute pressure (one reading per cylinder)

mmHg

Low fuel light

on/off

Oxygen sensor heater status

on/off
Injector Data

The data available under Injector Data is:

Item Checked

Result Unit

Injector 1 pulse time

milliseconds

Injector 2 pulse time

milliseconds

Injector 3 pulse time

milliseconds
Ignition Data

The data available under Ignition Data is:

Item Checked

Result Unit

Ignition timing cyl 1

degrees BTDC

Ignition timing cyl 2

degrees BTDC

Ignition timing cyl 3

degrees BTDC

Coil 1 dwell time

milliseconds

Coil 2 dwell time

milliseconds

Coil 3 dwell time

milliseconds
Idle Speed and Throttle Data

The data available under Idle Speed and Throttle Data is:

Item Checked

Result Unit

Engine speed

rpm

Idle reference speed

rpm

Idle speed control current steps

numeric

Idle speed control target steps

numeric

Throttle position

% open

Secondary air injection status

SAI on/off
Inputs

The data available under Inputs is:

Function Examined

Result Unit

EMS main relay status

relay on/off

Fuel pump relay status

on/off

Starter relay status

starter on/off

Starter switch status

switch on/off

Side stand status

up/down

Fall detection status

normal/over

Clutch switch status

release/grip

Neutral switch

gear/neutral

Vehicle speed

km/h

Malfunction indicator light status

MIL on/off

Cooling fan status

fan on/off

Calculated load

%

Purge valve duty cycle

%
Adaption Status

Because the fuel system is adaptive, the engine management system is able to automatically adjust to new working conditions, such as changes in fuel quality, component wear, air leaks etc. This screen displays information on the adaption status of the vehicle which will show if it has adapted or not.

Function Examined

Report Method

Closed throttle position adapted

adapted/not adapted

Idle speed control adaption status

%

Oxygen sensor adaption range (off idle)

%

Oxygen sensor adaption range (idle)

%

Oxygen sensor adaption status (off idle)

%

Oxygen sensor adaption status (idle)

%
Function Tests

The system allows the diagnostic software to perform a series of function tests on various actuators in the engine management system. In some cases it is necessary to make a visual observation of a component and in others, if faults are present, DTCs will be logged.

The Function Tests available are:

Function Examined

Report Method

Instrument panel

Observe instrument panel, refer to service manual

Idle air control stepper motor

Observe throttle position/Stored fault code*

Purge valve

Listen for valve operation/Stored fault code*

Fuel pump - priming

Listen for fuel pump operation/Stored fault code*

Fuel pump - continuous operation

Fuel pressure test/Listen for fuel pump operation/Stored fault code*

Cooling fan control

Observe the cooling fan/Stored fault code*

Secondary air injection

Listen for valve operation/Stored fault code*

* If a fault is detected.

Adjust Tune

To reset the adaptions, see Engine Management Adaption.

Freeze Frame Data

Freeze frame data is stored at the time a DTC is recorded (confirmed) by the ECM. If multiple DTCs are recorded, the freeze frame data which is stored will relate to the first recorded DTC only.

By calling up freeze frame data associated with the first recorded DTC, the technician can check the engine condition at the time the fault occurred. The data available is:

Function Examined

Report Method

DTC

Diagnostic Trouble Code (DTC) number

Fuel system status

open or closed loop operation

Calculated load

%

Coolant temperature

°C

Short term fuel trim

%

Intake manifold absolute pressure

mmHg

Engine speed

rpm

Vehicle speed

km/h

Ignition advance

degrees

Intake air temperature

°C

Throttle position

%

Oxygen sensor output voltage

Volts

Oxygen sensor short term fuel trim

%

Engine Electronic Control Module - Diagnostic Trouble Codes

Diagnostic trouble codes (DTCs) are logged in the ECM memory when there is a confirmed fault in the system.

The codes are reported to the Triumph diagnostic software as a four digit code.

As mentioned earlier, when the system detects a fault, it begins to count the number of times the fault occurs before illuminating the MIL and storing a fault code.

Similarly, if a fault clears, the ECM also records this fact and will turn off the MIL when sufficient no fault warm-up cycles have taken place. Any fault codes will remain in the ECM memory until the required number of no fault warm-up cycles have taken place. The number of warm-up cycles required to extinguish the MIL will always be less than the number required to remove a DTC from the ECM memory. DTCs can be removed at any time using the Triumph diagnostic software.

The system will log the diagnostic trouble codes listed below/over:

Diagnostic Trouble Code (DTC)

Fault Description

Number of no-fault cycles before turning off MIL

Number of no-fault cycles before DTC is erased

MIL illuminated when fault is logged

Pinpoint test page number

P0030

Oxygen sensor 1 heater open circuit or short to ground

3

40

Yes

Oxygen Sensor Heater

P0032

Oxygen sensor 1 heater short circuit to battery Voltage

3

40

Yes

Oxygen Sensor Heater

P0105

Manifold absolute pressure sensor 1 open circuit or short circuit to 5 Volt sensor supply

3

40

Yes

Manifold Absolute Pressure (MAP) Sensor

P0107

Manifold absolute pressure sensor 1 short circuit to ground

3

40

Yes

Manifold Absolute Pressure (MAP) Sensor

P0110

Intake air temperature sensor open circuit or short circuit to 5 Volt sensor supply

3

40

Yes

Inlet Air Temperature Sensor

P0112

Intake air temperature sensor short circuit to ground

3

40

Yes

Inlet Air Temperature Sensor

P0115

Engine coolant temperature sensor open circuit or short circuit to 5 Volt sensor supply

3

40

Yes

Coolant Temperature Sensor

P0117

Engine coolant temperature sensor short circuit to ground

3

40

Yes

Coolant Temperature Sensor

P0120

Throttle position sensor 1 short circuit or open circuit

3

40

Yes

Throttle Position Sensor

P0122

Throttle position sensor 1 short circuit to ground or open circuit

3

40

Yes

Throttle Position Sensor

P0130

Oxygen sensor 1 open circuit or short circuit to battery Voltage

3

40

Yes

Oxygen Sensor

P0131

Oxygen sensor 1 short circuit to ground

3

40

Yes

Oxygen Sensor

P0201

Injector 1 circuit malfunction

3

40

Yes

Fuel Injectors

P0202

Injector 2 circuit malfunction

3

40

Yes

Fuel Injectors

P0203

Injector 3 circuit malfunction

3

40

Yes

Fuel Injectors

P0220

Throttle position sensor 2 short circuit to battery Voltage or open circuit

3

40

Yes

Throttle Position Sensor

P0222

Throttle position sensor 2 short circuit to ground

3

40

Yes

Throttle Position Sensor

P0335

Crankshaft sensor circuit malfunction

3

40

Yes

Crankshaft Sensor

P0351

Ignition coil 1 malfunction

3

40

Yes

Ignition Coils

P0352

Ignition coil 2 malfunction

3

40

Yes

Ignition Coils

P0353

Ignition coil 3 malfunction

3

40

Yes

Ignition Coils

P0412

Secondary air injection short circuit to ground or open circuit

3

40

Yes

Secondary Air Injection Valve

P044F

Secondary air injection short circuit to battery Voltage

3

40

Yes

Secondary Air Injection Valve

P0443

Purge valve short circuit to ground or open circuit

3

40

Yes

Purge Valve

P0459

Purge valve short circuit to battery Voltage

3

40

Yes

Purge Valve

P0460

Fuel level sensor circuit malfunction

0

40

No

Fuel Level Sensor Circuit

P0560

System voltage - battery circuit malfunction

3

40

Yes

System Voltage

P0571

Brake switch 1 malfunction

0

40

Yes

Brake Switches

P0603

EEPROM Error

0

40

No

EEPROM Error

P0606

ECM internal error

0

0

Yes

Engine ECM Internal Error

P0616

Starter relay short circuit to ground or open circuit

3

40

Yes

Starter Motor Relay

P0617

Starter relay short circuit to battery Voltage

3

40

Yes

Starter Motor Relay

P0914

Gear position sensor short circuit to ground or open circuit

3

40

Yes

Gear Position Sensor

P0917

Gear position sensor short circuit to 5 Volt sensor supply

3

40

Yes

Gear Position Sensor

P1105

Manifold absolute pressure sensor 1 pipe malfunction

3

40

Yes

Manifold Absolute Pressure (MAP) Sensor

P1135

Traction Control prevented due to ABS malfunction

3

40

Yes

Traction Control Prevented Due to ABS Malfunction

P1231

Fuel pump relay short circuit to ground or open circuit

3

40

Yes

Fuel Pump Relay

P1232

Fuel pump relay short circuit to battery Voltage

3

40

Yes

Fuel Pump Relay

P1508

Unmatched Immobiliser ECM

3

40

Flashing

Immobiliser and TPMS Control Module ID Incompatable

P1520

Unmatched ABS module

3

40

Flashing

ABS Modulator ID Incompatible

P1521

CAN fault - lost communication with ABS module or ABS system status error

3

40

Yes

ABS Modulator Communication

P1552

Cooling fan relay short circuit to ground or open circuit

3

40

Yes

Cooling Fan Relay

P1553

Cooling fan relay short circuit to battery Voltage or over temp

3

40

Yes

Cooling Fan Relay

P1571

Brake switch 2 malfunction

3

40

Yes

Brake Switches

P1576

Brake switch 1 correlation error with brake switch 2

3

40

Yes

Brake Switches

P1577

Brake switch 2 correlation error with brake switch 1

3

40

Yes

Brake Switches

P1604

ECM tamper detected - return to Triumph

0

0

Yes

Engine ECM Tamper Detected

P1605

ECM locked by the tune lock function

Only if tune lock is unlocked

Flashing

Tune Lock

P1607

ECM ride by wire internal error

3

40

Yes

Engine ECM Internal Error

P1608

ECM ride by wire internal error

3

40

Yes

Engine ECM Internal Error

P1614

Instrument ID incompatible

Only if Instrument ID Matching

Flashing

Instrument ID Incompatible

P1619

Headlamp relay short circuit to ground or open circuit

0

40

No

Headlight Relay

P1620

Headlamp relay short circuit to battery Voltage

0

40

No

Headlight Relay

P1631

Fall detection circuit short circuit to ground

3

40

Yes

Fall Detection Switch

P1632

Fall detection circuit short circuit to battery Voltage

3

40

Yes

Fall Detection Switch

P1650

CAN fault - lost communication with Immobiliser ECM

3

40

Yes

Immobiliser Control Module Communication

P1659

Ignition power supply malfunction

3

40

Yes

EMS Ignition Voltage Input Circuit

P1685

Main relay circuit malfunction

3

40

Yes

EMS Main Relay Circuit

P1690

CAN Fault

3

40

Yes

CAN Communication

P1695

CAN fault - lost communication with instrument panel

0

40

No

Instrument Communication (CAN)

P1698

5 Volt sensor supply malfunction

3

40

Yes

5 Volt Sensor Supply Circuit

P2100

Throttle actuator control motor open circuit

3

40

Yes

Throttle Actuator Motor

P2102

Throttle actuator control internal motor relay does not operate

3

40

Yes

Throttle Valve Drive Error

P2103

Throttle actuator control internal motor relay operates continually

3

40

Yes

Throttle Valve Drive Error

P2111

Throttle valve drive error (stuck open)

3

40

Yes

Throttle Valve Drive Error

P2119

Throttle valve drive error

3

40

Yes

Throttle Valve Drive Error

P2120

Twist grip position sensor 1 short circuit to ground or open circuit

3

40

Yes

Twist Grip Position 1

P2123

Twist grip position sensor 1 short circuit to battery Voltage

3

40

Yes

Twist Grip Position 1

P2125

Twist grip position sensor 2 short circuit to ground or open circuit

3

40

Yes

Twist Grip Position 2

P2128

Twist grip position sensor 2 short circuit to vBatt

3

40

Yes

Twist Grip Position 2

P2135

Throttle position sensor 1 correlation error with throttle position sensor 2

3

40

Yes

Throttle Position Sensor

P2138

Twist grip position sensor 1 correlation error with twist grip position 2

3

40

Yes

Twist Grip Position Sensor 1 Correlation Error with Twist Grip Position 2

P2226

Ambient air pressure sensor circuit open circuit or short circuit to 5 Volt sensor supply

3

40

Yes

Ambient Air Pressure Sensor

P2228

Ambient air pressure sensor circuit short circuit to ground

3

40

Yes

Ambient Air Pressure Sensor

Immobiliser Control Module Diagnostic Trouble Codes

Diagnostic trouble codes (DTCs) are logged in the immobiliser/TPMS control module memory when there is a confirmed fault in the system.

The codes are reported to the Triumph Diagnostic Tool as a four digit code.

The system will log the Diagnostic Trouble Codes listed below:

Diagnostic Trouble Code (DTC)

Fault Description

Warning Light/Information

L0001

Front wheel sensor unit battery alert

For low battery Voltage -lo bAtt visible in the instrument display screen. the TPMS symbol in the display screen will indicate which sensor has low battery Voltage.For zero battery Voltage - Only dashes will be visible in the instrument display screen, TPMS warning light ON and the TPMS symbol in the display screen will flash ON and OFF

L0002

Rear wheel sensor unit battery alert

L0003

Front wheel sensor unit fault alert

TPMS warning light ON and the TPMS symbol in the display screen will flash ON and OFF

L0004

Rear wheel sensor unit fault alert

L0005

Front wheel sensor unit loss of communication error

L0006

Rear wheel sensor unit loss of communication error

L0007

Immobiliser ECM fault

L0008

Invalid key: Key authentication unsuccessful

Alarm/Immobiliser light ON

Further Diagnosis

The tables that follow will, if used correctly, help to pinpoint a fault in the system once a diagnostic trouble code has been stored.

Pinpoint Tests - Fuel

Ambient Air Pressure Sensor

Fault Code

Possible cause

Action

P2228

Ambient air pressure sensor circuit short circuit to ground

View and note 'freeze-frame' data if available.

View and note 'sensor' data.

Ensure sensor connector is secure.

Disconnect the engine ECM and proceed to pinpoint test 1:

P2226

Ambient air pressure sensor circuit open circuit or short circuit to 5 Volt sensor supply

Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B18

- ECM pin B34

- ECM pin B41

- Sensor pin 1, 2, 3

OK

Disconnect barometric pressure sensor and proceed to test 2

Faulty

Rectify fault, proceed to test 4

2

Check cable for short circuit:

- ECM pin B41 to ECM pin B18

- ECM pin B41 to ECM pin B34

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 4

3

Check cable for continuity:

- ECM pin B34 to sensor pin 3

- ECM pin B18 to sensor pin 1

- ECM pin B41 to sensor pin 2

OK

Renew barometric pressure sensor and proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 4

5

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Crankshaft Sensor

Fault Code

Possible cause

Action

P0335

Crankshaft sensor circuit malfunction

View and note diagnostic software freeze frame data if available

Ensure sensor is fitted correctly and connector is secure

Disconnect ECM and proceed to pinpoint test 1
Pinpoint Tests

Test

Result

Action

1

Check terminal and cable integrity:

- ECM pin A35

- ECM pin A36

OK

Disconnect sensor and proceed to

test 2

Faulty

Rectify fault, proceed to test 6

2

Check cable for short circuit:

- ECM pin A35 to ground

- ECM pin A36 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 6

3

Check cable continuity:

- ECM pin A35 to sensor pin 1

- ECM pin A36 to sensor pin 2

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 6

4

Check cable for short circuit:

- ECM pin A35 to ECM pin A36

OK

Renew crankshaft sensor, proceed to test 6

Short circuit

Locate and rectify wiring fault, proceed to test 6

5

Check crank toothed wheel:

- Damage to teeth - magnetic debris contamination

OK

Proceed to test 6

Faulty

Clean/renew toothed wheel, proceed to test 6

6

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Fuel Injectors

Fault Code

Possible cause

Action

P0201

Injector 1 circuit malfunction

View and note diagnostic software 'freeze-frame' data if available.

Ensure relevant injector connector is secure.

Disconnect engine ECM and proceed to pinpoint test 1:

P0202

Injector 2 circuit malfunction

P0203

Injector 3circuit malfunction
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A10

- ECM pin A11

- ECM pin A12

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 7

2

Check resistance value:

- ECM pin A01 to ECM pin A10 (injector 1)

- ECM pin A01 to ECM pin A11 (injector 2)

- ECM pin A01 to ECM pin A12 (injector 3)

OK

Proceed to test 3

Open circuit

Disconnect relevant injector and proceed to test 4

Short circuit

Disconnect relevant injector and proceed to test 5

3

Check cable for short circuit to ground:

- ECM pin A10 to ground

- ECM pin A11 to ground

- ECM pin A12 to ground

OK

Proceed to test 7

Short circuit

Locate and rectify wiring fault, proceed to test 7

4

Check cable continuity:

- EMS relay pin 5 to relevant injector pin 2

- ECM pin A10 to injector 1 pin 1

- ECM pin A11 to injector 2 pin 1

- ECM pin A12 to injector 3 pin 1

OK

Proceed to test 6

Open circuit

Locate and rectify wiring fault, proceed to test 7

5

Check cable for short circuit to supply box:

- ECM pin A01 to ECM pin A10 (injector 1)

- ECM pin A01 to ECM pin A11 (injector 2)

- ECM pin A01 to ECM pin A12 (injector 3)

OK

Proceed to test 6

Short circuit

Locate and rectify wiring fault, proceed to test 7

6

Check relevant injector resistance:

- Injector pin 1 to injector pin 2

11.4 Ohms to 12.6 Ohms

Proceed to test 7

Faulty

Renew relevant injector, proceed to test 7

7

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Throttle Position Sensor

Fault Code

Possible cause

Action

P0120

Throttle position sensor 1 short circuit to battery Voltage or open circuit

View and note diagnostic software 'freeze-frame' data if available.

View and note diagnostic software 'sensor' data.

Ensure throttle position sensor connector is secure. Disconnect engine ECM and proceed to pinpoint test 1:

P0122

Throttle position sensor 1 short circuit to ground or open circuit

P0220

Throttle position sensor 2 short circuit to battery Voltage or open circuit

P0222

Throttle position sensor 2 short circuit to ground or open circuit

P2135

Throttle position sensor 1 correlation error with throttle position sensor 2
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B19

- ECM pin B33

- ECM pin B20

- ECM pin B26

OK

Disconnect sensor and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin B20 to ground

- ECM pin B26 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check cable continuity:

- ECM pin B20 to throttle position sensor connector pin 3

- ECM pin B26 to throttle position sensor connector pin 4

- ECM pin B19 to throttle position sensor connector pin 5

- ECM pin B33 to throttle position sensor connector pin 2

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin B33 to ECM pin B20

- ECM pin B33 to ECM pin B26

OK

Renew throttle position sensor, proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Purge Valve

Fault Code

Possible cause

Action

P0443

Purge valve short circuit to ground or open circuit

View and note diagnostic software 'sensor' data.

Ensure purge valve connector is secure.

Disconnect engine ECM and proceed to pinpoint test 1:

P0459

Purge valve short circuit to battery Voltage

Disconnect the purge valve and proceed to pinpoint test 5:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B06

- EMS relay pin 5

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 7

2

Check resistance value:

- ECM pin A01 to ECM pin B06

22 Ohms to 30 Ohms

Proceed to test 3

Open circuit

Disconnect purge valve and proceed to test 4

Short circuit

Disconnect purge valve and proceed to test 5

3

Check cable for short circuit:

- ECM pin B06 to ground

OK

Proceed to test 7

Short circuit

Locate and rectify wiring fault, proceed to test 7

4

Check cable continuity:

- EMS relay pin 5 to valve pin 1

- ECM pin B06 to valve pin 2

OK

Proceed to test 6

Open circuit

Locate and rectify wiring fault, proceed to test 7

5

Check cable for short circuit:

- ECM pin A01 to ECM pin B06

OK

Proceed to test 6

Short circuit

Locate and rectify wiring fault, proceed to test 7

6

Check purge valve resistance:

- Valve pin 1 to valve pin 2

22 Ohms to 30 Ohms

Proceed to test 7

Faulty

Renew purge valve, proceed to test 7

7

Reconnect harness, clear fault code and run diagnostic software function test to visually verify operation of purge valve.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Ignition Coils

Fault Code

Possible cause

Action

P0351

Ignition coil 1 malfunction

View and note diagnostic software 'freeze-frame' data if available.

Ensure relevant ignition coil connector is secure.

Disconnect engine ECM and proceed to pinpoint test 1:

P0352

Ignition coil 2 malfunction

P0353

Ignition coil 3 malfunction
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B14

- ECM pin B15

- ECM pin B16

- EMS relay pin 5

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 7

2

Check resistance value:

ECM pin A01 to

- ECM pin B14 (ignition coil 1)

- ECM pin B15 (ignition coil 2)

- ECM pin B16 (ignition coil 3)

3.0 Ohms to 4.2 Ohms

Proceed to test 3

Open circuit

Disconnect relevant ignition coil and proceed to test 4

Short circuit

Disconnect relevant ignition coil and proceed to test 5

3

Check cable for short circuit:

- ECM pin B14 to ground

- ECM pin B15 to ground

- ECM pin B16 to ground

OK

Proceed to test 6

Short circuit

Locate and rectify wiring fault, proceed to test 6

4

Check cable continuity:

- EMS relay pin 5 to relevant ignition coil pin

- ECM pin B14 to ignition coil 1 pin 1

- ECM pin B15 to ignition coil 2 pin 1

- ECM pin B16 to ignition coil 3 pin 1

OK

Proceed to test 5

Open circuit

Locate and rectify wiring fault, proceed to test 6

5

Check relevant ignition coil resistance:

- Ignition coil pin 1 to ignition coil pin 2

3.0 Ohms to 4.2 Ohms

Proceed to test 6

Faulty

Renew relevant ignition coil, proceed to test 6

6

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Coolant Temperature Sensor

Fault Code

Possible cause

Action

P0115

Engine coolant temperature sensor open circuit or short circuit to 5 Volt sensor supply

View and note diagnostic software freeze frame data if available

View and note diagnostic software sensor data

Ensure sensor connector is secure

Disconnect ECM and proceed to pinpoint test 1

P0117

Engine coolant temperature sensor short circuit to ground

Disconnect sensor and proceed to test 4
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B40

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 7

2

Check resistance value:

- ECM pin B40 to ground (Temperature dependent - see below)

OK

Disconnect temp sensor and proceed to test 6

Open circuit

Disconnect sensor and proceed to test 3

Short circuit

Disconnect temp sensor and proceed to test 4

3

Check cable continuity:

- ECM pin B40 to sensor pin 1

- Ground to sensor pin 2

OK

Proceed to test 5

Open circuit

Locate and rectify wiring fault, proceed to test 7

4

Check cable for short circuit:

- ECM pin B40 to ground

OK

Proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 7

5

Check sensor resistance:

- Sensor pin 1 to sensor pin 2 (Temperature dependent - see below)

OK

Proceed to test 7

Faulty

Renew temp sensor, proceed to test 7

6

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Resistance data under typical conditions:

Warm engine: 200 to 400 Ohms

Cold engine:

20°C ambient 2.35 to 2.60 K Ohms

-10°C ambient 8.50 to 10.20 K Ohms

Inlet Air Temperature Sensor

Fault Code

Possible cause

Action

P0110

Intake air temperature sensor open circuit or short circuit to 5 volt sensor supply

View and note diagnostic software 'freeze-frame' data if available.

View and note diagnostic software 'sensor' data.

Ensure sensor connector is secure. Disconnect engine ECM and proceed to pinpoint test 1:

P0112

Intake air temperature sensor short circuit to ground

Disconnect engine ECM and sensor and proceed to pinpoint test 6:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B42

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 7

2

Check resistance value:

- ECM pin B42 to ground (Temperature dependent - see below)

OK

Proceed to test 6

Open circuit

Disconnect temp sensor and proceed to test 3

Short circuit

Disconnect temp sensor and proceed to test 4

3

Check cable continuity:

- ECM pin B42 to sensor pin 1

- Ground to sensor pin 2

OK

Proceed to test 5

Open circuit

Locate and rectify wiring fault, proceed to test 7

4

Check cable for short circuit:

- ECM pin B42 to ECM pin A01

- ECM pin B42 to ECM pin B34

OK

Proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 7

5

Check sensor resistance:

- Sensor pin 1 to sensor pin 2 (Temperature dependent - see below)

OK

Proceed to test 7

Faulty

Renew air temperature sensor, proceed to test 7

6

Check cable for short circuit:

- ECM pin B42 to ground

OK

Proceed to test 7

Short circuit

Locate and rectify wiring fault, proceed to test 7

7

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Resistance data:

If engine is warm, remove the sensor and allow time to cool to ambient temperature prior to test.

Ambient Temperature

Resistance Value

80ºC

200 to 400Ω

20ºC

2.35 to 2.65 KΩ

-10ºC

8.50 to 10.25 KΩ
Circuit Diagram

Fuel Pump Relay

Fault Code

Possible cause

Action

P1231

Fuel pump relay short circuit to ground or open circuit

Check if pump runs briefly when ignition is switched on

Ensure fuel pump relay connector is secure

Disconnect ECM and proceed to pinpoint test 1

P1232

Fuel pump relay short circuit to Vbatt

Disconnect fuel pump relay and proceed to pinpoint test 4
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A26

- Alarm pin 1

OK

Disconnect fuel pump relay and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit to ground:

- ECM pin A26 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check cable continuity:

- ECM pin A26 to fuel pump relay pin 2

- Alarm pin 1 to fuel pump relay pin 1

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin A26 to Alarm pin 1

OK

Proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run diagnostic software function test to verify operation of fuel pump.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

System Voltage

Fault Code

Possible cause

Action

P0560

Motorcycle voltage system fault

View and note diagnostic software 'sensor' data.

Ensure voltage across battery is acceptable, note voltage.

Disconnect engine ECM and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A01

- ECM pin A13

- EMS relay pin 5

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 3

2

With Ignition on check voltage at:

- ECM pin A01

Same as across battery voltage

Proceed to test 3

Less than across battery voltage

Locate and rectify wiring fault, proceed to test 3

3

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Cooling Fan Relay

Fault Code

Possible cause

Action

P1552

Cooling fan relay short circuit to ground or open circuit

View and note diagnostic software 'sensor' data.

Ensure fan relay connector is secure.

Disconnect engine ECM and proceed to pinpoint test 1:

P1553

Cooling fan relay short circuit to battery Voltage or over temp

Disconnect engine ECM and fan relay and proceed to pinpoint test 4:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A27

- Cooling fan relay pin 1

- Cooling fan relay pin 2

- Ignition switch pin 5

- Fuse box fuse 3

OK

Disconnect fan relay and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin A27 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check cable continuity:

- ECM pin A27 to fan relay pin 2

- Ignition pin 5 to fan relay pin 1

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin A27 to ECM pin A01

OK

Proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run diagnostic software function test to visually verify operation of cooling fan.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Oxygen Sensor

Fault Code

Possible cause

Action

P0130

Oxygen sensor 1 open circuit or short to ground

View and note 'freeze-frame' data if available.

View and note 'sensor' data.

Ensure sensor connector is secure.

Disconnect engine ECM and proceed to pinpoint test 1:

P0131

Oxygen sensor 1 short circuit to battery Voltage

Disconnect oxygen sensor and proceed to pinpoint test 4:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A21

OK

Disconnect oxygen sensors and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin A21 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check cable continuity:

- ECM pin A21 to oxygen sensor pin 2

OK

Proceed to test 5

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin A01 to ECM pin A21

OK

Renew oxygen sensor and proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine.

Check adaption status.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Oxygen Sensor Heater

Fault Code

Possible cause

Action

P0030

Oxygen sensor heater 1 circuit malfunction

View and note 'freeze-frame' data if available.

View and note 'sensor' data.

Ensure sensor connector is secure.

Disconnect engine ECM and proceed to pinpoint test 1:

P0032

Oxygen sensor heater ground open circuit or short circuit to battery Voltage
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B02

- EMS relay pin 5

OK

Disconnect oxygen sensors and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin B02 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 4

3

Check cable continuity:

- ECM pin B02 to oxygen sensor pin 4

- ECM pin A01 to oxygen sensor pin 3

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 4

4

Check cable for short circuit:

- ECM pin A01 to ECM pin B02

OK

Renew oxygen sensor, proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine.

Check adaption status.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Fall Detection Switch

Fault Code

Possible cause

Action

P1631

Fall detection circuit short circuit to ground

View and note 'freeze-frame' data if available.

View and note 'sensor' data.

Ensure switch connector is secure.

Disconnect the engine ECM and proceed to pinpoint test 1:

P1632

Fall detection circuit short circuit to battery Voltage
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B18

- ECM pin B34

- ECM pin B38

- Sensor pin 4, 5, 6

OK

Disconnect sensor and proceed to test 2

Faulty

Rectify fault, proceed to test 4

2

Check cable for short circuit:

- ECM pin B38 to ECM pin B18

- ECM pin B38 to ECM pin B34

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 4

3

Check cable continuity:

- ECM pin B34 to sensor pin 4

- ECM pin B18 to sensor pin 6

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 4

4

Reconnect harness, clear fault code.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Starter Motor Relay

Fault Code

Possible cause

Action

P0616

Starter relay short circuit to ground or open circuit

Ensure starter motor relay connector is secure.

Disconnect the engine ECM and proceed to pinpoint test 1:

P0617

Starter relay short circuit to battery Voltage

Disconnect the engine ECM and starter motor relay proceed to pinpoint test 4:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B25

- ECM pin A19

- Starter Relay pin 1

- Starter Relay pin 2

- fuse box fuse 8

OK

Disconnect starter relay and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin B25 to ground

- ECM pin A19 to ground

- ECM pin B25 to ECM pin A01

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

To access the black and grey connectors on the right hand switch housing, detach the front brake master cylinder from the handlebar (see Front Brake Master Cylinder - Removal).

Check cable continuity:

OK

Proceed to test 4

3.1 - ECM pin B25 to starter relay pin 2

Open circuit

Locate and rectify wiring fault, proceed to test 4

3.2 - ECM pin A19 to starter relay pin 1

3.3 - Fuse box fuse 8 to alarm pin 3

3.4 - Alarm pin 5 - ECM pin A19

Check the right hand switch housing black and grey connectors are properly inserted and repeat test. If fault still occurs proceed to test 3.5 and 3.6

3.5 - Alarm pin 5 to right hand switch housing grey connector pin 3

Locate and rectify wiring fault, proceed to test 4

3.6 - Alarm pin 5 to right hand switch housing black connector pin 3

4

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

CAN Communication

Fault Code

Possible cause

Action

P1690

CAN Fault

View and note 'freeze-frame' data if available.

View and note 'sensor' data.

Ensure Instrument connector is secure.

Disconnect the engine ECM and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A34

- ECM pin A33

- Instrument pin 24

- Instrument pin 25

- ABS module pin 2

- ABS module pin 11

- Diagnostic connector pin 6

- Diagnostic connector pin 14

- Immobiliser module pin 1

- Immobiliser module pin 6

- Bluetooth® module pin 3 ‡

- Bluetooth® module pin 4 ‡

OK

Disconnect instruments and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin A34 to ground

- ECM pin A33 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check cable continuity:

- ECM pin A34 to Instrument pin 24

- ECM pin A33 to Instrument pin 25

- ECM pin A34 to ABS control module pin 11

- ECM pin A33 to ABS control module pin 2

- ECM pin A34 to Diagnostic connector pin 14

- ECM pin A33 to Diagnostic connector pin 6

- ECM pin A34 to Immobiliser module pin 1

- ECM pin A33 to Immobiliser module pin 6

- ECM pin A34 to Bluetooth® module pin 4 ‡

- ECM pin A33 to Bluetooth® module pin 3 ‡

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin A34 to ECM pin A33

OK

Proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service

‡ Bluetooth® is an optional accessory.

Circuit Diagram

Instrument Communication (CAN)

Fault Code

Possible cause

Action

P1695

Lost communication with instrument panel

View and note 'freeze-frame' data if available.

Disconnect engine ECM and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A33

- ECM pin A34

- Instrument pin 24

- Instrument pin 25

OK

Disconnect instruments and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin A33 to ground

- ECM pin A34 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check cable continuity:

- ECM pin A33 to Instrument pin 25

- ECM pin A34 to Instrument pin 24

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin A33 to ECM pin A34

OK

Proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Manifold Absolute Pressure (MAP) Sensor

Fault Code

Possible cause

Action

P0107

Manifold absolute pressure sensor 1 short circuit to ground

View and note 'freeze-frame' data if available.

View and note 'sensor' data.

Ensure sensor connector is secure.

Disconnect the engine ECM and proceed to pinpoint test 1:

P0105

Manifold absolute pressure sensor 1 open circuit or short circuit to 5 Volt sensor supply

P1105

Manifold absolute pressure sensor 1 pipe malfunction

Check connection/condition of pipes from MAP sensors to throttle body.
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B18

- ECM pin B34

- ECM pin B36

- Sensor pin 1, 2, 3

OK

Disconnect MAP sensors and proceed to test 2

Faulty

Rectify fault, proceed to test 4

2

Check cable for short circuit:

- ECM pin B36 to ECM pin B18

- ECM pin B36 to ECM pin B34

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 4

3

Check cable for continuity:

- ECM pin B34 to MAP sensor pin 3

- ECM pin B18 to MAP sensor pin 1

- ECM pin B36 to MAP sensor pin 2

OK

Renew relevant MAP pressure sensor, proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 4

4

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Secondary Air Injection Valve

Fault Code

Possible cause

Action

P0412

Secondary air injection short circuit to ground or open circuit

View and note diagnostic tool sensor data.

Ensure SAI valve connector is secure.

Disconnect engine ECM and proceed to pinpoint test 1:

P044F

Secondary air injection short circuit to battery Voltage

Disconnect engine ECM and SAI valve and proceed to pinpoint test 5:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B07

- EMS Relay pin 5

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 7

2

Check resistance value:

- ECM pin A01 to ECM pin B07

18 Ohms to 24 Ohms

Proceed to test 3

Open circuit

Disconnect SAI valve and proceed to test 4

Short circuit

Disconnect SAI valve and proceed to test 5

3

Check cable for short circuit:

- ECM pin B07 to ground

OK

Proceed to test 7

Short circuit

Locate and rectify wiring fault, proceed to test 7

4

Check cable continuity:

- EMS relay pin 5 to SAI valve pin 2

- ECM pin B07 to SAI valve pin 1

OK

Proceed to test 6

Short circuit

Locate and rectify wiring fault, proceed to test 7

5

Check cable for short circuit:

- ECM pin A01 to ECM pin B07

OK

Proceed to test 6

Fault still present

Locate and rectify wiring fault, proceed to test 7

6

Check SAI valve resistance:

- SAI valve pin 1 to SAI valve pin 2

18 Ohms to 24 Ohms

Proceed to test 7

Faulty

Renew SAI valve, proceed to test 7

7

Reconnect harness, clear fault code and run diagnostic tool function test to visually verify operation of SAI valve.

OK

Action complete - quit test

Fault still present

Contact Triumph service

Gear Position Sensor

Fault Code

Possible cause

Action

P0914

Gear position sensor short circuit to ground or open circuit

View and note 'freeze-frame' data if available.

View and note 'sensor' data.

Ensure sensor connector is secure.

Disconnect the engine ECM and proceed to pinpoint test 1:

P0917

Gear position sensor short circuit to 5 Volt sensor supply
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B23

- ECM pin B44

OK

Disconnect sensor and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin B23 to ground

- ECM pin B34 to ground

- ECM pin B44 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check cable continuity:

- ECM pin B23 to sensor pin 2

- ECM pin B18 to sensor pin 3

- ECM pin B34 to sensor pin 4

- ECM pin B44 to sensor pin 1

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin B23 to ECM pin B44

- ECM pin B23 to ECM pin B34

OK

Renew gear position sensor and contact pin and proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Fuel Level Sensor Circuit

Fault Code

Possible cause

Action

P0460

Fuel level sensor circuit malfunction

View and note 'freeze-frame' data if available.

View and note 'sensor' data.

Ensure sensor connector is secure.

Disconnect engine ECM and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B22

OK

Disconnect sensor and proceed to test 2

Faulty

Rectify fault, proceed to test 4

2

Check cable for short circuit:

- ECM pin B22 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 4

3

Check cable continuity:

- ECM pin B22 to sensor pin 1

- Ground to sensor pin 2

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 4

5

Reconnect harness, clear fault code.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

EMS Main Relay Circuit

Fault Code

Possible cause

Action

P1685

Main relay circuit malfunction

Note that the starter motor cannot be powered if a main relay fault exists. Ensure the EMS main relay connector is secure.

Proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Ensure ignition has been switched off for greater than 90 seconds. Identify EMS main relay on the harness.

Check that relay operates when the ignition is switched ON and the stop and run switch is in the RUN position.

OK

Proceed to test 4

Faulty

Disconnect EMS main relay and engine ECM. Proceed to test 4

2

Check cable for short circuit:

- ECM pin B31 to ground

- ECM pin A01 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, replace Fuse 5 and proceed to test 6

3

Check cable and terminal integrity:

- ECM pin B31

- EMS main relay pin 1

- EMS main relay pin 2

- EMS main relay pin 3

- EMS main relay pin 5

OK

Disconnect main relay and proceed to test 4

Faulty

Rectify fault, proceed to test 5

4

Check fuse box fuse 8 integrity.

OK

Proceed to test 5

Short circuit

Replace fuse and proceed to test 5

5

Check cable continuity:

- ECM pin A01 to EMS main relay pin 5

- ECM pin B31 to EMS relay pin 1

- EMS main relay pin 2 to ground

- EMS main relay pin 3 to fuse box fuse 8

OK

Replace EMS main relay and proceed to test 6

Open circuit

Locate and rectify wiring fault, proceed to test 6

6

Reconnect harness, clear fault code. Switch ignition off for longer than 90 seconds. Switch ignition on and check that the EMS main relay operates. Start engine as final check.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

EMS Ignition Voltage Input Circuit

Fault Code

Possible cause

Action

P1659

Ignition power supply malfunction

Disconnect engine ECM and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check fuse box fuse 3 integrity.

OK

Proceed to test 3

Faulty

Proceed to test 2

2

Check cable for short circuit:

- ECM pin B01 to ground

OK

Replace Fuse 10 and proceed to test 3

Short circuit

Locate and rectify wiring fault, replace Fuse 10 and proceed to test 5

3

Check cable and terminal integrity:

- ECM pin B01

- Alarm connector pin 1

- Alarm connector pin 2

- Right hand switch housing pin 6 (black connector)

- Right hand switch housing pin 4 (black connector)

OK

Proceed to test 4

Faulty

Rectify fault, proceed to test 5

4

Check cable continuity:

- ECM pin B01 to fuse box fuse 3

Note that the engine stop switch must be in the RUN position and any alarm fitted must be disarmed.

OK

Proceed to test 5

Open circuit

Locate and rectify wiring, immobiliser or engine stop switch fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

5 Volt Sensor Supply Circuit

Fault Code

Possible cause

Action

P1698

5V sensor supply malfunction

View and note 'sensor' data. Note engine ECM sensors requiring a power supply will not be active.

Disconnect engine ECM and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B18

- ECM pin B34

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin B18 to ECM pin B34

OK

Proceed to test 4

Faulty

Proceed to test 3

3

Disconnect the following sensors in turn:

- MAP sensor

- Ambient pressure sensor

- Fall detection sensor

- Gear position sensor

and retest for short circuit

- ECM pin B18 to ECM pin B34

OK

Replace sensor last removed and proceed to test 5

Faulty

Proceed to test 4

4

Check cable for short circuit:

- ECM pin B18 to ground

- ECM pin B34 to ground

- ECM pin B18 to A01

- ECM pin B34 to A01

- ECM pin B18 to battery positive

- ECM pin B34 to battery positive

OK

Proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and use diagnostic software to check for correct sensor outputs and 5 volt sensor supply voltage level.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Twist Grip Position 1

Fault Code

Possible cause

Action

P2120

Twist grip position sensor 1 short circuit to ground or open circuit

View and note 'sensor' data. Note ECM sensors requiring a power supply will not be active.

Ensure twist grip position sensor is secure.

Disconnect the engine ECM and proceed to pinpoint test 1:

P2123

Twist grip position sensor 1 short circuit to battery Voltage
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B17

- ECM pin B21

- ECM pin B35

OK

Disconnect twist grip position sensor and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin B21 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check cable continuity:

- ECM pin B17 to sensor pin 5

- ECM pin B21 to sensor pin 3

- ECM pin B35 to sensor pin 1

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin B21 to ECM pin B17

- ECM pin B21 to ECM pin B35

OK

Renew twist grip position sensor, proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Twist Grip Position Sensor 1 Correlation Error with Twist Grip Position 2

Fault Code

Possible cause

Action

P2138

Twist grip position sensor 1 correlation error with twist grip position sensor 2

View and note diagnostic tool freeze frame data if available.

View and note diagnostic tool sensor data.

Disconnect twist grip position sensor and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Turn the ignition on and measure the

Voltage between:

- ECM pin B33 and ECM pin B19

- ECM pin B17 and ECM pin B35

5V DC

Proceed to test 2

Faulty

Rectify fault, proceed to test 2

2

Check cable continuity:

- ECM pin B21 to sensor pin 3

- ECM pin B28 to sensor pin 4

OK

Renew the twist grip and proceed to test 3

Open circuit

Rectify fault, proceed to test 3

3

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service

Circuit Diagram

Twist Grip Position 2

Fault Code

Possible cause

Action

P2125

Twist grip position sensor 2 short circuit to ground or open circuit

View and note 'sensor' data. Note ECM sensors requiring a power supply will not be active.

Ensure twist grip position sensor is secure.

Disconnect the engine ECM and proceed to pinpoint test 1:

P2128

Twist grip position sensor 2 short circuit to battery Voltage
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin B19

- ECM pin B28

- ECM pin B33

OK

Disconnect twist grip position sensor and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin B28 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check cable continuity:

- ECM pin B19 to sensor pin 6

- ECM pin B28 to sensor pin 4

- ECM pin B33 to sensor pin 2

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin B28 to ECM pin B19

- ECM pin B28 to ECM pin B33

OK

Renew twist grip position sensor, proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Throttle Actuator Motor

Fault Code

Possible cause

Action

P2100

Throttle actuator short circuit to ground or short circuit to battery Voltage

Throttle actuator with default spring open circuit

View and note diagnostic tool freeze frame data if available.

View and note diagnostic tool sensor data.

Ensure accelerator position sensor connector is secure.

Disconnect the engine ECM and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A02

- ECM pin A03

- Throttle actuator motor connector pin 1

- Throttle actuator motor connector pin 2

OK

Disconnect accelerator position sensor and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- ECM pin A02 to ground

- ECM pin A03 to ground

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed to test 5

3

Check fuse box fuse 3 integrity. Check cable continuity:

- ECM pin B17 to sensor pin 5

- ECM pin B21 to sensor pin 3

- ECM pin B35 to sensor pin 1

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- ECM pin A02 to ECM pin A01

- ECM pin A03 to ECM pin A01

OK

Renew twist grip position sensor, proceed to test 5

Short circuit

Locate and rectify wiring fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Immobiliser Control Module Communication

Fault Code

Possible cause

Action

P1650

Lost communication with Immobiliser ECM

View and note 'freeze-frame' data if available.

Ensure immobiliser control module connector is secure.

Ensure the ignition switch is turned to the OFF position.

Proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A33

- ECM pin A34

- Immobiliser pin 1

- Immobiliser pin 2

- Immobiliser pin 6

- Immobiliser pin 7

- Immobiliser pin 8

OK

Disconnect ECM and proceed to test 2

Faulty

Rectify fault, proceed to test 6

2

Check cable for short circuit:

- ECM pin A33 to ground

- ECM pin A34 to ground

OK

Disconnect immobiliser, ignition switch and proceed to test 3

Faulty

Locate and rectify wiring fault, proceed to test 6

3

Check fuse box fuse 3 integrity.

OK

Proceed to test 5

Faulty

Proceed to test 4

4

Check cable for short circuit:

- Immobiliser pin 2 to ground

- Immobiliser pin 8 to ground

OK

Proceed to test 5

Faulty

Locate and rectify wiring fault, replace relevant fuse, proceed to test 6

5

Check cable continuity:

- ECM pin A33 to immobiliser pin 6

- ECM pin A34 to Immobiliser pin 1

- Immobiliser pin 7 to ground

- Fuse box fuse 3 to immobiliser pin 2

OK

Proceed to test 6

Fault still present

Locate and rectify wiring fault, proceed to test 6

6

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

ABS Modulator Communication

Fault Code

Possible cause

Action

P1521

Lost communication with ABS

View and note 'freeze-frame' data if available.

Ensure ABS modulator connector is secure.

Proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ECM pin A33

- ECM pin A34

- ABS modulator pin 2

- ABS modulator pin 10

- ABS modulator pin 11

- ABS modulator pin 18

OK

Disconnect ECM and proceed to test 2

Faulty

Rectify fault, proceed to test 6

2

Check cable for short circuit:

- ECM pin A33 to ground

- ECM pin A34 to ground

OK

Disconnect ABS modulator and proceed to test 3

Faulty

Locate and rectify wiring fault, proceed to test 6

3

Check fuse box fuses 3 and 7 integrity.

OK

Proceed to test 5

Faulty

Proceed to test 4

4

Check cable for short circuit:

- ABS pin 2 to ground

- ABS pin 11 to ground

OK

Proceed to test 5

Faulty

Locate and rectify wiring fault, replace relevant fuse, proceed to test 6

5

Check cable continuity:

- ECM pin A33 to ABS pin 2

- ECM pin A34 to ABS pin 11

- ABS pin 10 to ground

- Fuse box fuse 7 to ABS pin 18

- Fuse box fuse 3 to ABS pin 4

OK

Proceed to test 6

Fault still present

Locate and rectify wiring fault, proceed to test 6

6

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Brake Switches

Fault Code

Possible cause

Action

P0571

Brake 1 switch malfunction

View and note freeze frame data if available.

Ensure brake switches connectors are secure.

Ensure battery voltage is greater than 10V.

Disconnect engine ECM and proceed to pinpoint test 1:

P1576

Brake 1 switch correlation error with brake switch 2

P1571

Brake 2 switch malfunction

P1577

Brake 2 switch correlation error with brake switch 1
Pinpoint Tests

Test

Result

Action

1

Turn ignition on, operate rear brake switch and check brake light operation.

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 6

2

Check cable and terminal integrity:

- ECM pin A06

- ECM pin A07

- Ignition switch pin 8

OK

Disconnect front and rear brake switch connectors, proceed to test 3

Faulty

Rectify fault, proceed to test 6

3

With brakes released, check front and rear brake switch operation:

The following should be short circuit:

- Front brake switch pin 2 to pin 3

- Rear brake light switch pin 2 to pin 3

- Rear brake light switch pin 1 to pin 3

The following should be open circuit:

- Front brake switch pin 1 to pin 3

With the front brake switch pressed the following should be short circuit:

- Front brake switch pin 1 to pin 3

The following should be open circuit:

- Front brake switch pin 2 to pin 3

With the rear brake switch pressed the following should be short circuit:

- Rear brake light switch pin 2 to pin 4

- Rear brake light switch pin 1 to pin 3

OK

Proceed to test 4

Faulty

Replace relevant brake switch, proceed to test 6

4

Check cable continuity:

- Engine ECM pin A07 to front brake switch pin 1

- Engine ECM pin A06 to rear brake switch pin 2

- Engine ECM pin A07 to brake switch relay pin 4

- Brake switch relay pin 2 to ground

- Engine ECM pin A06 to brake switch relay pin 4

OK

Proceed to test 5

Open Circuit

Locate and rectify wiring fault, proceed to test 6

5

Re-Connect the brake switch connectors. With the ignition switch on, measure the following Voltages:

- Engine ECM pin A06 to ground

- Rear brake switch pin 1 to ground

- Rear brake switch pin 2 to ground

- Rear brake switch pin 3 to ground

- Rear brake switch pin 4 to ground

- Brake switch relay pin 3 to ground

- Brake switch relay pin1 to ground

- Front brake switch pin 3 to ground

- Front brake switch pin 2 to ground

greater than 10V

Proceed to test 6

Less than 10V

Locate and rectify wiring fault, proceed to test 6

6

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Headlight Relay

Fault Code

Possible cause

Action

P1619

Headlamp relay short circuit to ground or open circuit

View and note 'freeze-frame' data if available.

Disconnect the engine ECM and proceed to pinpoint test 1:

P1620

Headlamp relay short circuit to battery Voltage

Disconnect the engine ECM and headlight relay and proceed to pinpoint test 4:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- Instruments pin 4

- Headlamp relay high beam pin 1

- Headlamp relay high beam pin 2

- Check fuse box fuses 3 and 9 integrity

OK

Disconnect headlight relay and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable for short circuit:

- Instruments pin 4 to ground

OK

Proceed to test 3

Faulty

Locate and rectify wiring fault, replace relevant fuse, proceed to test 5

3

Check cable continuity:

- Instruments pin 4 to headlight relay high beam pin 2

OK

Proceed to test 4

Faulty

Locate and rectify wiring fault, proceed to test 5

4

Check cable for short circuit:

- Instruments pin 4 to ignition switch pin 5

OK

Proceed to test 5

Short circuit

Renew headlight relay, proceed to test 5

5

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Quickshifter Fault

Fault Code

Possible cause

Action

Not applicable

Quickshifter not working

Quickshifter working intermittently

Quickshifter supply Voltage less than 4.5 V

Quickshifter open circuit

Quickshifter switch fault

Disconnect engine ECM and proceed to pinpoint test 1
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- Quickshifter pin 1

- Quickshifter pin 2

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 7

2

Disconnect quickshifter and check Voltage at:

- Quickshifter connector pin 1 (motorcycle harness side)

Voltage greater than 4.5 V

Proceed to test 3

Voltage less than or equal to 4.5 V

Contact Triumph service

3

Check cable continuity:

- Quickshifter connector pin 2 to ground (motorcycle harness side)

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, repeat test 3

4

Check quickshifter continuity in non activated state across quickshifter terminals:

No continuity

Proceed to test 5

Continuity

Replace quickshifter

5

Check quickshifter continuity in activated state across quickshifter terminals:

Continuity

Proceed to test 6

No Continuity

Replace quickshifter

6

Reconnect quickshifter and ECM connectors and test for correct operation.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

EEPROM Error

Fault Code

Possible cause

Action

P0603

EEPROM error

View and note 'freeze frame' data if available.

No tests available - contact Triumph service.

Engine ECM Internal Error

Fault Code

Possible cause

Action

P0606

Engine ECM internal error

Contact Triumph service.

P1607

P1608

Engine ECM ride by wire internal error

Traction Control Prevented Due to ABS Malfunction

Fault Code

Possible cause

Action

P1135

Traction Control prevented due to ABS malfunction

Check that there is no other DTC linked to the ABS system or CAN communication stored.

Contact Triumph service.

Throttle Valve Drive Error

Fault Code

Possible cause

Action

P2111

Throttle valve drive error (stuck open)

View and note 'freeze-frame' data if available.

View and note 'sensor' data.

Check throttle body for mechanical malfunctions. Clear fault code and contact Triumph service if fault is still present.

P2119

Throttle valve drive error

P2102

Throttle actuator control internal motor relay does not operate

P2103

Throttle actuator control internal motor relay operates continually

Tune Lock

Fault Code

Possible cause

Action

P1605

Engine ECM locked by the tune lock function

This is also identified by a fast flashing MIL indication, and a disabled engine management system.

Unlock the engine ECM using the diagnostic software and supplied unlock code from Triumph service.

Instrument ID Incompatible

Fault Code

Possible cause

Action

P1614

Instrument ID incompatible

This is also identified by a fast flashing MIL indication, and a disabled engine management system.

Pinpoint Tests

Test

Result

Action

1

Check engine ECM part number is correct for the motorcycle.

OK

Proceed to test 2

Incorrect

Replace engine ECM with correct part and proceed to test 3

2

Check that the tune is correct for the motorcycle, using the diagnostic software.

OK

Proceed to test 3

Incorrect

Update tune using diagnostic software, proceed to test 3

3

Clear fault code, check for normal operation.

OK

Action complete - quit test

Fault still present

Contact Triumph service

ABS Modulator ID Incompatible

Fault Code

Possible cause

Action

P1520

Unmatched ABS module

This is also identified by ABS warning light indication.

Proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check ABS modulator part number is correct for the motorcycle.

OK

Proceed to test 2

Incorrect

Replace ABS modulator with correct part and proceed to test 3

2

Check that the tune is correct for the motorcycle, using the diagnostic tool.

OK

Proceed to test 3

Incorrect

Update tune using service tool, proceed to test 3

3

Clear fault code, check for normal operation.

OK

Action complete - quit test

Fault still present

Contact Triumph service

Engine ECM Tamper Detected

Fault Code

Possible cause

Action

P1604

Engine ECM tamper detected - return to Triumph

Contact Triumph service

Fault Finding – Non Electrical

Symptom

Possible cause(s)

Poor throttle response at low rpm

Low fuel pressure caused by filter blockage/leaks

Low fuel pressure caused by loose fuel pipes to the fuel pump and filter

Cutting out at idle

Throttle bodies out of balance

Low fuel pressure caused by loose fuel pipes to the fuel pump and filter

Low fuel pressure

Weak mixture caused by air leak at the throttle body/transition piece to cylinder head face

Idle speed too low/high

Incorrect closed throttle position setting

Diagnostic software malfunctions during tune download procedure

Low battery voltage

Throttle hang-up

Incorrect closed throttle position setting

Motorcycle will start but cuts out immediately

Low fuel pressure caused by loose fuel pipes to the fuel pump and filter

Low fuel pressure caused by filter blockage/leaks

Abnormally high fuel pressure

Fuel pressure regulator inoperative

Temperature gauge reads cooler than normal

Cooling system air–locked resulting in coolant temperature sensor operating in air instead of coolant

Thermostat fault

Motorcycle will not start

Check the immobiliser system for faults

Ensure that the keys, Engine ECM and Chassis ECM are all correctly paired

Vehicle Speed Sensor

Fault Code

Possible cause

Action

P0500

Wheel speed sensor fault

Refer to the following ABS DTCs.

Pinpoint Tests - Immobiliser/TPMS

Immobiliser and TPMS Control Module ID Incompatable

Fault Code

Possible cause

Action

P1508

Unmatched Immobiliser/chassis ECM, causing the engine ECM to be disabled to prevent the motorcycle from being operated

This is also identified by a fast flashing MIL indication and a disabled engine management system.

Pinpoint Tests

Test

Result

Action

1

Follow the Pair ECM and Immobiliser procedure as described in the Triumph Diagnostic Tool user guide

OK

Action complete - quit test

Fault still present

Contact Triumph service

Front Wheel Unit Sensor Battery Alert

note
  • All the fault codes for the tyre pressure monitoring system and the immobiliser system can only be viewed in the Chassis section of the Triumph diagnostic software.

Fault Code

Possible cause

Action

L0001

or

The TPMS tyre symbol in the instrument pack will be on for 8 seconds with the 'F' symbol with 'lo bAtt' shown in the display screen

Low battery voltage

Replace the front wheel pressure sensor following the procedure described in the Triumph diagnostic tool user guide.

Record the new sensor's ID number into the owner handbook before fitting.

Rear Wheel Unit Sensor Battery Alert

Fault Code

Possible cause

Action

L0002

or

The TPMS tyre symbol in the instrument pack will be on for 8 seconds with the 'R' symbol with 'lo bAtt' shown in the display screen

Low battery voltage

Replace the rear wheel pressure sensor following the procedure described in the Triumph diagnostic tool user guide.

Record the new sensor's ID number into the owner handbook before fitting.

Front Wheel Unit Sensor Fault Alert

Fault Code

Possible cause

Action

L0003

Front wheel sensor unit fault alert

Note: This DTC will automatically be generated if DTC L0007 occurs

If the problem persists:

Replace the front wheel pressure sensor following the procedure described in the Triumph diagnostic tool user guide.

Record the new sensor's ID number into the owner handbook before fitting.

Rear Wheel Unit Sensor Fault Alert

Fault Code

Possible cause

Action

L0004

Rear wheel sensor unit fault alert

Note: This DTC will automatically be generated if DTC L0007 occurs

If the problem persists:

Replace the rear wheel pressure sensor following the procedure described in the Triumph diagnostic tool user guide.

Record the new sensor's ID number into the owner handbook before fitting.

Front Wheel Unit Sensor Loss of Communication

note
  • Refer to the owner's handbook for the wheel pressure sensors ID numbers.

Fault Code

Possible cause

Action

L0005

Front wheel sensor unit loss of communication error

Low battery voltage

Wrong sensor ID number has been registered in the immobiliser/TPMS control module

If the problem persists:

Using the Triumph diagnostic tool, check that the correct ID number for the front wheel pressure sensor is registered to the Immobiliser/TPMS control module.

Replace the front wheel pressure sensor following the procedure described in the Triumph diagnostic tool user guide.

Record the new sensor's ID number into the owner handbook before fitting.

Rear Wheel Unit Sensor Loss of Communication

note
  • Refer to the owner's handbook for the wheel pressure sensors ID numbers.

Fault Code

Possible cause

Action

L0006

Rear wheel sensor unit loss of communication error

Low battery voltage

Wrong sensor ID number has been registered in the immobiliser/TPMS control module

If the problem persists:

Using the Triumph diagnostic tool, check that the correct ID number for the rear wheel pressure sensor is registered to the Immobiliser/TPMS control module.

Replace the rear wheel pressure sensor following the procedure described in the Triumph diagnostic tool user guide.

Record the new sensor's ID number into the owner handbook before fitting.

Immobiliser/TPMS Control Module Fault

note
  • Refer to the owner's handbook for the wheel pressure sensors ID numbers.

Fault Code

Possible cause

Action

L0007

Immobiliser/TPMS control module fault

Low battery voltage

Wrong sensor ID numbers have been registered in the immobiliser/TPMS control module

Using the Triumph diagnostic tool, check that the correct ID numbers for the wheel pressure sensors are registered to the Immobiliser/TPMS control module.

If the correct IDs are registered, replace the front and rear wheel pressure sensor following the procedure described in the Triumph diagnostic tool user guide.

Record the new sensor's ID number into the owner handbook before fitting.

Invalid Key: Key Authentication Unsuccessful

Fault Code

Possible cause

Action

L0008

or

Alarm/immobiliser warning indicator light is on when the ignition switch is at the ON position (only visible on motorcycles without the accessory alarm fitted)

Invalid key: Key authentication unsuccessful

Check that the key has been registered with the immobiliser control module, if it is a new key or an additional key.

Check that there are no additional keys with a transponder chip fitted close to the ignition key and proceed to pinpoint test 1:

Pinpoint Tests

Test

Result

Action

1

If available, try to start the motorcycle with the second registered key:

OK

Transponder chip in the key not functioning correctly. Register a new key using the Triumph Diagnostic Tool then proceed to test 5

Faulty

Proceed to test 2

2

Check the condition of cable, connector housing and terminals for the following:

- Ignition switch

- Immobiliser control module

OK

Disconnect the ignition switch, proceed to test 3

Faulty

Rectify fault, proceed to test 5

3

Check antenna coil resistance:

- Ignition switch pin 2 to ignition switch pin 7

7 Ohms to 13 Ohms

Proceed to test 4

Faulty

Replace the ignition switch, register new keys and proceed to test 5

4

Check cable continuity:

- Ignition switch pin 2 to Immobiliser control module pin 5

- Ignition switch pin 7 to Immobiliser control module pin 10

OK

Proceed to test 4

Faulty

Rectify fault, proceed to test 5

5

Reconnect harness, clear fault code and run engine.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Removal and Installation - Fuel and Air Components

Fuel Tank - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.

A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly.

  1. Release the fixings securing the front of the fuel tank to the frame.

    1. Fixings
  2. Raise the fuel tank and disconnect the electrical connections to the fuel pump and the fuel level sensor.

    1. Fuel pump electrical connection

    2. Fuel level sensor connection

    warning

    If the fuel rail is dismantled without first reducing pressure, fuel may escape causing clothing and components to be coated with fuel.

    This would represent a serious fire hazard which could lead to burn injuries and damage to property.

    note
    • Because fuel stored in the fuel rail will be at 3.5 bar pressure, it is essential that the fuel pressure is reduced before any dismantling of the fuel rail takes place. To reduce pressure, briefly crank the engine with the fuel pump disconnected.
    • When disconnected, the fuel tank is self-sealing but a small amount of fuel may dribble from the hose.
  3. Ease the latch away from the connector until the release buttons are exposed.

    1. Locked position

    2. Unlocked position
  4. Disconnect the fuel hose by squeezing the sides of the connector and pulling the hose free from its spigot on the fuel pump plate.

    5. note
    • Before disconnection, note the position of the two breather hoses so that they can be returned to the same locations when refitting the tank.
  5. Disconnect the two breather hoses.

    1. Fuel line

    2. Breather hoses
  6. Lower the fuel tank and release the fixing securing the rear of fuel tank to the frame.

    1. Fixing
  7. Withdraw the spacer sleeve from the frame.

    1. Spacer sleeve
  8. Remove the fuel tank from the frame.

note
  • If fitting a new fuel tank, the barrel lock must be removed from the original fuel cap and fitted to the new one (see Fuel Cap Lock - Removal, Fuel Cap Lock - Installation).

Fuel Tank - Installation

  1. Align the fuel tank rear mounting to the frame.
  2. Refit the rear spacer sleeve. Fit and tighten the rear bolt to 8 Nm.
  3. With the fuel tank raised, connect the two breather hoses as noted for removal.

    4. note
    • The fuel hose has different coloured connectors on each end, to aid orientation. The orange end must be fitted to the fuel tank, the grey end must be fitted to the fuel rails.
  4. Reconnect the fuel feed hose by gently pushing inwards until the hose engages with a click.
  5. Slide the double check latch down (towards the spigot) until the release buttons are covered. If the latch will not slide into position, then the fuel hose is not fully home on its spigot and must therefore be refitted correctly.
  6. Reconnect the fuel pump electrical connection.
  7. Reconnect the fuel level sensor.

    1. Fuel hose

    2. Fuel pump electrical connection

    3. Fuel level sensor connection

    4. Breather hoses
  8. Lower the fuel tank and align the fuel tank front mounting to the frame. Refit the two bolts and tighten to 9 Nm.
  9. Reconnect the battery, positive (red) lead first. Tighten the battery terminals to 4.5 Nm.
  10. Start the engine and check carefully for fuel leaks. Rectify as necessary.

Perform the following operations:

Fuel Pressure Checking

warning

Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.

A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly.

Fuel pressure is checked using T3880001 - Fuel Pressure Gauge.

T3880001 - Fuel Pressure Gauge
  1. Remove the fuel tank (see Fuel Tank - Removal) and place on a suitable support, close to the motorcycle.
  2. Using the T3880123 - Extension Cable, carefully connect the fuel pump connection on the main harness to the fuel tank.
  3. Select the fuel pressure gauge adapter marked B from T3880001 - Fuel Pressure Gauge.

    4. warning

    Always use the correct fuel pressure gauge adapter. Use of an incorrect adapter will result in a fuel leak. A fuel leak can result in a fire causing damage to property and injury to persons.

  4. Connect the adapter hose to the fuel pump plate outlet as shown in the illustration below.

    1. Adaptor hose B

    2. Fuel pump plate outlet

    3. T3880123 - Extension Cable
  5. Connect the fuel hose to the adaptor hose as shown in the illustration below.

    1. Motorcycle fuel hose

    2. Adaptor hose B

    3. Fuel pump connection

    4. T3880123 - Extension Cable

    5. Fuel pump connection

    6. Fuel pump plate outlet
  6. Connect the fuel pressure gauge to the adaptor hose as shown below by pushing the gauge spigot into the adapter until a click can be heard.

    1. Adaptor hose

    2. Fuel pressure gauge

    note
    • To release the fuel pressure gauge from the adapter, slide the outer ferrule downwards. This will allow the gauge to spring upwards from the adapter.
  7. Ensure the gauge is visible to the side of the motorcycle.
  8. Temporarily reconnect the battery, positive (red) lead first and tighten the terminals to 4.5 Nm.
  9. Start the engine and observe the fuel pressure reading on the gauge.

    10. note
    • The fuel pressure should be 3.5 bar nominally.
  10. When fuel pressure checking is complete, disconnect the battery, negative (black) lead first.
  11. Disconnect the fuel pressure gauge adapter and wiring extension.

Perform the following operations:

Fuel Pump Assembly - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.

A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly.

note
  • The fuel pump and fuel filter is a sealed for life unit and must be replaced as a complete assembly.

Perform the following operations:

  1. Invert the fuel tank and place on a protective surface to prevent paint damage.
  2. Remove the fixings securing the fuel pump mounting plate to the fuel tank.

    1. Mounting plate

    2. Fixings
  3. Lift the fuel pump assembly and manoeuvre it from the fuel tank aperture.
  4. Disconnect the fuel level sensor electrical connector and remove the fuel pump and filter assembly.

    1. Fuel level sensor electrical connector
  5. Noting its orientation, remove and discard the sealing ring from the fuel pump assembly.

    1. Fuel pump assembly

    2. Sealing ring location

Fuel Pump Assembly - Installation

  1. Install a new sealing ring into the fuel pump assembly, with the seal lip facing uppermost, and ensure that it is correctly seated.

    1. Sealing ring

    2. Seal lip
  2. Taking care to ensure the sealing ring is not damaged or dislodged, manoeuvre the fuel pump assembly into the fuel tank aperture.
  3. Reconnect the fuel level sensor electrical connector and locate the fuel pump and filter assembly.
  4. Ensure the locating peg on the fuel pump assembly is located in the cut out on the mounting plate and the offset hole is positioned as shown below.

    1. Offset hole position

    2. Locating peg
  5. In the sequence shown below, tighten the mounting plate fixings to 9 Nm.

    6. Pump Mounting Plate Torque Sequence

Perform the following operations:

Fuel Level Sender Assembly/Float Replacement - Removal

Perform the following operations:

  1. Release the locking device and slide the bottom of the level sender to the fuel tank opening. Withdraw from the tank and allow any remaining fuel to drain into a suitable container.

    1. Fuel level sensor

    2. Locking device
Float Replacement
  1. Insert a small screwdriver into one of the tabs at the top of the float assembly and gently prise the lid free.

    1. Tab

    2. Lid
  2. Invert the assembly and allow the float unit to slide free.
  3. Discard the old float unit.
  4. Insert the new float unit in the orientation shown below ensuring the magnet cover on the face of the unit faces towards the bottom of the support tube.

    5. note
    • It is possible to fit the float unit upside down. An incorrect fuel level reading will be indicated during motorcycle operation if the float unit is fitted upside down.

    1. Support tube

    2. Float unit

    3. Lid

    4. Magnet cover

    5. Slider
  5. Refit the lid ensuring the tabs on the lid locate correctly with the cut-outs in the top of the support tube.

Fuel Level Sensor - Installation

  1. Align the lower lug first to the bracket then the upper lug. Ensure that the locking device is fully engaged to the bracket and is secure.

    1. Level sender

    2. Bracket, inside fuel tank

    3. Locking device

    4. Upper lug

    5. Lower lugs

Perform the following operations:

Fuel Delivery System

Fuel is delivered to the injectors by a pump located inside the fuel tank. Fuel flows in the direction of the arrows shown in the diagram below.

Incorporated in the fuel pump assembly is a filter, a pressure regulator and a pick-up strainer.

Air Filter Element - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the fixng and detach the air temperature sensor from the airbox.
  2. Detach the MAP sensor hose from the airbox.
  3. Release the fixing and detach the MAP sensor from the airbox.
  4. Release the two fixings and detach the engine ECM and its bracket from the airbox.

    1. Fixings

    2. Air temperature sensor

    3. MAP sensor hose

    4. MAP sensor

    5. Engine ECM

    note
    • The immobiliser/TPMS control module is attached to the inside surface of the airbox upper section. Note the routing of its harness for installation.
    • It is not necessary to disconnect the immobiliser/TPMS control module when changing the air filter.
  5. Release the nine fixings and detach the airbox upper section from the lower section.

    1. Airbox upper section

    2. Fixings

    note
    • Note the orientation of the air filter for installation.
  6. Remove the air filter from the airbox upper section.

    1. Air filter

    2. Airbox upper section

Air Filter Element - Installation

  1. Thoroughly clean the inside and outside of the airbox.

    2. note
    • The air filter will only fit one way, do not force fit the air filter.
  2. Align the air filter to its locating guides in the air box upper section in the orientation noted for removal. Push the filter fully down until it clicks into place.

    1. Locating guides
  3. Refit the airbox upper section. Ensure that the routing of the immobiliser/TPMS control module harness is as noted for removal. Tighten the fixings to 1.5 Nm.
  4. Refit the engine ECM and its bracket to the airbox. Tighten the two fixings to 1.5 Nm.
  5. Refit the MAP sensor to the airbox and tighten its fixing to 2.5 Nm.
  6. Secure the MAP sensor hose to the airbox.
  7. Refit the air temperature sensor and tighten its fixing to 2.5 Nm.

    1. Fixings

    2. Air temperature sensor

    3. MAP sensor hose

    4. MAP sensor

    5. Engine ECM

Perform the following operations:

Airbox - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the fixing and detach the air temperature sensor from the airbox.
  2. Detach the MAP sensor hose from the airbox.
  3. Release the fixing and detach the MAP sensor from the airbox.
  4. Release the two fixings and detach the engine ECM and its bracket from the airbox.

    1. Fixings

    2. Air temperature sensor

    3. MAP sensor hose

    4. MAP sensor

    5. Engine ECM

    note
    • The immobiliser/TPMS control module is attached to the inside surface of the airbox upper section. Note the routing of its harness for installation.
    • When detaching the air box upper section from the lower section, the air filter element will be attached to the upper section.
  5. Release the eight fixings and detach the airbox upper section from the lower section.

    1. Airbox upper section

    2. Fixings
  6. Remove the air filter element.
  7. Disconnect the multiplug for the immobiliser/TPMS control module, detach the main harness connector from its bracket and remove the airbox upper section.

    1. Immobiliser/TPMS control module multiplug

    2. Bracket

    3. Main harness connector

    4. Immobiliser/TPMS control module

    note
    • Note the positions and orientation of the airbox intake trumpets for installation.
  8. Release the six fixings and remove the airbox intake trumpets.
  9. Release the front fixing securing the airbox to the frame.

    1. Airbox intake trumpet fixings

    2. Airbox front fixing
  10. Disconnect the secondary air injection hose at the airbox.

    1. Secondary air injection hose
  11. Release the spring hose clip and disconnect the engine breather hose at the airbox.

    1. Engine breather hose

    2. Spring hose clip
  12. Remove the airbox from the motorcycle.

Airbox - Inspection

  1. Thoroughly clean the inside and outside of the airbox.
  2. Check the airbox and intake trumpets for damage.
  3. Check the air intake seal at the front of the airbox for damage.

Airbox - Installation

  1. Position the airbox to the frame.
  2. Connect the engine breather hose and refit the spring hose clip.
  3. Connect the secondary air injection hose.
  4. Align the front of the air box to the frame and loosely install the front fixing. Do not tighten the fixing at this stage.
  5. Align the rear of the airbox to the throttle bodies and fit the airbox intake trumpets, as noted for removal. Tighten the fixings to 6 Nm.
  6. Tighten the airbox front fixing to 8 Nm.

    1. Airbox intake trumpet fixings

    2. Airbox front fixing
  7. Attach the main harness connector to its bracket in the airbox upper section. Connect the multiplug for the immobiliser to the main harness.
  8. Fit the air filter element (see Air Filter Element - Installation).
  9. Refit the airbox upper section. Ensure that the routing of the immobiliser/TPMS control module harness is as noted for removal. Tighten the fixings to 1.5 Nm.
  10. Refit the engine ECM and its bracket to the airbox. Tighten the two fixings to 1.5 Nm.
  11. Refit the MAP sensor to the airbox and tighten its fixing to 2.5 Nm.
  12. Secure the MAP sensor hose to the airbox.
  13. Refit the air temperature sensor and tighten its fixing to 2.5 Nm.

    1. Fixings

    2. Air temperature sensor

    3. MAP sensor hose

    4. MAP sensor

    5. Engine ECM

Perform the following operations:

Throttle Bodies/Injectors - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

If the fuel rail is dismantled without first reducing pressure, fuel may escape causing clothing and components to be coated with fuel.

This would represent a serious fire hazard which could lead to burn injuries and damage to property.

note
  • Because fuel stored in the fuel rail will be at 3.5 bar pressure, it is essential that the fuel pressure is reduced before any dismantling of the fuel rail takes place. To reduce pressure, briefly crank the engine with the fuel pump disconnected.

Perform the following operations:

  1. Disconnect the throttle position sensor multiplug.
  2. Disconnect the fuel injector multiplugs.
  3. Disconnect the throttle actuator motor multiplug.
  4. Detach the fuel line from the fuel rail.
  5. Release the clips securing the throttle bodies to the transition pieces.

    1. Clip location
  6. Remove the throttle bodies.
  7. If required, release the fixings securing the fuel rail to the throttle bodies.

    1. Fuel rail

    2. Fixings
  8. Ease the fuel rail and injectors from the throttle bodies.
  9. To detach the injectors from the fuel rail, gently ease the injector from the rail.

    1. Injector

    2. Fuel rail
  10. Release the fixings and remove the transition pieces from the head. Discard the fixings.

    1. Transition piece

    2. Fixings

Throttle Bodies/Injectors - Inspection

  1. Check all joints and seals for splits, cuts and damage.
  2. Check the throttles for sticking, loose or damaged throttle plates.
  3. Check the transition piece rubber bead for damage, replace the transition piece if necessary.

Throttle Bodies/Injectors - Installation

  1. Thoroughly clean the transition piece to cylinder head mating faces.
  2. Refit the transition pieces to the head and tighten the new fixings to 8 Nm.

    1. Transition piece

    2. Fixings
  3. If the injectors have been removed from the fuel rail, refit them to the rail, ensuring the injector locating peg is fully engaged in the slot in the rail.

    1. Injector

    2. Fuel rail

    3. Locating peg
  4. Check the injector O-rings for splits and other damage. Replace as necessary.
  5. Refit the injectors and fuel rail to the throttle bodies. Tighten the fuel rail screws to 3.5 Nm.

    1. Fuel rail

    2. Fixings
  6. Fit the throttle bodies to the transition pieces and tighten the three clips to 1.5 Nm.
  7. Reconnect the fuel line to the fuel rail.
  8. Reconnect the throttle actuator motor multiplug.
  9. Reconnect the fuel injector multiplugs.
  10. Reconnect the throttle position sensor multiplug.

Perform the following operations:

Throttle Position Sensor

caution

The fixings for the throttle position sensor, throttle butterfly adjustment screws and the throttle hard stop blanking screw are marked with yellow paint and must not be loosened or removed.

If the fixings, adjustment screws or blanking screw have been loosened or removed the throttle body assembly must be replaced as there are no means to reset these items to their correct positions.

note
  • The fixings for the throttle position sensor, throttle butterfly adjustment screws and the throttle hard stop blanking screw are marked with yellow paint and must not be loosened or removed. If the fixings, adjustment screws or blanking screw have been loosened or removed any warranty claims for the throttle bodies will be rejected.

  1. Throttle position sensor fixings

  2. Throttle butterfly adjustment screws

  3. Throttle hard stop blanking screw

The throttle position sensor can not be removed, replaced or adjusted in service. If necessary, the throttle bodies and throttle position sensor must be replaced as an assembly.

Throttle Body Balancing

caution

The fixings for the throttle position sensor, throttle butterfly adjustment screws and the throttle hard stop blanking screw are marked with yellow paint and must not be loosened or removed.

If the fixings, adjustment screws or blanking screw have been loosened or removed the throttle body assembly must be replaced as there are no means to reset these items to their correct positions.

note
  • The fixings for the throttle position sensor, throttle butterfly adjustment screws and the throttle hard stop blanking screw are marked with yellow paint and must not be loosened or removed. If the fixings, adjustment screws or blanking screw have been loosened or removed any warranty claims for the throttle bodies will be rejected.
  • The three air bypass adjustment screws on the throttle bodies also have the yellow paint on them, these three screws can be moved for throttle balance only.

  1. Throttle position sensor fixings

  2. Throttle butterfly adjustment screws

  3. Throttle hard stop blanking screw

The throttle body balance adjustment is made with the air bypass adjustment screws only. This adjustment alters the amount of air that can flow through the air bypass drilling.

note
  • DO NOT remove the throttle hard stop blanking screw to adjust the throttle balance.

  1. Air bypass drilling (throttle bodies shown removed for clarity)

  2. Air bypass adjustment screws

  3. Throttle hard stop blanking screw

Adjust the air bypass screws such that there is a minimum amount of adjustment used on each adjustment screw to achieve throttle balance. For example, if MAP pressures were as follows and were shown to be out of balance:

Each cylinder should be adjusted to 450 mmHg, this will help minimise the amount of adjustment at each adjustment screw.

note
  • The throttles cannot be balanced using equipment to measure vacuum in each throttle. Instead, the Triumph diagnostic software must be used.

warning

If the engine has recently been running, the components beneath the fuel tank may be hot to the touch.

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Turn the ignition to the OFF position.

warning

Always use the correct fuel pressure gauge adapter (adapter 'B' ). Use of an incorrect adapter will result in a fuel leak. A fuel leak can result in a fire causing damage to property and injury to persons.

  1. Using T3880123 - Extension Cable carefully connect the fuel pump connection on the extension harness to the fuel tank. Connect the other end of the harness extension to the motorcycle main harness.
  2. Select the fuel pressure gauge adaptor marked B from T3880001 - Fuel Pressure Gauge.
  3. Connect the adaptor hose to the fuel pump plate outlet as shown in the illustration below.

    1. Adaptor hose B

    2. Fuel pump plate outlet

    3. T3880123 - Extension Cable
  4. Connect the fuel hose to the adaptor hose.

    5. note
    • If disconnected, temporarily reconnect the immobiliser multiplug.
  5. Attach exhaust extraction hoses to the silencer.
  6. Attach the Triumph diagnostic tool to the dedicated plug, refer to the Triumph Diagnostic Tool User Guide. Start the engine, and allow to idle.
  7. On the diagnostic software navigate to ADJUST TUNE.
  8. Select BALANCE THROTTLES.
  9. Click the Adjust button.

    10. Balance Throttles Screen

    note
    • The balance throttles screen will show the vacuum value of each throttle in mmHg. In addition, when the throttles are balanced to an acceptable range of each other the words THROTTLES BALANCED in green text will appear on the right of the screen. At this point, no further adjustment is necessary or productive.
    • If the throttles are not balanced to each other the word THROTTLES UNBALANCED in red text will appear on the right of the screen. At this point adjustment will be necessary.
    • There is an air bypass adjustment screw on each of the three cylinders.
    • DO NOT attempt to adjust the throttle hard stop screw, located below the throttle hard stop blanking screw. The stop screw is set at the factory during manufacture, and must not be adjusted.
  10. Using the air bypass adjustment screws, make adjustments to the three cylinders until the words THROTTLES BALANCED in green text appear.

    1. Air by-pass adjustment screws
  11. When balanced, stop the engine and disconnect the diagnostic tool.
  12. Disconnect the fuel pressure gauge adaptor and wiring extension.
  13. Remove the exhaust extraction hoses from the silencer.

Perform the following operations:

Secondary Air Injection

System Purpose and Operation

The secondary air injection system is an aid to reducing levels of pollutants in the exhaust gases. It does this by introducing a small amount of air into each exhaust port as the exhaust valve opens. The introduced air helps promote further combustion of the fuel mixture in the exhaust system after it has left the combustion chamber.

At certain specific engine speeds (determined by the factory programming of the engine management system), the secondary air injection control valve is opened by the ECM and allows an air feed into the secondary air system where, each time a pair of exhaust valves open, the exhaust gases in the exhaust port create a depression which causes reed valves in the secondary air injection system to open. When open, the depression in the exhaust port draws air from the control valve, through the open reed valves, into the exhaust port. This air promotes secondary combustion of the exhaust gases in the ports and the header system.

At other engine speeds, the system is disabled by closing the control valve in the system. This allows an oxygen sensor to control air to fuel ratios. If air was fed to the exhaust system when the oxygen sensor was operational, the incoming air would cause inaccuracies in the readings sensed by the oxygen sensor (which requires access to raw combustion gases) which would lead to rough running.

Secondary Air Injection Solenoid Valve - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the hoses attached to the valve.
  2. Disconnect the multiplug.

    1. Solenoid valve

    2. Retainer

    3. Hose clips

    4. Multiplug
  3. Gently pull the valve to detach it from its retainer.

Secondary Air Injection Solenoid Valve - Installation

  1. Locate the valve to the retainer.
  2. Reconnect the multiplug.
  3. Refit the hoses to the valve.

Perform the following operations:

Secondary Air Injection Reed Valves - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the spring clips and detach the secondary air injection feed hoses from the reed valves on the camshaft cover.

    1. Secondary air injection hose

    2. Hose clips

    note
    • Note that the mounting bracket for the secondary air injection solenoid valve is secured by the fixings for the left hand reed valve cover.
  2. Release the bolts securing the valve covers to the camshaft cover.

    1. Fixings

    2. Bracket
  3. Ease the valve covers from the valves.
  4. Detach the valves from the camshaft cover.

    1. Reed valves

Secondary Air Injection Reed Valves - Inspection

  1. Check for cracks, bending or other damage to the valve flaps. Replace as necessary.
  2. Check for damage to the seal areas. Replace as necessary.
  3. Check the valve body to cylinder head seal for damage.

Secondary Air Injection Reed Valves - Installation

  1. Fit the reed valves to the camshaft cover.
  2. Refit the valve covers and the bracket for the secondary air injection solenoid, as noted for removal. Tighten the fixings to 9 Nm.
  3. Refit the secondary air injection feed hoses to the reed valves.

    1. Secondary air injection hose

    2. Hose clips

Perform the following operations:

Removal and Installation - Engine Management Components

Engine Electrical Control Module (ECM) - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Remove the two fixings and detach the ECM bracket from the airbox.

    1. Fixings

    2. Engine ECM bracket
  2. Disconnect the two electrical connectors from the engine ECM (see Electrical Connectors) and remove the engine ECM.

Engine Electronic Control Module (ECM) - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit the engine ECM into the mounting bracket.

    1. Connector A

    2. Connector B

    3. Fixings
  2. Reconnect the engine ECM connectors (see Electrical Connectors).
  3. Secure the engine ECM bracket to the airbox and tighten the fixings to 1.5 Nm.

Perform the following operations:

Immobiliser/TPMS Control Module - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Disconnect the multiplug for the immobiliser/TPMS control module from the main harness.
  2. Release the two fixings and remove the immobiliser/TPMS control module.

    1. Immobiliser/TPMS control module multiplug

    2. Fixings

    3. Immobiliser/TPMS control module

Immobiliser/TPMS Control Module - Installation

  1. Fit the immobiliser/TPMS control module to the airbox upper section, tighten its fixings to 1.5 Nm.
  2. Connect the multiplug for the immobiliser/TPMS control module to the main harness.

Perform the following operations:

note
  • If a new immobiliser/TPMS control module is fitted, it must be paired with the engine ECM and ignition key as described in the Triumph Diagnostic Tool User Guide:

Twist Grip - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • The anti-tamper fixings on the twist grip housing must not be loosened or removed.
    • If the anti-tamper screws have been loosened or removed any warranty claims for the twist grip housing will not be honoured.
  1. Release the fixings and remove the clamp for the twist grip housing from the handlebar.

    1. Anti-tamper fixings

    2. Fixings

    note
    • Note the position and orientation of the twist grip to its housing for installation.
  2. Slide the twist grip assembly off the handlebar.

Twist Grip - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Slide the twist grip onto the handlebar and align it to the twist grip position sensor as noted for removal.
  2. Fit the twist grip clamp. Ensure the locating lug fits into its hole on the handlebar.

    1. Locating lug

    2. Hole

    3. Twist grip clamp
  3. Fit and fixings and tighten, upper one first, to 2.5 Nm.

Perform the following operations:

Twist Grip Position Sensor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the routing of the harnesses around the right hand side of the headstock for installation.
  1. Remove the cable guide on the right hand side of the headstock. Discard the fixings.
  2. Remove the rubber band from the cables on the right hand side of the headstock.

    1. Fixings

    2. Cable guide

    3. Rubber band
  3. Detach the twist grip harness electrical connector from its bracket and disconnect from the main harness.

    1. Twist grip connector

    2. Bracket

    note
    • Note the routing of the twist grip harness for installation.
  4. Route the twist grip harness out of the frame to the twist grip.

    5. note
    • Note the orientation of the twist grip position sensor for installation.
  5. Slide the twist grip position sensor off the handlebar.

Twist Grip Position Sensor - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Slide the twist grip position sensor onto the handlebar in the orientation noted for removal.
  2. Route the twist grip harness to the main harness as noted for removal.
  3. Connect the harness to the main harness the attach the connector to its bracket.

    1. Twist grip connector

    2. Bracket
  4. Position the harness around the headstock as noted for removal.
  5. Fit the cable guide to the headstock and tighten the new fixings to 13 Nm.
  6. Fit the rubber band as noted for removal.

    1. Fixings

    2. Cable guide

    3. Rubber band

Perform the following operations:

Intake Air Temperature Sensor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Disconnect the multiplug from the air temperature sensor.
  2. Release the fixing and remove the air temperature sensor.

  1. Fixing

  2. Multiplug

Intake Air Temperature Sensor - Installation

  1. Fit the air temperature sensor to the airbox. Tighten its fixing to 2.5 Nm.
  2. Reconnect the intake air temperature sensor multiplug. Ensure the multiplug is fully engaged and the locking device is holding it secure.

Perform the following operations:

Map Sensor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Detach the MAP sensor hose from the airbox.
  2. Release the fixing and detach the MAP sensor from the airbox.
  3. Disconnect the map sensor multiplug, the MAP sensor hose and remove the MAP sensor.

    1. MAP sensor hose

    2. MAP sensor

    3. Fixing

    4. Multiplug

Map Sensor - Installation

  1. Reconnect the map sensor multiplug.
  2. Refit the MAP sensor hose to the MAP sensor.
  3. Fit the sensor to the airbox, tightening the fixing to 2.5 Nm.
  4. Secure the MAP sensor hose to the airbox.

    1. MAP sensor hose

    2. MAP sensor

    3. Fixing

    4. Multiplug

Perform the following operations:

Ambient Air Temperature Sensor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    warning

    Operation of the motorcycle with an incorrectly adjusted instrument panel is dangerous.

    An incorrectly adjusted instrument panel will result in loss of instrument vision when riding and may cause a distraction leading to loss of control of the motorcycle and an accident.

    Always adjust the instrument panel to provide sufficient vision of the instruments before riding the motorcycle.

    caution

    Do not press directly onto the display panel.

    Only adjust the position of the instrument display using the adjustment handle.

    Pressing directly on the instrument display panel may damage the display panel.

    note
    • Note the position of the instrument screen in so that it can be returned to its original setting.
  1. Adjust the instrument display panel to its lowest position.

    1. Adjustment handle
  2. Release the two fixings and remove the fascia panel.

    1. Fascia panel

    2. Fixings
  3. Release the fixing and remove the flyscreen assembly. Disconnect the electrical connector for the ambient air pressure sensor for complete removal.

    1. Fascia panel

    2. Flyscreen Assembly

    3. Fixings
  4. Release the fixing and remove the ambient air temperature sensor.

    1. Fixing

    2. Ambient air temperature sensor

Ambient Air Temperature Sensor - Installation

  1. Fit the ambient air temperature sensor to the flyscreen. Tighten its fixing to 1.5 Nm.

    1. Fixing

    2. Ambient air temperature sensor
  2. Position the assembly to the motorcycle and reconnect the electrical connector for the ambient air temperature sensor.
  3. Ensure that the flyscreen and air intake duct assembly is correctly positioned to the front subframe and secure with the fixing. Tighten the fixing to 3 Nm.

    1. Flyscreen assembly

    2. Fixing
  4. Fit the fascia panel to the front subframe ensuring that its locating lugs are fully inserted into the rubber grommets. Secure with the two fixings and tighten to 3 Nm.

    1. Fascia panel

    2. Locating lugs

    3. Rubber grommets

    4. Fixings

Perform the following operations:

Ambient Air Pressure Sensor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the fixing securing the ambient air pressure sensor to the battery tray.
  2. Disconnect the electrical connector and remove the sensor.

    1. Ambient air pressure sensor

    2. Fixing

    3. Electrical connector

Ambient Air Pressure Sensor - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Reconnect the electrical connector to the ambient air pressure sensor.
  2. Fit the sensor to the battery tray and tighten its fixing to 1.5 Nm.

    1. Ambient air pressure sensor

    2. Fixing

    3. Electrical connector

Perform the following operations:

Fall Detection Switch - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Remove and discard the fixings securing the fall detection switch to its bracket on the battery tray.
  2. Disconnect the electrical connector and remove the fall detection switch.

    1. Fall detection switch

    2. Fixings

    3. Electrical connector

Fall Detection Switch - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Connect the electrical connector to the fall detection switch.
  2. Fit the fall detection switch to its bracket on the battery tray and tighten the new fixings to 3 Nm.

    1. Fall detection switch

    2. Fixings

    3. Electrical connector

Perform the following operations:

Gear Position Sensor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the routing of the harness for the gear position sensor for installation.
  1. Follow the route of the harness for the gear position sensor, disconnect its multiplug from the main harness.
  2. Release the fixings and remove the gear position sensor from the engine.

    1. Fixings

    2. Gear position sensor

    3. Harness
  3. Remove and discard the two O-rings from the gear position sensor.

Gear Position Sensor - Installation

  1. Fit two new O-rings to the gear position sensor. Lubricate the O-rings with a smear of petroleum jelly.
  2. Fit the gear position sensor to the engine. Ensure that the locating pin on the sensor fits into the hole in the end of the gear selector drum.

    1. Locating pin

    2. Hole
  3. Fit the gear position sensor fixings and tighten to 5 Nm.
  4. Route the gear position sensor as noted for removal and connect to the main harness.

Perform the following operations:

Coolant Temperature Sensor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Press the wire locking device fully in and disconnect the harness from the coolant temperature sensor.
  2. Remove the coolant temperature sensor.

    1. Wire locking device

    2. Connector
  3. Remove the coolant temperature sensor.

Coolant Temperature Sensor - Installation

  1. Fit the coolant temperature sensor into the cylinder head and tighten to 18 Nm.
  2. Refit harness to the coolant temperature sensor.

Perform the following operations:

Crankshaft Position Sensor

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

The alternator stator and crankshaft position sensor are supplied as an assembly and cannot be separated.

Perform the following operations:

Throttle Actuator Motor

The throttle actuator motor is an integral part of the throttle bodies and cannot be replaced separately.

Exhaust System Components

Exhaust Silencer - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid skin damage, always allow the hot parts to cool before working on the exhaust system.

Perform the following operations:

  1. Release the fixing for the front heat shield and remove the shouldered washer.
  2. Move the heat shield forward to detach it from its locating lugs and remove the front heat shield.

    1. Fixing

    2. Shouldered washer

    3. Heat shield

    4. Locating lugs location

    note
    • Always note the position and orientation of exhaust clamps prior to releasing them, and return them to the noted position and orientation on assembly.
  3. Release the clamp securing the silencer to the catalytic converter.

    1. Clamp

    2. Exhaust silencer

    3. Catalytic converter
  4. Remove the nut and bolt securing the silencer to the right hand control plate.
  5. While supporting the silencer, remove the nut and bolt securing the silencer to the frame.

    1. Nut and bolt

    2. Right hand control plate

    3. Nut and bolt to frame
  6. Move the silencer rearwards to disengage its locating lug on the left hand side from the frame and remove.

    1. Locating lug

    2. Silencer

Exhaust Silencer - Installation

    caution

    Do not install the exhaust system or run the engine without the exhaust heat shields fitted. Components protected by the exhaust heat shields may suffer severe damage or a fire if the motorcycle is operated without the heat shields being fitted.

  1. Fit a new exhaust silencer gasket to the catalytic converter.
  2. Position the locating lug on the silencer into its hole on the left hand side of the frame. Align the silencer to the catalytic converter.

    1. Locating lug

    2. Silencer
  3. While supporting the silencer, secure it to the frame with the nut and bolt, do not fully tighten at this stage.
  4. Fit the bolt and new lock nut that secures the silencer to the right hand control plate. Do not fully tighten at this stage.

    1. Nut and bolt

    2. Right hand control plate

    3. Nut and bolt to frame
  5. Fit a new gasket and the silencer clamp. Tighten the clamp to 5 Nm.

    1. Clamp

    2. Exhaust silencer

    3. Catalytic converter
  6. Tighten the bolt securing the silencer to the frame to 28 Nm.
  7. Tighten the lock nut and bolt securing the silencer to the right hand control plate to 28 Nm.

    1. Nut and bolt

    2. Right hand control plate

    3. Nut and bolt to frame
  8. Check the rubber grommets are on the lugs of the silencer.
  9. Slide the heat shield on to its retaining lugs on the silencer. Fit and tighten the fixing to 5 Nm.

    1. Fixing

    2. Shouldered washer

    3. Heat shield

    4. Locating lugs

Perform the following operations:

Exhaust Header Pipe - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid skin damage, always allow the hot parts to cool before working on the exhaust system.

Perform the following operations:

  1. Release the fixing for the front heat shield and remove the shouldered washer.
  2. Move the heat shield forward to detach it from its locating lugs and remove the front heat shield.

    1. Fixing

    2. Shouldered washer

    3. Heat shield

    4. Locating lugs

    note
    • Note the routing of the oxygen sensor harness for installation.
    • Note the position and orientation of the rubber band securing the oxygen sensor to the coolant hose for installation.
  3. Remove the rubber band securing the oxygen sensor harness to the coolant pipe.
  4. Disconnect the oxygen sensor's multiplug from the main harness.

    1. Rubber band

    2. Connector

    3. Oxygen sensor

    note
    • Always note the position and orientation of exhaust clamps prior to releasing them, and return them to the noted position and orientation on assembly.
  5. If required, remove the oxygen sensor.
  6. Release the clamp securing the silencer to the catalytic converter.

    1. Clamp

    2. Exhaust silencer

    3. Catalytic converter
  7. Release the fixings securing the header pipe joints to the cylinder head. Discard the fixings.

    1. Header pipes

    2. Fixings
  8. Remove the header pipe assembly and remove and discard the seals from the cylinder head ports.
  9. Remove and discard the exhaust header pipe gasket from the catalytic converter.

Exhaust Header Pipe - Installation

  1. Fit new seals to the cylinder head. Ensure that the face of the seal with the tab is facing the cylinder head.

    2. note
    • A smear of grease may be used to retain the seals in the cylinder head during assembly.
  2. Fit a new exhaust silencer gasket to the catalytic converter.
  3. Align the exhaust header pipes to the cylinder head and the catalytic converter to the exhaust silencer.
  4. Fit new nuts at the cylinder head, do not fully tighten at this stage.
  5. Align the catalytic converter to the exhaust silencer and fit the clamp, do not tighten at this stage.
  6. Tighten the header pipe to cylinder head nuts in the sequence shown below to 15 Nm.

    7. Exhaust Header Tightening Sequence
  7. Tighten the catalytic converter to exhaust silencer clamp to 5 Nm.

    1. Clamp

    2. Exhaust silencer

    3. Catalytic converter
  8. If removed, apply a thin smear of anti-seize compound to the threads of the oxygen sensor, install the oxygen sensor and tighten to 25 Nm.
  9. Route the oxygen sensor harness as noted for removal and connect to the main harness.
  10. Secure the oxygen sensor harness to the coolant pipe with the rubber band, as noted for removal.

    1. Rubber band

    2. Connector

    3. Oxygen sensor
  11. Check the rubber grommets are on the lugs of the catalytic converter.
  12. slide the heat shield on to its retaining lugs on the silencer. Fit and tighten the fixing to 5 Nm.

    1. Fixing

    2. Shouldered washer

    3. Heat shield

    4. Locating lugs

Perform the following operations:

Evaporative System Components

Component Locations

Carbon Filled Canister - under the seat.

Purge Control Valve - attached to the main harness conduit on the left hand side of the frame (electronically controlled by the ECM).

  1. Breather hoses

  2. Carbon filled canister

  3. Purge valve

  4. Purge hose to throttle bodies

Evaporative Emissions Control System

Certain Markets Only

Some models in certain markets are fitted with a system to control the evaporation of fuel vapour to the atmosphere.

A carbon filled canister absorbs vapour while the engine is not running. When the engine is started, the vapour is returned to the engine and burnt.

There are two distinct phases to the system's operation: engine off and engine running. These two conditions are explained overleaf.

Component Locations

Carbon Filled Canister - under the seat.

Purge Control Valve - attached to the main harness conduit on the left hand side of the frame (electronically controlled by the ECM).

  1. Breather hoses

  2. Carbon filled canister

  3. Purge valve

  4. Purge hose to throttle bodies

Evaporative Control System - Engine Off

When the engine is stationary, any pressure increase in the fuel tank due to a rise in ambient temperature will cause the fuel vapour to pass down the breather hose (1) to a carbon filled canister (2) which stores the vapour.

Once in the canister, vapour cannot enter the engine because the purge valve is closed.

  1. Breather hoses

  2. Carbon filled canister

  3. Purge valve (closed)

  4. Purge hose to throttle bodies

Evaporative Control System - Engine Running

When the engine is running, a vacuum is applied to the purge hose (4) from the throttle bodies.

At certain times, the ECM opens the purge valve. The vacuum applied to the purge hose (4) now begins to draw stored vapour from the carbon filled area of the canister and returns it to the throttle bodies for burning in the engine.

In order to control the speed at which the vapour is purged from the canister, the engine management system shuttles the purge control valve between the open and closed positions.

  1. Breather hoses

  2. Carbon filled canister

  3. Purge valve (open under engine ECM control)

  4. Purge hose to throttle bodies

Evaporative Canister - Removal

warning

Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.

A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly.

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

note
  • Note the position, orientation and routing of all hoses connected to the evaporative cannister for installation.

    1. Evaporative cannister

    2. Fuel tank hose

    3. Purge valve hose

    4. Air hose

    5. Drain hose

    6. Drain hose locating feature
  1. Disconnect the purge valve and fuel tank hoses from the right hand side of the evaporative cannister.
  2. Remove the evaporative cannister from the battery tray, withdrawing the air and drain hoses as you do so.
  3. If necessary, disconnect the air and drain hoses from the left hand side of the cannister.

Evaporative Canister - Installation

warning

Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.

A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly.

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. If disconnected, reconnect the air and drain hoses to the left hand side of the evaporative cannister in the position and orientation noted during removal.
  2. Refit the evaporative cannister to the battery tray, routing the air and drain hoses as noted during removal. Position the drain hose into its locating feature on the battery tray.

    1. Evaporative cannister

    2. Air hose

    3. Drain hose

    4. Drain hose locating feature
  3. Ensure that the ends of the air and drain hoses are passed through the opening in the battery tray.

    1. Evaporative cannister

    2. Air hose

    3. Drain hose

    4. Opening in battery tray
  4. Reconnect the fuel tank and purge valve hoses to the right hand side of the cannister in the positions noted during removal.

Perform the following operations:

Purge Control Valve (if fitted) - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Noting its position for installation, cut and remove the cable tie securing the purge control valve to the main harness conduit.

    1. Main harness conduit

    2. Cable tie
  2. Press the wire locking device fully in and disconnect the harness from the purge control valve.

    3. note
    • Note the position of the purge control valve hoses for installation.
  3. Disconnect the hoses and remove the purge control valve from the motorcycle.

    1. Connector

    2. Hose

    3. Purge control valve

Purge Control Valve - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Reconnect the hoses to the purge control valve as noted during removal.
  2. Reconnect the purge control valve electrical connector.
  3. Position the purge control valve to the main harness conduit, as noted for removal, and secure with a new cable tie.

Perform the following operations:

Cooling

Exploded View - Cooling System

Coolant

A year-round, Hybrid Organic Acid Technology (known as Hybrid OAT or HOAT) coolant is installed in the cooling system when the motorcycle leaves the factory. It is coloured green, contains a 50% solution of ethylene glycol based antifreeze, and has a freezing point of -35°C (-31°F).

Always change the coolant at the intervals specified in the Scheduled Maintenance chart.

warning

The standard coolant mixture contains toxic chemicals that are harmful to the human body. Never swallow neat antifreeze or any of the coolant mixture.

caution

The antifreeze incorporated in the coolant mixture contains a corrosion inhibitor that helps prevent damage to the cooling system and engine. Without this inhibitor, the coolant would 'attack' the metals and the resulting corrosion would cause blockages in the cooling system leading to engine overheating and damage.

Always use the antifreeze listed in the Specification section and never use a methanol based antifreeze as this does not contain the required corrosion inhibition properties.

note
  • HD4X Hybrid OAT coolant, as supplied by Triumph, is premixed and does not need to be diluted prior to filling or topping up the cooling system.

caution

If hard water is used in the cooling system, it will cause scale accumulation in the engine and radiator and considerably reduce the efficiency of the cooling system. Reduced cooling system efficiency may cause the engine to overheat and suffer severe damage.

Radiator Hoses

Check the radiator hoses for cracks or deterioration, and hose clamps for tightness in accordance with scheduled maintenance requirements.

Radiator and Cooling Fan Inspection

Radiator

caution

Using high pressure water, such as from a pressure-washer, can damage the radiator fins and impair the radiator's efficiency.

Do not obstruct or deflect airflow through the radiator by installing unauthorised accessories in front of the radiator or behind the cooling fan. Interference with the radiator airflow can lead to overheating and consequent engine damage.

  1. Check the radiator for stone damage.
  2. Check the radiator core, for damage to fins or obstructions to air flow.
  3. Clean off any obstructions with a stream of low-pressure water.

    4. caution

    To avoid overheating and consequent engine damage, replace the radiator if the cores are blocked or if the fins are badly deformed or broken.

  4. Rectify any damage.

Cooling Fan

warning

The cooling fan is switched on and off by the Engine Control Module in response to a signal received from the coolant temperature sensor. To prevent injury, never place loose clothing, fingers or hands near the cooling fan, until the engine is stopped. Loose clothing, fingers or the hands could become trapped during cooling fan operation and cause crushing injury to the fingers, hands or other parts of the anatomy.

The motorcycle is fitted with a thermostatically controlled electric fan situated behind the radiator. When the fan operates with the motorcycle stationary or at slow speed, cool air is drawn through the radiator from the front of the motorcycle.

  1. Check that the cooling fan spins freely and without tight spots.
  2. Check the cooling fan blades for signs of heat distortion.
  3. Rectify as necessary.

Coolant Level Inspection

note
  • The coolant level should be checked when the engine is cold (at room or ambient temperature).
  1. Position the motorcycle on level ground and in an upright position. The expansion tank can be viewed from the left hand side of the motorcycle, below and towards the front of the fuel tank.
  2. Check the coolant level in the expansion tank. The coolant level must be between the MAX and MIN marks. If the coolant is below the minimum level, the coolant level must be adjusted.

    1. Expansion tank

    2. Filler cap

    3. MAX mark

    4. MIN mark

Coolant Level Adjustment

warning

Do not remove the expansion tank or radiator pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator will be hot and also under pressure. Contact with this hot, pressurised coolant will cause scalds and skin damage.

note
  • If the coolant level is being checked because the coolant has overheated, with the motorcycle on level ground and in an upright position, also check the level in the radiator and top up if necessary.
  • In an emergency, distilled water can be added to the cooling system. However, the coolant must then be drained and replenished with HD4X Hybrid OAT coolant as soon as possible.

caution

If hard water is used in the cooling system, it will cause scale accumulation in the engine and radiator, and considerably reduce the efficiency of the cooling system. Reduced cooling system efficiency may cause the engine to overheat and suffer severe damage.

  1. Allow the engine to cool.
  2. Remove the cap from the expansion tank and add coolant mixture through the filler opening until the level reaches the MAX mark. Refit the cap.

    1. Expansion tank

    2. Filler cap

    3. MAX mark

    4. MIN mark

Coolant Replacement - Drainage

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

note
  • Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly.
  • Use T3880207 - Hose Clip Pliers for their removal and installation.

    warning

    Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.

  1. Remove the coolant pressure cap on the radiator.

    1. Radiator cap
  2. Position a container to collect the displaced coolant.
  3. Loosen the hose clip then release the coolant hose from the front of the crankcase and allow the coolant to drain.

    1. Coolant hose

    2. Hose clip

Coolant Replacement - Filling

  1. Reconnect the coolant hose to the front of the crankcase. Ensure the hose clip is positioned as noted for removal.
  2. Slowly add coolant mixture to the system, through the filler opening in the radiator, until the system is full.

    3. note
    • A hand operated vacuum pump or similar should be used to syphon the coolant through the system.
  3. If necessary, top up the system through the filler and refit the pressure cap.
  4. With the aid of an assistant, lean the motorcycle fully over to the right hand side, and then the left hand side, to release air trapped in the cooling system. Repeat as necessary.
  5. Refit the battery (see Battery - Installation).
  6. Start the motorcycle and allow to run for approximately 20 to 30 seconds. Briefly raise the engine speed several times to allow any air to be expelled from the system.
  7. Stop the engine. Check and top up the coolant level as necessary.
  8. With the aid of an assistant, lean the motorcycle fully over to the right hand side, and then the left hand side, to release air trapped in the cooling system.
  9. Start the motorcycle. Briefly raise the engine speed several times to allow any air to be expelled from the system.
  10. Allow the engine to run until the cooling fan operates.
  11. Stop the motorcycle and allow the engine to cool.

    12. warning

    Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the cooling system is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.

  12. Check and top up the coolant level as necessary (see Coolant Level Adjustment).

Perform the following operations:

Coolant Pressure Cap and Coolant System Testing

Inspection

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.

Perform the following operations:

  1. Allow the engine temperature to cool for at least 30 minutes.
  2. Remove the coolant pressure cap.
  3. Check condition of the upper and lower seals of the coolant pressure cap.

    1. Lower seal

    2. Upper seal

    3. Spring

    note
    • If there is any sign of damage or deterioration replace the cap.
  4. Pressure test the cap to the blow off pressure of 1.1 bar (15.95 lb/in²) as described using T3880147 - Radiator and Cap Tester Kit.

    5. note
    • It is recommended to carry out coolant pressure cap and cooling system pressure test consecutively.

Coolant Pressure Cap Test

  1. Hand held pump

  2. Bayonet type connector

  3. Pressure cap test adaptor 44 mm

  4. Pressure cap test adaptor 46 mm
  1. Select the correct test adaptor and securely fasten to the pressure cap.
  2. Carefully connect the hand pump to the adaptor ensuring an air tight seal is maintained.

    1. Pressure cap

    2. Test adaptor

    3. Hand held pump
  3. Pressure test the coolant cap to its 1.1 bar (15.95 lb/in²) blow off pressure. If the coolant cap opens at a lower pressure, fails to open at the correct pressure or the seal leaks, replace the cap.

Coolant System Pressure Test

  1. Allow the engine temperature to cool for at least 30 minutes.
  2. Check the condition of the radiator, hoses and seals of the coolant system visually for damage or leaks.
  3. Remove the coolant pressure cap.
  4. Select the bayonet type adaptor and securely fasten to the radiator.
  5. Carefully connect the hand pump to the bayonet connector ensuring an air tight seal is maintained.

    1. Radiator filler

    2. Bayonet type connector

    3. Hand held pump
  6. Pressurise the cooling system to its 1.1 bar (15.95 lb/in²) operating pressure, using the hand pump taking care not to exceed the maximum cap pressure.
  7. Hold the pressure for a minimum of 10 minutes, whilst visually inspecting the external components of the coolant system for leaks.
  8. Remove the engine oil filler cap/dipstick and check for contamination of the engine oil caused by coolant escaping into the engine sump.

    9. note
    • If the engine oil is contaminated further exploratory investigation will be required.
    • If the engine oil is contaminated rectify the cause of the problem and then renew the oil and filter.
  9. Depressurise the coolant test kit by using the pressure release valve.

    1. Radiator filler

    2. Bayonet type connector

    3. Hand held pump

    4. Pressure release valve
  10. Refit the coolant pressure cap.
  11. Fill the coolant to the maximum mark (see Coolant Replacement - Filling).

Perform the following operations:

Thermostat - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly.
  • Use T3880207 - Hose Clip Pliers for their removal and installation.

Perform the following operations:

    warning

    Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.

  1. Detach the top hose from the thermostat elbow.
  2. Release the fixings securing the thermostat elbow to the cylinder head.
  3. Remove the thermostat housing. Discard the O-ring.

    1. Thermostat housing

    2. Fixings
  4. Remove the thermostat from the cylinder head.

    1. Thermostat

    2. Bleed valve

Thermostat - Inspection

  1. Inspect the thermostat at room temperature. If the valve is open, the thermostat must be replaced.
  2. To check the valve opening temperature, suspend the thermostat in a container of water and raise the temperature of the water until the thermostat opens. The thermostat should start to open at 71°C +/- 5°C.
  3. If the temperature at which thermostat opening takes place is incorrect, replace the thermostat.

Thermostat - Installation

  1. Locate the thermostat into the cylinder head. Ensure the bleed valve is uppermost as shown below.

    1. Thermostat

    2. Bleed valve
  2. Fit a new O-ring to the thermostat elbow groove.

    1. O-ring groove
  3. Tighten the fixings to 9 Nm.
  4. Reconnect the top hose. Ensure the hose clip is positioned as noted for removal.

Perform the following operations:

Radiator - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly.
  • For models fitted with the constant tension hose clips, use T3880207 - Hose Clip Pliers for their removal and installation.

warning

Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.

Perform the following operations:

  1. Disconnect the horn's two electrical connectors and detach the harness from the cooling fan cowl.
  2. Release the fixing and remove the horn.

    1. Fixing

    2. Horn

    note
    • Note the routing of the harness for the cooling fan for installation.
  3. Follow the routing of the harness for the cooling fan and disconnect it from the main harness.
  4. Release the hose clip and disconnect the bypass hose from the radiator. Discard the clip.
  5. Detach the clutch cable retaining clip from the top of the radiator.

    1. Hose clip

    2. Bypass hose

    3. Retaining clip

    4. Clutch cable
  6. Loosen the hose clips then detach the top and bottom hoses from the radiator.

    1. Hose clips

    2. Top hose

    3. Bottom hose
  7. Release the radiator lower mounting.

    1. Fixing

    2. Radiator lower mounting

    note
    • Note the position of the rubber air deflector and its retaining plate in relation to the radiator's upper mounting bolts for installation.
  8. Release the fixings securing the radiator to the frame. Collect the retaining plate for the air deflector.

    1. Fixings

    2. Retaining plate
  9. Remove the radiator.

Radiator - Installation

  1. Align the radiator to the frame and lower mounting.
  2. Position the rubber air deflector and its retaining plate to the upper mountings as noted for removal.
  3. Fit the upper mounting fixings and tighten to 6 Nm.
  4. Fit and tighten the lower mounting fixing to 6 Nm.
  5. Reconnect the top and bottom hoses. Ensure the hose clips are positioned as noted for removal and secure with the hose clips.

    1. Hose clips

    2. Top hose

    3. Bottom hose
  6. Secure the clutch cable retaining clip to the top of the radiator.
  7. Connect the bypass hose to the radiator and secure with a new hose clip.

    1. Hose clip

    2. Bypass hose

    3. Retaining clip

    4. Clutch cable
  8. Route the harness for the cooling fan as noted for removal (ensure connectors are pushed through the air deflector) and connect to the main harness.
  9. Fit the horn to the radiator and tighten its fixing to 15 Nm.

    1. Fixing

    2. Horn
  10. Connect the horn's two electrical connectors.

Perform the following operations:

Coolant Expansion Tank - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the shouldered washer between the coolant expansion tank and cylinder head for installation.
  1. Remove The fixing securing the coolant expansion tank to the cylinder head.

    1. Fixing

    2. Coolant expansion tank cover

    note
    • Note the shouldered washer between the coolant expansion tank and frame for installation.
  2. Remove The fixings and detach the coolant expansion tank from the frame.

    1. Fixings

    2. Coolant expansion tank

    3. Hose clip

    4. Bypass hose
  3. Position a container to collect the displaced coolant.
  4. Release the hose clips, disconnect the bypass and over flow hoses from the coolant expansion tank.
  5. Remove the coolant expansion tank.

Coolant Expansion Tank - Installation

  1. Connect the bypass and coolant overflow hoses to the coolant expansion tank and secure with the hose clips.
  2. Fit the three shouldered washers to the coolant expansion tank, as noted for removal.
  3. Position the coolant expansion tank and its cover to the frame, as noted for removal. Fit the two fixings and tighten to 6 Nm.

    1. Fixings

    2. Coolant expansion tank

    3. Hose clip

    4. Bypass hose
  4. Secure the coolant expansion tank cover to the cylinder head and tighten the fixing to 6 Nm.

    1. Fixing

    2. Coolant expansion tank cover
  5. Top up the coolant level in the expansion tank (see Coolant Replacement - Filling).

Perform the following operations:

Front Suspension

Headstock Bearing - Inspection

warning

Only remove raised witness marks from within the frame. Removal of material below any raised areas will reduce the level of interference between the frame and the bearings. Loss of interference could cause the bearing to become loose in the frame leading to loss of motorcycle control and an accident.

  1. Examine the frame for any raised witness marks caused by the removal process. Remove any such marks with fine emery paper or a gentle file.

Exploded View – Handlebars and Upper Yoke

Exploded View - Front Forks, Bottom Yoke and Steering Head Bearings

Front Fork - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Raise and support the front of the motorcycle.
  2. Detach and support the front brake calipers (see Front Brake Caliper - Removal).

    3. warning

    Never allow the brake calipers to hang on the brake hoses as this may damage the hoses. A damaged brake hose can cause a reduction in braking efficiency leading to loss of motorcycle control and an accident.

  3. Remove the front wheel (see Front Wheel - Removal).
  4. Remove the front mudguard (see Front Mudguard - Removal).
  5. Detach the front ABS wheel speed sensor (and its harness if necessary) from the left hand fork leg (see Rear ABS Wheel Speed Sensor - Removal).

    6. caution

    Before loosening, cover the fork top cap with a suitable masking tape to protect its anodized finish from becoming damaged by the tool.

    note
    • If the forks are to be dismantled, loosen the fork top caps.
  6. Loosen the upper yoke pinch bolts.

    1. Upper yoke pinch bolt (right hand side shown)
  7. Loosen the lower yoke pinch bolts.

    1. Lower yoke pinch bolts

    caution

    Care must be taken when removing the forks, to ensure that the outer surfaces do not become scratched.

  8. Using a downward, twisting action, withdraw the forks from between the yokes.

Front Fork - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • When positioning the front forks to the yokes, make sure the fork top caps are correctly aligned as shown below.

  1. Fork top caps (correctly aligned)
  1. Position the forks within the yokes so that the lip of the outer tube, not the top cap, is 28 mm above the flat/machined surface on the underside of the upper yoke.

    2. Fork pull through measurement
  2. Tighten the lower yoke pinch bolts as follows:
  3. Tighten the upper yoke pinch bolts to 26 Nm.

    4. caution

    Before tightening, cover the fork top cap with a suitable masking tape to protect its anodized finish from becoming damaged by the tool.

  4. If the forks have been dismantled, tighten the fork top caps to 35 Nm.

note
  • Recheck the fork top caps for correct alignment as shown above. If necessary, loosen the upper and lower yoke pinch bolts and adjust the top cap alignment as required. Re-tighten the upper and lower yoke pinch bolts as described above.

Perform the following operations:

note
  • The air gap between the ABS pulser ring and the wheel speed sensor must be between 0.40 mm to 1.20 mm.

Fork Inspection

Examine each fork for any sign of damage or scratching of the slider surface or for oil leaks.

If any damage or oil leakage is found, strip and repair as described in this section or consult an authorised Triumph dealer.

Check for smooth operation of the forks as follows:

If roughness or excessive stiffness is detected, repair as described in this section or consult an authorised Triumph dealer.

warning

Riding the motorcycle with defective or damaged suspension can cause loss of motorcycle control and an accident. Never ride with damaged or defective suspension.

Fork Oil Change - Oil Draining

    caution

    When securing the fork in T3880171 - Fork Holding Tool, take care not to over tighten the clamp as this will cause the fork tube to distort beyond repair.

  1. Using a soft jawed vice, clamp the T3880171 - Fork Holding Tool such that the fork can be mounted vertically.
  2. With the top cap facing upwards, very gently clamp the fork inner tube into T3880171 - Fork Holding Tool.
  3. Using T3880186 - 45 mm Octagonal Socket carefully unscrew the top cap from the fork outer tube.

    1. T3880186 - 45 mm Octagonal Socket

    2. Fork outer tube

    warning

    The fork damping assembly is under pressure from the fork spring. As the last few threads of the damping assembly are unscrewed, keep the damping assembly pushed firmly into the tube to prevent it being forcibly expelled as the threads release. To prevent injury, always wear eye, face and hand protection when removing the top cap.

  4. Hold the fork inner tube fully into the fork outer tube. Using T3880367 - Wrench, Damper Cylinder, 33mm unscrew and remove the top cap and fork damping assembly from the fork inner tube.

    1. T3880367 - Wrench, Damper Cylinder, 33mm

    2. Top cap

    3. Damping rod

    4. Fork outer tube

    note
    • Note the orientation of the upper and lower spring collars as they are removed to ensure that they can be correctly refitted upon assembly.
  5. Lift out the upper spring collar and the spring.

    1. Upper spring collar

    2. Spring

    3. Fork outer tube
  6. Invert the fork and pour out the fork oil into a suitable container. Collect the lower spring collar. Pump the fork assembly to remove all oil.

    1. Lower spring collar

Fork Oil Change - Oil Refilling

The oil level is measured from the upper surface of the fork outer tube, with the fork fully compressed.

Fork Oil Level (fork fully compressed)

Fork Oil Level Chart

warning

Any variation from the figures quoted in the fork oil level chart could result in an unsafe riding condition leading to loss of motorcycle control and an accident.

Oil Level*

Oil Volume

Oil Grade

65 mm

515 cc

Showa SS47

*Fork fully compressed with the lower spring collar, spring, upper spring collar and damping assembly fitted.

warning

Make sure that the upper and lower spring collars are fitted in the correct orientation as noted during removal.

Incorrectly assembled components could lead to an unsafe riding condition resulting in loss of motorcycle control and an accident.

  1. Fit the lower spring collar into the fork inner tube as noted during removal.

    1. Lower spring collar
  2. Fit the spring and upper spring collar into the fork inner tube as noted during removal.

    1. Upper spring collar

    2. Spring

    3. Fork outer tube
  3. Fill the fork with the specified fork oil until the oil level passes the side holes in the fork inner tube.

    1. Hole (one of four shown)

    2. Fork inner tube
  4. Pump the fork outer tube several times to expel any trapped air then fully compress the fork and support it in an upright position. Leave the fork for a few minutes to allow the oil level to stabilise.

    5. note
    • When fitting the fork top cap and fork damping assembly, care must be taken not to damage the top ring of the damping assembly.
  5. With the fork fully compressed use T3880367 - Wrench, Damper Cylinder, 33mm to fit the fork damping assembly to the inner tube.

    1. T3880367 - Wrench, Damper Cylinder, 33mm

    2. Top cap

    3. Damping rod

    4. Fork outer tube
  6. With the lower end of the fork inner tube secure in T3880171 - Fork Holding Tool, tighten the damping assembly to 90 Nm using a torque wrench fitted with a suitable crow foot spanner adapter (see Use of Crow Foot Spanner Adapters with Torque Wrenches).
  7. Fill the fork with the specified fork oil until the oil level passes over the damping rod guide case.

    1. Fork damping rod

    2. Damping rod guide case
  8. Pump the fork several times to expel any trapped air then fully compress the fork and support it in an upright position. Leave the fork for a few minutes to allow the oil level to stabilise.
  9. Refer to the oil level chart and set the scale on 3880160 -T0301 - Fork Oil Filler/Evacuator to the specified level.

    1. 3880160 -T0301 - Fork Oil Filler/Evacuator

    2. Adjuster plate

    3. Scale area

    4. Hole (zero position)

    note
    • Zero level on the tool is set at the small exit hole in the side of the scale tube, NOT AT THE END TIP. Do not attempt to block this side hole as this will cause the final fluid level to be incorrect.
  10. Insert the scale end of the tool into the fork inner tube.
  11. Hold the tool adjuster plate level with the upper surface of the fork outer tube and draw fluid into the syringe until fluid flow ceases (empty the syringe if the body becomes full before fluid flow stops).
  12. The fluid level in the fork is now set to the height set on the tool scale. Check the tool scale setting and repeat the process if incorrectly set.
  13. Fit a new O-ring to the top cap.
  14. Lubricate the O-ring on the top cap with a smear of clean fork oil then screw the top cap fully into the outer tube.
  15. Using T3880186 - 45 mm Octagonal Socket tighten the top cap to 35 Nm.

    16. note
    • It is much easier to tighten the top cap when the fork has been refitted.

    1. T3880186 - 45 mm Octagonal Socket

    2. Fork outer tube

Front Fork - Disassembly

Fork Top Cap Removal

    note
    • It is only necessary to remove the fork top caps if they are to be replaced.
  1. If removal of the fork top cap is required, loosen the lock nut and unscrew the top cap from the joint rod. If necessary remove the O-ring joint seal from the top cap assembly.

    1. Fork top cap

    2. Lock nut

note
  • When removing the top caps, note the position of the inner and outer damping adjuster rods located inside the joint rod. Ensure both adjuster rods remain correctly located for installation.

  1. Damping assembly joint rod

  2. Outer damping adjuster rod

  3. Inner damping adjuster rod

Fork Inner and Outer Tube Disasembly

    caution

    When securing the fork in T3880171 - Fork Holding Tool, take great care not to over tighten the clamp as this will cause the fork tube to distort beyond repair.

  1. Ease the dust seal out of the outer tube.

    1. Dust seal

    2. Inner tube
  2. Carefully ease the circlip out from the top of the outer tube.

    1. Circlip
  3. Compress the fork then pull the inner tube sharply out of the outer tube. Repeat this procedure until the upper bush and seal are forced out of position and the inner and outer tube can be separated.
  4. Carefully slide the upper bush off the fork inner tube. Discard the upper bush.

    5. note
    • Note the orientation of the oil seal and dust seal for installation.
  5. Slide the lower bush, washer, oil seal, circlip and dust seal off the fork inner tube. Discard the lower bush, oil seal, circlip and dust seal.

    1. Upper bush

    2. Lower bush

    3. Washer

    4. Oil seal

    5. Circlip

    6. Dust seal

    7. Fork inner tube

Front Fork - Inspection

  1. Thoroughly clean and examine all components for damage, wear, scoring, corrosion etc., paying particular attention to the bushes and damper rod piston ring. Renew as necessary.
  2. Always renew the oil seal, dust seal and the damper rod bolt sealing washer every time the fork is dismantled.

Front Fork - Assembly

warning

The front forks comprise many precision machined parts. Total cleanliness must be observed at all times and assembly must take place in a dirt/dust-free environment.

Dirt ingress may cause damage to the fork parts, leading to incorrect operation, instability, loss of motorcycle control or an accident.

Fork Inner Tube and Outer Tube Assembly

  1. Lubricate the oil seal, upper and lower bushes for the inner tube with clean fork oil.
  2. Install T3880642 - Fork Seal Guide/Protector to the fork inner tube. Ensure the tool is not damaged and that it covers the bush groove fully.

    1. Fork inner tube

    2. T3880642 - Fork Seal Guide/Protector
  3. Slide a new dust seal on to the fork inner tube as noted for removal.
  4. Slide the circlip and a new oil seal on to the fork inner tube as noted for removal.
  5. Slide the washer and a new lower bush onto the inner tube.
  6. Remove T3880642 - Fork Seal Guide/Protector from the fork inner tube.
  7. Fit a new upper bush to the fork inner tube.

    1. Upper bush

    2. Lower bush

    3. Washer

    4. Oil seal

    5. Circlip

    6. Dust seal

    7. Fork inner tube
  8. Insert the fork inner tube assembly into the fork outer tube.
  9. Using the narrow end of T3880003 - Front fork Seal Installer, guide the lower bush, washer and oil seal into place.

    1. T3880003 - Front fork Seal Installer

    2. Oil seal

    3. Fork inner tube

    4. Fork outer tube
  10. Secure the oil seal in position with the circlip, ensuring it is correctly located in its groove.
  11. Position the dust seal to the outer tube.
  12. Invert T3880003 - Front fork Seal Installer and, using hand pressure only, push the dust seal squarely into the outer tube.

    1. T3880003 - Front fork Seal Installer

    2. Dust seal
  13. Return the fork to an upright position, with the lower end of the fork inner tube secure in T3880171 - Fork Holding Tool.

Fork Top Cap Installation

note
  • Before installing the top caps, ensure both adjuster rods are correctly located for in the joint rod as noted during removal.

  1. Damping assembly joint rod

  2. Outer damping adjuster rod

  3. Inner damping adjuster rod
  1. If removed, fit a new O-ring to the top cap.
  2. Position the fork top cap to the joint rod ensuring that the adjuster rod(s) are located correctly to the top cap.
  3. Screw the top cap fully onto the joint rod.
  4. Hold the top cap while tightening the lock nut to 27.5 Nm.

Steering Head Bearing - Check

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Raise and support the front of the motorcycle.
  2. Hold the bottom end of the front fork outer tubes as illustrated and rock with a front-to-rear motion. If free play can be detected, the headstock bearings require adjustment.

Steering Head Bearing - Adjustment

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Raise and support the front of the motorcycle.
  2. Release the fixings securing the handlebar clamps to the risers, detach the clamps and release the handlebar.
  3. As an assembly, raise the handle bars until clear of the upper yoke. Rest the assembly forward of the steering stem such that access to the headstock top nut and the adjustment nuts is unrestricted. Ensure the master cylinder remains in an upright position.
  4. Loosen the upper yoke pinch bolts.

    5. warning

    If the lower yoke fixings are also loosened, the forks will no longer support the weight of the motorcycle.

    Do not loosen the lower yoke fixings as, in this condition, the motorcycle could topple over causing damage and/or risk of injury.

    caution

    Care must be taken when removing the upper yoke centre nut, to ensure that the centre nut and upper yoke do not become scratched. Protect the surfaces with a suitable cloth or tape to prevent scratching.

  5. Remove the upper yoke centre nut from the steering stem.

    1. Upper yoke centre nut
  6. Ease the upper yoke from the forks and support while detached.

    7. note
    • When adjusting the bearing free play, ensure that the threaded part of the stem is free from grease.
  7. Adjust the bearing free play as follows, all using T3880023 - 50 mm Socket:

    8. warning

    It is essential that the adjuster nut is not over-tightened. If the adjuster nut is over-tightened it will cause a pre-load on the headstock bearings. This will introduce tight steering, which could cause loss of control and an accident.

    1. Adjuster nut

    2. Lock nut

    3. T3880023 - 50 mm Socket
  8. Refit the upper yoke assembly to the forks.
  9. Fit the upper yoke centre nut and tighten to 90 Nm.
  10. Tighten the upper yoke pinch bolts to 26 Nm.
  11. Locate the handlebar assembly in the lower halves of the clamps. Fit the upper clamps and bolts.
  12. Align the handlebar alignment mark with the front split line of the right hand riser.
  13. Tighten the front clamp bolts to 26 Nm, then the rears.

    1. Right hand split line

    2. Alignment mark
  14. Recheck the bearing adjustment (see Steering Head Bearing - Check).

Upper Yoke - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the routing of the harnesses around the right hand side of the headstock for installation.
  1. Remove the cable guide on the right hand side of the headstock. Discard the fixings.
  2. Remove the rubber band from the cables on the right hand side of the headstock.

    1. Fixings

    2. Cable guide

    3. Rubber band

    note
    • Note the position and the routing of the ignition switch harness for installation.
  3. Follow the routing of the ignition switch harness and disconnect it from the main harness. Free the ignition switch harness from the right hand frame infill panel.

    4. note
    • Note the routing of the harnesses through the upper yoke wire guide for installation.
  4. Release and discard the lock nuts and remove the wire guide from the underside of the upper yoke.

    1. Lock nut (right hand side shown)

    2. Wire guide
  5. Release the fixings securing the handlebar clamps to the risers, detach the clamps and release the handlebar.
  6. As an assembly, raise the handle bars until clear of the upper yoke. Rest the assembly forward of the steering stem such that access to the upper yoke centre nut is unrestricted. Ensure the master cylinder remains in an upright position.
  7. Loosen the upper yoke pinch bolts.

    8. warning

    If the lower yoke fixings are also loosened, the forks will no longer support the weight of the motorcycle.

    Do not loosen the lower yoke fixings as, in this condition, the motorcycle could topple over causing damage and/or risk of injury.

    caution

    Care must be taken when removing the upper yoke centre nut, to ensure that the centre nut and upper yoke do not become scratched. Protect the surfaces with a suitable cloth or tape to prevent scratching.

  8. Remove the upper yoke centre nut.

    1. Upper yoke centre nut
  9. Ease the upper yoke from the forks and remove from the motorcycle.

Upper Yoke - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Refit the upper yoke and tighten the upper yoke centre nut to 90 Nm.
  2. tighten the upper yoke pinch bolts to 26 Nm.
  3. Locate the handlebar assembly in the lower halves of the clamps. Fit the upper clamps and bolts.
  4. Align the handlebar alignment mark with the front split line of the right hand riser.
  5. Tighten the front clamp bolts to 26 Nm, then the rears.

    1. Right hand split line

    2. Alignment mark
  6. Refit the upper yoke wire guide ensuring that the harnesses are routed as noted during removal. Secure with new lock nuts and tighten to 20 Nm.

    1. Lock nut (right hand side shown)

    2. Wire guide
  7. Route the ignition switch harness as noted during removal and reconnect to the main harness. Attach the multiplug to the inside of the right hand frame infill as noted during removal.
  8. Position the harnesses around the headstock as noted during removal.
  9. Fit the cable guide to the headstock and tighten the new fixings to 13 Nm.
  10. Fit the rubber band as noted during removal.

    1. Fixings

    2. Cable guide

    3. Rubber band

Perform the following operations:

Lower Yoke and Headstock Bearings - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    caution

    Care must be taken when removing the headstock top nut, to ensure that the top nut and headstock do not become scratched. Protect the surfaces with a suitable cloth or tape to prevent scratching.

  1. Remove the upper yoke centre nut.

    1. Upper yoke centre nut
  2. As an assembly, raise the upper yoke and handle bars until clear of the steering stem. Rest the assembly forward of the steering stem such that access to the adjustment nuts is unrestricted. Ensure the master cylinder remains in an upright position.
  3. Using T3880023 - 50 mm Socket, remove the lock nut and tab washer. Discard the tab washer.

    1. Adjuster nut

    2. Lock nut

    3. T3880023 - 50 mm Socket
  4. Using the same tool, remove the adjuster nut.
  5. Remove the lower yoke from below the frame headstock.

    6. warning

    Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries if suitable protective apparel is not worn.

  6. Using a suitable drift, evenly and progressively drive the bearing races from the frame headstock.
  7. Remove the inner race and dust seal from the lower yoke using a press or puller.

Lower Yoke and Headstock Bearings - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit a new dust seal to the steering stem on the lower yoke.

    1. Steering stem

    2. Dust seal

    caution

    Protect the threads of the lower yoke when using a press or puller as damaged threads may mean replacing the yoke completely.

  2. Press a new lower bearing inner race onto the steering stem of the lower yoke.

    1. Bearing

    2. Lower yoke

    3. Press bed
  3. Evenly and progressively drive a new complete upper bearing into the frame headstock.
  4. Lubricate the lower bearing using a heavy duty, lithium based, NLGI 2 specification grease such as Castrol SpheerolTM LCX 222.
  5. Drive a new lower outer bearing into the frame headstock.
  6. Lubricate the upper bearing using a heavy duty, lithium based, NLGI 2 specification grease such as Castrol SpheerolTM LCX 222.
  7. Insert the lower yoke to the frame, fit the upper bearing and race, and retain with the adjuster nut.
  8. Ensure that the threads on the steering stem are free from grease and adjust the headstock bearings (see Steering Head Bearing - Adjustment).
  9. Locate the upper yoke to the steering stem. Install but do not fully tighten the upper yoke centre nut at this stage.
  10. Fit the forks (see Front Fork - Installation).
  11. Tighten the upper yoke centre nut to 90 Nm.
  12. Check that no free play exists in the headstock bearings. Adjust as necessary (see Steering Head Bearing - Check and Steering Head Bearing - Adjustment).

Handlebars - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the two fixings and remove the left hand grip from the handlebar. Collect the two washers.

    1. Fixing (one of two shown)
  2. Release the fixing and detach the clutch switch from the clutch lever assembly.

    1. Clutch switch

    2. Fixing
  3. Release the fixings and remove the clamp from the clutch lever assembly. Without disconnecting the clutch cable, lay the lever aside.
  4. Remove the cable tie securing the switch housing wiring harness to the left hand switch housing.

    1. Wiring harness

    2. Cable tie
  5. Gently pull on the wiring harness to disconnect the switch housing connectors.

    1. Switch housing connectors

    note
    • The T3880369 - Switch Housing Removal Tool is required to release the handlebar switch housings from their retaining clips.
    • When inserting T3880369 - Switch Housing Removal Tool into the switch housing, a click can be felt/heard as the retaining clip is released.
    • The retaining clip will remain in position on the handle bar as the switch housing is removed. Note the position and orientation of the clip for installation.
  6. Insert T3880369 - Switch Housing Removal Tool into the opening on the left hand switch housing until a click is felt/heard.

    1. Left hand switch housing

    2. Opening

    3. T3880369 - Switch Housing Removal Tool
  7. Slide the switch housing towards the end of the handlebar to free it from the retaining clip.
  8. Withdraw T3880369 - Switch Housing Removal Tool from the switch housing.

    1. Left hand switch housing

    2. T3880369 - Switch Housing Removal Tool

    3. Retaining clip
  9. Slide the switch housing off the handlebar and collect the retaining clip.

    1. Switch housing

    2. Retaining clip
  10. Release the fixings and remove the clamp from the front brake master cylinder. Taking care to not invert the brake fluid reservoir, lay the assembly aside.
  11. With the aid of an assistant, support the handlebar and release the fixings securing the handlebar clamp to the risers. Remove the handlebar clamp.

    1. Fixings

    2. Handlebar clamp
  12. Slide the twist grip position sensor off the handle bar. Without disconnecting any wiring, lay the sensor aside.
  13. Disconnect and remove the right hand switch housing as described in steps 4-9.

Handlebars - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit the right hand switch housing retaining clip to the handlebar as noted during removal.
  2. Slide the right hand switch housing onto the handlebar and over the retaining clip until it locks into position.

    1. Right hand switch housing

    2. Retaining clip
  3. Slide the twist grip position sensor onto the right hand side of the handlebar.
  4. Locate the handlebar onto the risers. Fit the handlebar clamp and fixings.
  5. Align the handlebar alignment mark with the front split line of the right hand riser.
  6. Tighten the front clamp bolts to 26 Nm, then the rears.

    1. Right hand split line

    2. Alignment mark
  7. Connect the right hand switch housing electrical connectors and secure the wiring harness to the switch housing using a new cable tie.
  8. Fit the retaining clip and left hand switch housing to the handle bar as described in steps 1 and 2.

    9. note
    • The left hand switch housing electrical connections are recessed into the switch housing body.
    • When inserting the connectors, carefully locate the connectors into their sockets, then use a suitable flat ended pin punch to push the connectors fully home. An audible click can be heard when the connectors are fully inserted.
    • Do not use sharp tools, such as a flat bladed screw driver, to insert the connectors.

    1. Switch housing electrical connectors
  9. Connect the left hand switch housing electrical connectors and secure the wiring harness to the switch housing using a new cable tie.
  10. Fit the left hand handlebar grip and secure with the fixings and washers. Tighten the fixings to 3 Nm.
  11. Position the clutch lever to the handlebar. Fit the clamp (UP arrow pointing upwards) and clamp fixings.
  12. Align the split line of the clutch lever with the alignment mark on the upper surface of the handlebar, then tighten the clamp fixings, upper first, to 12 Nm.
  13. Fit the clutch switch to the clutch lever assembly and tighten its fixing to 2 Nm.

    1. Clutch switch

    2. Fixing
  14. Position the front brake master cylinder assembly to the handlebar. Fit the clamp (Up arrow pointing upwards) and clamp fixings.
  15. Align the split line of the master cylinder clamp to the alignment mark on the upper surface of the handlebar and tighten the clamp fixings to 8 Nm.

Perform the following operations:

warning

Move the handlebars to left and right full lock while checking that the brake hose, clutch cable and electrical harnesses do not bind or that the steering feels tight or difficult to turn. A hose, cable or harness that binds, or steering that is tight/difficult to turn will restrict the steering and may cause loss of control and an accident.

Rear Suspension

Exploded View – Swinging Arm

Exploded View - Rear Suspension Unit

Rear Suspension Unit

warning

Contents under pressure. Never attempt to open this rear suspension unit. Never attempt to service this rear suspension unit. Never incinerate, puncture, or disassemble this rear suspension unit. Opening this rear suspension unit may result in severe injuries or even death.

The rear suspension units are sealed units and do not have any internally user serviceable parts.

For service, return this rear suspension unit to an authorised Öhlins service centre.

Rear Suspension Unit Spring Preload Setting

warning

The rear suspension unit spring preload is not adjustable.

Do not attempt to adjust the rear suspension unit preload from its original factory setting.

Any attempt to adjust the rear suspension unit preload from its original factory setting could result in a dangerous riding condition leading to loss of motorcycle control and an accident.

The rear suspension unit spring preload setting is not adjustable and should not be altered from its original factory setting.

However, if it is suspected that the preload setting has been altered, the setting can be checked and if necessary, restored to its original factory setting as follows:

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • The motorcycle is delivered from the factory with the rear suspension unit spring set to a preloaded length of 151.8 mm, as measured across the flat ends of the spring.

    1. Preload spring seat

    2. Locking ring
  1. Measure the length of the preloaded rear suspension unit spring. The spring should be set to a preloaded length of 151.8 mm.
  2. If necessary, release the locking ring and adjust the preload spring seat to achieve a preloaded spring length of 151.8 mm.
  3. Hold the preload spring seat to prevent rotation and tighten the locking ring to 42 Nm.

Perform the following operations:

Drag and Drop Links - Removal

warning

If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid skin damage, always allow the hot parts to cool before working on the exhaust system.

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Raise and support the rear of the motorcycle under the frame and engine. Position a block to support the rear wheel.
  2. Remove the two drag link fixings and remove the drag link plates. Discard the lock nuts.

    1. Drag link plates

    2. Fixings
  3. Remove the two drop link fixings. Discard the lock nuts.

    1. Drop link

    2. Swinging arm drop link fixing

    3. Rear suspension unit lower mounting fixing
  4. Using a suitable pin punch, through the drop link mount on the left hand side of the swinging arm, carefully drift out the drop link bearing sleeve and swinging arm spacer.
  5. Remove the drop link.

    1. Swinging arm (shown with rear wheel removed for clarity)

    2. Drop link

    3. Spacer

    4. Bearing sleeve
  6. Inspect the swinging arm bearing sleeve and spacer for any signs of damage. Replace as necessary.

Drag Link Frame Bearings - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the fixings and remove the left hand control plate assembly.

    1. Control plate assembly

    2. Fixings
  2. Release the fixings and remove the right hand heel guard. Temporarily refit the lower fixing to support the rear brake master cylinder.

    1. Heel guard

    2. Upper fixing

    3. Lower fixing

    note
    • Note the routing of the rear brake switch harness for installation.
  3. Detach the rear brake switch harness from the clip on the rear master cylinder brake hose and disconnect its multiplug.

    4. warning

    Do not allow the rear master cylinder to hang on the brake hose as this may damage the hose.

    Damaged hoses could cause brake failure leading to loss of motorcycle control and an accident.

  4. Remove the rear master cylinder fixings.

    1. Master cylinder

    2. Upper fixing

    3. Lower fixing
  5. Remove the brake pedal pivot bolt. Discard the bolt.

    6. note
    • Note the position and orientation of the clevis pin and clip for installation.
    • Note the position and orientation of the brake switch and brake pedal return springs for installation.
  6. Remove the clip and clevis pin and detach the rear brake pedal from the master cylinder push rod. Tie the rear master cylinder aside.
  7. Detach the springs from the rear brake pedal and remove the pedal.

    1. Brake pedal pivot bolt

    2. Clip

    3. Clevis pin

    4. Brake switch spring

    5. Brake pedal return spring
  8. Release the fixings and remove the right hand control plate and brake switch assembly.

    1. Control plate assembly

    2. Fixings
  9. Remove the flanged sleeves and rubber grommets from exhaust silencer mounting bracket.
  10. Release the fixings and remove the exhaust silencer mounting bracket.

    1. Bracket

    2. Fixings
  11. Set the drive chain adjustment to allow maximum free play in the drive chain (see Final Drive Chain Free-Movement Adjustment).

    12. note
    • The drag link frame bearings cannot be removed undamaged.
    • Protect both sides of the frame from damage during bearing removal by applying a suitable masking tape to the area shown below.

    1. Frame masking area (left hand side shown)
  12. Remove the drag link bearing sleeve and seals. Discard the seals.
  13. Using a suitable proprietary slide hammer bearing extraction tool, remove the drag link needle roller bearings from the frame.

    1. Bearing sleeve

    2. Seals

    3. Needle roller bearings

Drag Link Frame Bearings - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Bearing sleeve

  2. Seals

  3. Needle roller bearings

    note
    • The drag link bearings are 'dry fit' bearings and grease or other forms of lubrication should not be used during installation. However, a thin smear of multi-purpose NLGI 2 specification grease should be added to the bearing sleeve and seals.
    • T3880368 - Bearing Installer is required to install the new bearings to the correct depth.
    • Bearings are inserted by means of a draw bolt acting on the insertion tool. A support tool is located on the opposite side of the frame to the insertion tool and as the bolt is tightened, the bearing is drawn in to the frame.
    • Insert bearings with the marked or shielded side facing outwards and always fit new bearing seals.
    • Ensure that the frame bore is clean and free of debris before installing new bearings.
  1. Using the threaded rod and nuts provided with T3880053 - Wheel Bearing Extraction Kit, assemble a new bearing (marked side facing outwards) and the insertion collars from T3880368 - Bearing Installer to the frame bore as shown below.

    1. T3880368 - Bearing Installer

    2. Threaded rod and nut from T3880053 - Wheel Bearing Extraction Kit

    3. Bearing

    4. Frame bore
  2. Ensuring that the bearing is inserted squarely, progressively tighten the nut on T3880053 - Wheel Bearing Extraction Kit until the bearing is fully inserted.

    1. T3880368 - Bearing Installer

    2. Threaded rod and nut from T3880053 - Wheel Bearing Extraction Kit

    3. Bearing

    4. Frame bore
  3. Repeat steps 1 and 2 for the other side.
  4. Fit new bearing seals and carefully insert the bearing sleeve.
  5. Set the drive chain adjustment (see Final Drive Chain Free-Movement Adjustment).
  6. Fit the exhaust silencer mounting bracket to the frame. Tighten the fixings to 8 Nm.

    1. Bracket

    2. Fixings
  7. Refit the grommets and flanged sleeves to the exhaust silencer mounting bracket.
  8. Fit the right hand control plate assembly. Tighten the fixings to 24 Nm.

    1. Control plate assembly

    2. Fixings
  9. Align the rear brake pedal to the master cylinder push rod and secure with the clevis pin and clip as noted during removal.
  10. Secure the brake pedal to the control plate with a new pivot bolt and tighten to 22 Nm.
  11. Attach the brake switch and pedal return springs to the rear brake pedal as noted during removal.

    1. Brake pedal pivot bolt

    2. Clip

    3. Clevis pin

    4. Brake switch spring

    5. Brake pedal return spring
  12. Route the rear brake switch harness as noted during removal and connect the multiplug. Secure the harness into its clip on the rear master cylinder brake hose.
  13. Secure the master cylinder to the control plate as follows.

    1. Master cylinder

    2. Upper fixing

    3. Lower fixing
  14. Remove the lower M8 x 35 mm fixing.
  15. Secure the heel guard to the control plate as follows:

    1. Heel guard

    2. Upper fixing

    3. Lower fixing
  16. Refit the left hand control plate assembly. Tighten the fixings to 24 Nm.

    1. Control plate assembly

    2. Fixings

Perform the following operations:

Drop Link Bearing Replacement

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

warning

When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.

Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.

  1. Drop link

  2. Seals

  3. Needle roller bearings

  4. Bearing sleeve (drag link mounting)

Removal

  1. Remove the drop link bearing sleeves and seals. Discard the seals.
  2. Using a suitable press, remove the needle roller bearings.

Installation

note
  • The drop link bearings are 'dry fit' bearings and grease or other forms of lubrication should not be used during installation. However, a thin smear of multi-purpose NLGI 2 specification grease should be added to the bearing sleeve and seals.
  • T3880368 - Bearing Installer is required to install the new bearings to the correct depth.
  • Insert bearings with the marked or shielded side facing outwards and always fit new bearing seals.
  • Ensure that the bearing bore is clean and free of debris before installing new bearings.
  1. Install the new bearings (marked side facing outwards) to the correct depth using T3880368 - Bearing Installer and a suitable press.
  2. Fit new bearing seals and carefully insert the bearing sleeves.

Perform the following operations:

Drag and Drop Links - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Apply a thin smear of multi-purpose NLGI 2 specification grease to the drop link bearing sleeve.
  2. Locate the drop link to the swinging arm and insert the bearing sleeve and swinging arm spacer from the right hand side as noted during removal.

    1. Swinging arm (shown with rear wheel removed for clarity)

    2. Drop link

    3. Swinging arm spacer

    4. Drop link bearing sleeve.
  3. Fit the swinging arm drop link bolt from the right hand side. Loosely fit a new lock nut.
  4. Locate the drop link to the rear suspension unit lower mount. Fit the bolt from the right hand side and secure with a new lock nut. Hold the bolt to prevent rotation and tighten the lock nut to 48 Nm.

    1. Drop link

    2. Swinging arm drop link fixing

    3. Rear suspension unit lower mounting fixing
  5. Locate the drag link plates and fit the bolts from the right hand side. Loosely fit new lock nuts.

    1. Drag link plates

    2. Fixings

    note
    • When tightening the remaining rear suspension linkage fixings, hold the bolt to prevent rotation while tightening the lock nut to the specified torque.
  6. With the weight of the motorcycle on its wheels, tighten the:

Perform the following operations:

Rear Suspension Unit - Removal

warning

If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid skin damage, always allow the hot parts to cool before working on the exhaust system.

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Raise and support the rear of the motorcycle under the frame and engine. Position a block to support the rear wheel.
  2. Remove the two drag link fixings and remove the drag link plates. Discard the lock nuts.

    1. Drag link plates

    2. Fixings
  3. Remove the rear suspension unit lower mounting fixing and detach the unit from the drop link. Discard the lock nut.

    1. Drop link

    2. Rear suspension unit lower mounting fixing
  4. Remove the rear suspension unit upper mounting fixing. Discard the lock nut.
  5. Manoeuvre the suspension unit upwards through the swinging arm and clear of the motorcycle.

    1. Rear suspension unit

    2. Upper mounting

Rear Suspension Unit - Inspection

warning

Contents under pressure. Never attempt to open this rear suspension unit. Never attempt to service this rear suspension unit. Never incinerate, puncture, or disassemble this rear suspension unit. Opening this rear suspension unit may result in severe injuries or even death.

The rear suspension units are sealed units and do not have any internally user serviceable parts.

For service, return this rear suspension unit to an authorised Öhlins service centre.
  1. Clean all components and inspect for damage/wear to:
  2. Renew as necessary, see the following:

Rear Suspension Unit Lower Mounting Bearing Replacement

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

warning

When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.

Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.

  1. Bearing sleeve

  2. Seals

  3. Needle roller bearing

Removal

  1. Remove the bearing sleeve and seals. Discard the seals.
  2. Using a suitable press, remove the needle roller bearing.

Installation

note
  • The bearing is a 'dry fit' bearing and grease or other forms of lubrication should not be used during installation. However, a thin smear of multi-purpose NLGI 2 specification grease should be added to the bearing sleeve and seals.
  • When Inserting bearings always press against the marked or shielded side and always fit new bearing seals.
  • Ensure that the bearing bore is clean and free of debris before installing new bearings.
  1. Install the new bearing using a suitable press.
  2. Fit new bearing seals and carefully insert the bearing sleeve.

Perform the following operations:

Rear Suspension Unit Upper Mounting Bush Replacement

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

warning

When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.

Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.

  1. Rear suspension unit upper mounting

  2. Bush

Removal

  1. Using a suitable press, remove the upper mounting bush.

Installation

caution

When installing the upper mounting bush, ensure bush is pressed in by its outer sleeve.

Pressing the bush in by its inner sleeves will cause irreparable damage to the bush.

note
  • Ensure that the upper mounting bore is clean and free of debris before installing a new bush.
  1. Install the new bush using a suitable press.

Perform the following operations:

Rear Suspension Unit - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Refit the rear suspension unit to the motorcycle by lowering the unit downwards through the hole in the swinging arm.
  2. Locate the rear suspension unit upper mounting and fit the bolt from the right hand side. Loosely fit a new lock nut.

    1. Rear suspension unit

    2. Upper mounting
  3. Locate the drop link to the rear suspension unit lower mount. Fit the bolt from the right hand side and secure with a new lock nut. Hold the bolt to prevent rotation and tighten the lock nut to 48 Nm.

    1. Drop link

    2. Rear suspension unit lower mounting fixing
  4. Locate the drag link plates and fit the bolts from the right hand side. Loosely fit new lock nuts.

    1. Drag link plates

    2. Fixings

    note
    • When tightening the remaining rear suspension linkage fixings, hold the bolt to prevent rotation while tightening the lock nut to the specified torque.
  5. With the weight of the motorcycle on its wheels, tighten the:

Perform the following operations:

Swinging Arm - Removal

warning

If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid skin damage, always allow the hot parts to cool before working on the exhaust system.

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • Raise the rear of the motorcycle and support under the frame and engine.
  • Support the swinging arm to allow for removal of the rear wheel and rear suspension unit.

Perform the following operations:

    warning

    Do not allow the caliper to hang on the brake hose as this may damage the hose and could lead to an accident.

  1. Release the brake hose clips from the swinging arm and tie the rear brake caliper to one side.

    1. Rear brake hose clips
  2. If fitted, remove the fixings and remove the lower chain guard.
  3. Release the fixings and remove the left hand control plate assembly.

    1. Control plate assembly

    2. Fixings

    note
    • The left hand finisher for the swinging arm spindle is larger than the finisher for the right hand side.
  4. Loosen the swinging arm spindle finisher screws sufficiently to allow the removal of the finishers complete with their screws, sleeves and cylindrical nuts.

    1. Finisher, left hand side

    2. Screw

    3. Sleeve

    4. Cylindrical nut
  5. Remove the swinging arm spindle lock nut and washer. Discard the lock nut.
  6. Partially withdraw the swinging arm spindle from the right hand side, to allow access to the frame adjuster sleeve located on the left hand side of the frame.

    1. Swinging arm spindle
  7. Engage T3880104 - Swinging Arm Adjuster Wrench in the slots of the frame adjuster sleeve and rotate anticlockwise to loosen the sleeve fully.

    1. Frame adjuster sleeve

    2. T3880104 - Swinging Arm Adjuster Wrench
  8. Detach the chain from the front sprocket.

    9. caution

    Care must be taken when removing the swinging arm, not to damage any brake hoses or electrical harnesses that are routed in close proximity to the swinging arm.

    note
    • Support the drive chain while the swinging arm is being removed to protect it from contamination.
  9. Withdraw the swinging arm spindle from the right hand side and remove the swinging arm together with the drive chain.
  10. If the swinging arm is to be replaced, remove the drive chain, see Drive Chain Replacement.

Swinging Arm/Drive Chain - Inspection

  1. Check all swinging arm bearings for damage, pitting, and cracks. Replace as necessary.
  2. Check the swinging arm for damage. Replace as necessary.
  3. Check all bearing seals for damage, splits etc. Replace as necessary.
  4. Check the chain for wear, damage, etc. Replace as necessary.
  5. Check both sprockets for wear, damage, etc. Replace as necessary.
  6. Check the upper drive chain rubbing strip for wear and damage. Replace as necessary.
  7. Check the lower drive chain rubbing strip for wear and damage. Replace as necessary.

Swinging Arm - Disassembly

  1. Remove the fixing and fir tree clip and remove the upper drive chain rubbing strip. Discard the fir tree clip.

    1. Upper drive chain rubbing strip

    2. Fixing

    3. Fir tree clip
  2. Remove the fixing and remove the lower drive chain rubbing strip.

    1. Lower drive chain rubbing strip

    2. Fixing
  3. Remove the bearing sleeve and outer seal from the left hand side.
  4. Remove the spacer and seal from the right hand side.
  5. Release the circlip and remove the two ball bearings by drifting through from the left.
  6. Remove the spacer tube.

    7. note
    • The needle roller bearing and inner seal in the left hand side of the swinging arm cannot be removed undamaged.
  7. Remove the inner seal and needle roller bearing by drifting through from the right.

    1. Spacer

    2. Seal

    3. Circlip

    4. Ball bearings

    5. Spacer tube

    6. Inner seal

    7. Needle roller bearing

    8. Outer seal

    9. Sleeve

Swinging Arm - Assembly

    1. Spacer

    2. Seal

    3. Circlip

    4. Ball bearings

    5. Spacer tube

    6. Inner seal

    7. Needle roller bearing

    8. Outer seal

    9. Sleeve
  1. Install the bearings (marked faces outwards), seals, sleeves, spacers and circlip into the swinging arm in the order shown above. Use new seals throughout.
  2. Fit the lower drive chain rubbing strip. Tighten its fixing to 4 Nm.

    1. Lower drive chain rubbing strip

    2. Fixing
  3. Fit the upper drive chain rubbing strip and secure with the fixing and a new fir tree clip. Tighten the fixing to 4 Nm.

    1. Upper drive chain rubbing strip

    2. Fixing

    3. Fir tree clip

Swinging Arm - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. If removed, refit the drive chain to the swinging arm, see Drive Chain Replacement.

    2. caution

    Care must be taken when positioning the swinging arm, not to damage any brake hoses or electrical harnesses that are routed in close proximity to the swinging arm.

  2. Position the swinging arm to the frame ensuring the drive chain is in position on the rubbing strip.
  3. Refit the swinging arm spindle from the right hand side such that it will support the swinging arm, but not pass all the way through the frame adjuster sleeve. This will allow T3880104 - Swinging Arm Adjuster Wrench to engage in the slot in the frame adjuster sleeve.
  4. Using T3880104 - Swinging Arm Adjuster Wrench, tighten the frame adjuster sleeve to 6 Nm.

    1. Frame adjuster

    2. T3880104 - Swinging Arm Adjuster Wrench
  5. Fully insert the swinging arm spindle.
  6. Fit the washer and a new swinging arm spindle lock nut and tighten to 110 Nm.
  7. Fit the finishers to the swinging arm spindle. Tighten the screws to 1 Nm.

    1. Finisher, left hand side

    2. Screw

    3. Sleeve

    4. Cylindrical nut
  8. Fit the drive chain to the output sprocket.
  9. Release the caliper and refit the rear brake hose clips to the swinging arm. Tighten the fixings to 6 Nm.

    1. Rear brake hose clips
  10. If fitted, refit the lower chain guard and tighten its fixings to 6 Nm.
  11. Refit the left hand control plate assembly. Tighten the fixings to 24 Nm.

    1. Control plate assembly

    2. Fixings

Perform the following operations:

note
  • The rear suspension unit and linkage fixings (with the exception of the lower rear suspension unit mounting) should be tightened after the rear wheel has been installed, with the weight of the motorcycle on its wheels.

note
  • Pump the rear brake pedal several times to position the brake pads in the caliper. Rectify as necessary.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.

Brakes

Exploded Views

Exploded View - Front Brake Master Cylinder

Exploded View – ABS system

Exploded View - Front Brake Caliper and Disc

Exploded View - Rear Brake Master Cylinder - All Models

Exploded View - Rear Brake Caliper - All Models

Braking System Maintenance and Safety

Braking System Maintenance Safety Precautions

warning

Brake fluid is hygroscopic which means it will absorb moisture from the air. The absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction in braking efficiency.

Replace brake fluid in line with the Scheduled Maintenance chart. A dangerous riding condition could result if this important maintenance item is neglected.

Do not spill brake fluid onto any area of the bodywork as this will damage any painted or plastic surface.

Always use new brake fluid from a sealed container and never use fluid from an unsealed container or from one that has been previously opened.

Do not mix different brands of fluid. Check for fluid leakage around brake fittings, seals and joints.

Check regularly for brake hose damage.

FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING EFFICIENCY LEADING TO LOSS OF MOTORCYCLE CONTROL AND AN ACCIDENT.

warning

If there has been an appreciable drop in the level of the fluid in either brake fluid reservoir, consult your authorised Triumph dealer before riding.

If the brake lever or pedal feels soft when it is applied, or if the lever/pedal travel becomes excessive, there may be air in the brake lines or the brake may be defective.

It is dangerous to operate the motorcycle under such conditions and you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

warning

Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident.

Failure to change the brake fluid at the interval specified in the Scheduled Maintenance chart may reduce braking efficiency resulting in loss of motorcycle control and an accident.

warning

Never use mineral-based grease in any part of the braking system or in any area where contact with the braking system is possible. Mineral-based grease will damage the hydraulic seals in the calipers and master cylinders. Damage caused by contact with mineral-based grease may reduce braking efficiency resulting in loss of motorcycle control and an accident.

warning

Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid.

Never use solvents, petrol (gasoline), engine oil or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders.

A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.

warning

A magnetised brake disc and/or a magnetised ABS pulser ring may cause problems with the ABS sensor which will illuminate the ABS warning light and disable the ABS.

To prevent these parts becoming magnetised, we strongly recommend that magnets, and items that contain magnets, must not be stored near or placed on brake discs or ABS pulser rings.

This includes parts fitted to motorcycles, parts removed during motorcycle service and new parts in dealer stores.

Examples of items that may contain magnets, are listed below:

∙Alternator rotor

∙Magnetic fuel tank bags

∙Audio speakers

∙Magnetic dial test indicator stand

∙Magnetic parts tray.

If the ABS is not functioning, the brake system will continue to function as a non-ABS braking system. Do not continue to ride for longer than is necessary with the indicator light illuminated. Ride with extreme caution when performing diagnostic troubleshooting on a non-functioning ABS system. In this situation braking too hard will cause the wheels to lock resulting in loss of motorcycle control and an accident.

Changing Brake Fluid

Brake fluid must be changed every two calendar years, irrespective of the mileage the motorcycle has covered in that time.

Brake Pads Wear

Front and rear brake pad wear is automatically compensated for and has no effect on brake lever or pedal action.

Breaking-in New Brake Pads and Discs

After replacement brake discs and/or pads have been fitted to the motorcycle, we recommend a period of careful breaking-in that will optimise the performance and longevity of the discs and pads. The recommended distance for breaking in new pads and discs is 200 miles (300 km).

After fitting new brake discs and/or pads avoid extreme braking, ride with caution and allow for greater braking distances during the breaking-in period.

Front Brake Fluid Level Inspection

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

    1. Front brake fluid reservoir

    2. MAX level line

    3. MIN level line
  1. The brake fluid level in the reservoirs must be kept between the MAX and MIN level lines (reservoir held horizontal).
  2. Remove the reservoir cover.
  3. Noting its position, remove the sealing diaphragm.
  4. Fill the reservoir to the upper level line using new DOT 4 fluid from a sealed container.
  5. Refit the reservoir cover ensuring that the diaphragm seal is correctly fitted.
  6. Tighten the cover retaining screws to 0.7 Nm.

warning

If there has been an appreciable drop in the level of the fluid in either fluid reservoir, consult your authorised Triumph dealer for advice before riding. Riding with depleted brake fluid levels, or with a brake fluid leak is dangerous and will cause reduced brake performance potentially leading to loss of motorcycle control and an accident.

Rear Brake Fluid Level Inspection

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Rear brake fluid reservoir

  2. Upper level line

  3. Lower level line
  1. The reservoir is visible from the right hand side of the motorcycle, forward of the silencer, below the rider’s seat.
  2. To inspect the fluid level, check the level of fluid visible in the reservoir. The fluid level must be kept between the upper and lower level lines (reservoir held horizontal).
  3. To adjust the fluid level, remove the reservoir cap and diaphragm seal. Fill the reservoir to the upper level line using new DOT 4 fluid from a sealed container.
  4. Refit the reservoir cap ensuring that the diaphragm seal is correctly fitted.

warning

If there has been an appreciable drop in the level of the fluid in either fluid reservoir, consult your authorised Triumph dealer for advice before riding. Riding with depleted brake fluid levels, or with a brake fluid leak is dangerous and will cause reduced brake performance potentially leading to loss of motorcycle control and an accident.

Front Brake Wear inspection

Brake pads must be inspected in accordance with scheduled requirements and replaced if worn to, or beyond the minimum service thickness.

  1. Carrier plate

  2. Brake pad

Minimum lining thickness

1.0 mm

If the lining thickness of any pad is less than that specified in the table, replace all the pads on the wheel.

warning

Always have replacement brake pads supplied and fitted by your Triumph dealer.

The ABS calibration is optimised for use with the friction material provided on brake pads supplied by Triumph.

The use of proprietary brands of brake pads is not recommended as differing friction material specifications will affect the performance of the ABS, potentially causing loss of motorcycle control and an accident.

warning

Brake pads for this model supplied by Triumph are specifically designed for use with the brake calipers fitted to your motorcycle.

The use of proprietary brands of brake pads is not recommended as these may have a reduced carrier plate thickness when compared with the Triumph genuine parts.

Brake pads with an incorrect carrier plate thickness can potentially become dislodged from the caliper body as they wear, leading to brake failure, loss of motorcycle control and an accident.

Brake pads for this model supplied by Triumph will have the carrier plate at the correct thickness. Always have replacement brake pads supplied and fitted by your Triumph dealer.

  1. Carrier plate

  2. Brake pad lining

Rear Brake Wear inspection

If the lining thickness of any pad is less than that specified in the table, replace all the pads on the wheel.

Minimum lining thickness

1.5 mm

warning

Always have replacement brake pads supplied and fitted by your Triumph dealer.

The ABS calibration is optimised for use with the friction material provided on brake pads supplied by Triumph.

The use of proprietary brands of brake pads is not recommended as differing friction material specifications will affect the performance of the ABS, potentially causing loss of motorcycle control and an accident.

warning

Brake pads for this model supplied by Triumph are specifically designed for use with the brake calipers fitted to your motorcycle.

The use of proprietary brands of brake pads is not recommended as these may have a reduced carrier plate thickness when compared with the Triumph genuine parts.

Brake pads with an incorrect carrier plate thickness can potentially become dislodged from the caliper body as they wear, leading to brake failure, loss of motorcycle control and an accident.

Brake pads supplied by Triumph will have the carrier plate at the correct thickness. Always have replacement brake pads supplied and fitted by your Triumph dealer.

  1. Carrier plate

  2. Brake pad lining

Front Brake Discs - Wear

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Wear
  1. Replace any brake disc if it is worn beyond the service limit or exceeds the disc run-out limit.

Front Brake Disc Thickness

Standard

4.5 mm

Service Limit

4.0 mm

Front Brake Disc Run-out

Service Limit:

0.3 mm

Measure disc run out using an accurate dial gauge mounted on a surface plate.

  1. Disc

  2. Dial gauge

Bleeding the Front Brakes, Renewing Brake Fluid

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Brake lever

  2. Span adjuster

  3. Ratio adjuster

note
  • Two complete bleed cycles must be performed to correctly bleed the front brakes.
  • One complete bleed cycle consists of a Manual Bleed, followed by an ABS System Bleed, followed by another Manual Bleed.
Manual Bleed

    note
    • The master cylinder should always be bled last. Bleed each caliper in turn before bleeding the master cylinder.
  1. Remove the rubber cap from the bleed nipple on the right hand caliper.
  2. Attach a transparent tube to the bleed nipple.

    1. Bleed nipple

    2. Spanner

    3. Bleed tube

    4. Container
  3. Place the other end of the tube in a suitable receptacle containing new brake fluid.
  4. Turn the handlebars to bring the fluid reservoir to a level position.

    1. Front reservoir upper level

    2. Front reservoir lower level

    3. Screws
  5. Remove the screws from the brake reservoir cover.

    6. warning

    Ensure absolute cleanliness when adding brake fluid to the brake fluid reservoir. Do not allow moisture or debris to enter the cylinder as this will adversely affect the fluid properties. Always use fluid from a sealed container and do not use fluid from a container which has been opened for any period of time. Always check for fluid leakage around hydraulic fittings and for damage to hoses.

    A dangerous riding condition leading to an accident could result if this warning is ignored.

    caution

    To prevent body damage, do not spill brake fluid onto any area of the bodywork.
  6. Carefully remove the reservoir cover taking care not to spill any fluid.
  7. Check the condition of the sealing diaphragm for the reservoir. Replace if necessary.
  8. Release the bleed nipple.

    9. warning

    Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to an accident.

    Observe the brake fluid handling warnings given earlier in this section of the manual.

    note
    • During bleeding, do not allow the fluid level to fall below the lower level mark in the reservoir. If the level is allowed to fall below this mark, air may enter the system and the sequence of bleeding must be repeated.
  9. Slowly pull the brake lever to the handlebar and, holding the lever fully in, close the bleed nipple. Release the brake lever.
  10. Repeat steps 8 and 9 until no more air appears in the bleed tube.
  11. When all air has been expelled from the system, hold the lever in and close the bleed nipple. Tighten the nipple to 8 Nm.
  12. Fill the reservoir to the upper level with new DOT 4 fluid.
  13. Remove the transparent bleed tube and refit the rubber cap to the bleed nipple.
  14. Repeat the bleeding procedure for the left hand caliper.
  15. Repeat the bleed procedure for the bleed nipple on the master cylinder. Tighten the master cylinder bleed nipple to 14 Nm.

    1. Bleed nipple

    2. Spanner

    3. Bleed tube

    4. Container
  16. When both calipers and the master cylinder have been bled, ensure the brake lever operation has a firm resistive feel to it, does not feel spongy and that the lever cannot be pulled directly back to the handlebar. Take remedial action as necessary.
ABS System Bleed
  1. Connect the Triumph diagnostic tool (see Triumph Diagnostic Software - ABS).
  2. Follow the on screen menu to ABS Diagnostics. From the menu, select 'BLEED SYSTEM' (see Triumph Diagnostic Software - ABS).

    3. note
    • On pressing the Start button, the diagnostic software will send a command to the ABS ECM to begin the bleed sequence.
    • No action is required by the operator during the bleed sequence. After pressing start, allow the system to run through the complete bleed sequence before repeating the manual bleed procedure.
  3. Press the Start button to activate the bleed sequence on the diagnostic tool.
  4. The bleed sequence will run for a maximum of 20 seconds. If necessary, the bleed sequence can be stopped at any time by pressing the Stop button. Once the bleed sequence has completed the diagnostic tool will display a message ABS system bleed complete.
  5. Repeat the Manual Bleed procedure as described above.

    6. caution

    The ABS modulator must be allowed to cool between bleeding operations. Always allow the ABS modulator to cool for 5 minutes before starting the ABS bleed procedure again. Failure to follow this instruction may result in damage to the ABS modulator.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Bleeding the Rear Brakes, Renewing Brake Fluid

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • Two complete bleed cycles must be performed to correctly bleed the rear brake.
  • One complete bleed cycle consists of a Manual Bleed, followed by an ABS System Bleed, followed by another Manual Bleed.
Manual Bleed
  1. Remove the cap from the rear bleed nipple.
  2. Attach a transparent tube to the bleed nipple.

    1. Bleed nipple

    2. Spanner

    3. Bleed tube
  3. Place the other end of the tube in a suitable receptacle containing new brake fluid.

    4. caution

    To prevent body damage, do not spill brake fluid onto any area of the bodywork.
  4. Unscrew and remove the rear brake reservoir cover taking care not to spill any fluid.

    1. Rear reservoir

    2. Rear reservoir upper level

    3. Rear reservoir lower level

    warning

    Ensure absolute cleanliness when adding brake fluid to the brake fluid reservoir. Do not allow moisture or debris to enter the cylinder as this will adversely affect the fluid properties. Always use fluid from a sealed container and do not use fluid from a container which has been opened for any period of time. Always check for fluid leakage around hydraulic fittings and for damage to hoses.

    A dangerous riding condition leading to an accident could result if this warning is ignored.

  5. Check the condition of the sealing diaphragm. Replace the diaphragm as necessary.
  6. Release the bleed nipple.

    7. note
    • During bleeding, do not allow the fluid level to fall below the lower level mark in the reservoir. If the level is allowed to fall below this mark, air may enter the system and the sequence of bleeding must be repeated.
  7. Slowly depress the brake pedal and, holding the pedal fully down, close the bleed nipple. Release the brake pedal.
  8. Repeat steps 6 and 7 until no more air appears in the bleed tube.
  9. Maintain the brake fluid level between the upper and lower reservoir levels whilst bleeding is being carried out.
  10. When all air has been expelled from the system, hold down the brake pedal and close the bleed nipple. Tighten the nipple to 14 Nm.
  11. Fill the reservoir to the maximum level with new DOT 4 fluid.

    12. warning

    Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident.

    Observe the brake fluid handling warnings given earlier in this section of the manual.
ABS System Bleed
  1. Connect the Triumph diagnostic tool (see Triumph Diagnostic Software - ABS).
  2. Follow the on screen menu to ABS Diagnostics. From the menu, select 'BLEED SYSTEM' (see Triumph Diagnostic Software - ABS).

    3. note
    • On pressing the Start button, the diagnostic software will send a command to the ABS ECM to begin the bleed sequence.
    • No action is required by the operator during the bleed sequence. After pressing start, allow the system to run through the complete bleed sequence before repeating the manual bleed procedure.
  3. Press the Start button to activate the bleed sequence on the diagnostic tool.
  4. The bleed sequence will run for a maximum of 20 seconds. If necessary, the bleed sequence can be stopped at any time by pressing the Stop button. Once the bleed sequence has completed the diagnostic tool will display a message ABS system bleed complete.
  5. Repeat the Manual Bleed procedure as described above.

    6. caution

    The ABS modulator must be allowed to cool between bleeding operations. Always allow the ABS modulator to cool for 5 minutes before starting the ABS bleed procedure again. Failure to follow this instruction may result in damage to the ABS modulator.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Front ABS Sensor Air Gap Measurement

  1. Using feeler gauges, measure the air gap between the wheel speed sensor and the pulser ring.

    1. ABS sensor (front sensor shown)

    2. Shim

    3. Pulser ring

    4. Fixing
  2. Rotate the wheel and repeat the measurement in several places to ensure the pulser ring is not distorted or bent. Renew a damaged pulser ring.
  3. Adjust the air gap using the correct shim to achieve an air gap between 0.40 mm and 1.20 mm.
  4. Shims are available in the following sizes:
  5. If necessary, remove the wheel speed sensor, fit the correct thickness shim and refit the wheel speed sensor and tighten the fixing to 9 Nm.
  6. Repeat the air gap measurement. Readjust as necessary.

Rear ABS Sensor Air Gap Measurement

Air Gap Measurement

caution

Never lever directly against the disc, caliper or the pad lining material. Always use a levering tool made from a soft material which will not cause damage to the load bearing surfaces.

  1. Using feeler gauges, measure the air gap between the wheel speed sensor and the pulser ring.

    2. ABS Wheel Speed Sensor Air Gap Measurement
  2. Rotate the wheel and repeat the measurement in several places to ensure the pulser ring is not distorted or bent. Renew a damaged pulser ring.
  3. Adjust the air gap using the correct shim to achieve an air gap between 0.40 mm to 1.20 mm.

    4. note
    • Shims are available in the following sizes, 0.5 mm, 1.0 mm, 1.5 mm, and 2.0 mm.
  4. If necessary, remove the wheel speed sensor, fit the correct thickness shim and refit the wheel speed sensor and tighten the fixing to 9 Nm.

    1. Fixing

    2. ABS sensor

    3. Shim
  5. Repeat the air gap measurement. Re-adjust as necessary.

Rear Brake Disc - Wear

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Replace any brake disc worn beyond the service limit or that exceeds the disc run-out limit.

Rear Brake Disc Thickness

Standard

5.0 mm

Service Limit

4.5 mm

Rear Brake Disc Run-out

Service Limit

0.3 mm

Measure brake disc run-out using an accurate dial gauge mounted on a surface plate.

  1. Disc

  2. Dial gauge

Anti-lock Brake System (ABS) Management

Anti-lock Brake System (ABS)

System Description

This model is fitted with an electronic anti-lock brake system which is designed to prevent the wheels from locking or skidding by reducing braking effort to the front or rear brake caliper as required.

The system consists of a hydraulic modulator and ECM assembly mounted to a bracket beneath the riders seat, a front wheel speed sensor mounted to the front fork, and a rear wheel speed sensor mounted to the rear brake caliper carrier.

Both front and rear wheels have a pulser ring mounted on to the wheel hub.

The front and rear master cylinders are connected via lines to the modulator and from the modulator the lines connect to the brake calipers.

The front and rear brake circuits operate as separate systems. The front and rear brakes are not connected in any way inside the modulator.

The modulator ECM continuously calculates the front and rear wheel speeds, and from these inputs the ECM calculates the estimated motorcycle speed, wheel deceleration/acceleration, the wheel speed difference and the wheel slip (skid) rate. This is calculated by comparing the calculated wheel speeds with the calculated vehicle speed, so that if one wheel speed deviates significantly from the other two readings, this wheel is calculated to be slipping (skidding).

Under braking, if the modulator detects that either wheel is about to slip, due to the brake force exceeding the available traction between the tyre and road surface (the wheel will begin to slip or 'skid'), the ECM very rapidly releases and reapplies the brake pressure to prevent the wheel from slipping.

This is felt through the brake pedal or lever as a rapid 'pulsing'.

If the rider reduces braking effort, or traction increases (so that traction exceeds braking force, the wheel will rotate once more) the wheel will no longer lock up. The ABS system will detect this and stop controlling brake pressure, and return to its monitoring state.

The system has a self diagnostic function built-in which monitors the fail safe relay, solenoid valves, motor relay, wheel speed sensors, power supply and ground, as well as internal ECM functions. In the event of a malfunction being detected, the ECM will illuminate the ABS warning light, and store a diagnostic trouble code in the system memory. This stored data can then be recovered using the Triumph Diagnostic Tool which is mandatory for all Triumph dealers. In this way, precise diagnosis of a fault can be made and the fault quickly rectified.

Under normal operation, the ABS warning light will flash after the ignition is switched on and until the vehicle speed exceeds 6 mph (10 km/h). The ABS performs a self check and if no faults are found the flashing light is extinguished. If a trouble code is stored the ABS warning light will stay illuminated and the ABS will not function, however the brakes will operate as a non-ABS braking system. If the ABS warning light does not extinguish, or illuminates whilst the motorcycle is being ridden, refer to the ABS system diagnostics (see System Diagnostics).

warning

The ABS warning light will illuminate when the rear wheel is driven at high speed for more than 30 seconds when the motorcycle is on a stand, or driven on a dynamometer. This reaction is normal.

When the ignition is switched off and the motorcycle is restarted, the warning light will illuminate until the motorcycle reaches a speed exceeding 19 mph (30 km/h) when it will go off.

Diagnostic Trouble Code (DTC) C1612 will remain stored in the ABS ECM memory for 40 ignition cycles before being deleted (see Diagnostic Trouble Codes).

ABS Component Locations

Diagnostics and Testing

System Diagnostics

The ABS system has an on-board diagnostics feature which allows service technicians to retrieve stored data from the ECM using Triumph diagnostic software. Full details of the Triumph diagnostic software operation and how to interpret the results are given in the Triumph Diagnostic Tool User Guide.

The software is connected, via an interface cable, to the motorcycle using a dedicated diagnostic plug situated beneath the left hand side panel. By using a dedicated plug, no electrical connectors associated with the system are disturbed, reducing potential connector damage.

The software allows the user to retrieve data associated with the system sensors and actuators, test various component functions, read build data and make minor adjustments to the set-up of the system. The data and tests available are described on the following pages.

Diagnostic Tool Connection
  1. To connect the Triumph diagnostic interface to the motorcycle, remove the rider’s seat (see Seat - Removal) and release the diagnostic connector from its locating tang.

    1. Diagnostic connector
  2. Plug the diagnostic interface directly into the diagnostic connector.

    3. Diagnostic Interface
  3. When the diagnostic session is completed, disconnect the Triumph diagnostic interface.
  4. Refit the diagnostic connector to its locating tang and refit the rider’s seat (see page Seat - Installation).

Triumph Diagnostic Software - ABS

Described on the following pages is the range of information which can be retrieved from the ECM’s memory and the adjustments which can be performed using the Triumph diagnostic software.

The tables indicate which tests are performed by the on-board system and what information can be retrieved by the Triumph diagnostic software.

note
  • Full details of how to operate the software can be found in the Triumph Diagnostic Tool User Guide, which can be downloaded by authorised Triumph dealers from www.triumphonline.net.
Build Data

The Build Data screen will display the following information:

Function Examined

ECM type

ECM ID number

Software version number
Current Data

The Current Data screen will display the following information:

Function Examined

Result Reported (Scale)

Front wheel speed

km/h

Rear wheel speed

km/h

Brake switch status

On/Off

ABS warning light status

On/Off
Bleed System

Using the Triumph diagnostic tool, it is possible to bleed the ABS modulator of trapped air. This is necessary when the hydraulic brake system has been dismantled, or the ABS modulator renewed.

Full details of this procedure are provided in Bleeding the Front Brakes, Renewing Brake Fluid for front brakes or page Bleeding the Rear Brakes, Renewing Brake Fluid for rear brakes.

Diagnostic Trouble Codes

Diagnostic Trouble Codes (DTCs) are logged in the ABS ECM memory when there is a confirmed fault in the system.

The codes are reported to the Triumph diagnostic tool as a four digit code.

DTCs can be removed at any time using the Triumph diagnostic tool.

The system will log the diagnostic trouble codes listed below:

Diagnostic Trouble Code (DTC)

Fault Description

Pinpoint Test Page Number

Front wheel sensor short circuit to ground or open circuit

Front wheel sensor short circuit to ground or open circuit

Front Wheel Sensor Open Circuit/Short Circuit

Front wheel sensor incorrect or missing signal

Front wheel sensor incorrect or missing signal

Front Wheel Sensor Abnormal Input/Losing Contact

Rear wheel sensor short circuit to ground or open circuit

Rear wheel sensor short circuit to ground or open circuit

Rear Wheel Sensor Open Circuit/Short Circuit

Rear wheel sensor incorrect or missing signal

Rear wheel sensor incorrect or missing signal

Rear Wheel Sensor Abnormal Input/Losing Contact

Front wheel pulser ring missing teeth

Front wheel pulser ring missing teeth

Front Wheel Pulser Ring Missing Teeth

Rear wheel pulser ring missing teeth

Rear wheel pulser ring missing teeth

Rear Wheel Pulser Ring Missing Teeth

Front wheel input solenoid short circuit to ground or open circuit

Front wheel input solenoid short circuit to ground or open circuit

Front or Rear Input/Output Solenoid Open/Short Circuit

Front wheel output solenoid short circuit to ground or open circuit

Front wheel output solenoid short circuit to ground or open circuit

Front or Rear Input/Output Solenoid Open/Short Circuit

Rear wheel input solenoid short circuit to ground or open circuit

Rear wheel input solenoid short circuit to ground or open circuit

Front or Rear Input/Output Solenoid Open/Short Circuit

Rear wheel output solenoid short circuit to ground or open circuit

Rear wheel output solenoid short circuit to ground or open circuit

Front or Rear Input/Output Solenoid Open/Short Circuit

Master cylinder isolation valve short circuit to ground or open circuit

Master cylinder isolation valve short circuit to ground or open circuit

Front or Rear Input/Output Solenoid Open/Short Circuit

Low pressure feed valve short circuit to ground or open circuit

Low pressure feed valve short circuit to ground or open circuit

Front or Rear Input/Output Solenoid Open/Short Circuit

Front wheel Actuator (Hydraulic control) wheel lock

Front wheel Actuator (Hydraulic control) wheel lock

Front or Rear Wheel Actuator (Hydraulic Control) Wheel Lock

Rear wheel Actuator (Hydraulic control) wheel lock

Rear wheel Actuator (Hydraulic control) wheel lock

Front or Rear Wheel Actuator (Hydraulic Control) Wheel Lock

Motor circuit fault

Motor circuit fault

Motor – Lock; Motor Circuit Fault; Motor Does Not Run; Motor Runs Continually

Motor - does not run

Motor - does not run

Motor – Lock; Motor Circuit Fault; Motor Does Not Run; Motor Runs Continually

Motor - runs continually

Motor - runs continually

Motor – Lock; Motor Circuit Fault; Motor Does Not Run; Motor Runs Continually

Power source voltage too low

Power source voltage too low

Power Source Voltage Too Low/Voltage Too High

Power source voltage too high

Power source voltage too high

Power Source Voltage Too Low/Voltage Too High

ABS ECM internal error

ABS ECM internal error

ABS ECM Internal Error

CAN fault - lost communication with engine ECM

CAN fault - lost communication with engine ECM

CAN Fault

CAN fault - lost communication with instrument panel

CAN fault - lost communication with instrument panel

CAN Fault

CAN fault - all communication lost

CAN fault - all communication lost

CAN Fault

Modulator output (wheel) pressure sensor malfunction

Modulator output (wheel) pressure sensor malfunction

Modulator output (wheel) pressure sensor malfunction
ABS System Actions

Dependant on the DTC stored, the ABS ECM will act in one of two ways when a fault is detected:

  1. Inhibit ABS operation immediately, irrespective of the ABS operating state.
  2. Allow an ABS manoeuvre to complete before inhibiting ABS operation.

note
  • ABS manoeuvre means that the ABS system is in its active state and is controlling brake pressure to prevent the wheel(s) from slipping (skidding).

Once ABS operation has been inhibited, the ABS ECM will act in one of three ways:

  1. Allow the ABS to resume operation immediately if the fault clears.
  2. Allow the ABS to resume operation after an ignition cycle if the fault clears.
  3. Inhibit the ABS function until the fault is rectified and the DTC erased.

The ABS system will act on the DTC stored according to the table:

note
  • When vehicle speed has exceeded 6 mph (10 km/h) and the flashing ABS warning light has been extinguished, the ABS has initialised.

Fault code and description

ABS warning light Illuminated when fault is logged

ABS operation is inhibited immediately when fault is logged

ABS continues to operate if performing an ABS manouevre when fault is logged

Operation is inhibited when ABS manouevre is completed

ABS will automatically resume operation if fault clears(DTC still stored for 40 cycles)

Front wheel sensor short circuit to ground or open circuit

Front wheel sensor short circuit to ground or open circuit

Yes

Yes

No

DTC stored for 40 cycles.

Front wheel sensor incorrect or missing signal

Front wheel sensor incorrect or missing signal

Yes

Yes

Yes, if after ignition cycle, no fault is detected and ABS has initialised.

DTC stored for 40 cycles.

Rear wheel sensor short circuit to ground or open circuit

Rear wheel sensor short circuit to ground or open circuit

Yes

Yes

No

DTC stored for 40 cycles.

Rear wheel sensor incorrect or missing signal

Rear wheel sensor incorrect or missing signal

Yes

Yes

Yes, if after ignition cycle, no fault is detected and ABS has initialised.

DTC stored for 40 cycles.

Front wheel pulser ring missing teeth

Front wheel pulser ring missing teeth

Yes

Yes

Yes, if after ignition cycle, no fault is detected and ABS has initialised.

DTC stored for 40 cycles.

Rear wheel pulser ring missing teeth

Rear wheel pulser ring missing teeth

Yes

Yes

Yes, if after ignition cycle, no fault is detected and ABS has initialised.

DTC stored for 40 cycles.

Front wheel input solenoid short circuit to ground or open circuit

Front wheel input solenoid short circuit to ground or open circuit

Yes

Yes

No

Front wheel output solenoid short circuit to ground or open circuit

Front wheel output solenoid short circuit to ground or open circuit

Yes

Yes

No

Rear wheel input solenoid short circuit to ground or open circuit

Rear wheel input solenoid short circuit to ground or open circuit

Yes

Yes

No

Rear wheel output solenoid short circuit to ground or open circuit

Rear wheel output solenoid short circuit to ground or open circuit

Yes

Yes

No

Front wheel Actuator (Hydraulic control) wheel lock

Front wheel Actuator (Hydraulic control) wheel lock

Yes

Yes

Yes, if after ignition cycle, no fault is detected and ABS has initialised.

DTC stored for 40 cycles.

Rear wheel Actuator (Hydraulic control) wheel lock

Rear wheel Actuator (Hydraulic control) wheel lock

Yes

Yes

Yes, if after ignition cycle, no fault is detected and ABS has initialised.

DTC stored for 40 cycles.

Motor circuit fault

Motor circuit fault

Yes

Yes

Yes, if after ignition cycle, no fault is detected and ABS has initialised.

DTC stored for 40 cycles.

Motor - does not run

Motor - does not run

Yes

Yes

Yes, if after ignition cycle, no fault is detected and ABS has initialised.

DTC stored for 40 cycles.

Motor - runs continually

Motor - runs continually

Yes

Yes

Yes, if after ignition cycle, no fault is detected and ABS has initialised.

DTC stored for 40 cycles.

Power source voltage too low

Power source voltage too low

Yes

Yes

Yes, if voltage rises above a preset threshold.

Power source voltage too high

Power source voltage too high

Yes

Yes

Yes, if voltage drops below a preset threshold.

ABS ECM internal error

ABS ECM internal error

Yes

Yes

No

CAN fault - lost communication with engine ECM

CAN fault - lost communication with engine ECM

DTC stored for 40 cycles.

CAN fault - lost communication with instrument panel

CAN fault - lost communication with instrument panel

DTC stored for 40 cycles.

CAN fault - all communication lost

CAN fault - all communication lost

DTC stored for 40 cycles.

Modulator output (wheel) pressure sensor malfunction

Modulator output (wheel) pressure sensor malfunction

Yes

Yes

No

ABS Electrical Connectors

Before beginning any diagnosis, the following connector related information should be noted:

note
  • A major cause of hidden electrical faults can be traced to faulty electrical connectors.

For example:

For example, the ABS electronic control module (ABS ECM) relies on the supply of accurate information to enable it to monitor and control the brake system. One dirty terminal will cause an excessive voltage drop resulting in an incorrect signal to the ECM.

If, when carrying out fault diagnosis, a fault appears to clear by simply disconnecting and reconnecting an electrical plug, examine each disconnected plug for the following.

Before Disconnection:
When Disconnecting a Connector:
When Inspecting a Connector:
When Connecting a Connector:
Disconnection of ABS ECM Connector

caution

When disconnecting a connector, never pull directly on the wires as this may result in cable and connector damage.

caution

Never disconnect the ABS ECM when the ignition switch is in the ON position as this may cause multiple fault codes to be logged in the ECM memory.

Always disconnect an ECM after disconnecting the battery negative (black) lead first.
  1. Press the locking device and move the lever to the rear of the connector while disconnecting it from the ABS ECM.
  2. When disconnected, ensure the lever is fully to the rear of the connector. An audible click can be heard when it is locked in position.

    1. ABS modulator (shown removed for clarity)

    2. Connector

    3. Locking device

    4. Lever

    caution

    The ABS ECM is an integral part of the ABS modulator. Under no circumstances should the ECM be removed from the ABS modulator. If a new ECM is required, repair is by replacement of the ABS modulator and ECM as an assembly only.

Reconnection of the ABS ECM Connector

caution

Damage to the connector pins may result if an attempt to fit the connectors incorrectly is made.

caution

If the lever is not fully over to the rear position, it is possible that the connector may not fully engage into its socket.

  1. Ensure the lever on the connector is fully over to the unlocked position, as shown below:

    1. Lever

    2. Connector
  2. Align the connector to its socket on the ABS modulator such that the end of the lever aligns with the lug on the socket.

    1. Lever end

    2. Lug
  3. Release the lever by pushing it towards the front of the connector. At the same time, push the connector into its socket until the lever is fully forward and locked in position. An audible click can be heard when locked.

    1. ABS modulator (shown removed for clarity)

    2. Connector

    3. Locking device

    4. Lever

ABS System Circuit Tables

Key To Wiring Circuit Diagram

Key

Item Description

1

Fuse Box

2

Ignition Switch

3

Brake Light

4

Front Wheel Speed Sensor

5

Rear Wheel Speed Sensor

6

Diagnostic Connector

7

ABS Modulator
Key To Wiring Colour Codes

Code

Wiring Colour

B

Black

U

Blue

N

Brown

G

Green

S

Slate/Grey

O

Orange

K

Pink

R

Red

P

Purple

W

White

Y

Yellow

LG

Light Green

LU

Light Blue
ABS ECM Connector Pin Numbering

The above illustration shows the pin numbering system used in the ABS circuit diagram.

As viewed on the mating face with the ABS ECM (as per the illustration), pins are numbered from right to left with number one in the top right hand corner.

ABS System Circuit Diagram

Pinpoint Tests

ABS Warning Light ON (No DTCs Stored)

Fault Code

Possible cause

Action

ABS Warning Light ON (No DTCs Stored)

ABS Ignition supply fuse/circuit fault

Ensure ABS ECM connector is secure.

Disconnect ABS ECM connector and proceed to pinpoint test 1:

ABS Warning light circuit fault

Refer to CAN Fault.

Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ABS ECM connector pin 4 and ground pin 10

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 3

2

Check cable continuity of the ABS ignition supply circuit: With the ignition 'ON', check voltage between:

- ABS ECM connector pin 4 and ground pin 10

Voltage greater than 10 V

Proceed to test 3

Voltage less than 10 V

Locate and rectify wiring fault, proceed to test 3

3

Reconnect ABS ECM harness, clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

ABS Warning Light Does not Illuminate (No DTCs Stored)

Fault Code

Possible cause

Action

ABS Warning Light OFF (No DTCs Stored)

ABS ECM ground circuit fault

Ensure ABS ECM connector is secure.

Ensure ABS ECM ground connection is secure.

Disconnect ABS ECM connector and proceed to pinpoint test 1:

Warning light circuit fault

Refer to CAN Fault
Pinpoint Tests

Test

Result

Action

1

Check the ABS warning light circuit and ignition fuses - fuse 3 and fuse 7

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check cable and terminal integrity:

- ABS ECM connector pin 4 and ground pin 10

OK

Proceed to test 3

Faulty

Replace fuse, proceed to test 5

3

Check cable for short to voltage: With ignition 'OFF', check voltage between:

- ABS ECM connector pin 4 and ground

0 V

Proceed to test 4

Above 3 V

Locate and rectify wiring fault, proceed to test 5

4

Check cable for continuity: ABS ECM connector pin 10 and ground:

OK

Proceed to test 5

Faulty

Locate and rectify fault, proceed to test 5

5

Reconnect ABS ECM harness, clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Front Wheel Sensor Open Circuit/Short Circuit

Fault Code

Possible cause

Action

Front wheel sensor short circuit to ground or open circuit

Front wheel sensor short circuit to ground or open circuit

Ensure ABS ECM connector is secure.

Ensure wheel speed sensor connector is secure.

Disconnect ABS ECM connector and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ABS ECM connector pin 17 and ABS ECM connector pin 8

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 9

2

Check cable for short circuit:

- ABS ECM connector pin 8 and ground

OK

Proceed to test 4

Short circuit

Proceed to test 3

3

Disconnect the front wheel speed sensor connector. Check cable for short circuit:

- Wheel speed sensor connector pin 2 (motorcycle harness side) and ground

OK

Replace the wheel speed sensor, proceed to test 9

Short circuit

Locate and rectify wiring harness fault, proceed to test 9

4

Check cable for short circuit:

- ABS ECM connector pin 17 and ground

OK

Proceed to test 6

Short circuit

Proceed to test 5

5

Check cable for short circuit:

- Wheel speed sensor connector pin 1 (motorcycle harness side) and ground

OK

Replace the wheel speed sensor, proceed to test 9

Short circuit

Locate and rectify wiring harness fault, proceed to test 9

6

Check cable continuity:

- ABS ECM connector pin 8 and wheel speed sensor connector pin 2 (motorcycle harness side)

OK

Proceed to test 7

Open circuit

Locate and rectify wiring harness fault, proceed to test 9

7

Check cable continuity:

- ABS ECM connector pin 17 and wheel speed sensor connector pin 1 (motorcycle harness side)

OK

Proceed to test 8

Open circuit

Locate and rectify wiring harness fault, proceed to test 9

8

Reconnect the front wheel speed sensor connector. Check the wheel speed sensor operation:

- Connect a suitable voltage supply between 10 V and 16 V between ABS ECM connector pin 8 (positive) and pin 17 (negative), and measure the current consumption of the wheel speed sensor

1.8 mA to 16.8 mA

Proceed to test 9

Faulty

Replace the wheel speed sensor, proceed to test 9

9

Reconnect ABS ECM harness, clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Wheel speed sensor current consumption data under typical conditions:

Supply Voltage

Min

Typical

Max

10 - 16 V

5.9 mA

7.5 mA

16.8 mA

Rear Wheel Sensor Open Circuit/Short Circuit

Fault Code

Possible cause

Action

Rear wheel sensor short circuit to ground or open circuit

Rear wheel sensor short circuit to ground or open circuit

Ensure ABS ECM connector is secure.

Ensure wheel speed sensor connector is secure.

Disconnect ABS ECM connector and proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ABS ECM connector pin 6 and ABS ECM connector pin 15

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 9

2

Check cable for short circuit:

- ABS ECM connector pin 6 and ground

OK

Proceed to test 4

Short circuit

Proceed to test 3

3

Disconnect the rear wheel speed sensor connector. Check cable for short circuit:

- Wheel speed sensor connector pin 6 (motorcycle harness side) and ground

OK

Replace the wheel speed sensor, proceed to test 9

Short circuit

Locate and rectify wiring harness fault, proceed to test 9

4

Check cable for short circuit:

- ABS ECM connector pin 15 and ground

OK

Proceed to test 6

Short circuit

Proceed to test 5

5

Check cable for short circuit:

- Wheel speed sensor connector pin 1 (motorcycle harness side) and ground

OK

Replace the wheel speed sensor, proceed to test 9

Short circuit

Locate and rectify wiring harness fault, proceed to test 9

6

Check cable continuity:

- ABS ECM connector pin 6 and wheel speed sensor connector pin 2 (motorcycle harness side)

OK

Proceed to test 7

Open circuit

Locate and rectify wiring harness fault, proceed to test 9

7

Check cable continuity:

- ABS ECM connector pin 15 and wheel speed sensor connector pin 1 (motorcycle harness side)

OK

Proceed to test 8

Open circuit

Locate and rectify wiring harness fault, proceed to test 9

8

Reconnect the rear wheel speed sensor connector. Check the wheel speed sensor operation:

- Connect a suitable voltage supply between 10 V and 16 V between ABS ECM connector pin 6 (positive) and pin 15 (negative), and measure the current consumption of the wheel speed sensor

1.8 mA to 16.8 mA

Proceed to test 9

Faulty

Replace the wheel speed sensor, proceed to test 9

9

Reconnect ABS ECM harness, clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Wheel speed sensor current consumption data under typical conditions:

Supply Voltage

Min

Typical

Max

10 - 16 V

5.9 mA

7.5 mA

16.8 mA

Front Wheel Sensor Abnormal Input/Losing Contact

Fault Code

Possible cause

Action

Front wheel sensor incorrect or missing signal

Front wheel sensor incorrect or missing signal

Incorrect wheel speed sensor air gap

Damaged or dirty pulser ring

Loose or incorrectly installed wheel speed sensor

Ensure ABS ECM connector is secure.

Ensure wheel speed sensor connector is secure.

Proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Measure the air gap of the front wheel speed sensor between the sensor and the pulser ring:

- Air gap between 0.40 mm and 1.20 mm

OK

Proceed to test 2

Faulty

Rectify the fault and proceed to test 5

2

Check the pulser ring for damage or contamination by road grime or ferrous metal filings.

OK

Proceed to test 3

Faulty

Clean or replace the ABS pulser ring, proceed to test 5

3

Check the wheel speed sensors for correct installation, and the fixings for correct torque.

OK

Proceed to test 4

Faulty

Rectify the fault and proceed to test 5

4

Check the wheel speed sensor circuit (see Front Wheel Sensor Open Circuit/Short Circuit).

OK

Proceed to test 5

Faulty

Rectify the fault and proceed to test 5

5

Clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service

Rear Wheel Sensor Abnormal Input/Losing Contact

Fault Code

Possible cause

Action

Rear wheel sensor incorrect or missing signal

Rear wheel sensor incorrect or missing signal

Incorrect wheel speed sensor air gap

Damaged or dirty pulser ring

Loose or incorrectly installed wheel speed sensor

Ensure ABS ECM connector is secure.

Proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Measure the air gap of the rear wheel speed sensor between the sensor and the pulser ring:

- Air gap between 0.40 mm and 1.20 mm

OK

Proceed to test 2

Faulty

Rectify the fault and proceed to test 5

2

Check the pulser ring for damage or contamination by road grime or ferrous metal filings.

OK

Proceed to test 3

Faulty

Clean or replace the ABS pulser ring, proceed to test 5

3

Check the wheel speed sensors for correct installation, and the fixings for correct torque.

OK

Proceed to test 4

Faulty

Rectify the fault and proceed to test 5

4

Check the wheel speed sensor circuit (see Rear Wheel Sensor Open Circuit/Short Circuit).

OK

Proceed to test 5

Faulty

Rectify the fault and proceed to test 5

5

Clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service

Front Wheel Pulser Ring Missing Teeth

Fault Code

Possible cause

Action

Front wheel pulser ring missing teeth

Front wheel pulser ring missing teeth

Damaged or dirty pulser ring

Loose or incorrectly installed wheel speed sensor

Damaged/incorrect wheels

Ensure ABS ECM connector is secure.

Proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Measure the air gap of the front wheel speed sensor between the sensor and the pulser ring:

- Air gap between 0.40 mm and 1.20 mm

OK

Proceed to test 2

Faulty

Rectify the fault and proceed to test 5

2

Check the pulser ring for damage or contamination by road grime or ferrous metal filings.

OK

Proceed to test 3

Faulty

Clean or replace the ABS pulser ring, proceed to test 5

3

Check the wheel speed sensors for correct installation, and the fixings for correct torque.

OK

Proceed to test 4

Faulty

Rectify the fault and proceed to test 5

4

Check the motorcycle wheel for damage/incorrect size.

OK

Proceed to test 5

Faulty

Rectify the fault and proceed to test 5

5

Clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service

Rear Wheel Pulser Ring Missing Teeth

Fault Code

Possible cause

Action

Rear wheel pulser ring missing teeth

Rear wheel pulser ring missing teeth

Damaged or dirty pulser ring

Loose or incorrectly installed wheel speed sensor

Damaged/incorrect wheels

Ensure ABS ECM connector is secure.

Proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Measure the air gap of the rear wheel speed sensor between the sensor and the pulser ring:

- Air gap between 0.40 mm and 1.20 mm

OK

Proceed to test 2

Faulty

Rectify the fault and proceed to test 5

2

Check the pulser ring for damage or contamination by road grime or ferrous metal filings.

OK

Proceed to test 3

Faulty

Clean or replace the ABS pulser ring, proceed to test 5

3

Check the wheel speed sensors for correct installation, and the fixings for correct torque.

OK

Proceed to test 4

Faulty

Rectify the fault and proceed to test 5

4

Check the motorcycle wheel for damage/incorrect size.

OK

Proceed to test 5

Faulty

Rectify the fault and proceed to test 5

5

Clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service

Front or Rear Input/Output Solenoid Open/Short Circuit

Fault Code

Possible cause

Action

Front wheel input solenoid short circuit to ground or open circuit

Front wheel input solenoid short circuit to ground or open circuit

Ensure ABS ECM connector is secure.

Disconnect ABS ECM connector and proceed to pinpoint test 1:

Front wheel output solenoid short circuit to ground or open circuit

Front wheel output solenoid short circuit to ground or open circuit

Rear wheel input solenoid short circuit to ground or open circuit

Rear wheel input solenoid short circuit to ground or open circuit

Rear wheel output solenoid short circuit to ground or open circuit

Rear wheel output solenoid short circuit to ground or open circuit

Master cylinder isolation valve short circuit to ground or open circuit

Master cylinder isolation valve short circuit to ground or open circuit

Low pressure feed valve short circuit to ground or open circuit

Low pressure feed valve short circuit to ground or open circuit
Pinpoint Tests

Test

Result

Action

1

Check the ABS main fuse 7:

OK

Proceed to test 3

Faulty

Proceed to test 2

2

Check cable and terminal integrity:

- ABS ECM connector pin 18 and ground pin 10

OK

Replace fuse, proceed to test 5

Faulty

Rectify fault, replace fuse, proceed to test 5

3

Check cable for short to ground: With ignition 'ON', check voltage between:

- ABS ECM connector pin 18 and ground pin 10

Voltage greater than 11 V

Proceed to test 4

Voltage less than 11 V

Locate and rectify fault, proceed to test 5

4

Check cable for continuity:

- ABS ECM connector pin 10 and ground

OK

Proceed to test 5

Faulty

Locate and rectify fault, proceed to test 5

5

Clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Front or Rear Wheel Actuator (Hydraulic Control) Wheel Lock

Fault Code

Possible cause

Action

Front wheel Actuator (Hydraulic control) wheel lock

Front wheel Actuator (Hydraulic control) wheel lock

Binding brake

Incorrect Wheel speed sensor air gap

Loose or incorrectly installed wheel speed sensor

Ensure ABS ECM connector is secure.

Proceed to pinpoint test 1:

Rear wheel Actuator (Hydraulic control) wheel lock

Rear wheel Actuator (Hydraulic control) wheel lock

Binding brake

Incorrect Wheel speed sensor air gap

Loose or incorrectly installed wheel speed sensor
Pinpoint Tests

Test

Result

Action

1

Check the relevant wheel for brake bind caused by caliper or master cylinder faults, or other mechanical causes.

OK

Proceed to test 2

Faulty

Rectify the fault and proceed to test 4

2

Measure the air gap of the wheel speed sensor between the sensor and the pulser ring:

- Air gap between 0.40 mm to 1.20 mm

OK

Proceed to test 3

Faulty

Rectify the fault and proceed to test 4

3

Check the wheel speed sensors for correct installation, and the fixings for correct torque.

OK

Proceed to test 4

Faulty

Rectify the fault and proceed to test 4

4

Clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service

Motor – Lock; Motor Circuit Fault; Motor Does Not Run; Motor Runs Continually

Fault Code

Possible cause

Action

Motor circuit fault

Motor circuit fault

Ensure ABS ECM connector is secure.

Turn the ignition 'ON'.

Proceed to pinpoint test 1:

Motor - does not run

Motor - does not run

Motor - runs continually

Motor - runs continually
Pinpoint Tests

Test

Result

Action

1

Check the ABS main fuse 7.

OK

Proceed to test 2

Faulty

Replace fuse and proceed to test 5

2

Check the motor function:

Check that with the motorcycle stationary and the ABS ECM modulator connected, the motor does not operate

OK

Proceed to test 3

Motor runs continually

Contact Triumph service

3

Check cable continuity: With ignition 'ON', check voltage between:

- ABS ECM connector pin 18 and ground pin 10

Voltage greater than 11 V

Proceed to test 4

Voltage less than 11 V

Locate and rectify wiring fault, proceed to test 5

4

Check cable for continuity:

- ABS ECM connector pin 10 and ground

OK

Proceed to test 5

Faulty

Locate and rectify fault, proceed to test 5

5

Reconnect ABS ECM harness, clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

Power Source Voltage Too Low/Voltage Too High

Fault Code

Possible cause

Action

Power source voltage too low

Power source voltage too low

Ensure ABS ECM connector is secure.

Disconnect ABS ECM connector and proceed to pinpoint test 1:

Power source voltage too high

Power source voltage too high
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ABS ECM connector pin 4 and ground pin 10

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check the cable for continuity:

- ABS ECM connector pin 10 and ground

OK

Proceed to test 3

Faulty

Rectify wiring harness fault, proceed to test 5

3

Check battery voltage: With ignition 'ON', check the voltage between:

- ABS ECM connector pin 4 and ground pin 10

Voltage greater than 11 V

Proceed to test 4

Voltage less than 11 V

Locate and rectify fault, proceed to test 5

4

Check battery voltage: Reconnect ABS ECM connector and start the engine, check the voltage between:

- Battery positive (red) terminal and negative (black) terminal

Voltage between 11 V and 16 V

Proceed to test 5

Voltage greater than 16 V

Check the battery charging circuit. Locate and rectify fault, proceed to test 5

5

Clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

CAN Fault

Fault Code

Possible cause

Action

CAN fault - lost communication with engine ECM

CAN fault - lost communication with engine ECM

Ensure ABS ECM connector is secure.

Proceed to pinpoint test 1:

CAN fault - lost communication with instrument panel

CAN fault - lost communication with instrument panel

CAN fault - all communication lost

CAN fault - all communication lost
Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- ABS ECM connector pin 2

- ABS ECM connector pin 11

OK

Disconnect instruments and proceed to test 2

Faulty

Rectify fault, proceed to test 5

2

Check the cable for continuity:

- ABS ECM pin 2 to ground

- ABS ECM pin 11 to ground

OK

Proceed to test 3

Short circuit

Rectify wiring harness fault, proceed to test 5

3

Check cable continuity:

- ABS ECM pin 2 to ECM pin A33

- ABS ECM pin 11 to ECM pin A34

- ABS ECM pin 2 to Instruments pin 25

- ABS ECM pin 11 to Instruments pin 24

- ABS ECM pin 2 to Diagnostic connector pin 6

- ABS ECM pin 11 to Diagnostic connector pin 14

- ABS ECM pin 2 to Immobiliser module pin 6

- ABS ECM pin 11 to Immobiliser module pin 1

OK

Proceed to test 4

Open circuit

Rectify wiring harness fault, proceed to test 5

4

Check cable for short circuit:

- ABS ECM pin 2 to ABS ECM pin 11

OK

Proceed to test 4

Short circuit

Rectify wiring harness fault, proceed to test 5

5

Clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service
Circuit Diagram

ABS ECM Internal Error

Fault Code

Possible cause

Action

ABS ECM internal error

ABS ECM internal error

Incorrect wheel speed sensor air gap

Damaged or dirty pulser ring

Loose or incorrectly installed wheel speed sensor

Ensure ABS ECM connector is secure.

Proceed to pinpoint test 1:
Pinpoint Tests

Test

Result

Action

1

Measure the air gap of the wheel speed sensors between the sensor and the pulser ring:

- Air gap between 0.40 mm to 1.20 mm

OK

Proceed to test 1

Faulty

Rectify the fault and proceed to test 4

2

Check the pulser rings for damage or contamination by road grime or ferrous metal filings.

OK

Proceed to test 2

Faulty

Clean or replace the ABS pulser ring, proceed to test 4

3

Check the wheel speed sensors for correct installation, and the fixings for correct torque.

OK

Proceed to test 4

Faulty

Rectify the fault and proceed to test 4

4

Clear fault code and test ABS to verify fault cleared.

OK

Action complete - quit test

Fault still present

Contact Triumph service

Modulator output (wheel) pressure sensor malfunction

Fault Code

Possible Cause

Action

Modulator output (wheel) pressure sensor malfunction

Modulator output (wheel) pressure sensor malfunction

Contact Triumph service

Removal and Installation - Front Brakes Components

Front Brake Pads - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

Do not allow a brake component to hang unsupported on the brake hose or line.

Brake hoses or lines that are not supported may become damaged or bent.

Bent or damaged brake hoses or lines lead to reduced braking efficiency causing loss of motorcycle control and an accident.

  1. Remove the caliper mounting fixings and slide the caliper off the disc.

    1. Caliper mounting fixings

    2. Caliper
  2. Release the brake pad retaining lug from its mounting in the caliper and remove the brake pad.

    1. Brake pad retaining lug
  3. Repeat for the other brake pad.

    4. note
    • Note the position and orientation of the anti-rattle spring for installation.
    • Note that the arrow on the anti-rattle spring is pointing in the same direction as the arrow on the caliper.

    1. Arrow, anti-rattle spring

    2. Arrow, front caliper

    note
    • Complete the installation of the brake pads to one caliper (see Front Brake Pads - Installation) before removing the pads from the other caliper.

Front Brake Pads - Inspection

Front Brake Pads - Installation

warning

Always have replacement brake pads supplied and fitted by your Triumph dealer.

The ABS calibration is optimised for use with the friction material provided on brake pads supplied by Triumph.

The use of proprietary brands of brake pads is not recommended as differing friction material specifications will affect the performance of the ABS, potentially causing loss of motorcycle control and an accident.

warning

Brake pads for this model supplied by Triumph are specifically designed for use with the brake calipers fitted to your motorcycle.

The use of proprietary brands of brake pads is not recommended as these may have a reduced carrier plate thickness when compared with the Triumph genuine parts.

Brake pads with an incorrect carrier plate thickness can potentially become dislodged from the caliper body as they wear, leading to brake failure, loss of motorcycle control and an accident.

warning

Never use mineral-based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral-based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders.

Damage caused by contact with mineral-based grease may reduce braking efficiency resulting in loss of motorcycle control and an accident.

caution

Never lever directly against the disc, caliper or the pad lining material as this will damage these components. Always use a levering tool made from a soft material which will not cause damage to the load bearing surfaces.

Brake fluid will be displaced as the caliper pistons are compressed. To prevent body damage, ensure that the displaced fluid does not come into contact with any part of the bodywork.

  1. If new pads are being installed, push the pistons fully back into the caliper body. Keep an eye on the fluid level in the reservoir whilst retracting the pistons to prevent fluid spillage.
  2. Ensure that the anti-rattle spring position and orientation is as noted for removal.
  3. Fit one of the brake pad's retaining lugs into its mounting in the caliper with its friction material surfaces facing the other side of the caliper.

    1. Anti-rattle spring

    2. Retaining lug

    3. Retaining lug mounting
  4. Using finger pressure only, fit the pad's other retaining lug into its mounting of the caliper. Ensure that both retaining lugs are fully fitted into their mountings.
  5. Repeat steps 2 to 4 for the other brake pad.
  6. Thoroughly clean the threaded fixing holes for the front fork brake caliper fixings.
  7. Thoroughly clean the threaded part of the brake caliper fixings and smear the first four threads with a proprietary copper based grease.
  8. Position the brake caliper over the disc.
  9. Secure the brake caliper with the fixings and tighten sufficiently to bring the caliper into contact its mounting points, while allowing a small amount of lateral movement. Do not fully tighten at this stage.

    1. Caliper mounting fixings

    2. Caliper

    note
    • Before tightening, the brake caliper should be positioned such that it is aligned as centrally as possible over the brake disc.
  10. Visually check the clearances between the caliper body and brake disc in the four locations shown below.

    1. Caliper body

    2. Brake disc
  11. Slide the caliper body inwards or outwards against its fixings as required to achieve the most equal clearances possible on either side of the brake disc.
  12. Holding the caliper in position against its mounting fixings, tighten the fixings to 45 Nm.

    13. note
    • When the brake caliper is fitted, there must be a minimum gap of 0.3 mm between the caliper and brake disc.
  13. Using feeler gauges, measure the gap between the front brake caliper and the brake disc at the four measurement points shown in the following illustration. Minimum gap to be 0.3 mm.

    1. Front brake caliper

    2. Front brake disc
  14. If necessary, loosen the caliper bolts and adjust the caliper alignment to achieve the minimum gap of 0.3 mm on all four measurement points. Re-tighten the bolts to 45 Nm.
  15. Pump the brake lever to correctly position the caliper pistons.
  16. Repeat the removal, inspection and installation process for the other caliper.

    17. warning

    Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to an accident. Observe the brake fluid handling warnings given in the General Information section (see Brakes).

    caution

    To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.

  17. Check the front brake fluid level and top up as required with new DOT 4 fluid.
  18. Check for correct brake operation. Rectify as necessary.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Front Brake Caliper - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

caution

To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.

  1. Disconnect the brake hose at the front caliper and place the free end of the hose in a suitable container to collect the brake fluid. Discard the two sealing washers.
  2. Remove the caliper mounting fixings and slide the caliper off the disc.

    1. Caliper mounting fixings

    2. Caliper
  3. If required, remove the brake pads (see Front Brake Pads - Removal).

Front Brake Caliper - Disassembly

warning

To prevent injury, never place fingers or hands inside the caliper opening when removing the pistons. Always wear eye, hand and face protection when using compressed air. Eye, face and skin damage will result from direct contact with compressed air.

warning

Ensure the seal grooves in the caliper bores are not damaged during the removal of the seals. Damage to the seal grooves may allow brake fluid to leak past the seals resulting in a dangerous riding condition leading to loss of motorcycle control and an accident.

  1. Cover the caliper opening with a clean heavy cloth and using either compressed air or by reconnecting the master cylinder and pumping the brake lever, remove the pistons one at a time.

    1. Dust seal

    2. Piston seal

    3. Pistons

    4. Caliper
  2. Extract the dust seals and piston seals, taking care not to damage the caliper bores. Discard the old seals, these must not be re-used.

    3. note
    • The piston seals are slightly thicker than the dust seals.

    1. Piston seals

    2. Dust seals
  3. Check the pistons, caliper and mounting bracket for signs of damage, paying particular attention to the caliper bores and pistons. If damage is present, renew the worn component or the complete caliper assembly.

Front Brake Caliper - Inspection

warning

Always renew caliper seals and pistons after removal from the caliper. An effective hydraulic seal can only be made if new components are used.

A dangerous riding condition leading to loss of control of the motorcycle or an accident could result if this warning is ignored.

  1. Check the pistons and caliper bores for corrosion, scoring and damage. Renew as necessary.
  2. Inspect the brake pads for damage and wear beyond the service limit. Renew as necessary.

Front Brake Caliper - Assembly

warning

Never use mineral-based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral-based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders.

Damage caused by contact with mineral-based grease may reduce braking efficiency resulting in loss of motorcycle control and an accident.

warning

Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid.

Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders.

A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.

If all components are serviceable, obtain a piston seal kit and reassemble the caliper as follows:

  1. Ensure all components are clean, then fit the new seals to their grooves in the caliper bores.
  2. Lubricate the fluid seals, caliper bore and the outside of the pistons with clean DOT 4 brake fluid.
  3. Ease the pistons squarely back into the bores, taking care not to displace the seals.

Front Brake Caliper - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Remove the front wheel (see Front Wheel - Removal).
  2. Temporarily fit the calipers to the forks.
  3. Connect the brake hoses to the calipers incorporating new sealing washers on each side of the hose connections.
  4. Ensure the orientation of the brake hose is as noted for removal and tighten the union bolt to 25 Nm.

    5. warning

    Do not allow the calipers to hang on the brake hoses as this may damage the hoses and could lead to loss of motorcycle control and an accident.

  5. Detach the calipers from the front forks and refit the wheel (see Front Wheel - Installation).
  6. If removed, fit the brake pads (see Front Brake Pads - Installation).
  7. Thoroughly clean the threaded fixing holes for the front fork brake caliper fixings.
  8. Thoroughly clean the threaded part of the brake caliper fixings and smear the first four threads with a proprietary copper based grease.
  9. Position the brake caliper over the disc.
  10. Secure the brake caliper with the fixings and tighten sufficiently to bring the caliper into contact its mounting points, while allowing a small amount of lateral movement. Do not fully tighten at this stage.

    1. Caliper mounting fixings

    2. Caliper

    note
    • Before tightening, the brake caliper should be positioned such that it is aligned as centrally as possible over the brake disc.
  11. Visually check the clearances between the caliper body and brake disc in the four locations shown below.

    1. Caliper body

    2. Brake disc
  12. Slide the caliper body inwards or outwards against its fixings as required to achieve the most equal clearances possible on either side of the brake disc.
  13. Holding the caliper in position against its mounting fixings, tighten the fixings to 45 Nm.

    14. note
    • When the brake caliper is fitted, there must be a minimum gap of 0.3 mm between the caliper and brake disc.
  14. Using feeler gauges, measure the gap between the front brake caliper and the brake disc at the four measurement points shown in the following illustration. Minimum gap to be 0.3 mm.

    1. Front brake caliper

    2. Front brake disc
  15. If necessary, loosen the caliper bolts and adjust the caliper alignment to achieve the minimum gap of 0.3 mm on all four measurement points. Re-tighten the bolts to 45 Nm.

warning

Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident.

Observe the brake fluid handling warnings given earlier in this section of the manual.

caution

To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Front Brake Disc - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

Do not renew front brake discs individually. Discs must always be renewed in pairs even if one of a pair is serviceable.

A dangerous riding condition leading to an accident could result if this warning is ignored.

note
  • The fixings securing the left hand brake disc to the wheel also secure the ABS pulser ring. Note the orientation of the brake discs and the ABS pulser ring for installation.
  1. Remove the front wheel (see Front Wheel - Removal).
  2. Support the wheel on blocks as illustrated to avoid damage to the wheel centre.

    1. Wheel

    2. Support blocks
  3. Remove and discard the five fixings and remove the brake disc.
  4. Repeat for the other disc.
  5. Collect the ABS pulser ring from the left hand brake disc.

Front Brake Disc - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Locate the left hand brake disc and ABS pulser ring to the wheel as noted during removal.
  2. Fit new fixings and tighten to 22 Nm.
  3. Fit the other disc in the same way.
  4. Refit the front wheel (see Front Wheel - Installation).
  5. Check, and if necessary, adjust the air gap between the wheel speed sensor and the ABS pulser ring (see Front ABS Sensor Air Gap Measurement).
  6. Check for correct brake operation. Rectify as necessary.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Front Brake Master Cylinder - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

caution

To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.

  1. To drain the fluid from the master cylinder, attach a tube to the right hand caliper bleed nipple, loosen the nipple and allow the fluid to drain into a suitable container. Operate the brake lever until all fluid has been expelled.

    2. note
    • Note the position of the brake light switch for installation.
  2. Disconnect from the master cylinder the:
  3. Release the clamp screws from the handlebar to remove the master cylinder assembly.

Brembo Front Brake Master Cylinder - Disassembly

The following items can be replaced on the front brake master cylinder:

Brake Lever
  1. Note the setting of the brake lever adjuster(s) to ensure they are returned to the same position when the overhaul operation is complete.
  2. Remove the lock nut from the brake lever pivot bolt.
  3. Remove the brake lever pivot bolt.
  4. Release the brake lever from the master cylinder assembly.

    5. note
    • The T3880636 - Kit, Brake Lever Pivot Sleeve is required to remove the front brake lever pivot sleeve.

    T3880636 - Kit, Brake Lever Pivot Sleeve

    1. Mandrel

    2. Extractor

    3. Installer piece

    4. Support piece

    warning

    When removing the brake lever pivot sleeve, always wear overalls, eye, face and hand protection. The brake lever sleeve is hardened and liable to splinter if broken. Debris from broken components could cause injury to eyes, face and any unprotected parts of the body.

  5. Fit the extractor to the mandrel as shown.

    1. Mandrel

    2. Extractor
  6. Position the brake lever assembly with the pivot facing towards the support piece as shown.

    1. Brake lever

    2. Pivot

    3. Support piece
  7. Position the mandrel and extractor to the brake lever and press out the pivot sleeve from the brake lever assembly.

    1. Mandrel

    2. Support piece

    3. Extractor

    4. Front brake lever

    5. Pivot

    6. Return spring
  8. Retain the brake lever pivot sleeve for reuse during assembly.

    9. warning

    Always wear eye, hand and face protection when separating brake lever components. Uncontrolled release of the brake lever components may cause the spring to become detached during dismantling. Flying springs may cause injury to eyes, face and any unprotected parts of the body.

    note
    • Note the orientation of the return spring, push rod and brake lever pivot for installation.
  9. Carefully remove the extractor from the brake lever assembly.
  10. Collect the brake lever pivot sleeve from the support piece.
  11. Carefully detach the lever from the pivot assembly.
Bleed Screw
  1. Remove the cover from the bleed screw. Release the bleed screw and remove from the master cylinder assembly.

    1. Bleed screw

    2. Front brake master cylinder
Brake Switch
  1. Pulling carefully on the brake switch housing, remove the brake switch from the master cylinder assembly.

    1. Brake switch

    2. Location holes

Brembo Front Brake Master Cylinder - Assembly

Brake Lever

note
  • The T3880636 - Kit, Brake Lever Pivot Sleeve is required to refit the front brake lever pivot sleeve.

T3880636 - Kit, Brake Lever Pivot Sleeve

  1. Mandrel

  2. Extractor

  3. Installer piece

  4. Support piece
  1. Locate the pivot sleeve over the shank of the installer piece.

    1. Pivot sleeve

    2. Installer piece

    3. Mandrel
  2. Screw the installer piece into the mandrel.

    1. Mandrel

    2. Pivot sleeve

    3. Installer piece
  3. Align the brake lever to the brake lever pivot ensuring the return spring is located as noted during removal.
  4. Using the service tool align the installer piece to the brake lever and gently push down on the mandrel locating the installer piece, through the lever and pivot.
  5. Place the lower surface of the brake lever onto the support piece, and then using a press push the pivot sleeve through the brake lever pivot until the mandrel touches the upper brake lever surface.

    1. Mandrel

    2. Support piece

    3. Installer piece

    4. Front brake lever

    5. Pivot

    6. Return spring
  6. Support the brake lever, hold the mandrel and turn the installer piece anticlockwise to release it from the mandrel.

    1. Mandrel

    2. Installer piece

    3. Thread
  7. Visually check the pivot sleeve, return spring, brake lever pivot are installed as noted during removal.
  8. Position the lever assembly to the master cylinder ensuring that the ball end of the push rod is located into the lever adjuster wheel.

    1. Front brake master cylinder

    2. Push rod

    3. Adjuster wheel

    4. Brake lever
  9. Line up the holes of the brake lever and master cylinder, and insert the pivot bolt. Tighten the pivot bolt to 1 Nm.
  10. Fit the pivot bolt lock nut and tighten to 6 Nm.
  11. Check lever operation and ensure the rubber seal is still correctly seated.

warning

Always return the lever adjuster to the original setting noted during removal. Operating the motorcycle with lever settings which are unfamiliar may lead to loss of control or an accident.

Bleed Screw
  1. Fit the bleed screw to the master cylinder and tighten to 14 Nm

    1. Bleed screw

    2. Front brake master cylinder
  2. Fit the rubber cover to the bleed screw.
Brake Switch
  1. Position the brake switch to the master cylinder. Locate the brake switch in the location holes and push firmly home.

    1. Brake switch

    2. Location holes

Front Brake Master Cylinder - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Locate the master cylinder to the handlebars and position the clamp with the UP arrow pointing upwards.
  2. Align the master cylinder/clamp split line with the alignment mark on the handlebar.

    1. UP arrow

    2. Alignment mark
  3. Tighten the clamp bolts, upper first and then the lower to 8 Nm.
  4. Connect the brake hose to the master cylinder incorporating new sealing washers. Tighten the union bolt to 25 Nm.
  5. Attach the brake light switch to the master cylinder as noted during removal.

    6. warning

    Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident.

    Observe the brake fluid handling warnings given earlier in this section of the manual.
  6. Fill and bleed the front brakes (see Bleeding the Front Brakes, Renewing Brake Fluid).

    7. warning

    Always return the lever adjuster to the original setting noted during removal. Operating the motorcycle with lever settings which are unfamiliar may lead to loss of control or an accident.

  7. Reset the brake lever adjusters to the original settings.
  8. Examine the system for correct operation and fluid leaks. Rectify as necessary.

Perform the following operations:

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Removal and Installation - Rear Brakes Components

Rear Brake Pads - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • Before removing the brake pads, note the relationship of the pads to the caliper and ensure that, on assembly, they are fitted in the same way.
  1. Push the brake caliper inwards towards the wheel in order to displace the caliper piston.

    2. note
    • Note the orientation of the R-clip for installation.
  2. Remove the R-clip from the pad retaining pin.
  3. Using a suitable pin punch, tap the pad retaining pin out in the direction towards the wheel.

    1. R-clip

    2. Pad retaining pin
  4. Remove the brake pads.

    1. Brake pad
  5. For inspection and replacing the anti-rattle spring, remove the caliper (see Rear Brake Caliper - Removal).

Rear Brake Pads - Installation

warning

Always have replacement brake pads supplied and fitted by your Triumph dealer.

The ABS calibration is optimised for use with the friction material provided on brake pads supplied by Triumph.

The use of proprietary brands of brake pads is not recommended as differing friction material specifications will affect the performance of the ABS, potentially causing loss of motorcycle control and an accident.

warning

Brake pads for this model supplied by Triumph are specifically designed for use with the brake calipers fitted to your motorcycle.

The use of proprietary brands of brake pads is not recommended as these may have a reduced carrier plate thickness when compared with the Triumph genuine parts.

Brake pads with an incorrect carrier plate thickness can potentially become dislodged from the caliper body as they wear, leading to brake failure, loss of motorcycle control and an accident.

warning

Never use mineral-based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral-based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders.

Damage caused by contact with mineral-based grease may reduce braking efficiency resulting in loss of motorcycle control and an accident.

caution

To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.

  1. If fitting new pads, use hand pressure to compress the caliper piston fully into its bore. Keep an eye on the fluid level in the reservoir whilst retracting the pistons to prevent fluid spillage.
  2. Fit the brake pads to the caliper in the positions noted during removal.

    3. warning

    Do not apply more than a minimum coating of grease to the pad retaining pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced braking efficiency and an accident.

  3. Lubricate the pad retaining pin using a minimum amount of proprietary high temperature brake grease.
  4. Install the brake pad retaining pin.
  5. Install the R-clip to the brake pad retaining pin, as noted for removal.
  6. Pump the brake pedal to correctly position the caliper pistons.
  7. Check the brake fluid level in the rear reservoir and top-up as required with new DOT 4 fluid.

    8. warning

    Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident.

    Observe the brake fluid handling warnings given earlier in this section of the manual.
  8. Check for correct brake operation. Rectify as necessary.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Rear Brake Caliper - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

caution

To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.

  1. Remove the brake pads (see Rear Brake Pads - Removal).
  2. Release the fixing and remove the rear ABS wheel speed sensor. Collect the shim from between the sensor and rear caliper carier and discard the fixing.

    1. Fixing

    2. Rear ABS wheel speed sensor
  3. Disconnect the rear brake hose at the caliper and place the free end of the hose in a suitable container to collect the brake fluid. Discard the sealing washers

    4. note
    • Note the position of the rear brake caliper for installation.
  4. Remove the rear wheel (see Rear Wheel - Removal).
  5. Remove the brake caliper and carrier assembly.

    1. Caliper and carrier assembly

    2. Caliper carrier boss

    3. Swinging arm slot

    4. Swinging arm

Rear Brake Caliper - Disassembly

The following items can be replaced on the rear brake caliper:

  1. Slide the caliper off the carrier.
  2. Remove the anti-rattle spring.

Rear Brake Caliper - Inspection

  1. Inspect the sliding pin gaiters for damage, replace if necessary.

    2. Sliding pin gaiters

Rear Brake Caliper - Assembly

warning

Never use mineral-based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral-based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders.

Damage caused by contact with mineral-based grease may reduce braking efficiency resulting in loss of motorcycle control and an accident.

  1. Install the anti-rattle spring into the caliper.

    2. warning

    Do not apply more than a minimum coating of grease to the caliper sliding pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced braking efficiency and an accident.

  2. Lubricate the sliding pins with silicone based grease (such as T2022021 supplied by Triumph) then reassemble the carrier to the caliper. Ensure the pin gaiters are correctly located on both the carrier and caliper.

    3. Sliding pins

Rear Brake Caliper - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Position the caliper and carrier assembly to the swinging arm as noted for removal. Align the boss on the carrier with the slot on the swinging arm.

    1. Caliper and carrier assembly

    2. Caliper carrier boss

    3. Swinging arm slot

    4. Swinging arm
  2. Fit the rear wheel (see Rear Wheel - Installation).
  3. Connect the brake hose to the caliper incorporating new washers on each side of the union bolt.
  4. Tighten the union bolt to 25 Nm.
  5. Position the wheel speed sensor to the caliper carrier with its shim between the sensor and caliper carrier. Fit a new bolt and tighten to 9 Nm.

    1. Fixing

    2. Rear ABS wheel speed sensor
  6. Fit the brake pads (see Rear Brake Pads - Installation).

    7. warning

    Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident.

    Observe the brake fluid handling warnings given earlier in this section of the manual.
  7. Fill the master cylinder with new, DOT 4 brake fluid from a sealed container.
  8. Bleed the rear brake (see Bleeding the Rear Brakes, Renewing Brake Fluid).
  9. The air gap between the wheel speed sensor and the pulser ring must be between 0.4 mm and 1.2 mm. Check, and if necessary, adjust the air gap (see Rear ABS Sensor Air Gap Measurement).
  10. Check for correct brake operation. Rectify as necessary.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Rear Brake Disc - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Remove the rear wheel (see Rear Wheel - Removal).
  2. Support the wheel on blocks as illustrated to avoid damage to the wheel centre.

    1. Wheel

    2. Support blocks

    note
    • The fixings securing the rear brake disc to the wheel also secure the ABS pulser ring. Note the orientation of the brake disc and the ABS pulser ring for installation.
  3. Remove and discard the four fixings and remove the brake disc. Collect the rear ABS pulser ring.

Rear Brake Disc - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Locate the brake disc and ABS pulser ring to the rear wheel as noted during removal.
  2. Fit new fixings and tighten to 22 Nm.
  3. Refit the rear wheel (see Rear Wheel - Installation).
  4. Check, and if necessary, adjust the air gap between the wheel speed sensor and the ABS pulser ring (see Rear ABS Sensor Air Gap Measurement).
  5. Check for correct brake operation. Rectify as necessary.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Rear Master Cylinder - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

caution

To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.

  1. Drain the fluid from the master cylinder by bleeding the system at the rear caliper until all fluid has been expelled.
  2. Disconnect from the master cylinder the:

    3. note
    • The lower heel guard fixing also secures the master cylinder.
  3. Remove the fixings securing the heel guard to the right hand control plate and remove the heel guard.

    1. Heel guard

    2. Upper fixing

    3. Lower fixing
  4. Temporarily refit the lower fixing to secure the master cylinder while its upper fixing is loosened.
  5. Loosen the upper master cylinder fixing. Remove both fixings and detach the master cylinder from the right hand control plate.

    1. Master cylinder

    2. Upper fixing

    3. Lower fixing
  6. Remove the lock nut, bolt and finisher securing the silencer to the right hand control plate.

    7. note
    • Note the routing of the rear brake switch harness for installation.
  7. Detach the rear brake switch harness from the clip on the rear master cylinder brake hose and disconnect its multiplug.
  8. Remove the two fixings securing the right hand control plate to the frame and remove the control plate. Collect the flanged sleeves and grommets from the silencer mounting.

    1. Lock nut

    2. Bolt

    3. Finisher

    4. Control plate fixings

    note
    • Note the position and orientation of the clevis pin and clip for installation.
    • Note the position and orientation of the brake switch and brake pedal return springs for installation.
  9. Remove and discard the rear brake pedal pivot bolt.
  10. Remove the clip and clevis pin at the lower end of the brake push rod and remove the master cylinder.

    1. Pivot bolt

    2. Clip

    3. Clevis pin

    4. Rear brake pedal

Rear Master Cylinder - Disassembly

  1. Remove the boot from the cylinder and pushrod.
  2. Remove the circlip retaining the pushrod to the cylinder.
  3. Remove the pushrod and piston set from the master cylinder bore noting the relative position of the seals and piston components.

Rear Master Cylinder - Inspection

  1. Visually inspect the master cylinder bore for wear, scratches or corrosion. Replace as necessary.
  2. Check the piston and cylinder bore for damage, wear or deterioration. Replace as necessary. Always renew the piston seals if the cylinder has been dismantled.
  3. Examine the pushrod for bends and damage. Replace as necessary.

Rear Master Cylinder - Assembly

warning

Never use mineral-based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral-based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders.

Damage caused by contact with mineral-based grease may reduce braking efficiency resulting in loss of motorcycle control and an accident.

warning

Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid.

Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders.

A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.

  1. Clean the master cylinder bore, piston and seals, with new brake fluid.
  2. Ensure all ports are clear of obstruction.

    3. warning

    Ensure that the piston and piston seal are fitted facing the same way as noted during removal. A dangerous riding condition leading to an accident could result from incorrect assembly of the master cylinder.

  3. Install the spring and piston set together.
  4. Apply a small amount of brake grease to the push rod.
  5. Install the push rod in the master cylinder and retain with a new circlip.
  6. Refit the boot.

    1. Reservoir hose

    2. Piston set

    3. Dust boot

    4. Push rod

    5. Clevis pin

    6. Clip

    7. Circlip
  7. If the push rod has been disassembled, set the push rod free length to 75.5 mm, as shown below:

    1. Push rod

    2. Lock nut
  8. Tighten the lock nut to 18 Nm.

Rear Master Cylinder - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Align the rear brake pedal to the master cylinder push rod and secure with the clevis pin and clip as noted during removal.
  2. Secure the brake pedal to the control plate with a new pivot bolt and tighten to 22 Nm.
  3. Attach the brake switch and pedal return springs to the rear brake pedal as noted during removal.

    1. Pivot bolt

    2. Clip

    3. Clevis pin

    4. Rear brake pedal
  4. Fit the grommets and flanged sleeves to the control plate silencer mounting.

    1. Grommets

    2. Flanged sleeves
  5. Fit the right hand control plate to the frame and tighten its fixings to 24 Nm.
  6. Secure the silencer to the right hand control plate with its bolt, finisher and new lock nut and tighten to 28 Nm.

    1. Lock nut

    2. Bolt

    3. Finisher

    4. Control plate fixings
  7. Route the rear brake switch harness as noted during removal and connect the multiplug. Secure the harness into its clip on the rear master cylinder brake hose.
  8. Secure the master cylinder to the control plate as follows:

    1. Master cylinder

    2. Upper fixing

    3. Lower fixing
  9. Remove the lower M8 x 35 mm fixing.
  10. Secure the heel guard to the control plate as follows:

    1. Heel guard

    2. Upper fixing

    3. Lower fixing
  11. Incorporating new washers, fit the brake hose to the master cylinder. Ensuring correct orientation of the brake hose, tighten the union bolt to 25 Nm.
  12. Reconnect the reservoir hose to the master cylinder.

    13. warning

    Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident.

    Observe the brake fluid handling warnings given earlier in this section of the manual.
  13. Fill and bleed the rear brake system (see Bleeding the Rear Brakes, Renewing Brake Fluid).

Perform the following operations:

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Removal and Installation - ABS Components

Front ABS Wheel Speed Sensor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

note
  • Note the routing of the front ABS wheel speed sensor harness and its retaining clips for installation.
  • The front ABS wheel speed sensor multiplug is identified as the white connector located above the camshaft cover, near the left hand side.

  1. Front ABS wheel speed sensor multiplug
  1. Disconnect the front ABS wheel speed sensor multiplug.
  2. Detach the wheel speed sensor harness from its clips on the front brake hose and the rubber cap on the caliper bleed nipple.
  3. Release the three fixings and remove the wheel speed sensor harness cover from the left fork leg. Discard the fixings.

    1. Wheel speed sensor harness cover

    2. Fixings

    3. Sensor

    4. Sensor harness
  4. Release the fixing and remove the sensor. Collect the shim from between the sensor and fork leg.

    1. Front ABS wheel speed sensor

    2. Fixing

    3. Sensor harness

    4. Rubber bleed nipple cap

Front ABS Wheel Speed Sensor - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • Check the condition of the shim before use. Do not use a shim which is bent or damaged.
  1. Position the wheel speed sensor to the fork leg with its shim between the sensor and fork leg. Tighten the fixing to 9 Nm.

    2. caution

    Care must be taken when fitting the wheel speed sensor harness cover, not to trap the harness between the cover and fork leg.

  2. Route the sensor harness into its channel on the left fork leg as noted for removal. Refit the harness cover and secure with three new fixings. Tighten the fixings to 2 Nm.
  3. Route the remaining length of harness and secure to the brake hose clips and caliper bleed nipple cap as noted for removal.
  4. Connect the wheel speed sensor multiplug.

Perform the following operations:

Front ABS Pulser Ring - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • The fixings securing the ABS pulser ring to the wheel also secure the left hand brake disc. Note the orientation of the brake disc and the ABS pulser ring for installation.
  1. Remove the front wheel (see Front Wheel - Removal).
  2. Support the wheel on blocks with the ABS pulser ring and left hand brake disc facing upwards.

    1. Wheel

    2. Support blocks
  3. Remove and discard the five fixings and remove the ABS pulser ring.

Front ABS Pulser Ring - Inspection

  1. Check the pulser ring for damaged, missing or cracked teeth or distortion. Renew the pulser ring as necessary.

Front ABS Pulser Ring - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Locate the left hand brake disc and ABS pulser ring to the wheel as noted during removal.
  2. Fit new fixings and tighten to 22 Nm.
  3. Refit the front wheel (see Front Wheel - Installation).
  4. Check, and if necessary, adjust the air gap between the wheel speed sensor and the ABS pulser ring (see Front ABS Sensor Air Gap Measurement).
  5. Check for correct brake operation. Rectify as necessary.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Rear ABS Wheel Speed Sensor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the routing of the harness and its retaining clips for installation.
  1. Detach the rear ABS wheel speed sensor multiplug from its bracket on the crankcase breather cover and disconnect from the main harness.

    1. Rear ABS wheel speed sensor multiplug

    2. Bracket
  2. Release the sensor harness from its retaining clips and the rear caliper bleed nipple cap.
  3. Release the fixing and remove the sensor. Collect the shim from between the sensor and fork leg and discard the fixing.

    1. Fixing

    2. Rear ABS wheel speed sensor

Rear ABS Pulser Ring - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Remove the rear wheel (see Rear Wheel - Removal).
  2. Support the wheel on blocks as illustrated to avoid damage to the wheel centre.

    1. Wheel

    2. Support blocks

    note
    • The fixings securing the ABS pulser ring to the wheel also secure the rear brake disc. Note the orientation of the brake disc and the ABS pulser ring for installation.
  3. Remove and discard the four fixings and remove the rear ABS pulser ring.

Rear ABS Pulser Ring - Inspection

  1. Check the pulser ring for damaged, missing or cracked teeth or distortion. Renew the pulser ring as necessary.

Rear ABS Pulser Ring - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Locate the brake disc and ABS pulser ring to the rear wheel as noted during removal.
  2. Fit new fixings and tighten to 22 Nm.
  3. Refit the rear wheel (see Rear Wheel - Inspection).
  4. Check, and if necessary, adjust the air gap between the wheel speed sensor and the ABS pulser ring (see Rear ABS Sensor Air Gap Measurement).
  5. Check for correct brake operation. Rectify as necessary.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

ABS Hydraulic Modulator/ECM - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

caution

To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.

  1. Drain the fluid from the front master cylinder by bleeding the system at the front caliper until all fluid has been expelled (see Bleeding the Front Brakes, Renewing Brake Fluid).
  2. Drain the fluid from the rear master cylinder by bleeding the system at the rear caliper until all fluid has been expelled (see Bleeding the Rear Brakes, Renewing Brake Fluid).

    3. warning

    Before the disassembly of any brake lines in the ABS hydraulic circuit, always mark their position so that they can be returned to the same position when assembled.

    If the brake lines are incorrectly assembled the performance of the ABS system will be seriously compromised, leading to loss of motorcycle control and an accident.

    warning

    Do not allow the brake hard lines to become bent or kinked during ABS modulator removal.

    If the brake lines are bent or kinked the performance of the ABS system will be seriously compromised, leading to loss of motorcycle control and an accident.

  3. Remove the union bolts and carefully disconnect the four brake lines from the ABS modulator. Discard the sealing washers.

    1. ABS modulator

    2. Brake line unions
  4. Remove and discard the two fixings and remove the ABS modulator from its bracket.

    1. ABS modulator

    2. ABS modulator bracket

    3. Fixings
  5. If necessary, release the fixing and remove the anti-rotation moulding from the ABS modulator.

    1. ABS modulator

    2. Fixing

    3. Anti-rotation moulding

ABS Hydraulic Modulator/ECM - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. If removed, fit the anti-rotation moulding and tighten its fixing to 3 Nm.

    1. ABS modulator

    2. Fixing

    3. Anti-rotation moulding
  2. Position the ABS modulator onto its bracket. Fit new fixings and tighten to 9 Nm.

    1. ABS modulator

    2. ABS modulator bracket

    3. Fixings
  3. Incorporating new washers to either side of the unions, fit the brake lines to the ABS modulator as noted for removal. Tighten the brake line unions to 25 Nm.

    1. ABS modulator

    2. Brake line unions
  4. Perform the following operations:

    5. warning

    Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to an accident.

    Observe the brake fluid handling warnings given earlier in this section of the manual.
  5. Bleed the front brakes (see Bleeding the Front Brakes, Renewing Brake Fluid).
  6. Bleed the rear brakes (see Bleeding the Rear Brakes, Renewing Brake Fluid).

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

ABS Hydraulic Circuit Layout

Wheels and Tyres

Exploded View - Front Wheel

Exploded View – Rear Wheel

Tyres

This model is equipped with tubeless tyres, valves, and wheel rims. Only tyres marked TUBELESS and tubeless type tyre valves mounted on rims marked SUITABLE FOR TUBELESS TYRES can be used.

Typical Wheel Marking (front wheel shown)

Typical Tyre Marking

warning

Tyres that have been used on a rolling road dynamometer may become damaged. In some cases, the damage may not be visible on the external surface of the tyre.

Tyres must be replaced after such use as continued use of a damaged tyre may lead to instability, loss of control and an accident.

Tyre Pressure Monitoring System (TPMS) - (if fitted)

warning

Incorrect tyre inflation will cause abnormal tread wear and instability problems that may lead to loss of control and an accident.

Underinflation may result in the tyre slipping on, or coming off the rim. Overinflation will cause instability and accelerated tread wear.

Both conditions are dangerous as they may cause loss of control leading to an accident.

warning

The tyre pressure monitoring system is not to be used as a tyre pressure gauge when adjusting the tyre pressures. For correct tyre pressures, always check the tyre pressures when the tyres are cold and using an accurate tyre pressure gauge.

Use of the TPMS system to set inflation pressures may lead to incorrect tyre pressures leading to loss of motorcycle control and an accident.

caution

Do not use anti puncture fluid or any other item likely to obstruct air flow to the TPMS sensor’s orifices. Any blockage to the air pressure orifice of the TPMS sensor during operation will cause the sensor to become blocked, causing irreparable damage to the TPMS sensor assembly. Damage caused by the use of anti puncture fluid or incorrect maintenance is not considered a manufacturing defect and will not be covered under warranty. Always have your tyres fitted by your authorised Triumph dealer and inform them that tyre pressure sensors are fitted to the wheels.

Wheels fitted with a tyre pressure sensor can be identified with the letters TPMS on the side of the tyre valve and/or with a warning label near the tyre valve, as shown in the illustration below.

  1. TPMS on tyre valve

  2. Warning label

Function

Tyre pressure sensors are fitted to the front and rear wheels. These sensors measure the air pressure inside the tyre and transmit pressure data to the instruments. These sensors will not transmit the data until the motorcycle is travelling at a speed greater than 12 mph (20 km/h). Two dashes will be visible in the display area until the tyre pressure signal is received.

When the battery voltage in a pressure sensor is low, BATTERY LOW FRONT/REAR TYRE will be displayed and a message will indicate which wheel sensor has the low battery voltage. If the batteries are completely flat, only dashes will be shown in the display screen, the red TPMS warning light will be on and the TPMS symbol will flash continuously.

The tyre pressure warning light works in conjunction with the tyre pressure monitoring system.

It will illuminate for the following conditions:

Front Tyre Pressure

Rear Tyre Pressure

2.00 bar (29 lb/in²)

2.48 bar (36 lb/in²)

When the warning light is illuminated, the TPMS symbol will indicate which is the deflated tyre and its pressure will automatically be visible in the display area.

Tyre Inflation Pressures

warning

Incorrect tyre inflation will cause abnormal tread wear and instability problems that may lead to loss of control and an accident.

Underinflation may result in the tyre slipping on, or coming off the rim. Overinflation will cause instability and accelerated tread wear.

Both conditions are dangerous as they may cause loss of control leading to an accident.

Correct inflation pressure will provide maximum stability, rider comfort and tyre life. Always check tyre pressures before riding when the tyres are cold. Check tyre pressures daily and adjust if necessary. See the Specification section for details of the correct inflation pressures.

Tyre Wear/Wheel Inspection

As the tyre tread wears down, the tyre becomes more susceptible to puncture and failure. It is estimated that 90% of all tyre failures occur during the last 10% of tread life (90% worn). It is false economy and unsafe to use tyres until they are worn to their minimum.

All tyres are fitted with tread wear indicators. When the tyre becomes worn down as far as the top of a tread wear indicator, the tyre is worn beyond its service life and must be replaced.

  1. Tread wear indicator

Attention must also be paid to the legal limits for tread wear, which differ from country to country. Tyres that have worn to the legal limit in the country or region in which the motorcycle is operated must be replaced, even if tread wear has not yet reached the level of the tread wear indicators.

In accordance with the scheduled maintenance chart, measure the depth of the tread with a depth gauge, and replace any tyre that has worn to, or beyond the minimum allowable tread depth.

Inspect wheels for cracks, splits and kerb damage. Always replace wheels that are suspected of having become damaged.

Minimum Recommended Tread Depth

warning

Operation with excessively worn tyres is hazardous and will adversely affect traction, stability and handling which may lead to loss of control and an accident.

When tubeless tyres become punctured, leakage is often very slow. Always inspect tyres very closely for punctures. Check the tyres for cuts, embedded nails or other sharp objects. Operation with punctured or damaged tyres will adversely affect motorcycle stability and handling which may lead to loss of control or an accident.

Check the rims for dents or deformation. Operation with damaged or defective wheels or tyres is dangerous and loss of motorcycle control or an accident could result.

Always consult your authorised Triumph dealer for tyre replacement, or for a safety inspection of the tyres.

In accordance with the periodic maintenance chart, measure the depth of the tread with a depth gauge, and replace any tyre that has worn to, or beyond the minimum allowable tread depth specified in the table below:

Under 80 mph (130 km/h)

2 mm (0.08 in)

Over 80 mph (130 km/h)

Front 2 mm (0.08 in)

Rear 3 mm (0.12 in)

warning

This Triumph motorcycle must not be operated above the legal road speed limit except in authorised closed course conditions.

warning

Only operate this Triumph motorcycle at high speed in closed course, on-road competition or on closed course racetracks. High speed operation should only then be attempted by riders who have been instructed in the techniques necessary for high speed riding and are familiar with the motorcycle’s characteristics in all conditions. High speed operation in any other circumstances is dangerous and will lead to loss of motorcycle control and an accident.

Important Tyre Information

All Triumph motorcycles are carefully and extensively tested in a range of riding conditions to ensure that the most effective tyre combinations are approved for use on each model. It is essential that approved tyre combinations are used when purchasing replacement tyres as the use of non-approved tyres or approved tyres in non-approved combinations may lead to motorcycle instability. A list of approved tyres specific to this model is available from your authorised Triumph dealer, or on the internet at www.triumph.co.uk.

warning

The ABS computer operates by comparing the relative speed of the front and rear wheels. Use of non-recommended tyres can affect wheel speed and cause the ABS function not to operate, potentially leading to loss of motorcycle control and an accident in conditions where the ABS would normally function.

warning

Always check tyre pressures before riding when the tyres are cold. Operation with incorrectly inflated tyres may affect handling leading to loss of control and an accident.

warning

Operation with excessively worn or damaged tyres will adversely affect handling and control leading to loss of control or an accident.

warning

Inner tubes must only be used on motorcycles fitted with spoked wheels and with tyres marked 'TUBE-TYPE'.

Use of an inner tube with a tyre marked 'TUBELESS' and/or on an alloy wheel can lead to loss of motorcycle control and an accident.

All Triumph motorcycles are carefully and extensively tested in a range of riding conditions to ensure that the most effective tyre combinations are approved for use on each model. It is essential that approved tyre combinations are used when purchasing replacement tyres as the use of non-approved tyres or approved tyres in non-approved combinations may lead to motorcycle instability. A list of approved tyres specific to this model is available from your authorised Triumph dealer, or on the internet at www.triumph.co.uk.

warning

If a tyre or inner tube sustains a puncture, the tyre and inner tube must be replaced together. Failure to replace a punctured tyre and inner tube together, or operation with a repaired tyre or inner tube can lead to instability, loss of motorcycle control or an accident.

If tyre or inner tube damage is suspected, such as after striking the kerb, ask your authorised Triumph dealer to inspect the tyre both internally and externally and to also inspect the inner tube. Remember, tyre damage may not always be visible from the outside. Operation of the motorcycle with damaged tyres could lead to loss of motorcycle control and an accident.

When replacing a 'TUBE-TYPE' tyre on a spoked wheel, always inspect the rim tape (rim protection band) to ensure that it is correctly protecting the tube from the spoke threads. A damaged rim tape may lead to rapid tyre deflation causing loss of control and an accident.

warning

Do not install tube-type tyres on tubeless rims. The bead will not seat and the tyres could slip on the rims, causing tyre deflation that may result in a loss of motorcycle control and an accident.

Do not install an inner tube inside a tubeless tyre. This may cause instability and excessive heat build-up may cause the tube to burst resulting in rapid tyre deflation, loss of vehicle control and an accident.

warning

The use of tyres other than those listed at your authorised Triumph dealer, or on the internet, at www.triumph.co.uk, may adversely affect handling leading to loss of motorcycle control or an accident. Use the recommended tyre options only in the combinations listed at your authorised Triumph dealer, or on the internet at www.triumph.co.uk. Do not mix tyres from different manufacturers or tyres from the same manufacturer but from another option.

warning

Accurate wheel balance is important for safe, stable handling of the motorcycle. Do not remove or change any wheel balance weights. Incorrect wheel balance may cause instability leading to loss of motorcycle control and an accident.

When wheel balancing is required, such as after tyre replacement, see your authorised Triumph dealer.

Only use self-adhesive weights. Clip-on weights will damage the wheel and tyre potentially resulting in tyre deflation, loss of motorcycle control and an accident.

warning

When replacement tyres are required, consult your authorised Triumph dealer who will arrange for the tyres to be fitted according to the tyre manufacturer’s instructions.

When tyres are replaced, allow time for the tyre to seat itself to the rim (approximately 24 hours). During this seating period, ride cautiously as an incorrectly seated tyre could cause loss of motorcycle control or an accident. Initially, the new tyre will not produce the same handling characteristics as the worn tyre and the rider must allow adequate riding distance (approximately 100 miles/160 km) to become accustomed to the new handling characteristics.

After both 24 hours and 100 miles (160 km), the tyre pressures should be checked and adjusted and the tyre examined for correct seating and rectified as necessary.

Use of a motorcycle when not accustomed to its handling characteristics, with incorrect tyre pressures or an incorrectly seated tyre is dangerous and may lead to loss of motorcycle control and an accident.

Front Wheel - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Detach and support the front brake calipers (see Front Brake Caliper - Removal).

    2. note
    • It is not necessary to disconnect the brake hoses.

    warning

    Do not allow the calipers to hang on the brake hoses as this may damage the hoses.

    Damaged hoses could cause brake failure leading to loss of control and an accident.
  2. Raise and support the front of the motorcycle.
  3. Loosen both pinch bolts at the lower end of the right hand fork.
  4. Release and remove the wheel spindle.
  5. Remove the wheel and the wheel spacers.

    1. Fork pinch bolts

    2. Wheel spindle

    3. Wheel spacers (right hand shown)
  6. Place the wheel on wooden blocks.

    7. warning

    Do not allow the wheel to rest on either brake disc as this may damage the disc and could lead to an accident.

    caution

    To prevent wheel and bearing damage, observe absolute cleanliness and ensure there is no dirt ingress to the wheel bearings while the wheel is removed.

  7. Thoroughly clean all components and inspect for wear or damage.

Front Wheel - Inspection

  1. Check the wheel bearings spin smoothly with no signs of play. If not, renew the bearings (see Front Wheel Bearings - Removal).

Front Wheel - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Lightly smear the wheel spacers with grease and locate in the hubs.
  2. Position the wheel between the forks ensuring the spacers remain in position on both sides.
  3. Refit the wheel spindle from the right hand side and tighten to 65 Nm.
  4. Lower the motorcycle to the ground and position the front wheel up against a fixed surface. Bounce the front suspension numerous times to allow the right hand fork to float to its natural position on the wheel spindle.

    5. note
    • Do not lean on the motorcycle or compress the front suspension prior to tightening the fork pinch bolts.
  5. Tighten the fork pinch bolts to 22 Nm.

    1. Fork pinch bolts

    2. Wheel spindle

    3. Wheel spacers (right hand shown)
  6. Thoroughly clean and degrease the brake discs.
  7. Refit the front brake calipers (see Front Brake Caliper - Installation).

Rear Wheel - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Raise and support the rear of the motorcycle to allow removal of the rear wheel.

    2. warning

    If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries.

  2. Remove the nut from the rear wheel spindle.

    3. Rear wheel spindle nut
  3. Support the wheel and withdraw the wheel spindle.
  4. Noting its position, release the brake caliper and carrier from the slot on the swinging arm and roll the wheel forward until the chain can be detached from the rear sprocket.

    5. warning

    Do not allow the caliper to hang on the brake hose as this may damage the hose.

    Damaged hoses could cause brake failure leading to loss of control and an accident.
  5. Tie the rear brake caliper aside.
  6. Withdraw the wheel and collect the flanged spacer from the right hand side and the plain spacer from the left hand side.
  7. Place the wheel on wooden blocks with the drive sprocket uppermost.
  8. If required, remove the final drive (see Final Drive - Removal).
  9. Reposition the wheel on wooden blocks with the rear brake disc uppermost.
  10. If required, remove the rear brake disc (see Rear Brake Disc - Removal).

Rear Wheel - Inspection

  1. Check the wheel bearings spin smoothly with no signs of play. If not, renew the bearings (see Rear Wheel Bearing - Removal).

Rear Wheel - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Thoroughly clean and degrease the brake disc.
  2. If removed, refit the brake disc (see Rear Brake Disc - Installation).
  3. Refit the final drive assembly (see Final Drive - Installation).
  4. Position the wheel within the swinging arm and refit the chain to the final drive sprocket.

    1. Fitting the chain
  5. Position the rear brake caliper and carrier to the swinging arm as noted prior to removal. Align the boss on the carrier with the slot in the swinging arm.

    1. Caliper carrier, wheel shown removed for clarity

    2. Caliper carrier boss

    3. Swinging arm slot

    4. Swinging arm
  6. Refit the wheel spacers, flanged spacer to the right hand side (flange facing outwards) and plain spacer to the left.

    1. Wheel spacer (right hand shown)
  7. Lift the rear wheel into position, aligning the wheel, caliper carrier and swinging arm.

    8. warning

    Check that the spacers are still correctly positioned. Incorrectly fitted wheel spacers will cause a dangerous riding condition leading to loss of motorcycle control and an accident.

  8. Fit the wheel spindle with the threaded end facing to the left.
  9. Keeping the chain adjuster blocks in contact with the adjuster bolts, tighten the wheel spindle nut to 110 Nm.

    1. Rear wheel spindle nut
  10. Lower the motorcycle to the ground.

    11. warning

    It is dangerous to operate the motorcycle with defective brakes and you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

  11. Check the operation of the rear brake.
  12. Check and, if necessary, adjust the chain (see Final Drive Chain Free-Movement Adjustment).

Tyre Pressure Sensor - Removal - (if fitted)

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • The method for the removal of the tyre pressure sensor is the same for the front and rear wheels.

Wheels fitted with a tyre pressure sensor can be identified with the letters TPMS on the side of the tyre valve and/or with a warning label near the tyre valve, as shown in the illustration below.

  1. TPMS on tyre valve

  2. Warning label

If fitting new wheels and using the original tyre pressure sensors, make a note of the front and rear pressure sensor serial numbers to ensure they are fitted to the correct wheel.

  1. Tyre pressure sensor

  2. ID number

Perform the following operations:

  1. For the removal of the tyre note the following:

    1. Position for tyre lever/removal tool

    2. Tyre valve

    3. Tyre pressure sensor

    4. Direction of wheel rotation

    note
    • Note the orientation of the tyre valve for installation.
  2. Release the fixing and remove the tyre pressure sensor and the tyre valve.

    1. Tyre pressure sensor

    2. Tyre valve

    3. Fixing

Tyre Pressure Sensor - Installation - (if fitted)

warning

When the tyre valve is removed, the seal on the tyre valve must be replaced. Failure to change the seal may result in tyre pressure loss leading to loss of motorcycle control and an accident.

note
  • If fitting the original tyre pressure sensors, ensure they are fitted to the correct wheel using the serial number on the sensor as noted for removal.
  • If fitting new tyre pressure sensors, record the serial numbers of the front and rear tyre pressure sensors in the spaces provided on the relevant page of the Owner’s Handbook.

note
  • The method for the installation of the tyre pressure sensor is the same for the front and rear wheels.
  1. Ensure the mounting hole on the wheel rim and the area around it is free from any dirt or grease.
  2. Ensure a new seal is fitted to the tyre valve.

    1. Tyre valve

    2. Seal
  3. Align the tyre valve to its mounting hole in the wheel rim. Ensure the tyre valve orientation is the same as noted for removal.

    1. Tyre valve

    2. Hole

    caution

    The edges of the tyre pressure sensor must be parallel to the walls of the wheel well. Damage to the sensor may result if the sensor is not correctly installed.

  4. Fit the sensor to the tyre valve and tighten the fixing of the sensor to 5 Nm. Ensure that the sensor is not forced against the walls of the wheel well while tightening.

    1. Tyre pressure sensor

    2. Tyre valve

    3. Fixing
  5. Ensure that the position of the sensor is parallel to the walls of the wheel rim, as shown in the illustration below.

    1. Tyre pressure sensor

    2. Fixing
  6. When secure, the gap between the sensor and the wheel rim must be a minimum of 0.8 mm and must have a limited twist movement around its fixing.

    1. Wheel rim

    2. Fixing
  7. Refit the tyre noting the following:

    1. Position for tyre lever/installation tool

    2. Tyre valve

    3. Tyre pressure sensor

    4. Direction of wheel rotation
  8. Check and, if necessary, adjust the balance of the wheel.

Perform the following operations:

Front Wheel Bearings - Removal

  1. Remove the front wheel (see Front Wheel - Removal).

    2. caution

    Do not allow the wheel to rest on the brake discs, as this may damage the discs. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake discs are raised above the ground.

  2. Place the wheel on wooden blocks to prevent damage to the brake discs.
  3. Remove and discard the seals and the bearing circlip.

    4. warning

    Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries if suitable protective apparel is not worn.

    caution

    To prevent wheel damage and to aid bearing removal, always apply force evenly on both sides of the bearing to prevent it from tipping and becoming stuck. Application of uneven force will lead to difficulty in removing the bearing and to a damaged wheel.

  4. Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect the centre sleeve.

    5. Wheel Bearing Removal

Front Wheel Bearing - Installation

note
  • Refer to the chart below for the correct tool and tool face when inserting bearings. Bearings are inserted by means of a draw-bolt acting on the insertion tool. A support tool is located on the opposite side of the wheel to the insertion tool and as the bolt is tightened, the bearing is drawn into the wheel.
  • Insert bearings with the marked or shielded side facing outwards and always fit a new bearing circlip and seals.

Bearing insertion tool

Support tool

Left bearing

T3880053 - Wheel Bearing Extraction Kit

Small face to bearing

3880065-T0301 - Bearing Installer

Large face to wheel

Right bearing

T3880053 - Wheel Bearing Extraction Kit

Small face to bearing

3880065-T0301 - Bearing Installer

Large face to wheel

  1. Fit the wheel bearings and centre sleeve using the method described above.

    1. T3880053 - Wheel Bearing Extraction Kit

    2. 3880065-T0301 - Bearing Installer
  2. Fit a new circlip.
  3. Lubricate and fit new seals to the front wheel. Lubricate the seal’s knife-edge with grease to NLGI 2 specification.
  4. Fit the front wheel (see Front Wheel - Installation).

Rear Wheel Bearing - Removal

  1. Remove the rear wheel (see Rear Wheel - Removal).

    2. caution

    Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above the ground.

  2. Place the wheel on wooden blocks to prevent damage to the brake disc.
  3. Remove and discard the seals and the bearing circlip.

    4. warning

    Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries if suitable protective apparel is not worn.

    caution

    To prevent wheel damage and to aid bearing removal, always apply force evenly on both sides of the bearing to prevent it from tipping and becoming stuck. Application of uneven force will lead to difficulty in removing the bearing and to a damaged wheel.

  4. Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect the centre sleeve.

    5. Rear Wheel Bearing Removal

Wheel Bearings - Inspection

warning

Only remove raised witness marks from within the wheel. Removal of material below any raised areas will reduce the level of interference between the wheel and the bearings. Loss of interference could cause the bearing to become loose in the wheel leading to loss of motorcycle control and an accident.

  1. Examine the wheel for any raised witness marks caused by the bearing removal process. Remove any such marks with fine emery paper or a gentle file.

Rear Wheel Bearing - Installation

note
  • Refer to the chart below for the correct tool and tool face when inserting bearings. Bearings are inserted by means of a draw-bolt acting on the insertion tool. A support tool is located on the opposite side of the wheel to the insertion tool and as the bolt is tightened, the bearing is drawn into the wheel.
  • Insert bearings with the marked or shielded side facing outwards and always fit a new bearing circlip and seals.

Bearing insertion tool

Support tool

Left bearing

3880070-T0301 - Bearing Installer

Small face to bearing

3880065-T0301 - Bearing Installer

Large face to wheel

Right bearing

3880070-T0301 - Bearing Installer

Small face to bearing

3880065-T0301 - Bearing Installer

Large face to wheel

  1. Fit the wheel bearings and centre sleeve using the method described on the previous page.

    2. 3880070-T0301 - Bearing Installer
  2. Fit a new circlip.
  3. Lubricate and fit new seals to the rear wheel. Lubricate the seal’s knife-edge with grease to NLGI 2 specification.
  4. Fit the rear wheel (see Rear Wheel - Installation).

Final Drive Chain Lubrication

Lubrication is necessary every 200 miles (300 km) and also after riding in wet weather, on wet roads, or any time that the chain appears dry.

Use the special drive chain lubricant as recommended in the specification section.

Correct application is critical for drive chain lubrication. Apply the lubricant for one full drive chain revolution only, then leave for eight hours before riding. This allows the lubricant’s solvent (used to thin the oil) to evaporate and the oil to 'soak' into all parts of the drive chain. If the lubricant is applied and the motorcycle is ridden shortly afterwards, the lubricant is unlikely to reach all parts and the majority will be flung off and wasted. Applying excessive amounts is not helpful under any circumstances.

It should be noted that the lubricant is applied to the drive chain to lubricate its action across the sprockets. In an O-ring chain, external lubrication does not penetrate to the bushes and rollers as the O-ring seals prevents this from happening.

caution

Do not use a power jet washer to clean the chain as this may cause damage to the chain components.

Final Drive

Exploded View – Final Drive

Final Drive Chain

For safety and to prevent excessive wear, the drive chain must be checked, adjusted and lubricated in accordance with scheduled maintenance requirements. Checking, adjustment and lubrication must be carried out more frequently for extreme conditions such as salty or heavily gritted roads.

If the drive chain is badly worn or incorrectly adjusted (either too loose or too tight) the drive chain could jump off the sprockets or break.

warning

A drive chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing an accident. Never neglect chain maintenance.

note
  • Lubrication of the drive chain should ideally be carried out with the motorcycle set up so that the rear wheel is free to rotate.
  • The drive chain must be adjusted with the motorcycle in an upright position, resting on its wheels, and with no additional weight on it.

Final Drive Chain Free-Movement Inspection

  1. Maximum movement position

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Place the motorcycle on a level surface and hold it in an upright position with no weight on it.
  2. Rotate the rear wheel by pushing the motorcycle to find the position where the chain is tightest, and measure the vertical movement of the chain midway between the sprockets.
  3. If correct, the vertical movement of the drive chain midway between the sprockets should be 20-30 mm.

Final Drive Chain Free-Movement Adjustment

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

The vertical movement of the drive chain must be in the range 20-30 mm.

  1. Loosen the wheel spindle nut.
  2. Loosen the lock nuts on both the left hand and right hand chain adjuster bolts.
  3. Moving both adjusters by an equal amount, turn the adjuster bolts clockwise to increase chain free movement and anticlockwise to reduce chain free movement.

    1. Adjuster bolt

    2. Adjuster bolt lock nut

    3. Rear wheel spindle nut
  4. When the correct amount of chain free movement has been set, push the wheel into firm contact with the adjusters. Tighten both adjuster lock nuts to 20 Nm and the rear wheel spindle nut to 110 Nm.
  5. Repeat the chain adjustment check. Readjust if necessary.

    6. warning

    Operation of the motorcycle with insecure adjuster lock nuts or a loose wheel spindle may result in impaired stability and handling of the motorcycle. This impaired stability and handling may lead to loss of control or an accident.

  6. Check the rear brake effectiveness. Rectify if necessary.

warning

It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.

Final Drive Chain and Sprocket Wear Inspection

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Measure across 20 links

  2. Weight
  1. Remove the chain guard.
  2. Stretch the chain taut by hanging a 10 - 20 kg (20 - 40 lb) weight on the chain.
  3. Measure the length of 20 links on the straight part of the chain from pin centre of the 1st pin to the pin centre of the 21st pin. Since the chain may wear unevenly, take measurements in several places.
  4. If the length exceeds the maximum service limit of 319 mm, the chain must be replaced.
  5. Rotate the rear wheel and inspect the drive chain for damaged rollers, and loose pins and links.
  6. Also inspect the sprockets for unevenly or excessively worn or damaged teeth.
  7. If there is any irregularity, have the drive chain and/or the sprockets replaced by an authorised Triumph dealer.
  8. Refit the chain guard, tightening the fixings to 4 Nm.

warning

Never neglect chain maintenance and always have chains installed by an authorised Triumph dealer.

Use a genuine Triumph-supplied chain as specified in the Triumph Parts Catalogue.

The use of non-approved chains may result in a broken chain or may cause the chain to jump off the sprockets leading to loss of motorcycle control or an accident.

caution

If the sprockets are found to be worn, always replace the sprockets and drive chain together.

Replacing worn sprockets without also replacing the chain will lead to premature wear of the new sprockets.

Drive Chain Replacement

Rivet link type

As the drive chain passes through the swinging arm casting, the chain must be split for removal from the motorcycle. Removal of the swinging arm is not required for drive chain replacement. The following instructions for the replacement of rivet link type drive chains requires the use of T3880027 - Chain Link Tool Kit.

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Support the motorcycle on a stand so the rear wheel is clear of the ground.
  2. Insert the hollow chain cutting tail piece into the tool body so its larger diameter end is facing towards the large pressure screw as shown.

    1. T3880027 - Chain Link Tool Kit

    2. Large pressure screw

    3. Chain cutting tail piece
  3. Position the chain to the tool ensuring that the chain link pin which is to be removed is aligned with the holes in the chain cutting tail piece and the large pressure screw. Tighten the large pressure screw by hand to grip the chain.

    1. T3880027 - Chain Link Tool Kit

    2. Large pressure screw

    3. Chain

    4. Chain cutting tail piece
  4. Insert the small pressure screw into the larger pressure screw as shown below, until the cutting pin on the small pressure screw contacts the link pin. Ensure that the cutting pin is centralised on the link pin to be removed.

    1. T3880027 - Chain Link Tool Kit

    2. Small pressure screw
  5. Retain the tool body then tighten the small pressure screw until the link pin is pressed out from the chain.
  6. Repeat steps 3 to 5 on the remaining chain link pin.
  7. Remove the tool and separate the two ends of the chain.
  8. Remove the chain cutting tail piece from the body.

    9. caution

    The replacement chain is supplied in a split condition, complete with a link kit to join the two ends.

    caution

    The component parts of the new link kit are coated with a special grease which must not be removed. Removal of this special grease will severely reduce the service life of the chain.

  9. Use the old drive chain to pull the new chain into position as follows: Temporarily attach the end of the new chain to a free end of the old chain using the old connector link. Carefully pull the other end of the old chain to pull the new chain around the sprockets.

    10. caution

    Do not use the new connector link as the special grease on it may be removed.
  10. Using the new link supplied with the chain kit, join the two ends of the chain. Ensure that the O-rings are positioned as shown below and the link plate is fitted with its markings facing outwards.

    1. O-rings

    2. Link

    3. Link plate
  11. Insert the riveting tail piece into the tool body so its larger diameter end is facing towards the large pressure screw as shown.

    12. caution

    The T3880027 - Chain Link Tool Kit includes two link plate holders, one is for riveted link plates (marked PH5060R), the other is for link plates retained by a spring clip (marked PH4060C). The holder for riveted link plates has a shallow groove to allow for chain link clearance, the holder for clipped link plates has a deep groove to allow for chain link clearance.

  12. Insert the link plate holder (marked PH5060R) into the large pressure screw.

    1. Tool body

    2. Large pressure screw

    3. Link plate holder (marked PH5060R)

    4. Riveting tail piece
  13. Position the tool to the chain. Ensure the link plate holder is correctly located in the large pressure screw.

    1. Tool body

    2. Link plate holder (marked PH5060R)

    3. Link plate

    4. Link

    5. Large pressure screw
  14. Locate the split link pins such that the pins will enter the groove in the link plate holder when the link plate is pressed on to the link.

    1. Link plate holder

    2. Link plate

    3. Chain link

    4. Link plate holder groove
  15. Retain the tool body and tighten the large pressure screw until the link plate is pressed fully onto the link.
  16. Back off the pressure screw, slide the tool assembly to one side and check that the split link is correctly assembled.
  17. Remove the link plate holder from the tool. Do not remove the riveting tail piece from the tool
  18. Insert the flare pin into the large pressure screw.

    1. Tool body

    2. Large pressure screw

    3. Riveting tail piece

    4. Flair pin
  19. Locate one of the split link pins into the riveting tail piece and screw the large pressure screw in until the flare pin contacts the split link end. Ensure the split link pin is centrally located on the flare pin.
  20. Retain the tool body and tighten the large pressure screw until the split link end is riveted-over.

    1. Tool body

    2. Large pressure screw

    3. Flare pin
  21. Back off the large pressure screw and rivet the remaining split link pin as described above.
  22. Remove the tool from the chain and check that both the split link pins are correctly riveted as shown below.

    1. Correct riveting

    2. Insufficient riveting

    3. Excessive riveting

    4. Riveting off-centre

warning

If either split link pin is not correctly riveted, the split link must be removed and replaced with a new link. Never operate the motorcycle with an incorrectly riveted split link as the link could fail resulting in an unsafe riding condition leading to loss of control and an accident.

Front Sprocket - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Bend back the front sprocket lock washer.
  2. Have an assistant sit on the motorcycle, select sixth gear and apply the front and rear brakes hard.
  3. Loosen the front sprocket nut.

    1. Nut

    2. Lock washer

    3. Front sprocket
  4. Remove the front sprocket nut and discard the lock washer.
  5. Set the drive chain adjustment to allow maximum free play in the drive chain.

    6. note
    • Note the orientation of the front sprocket for installation.
  6. Disengage the front sprocket from the drive chain and slide it off the output shaft.

Front Sprocket - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit the front sprocket, as noted for removal, and engage it with the drive chain.
  2. Fit a new lock washer engaging it with the output shaft splines, and fit the sprocket nut hand tight.

    1. Nut

    2. Lock washer

    3. Front sprocket
  3. Have an assistant sit on the motorcycle, select sixth gear and apply the front and rear brakes hard.
  4. Tighten the front sprocket nut to 85 Nm.
  5. Secure the front sprocket nut in position by bending the lock washer down to contact one of the nut flats.

Perform the following operations:

Final Drive - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    caution

    Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above the ground.

  1. Place the wheel on wooden blocks with the drive sprocket uppermost.
  2. Gently lever the drive flange from the wheel hub.

    1. Drive flange
  3. Remove the cush drive rubbers.

    1. Cush drive

Rear Sprocket Carrier Bearings - Disassembly

Perform the following operations:

  1. Remove and discard the seal.

    1. Sprocket carrier

    2. Seal
  2. Remove and discard the bearing circlip.

    1. Sprocket carrier

    2. Circlip

    warning

    Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries if suitable protective apparel is not worn.

    caution

    To prevent sprocket carrier damage and to aid bearing removal, always apply force evenly on both sides of the bearing to prevent it from 'tipping' and becoming stuck. Application of uneven force will lead to difficulty in removing the bearing and to a damaged drive flange.

  3. Turn the sprocket carrier over, and use a pin punch to drift out the ball bearing.

    1. Sprocket carrier

    2. Ball bearing

Rear Sprocket Carrier and Cush Drive - Inspection

  1. Check the cush drive rubbers for deterioration and cracks.
  2. Inspect the sprocket teeth for wear, damage and chips.
  3. Check the wheel and drive flange for wear, cracks and damage.

Rear Sprocket Carrier Bearings - Assembly

warning

When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.

Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.

  1. Position the ball bearing, marked side facing outwards, to the drive flange.
  2. Using a suitable press, fully insert the ball bearing into the sprocket carrier.
  3. Fit a new circlip.
  4. Install a new seal, marked side facing outwards, to the sprocket carrier.
  5. Lubricate the seal’s knife-edge with grease to NLGI 2 specification.
  6. Install the cush drive rubbers to the wheel hub.
  7. Fit the spacer to the wheel hub as noted for removal.
  8. Refit the sprocket carrier to the wheel.

Final Drive - Installation

  1. Install the cush drive rubbers to the wheel.
  2. Refit the drive flange to the wheel.
  3. Refit the rear wheel (see Rear Wheel - Installation).

Rear Sprocket - Removal

caution

Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above the ground.

Perform the following operations:

  1. Place the wheel on wooden blocks with the drive chain sprocket uppermost.

    2. note
    • If the studs for the rear sprocket become loose or removed, they must be replaced.
  2. Evenly and progressively, remove and discard the rear sprocket lock nuts.

    3. note
    • Note the orientation of the rear sprocket for installation.
  3. Remove the rear sprocket.

    1. Lock nut

    2. Sprocket

Rear Sprocket - Installation

caution

Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above the ground.

  1. If necessary, replace any rear sprocket studs that have been loosened or removed as follows:

    1. Height of stud (16.5 to 18.5 mm)
  2. Fit the rear sprocket to the sprocket carrier as noted for removal.
  3. Fit new lock nuts, evenly and progressively tighten to 55 Nm.

Perform the following operations:

Frame and Bodywork

Exploded View - Frame and Fixings

Exploded View - Rear Subframe

Exploded View - Cockpit and mountings

Exploded View - Side Panels

Exploded View - Front Mudguard

Exploded View - Rear Mudguard

Exploded View - Rear Panels

Exploded View - Seat

Exploded View - Footrests and Mountings

Exploded View - Side Stand

Exploded View - Belly Pan

Exploded View - Grab Handles

Exploded View - Mirrors

General Frame Inspection

  1. Inspect the frame, bodywork and footrests for accident and other damage, cracks, splits and general dilapidation. Check all fixings for security. If any faults are found, rectify as necessary. If any faults with the frame are found, the frame must be replaced; repairs to the frame are not permitted.

    2. warning

    If the motorcycle is involved in an accident or collision it must be taken to an authorised Triumph dealer for inspection and repair before it is ridden again.

    warning

    The frame must not be modified in any way. Any modification to the frame, such as welding or drilling, may weaken the structure causing an unsafe riding condition leading to loss of motorcycle control and an accident.

  2. Check the operation of the side stand to make sure it is securely held in the retracted position by the spring. Rectify any faults.

warning

If the return spring is faulty, the side stand could extend whilst the motorcycle is being ridden. This will cause an unsafe riding condition, which could lead to loss of motorcycle control and an accident.

Bank Angle Indicators

  1. Inspect the bank angle indicators on the rider's footrests for wear. The bank angle indicators are worn out when 5 mm of the bank indicator remains.

    1. Bank angle indicator

    2. Wear limit measurement

    warning

    Use of a motorcycle with bank angle indicators worn beyond the maximum limit (when the bank angle indicator is worn to a minimum 5 mm in length) will allow the motorcycle to be banked to an unsafe angle. Therefore, always replace the bank angle indicator pegs when they are worn to 5 mm in length.

    Banking to an unsafe angle may cause instability, loss of motorcycle control and an accident.

    warning

    The bank angle pegs must not be used as a guide to how far the motorcycle may be safely banked. This depends on many various conditions including, but not limited to, road surface, tyre condition and weather. Banking to an unsafe angle will lead to loss of motorcycle control and an accident.

Seat - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

caution

To prevent damage to the seats or seat covers, care must be taken not to drop the seats. Do not lean the seats against the motorcycle or any surface which may damage the seats or seat covers. Instead, place the seats, with the seat cover facing upwards, on a clean, flat surface which is covered with a soft cloth.

Do not place any item on the seats which may cause damage or staining to the seat covers.

note
  • The passenger seat or the seat cowl must be removed prior to removing the rider’s seat.

Passenger Seat/Seat Cowl

  1. Insert the ignition key into the seat lock and turn it anticlockwise while pressing down on the front of the seat. This will release the passenger seat from its lock and allow it to be slid forwards for complete removal from the motorcycle

    1. Seat lock

    2. Passenger seat shown

Rider’s Seat

  1. Remove the passenger seat/seat cowl as described above.
  2. Remove the fixing at the rear of the seat.
  3. Lift the seat up from the back and slide rearwards for complete removal from the motorcycle.

    1. Fixing

Seat - Installation

Rider’s Seat

  1. Engage the seat’s tongue under the fuel tank.
  2. Lower the rear of seat ensuring its hooks locate into the slots on the seat bridge.
  3. Fit the fixing to the rear of the seat and tighten to 9 Nm.

    1. Fixing

    warning

    The rider's seat is only correctly retained and supported once the fixing is correctly tightened. Never ride the motorcycle with the fixing loose or removed, as the rider’s seat will not be secure and may move.

    A loose or detached seat may cause loss of motorcycle control and an accident.
  4. Grasp the seat and pull firmly upwards to ensure that it is securely retained.
  5. Refit the passenger seat/seat cowl as described below.

Passenger Seat/Seat Cowl

  1. Engage the seat's tongue into the rear seat bridge.
  2. Align the locating peg to the lock and press down engaging the seat lock. An audible click can be heard when the seat is fully engaged in its lock.

    1. Locating peg

    2. Lock

    3. Rear seat bridge

    4. Tongue

    warning

    Never ride the motorcycle with the passenger seat or seat cowl detached or removed.

    To prevent detachment of the seat during riding, after fitting always grasp the seat and pull firmly upwards. If the seat is not correctly secured it will detach from the lock. A loose or detached seat could cause loss of motorcycle control and an accident.

  3. Grasp the seat and pull firmly upwards to ensure that it is securely retained.

Mirrors - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Remove the handlebar end weight. Discard the fixing.

    2. note
    • Note the orientation of the mirror for installation.
  2. Loosen the mirror pinch bolt and remove the mirror.

    1. Fixing (bar end weight)

    2. Bar end weight

    3. Pinch bolt

Mirrors - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Refit the mirror as noted for removal and tighten the pinch bolt to 1 Nm.
  2. Refit the right hand handlebar end weight and secure with a new fixing. Do not fully tighten the fixing at this stage.

    1. Fixing (bar end weight)

    2. Bar end weight

    3. Pinch bolt
  3. Position the mirrors to give rear visibility in the riding position. Do not rotate the mirror beyond 75°, measured from the vertical section of the mirror arm.

    1. Fixing (bar end weight)
  4. Tighten the handlebar end weight fixing to 8 Nm.

Side Stand - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Raise and support the motorcycle.

    2. warning

    Wear hand, eye and face protection when unhooking the stand spring. Take great care to minimise the risk of personal injury and loss of components.

    note
    • Note the orientation of the side stand spring so that it can be fitted in its correct orientation upon installation.
  2. With the side stand in the up position, unhook the spring from the side stand and remove it from the motorcycle.
  3. Unscrew and discard the lock nut from the side stand pivot bolt.
  4. Unscrew the pivot bolt and remove the stand from the bike.

    1. Side stand

    2. Pivot bolt

    3. Lock nut

    4. Spring

Side Stand - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Lubricate the pivot bolt shoulder and side stand pivot with multipurpose grease.
  2. Fit the stand to the bike and insert the pivot bolt, tightening it to 20 Nm.
  3. Fit a new lock nut to the pivot bolt. Hold the pivot bolt to prevent rotation and tighten the lock nut to 9 Nm.

    4. warning

    Wear hand, eye and face protection when fitting the stand spring. Take great care to minimise the risk of personal injury and loss of components.

  4. In the orientation noted during removal, hook the spring onto its frame lug then carefully hook it onto the stand lug.

    1. Side stand

    2. Pivot bolt

    3. Lock nut

    4. Spring
  5. Check the operation of the side stand before riding the motorcycle. Ensure the spring holds the stand securely in the retracted position.

Front Mudguard - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Remove the four fixings securing the front mudguard to the front forks and carefully remove the mudguard.

    1. Fixings

    2. Front mudguard

Front Mudguard - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Carefully position the front mudguard to the front forks and secure with the four fixings. Tighten the fixings to 6 Nm.

    1. Fixings

    2. Front mudguard

Flyscreen - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    warning

    Operation of the motorcycle with an incorrectly adjusted instrument panel is dangerous.

    An incorrectly adjusted instrument panel will result in loss of instrument vision when riding and may cause a distraction leading to loss of control of the motorcycle and an accident.

    Always adjust the instrument panel to provide sufficient vision of the instruments before riding the motorcycle.

    caution

    Do not press directly onto the display panel.

    Only adjust the position of the instrument display using the adjustment handle.

    Pressing directly on the instrument display panel may damage the display panel.

    note
    • Note the position of the instrument screen inso that it can be returned to its original setting.
  1. Adjust the instrument display panel to its lowest position.

    1. Adjustment handle
  2. Release the two fixings and remove the fascia panel.

    1. Fascia panel

    2. Fixings
  3. Release the fixing and remove the flyscreen assembly. Disconnect the electrical connector for the ambient air pressure sensor for complete removal.

    1. Fascia panel

    2. Flyscreen Assembly

    3. Fixings
  4. Release the two rivets and two fasteners and remove the air intake duct from the flyscreen assembly.

    1. Rivets

    2. Flyscreen assembly

    3. Fasteners

    4. Duct
  5. Release the two fixings from the air intake finisher.
  6. Press the flyscreen locating tang inwards to release the air intake finisher. Remove the finisher.

    1. Fixings

    2. Flyscreen locating tang

    3. Air intake finisher

Flyscreen - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit the air intake finisher to the flyscreen ensuring that the finisher is located correctly onto the locating tang. Secure with two fixings and tighten to 1.5 Nm.

    1. Fixings

    2. Flyscreen locating tang

    3. Air intake finisher
  2. Fit the air intake duct to the flyscreen assembly and secure with two fasteners and two rivets.

    1. Rivets

    2. Flyscreen assembly

    3. Fasteners

    4. Air intake duct

    1. Fasteners

    2. Air intake finisher

    3. Air intake duct
  3. Position the assembly to the motorcycle and reconnect the electrical connector for the ambient air temperature sensor.
  4. Ensure that the flyscreen and air intake duct assembly is correctly positioned to the front subframe and secure with the fixing. Tighten the fixing to 3 Nm.

    1. Flyscreen assembly

    2. Fixing
  5. Fit the fascia panel to the front subframe ensuring that its locating lugs are fully inserted into the rubber grommets. Secure with the two fixings and tighten to 3 Nm.

    1. Fascia panel

    2. Locating lugs

    3. Rubber grommets

    4. Fixings

Perform the following operations:

Side Panel - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Detach the grommet on the side panel infill from the lug on the underside of the frame.

    1. Side panel infill (left side panel shown)

    2. grommet

    3. lug
  2. Detach the side panel rear locating lug from the grommet on the side panel bracket.

    1. Rear mounting lug

    2. Grommet

    3. Side panel bracket

    note
    • The grommet on the front locating lug may withdraw with the side panel assembly when detaching the front mounting.
  3. Detach the front mounting from the locating lug on the radiator and remove the side panel assembly.

    1. Front mounting

    2. Locating lug
  4. If required, remove the two fixings and remove the radiator finisher.

    1. Radiator finisher

    2. M6 x 16 mm fixing

    3. M6 x 12 mm fixing
  5. If required, remove the fixing and remove the side panel bracket.

    1. Side panel bracket

    2. Fixing

Side Panel - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. If removed, fit the side panel bracket to the radiator and secure with the lower fixing. Tighten the fixing to 8 Nm.
  2. If removed, fit the radiator finisher to the radiator and secure as follows:

    1. Radiator finisher

    2. M6 x 16 mm fixing

    3. M6 x 12 mm fixing
  3. Tighten both fixings to 4 Nm.
  4. If detached during removal, refit the grommet to the front mounting lug on the radiator.

    1. Front mounting lug

    2. Grommet
  5. Position the side panel assembly to the motorcycle and align the front mounting to the locating lug on the radiator.

    1. Front mounting lug
  6. Secure the rear mounting lug into the grommet on the side panel bracket.

    1. Lug

    2. Grommet

    3. Side panel bracket
  7. Secure the grommet on the side panel infill to the lug on the underside of the frame.

    1. Side panel infill

    2. Grommet

    3. lug

Perform the following operations:

Belly Pan - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid skin damage, always allow the hot parts to cool before working on the exhaust system.

  1. Release the fixing for the catalytic converter heat shield and remove the shouldered washer.
  2. Move the heat shield forward to detach it from its locating lugs and remove from the motorcycle.
  3. Release the two fixings that secure the rear belly pan mountings to the sump.
  4. Carefully slide the belly pan forward to detach it from the front mounting grommets.

    1. Catalytic converter heat shield

    2. Fixing

    3. Belly pan

    4. Rear mounting fixings

    5. Front mounting grommet (right side visible, left side similar)

    6. Front mounting

    7. Belly pan front mounting slot

Belly Pan - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Position the belly pan onto the front mounting grommets and slide rearwards to locate the front mounting slots.
  2. Secure the rear mountings to the sump with the two fixings and tighten to 7 Nm.
  3. Check that the rubber grommets are fitted to the heat shield retaining lugs on the catalytic converter.
  4. Slide the heat shield onto its retaining lugs on the catalytic converter. Fit the fixing and shouldered washer and tighten to 5 Nm.

    1. Catalytic converter heat shield

    2. Fixing

    3. Belly pan

    4. Rear mounting fixings

    5. Front mounting grommet (right side visible, left side similar)

    6. Front mounting

    7. Belly pan front mounting slot

Rear Hugger and Chain Guard Moulding - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Release the fixing securing the chain guard section of the moulding to the swinging arm.

    1. Chain guard

    2. Fixing
  2. Release the three fixings located at the front of the rear hugger and remove the rear hugger.

    1. Rear hugger

    2. Fixings
  3. If required, remove the fixing and remove the rear hugger mounting bracket from the swinging arm.

    1. Bracket

    2. Fixing

Rear Hugger and Chain Guard Moulding - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. If removed, fit the rear hugger mounting bracket to the swinging arm and tighten its fixing to 4 Nm.
  2. Fit the rear hugger and chain guard moulding to the swinging arm and secure with the four fixings. Tighten the fixings to 4 Nm.

Rear Footrest Hangers - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the two fixings and remove the footrest hanger.

    1. Rear footrest hanger mountings

    2. Fixings
  2. Repeat for the other side.

Rear Footrest Hangers - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Position the rear footrest hanger to the rear frame and secure with the two fixings. Tighten the fixings to 27 Nm.

    1. Rear footrest hanger mountings

    2. Fixings
  2. Repeat for the other side.

Perform the following operations:

Rear Panel - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Remove the fixings and remove the rear panels.

    1. Rear panels

    2. Fixings

Rear Panel - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit the left hand rear panel to the frame. Ensure that the locating lug aligns with its slot in the lower panel.

    1. Rear panel

    2. Locating lug

    3. Slot, for locating lug
  2. Secure the panel with the fixings and tighten to 3 Nm.
  3. Fit the right hand rear panel in the same way.

    1. Rear panels

    2. Fixings

Perform the following operations:

Rear Direction Indicator Hanger - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the routing of the rear indicator harness for installation.
  1. Disconnect the electrical connector for the rear direction indicators.

    2. note
    • Note the position and orientation of the mounting plate and the seal of the rear direction indicator hanger for installation.
    • Note the position and orientation of the flanged sleeves for installation.
  2. Release the four fixings and remove the rear direction indicator hanger. Collect the four flanged sleeves from beneath the fixings.

    1. Electrical connector

    2. Fixings and flanged sleeves

    3. Rear direction indicator hanger

Rear Direction Indicator Hanger - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Refit the flanged sleeves into the holes on the rear subframe cross member as noted during removal.

    2. note
    • Route the rear direction indicator harness as noted for removal.
  2. With the mounting plate and the seal positioned as noted for removal, fit the rear direction indicator hanger and tighten its fixings to 8 Nm.
  3. Connect the electrical connector for the rear direction indicators.

    1. Electrical connector

    2. Fixings and flanged sleeves

    3. Rear direction indicator hanger

Perform the following operations:

note
  • Check the operation of the rear direction indicators and license plate light. Rectify any faults as necessary.

Rear Undertray - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

note
  • Note the routing of the rear light harness during rear undertray removal.
  1. Release the two fixings and remove the rear undertray towards the rear of the motorcycle.

    1. Rear undertray

    2. Fixing (left hand side shown)
  2. Disconnect the electrical connector from the rear light for complete removal.

Rear Undertray - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Reconnect the rear light electrical connector.

    2. note
    • Route the rear light harness as noted during removal.
  2. Position the rear undertray to the motorcycle as follows:

    1. Locating lugs

    2. Battery tray slots

    3. Rear light mounting rubber

    4. Rear light
  3. Secure the rear undertray with the two fixings and tighten to 3 Nm.

Perform the following operations:

note
  • Check the operation of all rear lights. Rectify any faults as necessary.

Seat Bridge - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the routing of the alarm connector block harness for installation.
  1. Remove the two fixings securing the rear undertray to the seat bridge.

    1. Rear undertray

    2. Fixing (left hand side shown)
  2. Detach the alarm connector block from its clip on the seat bridge.
  3. Remove the two seat lock fixings. Discard the fixings.
  4. Remove the four fixings securing the seat bridge to the rear subframe.

    1. Alarm connector block

    2. Seat bridge

    3. Seat lock fixings

    4. Seat bridge fixings

    note
    • The seat lock mechanism and USB socket are mounted to a bracket which clips to the underside of the seat bridge. Note the position and orientation of the bracket for installation.
    • Note the routing of the seat lock cable and USB socket harness for installation.
  5. Carefully detach the seat lock bracket from the underside of the seat bridge and remove the seat bridge.

    1. Seat lock bracket

    2. Seat bridge (underside)

    3. Seat lock mechanism

    4. USB socket

    note
    • Note the position and orientation of the seat lock mechanism and USB socket on the bracket for installation.
  6. If required, detach the seat lock mechanism and USB socket from the clips on the bracket and remove the bracket.

    1. Seat lock bracket

    2. Seat lock mechanism

    3. USB socket

    4. Clips

Seat Bridge - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. If removed, clip the seat lock mechanism and USB socket into the seat lock bracket as noted during removal.

    1. Seat lock bracket

    2. Seat lock mechanism

    3. USB socket

    4. Clips
  2. Align the seat lock bracket to the seat bridge as noted during removal. Use finger pressure to press the bracket assembly into position on the seat bridge and engage its clips.

    1. Seat lock bracket

    2. Seat bridge (underside)

    3. Seat lock mechanism

    4. USB socket
  3. Position the seat bridge assembly to the motorcycle ensuring that the seat lock cable, USB socket harness and alarm connector block harness are routed as noted during removal. Secure with the four fixings and tighten to 5 Nm.
  4. Fit new seat lock fixings and tighten to 5 Nm.
  5. Attach the alarm connector block to its clip on the seat bridge.

    1. Alarm connector block

    2. Alarm connector block clip

    3. Seat bridge

    4. Seat lock fixings

    5. Seat bridge fixings
  6. Refit the fixings securing the rear undertray to the seat bridge. Tighten to 3 Nm.

Perform the following operations:

Battery Tray - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

note
  • Note the routing of the seat lock cable and all electrical harnesses for installation.
  1. Detach the starter solenoid and main fuse from the fall detection switch bracket.
  2. Disconnect the electrical connectors from the starter solenoid.
  3. Disconnect the main fuse electrical connector, identified as the white connector located below the fall detection switch mounting.
  4. Position the starter solenoid, main fuse and starter leads aside.
  5. Release the two fixings and detach the fall detection switch mounting bracket from the battery tray.

    1. Fall detection switch bracket

    2. Fixings
  6. Detach the two relay clusters from their locating tangs on the battery tray.

    1. Relay clusters

    2. Locating tangs
  7. Disconnect the ABS modulator multiplug (see ABS Electrical Connectors).
  8. Remove the four fixings securing the rear light bracket to the rear subframe.

    1. Real light mounting bracket

    2. Fixings
  9. Remove and discard the fixing and detach the rear brake fluid reservoir from the frame. Ensure the brake fluid reservoir is supported in an upright position. Position the rear brake hose bracket aside.
  10. Remove and discard the two fixings securing the underside of the battery tray.

    1. Fixing (left hand side shown)

    2. Battery tray (underside)
  11. Remove and discard the fixing securing the harness conduit and battery tray to the rear subframe. Collect the washer.

    1. Rear harness conduit

    2. Battery tray

    3. Fixing
  12. Carefully raise the rear harness conduit clear of the rear subframe and position aside.

    13. note
    • Note the position of the three remaining battery tray fixings for installation.
  13. Remove and discard the remaining three fixings securing the battery tray to the rear subframe. Collect the washers.

    1. Battery tray

    2. Fixings
  14. Carefully manoeuvre the battery tray upwards through the rear subframe and remove it from the motorcycle.

Battery Tray - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Carefully manoeuvre the battery tray into position on the rear subframe. Secure the battery tray with three new fixings and washers, in the positions noted during removal. Do not fully tighten at this stage.

    1. Battery tray

    2. Fixings
  2. Secure the underside of the battery tray with two new fixings. Do not fully tighten at this stage.

    1. Fixing (left hand side shown)

    2. Battery tray (underside)
  3. Secure the rear light bracket to the rear subframe with the four fixings. Do not fully tighten at this stage.

    1. Real light mounting bracket

    2. Fixings
  4. Tighten the left hand rear battery tray fixing to 4 Nm.
  5. Carefully lower the harness conduit into position on the battery tray. Secure the harness conduit and battery tray to the rear subframe with a new fixing and washer and tighten to 4 Nm.

    1. Rear harness conduit

    2. Battery tray

    3. Fixing
  6. Tighten all remaining battery tray fixings to 4 Nm.
  7. Tighten the rear light bracket fixings to 12 Nm.
  8. Reconnect the ABS modulator multiplug (see ABS Electrical Connectors).
  9. Attached the two relay clusters to the tangs on the battery tray as noted during removal.

    1. Relay clusters

    2. Locating tangs
  10. Refit the bracket for the fall detection switch and tighten the fixings to 4 Nm.

    1. Fall detection switch bracket

    2. Fixings
  11. Reconnect the main fuse electrical connector.
  12. Reconnect the electrical connectors to the starter solenoid.
  13. Fit the starter solenoid onto its locating tangs on the fall detection switch bracket. Ensure that the solenoid is pushed fully onto the tangs.
  14. Fit the main fuse to its clip on the fall detection switch bracket.
  15. Reposition the rear brake fluid reservoir and rear brake hose bracket to the frame. Secure with a new fixing and tighten to 6 Nm.

Perform the following operations:

Rear Subframe - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the two fixings and remove the seat lock. Discard the fixings.

    1. Seat lock

    2. Fixings

    note
    • The seat lock bracket fixings also secure the ABS modulator bracket to the rear subframe.
  2. Release the two fixings and remove the seat lock bracket. discard the fixings.

    1. Seat lock bracket

    2. Fixings

    3. ABS modulator bracket

    note
    • Note the positions of the three grommets on the ABS modulator bracket.
  3. Release the fixing and remove the ABS modulator bracket. Collect the flanged sleeve. Discard the fixing.

    1. ABS modulator bracket

    2. Fixing

    3. Flanged sleeve

    note
    • Note the routing of the evaporative system hoses for installation.
  4. Release the fixing and remove the wire guide for the evaporative system hoses. Detach the hoses from the rear subframe.

    1. Wire guide

    2. Fixing

    3. Evaporative hoses
  5. Release the four fixings and remove the rear subframe assembly. Discard the lock nuts from the upper fixings.

    1. Upper fixing (left hand side shown)

    2. Lower fixing
  6. Release the bolt and lock nut securing the two halves of the rear subframe. Discard the lock nut.

    1. Bolt

    2. Lock nut

    note
    • The two halves of the rear subframe are joined at the cross member by a locating dowel. The locating dowel may remain seated in either half of the rear subframe as the two halves are separated.
  7. Separate the two halves of the rear subframe. Collect the locating dowel.

    1. Locating dowel
  8. If required remove the infill panels from both sides of the rear subframe. Inspect the infill panel locating lugs for damage and replace as necessary.

Rear Subframe - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. If removed, refit the infill panels to both halves of the rear subframe.
  2. Assemble the two halves of the rear subframe together using the locating dowel as noted during removal.

    1. Locating dowel
  3. Secure the two halves of the rear subframe with the bolt and new lock nut. Do not fully tighten at this stage.

    1. Bolt

    2. Lock nut
  4. Position the rear subframe assembly to the motorcycle and secure as follows:

    1. Upper fixing (left hand side shown)

    2. Lower fixing
  5. Tighten the rear subframe fixings as follows.
  6. Position the evaporative hoses to the rear subframe as noted during removal. Fit the wire guide and tighten its fixing to 7 Nm.

    1. Wire guide

    2. Fixing

    3. Evaporative hoses
  7. Ensure that the three grommets are fitted to the ABS modulator bracket as noted during removal. Fit the flanged sleeve to the right hand grommet.
  8. Fit the seat lock bracket to the ABS modulator bracket, inserting its locating sleeves into the grommets as shown.

    1. ABS modulator bracket

    2. Grommets

    3. Flanged sleeve

    4. Seat lock bracket
  9. Position the ABS modulator bracket assembly to the rear subframe and secure with new fixings. Tighten the fixings to 9 Nm.
  10. Fit the seat lock to its bracket ensuring that the barrel is located into its opening in the rear subframe infill. Tighten the new fixings to 9 Nm.

    1. Seat lock

    2. Fixings

Perform the following operations:

Fuel Cap Lock - Removal

warning

Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.

A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly.

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

A new filler cap is supplied without the barrel lock. Therefore, the barrel in the original filler cap will need to be removed and fitted to the filler cap.

  1. Remove the fuel tank (see Fuel Tank - Removal).
  2. Drain the fuel tank into a suitable fuel proof container.
  3. Open the fuel cap on the original fuel tank.
  4. Remove the screws shown in the illustration below, then remove the fuel filler cap.

    1. Screws

    2. Filler cap

    note
    • When removing the lock housing and sealing ring, the four sealing ring springs will become loose.
    • Note the position and orientation of the lock housing, sealing ring and springs for installation.
  5. Remove the screws, then carefully remove the lock housing and sealing ring from the fuel cap and collect the four springs.

    1. Screws

    2. Lock housing

    3. Sealing ring
  6. Remove the O-ring from the fuel cap.

    1. O-ring
  7. Remove the two washers (one washer is behind the other).

    1. Washers
  8. Using a suitable flat blade screwdriver, release the locking device for the barrel lock and push the barrel out of the fuel cap.

    1. Locking device

    2. Barrel lock
  9. If still attached, remove the barrel lock seal.

    1. Seal

    2. Barrel lock

Fuel Cap Lock - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Insert the key into the barrel lock.

    1. Key

    2. Barrel lock
  2. Align the locking device on the barrel to the small slot in the upper left hand side of the housing, as indicated in the illustration below.

    1. Slot

    2. Housing

    3. Locking device
  3. Push the barrel lock half way into the fuel cap.
  4. Turn the lock clockwise until the key is vertical in the fuel cap.

    5. note
    • An audible click can be heard when the lock is pushed fully into the fuel cap.
  5. Push the barrel fully into the fuel cap.
  6. Fit the two washers to the fuel cap.
  7. Fit the O-ring to the fuel cap.
  8. Fit the lock housing, sealing ring and springs as noted during removal and secure with the screws.
  9. Test the lock for normal operation.
  10. Fit the filler cap to the fuel tank and secure with the screws shown in the illustration below. Tighten the screws to 4 Nm.

    1. Screws

    2. Filler cap
  11. Fit the fuel tank (see Fuel Tank - Installation).
  12. Refill the fuel tank with the fuel drained earlier.

Electrical

Exploded Views

Exploded View - Instruments

Exploded View - Alternator and Starter Motor

Exploded View - Headlights

Exploded View - Rear Light and Licence Plate Light

Exploded View - Direction Indicators

Exploded View - Main Harness

Battery

Battery

warning

Under some circumstances, the battery can give off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an enclosed space.

The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.

If electrolyte gets on your skin, flush with water immediately.

If electrolyte gets in your eyes, flush with water for at least 15 minutes and SEEK MEDICAL ATTENTION IMMEDIATELY.

If electrolyte is swallowed, drink large quantities of water and SEEK MEDICAL ATTENTION IMMEDIATELY.

KEEP ELECTROLYTE OUT OF THE REACH OF CHILDREN.

warning

The battery contains harmful materials. Always keep children away from the battery whether or not it is fitted in the motorcycle.

Do not attach jump leads to the battery, touch the battery cables together or reverse the polarity of the cables as any of these actions may cause a spark which would ignite battery gases causing a risk of personal injury.

Battery Disposal

Should the battery ever require replacement, the original battery must be handed to a recycling agent who will ensure that the dangerous substances from which the battery is manufactured do not pollute the environment.

Battery Commissioning and Charging

New Battery

In order to correctly and safely commission a new battery, the battery commissioning procedure listed below must be carefully followed. This is the only battery commissioning procedure that Triumph recommends. The procedure is designed to ensure that the battery is at its best when fitted to the motorcycle, and will provide the best possible performance and reliability.

Failure to comply with this procedure may lead to reduced battery performance and/or shorten the life of the battery.

warning

The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an enclosed space.

The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.

If electrolyte gets on your skin, flush with water immediately.

If electrolyte gets in your eyes, flush with water for at least 15 minutes and SEEK MEDICAL ATTENTION IMMEDIATELY.

If electrolyte is swallowed, drink large quantities of water and SEEK MEDICAL ATTENTION IMMEDIATELY.

KEEP ELECTROLYTE OUT OF THE REACH OF CHILDREN.
  1. Ensure the VIN number printed on the anti-tamper label attached to the battery matches the motorcycle VIN.
  2. Check the battery carefully for damage.

    3. caution

    Ensure the electrolyte container part number matches the battery part number to be filled. Battery life will be greatly reduced if the incorrect volume (either too little or too much) of acid is added to the battery.

  3. Read the instructions and warnings delivered with the battery.
  4. Place the battery on a flat level surface and remove the sealing foil.
  5. Remove the battery sealing strip from the electrolyte container and save for later in this procedure. Place the sealing strip on a clean surface, with the upper side facing downwards to avoid contamination of the sealing strip. Do not break the seal on the electrolyte container.
  6. Place the electrolyte container on the battery and fill the battery according to the manufacturers instructions.
  7. After starting to fill the battery with electrolyte, allow the battery to stand for 30 minutes with the filling container in place.
  8. Check that all of the electrolyte has drained from the container. Do not remove the container at this point. If the container has not completely drained, tap the sides of the container to start the electrolyte flowing again.
  9. After the electrolyte has drained into the battery, allow the battery to stand with the electrolyte container in place for a further 2 hours.
  10. Remove the electrolyte container carefully, and dispose of immediately.
  11. Place the sealing cap strip LOOSELY over the filling holes of the battery.
  12. Charge the battery using the BatteryMate Battery Charger - See Latest Parts Catalogue for Part Number Information. Refer to the instructions supplied with the BatteryMate Battery Charger - See Latest Parts Catalogue for Part Number Information.

    13. caution

    The caps must be fitted (after charging) within two hours of filling the battery with acid. Leaving the battery open to the atmosphere for longer than is necessary will start to reverse the chemical reaction which takes place within the battery, greatly reducing the battery’s service life.

  13. After charging is complete, press down firmly with both hands to seat the caps (do not use tools or force the caps into position).
  14. Disconnect the charger and allow the battery to stand for 1 hour before fitting to the motorcycle.
  15. Fit the battery to the motorcycle, positive (red) lead first.

Battery Maintenance

The battery is a sealed type and does not require any maintenance other than checking the voltage and routine recharging such as during storage.

It is not possible to adjust the electrolyte level in the battery.

note
  • The charge level in the battery must be maintained to maximise the battery life.

With normal use of the motorcycle, the charging system will keep the battery charged. If the motorcycle is unused, the battery will gradually discharge due to battery self discharge and the continuous current drain for the clock and the engine control module memory.

The rate of battery discharge can be greatly increased by the addition of electrical security systems or other accessories.

Allowing a battery to discharge, or leaving it discharged over a period of time, causes sulphation of the lead plates within the battery.

Sulphation is a normal chemical reaction inside the battery and over a period of time sulphate will crystallise on to the lead plates making charging difficult or impossible. The result is a permanently damaged battery, which would not be covered by the motorcycle warranty.

Keeping a battery at full charge reduces the chance of it freezing in cold conditions. Allowing a battery to freeze can cause serious internal damage to the battery.

When leaving the motorcycle standing for more than a few days, regularly check the battery voltage using a digital multimeter. Should the battery voltage fall below 12.8 V, charge the battery using the BatteryMate Battery Charger - see latest Parts Catalogue for part number information. Refer to the instructions supplied with the BatteryMate Battery charger.

For extended periods of storage (beyond two weeks) the battery should be removed and the battery voltage checked regularly and charged when below 12.8 V.

Battery Already in Service

note
  • Before carrying out the following procedure the battery must be disconnected and removed from the motorcycle.

Use the guidelines in the table below for charging. Always verify the battery condition before charging, and 30 minutes after charging.

note
  • A fully charged battery should read 12.8 volts or higher after the battery has been off the charger for 30 minutes or more.
Table of Battery Charging Times

State of charge

Voltage

Action

Charge time (using BatteryMate 150-9)

100%

12.8 V - 13.0 V

None. Check at 6 months from date of manufacture

None required

75% - 100%

12.5 V - 12.8 V

May need slight charge. If no charge given, check in 3 - 4 months

3 - 6 hours

50% - 75%

12.0 V - 12.5 V

Needs charge

5 - 11 hours

25% - 50%

11.5 V - 12.0 V

Needs charge

At least 13 hours

0% - 25%

11.5 V or less

Needs recovery using BatteryMate 150-9. Retest after recovery

20 hours

Battery - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Disconnect the battery leads, negative (black) lead first.
  2. Remove the battery strap.

    1. Battery

    2. Negative (-) terminal

    3. Positive (+) terminal

    4. Battery strap

    warning

    Ensure that the battery terminals do not touch the motorcycle frame as this may cause a short circuit or spark, which would ignite battery gases causing a risk of personal injury.

  3. Take the battery out of the case.

Battery - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

warning

Ensure that the battery terminals do not touch the motorcycle frame as this may cause a short circuit or spark, which would ignite battery gases causing a risk of personal injury.

  1. Place the battery in the battery case.
  2. Reconnect the battery, positive (red) lead first and tighten the battery terminals to 4.5 Nm.
  3. Apply a light coat of grease to the terminals to prevent corrosion.
  4. Cover the positive terminal with the protective cap.

    1. Battery

    2. Negative (-) terminal

    3. Positive (+) terminal

    4. Battery strap

Fuse Identification

warning

Always replace blown fuses with new ones of the correct rating (as specified on the fuse box cover) and never use a fuse of higher rating.

Use of an incorrect fuse could lead to an electrical problem, resulting in motorcycle damage, loss of motorcycle control and an accident.

A blown fuse is indicated when all of the systems protected by that fuse become inoperative. When checking for a blown fuse, refer to the fuse identification table to establish which fuse has blown.

The fuse box is located underneath the seat.

To allow access to the fuse box, the seat must be removed (see Seat - Removal).

note
  • Numbers shown in the following illustration correspond to the position numbers in the fuse identification table.

Fuse Box

Position

Circuit Protected

Rating (Amps)

1

Accessory socket

10

2

Fuel pump

10

3

Heated handlebar grips

5

4

Ignition switch, starter circuit

15

5

Auxiliary lights

10

6

Cooling fan

10

7

ABS

25

8

Engine management system

20

9

Dip and high headlight beams

20

Relays

Identification and Location

The relays are located underneath the rider’s seat. To gain access to the relays, remove the rider’s seat (see Seat - Removal).

  1. Engine management relay (EMS)

  2. Main beam

  3. Cooling fan

  4. Brake switch

  5. Starter motor

  6. Fuel pump

  7. Horn

  8. Headlight

Diagnostics - Starter and Charging Circuits

Starting Circuit

All Triumph models are equipped with an electric start system. This system consists of a starter relay, starter motor, starter switch, side stand switch, engine stop switch, clutch switch and the sprag clutch. The starter motor is connected to the starter relay and the battery by heavy duty cables in order to supply the large currents required by the motor to start the engine. When the starter button is pressed, the relay is energised, which then allows current to the starter motor. The starter motor will not operate unless the clutch lever is pulled in. Also, the starter will not operate if the side stand is down, unless the transmission is in neutral. If the starter motor does not operate, the following basic checks must be carried out before further diagnosis is performed:

note
  • On all new models from Daytona 675 onwards which use a CAN communication, the engine will not crank if the instruments, ABS ECM, or immobiliser/chassis ECM (if fitted) are disconnected.

Rectify any defects as necessary.

General Fault Finding – Starter Motor and Relay

Symptom

Possible cause(s)

Starter relay does not click, starter motor does not turn

Battery discharged or defective

Blown main or starter relay fuse

Defective starter relay wiring or starter switch

Check that the side stand, transmission and clutch lever are positioned for engine starting i.e. transmission in neutral, clutch lever pulled in and the side stand down

Defective alarm system - ensure any alarm fitted is working correctly

Starter motor turns slowly

Battery discharged or defective

Loose, corroded or dirty battery connections

Loose, corroded or dirty starter motor or starter relay connections

Defective starter motor

Loose, corroded or dirty battery ground connections

Starter relay clicks but engine does not turn over

Battery discharged or defective

Crankshaft does not turn due to engine defect

Defective starter motor

Starter cable open circuit

Defective starter relay

Starter motor turns but engine does not turn over

Starter motor or starter ring gear

Diagnosis – Starter Circuit

note
  • Prior to carrying out the diagnosis, ensure the battery voltage is 12 - 13.5 V, the immobiliser system (if fitted) is functioning correctly, the transmission is in neutral and the clutch lever is pulled fully to the handlebar.

Alternator/Charging System

The charging system consists of an alternator, a rectifier/regulator assembly and the battery. The alternator is made up of two parts, the stator, which is mounted to the crankcase or the engine cover, and the rotor, mounted to the end of the crankshaft. The stator is an assembly of 18 coils, arranged into 3 phases. The rotor is a series of magnets mounted in the engine flywheel, which are arranged so as to be positioned around the outside of the stator coils. As the engine rotates the alternator produces an AC (alternating current) voltage in each of the three phases of the alternator, typically of around 35 to 40 volts AC at 4,000 - 5,000 rpm, although this figure varies between models. As the battery requires DC (direct current) voltage for correct charging, this AC voltage must be first rectified to DC current, and then regulated to the correct voltage for the battery of 14.5 +/- 0.5 volts. This is done by the rectifier/regulator, which uses diodes to convert the alternator output to DC Volts and limits the resulting output to the correct figure required for optimal battery charging.

If the charging circuit does not operate correctly, the following basic checks must be carried out before further diagnosis is performed:

Rectify any defects as necessary.

Diagnosis – Charging Circuit

Regulator/Rectifier

Internally the rectifier/regulator consists of three diodes, one between each input and the positive terminal, and three Field Effect Transistors (FETs), one between each input and the ground terminal.

As the voltage of the AC signal from the alternator rises, the voltage controller switches the FETs to avoid over voltage on the output.

The diodes and FETs can be checked using a multimeter on DIODE setting. Disconnect the two electrical connectors from the rectifier/regulator and check the readings as indicated below.

note
  • This test does not check for voltage regulation.

Fault

Possible cause

Action

Battery not charging

Main Fuse

Check the condition of the main 30A fuse:

Battery

Check the condition of the battery. Test the battery using the BatteryMate 150-9. Refer to the instructions supplied with the BatteryMate 150-9.

Ensure the battery is serviceable.

Regulator/Rectifier

Disconnect the black and the grey connectors from the rectifier/regulator and proceed to pinpoint test 1:

Alternator

Test the alternator stator (see Alternator Stator).

Pinpoint Tests

Test

Result

Action

1

Check FET forward bias:

Positive (+) probe to rectifier black socket pin 1 to:

- Negative (-) probe to rectifier grey socket pin 1

- Negative (-) probe to rectifier grey socket pin 2

- Negative (-) probe to rectifier grey socket pin 3

0.4 V to 0.7 V

Proceed to test 2

Open circuit or short circuit

Replace the unit. Proceed to test 4

2

Check diodes function forward bias:

Negative (-) probe to rectifier black socket pin 3 to:

- Positive (+) probe to rectifier grey socket pin 1

- Positive (+) probe to rectifier grey socket pin 2

- Positive (+) probe to rectifier grey socket pin 3

0.1 V to 0.3 V

Proceed to test 3

Open circuit or short circuit

Replace the unit. Proceed to test 4

3

Check diodes reverse bias:

Negative (-) probe to rectifier black socket pin 1 to:

- Positive (+) probe to rectifier grey socket pin 1

- Positive (+) probe to rectifier grey socket pin 2

- Positive (+) probe to rectifier grey socket pin 3

Positive (+) probe to rectifier black socket pin 3 to:

- Negative (-) probe to rectifier grey socket pin 1

- Negative (-) probe to rectifier grey socket pin 2

- Negative (-) probe to rectifier grey socket pin 3

More than 1.4 V or OL on meter

Proceed to test 4

Less than 1.4 V or short circuit

Replace the unit. Proceed to test 4

4

Reconnect the harness and run the engine. Check the charging voltage at 2,000 rpm:

13 V - 15 V

Action complete - quit test

Fault still present

Test alternator stator (see Alternator Stator)

If alternator stator is serviceable, contact Triumph service
Circuit Diagram

Alternator Stator

The stator is an assembly of 18 coils, arranged into three phases. It is possible to check for continuity and short circuits through the coils and to earth.

note
  • Only repair the stator harness between the rectifier and where the harness goes into the crankcase.
  • Do not attempt to repair the stator coils.
  • If the battery is not fully charged, the charging voltage may be lower than specified when checking at 2,000 rpm.
  • Ensure all additional accessories (auxiliary lights, heated grips etc.) are switched off.

Fault

Possible cause

Action

Battery not charging

Main fuse in front of the battery

Check the condition of the fuse.

Battery

Check the condition of the battery. Test the battery using the BatteryMate 150-9. Refer to the instructions supplied with the BatteryMate 150-9.

Ensure the battery is serviceable:

Alternator

Proceed to pinpoint test 1:

Regulator/Rectifier

Test the regulator/rectifier (see Regulator/Rectifier)

Pinpoint Tests

Test

Result

Action

1

Check cable and terminal integrity:

- Battery positive (+)

- Battery negative (-)

- Rectifier/regulator to main wiring harness connector pin 1

- Rectifier/regulator to main wiring harness connector pin 2

- Rectifier/regulator to main wiring harness connector pin 3

- Rectifier/regulator to main wiring harness connector pin 4

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test 6

2

Check cable and terminal integrity:

- Rectifier/regulator to alternator harness connector pin 1

- Rectifier/regulator to alternator harness connector pin 2

- Rectifier/regulator to alternator harness connector pin 3

OK

Disconnect the battery leads, negative (black) lead first. Disconnect rectifier/regulator to main wiring harness connector (4 pin). Proceed to test 3

Faulty

Locate and rectify wiring fault, proceed to test 6

3

Check cable continuity:

- Rectifier/regulator main harness connector pin 1 to battery lead negative

- Rectifier/regulator main harness connector pin 2 to battery lead negative

- Rectifier/regulator main harness connector pin 3 to battery lead positive

- Rectifier/regulator main harness connector pin 4 to battery lead positive

OK

Reconnect the battery leads, positive (red) lead first. Reconnect the rectifier/regulator to main wiring harness connector (4 pin). Disconnect the rectifier/regulator to alternator harness connector (3 pin). Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed to test 6

4

Check resistance through the coils:

- Alternator harness pin 1 to 2

- Alternator harness pin 2 to 3

- Alternator harness pin 3 to 1

0.4 Ohms to 0.6 Ohms

Proceed to test 5

Open circuit or short circuit

If the fault is between the connector and the crankcase, repair the harness. proceed to test 6

If the fault is after the crankcase, replace the unit. Proceed to test 6

5

Check for short to earth:

- Alternator harness pin 1 to metal frame

- Alternator harness pin 2 to metal frame

- Alternator harness pin 3 to metal frame

Open circuit

Proceed to test 6

Short circuit

Replace unit. Proceed to test 6

6

Reconnect the harness and run the engine. Check the charging voltage at 2,000 rpm:

13.5 V - 15 V

Action complete - quit test

Fault still present

Test rectifier/regulator (see Regulator/Rectifier).

If rectifier/regulator is serviceable, contact Triumph service
Circuit Diagram

Lighting Adjustment and Bulb Replacement

Headlight

warning

Adjust road speed to suit the visibility and weather conditions in which the motorcycle is being operated.

Make sure that the beam is adjusted to illuminate the road surface sufficiently far ahead without dazzling oncoming traffic. An incorrectly adjusted headlight may impair visibility causing an accident.

warning

Never attempt to adjust a headlamp beam when the motorcycle is in motion.

Any attempt to adjust a headlamp beam when the motorcycle is in motion may result in loss of control and an accident.

caution

Do not cover the headlight or lens with any item likely to obstruct air flow to, or prevent heat escaping from, the headlight lens.

Covering the headlight lens during operation with items of clothing, luggage, adhesive tape, devices intended to alter or adjust the headlight beam or non genuine headlight lens covers will cause the headlight lens to overheat and distort, causing irreparable damage to the headlight assembly.

Damage caused by overheating is not considered a manufacturing defect and will not be covered under warranty.

If the headlight must be covered during use - such as taping of the headlight lens required during closed‑course conditions - the headlight must be disconnected.

Headlight Adjustment

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Vertical Adjustment

note
  • The vertical beams of the left hand and right hand headlights can only be adjusted together. Independent adjustment is not possible.
  1. Switch the headlight dipped beam on.
  2. Loosen the two fixings securing the headlight bracket to the front subframe sufficiently to allow restricted movement of the headlights.
  3. Using the mark on the bracket and the markings on the front subframe, adjust the position of the headlights to give the required beam setting. Each mark on the front subframe represents 1°. Moving the bracket forwards will move the headlight upwards. Moving the bracket rearwards will move the headlights downwards.

    1. Fixings

    2. Front subframe alignment marks

    3. Headlight bracket
  4. Tighten the headlight bracket fixings to 7 Nm.
  5. Re-check the headlight beam settings.

Headlight Bulb Replacement

Perform the following operations:

Each headlight bulb can be replaced as follows:

warning

The bulb becomes hot during use. Always allow sufficient time for the bulb to cool before handling.

Avoid touching the glass part of the bulb. If the glass is touched or gets dirty, clean with alcohol before re-use.

warning

Do not reconnect the battery until the assembly process has been completed. Premature battery reconnection could result in ignition of the battery gases causing risk of injury.

  1. Unscrew the headlight bulb cover from the rear of the headlight assembly and remove with the gasket.

    1. Headlight assembly

    2. Headlight bulb cover
  2. Disconnect the multi-pin electrical connector from the headlight bulb.

    1. Headlight assembly

    2. Headlight bulb

    3. Multi-pin connector
  3. Detach the wire retainer from its clip (do not remove the screw) then remove the bulb from the light unit.

    1. Wire retainer

    2. Screw

    3. Headlight bulb
  4. Installation is the reverse of the removal procedure noting the following:
Daytime Running Lights (DRLs) and LED Position Lights

This model is fitted with either daytime running lights (DRL) or LED position lights. The DRL or LED position light are situated within the headlight assembly and are sealed, maintenance free LED units. The headlight unit must be replaced in the event of the failure of the DRLs or LED position lights.

Rear Light Bulb Replacement - LED

The rear light unit is a sealed, maintenance free LED unit.

Direction Indicators - Bulb Replacement

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Direction indicator lens

  2. Fixing
  1. Release the fixing and remove the lens to gain access to the bulb for replacement.

LED Direction Indicators

The LED direction indicators are sealed for life units and must be replaced in the event of a failure.

Licence Plate Light Bulb Replacement

  1. Release the screw and detach the licence plate light from the licence plate bracket.

    1. Fixing

    2. Lens

    3. Bulb
  2. Replace the bulb, refit the lens and tighten its fixing to 1 Nm.

Removal and Installation - Electrical Components

Instruments - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the position and routing of the main harness and headlight multiplug for installation.
  1. Detach the main harness and headlight multiplug from their clips on the front subframe.
  2. Disconnect the multiplug from the instruments.

    3. note
    • Note the position of the instrument and mounting plate assembly on the front subframe.
  3. Release the lock nuts securing the instrument and mounting plate assembly to the hinge on the front subframe.
  4. Remove the instrument and mounting plate assembly from the front subframe, unhooking the mounting plate pivot stop as you do so.

    1. Lock nuts (shown with harnesses removed for clarity)

    2. Instrument and mounting plate assembly

    3. Hinge

    4. Mounting plate pivot stop

    note
    • Note the positions of the grommets and the hinge mounting studs assembly on the instrument mounting plate.
  5. Release the fixings and washers and remove the instruments from the mounting plate. Collect the hinge mounting studs assembly.

    1. Instruments

    2. Mounting plate

    3. Fixings

    4. Washers

    5. Hinge mounting studs assembly

Instruments - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

    note
    • Ensure the rubber grommets are fitted to the instrument mounting plate as noted during removal.
  1. Fit the hinge mounting studs assembly to the instrument mounting plate as noted during removal.
  2. Fit the instruments to the mounting plate, ensuring that the locating lugs are correctly inserted into the mounting plate grommets. Secure with the fixings and washers and tighten to 3.5 Nm.

    1. Instruments

    2. Mounting plate

    3. Fixings

    4. Washers

    5. Hinge mounting studs assembly
  3. Position the instrument and mounting plate assembly to the hinge on the front subframe as noted during removal. Ensure the mounting plate pivot stop is correctly located into its slot on the front subframe.
  4. Secure the assembly with new lock nuts and tighten to 5 Nm.

    1. Lock nuts (shown with harnesses removed for clarity)

    2. Instrument and mounting plate assembly

    3. Hinge

    4. Mounting plate pivot stop
  5. Connect the instruments multiplug.
  6. Attach the main harness and headlight multiplug to their clips on the front subframe as noted during removal.

Perform the following operations:

Ignition Switch - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Remove the sheared bolts then remove the ignition switch.

    1. Sheared bolts

    2. Ignition switch

Ignition Switch - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit the ignition switch to the upper yoke.
  2. Fit new shear bolts and tighten to 16 Nm.

    1. Shear bolts

    2. Ignition switch

Perform the following operations:

Headlights - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Disconnect headlight lead from the harness.

    1. Headlight lead connector

    note
    • Note the headlight lead routing through the cable guides for installation.
  2. Remove the top two fixings and washers securing the headlight assembly to the front subframe.
  3. Remove the two fixings securing the headlight bracket to the front subframe.

    4. Headlight assembly (front subframe shown removed for clarity).

    1. Headlight Fixing

    2. Washer

    3. Rubber grommet

    4. Headlight assembly

    5. Headlight bracket fixings
  4. Release the two fixings and washers and remove the headlight bracket from the headlight assembly.

    1. Fixing

    2. Washer

    3. Rubber grommet

    4. Headlight bracket

    5. Headlight assembly

    6. Headlight cable rubber grommet

Headlights - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Ensure the two rubber grommets are fitted to the headlight bracket.
  2. Fit the headlight bracket to the headlight assembly with two fixings and washers ensuring the rubber grommet from the headlight cable is fitted to the bracket. Tighten to 3 Nm.

    1. Fixing

    2. Washer

    3. Rubber grommet

    4. Headlight bracket

    5. Headlight assembly

    6. Headlight cable rubber grommet
  3. Install the headlight assembly to the front subframe with two fixings and washers, ensuring the rubber grommets are fitted to the front subframe. Tighten to 3 Nm.
  4. Install the two headlight bracket screws and tighten to 7 Nm.

    5. Headlight assembly (front subframe shown removed for clarity)

    1. Headlight fixing

    2. Washer

    3. Rubber grommet

    4. Headlight assembly

    5. Headlight bracket fixings
  5. Connect the headlight lead to the harness.

    1. Headlight lead connector

Perform the following operations:

Rear Light - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Release the fixings and remove the rear light from the undertray.

    1. Rear light

    2. Rear undertray

    3. Fixings

Rear Light - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit the rear light to the rear undertray and tighten the fixings to 4 Nm

    1. Rear light

    2. Rear undertray

    3. Fixings

Perform the following operations:

Front Direction Indicator - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

note
  • Note the routing of the direction indicator harness for installation.
  1. Release the direction indicator harness from its clip inside the side panel and ease the electrical connectors out from beneath the frame. Disconnect the electrical connectors.

    1. Harness

    2. Clip
  2. Remove the fixing and remove the direction indicator, feeding the harness through the hole in the side panel.

    1. Direction Indicator

    2. Fixing

Front Direction Indicator - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit the direction indicator to the side panel, passing its harness through the hole as you do so. Secure with the fixing and tighten to 3 Nm.
  2. Route the harness as noted during removal and secure to the clip on the inside of the side panel.
  3. Reconnect the electrical connectors and position them beneath the frame as noted during removal.

Perform the following operations:

Rear Direction Indicators - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    note
    • Note the position and orientation of the mounting plate and the seal of the rear indicator hanger for installation.

    1. Gasket

    2. Mounting plate
  1. Carefully release the clips and remove the reflector from the indicator hanger.

    1. Clips

    2. Reflector
  2. Release the fixings and remove the licence plate bracket.

    1. Fixings

    2. Licence plate bracket
  3. Release the fixings and detach the indicators from the hanger.

    1. Fixing

    2. Indicator
  4. Carefully remove the lower moulding from the upper moulding of the hanger.

    1. Lower moulding

    2. Upper moulding

    note
    • Note the routing of the harnesses in the upper moulding.
    • Note that the right hand indicator harness can be identified by the red tape on it.
  5. Disconnect the indicator from the sub-harness and remove the indicator.

  1. Left hand indicator harness

  2. Red tape

  3. Right hand indicator harness

Rear Direction Indicators - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

note
  • Note that the right hand indicator harness can be identified by the red tape on it.
  1. Feed the indicator harnesses into the upper moulding as noted for removal and connect them to the sub-harness.
  2. Carefully attach the lower moulding to the upper moulding. Ensure that the mounting plate is positioned as noted for removal.
  3. Secure the indicators onto the indicator hanger and tighten their fixings to 3 Nm.
  4. Fit the licence plate bracket to the indicator hanger and tighten the:

    1. M5 screw

    2. Lock nuts
  5. Fit the rear reflector and secure in position with the clips.

    6. note
    • Ensure that the gasket is positioned as noted for removal.

Perform the following operations:

Starter Motor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Release the fixing and detach the engine sub-harness from the engine breather cover.

    1. Fixing

    2. Engine sub-harness

    3. Breather cover
  2. Disconnect the low oil pressure warning light switch.
  3. Ease the boot from the starter cable terminal and then release the cable bolt.
  4. Detach the cable from the starter motor.

    5. note
    • Note the position of the mounting bracket for the crankshaft position sensor's multiplug for installation.
  5. Release the fixings securing the starter to the crankcase.

    1. Fixings

    2. Starter motor

    3. Multiplug, crankshaft position sensor
  6. Ease the starter motor from the upper crankcase.

Starter Motor Inspection

  1. Ensure the starter turns freely and without binding.
  2. Check the starter O-ring for damage and deterioration. Replace as necessary.

Starter Motor - Installation

  1. Lubricate the starter motor O-ring with a small amount of petroleum jelly.
  2. Fit the starter motor to the upper crankcase with the multiplug for the crankshaft position sensor as noted for removal. Ensure that the O-ring does not become damaged during installation.
  3. Fit and tighten the starter bolts to 10 Nm.
  4. Refit the starter cable and secure with the bolt. Tighten to 3 Nm.
  5. Refit the starter cable boot.
  6. Connect the low oil pressure warning light switch.
  7. Secure the multiplug for the engine's sub-harness to the engine breather cover, tighten the fixing to 9 Nm.

Perform the following operations:

Alternator Stator - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

note
  • If the alternator stator needs to be replaced, the crankshaft position sensor will also be replaced as they are one assembly.

    note
    • Note the routing of the stator harness for installation.
  1. Remove and discard the fixings securing the crankshaft position sensor to the alternator cover.
  2. Remove and discard the fixing securing the cable bracket to the alternator cover.
  3. Remove and discard the fixings securing the stator to the alternator cover and remove the stator.

    1. Fixings

    2. Crankshaft position sensor

    3. Cable brackets

    4. Alternator stator

Alternator Stator - Installation

  1. Locate the stator and crankshaft position sensor to the engine cover.
  2. Apply silicone sealer to the cable grommet (at the factory, ThreeBond 1215 is used) and align the cable to the exit slot.
  3. Fit the cable retainer brackets and tighten the new fixings to 6 Nm.
  4. Tighten the alternator stator new fixings to 12 Nm.
  5. Tighten the crankshaft position sensor new fixings to 6 Nm.

    1. Fixings

    2. Crankshaft position sensor

    3. Cable brackets

    4. Alternator stator

Perform the following operations:

Alternator Rotor - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

  1. Withdraw the starter idler gear and shaft, noting the fitted position of the components.

    1. Idler gear

    2. Idler shaft

    caution

    Do not use tools to tighten T3880375 - Alternator Rotor Holder. Tighten the tool by hand only. Over-tightening of the tool will lead to damage to the alternator rotor.

  2. To remove the rotor, clean the alternator rotor to remove all traces of oil, and fit T3880375 - Alternator Rotor Holder to the rotor as shown below. Retain the tool to prevent the crankshaft from rotating and remove the centre bolt from the crankshaft.

    1. Rotor

    2. T3880375 - Alternator Rotor Holder
  3. With the bolt removed, locate the spigot from the larger of the two thrust pads supplied with T3880365 - Alternator Housing Puller to the crankshaft.

    1. Thrust pad

    note
    • Ensure that the thrust pad does not fall out during assembly of the tool.
  4. Assemble T3880365 - Alternator Housing Puller to the threaded centre section of the rotor.
  5. Hold the centre of T3880365 - Alternator Housing Puller to prevent rotation then tighten the draw-bolt in the centre of the tool to release the taper seating of the rotor from the crankshaft.

    1. Rotor

    2. T3880365 - Alternator Housing Puller
  6. Withdraw the rotor and tool as an assembly and then separate the tool from the rotor. Collect the Woodruff key and the tool thrust pad from the crankshaft.

Alternator Rotor - Installation

  1. Refit the Woodruff key to the crankshaft.
  2. Assemble the rotor to the keyway on the crankshaft, ensuring the Woodruff key remains in position.

    3. caution

    Do not use tools to tighten T3880375 - Alternator Rotor Holder. Tighten the tool by hand only. Over-tightening of the tool will lead to damage to the alternator rotor.

  3. Refit the T3880375 - Alternator Rotor Holder to prevent the crankshaft from rotating, ensuring the rotor is free from oil and the tool is not over-tightened.
  4. Tighten the rotor retaining bolt in two stages:

    1. Rotor

    2. T3880375 - Alternator Rotor Holder
  5. Remove the T3880375 - Alternator Rotor Holder.
  6. Lubricate the idler gear shaft with new engine oil which meets specification API SH (or higher) and JASO MA.
  7. Fit the starter idler gear and shaft to the crankcase.

    1. Idler gear

    2. Idler shaft

Perform the following operations:

Alternator Regulator/Rectifier - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

The alternator regulator/rectifier is located in between the rear suspension unit and the gearbox.

Perform the following operations:

  1. Release the two fixings and detach the regulator/rectifier and bracket assembly from the frame.

    2. note
    • Note the position of the two electrical connectors for installation.
  2. Disconnect the two electrical connectors.

    1. Fixings

    2. electrical connectors

    3. Regulator/Rectifier

    4. Mounting bracket
  3. Detach the two brake lines from their clip on the back of the regulator/rectifier mounting bracket.

    1. ABS brake lines

    2. Clip

    3. Mounting bracket
  4. Release the fixings and remove the regulator/rectifier from its bracket.

    1. Fixings

Alternator Regulator/Rectifier - Installation

  1. Fit the regulator/rectifier to its bracket and tighten its fixings to 9 Nm.
  2. Attach the two brake lines to their clip on the back of the regulator/rectifier mounting bracket.
  3. Reconnect the two electrical connectors as noted for removal.
  4. Fit the regulator/rectifier and bracket assembly to the frame and tighten its fixings to 12 Nm.

Perform the following operations:

Side Stand Switch - Removal

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Perform the following operations:

    caution

    Note the routing and the retaining clips of the side stand switch harness for installation.
  1. Disconnect the side stand switch electrical connector from the main harness and feed it down to the side stand switch.

    1. Side stand switch electrical connector

    warning

    Wear hand, eye and face protection when unhooking the stand spring. Take great care to minimise the risk of personal injury and loss of components.

    note
    • Note the orientation of the side stand spring for installation.
  2. With the side stand in the up position, unhook the spring from the side stand and remove it from the motorcycle.

    3. note
    • Note the routing of the two hoses between the side stand switch heat shields for installation.
  3. Release the fixings and remove the side stand and mounting assembly. At the same time remove the two hoses from between the two heat shields.

    1. Fixings

    2. Hoses

    3. Side stand mounting
  4. Release the retaining clips and remove the heat shields
  5. Release the fixings and remove the side stand switch. Discard the fixings.

    1. Heat shield retaining clips

    2. Heat shields

    3. Switch fixings

    4. Switch

Side Stand Switch - Installation

warning

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

  1. Fit the side stand switch to the side stand mounting and tighten the new fixings to 7 Nm.
  2. Fit the heat shield ensuring it is fully secured by its retaining clips.

    1. Heat shield retaining clips

    2. Heat shields

    3. Switch fixings

    4. Switch
  3. Feed the two hoses between the two heat shields as noted for removal.
  4. Fit the side stand and mounting assembly to the frame and tighten the new fixings to 45 Nm.

    1. Fixings

    2. Hoses

    3. Side stand mounting

    warning

    Wear hand, eye and face protection when fitting the stand spring. Take great care to minimise the risk of personal injury and loss of components.

  5. Hook the spring onto its frame lug then carefully hook it onto the stand lug as noted for removal.
  6. Route the side stand harness up to the main harness as noted for removal. Connect the side stand to the main harness.

    1. Side stand switch electrical connector

Perform the following operations:

Circuit Diagrams

Lighting Circuit Tables

Key to Circuit Diagram

Key

Item Description

1

Fuse Box

2

Ignition Switch

3

Headlight Power Relay

4

Headlight Low/High Beam Relay

5

Headlight

6

Instruments

7

Oil Pressure Warning Light

8

Engine Sub-harness Connector

9

Rear Light

10

Rear Light Sub-harness Connector
Key To Wiring Colour Codes

Code

Wiring Colour

B

Black

U

Blue

N

Brown

G

Green

S

Slate/Grey

O

Orange

K

Pink

R

Red

P

Purple

W

White

Y

Yellow

LG

Light Green

LU

Light Blue

Lighting Circuit Diagram

Starting and Charging Circuit Tables

Key to Circuit Diagram

Key

Item Description

1

Battery

2

Starter Solenoid

3

Starter Motor

4

Main Fuse

5

Regulator/Rectifier

6

Fuse Box

7

Fuel Pump Relay

8

Starter Motor Relay

9

Engine Electronic Control Module - Connector B

10

Engine Electronic Control Module - Connector A

11

Alarm

12

Engine Stop/Start Switch (left hand switch housing)

13

Immobiliser

14

Instruments

15

Ignition Switch

16

Engine Management System Relay
Key To Wiring Colour Codes

Code

Wiring Colour

B

Black

U

Blue

N

Brown

G

Green

S

Slate/Grey

O

Orange

K

Pink

R

Red

P

Purple

W

White

Y

Yellow

LG

Light Green

LU

Light Blue

Starting and Charging Circuit Diagram

Auxiliary and Accessory Circuit Tables

Key to Circuit Diagram

Key

Item Description

1

Fuse Box

2

Accessory Socket

3

Bluetooth® Module

4

Ignition Switch

5

Rear Brake Switch

6

Brake Switch Relay

7

Front Brake Switch Connector

8

Brake Light

9

ABS Module

10

Horn Relay

11

Horn 1

12

Horn 2

13

Diagnostic Connector

14

Heated Grips

15

Left Hand Front Direction Indicator

16

Right Hand Front Direction Indicator

17

Rear Light Sub-harness Connector

18

Alarm Connector

19

Ambient Air Temperature Sensor

20

Instruments

21

Right Hand Switch Housing Black Connector

22

Right Hand Switch Housing Grey Connector

23

Left Hand Switch Housing Connector 1
Key To Wiring Colour Codes

Code

Wiring Colour

B

Black

U

Blue

N

Brown

G

Green

S

Slate/Grey

O

Orange

K

Pink

R

Red

P

Purple

W

White

Y

Yellow

LG

Light Green

LU

Light Blue

Auxiliary and Accessory Circuit Diagram

ABS System Circuit Tables

Key To Wiring Circuit Diagram

Key

Item Description

1

Fuse Box

2

Ignition Switch

3

Brake Light

4

Front Wheel Speed Sensor

5

Rear Wheel Speed Sensor

6

Diagnostic Connector

7

ABS Modulator
Key To Wiring Colour Codes

Code

Wiring Colour

B

Black

U

Blue

N

Brown

G

Green

S

Slate/Grey

O

Orange

K

Pink

R

Red

P

Purple

W

White

Y

Yellow

LG

Light Green

LU

Light Blue
ABS ECM Connector Pin Numbering

The above illustration shows the pin numbering system used in the ABS circuit diagram.

As viewed on the mating face with the ABS ECM (as per the illustration), pins are numbered from right to left with number one in the top right hand corner.

ABS System Circuit Diagram

Engine Management Circuit Tables

Key to Circuit Diagram

Key

Item Description

1

Engine Electronic Control Module

2

Diagnostic Connector

3

Bluetooth Module

4

Instruments

5

ABS Module

6

Immobiliser

7

Clutch Switch

8

Side Stand Switch

9

Ignition Switch

10

Fuel Level Sender

11

Gear Position Sensor

12

Fall Detection Switch

13

Ambient Pressure Sensor

14

Manifold Absolute Pressure (MAP) Sensor

15

Intake Air Temperature Sensor

16

Quickshifter

17

Twist Grip Position Sensor

18

Throttle Position Sensor

19

Throttle Actuator Motor

20

Fuel Pump Relay

21

Fuel Pump

22

Cooling Fan Relay

23

Cooling Fan

24

Brake Lamp

25

Front Brake Switch

26

Rear Brake Switch

27

Ignition Coil 3

28

Ignition Coil 2

29

Ignition Coil 1

30

Oxygen Sensor

31

Secondary Air Injection Solenoid

32

Fuel Injector 3

33

Fuel Injector 2

34

Fuel Injector 1

35

Purge Valve

36

Engine Management System Relay

37

Fuse Box

38

Crankshaft Position Sensor

39

Coolant Temperature Sensor

40

Engine Sub-harness

41

Ignition Switch
Key To Wiring Colour Codes

Code

Wiring Colour

B

Black

U

Blue

N

Brown

G

Green

S

Slate/Grey

O

Orange

K

Pink

R

Red

P

Purple

W

White

Y

Yellow

LG

Light Green

LU

Light Blue

Engine Management Circuit Diagram

Complete Main Harness Table

Key to Circuit Diagram

Key

Item Description

1

Engine Electronic Control Module

2

Crankshaft Position Sensor

3

Oil Pressure Switch

4

Engine Coolant Temperature Sensor

5

Engine Sub-harness Connector

6

Cooling Fan

7

Cooling Fan Relay

8

Engine Management System Relay

9

Fuel Pump

10

Fuel Pump Relay

11

Rear Brake Switch

12

Brake Light

13

Rear Light

14

License Plate Light

15

Left Hand Rear Direction Indicator

16

Right Hand Rear Direction Indicator

17

Rear Light Sub-harness Connector

18

Low/High Beam Headlight Relay

19

Alarm Connector

20

Brake Switch Relay

21

Headlight Power Relay

22

Starter Motor Solenoid Relay

23

Starter Motor

24

Starter Motor Solenoid

25

Regulator/Rectifier

26

Battery

27

Main Fuse

28

Fuse Box

29

USB Connector

30

Key Antenna

31

Ignition Switch Connector

32

Rider Accessory Socket

33

Immobiliser

34

Front Brake Switch

35

Right Hand Switch Housing Black Connector

36

Right Hand Switch Housing Grey Connector

37

Left Hand Switch Cube Connector B (2 Pin)

38

39

Ambient Air Temperature Sensor

40

Heated Grips

41

Bluetooth Connector

42

Rear Wheel Speed Sensor

43

Front Wheel Speed Sensor

44

ABS Modulator

45

Diagnostic Connector

46

Headlight

47

Front Side Light

48

Right Hand Front Direction Indicator

49

Left Hand front Direction Indicator

50

Horn Relay

51

Horn

52

Instruments

53

MAP Sensor

54

Ambient Air Pressure Sensor

55

Fuel Level Sender

56

Side Stand Switch

57

Fall Detection Switch

58

Gear Position Sensor

59

Ignition Coil 1

60

Ignition Coil 2

61

Ignition Coil 3

62

Oxygen Sensor

63

Intake Air Temperature Sensor

64

Injector 1

65

Injector 2

66

Injector 3

67

Purge Valve

68

Secondary Air Injection Solenoid

69

Drive By Wire Throttle Actuator Motor

70

Throttle Position Sensor

71

Twist Grip Position Sensor

72

Quickshifter
Key To Wiring Colour Codes

Code

Wiring Colour

B

Black

U

Blue

N

Brown

G

Green

S

Slate/Grey

O

Orange

K

Pink

R

Red

P

Purple

W

White

Y

Yellow

LG

Light Green

LU

Light Blue

Complete Main Harness Diagram