Triumph Scrambler 1200 XC Service Manual
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Triumph Scrambler 1200 XC Service Manual

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Table Of Contents
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Table of Contents

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Service Manual - Scrambler 1200
XC
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:
Accurately follow the maintenance requirements of the periodic maintenance
chart in the Service Manual.
Do not allow problems to develop. Investigate unusual noises and changes in
the riding characteristics of the motorcycle. Rectify all problems as soon as
possible (immediately if safety related).
Use only genuine Triumph parts as listed in the electronic parts catalogue (EPC).
Follow the procedures in this manual carefully and completely. Do not take short
cuts.
Keep complete records of all maintenance and repairs with dates and any new
parts installed.
Service Manual - Scrambler 1200 XC
1 of 640

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  • Page 1 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.

  • Page 2: How To Use This Manual

    The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Service Manual - Scrambler 1200 XC 2 of 640...
  • Page 3 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...
  • Page 4 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. Service Manual - Scrambler 1200 XC 4 of 640...
  • Page 5 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 Service Manual - Scrambler 1200 XC 5 of 640...
  • Page 6 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...

  • Page 7: Health Protection Precautions

    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 Service Manual - Scrambler 1200 XC 7 of 640...
  • Page 8 It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph dealer before riding the Service Manual - Scrambler 1200 XC 8 of 640...

  • Page 9: Safety Instructions

    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 Service Manual - Scrambler 1200 XC 9 of 640...
  • Page 10 '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 Service Manual - Scrambler 1200 XC 10 of 640...
  • Page 11 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 Service Manual - Scrambler 1200 XC 11 of 640...
  • Page 12 A fixing which fails in service could cause component detachment leading to loss of control and an accident. Service Manual - Scrambler 1200 XC 12 of 640...
  • Page 13 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.
  • Page 14 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. Service Manual - Scrambler 1200 XC 14 of 640...
  • Page 15 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: ceon Service Manual - Scrambler 1200 XC 15 of 640...
  • Page 16 Grease must be forced between the inner race and the roller carrier. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts. Any excess grease should be smeared on the outside of the rollers. Service Manual - Scrambler 1200 XC 16 of 640...

  • Page 17: Fuel Handling Precautions

    Disassemble the parts as necessary to access the bush. Remove the old grease. Apply fresh grease to the metal bush. Fuel Handling Precautions General The following information provides basic precautions which must be observed if Service Manual - Scrambler 1200 XC 17 of 640...
  • Page 18 (gasoline). Repairs carried out by untrained personnel could bring about a safety hazard leading to a risk of personal injury. Service Manual - Scrambler 1200 XC 18 of 640...

  • Page 19: Electrical Precautions

    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.
  • Page 20 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. Service Manual - Scrambler 1200 XC 20 of 640...
  • Page 21 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 Service Manual - Scrambler 1200 XC 21 of 640...
  • Page 22 For example, if a battery of 12 V is connected to a bulb of 60 W: the current flowing in the circuit can be calculated by using - the bulb resistance can be calculated by using - Service Manual - Scrambler 1200 XC 22 of 640...
  • Page 23 Circuits diagrams may look confusing at first but when they are studied closely they soon become logical. Service Manual - Scrambler 1200 XC 23 of 640...
  • Page 24 Due to the complex circuits and the number of individual wires, Triumph uses two types of circuit diagram in its Service Manuals. Within the manual, conventional circuit diagrams are used to show the layout of the main circuits of the motorcycle. These are: Engine management/ignition, Lighting, Starting and Charging and Auxiliary and Accessory.
  • Page 25 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. Ω Service Manual - Scrambler 1200 XC 25 of 640...
  • Page 26 Connect the black (ground) lead of the DMM to a reliable ground connection (usually the battery or frame ground). Locate the positive terminal of the wire or component to be tested. Service Manual - Scrambler 1200 XC 26 of 640...
  • Page 27 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 Service Manual - Scrambler 1200 XC 27 of 640...
  • Page 28 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 Service Manual - Scrambler 1200 XC 28 of 640...
  • Page 29 The fault would then be reported by a DTC (Diagnostic Trouble Code). Triumph currently uses CAN for communication between the following ECMs: Engine ECM Instruments ABS ECM Immobiliser or Chassis ECM Diagnostic connector Inertial Measurement Unit (if fitted)
  • Page 30 The instruments confirm the data has been received correctly and that the data is valid. Once confirmed the headlight main beam is switched on. Triumph currently uses LIN on certain models for communication between the instruments and the following components: Fog light button...
  • Page 31 T3880016 - Balancer Gear C-Spanner T3880039 T3880023 - 50 mm Socket T3880039 - Idler Gear Timing Pin T3880041 cczb T3880041 - Idler Gear Timing Wrench T3880053 - Wheel Bearing Extraction Kit Service Manual - Scrambler 1200 XC 31 of 640...
  • Page 32 T3880057 - Triumph Diagnostic Interface T3880067 - Fork Spring Compressor ccgs cczb T3880075 - Bearing Installer T3880085 - Fork Piston Holder cdoa T3880104 - Swinging Arm Adjuster T3880105 - Torque Angle Gauge Wrench Service Manual - Scrambler 1200 XC 32 of 640...

  • Page 33: Specifications

    35.60 mm Exhaust 29.70 mm Valve Lift Inlet 10.3 mm Exhaust 9.2 mm Valve Stem Diameter Inlet 4.975 - 4.990 mm (standard) 4.965 mm (service limit) Exhaust 4.970 - 4.980 mm (standard) Service Manual - Scrambler 1200 XC 33 of 640...
  • Page 34 90° inclusive Valve Spring Length 49.9 mm Inlet/Exhaust Valve Spring 'Load at Length' 214 N +/- 10 at 39.5 mm Valve Clearance Inlet 0.05 - 0.13 mm Exhaust 0.12 - 0.22 mm Service Manual - Scrambler 1200 XC 34 of 640...
  • Page 35 Camshaft Run-out 0.015 mm (standard) Clutch and Primary Drive Primary Drive Type Gear Reduction Ratio 1.26:1 (93/74) Clutch Type Wet multi-plate No. of Friction Plates Steel Plate Flatness Limit 0.15 mm Service Manual - Scrambler 1200 XC 35 of 640...
  • Page 36 Second 0.02 - 0.06 mm (standard) 0.075 mm (service limit) Piston Ring Groove Width 1.21 - 1.24 mm (standard) Second 1.01 - 1.03 mm (standard) 2.51 - 2.53 mm (standard and Service Manual - Scrambler 1200 XC 36 of 640...
  • Page 37 41.000 - 41.009 mm (standard) Connecting Rod Big End Side Clearance 0.15 - 0.30 mm (standard) 0.50 mm (service limit) Crankshaft Crankshaft Big End Journal Diameter 38.000 - 37.984 mm (standard) 37.9469 mm (service limit) Service Manual - Scrambler 1200 XC 37 of 640...
  • Page 38 Crankshaft Run-out 0.02 mm (standard) 0.035 mm (service limit) Transmission Type 6 Speed, Constant Mesh Gear Ratios Primary 1.26:1 (93/74) 3.50:1 (49/14) 2.50:1 (45/18) 1.85:1 (37/20) 1.48:1 (37/25) 1.30:1 (35/27) 1.17:1 (34/29) Service Manual - Scrambler 1200 XC 38 of 640...
  • Page 39 Oil and Filter Change 3.40 litres Oil Change only 3.20 litres Recommended Oil API SH (or higher) and JASO MA Approval Rating Viscosity 10W/40 or 10W/50 Type Semi or fully synthetic Service Manual - Scrambler 1200 XC 39 of 640...

  • Page 40: Ignition System

    NGK LMAR8A-9 Spark Plug Gap 0.9 mm +0.0/-0.1 mm Fuel System Fuel Type Unleaded, 91 RON (CLC or AKI octane rating (R+M)/2 of 87 or higher) Fuel Tank Capacity 16 litres Service Manual - Scrambler 1200 XC 40 of 640...
  • Page 41 One, in the catalytic converter box Oxygen Sensor One per cylinder, heated, in header pipe Evaporative Control Activated carbon canister (certain markets only) Cooling System Coolant Mixture Premixed Antifreeze Type Triumph HD4X Hybrid OAT coolant Service Manual - Scrambler 1200 XC 41 of 640...
  • Page 42 (not the top cap) Fork Spring Rate 4.5 N/mm Rear Wheel Travel 200 mm Brakes Front Type Four piston monobloc calipers acting on twin discs Service Manual - Scrambler 1200 XC 42 of 640...
  • Page 43 Rear Caliper Piston 28mm Diameter Rear Disc Diameter 255mm Rear Disc Thickness 5.5mm Rear Disc Run-out Max. 0.25mm Rear Master Cylinder 14mm Diameter Recommended Fluid DOT 4 Frame Frame Type Tubular steel Service Manual - Scrambler 1200 XC 43 of 640...
  • Page 44 Rear Wheel Rim Radial 1 mm Run-out Approved Tyres A list of approved tyres specific to these models is available from your authorised Triumph dealer, or on the Internet at www.triumph.co.uk. Electrical Equipment Service Manual - Scrambler 1200 XC 44 of 640...

  • Page 45: Torque Wrench Settings

    16 Nm barrel Camshaft frame to cylinder head See Camshaft - Installation Camshaft idler shaft bolt 10 Nm Fit new fixing(s) if loosened or removed Camshaft sprocket to camshaft See Camshaft - Service Manual - Scrambler 1200 XC 45 of 640...
  • Page 46 98 Nm Fit new fixing(s) if loosened or removed Fit new Belleville washer Clutch lever clamp bolts 12 Nm Clutch lever nut 3.4 Nm Clutch pressure plate to centre 10 Nm Service Manual - Scrambler 1200 XC 46 of 640...
  • Page 47 Fit new fixing(s) if loosened or removed Flanged plug 10 Nm Fit new fixing(s) if loosened or removed Oil filler cap 3 Nm Plug, front balancer shaft adjuster clamp 23 Nm Service Manual - Scrambler 1200 XC 47 of 640...
  • Page 48 Clutch cover embellisher to clutch cover 4 Nm Fit new fixing(s) if loosened or removed Clutch cover plug 10 Nm Clutch cover to crankcase Fit new fixing(s) if loosened or removed See Clutch Cover - Installation Service Manual - Scrambler 1200 XC 48 of 640...
  • Page 49 Gear change pedal pinch bolt 8 Nm Input selector fork plug 22 Nm Fit new fixing(s) if loosened or removed Input shaft bearing retainer 7 Nm Fit new fixing(s) if loosened or removed Service Manual - Scrambler 1200 XC 49 of 640...

  • Page 50: Lubrication System

    Oil pump drive sprocket to oil pump 12 Nm Oil pump rotor cover to oil pump body 10 Nm Oil pump to crankcase 10 Nm Fit new fixing(s) if loosened or removed Service Manual - Scrambler 1200 XC 50 of 640...
  • Page 51 4 Nm Exhaust centre cover assembly 6 Nm Exhaust headers to cylinder head Left Hand Header Pipe - Installation Exhaust Catalytic Converter - Installation Exhaust rear cover and bracket 6 Nm Service Manual - Scrambler 1200 XC 51 of 640...
  • Page 52 Fit new fixing(s) if loosened or removed Fuel tank to frame 8 Nm Gear position sensor 5 Nm Fit new fixing(s) if loosened or removed Heatshield to exhaust silencer 6 Nm Service Manual - Scrambler 1200 XC 52 of 640...
  • Page 53 19 Nm Coolant filler neck 3 Nm Coolant manifold to crankcase 9 Nm Fit new fixing(s) if loosened or removed Coolant temperature sensor 18 Nm Apply ThreeBond 1374 to the threads Service Manual - Scrambler 1200 XC 53 of 640...
  • Page 54 Fit new fixing(s) if loosened or removed Headstock bearing adjuster and lock nut See Steering Head Bearing - Adjustment Left hand heated grip 2 Nm Left hand heated grip switch housing 0.5 Nm fixings Service Manual - Scrambler 1200 XC 54 of 640...

  • Page 55: Rear Suspension

    Fit new fixing(s) if loosened or removed Rear suspension unit shroud 4 Nm Swinging arm pivot bolt adjuster See Swinging Arm - Installation Swinging arm pivot nut See Swinging Arm - Installation Wheels Service Manual - Scrambler 1200 XC 55 of 640...

  • Page 56: Front Brakes

    Brake caliper to front fork 55 Nm Brake disc to wheel 22 Nm Fit new fixing(s) if loosened or removed Brake hose to front caliper 25 Nm Fit new sealing washer(s) Service Manual - Scrambler 1200 XC 56 of 640...

  • Page 57: Rear Brakes

    Brake master cylinder reservoir to frame 3 Nm Fit new sealing washer(s) Brake master cylinder to right hand control 18 Nm plate Brake pedal pivot bolt 22 Nm Fit new fixing(s) if loosened or removed Service Manual - Scrambler 1200 XC 57 of 640...

  • Page 58: Abs System

    Frame, Footrests, Control Plates and Engine Mountings Application Torque Notes (Nm) Bank angle indicator 9 Nm Fit new fixing(s) if loosened or removed Control plate, left hand, front bolt 40 Nm Service Manual - Scrambler 1200 XC 58 of 640...
  • Page 59 See Engine - Installation Engine upper rear mounting lock nuts See Engine - Installation Frame adjuster See Engine - Installation Front left hand cylinder head bolt to frame See Engine - Service Manual - Scrambler 1200 XC 59 of 640...
  • Page 60 Fuel tank infill panel 3 Nm Grab rail front fixings 28 Nm Grab rail mounting to frame 10 Nm Fit new fixing(s) if loosened or removed Grab rail rear fixings 28 Nm Service Manual - Scrambler 1200 XC 60 of 640...
  • Page 61 Rear footrest hanger 24 Nm Rear footrest rubber inserts 6 Nm Fit new fixing(s) if loosened or removed Rear mudguard tray to ABS bracket 9 Nm Rear mudguard tray to airbox 1.5 Nm Service Manual - Scrambler 1200 XC 61 of 640...
  • Page 62 Sump guard to bracket 4 Nm Sump guard to frame 6 Nm Fit new fixing(s) if loosened or removed Sump guard side panels 4 Nm Upper rear crankcase mounting See Engine - Installation Service Manual - Scrambler 1200 XC 62 of 640...
  • Page 63 Fall detection switch 3 Nm Fit new fixing(s) if loosened or removed Fall detection switch bracket 4 Nm Front direction indicators 5 Nm Fit new fixing(s) if loosened or removed Service Manual - Scrambler 1200 XC 63 of 640...
  • Page 64 Headstock tidy outer cover, top fixing 5 Nm Heated grip, left hand 2 Nm Heated grip switch housing 0.5 Nm Horn 24 Nm Ignition coil bracket 3 Nm Instrument adjustment bearing 5.5 Nm Service Manual - Scrambler 1200 XC 64 of 640...
  • Page 65 Rear light assembly to mudguard and 9 Nm support bracket (nuts) Rear light assembly to rear mudguard 8 Nm Fit new fixing(s) if loosened or removed Rear reflector bracket 1 Nm Relay bracket 1.5 Nm Service Manual - Scrambler 1200 XC 65 of 640...

  • Page 66: Main Wiring Harness Routing

    Fit new fixing(s) if loosened or removed Starter motor power lead connection 5 Nm Starter motor solenoid lead connection 5 Nm Starter motor to crankcase 7 Nm Routings Main Wiring Harness Routing Service Manual - Scrambler 1200 XC 66 of 640...
  • Page 67 Evaporative Hose Routing Service Manual - Scrambler 1200 XC 67 of 640...

  • Page 68: Clutch Cable Routing

    Clutch Cable Routing ckjx ABS Brake Hose Routing Service Manual - Scrambler 1200 XC 68 of 640...

  • Page 69: Routine Maintenance

    Routine Maintenance Scheduled Maintenance WARNING Triumph Motorcycles cannot accept any responsibility for damage or injury resulting from incorrect maintenance or improper adjustment carried out by the owner. Incorrect or neglected maintenance can lead to a dangerous riding condition. Service Manual - Scrambler 1200 XC...
  • Page 70 Scheduled maintenance may be carried out by your authorised Triumph dealer in three ways; annual maintenance, mileage based maintenance or a combination of both, depending on the mileage the motorcycle travels each year.

  • Page 71: Scheduled Maintenance Table

    The general warning symbol will flash if an ABS or engine management fault has occurred and the ABS and/or MIL warning lights are illuminated. Contact an authorised Triumph dealer as soon as possible to have the fault checked and rectified.
  • Page 72 Every 4 years regardless of mileage - renew Ignition System Spark plugs - check • Spark plugs - renew • • Cooling System Cooling system - check • • • • • for leaks Service Manual - Scrambler 1200 XC 72 of 640...
  • Page 73 Wheels - inspect for • • • • • damage Wheel bearings - check • • • • • for wear/smooth operation Wheels - check for • • • • • broken or damaged Service Manual - Scrambler 1200 XC 73 of 640...
  • Page 74 Front and rear • • • • • suspension - check for damage/leaks/smooth operation Fork oil - renew • Brakes Brake pads - check wear • • • • • levels Service Manual - Scrambler 1200 XC 74 of 640...
  • Page 75 Drive chain rubbing strip • • • • • - check for wear, cracks or damage. Replace if necessary Electrical Lights, instruments and • • • • • electrical systems - check/adjust General Service Manual - Scrambler 1200 XC 75 of 640...
  • Page 76 • • • clean Rear brake pedal • • • • • adjuster pivot pin - clean/lubricate Carry out all outstanding • • • • • Service Bulletin and warranty work Service Manual - Scrambler 1200 XC 76 of 640...
  • Page 77 Spark Plug Type NGK LMAR8A-9 Spark Plug Gap 0.9 mm +0.0/-0.1 mm Coolant Type Triumph HD4X Hybrid OAT coolant Coolant Capacity 1.89 litres Cutch Lever Free 2.0 - 3.0 mm Play Service Manual - Scrambler 1200 XC 77 of 640...
  • Page 78 Front Brake Pad 1.0 mm Minimum Thickness Front Brake Disc 4.0mm Minimum Thickness Front Brake Disc 0.25mm Maximum Run Out Rear Brake Pad 1.5 mm Minimum Thickness Rear Brake Disc Minimum Thickness Service Manual - Scrambler 1200 XC 78 of 640...
  • Page 79 Oil Filter Apply clean engine oil to the seal(s) Sump Plug Fit new sealing washer(s) Air Filter to Airbox Spark Plugs Camshaft Cover See Camshaft Cover - Installation for tightening sequence Service Manual - Scrambler 1200 XC 79 of 640...
  • Page 80 Front Brake Caliper Bleed 8 Nm Screw Rear Brake Master Cylinder 3 Nm Reservoir Rear Brake Hose to Master Cylinder Rear Brake Master Cylinder to Control Plate Rear Brake Caliper Bleed 6 Nm Service Manual - Scrambler 1200 XC 80 of 640...
  • Page 81 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. Service Manual - Scrambler 1200 XC 81 of 640...
  • Page 82 Note the oil level visible in the sight glass. When correct, oil should be visible at a point between the upper level and the lower level on the sight glass. L0915 Service Manual - Scrambler 1200 XC 82 of 640...
  • Page 83 To prevent pollution of watercourses etc., dispose of used oil sensibly. If in doubt contact your local authority. Warm up the engine thoroughly, and then stop the engine. Place a waste oil catch tray beneath the engine. Service Manual - Scrambler 1200 XC 83 of 640...
  • Page 84 JASO MA, such as Castrol Power 1 Racing 4T, sold as Castrol Power RS Racing 4T in some countries. Fit a new sealing washer to the oil filler cap. Fit and tighten the oil filler plug to 3 Nm. Service Manual - Scrambler 1200 XC 84 of 640...
  • Page 85 Perform the following operations: Remove the left hand Side Panels Detach the main fuse and the keyless electronic control module (ECM) multiplug from the relay bracket. Service Manual - Scrambler 1200 XC 85 of 640...
  • Page 86 Remove the fixings and detach the relay bracket from the left hand side of the airbox. L0916a Fixings Relay bracket Release the four fixings securing the air filter cassette to the airbox and remove the air filter cassette. Service Manual - Scrambler 1200 XC 86 of 640...
  • Page 87 Fit the air filter and cassette assembly to the airbox and tighten its fixings to 1 Nm. Attach the relay bracket to the airbox and tighten its fixings to 1.5 Nm. Service Manual - Scrambler 1200 XC 87 of 640...
  • Page 88 Attach the main fuse and the keyless electronic control module (ECM) multiplug to the relay braket. L0916 Main fuse Keyless (ECM) multiplug Perform the following operations: Refit the left hand Side Panels Fuel Filter - Renew Removal Service Manual - Scrambler 1200 XC 88 of 640...
  • Page 89 Release the two fuel hose clips from either side of the fuel filter. Remove the hose bracket from the fuel pump bracket. civv Hose clips Hose bracket Carefully detach the baffle housing from the fuel pump. Service Manual - Scrambler 1200 XC 89 of 640...
  • Page 90 Hose clip Remove the fuel pump securing bolt and strap. civx Strap Bolt Disconnect the fuel pump hose from the fuel filter inlet. Remove and discard the two fuel filter cable ties. Service Manual - Scrambler 1200 XC 90 of 640...
  • Page 91 Install the fuel filter to the outlet hose, ensuring the arrow on the filter points away from the pump. Secure the hose with the hose clip. Check and ensure that the feet of the rubber isolator engage correctly in the fork. Service Manual - Scrambler 1200 XC 91 of 640...
  • Page 92 Fuel/evaporative hoses must be secure and routed in such a way that they do not chafe against moving parts of the motorcycle. Fuel/evaporative hoses must not be routed around sharp curves. This could cause restrictions in the flow of fuel. Service Manual - Scrambler 1200 XC 92 of 640...
  • Page 93 Damaged fuel/evaporative system components must be replaced. An incorrectly fitting fuel cap must be replaced. Autoscan Actions required Perform an Autoscan using the Triumph Diagnostic Software in accordance with the Triumph Diagnostic Tool User Guide. Check Check all results pass the Autoscan, and save the results.
  • Page 94 Check and if necessary adjust the spark plug gap to 0.9 mm +0.0/-0.1 mm. Refit the spark plugs or, if required, fit new spark plugs and tighten to 12 Nm. ckhy Spark plug cap Spark plug Service Manual - Scrambler 1200 XC 94 of 640...
  • Page 95 - depending on the actual liquid present at the firing tip. Signs of fouling or excessive heat must be traced quickly to prevent further deterioration of performance and possible engine damage. Normal Condition Service Manual - Scrambler 1200 XC 95 of 640...
  • Page 96 10 Ohms, the engine can be started normally. If the insulation resistance drops to 0 Ohms, the firing end is fouled by either wet or dry carbon. Overheating Service Manual - Scrambler 1200 XC 96 of 640...
  • Page 97 Deposits The accumulation of deposits on the firing end is influenced by oil leakage, fuel quality and the engines operating duration. Breakage Service Manual - Scrambler 1200 XC 97 of 640...
  • Page 98 A worn spark plug not only wastes fuel but also strains the whole ignition system because the expanded gap (due to erosion) requires higher voltages. Normal rates of gap growth are: 0.00063 - 0.000126 inches per 1000 miles (0.01 - 0.02 mm per 1000 km) Service Manual - Scrambler 1200 XC 98 of 640...
  • Page 99 The material of the electrodes has oxidised, and when the oxidation is heavy, it will be green on the surface. The surface of the electrodes will also be fretted and rough. Service Manual - Scrambler 1200 XC 99 of 640...

  • Page 100: Coolant Level Inspection

    Position the motorcycle on level ground and in an upright position. The coolant level must be between the MAX (upper line) and MIN (lower line) marks in the expansion tank. ckig_1 MAX mark MIN mark Service Manual - Scrambler 1200 XC 100 of 640...

  • Page 101: Coolant Level Adjustment

    Remove the sump guard (see Sump Guard - Removal). 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. ckig Maximum level Service Manual - Scrambler 1200 XC 101 of 640...
  • Page 102 Contact with hot coolant will cause scalds and skin damage. Allow the engine to cool for a minimum of 30 minutes. Drain the coolant (see Coolant Replacement - Drainage). Refill the coolant with Triumph HD4X Hybrid OAT coolant (see Coolant Replacement - Filling). Valve Clearance Adjustment WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
  • Page 103 Feeler gauges Measure and record all valve clearances as described previously. Release the two rocker shaft retaining bolts and remove the rocker shaft and rocker arm of a valve that requires adjustment. Service Manual - Scrambler 1200 XC 103 of 640...
  • Page 104 Calculate the shim thickness required to give the correct clearance, for specifications refer toService Specifications. Clearance too small - Fit a thinner shim. Clearance too large - Fit a thicker shim. Service Manual - Scrambler 1200 XC 104 of 640...
  • Page 105 Clutch Cable - Check/adjust 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. Service Manual - Scrambler 1200 XC 105 of 640...
  • Page 106 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. Service Manual - Scrambler 1200 XC 106 of 640...
  • Page 107 Always consult your authorised Triumph dealer for tyre replacement, or for a safety inspection of the tyres. As the tyre tread wears down, the tyre becomes more susceptible to puncture and failure.
  • Page 108 Operation with damaged or defective wheels is dangerous and loss of motorcycle control or an accident could result. Always consult your authorised Triumph dealer for a safety inspection of the wheels, or for wheel replacement. Check for broken or damaged spokes and check spoke tightness.
  • Page 109 Check the wheel bearings spin smoothly with no signs of play. If the bearings do not spin smoothly or there is excessive play in the wheel bearings, replace all bearings in that wheel. Service Manual - Scrambler 1200 XC 109 of 640...

  • Page 110: Steering Check

    Rectify as necessary. Fork 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 Service Manual - Scrambler 1200 XC 110 of 640...
  • Page 111 If roughness or excessive stiffness is detected, repair as described in the Front suspension section of this service manual or consult an authorised Triumph dealer. WARNING Riding the motorcycle with defective or damaged suspension can cause loss of motorcycle control and an accident.
  • Page 112 Refit the upper yoke (see Upper Yoke - Installation). Headstock Bearings - Lubricate 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 Service Manual - Scrambler 1200 XC 112 of 640...
  • Page 113 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 Service Manual - Scrambler 1200 XC 113 of 640...

  • Page 114: Brake Pad Wear Inspection

    WARNING Do not replace individual brake pads; replace both pads in the brake caliper. On the front where two calipers are mounted on the same wheel, all the pads in both Service Manual - Scrambler 1200 XC 114 of 640...

  • Page 115: Brake Fluid Level Inspection

    The brake fluid level must be kept between the upper and lower level lines with the motorcycle on its side stand and the steering on full left lock. jajc_2 Fixings Reservoir cap Upper level line Lower level line Service Manual - Scrambler 1200 XC 115 of 640...
  • Page 116 The brake fluid level must be kept between the upper and lower level lines (reservoir held horizontal). ckhe_1 Upper level line Lower level line Rear Brake Fluid Level Adjustment Release the fixings and remove the front sprocket outer cover. Service Manual - Scrambler 1200 XC 116 of 640...
  • Page 117 Release the fixing and remove the front sprocket middle cover. Discard the fixing. ckhd Fixings Sprocket middle cover Detach the brake fluid reservoir from the sprocket cover. Service Manual - Scrambler 1200 XC 117 of 640...
  • Page 118 A dangerous riding condition leading to loss of control of the motorcycle or an accident could result if this warning is ignored. Service Manual - Scrambler 1200 XC 118 of 640...
  • Page 119 This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Drive Chain Free Movement Inspection Maximum movement position Place the motorcycle on a level surface and hold it in an upright position with no Service Manual - Scrambler 1200 XC 119 of 640...
  • Page 120 Check for equal adjustment on both sides using the graduation marks on the swinging arm. Tighten both adjuster lock nuts to 20 Nm and the rear wheel spindle nut to 110 Service Manual - Scrambler 1200 XC 120 of 640...
  • Page 121 This is because the drive chain may wear unevenly. If the length exceeds the service limit of 319 mm (12.56 in), the chain must be Service Manual - Scrambler 1200 XC 121 of 640...
  • Page 122 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. Service Manual - Scrambler 1200 XC 122 of 640...
  • Page 123 With the side stand in the up position, unhook the spring from the side stand and remove it from the motorcycle. Remove and discard the E-clip securing the pivot pin. Remove the pivot pin and remove the side stand. Service Manual - Scrambler 1200 XC 123 of 640...
  • Page 124 Prior to fitting the side stand ensure the pivot pin and the bushes in the side stand are clean and free from grease. Fit the side stand to the motorcycle and insert the pivot pin. Fit a new E-clip to secure the pivot pin. Service Manual - Scrambler 1200 XC 124 of 640...
  • Page 125 Fully dry the cleaned area. Apply Castrol Chain Spray O-R, or an equivalent lubricant, to the shaded area shown below. L0897 Service Manual - Scrambler 1200 XC 125 of 640...
  • Page 126 Inspect the bank angle indicators on the rider's footrests for wear. The bank angle indicators have a wear indicator groove. Replace a bank angle indicator if it has worn down to the groove. Service Manual - Scrambler 1200 XC 126 of 640...
  • Page 127 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. Check for the latest calibration download for the following using the Triumph Diagnostic Tool: Instruments (If applicable)

  • Page 128: Road Test

    The ABS function is for use in emergency situations only. Any attempt to artificially create an emergency situation is extremely hazardous and could lead to a collision with a following vehicle or loss of motorcycle control and an accident. Service Manual - Scrambler 1200 XC 128 of 640...
  • Page 129 6 mph (10 km/h). Clutch Standard required: The clutch should engage smoothly, without judder, slipping or noise. Gear Change Standard required: Changing between gears must be smooth and easily accomplished. Throttle Response Standard required: Service Manual - Scrambler 1200 XC 129 of 640...
  • Page 130 Check the correct action of the rear suspension, including the damper action. Cruise Control (if fitted) Standard required: All cruise control switches must operate correctly. All functions and displays must operate as described in the Owner’s Handbook. Service Manual - Scrambler 1200 XC 130 of 640...
  • Page 131 Service Indicator and Service Maintenance Book Reset the service indicator using the Triumph Diagnostic Tool. See the Triumph Diagnostic Tool User Guide for more information. Stamp and date the relevant section of the Service Record. Post Road Test...
  • Page 132 The engine should start easily when at normal operating temperature and run smoothly at idle. Action: Switch off the engine (if running) and wait thirty seconds. Start the engine and allow to idle. Switch off the engine. Engine Service Manual - Scrambler 1200 XC 132 of 640...
  • Page 133 Standard required: The motorcycle bodywork must be clean and free from damage. Check: Check the motorcycle bodywork for new damage. Check the motorcycle bodywork for cleanliness. Engine Covers Exploded View – Sump Service Manual - Scrambler 1200 XC 133 of 640...
  • Page 134 Exploded View – Clutch Cover Service Manual - Scrambler 1200 XC 134 of 640...
  • Page 135 Exploded View – Alternator Cover Service Manual - Scrambler 1200 XC 135 of 640...
  • Page 136 Exploded View – Sprocket Cover Exploded View – Camshaft Cover Service Manual - Scrambler 1200 XC 136 of 640...
  • Page 137 The exhaust system will be hot if the engine has recently been running. Always allow sufficient time for the exhaust to cool before working on or near the exhaust system. Contact with a hot exhaust could result in burn injuries. Perform the following operations: Service Manual - Scrambler 1200 XC 137 of 640...
  • Page 138 Remove the sump to lower crankcase fixings. L0152 Sump Fixings Release the sump from the lower crankcase. Note The water pump drain tube may remain attached to the water pump or become detached with the sump. Service Manual - Scrambler 1200 XC 138 of 640...
  • Page 139 Incorporating a new sump gasket/baffle, position the sump to the lower crankcase. Tighten the sump fixings to 10 Nm in the sequence shown below. Retighten the fixings one and two to 10 Nm. Service Manual - Scrambler 1200 XC 139 of 640...
  • Page 140 T3880313 - Oil Filter Wrench and tighten to 10 Nm. L0151 Oil filter Oil drain plug Perform the following operations: Cradle Assemblies - Installation Fuel Tank - Installation Battery - Installation Service Manual - Scrambler 1200 XC 140 of 640...
  • Page 141 Seat - Removal Battery - Removal Disconnect the clutch cable at the clutch cover (see Clutch Cable - Removal). Release the fixing and disconnect the gear change actuator arm at the clutch cover. Service Manual - Scrambler 1200 XC 141 of 640...
  • Page 142 Place an oil catch tray beneath the clutch cover to collect any oil that may spill out on removal. Carefully withdraw the cover. Remove the gasket and clean the surfaces of the crankcase and the clutch cover Service Manual - Scrambler 1200 XC 142 of 640...
  • Page 143 CAUTION Do not drill or tap the latest condition clutch cover to fit the sound suppression assembly. Attempting to drill or tap the latest condition clutch cover may crack the boss. Service Manual - Scrambler 1200 XC 143 of 640...
  • Page 144 Tighten fixings 1 to 13 in the sequence shown below to 10 Nm. Fit the clutch cable bracket and tighten fixings 14 and 15 to 10 Nm. Retighten fixings one, two and six to 10 Nm. Service Manual - Scrambler 1200 XC 144 of 640...
  • Page 145 Actuator arm alignment mark Gear change actuator arm split line Refit and adjust the clutch cable (see Clutch Cable - Installation). Perform the following operations: Battery - Installation Seat - Installation Service Manual - Scrambler 1200 XC 145 of 640...
  • Page 146 Rear Mudguard - Removal Route the alternator harness from the alternator regulator/rectifier to the harness guide on the crankcase. Remove and discard the fixings and detach the harness guide from the crankcase. L0706 Fixings Service Manual - Scrambler 1200 XC 146 of 640...
  • Page 147 Harness Place an oil catch tray beneath the alternator cover to collect any oil that may spill out on removal. Release the fixings securing the alternator cover to the crankcases. ciuo Service Manual - Scrambler 1200 XC 147 of 640...
  • Page 148 Thoroughly clean the crankcase, harness grommet and alternator cover mating faces. Fit new O-rings to the balancer dead shaft. Service Manual - Scrambler 1200 XC 148 of 640...
  • Page 149 ThreeBond 1216E is used. ckjh Sealant area Gasket Apply a 2 mm (+/-0.5 mm) bead of silicone sealant to the area of the alternator Service Manual - Scrambler 1200 XC 149 of 640...
  • Page 150 ThreeBond 1216E is used. ckjc Sealant area Alternator cover Rubber grommet (harness removed for clarity) Fit the alternator cover and tighten the fixings to 10 Nm, in the sequence shown below. ciuo Tightening Sequence Service Manual - Scrambler 1200 XC 150 of 640...
  • Page 151 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: Service Manual - Scrambler 1200 XC 151 of 640...
  • Page 152 Lubricate the new camshaft cover fixing seals with clean engine oil. Fit the camshaft cover fixings and seals and tighten until finger tight. Tighten the fixings in the sequence shown to 14 Nm. Retighten fixings one to four to 14 Nm. Service Manual - Scrambler 1200 XC 152 of 640...
  • Page 153 Perform the following operations: Seat - Removal Battery - Removal Release the fixings and remove the front sprocket outer cover. Service Manual - Scrambler 1200 XC 153 of 640...
  • Page 154 CAUTION To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. Detach the brake fluid reservoir from the sprocket cover. Service Manual - Scrambler 1200 XC 154 of 640...
  • Page 155 Brake fluid reservoir Sprocket cover Secure the rear brake fluid reservoir in an upright position. Release the fixings and remove the sprocket cover. ckhn_1 Fixings Sprocket cover Front Sprocket Cover - Inspection WARNING Service Manual - Scrambler 1200 XC 155 of 640...
  • Page 156 If removed, refit the grommets to the sprocket cover. Fit the sprocket cover, ensuring that the flanged sleeves remain in the correct position. Fit the sprocket cover fixings and evenly and progressively tighten to 9 Nm. Service Manual - Scrambler 1200 XC 156 of 640...
  • Page 157 Sprocket cover Attach the brake fluid reservoir to the sprocket cover. ckhn Brake fluid reservoir Sprocket cover Refit the sprocket middle cover and tighten the new fixing to 3 Nm. ckhd Service Manual - Scrambler 1200 XC 157 of 640...
  • Page 158 Refit the sprocket outer cover and tighten the fixings to 9 Nm. ckhe Fixings Sprocket outer cover Perform the following operations: Battery - Installation Seat - Installation Cylinder Head Exploded View – Camshaft and Camshaft Drive Service Manual - Scrambler 1200 XC 158 of 640...
  • Page 159 Exploded View – Cylinder Head Service Manual - Scrambler 1200 XC 159 of 640...
  • Page 160 The camshaft lobes are splash fed by oil coming from the rocker arms. Camshaft Drive Chain Tensioner - Removal WARNING Service Manual - Scrambler 1200 XC 160 of 640...
  • Page 161 T3880601 - Camshaft Timing Pin Timing hole in alternator rotor In addition to the alignment mark, at TDC, the offset slot on the camshaft will align with the upper surface of the cylinder head. Service Manual - Scrambler 1200 XC 161 of 640...
  • Page 162 The hydraulic tensioner is under spring tension. Always wear hand, eye, and face protection when withdrawing the tensioner. Take great care to minimise the risk of injury and loss of components. Service Manual - Scrambler 1200 XC 162 of 640...
  • Page 163 Check that the camshaft alignment slot aligns with the cylinder head. To set the hydraulic tensioner onto the first tooth of the ratchet (i.e. minimum extension) carry out the following: Note Service Manual - Scrambler 1200 XC 163 of 640...
  • Page 164 Hold the resister ring ends together and pull out the plunger. cfei_2 Resister ring ends Plunger Remove the spring. Service Manual - Scrambler 1200 XC 164 of 640...
  • Page 165 Support the tensioner in a soft jawed vice. Hold the resister ends together, close the vice allowing the plunger to be pushed through the resister ring until the snap ring aligns with the snap ring groove. Service Manual - Scrambler 1200 XC 165 of 640...
  • Page 166 To release the plunger from the snap ring holding the hydraulic tensioner, rotate the crankshaft anticlockwise until the plunger is released. Rotate the crankshaft clockwise until the T3880601 - Camshaft Timing Pin aligns Service Manual - Scrambler 1200 XC 166 of 640...
  • Page 167 Ensure that the T3880601 - Camshaft Timing Pin aligns with the hole in the crankcase and the crankshaft. civb T3880601 - Camshaft Timing Pin Timing hole in alternator rotor Check that the camshaft timing marks align as shown below. Service Manual - Scrambler 1200 XC 167 of 640...
  • Page 168 The camshaft drive chain tensioner blade can be removed without removing the cylinder head. Perform the following operations: Seat - Removal Battery - Removal Fuel Tank - Removal Engine - Removal Service Manual - Scrambler 1200 XC 168 of 640...
  • Page 169 Refit the camshaft drive chain rubbing blade. Ensure the lower mounting tip is correctly located in the upper crankcase and the lugs are located in the barrel as noted during removal. Service Manual - Scrambler 1200 XC 169 of 640...
  • Page 170 '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 Service Manual - Scrambler 1200 XC 170 of 640...
  • Page 171 Note the side of which the marked outer plate is facing for installation. Secure the idler gear in position using the locking plate supplied with T3880016 - Balancer Gear C-Spanner-2 by locking the gear teeth as shown below. cizk Idler gear Service Manual - Scrambler 1200 XC 171 of 640...
  • Page 172 Remove and discard the fixing from the idler gear shaft. cjac Fixing Withdraw the idler gear shaft and collect the idler gear and camshaft drive chain from the upper crankcase. cizl Idler gear shaft Service Manual - Scrambler 1200 XC 172 of 640...
  • Page 173 For a more thorough check, proceed as follows: Remove the drive chain from the engine. Suspend the drive chain from a pin or hook with a 13 kg weight attached at the lower end. Service Manual - Scrambler 1200 XC 173 of 640...
  • Page 174 22 23 cajt Check for severe wear of the inner surface of the outer plates at the side-contact points with the sprocket teeth. ccru Check for signs of stiffness or kinking. Service Manual - Scrambler 1200 XC 174 of 640...
  • Page 175 Preload the backlash gear using T3880041 - Idler Gear Timing Wrench and locking plate T3880016 - Balancer Gear C-Spanner-2 as shown below. cizm Idler gear Locking plate (part of T3880016 - Balancer Gear C-Spanner) T3880041 - Idler Gear Timing Wrench Service Manual - Scrambler 1200 XC 175 of 640...
  • Page 176 Camshaft drive chain Install T3880039 - Idler Gear Timing Pin through the hole in the crankcase (alternator side) and through the smaller hole in the idler gear, as shown below. cjac Service Manual - Scrambler 1200 XC 176 of 640...
  • Page 177 Remove T3880039 - Idler Gear Timing Pin from the idler gear. Perform the following operations: Camshaft Cover - Installation Alternator Cover - Installation Engine - Installation Fuel Tank - Installation Battery - Installation Seat - Installation Exhaust Decompressors Service Manual - Scrambler 1200 XC 177 of 640...
  • Page 178 Camshaft Cover - Removal Alternator Cover - Removal Rotate the engine until T3880601 - Camshaft Timing Pin can be inserted through the hole in the alternator rotor, crankcase and into the idler gear. civb Service Manual - Scrambler 1200 XC 178 of 640...
  • Page 179 To avoid damage to the camshaft frames, always ensure as many camshaft lobes as possible are facing downwards. This will reduce stress on the camshaft frames during removal. Damage to the camshaft frames will result in replacement of the complete cylinder head. Service Manual - Scrambler 1200 XC 179 of 640...
  • Page 180 Remove the camshaft frames. Release the front camshaft timing chain tensioner blade and discard the fixings. Raise the camshaft slightly from the bearing journals, and remove the camshaft Service Manual - Scrambler 1200 XC 180 of 640...
  • Page 181 Tensioner guide Bearing journal Camshaft Detach the camshaft drive chain from the camshaft. Slide the camshaft to the right and remove it from the cylinder head. cjak Camshaft Camshaft drive chain Service Manual - Scrambler 1200 XC 181 of 640...
  • Page 182 CAUTION The camshaft sprockets are attached to the camshafts using slotted fixing holes. This allows for very accurate valve timing and therefore improved performance and fuel economy. Service Manual - Scrambler 1200 XC 182 of 640...
  • Page 183 Align the slot in the camshaft end to the upper surface of the cylinder head. Lift the camshaft slightly from the bearing journals, refit the camshaft drive chain tensioner blade. Tighten the new fixings to 10 Nm. cizr Tensioner blade Bearing journal Camshaft Note Service Manual - Scrambler 1200 XC 183 of 640...
  • Page 184 Adjust the camshaft sprocket, so that the camshaft chain is taut on the inlet side (rear) of the engine. Ensure there is no slack in the chain between the crankshaft and the sprocket and the sprocket fixings are centrally located within the slotted holes. Service Manual - Scrambler 1200 XC 184 of 640...
  • Page 185 Check that the camshaft drive chain is engaged around the idler gear and the camshaft sprocket is positioned against the tensioner blade. Fit the T3880651 - Timing Chain Tensioner and tighten to 16 Nm. Service Manual - Scrambler 1200 XC 185 of 640...
  • Page 186 The T3880609 - Timing Torque Limiter is pre-set to 0.6 Nm. Using the T3880609 - Timing Torque Limiter, tighten the internal screw thread to 0.6 Nm cizu T3880651 - Timing Chain Tensioner Adaptor Service Manual - Scrambler 1200 XC 186 of 640...
  • Page 187 Before inserting the timing pin, ensure the slot on the camshaft is aligned with the upper surface of the cylinder head. Insert the T3880601 - Camshaft Timing Pin into the timing holes in the crankcase and crankshaft. Service Manual - Scrambler 1200 XC 187 of 640...
  • Page 188 Fit the shims to the valves as noted during removal. Position cylinder one camshaft frame to the cylinder head. cizw Camshaft ladder (cylinder 2) Camshaft ladder (cylinder 1 Shims (cylinder 2 inlet) Service Manual - Scrambler 1200 XC 188 of 640...
  • Page 189 The rocker shaft must be fitted with the dot marks facing upwards and toward the camshaft drive gear. Fit the inlet and exhaust rockers and shafts to cylinder number two. Do not fully tighten at this stage. Service Manual - Scrambler 1200 XC 189 of 640...
  • Page 190 Damage to the camshaft frame will result in replacement of the cylinder head. In the sequence shown below, Tighten cylinder one camshaft frame fixings to 5 Nm. Tighten cylinder one camshaft frame fixings to 12 Nm. Service Manual - Scrambler 1200 XC 190 of 640...
  • Page 191 (see Valve Clearance Adjustment). Perform the following operations: Alternator Cover - Installation Camshaft Cover - Installation Ignition Coils - Installation Fuel Tank - Installation Battery - Installation Seat - Installation Service Manual - Scrambler 1200 XC 191 of 640...

  • Page 192: Valve Clearance

    Select a high gear and, using the rear wheel, rotate the engine until a camshaft lobe is positioned pointing directly away from the roller on the rocker shaft. Using feeler gauges, measure and record the clearances for this pair of valves only. Service Manual - Scrambler 1200 XC 192 of 640...
  • Page 193 Rocker shaft Rocker arm Shims (cylinder 1 inlet shown) Camshaft Note The underside of the shim displays the shim size. Always place the shim with the shim size facing towards the valve. Service Manual - Scrambler 1200 XC 193 of 640...
  • Page 194 Shims are available ranging from 2.00 mm to 3.20 mm in increments of 0.025 Fit the selected shim to the valve. Refit the rocker arm and shaft, tighten the bolts in the sequence shown below to 10 Nm. Service Manual - Scrambler 1200 XC 194 of 640...
  • Page 195 Camshaft - Removal Noting their position and the thickness of the shims, remove all eight shims from the cylinder head. Progressively release the cylinder head bolts in the order shown below. Service Manual - Scrambler 1200 XC 195 of 640...
  • Page 196 Note the position of the camshaft drive chain rubbing blade upper mounting for installation. Lift the camshaft drive chain tensioner rubbing blade out of the crankcase. cftg Camshaft drive chain tensioner rubbing blade Service Manual - Scrambler 1200 XC 196 of 640...
  • Page 197 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. Service Manual - Scrambler 1200 XC 197 of 640...
  • Page 198 Refit the camshaft drive chain rubbing blade. Ensure the lower mounting tip is correctly located in the upper crankcase and the lugs are located in the barrel as noted during removal. cftg Service Manual - Scrambler 1200 XC 198 of 640...
  • Page 199 Failure to follow the correct tightening procedure may lead to engine damage and premature failure of the cylinder head gasket. In the following sequence, tighten the cylinder new head bolts in four stages as Service Manual - Scrambler 1200 XC 199 of 640...
  • Page 200 Start the engine and allow it to idle while checking for air, oil, coolant and exhaust leaks. Rectify as necessary. Valves and Valve Stem Seals - Removal Remove each valve from the head using a valve spring compressor. The Service Manual - Scrambler 1200 XC 200 of 640...
  • Page 201 Valve removal Once the collets are released, remove the following items: Valve spring retainer Valve spring Valve spring base Valve stem oil seal Valve (deburr before removal). ca rr Service Manual - Scrambler 1200 XC 201 of 640...
  • Page 202 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 Service Manual - Scrambler 1200 XC 202 of 640...
  • Page 203 If a valve stem is found to be worn beyond the service limit, the valve must be renewed. Refer to Cylinder Head and Valves. Barrels and Pistons Exploded View - Barrels and Pistons Service Manual - Scrambler 1200 XC 203 of 640...
  • Page 204 This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Perform the following operations: Seat - Removal Battery - Removal Fuel Tank - Removal Service Manual - Scrambler 1200 XC 204 of 640...
  • Page 205 CAUTION Support the pistons as the barrels are removed to prevent piston damage. Lift off the barrels and recover the locating dowels. ciyg Locating dowels Remove and discard the base gasket. Service Manual - Scrambler 1200 XC 205 of 640...
  • Page 206 Piston and/or crankcase damage could occur if the pistons are not supported while turning the engine. Ensure the piston ring end gaps are correctly positioned (see Piston Rings - Assembly). Note Ensure the barrels and pistons are clean prior to installation. Service Manual - Scrambler 1200 XC 206 of 640...
  • Page 207 Refit the cylinder head (see Cylinder Head - Installation). Refit the camshafts (see page Camshaft - Installation). Recheck the tensioner plunger location against the camshaft drive chain tensioner blade. Remove T3880039 - Idler Gear Timing Pin from the crankcase. Service Manual - Scrambler 1200 XC 207 of 640...
  • Page 208 Remove and discard the gudgeon pin circlip from one side of the piston. 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. Service Manual - Scrambler 1200 XC 208 of 640...
  • Page 209 If any sign of damage is found, renew the piston. Measure the piston outside diameter 10 mm +/- 3 mm from the bottom of the piston and at 90° to the direction of the gudgeon pin. Service Manual - Scrambler 1200 XC 209 of 640...
  • Page 210 WARNING Failure to use new gudgeon pin circlips could allow the pin to detach from the piston. This could seize the engine resulting in loss of motorcycle control and an accident. Service Manual - Scrambler 1200 XC 210 of 640...
  • Page 211 Insert the gudgeon pin into the piston and push it fully into position. T908_7 Gudgeon Pin Secure the gudgeon pin in position with the remaining new circlip. Ensure the circlip is correctly located in the piston groove. CAUTION Service Manual - Scrambler 1200 XC 211 of 640...
  • Page 212 Barrels - Installation Fuel Tank - Installation Battery - Installation Seat - Installation Piston Ring to Groove - Clearance Note Prior to removing the rings, check the ring-to-groove clearance of each compression ring. Service Manual - Scrambler 1200 XC 212 of 640...
  • Page 213 The rings are brittle and will break if expanded too much. Ease the top compression ring out of its groove and remove it from the top of the piston. Remove the second compression ring in the same way. Note Service Manual - Scrambler 1200 XC 213 of 640...
  • Page 214 Remove the piston and measure the gap between the ends of the piston ring, using a feeler gauge. Service Manual - Scrambler 1200 XC 214 of 640...
  • Page 215 The second and top compression rings are different and are not interchangeable. The top ring can be identified by the chamfer on its upper inside edge. The second ring has no chamfer. Service Manual - Scrambler 1200 XC 215 of 640...
  • Page 216 Position the piston ring end gaps as follows (piston viewed from above, triangular mark facing forwards). caqj_4 Piston Ring End Gap Locations Top ring Second ring First steel oil control ring Oil control ring expander Service Manual - Scrambler 1200 XC 216 of 640...
  • Page 217 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. Clutch Exploded View – Clutch Controls Service Manual - Scrambler 1200 XC 217 of 640...
  • Page 218 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. Service Manual - Scrambler 1200 XC 218 of 640...
  • Page 219 Loosen the cable lock nut and release the adjuster at the clutch cover end to give maximum play in the cable. L0705 Clutch cable Adjuster nut Lock nut From the left hand side of the headstock, remove the cable retaining bracket and discard its fixings. L0713 Service Manual - Scrambler 1200 XC 219 of 640...
  • Page 220 Align the cable adjuster and lever bracket slots. Pull in the clutch lever and turn the inner cable adjuster anticlockwise through the lock nut, until the cable can be detached from the lever. Service Manual - Scrambler 1200 XC 220 of 640...
  • Page 221 Attach the inner cable to the boss on the clutch actuating arm using a reversal of the removal process. Refit the outer cable to the adjuster bracket at the clutch cover end. Service Manual - Scrambler 1200 XC 221 of 640...
  • Page 222 Tighten the clutch adjuster bracket lock nut at the clutch cover end to 3 Nm. Set the final adjustment of the cable to give 1 - 2 mm of free play at the lever by Service Manual - Scrambler 1200 XC 222 of 640...
  • Page 223 Note the orientation of the clutch lifter arm for installation. Note the position and orientation of the lifter arm spring for installation. Remove the clutch lifter arm spring. Service Manual - Scrambler 1200 XC 223 of 640...
  • Page 224 Using a suitable tool, carefully remove the oil seal in the clutch cover without damaging the clutch cover. Check the condition of the needle roller bearings and the lifter arm for damage. If necessary renew the needle roller bearings and clutch lifter arm. Service Manual - Scrambler 1200 XC 224 of 640...
  • Page 225 Press a new clutch lifter rod oil seal to the clutch cover, ensure the sealing lip is facing inwards. Lubricate the seal lip with molybdenum disulphide grease and fit the clutch lifter arm into the clutch cover as noted for removal. ckfg Service Manual - Scrambler 1200 XC 225 of 640...
  • Page 226 Clutch lifter arm plate Note The horizontal tang on the spring fits into the slot of the clutch lifter arm. Fit the spring as noted for removal. ckfh Service Manual - Scrambler 1200 XC 226 of 640...
  • Page 227 Note The spring seats will remain seated in the pressure plate during removal. Release the three fixings, remove the stopper plate, springs and pressure plate. Fixings Stopper plate Springs Spring seats Service Manual - Scrambler 1200 XC 227 of 640...
  • Page 228 Refer to Friction Plate Inspection for details of clutch friction plate inspection. Engage second gear and lock the inner and outer clutch drums together using T3880307 - Clutch Anti-rotation Jig as shown below. Service Manual - Scrambler 1200 XC 228 of 640...
  • Page 229 Slide the bearing sleeve forward and backwards a maximum of 10 mm to allow the needle roller bearing to become dislodged. Remove the needle roller bearing from the clutch outer drum. cixd Bearing sleeve Needle roller bearing Service Manual - Scrambler 1200 XC 229 of 640...
  • Page 230 If the feeler gauge can be passed beneath the steel plate at any point, renew the plates as a set. Service Manual - Scrambler 1200 XC 230 of 640...
  • Page 231 1 x new inner friction plate 6 x steel plates, 2.0 mm thick 1 x outer steel plate, 2.0 mm thick. Arrange the new friction and new steel plates in a stack as shown below. Service Manual - Scrambler 1200 XC 231 of 640...
  • Page 232 7. If the clutch pack is too low, continue from step 6. Note 1.6 mm and 2.3 mm steel plates are available, refer to the Parts Catalogue for part numbers. Service Manual - Scrambler 1200 XC 232 of 640...
  • Page 233 No more than one 2.3 mm thick steel plate is to be used in the clutch pack. 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. Service Manual - Scrambler 1200 XC 233 of 640...
  • Page 234 Pump sprocket Position the clutch outer drum assembly to the input shaft and align the oil pump sprocket drive pegs with the corresponding holes in the rear of the clutch outer Service Manual - Scrambler 1200 XC 234 of 640...
  • Page 235 Clutch outer drum sprocket drive holes While holding the clutch outer drum in position and ensuring correct engagement with the oil pump drive, refit the bearing. ciwy Outer drum Bearing sleeve Needle roller bearing Service Manual - Scrambler 1200 XC 235 of 640...
  • Page 236 Using T3880307 - Clutch Anti-rotation Jig, lock the inner and outer drums together. Depress the rear brake pedal to prevent the engine rotating, and tighten the centre nut to 98 Nm. Remove T3880307 - Clutch Anti-rotation Jig. Service Manual - Scrambler 1200 XC 236 of 640...
  • Page 237 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. ciww Clutch outer drum Service Manual - Scrambler 1200 XC 237 of 640...
  • Page 238 Fit the springs and stopper plate, ensure that the OUT mark on the stopper plate is facing outwards. Secure with the fixings and tighten to 10 Nm. Fixings Stopper plate Springs Spring seats Service Manual - Scrambler 1200 XC 238 of 640...
  • Page 239 Pressure plate Perform the following operations: Clutch Cover - Installation Clutch Cable - Installation Battery - Installation Seat - Installation Crankcase, Crankshaft and Connecting Rods Exploded View – Crankshaft and Connecting Rod Service Manual - Scrambler 1200 XC 239 of 640...
  • Page 240 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: Seat - Removal Service Manual - Scrambler 1200 XC 240 of 640...
  • Page 241 T3880039 - Idler Gear Timing Pin Remove the oil and water pump (see Oil and Water Pump - Removal). Release the fixing and remove the coolant drain tube, discard the fixing and the O-ring. Service Manual - Scrambler 1200 XC 241 of 640...
  • Page 242 Coolant drain tube Fixing Release the lower crankcase fixings noting their positions in the sequence shown below. ciyl Service Manual - Scrambler 1200 XC 242 of 640...
  • Page 243 Perform the following operations: Front Balancer Shaft - Removal Rear Balancer Shaft - Removal Crankshaft - Removal Selector Forks and Drum - Removal Coolant Manifold - Removal Breather Plate - Removal Crankcase - Assembly Service Manual - Scrambler 1200 XC 243 of 640...
  • Page 244 Balancer Shaft - Installation). Lubricate the crankshaft journals with clean engine oil. Apply a 2 mm (+/-0.5 mm) bead of silicone sealant to the lower crankcase mating faces, (during manufacture, ThreeBond 1216E is used). Service Manual - Scrambler 1200 XC 244 of 640...
  • Page 245 Check that the dot mark on the rear balancer shaft gear is aligned with the tab on the crankcase, as shown below. cjcm Lower crankcase identification mark Rear balancer shaft dot mark Service Manual - Scrambler 1200 XC 245 of 640...
  • Page 246 Failure to follow the correct tightening sequence may result in permanent crankcase damage. Stage 1 - All Fixings In the sequence shown below: Tighten all of the crankcase fixings to 10 Nm. Service Manual - Scrambler 1200 XC 246 of 640...
  • Page 247 All Fixings Tightening Sequence Stage 2 In the sequence shown below: Loosen fixings 1 to 8. through 140°, using T3880105 - Torque Angle Gauge or similar to measure the torque-angle. ciyl Service Manual - Scrambler 1200 XC 247 of 640...
  • Page 248 Tighten fixings 1 to 8 to 11 Nm. ciyl Fixings 1 to 8 Tightening Sequence In the sequence shown below: Tighten fixings 1 to 8 through a further 75° using T3880105 - Torque Angle Gauge Service Manual - Scrambler 1200 XC 248 of 640...
  • Page 249 Fixings 1 to 8 Tightening Sequence Stage 4 In the sequence shown below: Tighten fixings 9 to 13 to 32 Nm. Service Manual - Scrambler 1200 XC 249 of 640...
  • Page 250 Fixings 9 to 13 Tightening Sequence Stage 5 In the sequence shown below: Tighten fixings 14 to 24 to 12 Nm. Service Manual - Scrambler 1200 XC 250 of 640...
  • Page 251 Prior to fitting an O-ring coat the surfaces with a commercially available petroleum jelly. Refit the breather drain tube, fit a new O-ring, tighten the new fixing to 9 Nm. ciyk Service Manual - Scrambler 1200 XC 251 of 640...
  • Page 252 Connecting Rods - Removal Note Support the connecting rods during crankshaft removal to prevent damage to the rods, liners and upper crankcase. Remove the crankshaft from the upper crankcase. Crankshaft - Installation CAUTION Service Manual - Scrambler 1200 XC 252 of 640...
  • Page 253 Start the engine and ensure that the low oil pressure warning light goes out shortly after starting. Stop the engine and check the engine oil level. Adjust if necessary (see Engine Oil - Level Inspection). Connecting Rods - Removal Service Manual - Scrambler 1200 XC 253 of 640...
  • Page 254 Connecting rod cap Connecting rod Collect the connecting rod caps. Collect the piston and connecting rod. Label the assembly to identify the cylinder from which it was removed. Connecting Rod - Installation Note Service Manual - Scrambler 1200 XC 254 of 640...
  • Page 255 Fit new bolts to the connecting rods. Tighten the bolts, in two stages as follows: Tighten to 15 Nm. Tighten through 210° using T3880105 - Torque Angle Gauge or similar. Service Manual - Scrambler 1200 XC 255 of 640...
  • Page 256 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). Remove the bearing cap from the journal to be checked.
  • Page 257 Measure and record the diameter of each crankshaft bearing journal. Measure and record each bearing bore diameter (bearings removed, journal caps fitted and all fixings fully torqued) (see Connecting Rod - Installation). Service Manual - Scrambler 1200 XC 257 of 640...
  • Page 258 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. Measure the bearing to crankshaft journal clearance as follows. Note Service Manual - Scrambler 1200 XC 258 of 640...
  • Page 259 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). Wipe the exposed areas of the crankshaft journals, and the bearing face inside the cap.
  • Page 260 Blue 46.123 to 43.108 to 43.100 0.042 to 0.019 46.114 Green 46.123 to 43.099 to 43.092 0.042 to 0.020 46.114 For instance: Crankcase Bore 46.123 mm Crankshaft Journal Diameter 43.108 mm Service Manual - Scrambler 1200 XC 260 of 640...
  • Page 261 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. Service Manual - Scrambler 1200 XC 261 of 640...
  • Page 262 Release the fixings and remove the coolant manifold, discard the fixings and the sealing ring. ciyo Coolant manifold Fixings Coolant Manifold - Installation Fit a new sealing ring to the coolant manifold. cizf Service Manual - Scrambler 1200 XC 262 of 640...
  • Page 263 Start the engine and ensure that the low oil pressure warning light goes out shortly after starting. Stop the engine and check the engine oil level. Adjust if necessary (see Engine Oil - Level Inspection). Seat - Installation Breather Plate - Removal WARNING Service Manual - Scrambler 1200 XC 263 of 640...
  • Page 264 Remove the breather drain tube from the crankcase, discard the fixing and the O-ring. Remove the input and output shafts. Remove the engine oil breather plate and baffle, discard the fixings. ciyz Oil breather plate Fixings Breather drain tube Service Manual - Scrambler 1200 XC 264 of 640...
  • Page 265 Put a new O-ring onto each end of the breather tube and install the breather drain tube into the crankcase. Make sure that the tube is correctly installed in the breather plate housing. Install a new fixing and tighten to 9 Nm. Service Manual - Scrambler 1200 XC 265 of 640...
  • Page 266 Start the engine and ensure that the low oil pressure warning light goes out shortly after starting. Stop the engine and check the engine oil level. Adjust if necessary (see Engine Oil - Level Inspection). Seat - Installation Balancer Exploded View – Balancers Service Manual - Scrambler 1200 XC 266 of 640...
  • Page 267 Perform the following operations: Seat - Removal Battery - Removal Fuel Tank - Removal Engine - Removal Crankcase - Disassembly Remove the input and output shafts. Note Service Manual - Scrambler 1200 XC 267 of 640...
  • Page 268 Dead shaft clamp Locking screw Securing screw Washer Dead shaft Release the dead shaft screw and washer. Discard the dead shaft screw and retain the washer. Service Manual - Scrambler 1200 XC 268 of 640...
  • Page 269 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: Seat - Removal Service Manual - Scrambler 1200 XC 269 of 640...
  • Page 270 Remove and discard the connecting rod bolts. ciyh Connecting rod bolts Connecting rod cap Connecting rod Remove the crankshaft. Remove the front balancer shaft blanking screw and, discard the washer. Service Manual - Scrambler 1200 XC 270 of 640...
  • Page 271 Dead shaft clamp Locking screw Securing screw Washer Dead shaft Support the balancer shaft and noting its orientation slide the dead shaft from the crankcase. Service Manual - Scrambler 1200 XC 271 of 640...
  • Page 272 Dead shaft Dead shaft clamp Remove the balancer shaft. Remove and discard the O-rings from the deadshaft. Deadshaft O-rings Balancer shafts - Inspection Inspect all gears for chipped or missing teeth. Service Manual - Scrambler 1200 XC 272 of 640...
  • Page 273 The balancer shaft gear is designed to mesh with the crankshaft gear. Correct adjustment of the balancer shafts is critical to the performance of the engine and comfort of the rider. Service Manual - Scrambler 1200 XC 273 of 640...
  • Page 274 The static alignment of the balancer shaft will allow for initial starting of the engine. Final adjustment must be carried out with the engine running and at operating temperature, see Balancer Shafts Dynamic Adjustment. Service Manual - Scrambler 1200 XC 274 of 640...
  • Page 275 Balancer shaft Balancer shaft 'F' (front) mark Balancer shaft alignment mark T3880811 - Front Balancer Timing Tool Crankcase Clean the crankshaft, crankshaft bearings and big end bearings with a high Service Manual - Scrambler 1200 XC 275 of 640...
  • Page 276 The alignment mark on the balancer shaft is visible through the screw hole in the dead shaft clamp. The T3880601 - Camshaft Timing Pin can be inserted fully, locking the crankshaft in position. Service Manual - Scrambler 1200 XC 276 of 640...
  • Page 277 Refit the dead shaft clamp and tighten the new securing screw to 10 Nm and then tighten the dead shaft clamp locking screw to 11 Nm. ciza Dead shaft clamp Locking screw Securing screw Service Manual - Scrambler 1200 XC 277 of 640...
  • Page 278 Lubricate the balancer shaft, needle roller bearings and O-rings with clean engine oil. Position the balancer shaft as noted during removal. Fit the deadshaft into the crankcase as noted during removal and insert the Service Manual - Scrambler 1200 XC 278 of 640...
  • Page 279 Position the balancer shaft so that the preload mark aligns with the crankcase identification mark. Refit the dead shaft clamp and tighten the new securing screw to 10 Nm and then tighten the dead shaft clamp locking screw to 11 Nm. Service Manual - Scrambler 1200 XC 279 of 640...
  • Page 280 Securing screw Washer Balancer shaft Lock the balancer shaft into position using T3880809 - Rear Balancer Timing Tool. Lubricate the crankshaft and bearings with clean engine oil. ciyn Crankcase identification mark Service Manual - Scrambler 1200 XC 280 of 640...
  • Page 281 To avoid skin damage, always allow the hot parts to cool before working on the exhaust system. WARNING The cooling fan is switched on and off by the Engine Control Module in response Service Manual - Scrambler 1200 XC 281 of 640...
  • Page 282 The balancer shafts must always be adjusted in the same operation. Adjusting the front or rear balancer shafts individually may cause the engine to whine or rattle. Unsatisfactory adjustment of the balancer shafts may cause severe engine damage. Service Manual - Scrambler 1200 XC 282 of 640...
  • Page 283 Stop the engine. Remove the embellisher from the alternator cover and discard the fixings. Remove the dead shaft clamp blanking plug and discard the washer. cizg Service Manual - Scrambler 1200 XC 283 of 640...
  • Page 284 Allowing the gears to mesh incorrectly for extended periods may cause damage to the gears and or bearings. Start the engine and allow to idle. Gently rotate the dead shaft clockwise until a whining noise can just be heard. Service Manual - Scrambler 1200 XC 284 of 640...
  • Page 285 Dead shaft Rotate the dead shaft anticlockwise until the whining noise can no longer be heard. ciyc Dead shaft Tighten the dead shaft clamp locking screw to 11 Nm. Stop the engine. Service Manual - Scrambler 1200 XC 285 of 640...
  • Page 286 Refit the embellisher cover to the alternator cover, tighten the new fixings to 4 Nm. cizg Embellisher Fixings Dead shaft clamp blanking plug Oil filler cap Rear Balancer shaft Dynamic Adjustment Remove the clutch cover plug. Service Manual - Scrambler 1200 XC 286 of 640...
  • Page 287 Using T3880652 - Dead Shaft Key Tool, loosen the dead shaft clamp locking screw a maximum of two complete turns to allow smooth rotation of the balancer dead shaft in the clamp. Service Manual - Scrambler 1200 XC 287 of 640...
  • Page 288 Start the engine and allow to idle. Rotate the rear dead shaft clockwise until a whining noise can be heard. Dead shaft Rotate the dead shaft anticlockwise until the whining noise can no longer be heard. Service Manual - Scrambler 1200 XC 288 of 640...
  • Page 289 Wipe away any spilled oil from the upper crankcase. Using a new O-ring refit the oil filler cap and tighten to 3 Nm. cizg Oil filler cap Refit the clutch cover plug and tighten to 10 Nm. Service Manual - Scrambler 1200 XC 289 of 640...
  • Page 290 Clutch cover plug Clutch cover Inspect the engine oil level (see Engine Oil - Level Inspection). Transmission Exploded View – Input and Output Shafts Service Manual - Scrambler 1200 XC 290 of 640...
  • Page 291 Exploded View – Gear Selector Service Manual - Scrambler 1200 XC 291 of 640...
  • Page 292 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: Seat - Removal Service Manual - Scrambler 1200 XC 292 of 640...
  • Page 293 Remove and discard the fixings and remove the oil pump drive chain guide from the crankcase. cjcb Oil pump drive chain guide Fixings Withdraw the abutment dowel from the crankcase. cjca Abutment dowel Abutment spring Service Manual - Scrambler 1200 XC 293 of 640...
  • Page 294 This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Position the selector mechanism into the crankcase and locate the pivot plate to the detent wheel. Service Manual - Scrambler 1200 XC 294 of 640...
  • Page 295 Insert the abutment dowel with the spring tangs positioned to either side. cjca Abutment dowel Abutment spring Refit the pump drive chain guide to the crankcase. Tighten the new fixings to 7 Service Manual - Scrambler 1200 XC 295 of 640...
  • Page 296 Gear Change Shaft - Removal Remove the gear change shaft (see Gear Change Shaft - Removal). Release the detent arm spring. Release the detent arm fixing and remove the detent arm. Discard the fixing. Service Manual - Scrambler 1200 XC 296 of 640...
  • Page 297 Prevent the drum from turning and tighten the fixing to 12 Nm. cfwy Selector drum Detent wheel Slot Refit the spacer, detent arm, washer and a new fixing as noted during removal. Service Manual - Scrambler 1200 XC 297 of 640...
  • Page 298 This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Perform the following operations: Seat - Removal Battery - Removal Fuel Tank - Removal Engine - Removal Crankcase - Disassembly Service Manual - Scrambler 1200 XC 298 of 640...
  • Page 299 Remove and discard the fixing securing the output selector shaft retainer. cjci Fixing Output selector shaft retainer Output selector shaft Remove and discard the fixing securing the input selector shaft. cjck Service Manual - Scrambler 1200 XC 299 of 640...
  • Page 300 Output selector shaft Input selector shaft Selector fork (input shaft) Selector fork (output shaft) Selector fork (output shaft) Remove the selector drum bearing keeper plate and discard the fixing. Remove the selector drum. Service Manual - Scrambler 1200 XC 300 of 640...
  • Page 301 If removed, refit the detent wheel to the selector drum, ensuring the pin on the drum locates in the slot in the detent wheel. Prevent the drum from turning and tighten the new fixing to 12 Nm. cfwy Selector drum Service Manual - Scrambler 1200 XC 301 of 640...
  • Page 302 Position the output selector fork shaft and selector forks to the crankcase as noted during removal, Position the input selector fork shaft and selector fork to the crankcase as noted during removal. Service Manual - Scrambler 1200 XC 302 of 640...
  • Page 303 Using a new fixing secure the output selector shaft retainer, tighten the fixing to 12 cjci Fixing Retainer Selector shaft Using a new fixing secure the input selector shaft, tighten the fixing to 22 Nm. Service Manual - Scrambler 1200 XC 303 of 640...
  • Page 304 Gear Position Sensor - Installation Gear Change Shaft - Installation Refit the transmission shafts Crankcase - Assembly Engine - Installation Fuel Tank - Installation Battery - Installation Seat - Installation Exploded View - Output Shaft Service Manual - Scrambler 1200 XC 304 of 640...
  • Page 305 Circlip Sixth gear Thrust washer Plain bush Second gear Second gear spacer Outer bearing Snap ring Distance sleeve Output shaft seal Sprocket Tab washer Sprocket nut Output Shaft - Disassembly WARNING Service Manual - Scrambler 1200 XC 305 of 640...
  • Page 306 Bearing outer carrier Needle roller bearing Remove and discard the circlip. Noting its orientation, remove the bearing from the output shaft. Remove the thrust washer. Service Manual - Scrambler 1200 XC 306 of 640...
  • Page 307 Output shaft seal Roller bearing Distance sleeve Mark one side of first gear to denote its correct orientation and remove it from the shaft. Remove the needle roller bearing from the shaft. Service Manual - Scrambler 1200 XC 307 of 640...
  • Page 308 Mark one side of fifth gear to denote its correct orientation and remove it from the shaft. cjgg_1 Fifth gear Output shaft Remove the circlip and splined thrust washer. Discard the circlip. Service Manual - Scrambler 1200 XC 308 of 640...
  • Page 309 Noting its orientation, remove the plain bush which runs inside the gear. cjgf Circlip Splined thrust washer Fourth gear Plain bush Output shaft Working on the opposite end of the shaft, attach a proprietary bearing separator Service Manual - Scrambler 1200 XC 309 of 640...
  • Page 310 Mark one side of second gear to denote its correct orientation and remove it from the shaft. Noting its orientation, remove the plain bush from the shaft. Remove the thrust washer from the shaft. Service Manual - Scrambler 1200 XC 310 of 640...
  • Page 311 Second gear spacer Second gear Bush Thrust washer Output shaft Noting its orientation, remove the sixth gear. cjgd_1 Sixth gear Output shaft Remove the circlip and the splined thrust washer, discard the circlip. Service Manual - Scrambler 1200 XC 311 of 640...
  • Page 312 Replace all defective components and always use new circlips, a new output shaft seal and a new sprocket tab washer to assemble the shaft. Output Shaft - Assembly Service Manual - Scrambler 1200 XC 312 of 640...
  • Page 313 Lubricate each gear, thrust washer and bush with clean engine oil during assembly. Locate third gear and the plain bush to the shaft as noted during disassembly. Fit the splined thrust washer and retain with a new circlip as shown below. Service Manual - Scrambler 1200 XC 313 of 640...
  • Page 314 Circlip Splined washer Third gear Output shaft Fit the sixth gear as noted during disassembly. cjgd_1 Sixth gear Output shaft Fit the thrust washer. CAUTION Service Manual - Scrambler 1200 XC 314 of 640...
  • Page 315 Place the output shaft on a press bar, align the inner race of the ball bearing to the output shaft. Press the output shaft through the bearing until the bearing face contacts the thrust washer. Service Manual - Scrambler 1200 XC 315 of 640...
  • Page 316 Press the output shaft through the distance sleeve until it comes into contact with the bearing face. cjgb_1 Distance sleeve Ball bearing Spacer Output shaft Lubricate and fit a new output shaft seal. Service Manual - Scrambler 1200 XC 316 of 640...
  • Page 317 Working from the opposite end of the shaft, fit the plain bush as noted during disassembly. Fit fourth gear as noted during disassembly. Fit the splined thrust washer and retain using a new circlip, as shown below. Service Manual - Scrambler 1200 XC 317 of 640...
  • Page 318 Fit fourth gear as noted during disassembly. Ensure that the smaller dogs face towards fourth gear. cjgg_1 Fifth gear Output shaft Fit the plain bush as noted during disassembly. Fit first gear as noted during disassembly. Fit the thrust washer. Service Manual - Scrambler 1200 XC 318 of 640...
  • Page 319 T908.07.27 Circlip Needle roller bearing Thrust washer Lubricate the bearing with oil and then slide the bearing outer roller carrier over the needle roller bearing in the orientation noted during disassembly. Service Manual - Scrambler 1200 XC 319 of 640...
  • Page 320 Bearing outer carrier Needle roller bearing Exploded View - Input Shaft Bearing retainer bolts Bearing retainer plate Ball bearing Input shaft Plain bush Service Manual - Scrambler 1200 XC 320 of 640...
  • Page 321 The gears on the input shaft can not be fully disassembled or assembled in service. If for any reason a gear requires replacing, the complete input shaft assembly must be replaced. Remove the restrictor washer, and roller bearing. Service Manual - Scrambler 1200 XC 321 of 640...
  • Page 322 Attach T3880109 - Bearing Separator to the bearing, ensuring the flat side of the tool’s jaws are in contact with the bearing. Service Tool Installation Support the T3880109 - Bearing Separator on press bars, then press the shaft through the bearing. Discard the bearing. Service Manual - Scrambler 1200 XC 322 of 640...
  • Page 323 Note Lubricate the bearings with clean engine oil during assembly. Position a new bearing to the input shaft. Service Manual - Scrambler 1200 XC 323 of 640...
  • Page 324 Press the bearing fully on to the shaft. cjcg Input shaft Bearing Press plates Fit the roller bearing and restrictor washer to the input shaft. cjbx Restrictor washer Roller bearing Service Manual - Scrambler 1200 XC 324 of 640...
  • Page 325 Input shaft Starter Drive and Sprag Clutch Exploded View - Starter and Sprag Starter Drive/Sprag Clutch - Removal WARNING Service Manual - Scrambler 1200 XC 325 of 640...
  • Page 326 Starter sprag gear Using T3880375 - Alternator Rotor Holder to retain the flywheel, remove and discard the fixings securing the starter gear thrust washer to the sprag clutch housing, as shown below. Service Manual - Scrambler 1200 XC 326 of 640...
  • Page 327 T3880375 - Alternator Rotor Holder Sprag clutch housing Thrust washer Remove and discard the fixings securing the sprag clutch housing to the flywheel. ciwt Fixings Withdraw the starter sprag gear and sprag clutch assembly. Service Manual - Scrambler 1200 XC 327 of 640...
  • Page 328 Starter Sprag Gear Remove the starter sprag gear from the sprag clutch housing assembly. cixh Starter sprag gear Sprag clutch housing Sprag clutch Remove the sprag clutch from the sprag clutch housing. Service Manual - Scrambler 1200 XC 328 of 640...
  • Page 329 Sprag clutch housing Sprag clutch Fit the starter sprag gear to the sprag clutch. Lubricate the crankshaft bearing with engine oil. Service Manual - Scrambler 1200 XC 329 of 640...
  • Page 330 Ensure the sprag is seated and flush fitting to the housing before tightening the fixings fully. Align the drilled holes in the sprag clutch housing with the holes in the flywheel. ciws Service Manual - Scrambler 1200 XC 330 of 640...
  • Page 331 Using tool T3880375 - Alternator Rotor Holder Tool to retain the flywheel and using new fixings secure the starter gear thrust washer to the flywheel. Tighten the fixings to 12 Nm. ciwv Service Manual - Scrambler 1200 XC 331 of 640...
  • Page 332 Starter idler gear (second) Starter idler gear (first) Starter sprag gear Perform the following operations: Clutch Cover - Installation Battery - Installation Seat - Installation Lubrication Exploded View – Oil Filter and Pump Service Manual - Scrambler 1200 XC 332 of 640...
  • Page 333 Oil Circuit Diagram Service Manual - Scrambler 1200 XC 333 of 640...

  • Page 334: Oil Circuit

    One of the bolt drilling’s feeds the left hand cam shaft frame and the other feeds the right hand camshaft frame. Drillings and grooves in the camshaft frames allow oil to flow to the camshaft Service Manual - Scrambler 1200 XC 334 of 640...
  • Page 335 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 motorcycle and with this objective in mind have tested many of the engine lubricants currently available to the limits of their performance.
  • Page 336 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.
  • Page 337 Release the oil pick-up from the oil seal. Remove and discard the oil seal. cja q Oil pick-up Oil seal Slide the oil pump drive sprocket gently backwards and forwards to release the needle roller bearing. Service Manual - Scrambler 1200 XC 337 of 640...
  • Page 338 Support the oil pump drive sprocket and carefully remove the bush, spacer and needle roller bearing while noting it’s orientation. ciue Oil pump drive sprocket Needle roller bearing Spacer Bush Release and discard the fixings securing the oil and water pump. Service Manual - Scrambler 1200 XC 338 of 640...
  • Page 339 Carefully withdraw the oil and water pump from the crankcase. Note The water pump inlet sleeve/O-rings can become dislodged during removal of the oil pump. Remove the coolant outlet sleeve and the oil pump outlet sleeve from the crankcase. Service Manual - Scrambler 1200 XC 339 of 640...
  • Page 340 Remove and discard the four O-rings from the coolant outlet sleeve and then remove and discard the two O-rings from the oil outlet sleeve. ciuh Coolant outlet sleeve O-ring (coolant) Oil outlet sleeve O-ring (oil) Service Manual - Scrambler 1200 XC 340 of 640...

  • Page 341: Oil Pump Inspection

    Replace the pump assembly if necessary. Oil Pump - Disassembly Using T3880603 - Oil Pump Restraint release the fixing and remove the drive sprocket and spacer washer. Service Manual - Scrambler 1200 XC 341 of 640...
  • Page 342 Check the shaft and shaft bearings for side and end float. Replace the pump if wear is found. Carry out a visual inspection for corrosion and scale build-up around the coolant pump impeller and in the coolant pump body. Replace the pump assembly if Service Manual - Scrambler 1200 XC 342 of 640...
  • Page 343 Measure the rotor tip clearance using feeler gauges. For specifications refer toLubrication. chho_1 Rotor Tip Clearance Oil Pump Body Clearance Measure the pump body clearance using feeler gauges. For specifications refer toLubrication. chhp Service Manual - Scrambler 1200 XC 343 of 640...
  • Page 344 Wipe the exposed areas of the rotors and the machined face of the end plate. Note The oil pump end clearance is measured using Plastigauge (Triumph part number 3880150-T0301). Do not turn the oil pump during the clearance measurement as this will damage the 'Plastigauge'.
  • Page 345 If all clearances are within service limits, liberally apply clean engine oil to all internal components and refit the rotor to the oil pump body. Refit the end plate. Apply ThreeBond 1374 to the fixings, refit and tighten to 10 ciuk Service Manual - Scrambler 1200 XC 345 of 640...
  • Page 346 This will cause the engine to run without engine oil pressure and will lead to severe engine damage. Install four new O-rings to the water pump outlet sleeve. Install two new O-rings to the oil pump outlet sleeve. Service Manual - Scrambler 1200 XC 346 of 640...
  • Page 347 Oil outlet sleeve O-ring (coolant inlet) 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. Service Manual - Scrambler 1200 XC 347 of 640...
  • Page 348 Refit the oil and water pump. Install new fixings and tighten to 10 Nm in the sequence shown below. ciud_1 Tightening Sequence Support the oil and water pump drive sprocket and carefully refit the bush spacer and needle roller bearing as noted during removal. Service Manual - Scrambler 1200 XC 348 of 640...
  • Page 349 Perform the following operations: Clutch - Installation Sump - Installation Engine Oil and Filter Renew Coolant Replacement - Filling Battery - Installation Seat - Installation Oil Pressure Relief Valve - Removal WARNING Service Manual - Scrambler 1200 XC 349 of 640...
  • Page 350 Battery - Removal Sump - Removal WARNING The oil may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned. Remove the blanking plug. Service Manual - Scrambler 1200 XC 350 of 640...
  • Page 351 Refit the sump, ensuring the water pump drain tube is correctly installed (see Sump - Installation). Perform the following operations: Battery - Installation Seat - Installation Low Oil Pressure Warning Light Switch - Removal WARNING Service Manual - Scrambler 1200 XC 351 of 640...
  • Page 352 Brake hoses or lines that are not unsupported 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. Remove the fixings and remove the right hand heel guard. Service Manual - Scrambler 1200 XC 352 of 640...
  • Page 353 Low oil pressure warning light switch Low Oil Pressure Warning Light Switch - Installation Incorporating a new sealing washer, fit the low oil pressure light switch. Tighten the switch to 15 Nm. Service Manual - Scrambler 1200 XC 353 of 640...
  • Page 354 Stop the engine and check the oil level as described (see Engine Oil - Level Inspection). Adjust if necessary. Perform the following operations: Seat - Installation Engine Remove and Install Engine - Removal WARNING Service Manual - Scrambler 1200 XC 354 of 640...
  • Page 355 Coolant temperature sensor. Disconnect the clutch cable from the crankcase (see Clutch Cable - Removal). On the right side of the airbox, disconnect the gear position sensor electrical connector from the main harness. Service Manual - Scrambler 1200 XC 355 of 640...
  • Page 356 Disconnect the starter motor lead from the starter motor solenoid. ckjp Crankshaft position sensor electrical connector Starter motor lead Route the three cables down to the engine. Release the two hose clips and remove the engine breather hose. Service Manual - Scrambler 1200 XC 356 of 640...
  • Page 357 Remove the fixing and remove the air intake finishers. L0825 Fixing Air intake finisher (right hand side shown) Remove the two fixings and remove the mountings for the air intake finisher. Service Manual - Scrambler 1200 XC 357 of 640...
  • Page 358 Loosen the throttle body hose clamp. Remove the four fixings securing the inlet manifold to the cylinder head and detach it from the cylinder head. Remove and discard the two seals on the inlet manifold. Service Manual - Scrambler 1200 XC 358 of 640...
  • Page 359 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. Service Manual - Scrambler 1200 XC 359 of 640...
  • Page 360 Spilled brake fluid will damage paintwork. Release the fixings and detach the right hand control plate from the frame. ckjo Fixings Right hand control plate Disconnect the oil pressure switch electrical connector. ciua _1 Service Manual - Scrambler 1200 XC 360 of 640...
  • Page 361 Partially remove the swinging arm spindle to access the frame adjuster sleeve. Engage T3880104 - Swinging Arm Adjuster Wrench in the slots of the frame adjuster sleeve and rotate anticlockwise to loosen the sleeve fully. Service Manual - Scrambler 1200 XC 361 of 640...
  • Page 362 Note the routing of the components attached to the brake line tidy for installation. While carefully lowering the engine, detach the brake lines and harnesses from the brake line tidy and position away from the crankcase. Service Manual - Scrambler 1200 XC 362 of 640...
  • Page 363 While carefully locating the engine to the frame, attach the brake lines and harnesses to the brake line tidy as noted for removal. ckjl Brake line (front brake master cylinder) Service Manual - Scrambler 1200 XC 363 of 640...
  • Page 364 Withdraw the cylinder head rear mounting bolt and tighten the frame adjuster to 5 Nm using T3880377 - Engine Mounting Adjuster. Service Manual - Scrambler 1200 XC 364 of 640...
  • Page 365 105 Nm. Fit the washer and a new lock nut to the cylinder head front left hand mounting bolt. Counter hold the nut and tighten the bolt to 105 Nm. Service Manual - Scrambler 1200 XC 365 of 640...
  • Page 366 Refit the swinging arm pivot cover to the left hand side of the frame. On the left hand side, connect the engine ground cable. Refit the rider’s left hand control plate, fit the upper fixing only and do not fully tighten at this stage. Service Manual - Scrambler 1200 XC 366 of 640...
  • Page 367 Bent or damaged brake hoses or lines lead to reduced braking efficiency causing loss of motorcycle control and an accident. CAUTION To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Service Manual - Scrambler 1200 XC 367 of 640...
  • Page 368 Refit the rider’s right hand control plate, fit the upper fixing only and do not fully tighten at this stage. ckjo Upper fixing Right hand control plate Refit the engine breather hose and secure with the hose clips. L0758_1 Service Manual - Scrambler 1200 XC 368 of 640...
  • Page 369 Connect the alternator harness to the regulator/rectifier and refit the rear mudguard (see Rear Mudguard - Installation). On the right side of the airbox, connect the gear position sensor electrical connector to the main harness. Service Manual - Scrambler 1200 XC 369 of 640...
  • Page 370 Connect the MAP hose and the evaporative emissions hose to the inlet manifold, as noted for removal. Fit the mountings for the air intake finisher and tighten its fixings to 3 Nm. Service Manual - Scrambler 1200 XC 370 of 640...
  • Page 371 Refit the exhaust catalytic system (see Exhaust Catalytic Converter - Installation, Left Hand Header Pipe - Installation and Exhaust Silencer - Installation). Refit the cradle assemblies (see Cradle Assemblies - Installation). Service Manual - Scrambler 1200 XC 371 of 640...
  • Page 372 Right hand control plate Refit the right hand heel guard and tighten its fixings to 7 Nm. L0904 Fixings Heel guard Tighten the rider’s left hand control plate upper fixing to 25 Nm. Service Manual - Scrambler 1200 XC 372 of 640...
  • Page 373 If required, refill the engine with engine oil - Engine Oil and Filter Renew Reset the neutral position adaption (see Neutral Position Adaption). Fuel and Exhaust System and Engine Management Exploded Views Exploded View – Fuel Tank Service Manual - Scrambler 1200 XC 373 of 640...
  • Page 374 Exploded View – Fuel Pump Service Manual - Scrambler 1200 XC 374 of 640...
  • Page 375 Exploded View – Fuel Rail, Throttles and Injectors Service Manual - Scrambler 1200 XC 375 of 640...
  • Page 376 Exploded View - Engine Management Exploded View – Airbox Service Manual - Scrambler 1200 XC 376 of 640...
  • Page 377 Exploded View – Exhaust System Service Manual - Scrambler 1200 XC 377 of 640...
  • Page 378 Exploded View – Evaporative System (if fitted) Service Manual - Scrambler 1200 XC 378 of 640...
  • Page 379 Ethanol Ethanol is added to petrol in volumes up to 10% in Europe and up to 85% in other countries. Triumph motorcycles can use fuel containing ethanol up to 25%. Fuel Requirements - USA In the United States of America where the octane rating of fuel is measured in a...
  • Page 380 '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 T ertiary Butyl Ether) The use of gasolines containing up to 15% MTBE (Methyl Tertiary Butyl Ether) is permitted in Triumph motorcycles.
  • Page 381 Cruise control cancel sw itch (if fitted) A switch located in the twist grip housing, used to cancel the cruise control. The switch is operated by the over-closing of the twist grip. Diagnostic Trouble Code. Service Manual - Scrambler 1200 XC 381 of 640...
  • Page 382 Idle reference speed The target idle speed as determined by the engine Electronic Control Module (ECM). (It should be the same as the actual idle speed if the motorcycle is operating Service Manual - Scrambler 1200 XC 382 of 640...
  • Page 383 Keyless ECM (if fitted) Keyless Electronic Control Module. Long term fuel trim Fueling after adapting to the engine's long term fueling requirements (closed loop only). See also short term fuel trim. Service Manual - Scrambler 1200 XC 383 of 640...
  • Page 384 The time the purge valve is open in an open/close cycle, expressed as a percentage of the cycle time. Road speed sensor The rear wheel speed sensor is used to supply road speed data to the engine ECM. Service Manual - Scrambler 1200 XC 384 of 640...
  • Page 385 The position of the throttle butterfly given as a percentage of the movement range. When the data is displayed on the diagnostic software, fully open need not be 100% nor fully closed 0%. Throttle Voltage Voltage at the throttle potentiometer. TPMS (if fitted) Service Manual - Scrambler 1200 XC 385 of 640...
  • Page 386 Clutch switch - situated on the clutch lever. The clutch must be pulled in for the Service Manual - Scrambler 1200 XC 386 of 640...
  • Page 387 This is used to prevent the engine from starting if the transmission is in gear. The sensor also provides information to the neutral lamp in the instruments. Sensor Locations Gear position sensor Service Manual - Scrambler 1200 XC 387 of 640...
  • Page 388 Injectors - located in the cylinder head. The engine is fitted with two injectors. The spray pattern of the injectors is fixed but the length of time each injector can Service Manual - Scrambler 1200 XC 388 of 640...
  • Page 389 It will not operate at any other time. Note In this system, the starter lockout system (clutch switch, neutral switch, side stand switch) all operate through the engine management ECM. Actuator Locations Service Manual - Scrambler 1200 XC 389 of 640...
  • Page 390 ECM and the ignition keys which each contain a transponder chip. If all the components are correctly paired, the immobiliser will allow the engine to start. These components can only be paired using the Triumph diagnostic tool.. 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 keyless ECM memory.
  • Page 391 A previously paired key must be present when pairing a new key. Ensure all keys to be paired are present before starting the key pairing process. Keys can be deleted or added to the immobiliser system using the Triumph diagnostic tool. To ensure the immobiliser system functions correctly note the following: Do not put any magnetic materials on the same key ring as the motorcycle key.
  • Page 392 All adaptive changes are automatic and require no intervention by rider or dealer. Service Manual - Scrambler 1200 XC 392 of 640...
  • Page 393 The term 'range' indicates how much (in percentage terms) of the adjustment range has been used to reach the current operating status. Service Manual - Scrambler 1200 XC 393 of 640...
  • Page 394 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 Service Manual - Scrambler 1200 XC 394 of 640...
  • Page 395 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.
  • Page 396 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. Service Manual - Scrambler 1200 XC 396 of 640...
  • Page 397 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. Service Manual - Scrambler 1200 XC 397 of 640...
  • Page 398 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.
  • Page 399 60 miles (100 km). The service symbol will illuminate permanently when the mileage is reached, it will remain permanently illuminated until the service interval is reset using the Triumph Diagnostic tool.
  • Page 400 System Diagnostic Tool Connection Diagnostic T ool Connection To connect the Triumph diagnostic interface to the motorcycle, remove the left hand side panel (see Side Panels) and release the diagnostic connector from its locating tang.
  • Page 401 T3880057 - Triumph Diagnostic Interface When the diagnostic session is completed, disconnect the Triumph diagnostic interface. Refit the diagnostic connector to its locating tang and refit the left hand side panel (see Side Panels). 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...
  • Page 402 Bank 1 - oxygen sensor 1 - short term fuel trim Bank 2 - oxygen sensor 2 Volts Bank 2 - oxygen sensor 2 - short term fuel trim Sensor Data Service Manual - Scrambler 1200 XC 402 of 640...
  • Page 403 Volts ‡ Applies to models fitted with an exhaust butterfly valve only. All other models will show Not Applicable in this field. Sensor Readings The data available under Sensor Readings is: Service Manual - Scrambler 1200 XC 403 of 640...
  • Page 404 Injector 2 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 Service Manual - Scrambler 1200 XC 404 of 640...
  • Page 405 Not Applicable in this field. Inputs The data available under Inputs is: Item Checked Result Unit Starter switch status switch on/off Side stand status up/down Fall detection switch status normal/over Clutch switch status release/grip Service Manual - Scrambler 1200 XC 405 of 640...
  • Page 406 This screen displays information on the adaption status of the vehicle which will show if it has adapted or not. Function Examined Report Method Service Manual - Scrambler 1200 XC 406 of 640...
  • Page 407 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 Observe throttle position/Stored fault code* Motor † Service Manual - Scrambler 1200 XC 407 of 640...
  • Page 408 * If a fault is detected. †Test will only be displayed if the component is fitted. Adj ust Calibration Using the Triumph diagnostic software, it is possible to: reset the adaptions balance the throttle bodies. Freeze-Frame Data Freeze-frame data is stored at the time a DTC is recorded (confirmed) by the ECM.
  • Page 409 0.5 to 4.5 Volts. The output voltage is used to determine which gear is currently engaged. Voltage Characteristics The gear position is determined by the following voltage ranges: Gear Minimum Voltage Maximum Voltage Service Manual - Scrambler 1200 XC 409 of 640...
  • Page 410 3.5 V 3.7 V 4.3 V 4.5 V The sensor voltage can be read using the Triumph diagnostic tool. Further Diagnostics Refer to Gear Position Sensor for details of pinpoint tests relating to diagnostic trouble codes P0914 and P0917. Neutral Position Adaption The motorcycle is delivered from the factory with the neutral position fully adapted.
  • Page 411 The gear position sensor has been removed or disconnected. Adaption Reset To reset the neutral position adaption: Connect the Triumph diagnostic tool and turn the ignition ON. Select ENGINE DIAGNOSTICS. Check and erase any stored DTCs. Select ADJUST TUNE then select Gear Position/Neutral Position Adaption Reset.
  • Page 412 If the cruise control is turned on, you will be prompted to turn it off before the test will start. Follow the on-screen instructions to operate and then release each switch in turn. Service Manual - Scrambler 1200 XC 412 of 640...
  • Page 413 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.
  • Page 414 P0115 Engine coolant Coolant temperature sensor Temperature open circuit or short Sensor circuit to 5 Volt sensor supply P0117 Engine coolant Coolant temperature sensor Temperature short circuit to Sensor ground Service Manual - Scrambler 1200 XC 414 of 640...
  • Page 415 Voltage P0151 Oxygen sensor 2 Oxygen Sensor short circuit to ground P0201 Injector 1 circuit Fuel Injectors malfunction P0202 Injector 2 circuit Fuel Injectors malfunction P0220 Throttle position Throttle Service Manual - Scrambler 1200 XC 415 of 640...
  • Page 416 Voltage P0460 Fuel level sensor Fuel Level circuit malfunction Sensor Circuit P0500 Vehicle speed Vehicle Speed sensor malfunction Sensor P0560 System voltage - System Voltage battery circuit malfunction Service Manual - Scrambler 1200 XC 416 of 640...
  • Page 417 Sensor to ground or open circuit P0917 Gear position Gear Position sensor short circuit Sensor to 5 Volt sensor supply P1105 Manifold absolute Manifold pressure sensor 1 Absolute Service Manual - Scrambler 1200 XC 417 of 640...
  • Page 418 ID Incompatible P1520 Unmatched ABS Flashing Linked module procedure not present at the moment. P1521 CAN fault - lost ABS Modulator communication with Communication ABS module or ABS system status error Service Manual - Scrambler 1200 XC 418 of 640...
  • Page 419 1 P1604 ECM tamper Linked detected - return to procedure not Triumph present at the moment. P1605 ECM locked by the Only if Flashing Calibration Calibration Lock tune lock Lock Service Manual - Scrambler 1200 XC 419 of 640...
  • Page 420 Voltage P1650 CAN fault - lost Keyless ECM communication with Communication Immobiliser ECM P1659 Ignition power EMS Ignition supply malfunction Voltage Input Circuit P1685 Main relay circuit EMS Main Relay Service Manual - Scrambler 1200 XC 420 of 640...
  • Page 421 P2111 Throttle valve drive Linked error (stuck open) procedure not present at the moment. P2119 Throttle valve drive Linked error procedure not present at the moment. Service Manual - Scrambler 1200 XC 421 of 640...
  • Page 422 1 Correlation position sensor 2 Error with Twist Grip Position 2 P2226 Ambient air Ambient Air pressure sensor Pressure circuit open circuit or Sensor short circuit to 5 Volt sensor supply Service Manual - Scrambler 1200 XC 422 of 640...
  • Page 423 Oxygen sensor 1 heater Disconnect oxygen sensor and short circuit to battery proceed to pinpoint test 4: Voltage P0052 Oxygen sensor 2 heater short circuit to battery Voltage Pinpoint T ests Test Result Action Service Manual - Scrambler 1200 XC 423 of 640...
  • Page 424 5 (right hand oxygen sensor) Reconnect harness, clear fault Action complete - quit test code and run engine. Check adaption status. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 424 of 640...
  • Page 425 Disconnect the engine ECM and circuit or short circuit to 5 proceed to pinpoint test 1: Volt sensor supply P1105 Manifold absolute Check connection/condition of pressure sensor 1 pipe pipes from MAP sensors to Service Manual - Scrambler 1200 XC 425 of 640...
  • Page 426 - Engine ECM pin B36 to MAP circuit proceed to test 4 sensor pin 2 Reconnect harness, clear fault Action complete - quit test code and run engine. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 426 of 640...
  • Page 427 Coolant Temperature Sensor Throttle Position Sensor Oxygen Sensor Fuel Injectors Crankshaft Sensor Ignition Coils Purge Valve Fuel Level Sensor Circuit Vehicle Speed Sensor System Voltage Twist Grip – Cruise Cancel Switch Circuit Malfunction Service Manual - Scrambler 1200 XC 427 of 640...
  • Page 428 Result Action Check cable and terminal Proceed to test 2 integrity: - Engine ECM pin B42 - Sensor pin 1 Faulty Rectify fault, proceed to test 7 - Sensor pin 2 Service Manual - Scrambler 1200 XC 428 of 640...
  • Page 429 Fault still Contact Triumph service present Resistance data: If engine is warm, remove the sensor and allow time to cool to ambient temperature prior to test. Ambient Temperature Resistance Value Service Manual - Scrambler 1200 XC 429 of 640...
  • Page 430 Engine Electronic Control Module - Connector A Engine Electronic Control Module - Connector B Fault Code Possible cause Action P0115 Engine coolant View and note diagnostic temperature sensor software 'freeze-frame' data if Service Manual - Scrambler 1200 XC 430 of 640...
  • Page 431 - Ground to sensor pin 2 Check cable for short circuit: Proceed to test 5 - Engine ECM pin B40 to ECM pin A01 Short Locate and rectify wiring fault, circuit proceed to test 7 Service Manual - Scrambler 1200 XC 431 of 640...
  • Page 432 Resistance data under typical conditions: Cold engine: Resistance Value 20ºC ambient 2.22 to 2.71 K Ohms -10ºC ambient 8.50 to 10.25 K Ohms Warm engine: Resistance Value 100 to 400 Ohms Circuit Diagram Service Manual - Scrambler 1200 XC 432 of 640...
  • Page 433 2 short circuit to battery Voltage or open circuit P0222 Throttle position sensor 2 short circuit to ground P2135 Throttle position sensor 1 correlation error with throttle position sensor 2 Pinpoint T ests Service Manual - Scrambler 1200 XC 433 of 640...
  • Page 434 5 pin B26 Reconnect harness, clear fault Action complete - quit test code and run engine to verify fault cleared. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 434 of 640...
  • Page 435 Short Locate and rectify wiring fault, - ECM pin B03 to ground circuit proceed to test 4 Check cable continuity: Proceed to test 4 - ECM pin B02 to left hand Service Manual - Scrambler 1200 XC 435 of 640...
  • Page 436 5 (right hand oxygen sensor) Reconnect harness, clear fault Action complete - quit test code and run engine. Check adaption status. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 436 of 640...
  • Page 437 - ECM pin A11 -Injector 1 pin 1 -Injector 1 pin 2 Faulty Rectify fault, proceed to test 8 -Injector 2 pin 1 -Injector 2 pin 2 -EMS relay pin 5 Service Manual - Scrambler 1200 XC 437 of 640...
  • Page 438 Renew relevant injector, proceed to test 9 Switch on ignition, measure Battery Proceed to test 9 voltage at EMS relay pin 5 voltage Less Rectify fault and proceed to than test 9 Service Manual - Scrambler 1200 XC 438 of 640...
  • Page 439 Action complete - quit test code and run engine to verify fault cleared. Fault still Contact Triumph service present Circuit Diagram 11 10 EMS Relay Fuel Injectors Engine Electronic control Unit Service Manual - Scrambler 1200 XC 439 of 640...
  • Page 440 Proceed to test 5 - Engine ECM pin A35 to Engine ECM pin A36 Short Locate and rectify wiring fault, circuit proceed to test 6 Check crankshaft toothed wheel: Renew crankshaft sensor, Service Manual - Scrambler 1200 XC 440 of 640...
  • Page 441 'freeze-frame' data if available. Ensure relevant ignition coil connector is secure. P0352 Ignition coil 2 malfunction Disconnect the engine ECM and proceed to pinpoint test 1: Pinpoint T ests Service Manual - Scrambler 1200 XC 441 of 640...
  • Page 442 Renew relevant ignition coil, proceed to test 6 Reconnect harness, clear fault Action complete - quit test code and run engine to verify fault cleared. Fault still Contact Triumph service present Service Manual - Scrambler 1200 XC 442 of 640...
  • Page 443 Possible cause Action P0443 Purge valve short circuit View and note diagnostic to ground or open circuit software 'sensor' data. Ensure purge valve connector is secure. Disconnect the engine ECM and Service Manual - Scrambler 1200 XC 443 of 640...
  • Page 444 - EMS relay pin 5 to valve pin 2 Open Locate and rectify wiring fault, - ECM pin B06 to valve pin 1 circuit proceed to test 8 Check cable continuity: Proceed to test 7 Service Manual - Scrambler 1200 XC 444 of 640...
  • Page 445 Reconnect harness, clear fault Action complete - quit test code and run diagnostic software function test to visually Fault still Contact Triumph service verify operation of purge valve. present Circuit Diagram Service Manual - Scrambler 1200 XC 445 of 640...
  • Page 446 - Engine ECM pin B34 - Sensor pin 1 Faulty Rectify fault, proceed to test 4 - Sensor pin 2 - Sensor pin 4 Check cable for short circuit: Proceed to test 3 Service Manual - Scrambler 1200 XC 446 of 640...
  • Page 447 4 - Engine ECM pin B18 to sensor pin 1 Reconnect harness, clear fault Action complete - quit test code. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 447 of 640...
  • Page 448 12.0 Volts, note voltage. Disconnect the engine ECM and proceed to pinpoint test 1: Pinpoint T ests Test Result Action Check cable and terminal Proceed to test 2 integrity: Service Manual - Scrambler 1200 XC 448 of 640...
  • Page 449 4 across battery voltage Reconnect harness, clear fault Action complete - quit test code and run engine to verify fault cleared. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 449 of 640...
  • Page 450 Position cancel) position and note sensor 1 the following voltages: voltage lower - Twist Grip Position Sensor than 0.8 V Position - Twist Grip Position Sensor sensor 2 voltage higher than Service Manual - Scrambler 1200 XC 450 of 640...
  • Page 451 1: P1571 Brake 2 switch malfunction P1577 Brake 2 switch correlation error with brake switch 1 Pinpoint T ests Test Result Action Turn ignition on, operate rear Proceed to test 2 Service Manual - Scrambler 1200 XC 451 of 640...
  • Page 452 -Front brake switch pin 1 to pin 3 -Rear brake switch pin 1 to pin 3 Check cables continuity: Proceed to test 6 - ECM pin A07 to front brake Service Manual - Scrambler 1200 XC 452 of 640...
  • Page 453 - Front brake switch pin 3 - Ignition switch relay pin 5 Reconnect harness, clear fault Action complete - quit test code and run engine. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 453 of 640...
  • Page 454 1: P0617 Starter relay short circuit Disconnect the engine ECM and to battery Voltage starter motor relay proceed to pinpoint test 4: Pinpoint T ests Test Result Action Service Manual - Scrambler 1200 XC 454 of 640...
  • Page 455 Locate and rectify wiring fault, circuit proceed to test 5 Reconnect harness, clear fault Action complete - quit test code and run engine to verify fault cleared Fault still Contact Triumph service Service Manual - Scrambler 1200 XC 455 of 640...
  • Page 456 Right Hand Switch Housing Fuse Box Right Hand Switch Housing Grey Connector Right Hand Switch Housing Black Connector Engine Electronic Control Module - Connector A Engine Electronic Control Module - Connector B Service Manual - Scrambler 1200 XC 456 of 640...
  • Page 457 - Engine ECM pin B23 to ECM to test 5 pin B34 Short Locate and rectify wiring fault, circuit proceed to test 5 Reconnect harness, clear fault Action complete - quit test Service Manual - Scrambler 1200 XC 457 of 640...
  • Page 458 When the pin point tests have been completed, reset the neutral position sensor adaption (see Neutral Position Adaption). Circuit Diagram Gear Position Sensor Engine Electronic Control Module Engine Electronic Control Module - Connector B Service Manual - Scrambler 1200 XC 458 of 640...
  • Page 459 Check cable for short circuit: Proceed to test 3 - Engine ECM pin A26 to ground Short Locate and rectify wiring fault, circuit proceed to test 5 Check cable continuity: Proceed to test 4 Service Manual - Scrambler 1200 XC 459 of 640...
  • Page 460 Reconnect harness, clear fault Action complete - quit test code and run diagnostic software function test to verify Fault still Contact Triumph service fault cleared. present Circuit Diagram Fuel Pump Relay Service Manual - Scrambler 1200 XC 460 of 640...
  • Page 461 Proceed to pinpoint test 1: Pinpoint T ests Test Result Action Check fuse box Fuse 6 and 7 Proceed to test 2 integrity. Faulty Rectify fault, proceed to test 6 Service Manual - Scrambler 1200 XC 461 of 640...
  • Page 462 - Fuse box Fuse 5 to ABS pin 18 - Fuse box Fuse 7 to ABS pin 4 Reconnect harness, clear fault Action complete - quit test code and run engine. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 462 of 640...
  • Page 463 1: P1553 Cooling fan relay short Disconnect the engine ECM and circuit to battery Voltage fan relay and proceed to pinpoint or over temp test 4: Pinpoint T ests Service Manual - Scrambler 1200 XC 463 of 640...
  • Page 464 Reconnect harness, clear fault Action complete - quit test code and run diagnostic software function test to visually Fault still Contact Triumph service verify operation of cooling fan. present Circuit Diagram Service Manual - Scrambler 1200 XC 464 of 640...
  • Page 465 Engine Electronic Control Module - Connector A Fuse Box Cruise Control Disabled Until Button Press Sequence Completed Calibration Lock Instrument ID Incompatible Fault Code Possible Cause Action P1574 Cruise control prevented Check that there is no Service Manual - Scrambler 1200 XC 465 of 640...
  • Page 466 This is also identified by a fast the calibration lock flashing MIL indication, and a function disabled engine management system. Unlock the engine ECM using the diagnostic software and supplied unlock code from Service Manual - Scrambler 1200 XC 466 of 640...
  • Page 467 Fault Code Possible cause Action P1650 Lost communication with View and note 'freeze-frame' data Keyless ECM if available. Ensure keyless ECM connector is secure. Proceed to pinpoint test 1: Pinpoint T ests Service Manual - Scrambler 1200 XC 467 of 640...
  • Page 468 6 - Keyless ECM pin 4 to ground - Fuse box 2 Fuse 1 to keyless ECM pin 12 Reconnect harness, clear fault Action complete - quit test Service Manual - Scrambler 1200 XC 468 of 640...
  • Page 469 Fuse Box Engine Electronic Control Module Engine Electronic Control Module - connector A Keyless Electronic Control Module Fault Code Possible cause Action P1631 Fall detection circuit View and note 'freeze-frame' data Service Manual - Scrambler 1200 XC 469 of 640...
  • Page 470 - ECM pin B18 to sensor pin 6 circuit proceed to test 4 Reconnect harness, clear fault Action complete - quit test code. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 470 of 640...
  • Page 471 Check fuse box 1 Fuse 6 Proceed to test 3 integrity. Faulty Proceed to test 2 Check cable for short circuit: Replace Fuse 10 and proceed to test 3 - ECM pin B01 to ground Service Manual - Scrambler 1200 XC 471 of 640...
  • Page 472 Reconnect harness, clear fault Action complete - quit test code and run engine to verify fault cleared. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 472 of 640...
  • Page 473 Note that the starter motor malfunction cannot be powered if a main relay fault exists. Ensure the EMS main relay connector is secure. Proceed to pinpoint test 1: Pinpoint T ests Test Result Action Service Manual - Scrambler 1200 XC 473 of 640...
  • Page 474 - EMS main relay pin 2 to ground circuit proceed to test 6 - EMS main relay pin 3 to fuse box fuse 5 Reconnect harness, clear fault Action complete - quit test Service Manual - Scrambler 1200 XC 474 of 640...
  • Page 475 Circuit Diagram EMS Relay Fuse Box Engine Electronic Control Module Engine Electronic Control Module - Connector A Engine Electronic Control Module - Connector B Fault Code Possible cause Action Service Manual - Scrambler 1200 XC 475 of 640...
  • Page 476 Check cable continuity: Proceed to test 4 - Engine ECM pin A34 to Instrument pin 24 - Engine ECM pin A33 to Instrument pin 25 - Engine ECM pin A34 to ABS Service Manual - Scrambler 1200 XC 476 of 640...
  • Page 477 Locate and rectify wiring fault, circuit proceed to test 5 Reconnect harness, clear fault Action complete - quit test code and run engine. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 477 of 640...
  • Page 478 Removal and Installation - Fuel and Air Components Fuel Cap Cover - Removal Fuel Cap Cover - Installation Fuel Tank - Removal Fault Code Possible cause Action P1695 Lost communication with View and note 'freeze-frame' data Service Manual - Scrambler 1200 XC 478 of 640...
  • Page 479 Locate and rectify wiring fault, circuit proceed to test 5 Reconnect harness, clear fault Action complete - quit test code and run engine. Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 479 of 640...
  • Page 480 Note ECM sensors requiring a power supply will not be active. Disconnect the engine ECM and proceed to pinpoint test 1: Pinpoint T ests Test Result Action Check cable and terminal Proceed to test 2 Service Manual - Scrambler 1200 XC 480 of 640...
  • Page 481 Action complete - quit test code and use diagnostic software to check for correct Fault still Contact Triumph service sensor outputs and 5 volt present sensor supply voltage level. Circuit Diagram Service Manual - Scrambler 1200 XC 481 of 640...
  • Page 482 Throttle actuator short View and note diagnostic tool circuit to ground or short freeze frame data if available. circuit to battery Voltage View and note diagnostic tool Throttle actuator with sensor data. Service Manual - Scrambler 1200 XC 482 of 640...
  • Page 483 - Engine ECM pin A03 to ECM circuit proceed to test 5 pin A01 Reconnect harness, clear fault Action complete - quit test code and run engine. Fault still Contact Triumph service present Service Manual - Scrambler 1200 XC 483 of 640...
  • Page 484 Ensure twist grip position sensor is secure. P2123 Twist grip position sensor 1 short circuit to Disconnect the engine ECM and battery Voltage proceed to pinpoint test 1: Pinpoint T ests Test Result Action Service Manual - Scrambler 1200 XC 484 of 640...
  • Page 485 5 ECM pin B35 Reconnect harness, clear fault Action complete - quit test code and run engine to verify fault cleared Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 485 of 640...
  • Page 486 Ensure twist grip position sensor is secure. P2128 Twist grip position sensor 2 short circuit to Disconnect the engine ECM and battery Voltage proceed to pinpoint test 1: Pinpoint T ests Test Result Action Service Manual - Scrambler 1200 XC 486 of 640...
  • Page 487 5 ECM pin B33 Reconnect harness, clear fault Action complete - quit test code and run engine to verify fault cleared Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 487 of 640...
  • Page 488 Turn the ignition on and 5V DC Proceed to test 2 measure the Voltage between: - Engine ECM pin B33 and Engine ECM pin B19 Faulty Rectify fault, proceed to test 2 Service Manual - Scrambler 1200 XC 488 of 640...
  • Page 489 - Engine ECM pin B28 to sensor circuit pin 4 Reconnect harness, clear fault Action complete - quit test code and run engine to verify fault cleared Fault still Contact Triumph service present Circuit Diagram Service Manual - Scrambler 1200 XC 489 of 640...
  • Page 490 - ECM pin B18 to sensor pin 1 Open Locate and rectify wiring fault, - ECM pin B41 to sensor pin 2 circuit proceed to test 4 Reconnect harness, clear fault Action complete - quit test Service Manual - Scrambler 1200 XC 490 of 640...
  • Page 491 Fault still Contact Triumph service present Circuit Diagram Ambient Air Pressure Sensor Engine Electronic Control Module Engine Electronic Control Module - Connector B Fuel Pressure Checking WARNING Service Manual - Scrambler 1200 XC 491 of 640...
  • Page 492 Using a suitable proprietary lever, remove the plastic locking ring. cjwf Plastic locking ring Locating lug (2 shown) Turn the fuel cap cover clockwise to release its four locating lugs from the fuel tank filler neck. Service Manual - Scrambler 1200 XC 492 of 640...
  • Page 493 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 Service Manual - Scrambler 1200 XC 493 of 640...
  • Page 494 Note the four locating lugs on the plastic locking ring that fit into the cut outs in the fuel tank filler neck. Position the fuel cap cover and then turn anticlockwise to lock its four locating lugs into the fuel tank filler neck. cjwg Service Manual - Scrambler 1200 XC 494 of 640...
  • Page 495 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. Service Manual - Scrambler 1200 XC 495 of 640...
  • Page 496 Remove the fixing securing the rear of the fuel tank to the frame. Discard the lock nut. L0768 Fixings Pivot the fuel tank upwards at the rear. Detach the breather hose from its retaining clips on the fuel tank then disconnect it from the fuel tank. Service Manual - Scrambler 1200 XC 496 of 640...
  • Page 497 This would represent a serious fire hazard which could lead to burn injuries and damage to property. Temporarily reconnect the battery, positive (red) lead first and tighten the terminals to 4.5 Nm. Note Service Manual - Scrambler 1200 XC 497 of 640...
  • Page 498 Disconnect the fuel hose by squeezing the sides of the connector and pulling the hose free from its spigot on the fuel pump rail. Collect any fuel remaining in the hose in a suitable container. Service Manual - Scrambler 1200 XC 498 of 640...
  • Page 499 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 Service Manual - Scrambler 1200 XC 499 of 640...
  • Page 500 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. Service Manual - Scrambler 1200 XC 500 of 640...
  • Page 501 Throttle Body and Inlet Manifold Assembly - Removal Throttle Body and Inlet Manifold Assembly - Installation WARNING Observe the fuel handling precautions given in the General Information section. Fuel pressure is checked using T3880001 - Fuel Pressure Gauge. Service Manual - Scrambler 1200 XC 501 of 640...
  • Page 502 A fuel leak can result in a fire causing damage to property and injury to persons. Connect the adaptor hose to the fuel pump plate outlet and fuel hose as shown in the illustration below. Service Manual - Scrambler 1200 XC 502 of 640...
  • Page 503 Reconnect the battery, positive (red) lead first. Start the engine and observe the fuel pressure reading on the gauge. Note The fuel pressure should be 3.5 bar nominally. Service Manual - Scrambler 1200 XC 503 of 640...
  • Page 504 A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly. Perform the following operations: Seat - Removal Battery - Removal WARNING Never drain fuel from the tank using non-approved, non-professional standard fuel Service Manual - Scrambler 1200 XC 504 of 640...
  • Page 505 Remove the ring of fixings securing the fuel pump mounting plate to the tank. ciwg Fuel pump mounting plate Fixing Detach the pump assembly from the fuel tank. Disconnect the fuel level sensor from the fuel pump assembly harness. Service Manual - Scrambler 1200 XC 505 of 640...
  • Page 506 Route the fuel level sensor harness under the baffle hose and fuel pump assembly harness, as shown in the illustration below, and connect to the fuel pump assembly harness. ckgv Fuel level sensor harness Service Manual - Scrambler 1200 XC 506 of 640...
  • Page 507 Perform the following operations: Battery - Installation Seat - Installation Perform the following operations: Fuel Pump Assembly - Removal Remove and discard the circlip securing the fuel pressure regulator in its housing. Service Manual - Scrambler 1200 XC 507 of 640...
  • Page 508 Check all hose clamps for cracks and signs of distortion. Replace as necessary. Check the mesh filter for damage and replace the fuel pump if necessary. Install new O-rings to the fuel pressure regulator. Service Manual - Scrambler 1200 XC 508 of 640...
  • Page 509 Perform the following operations: Fuel Pump Assembly - Removal Release the fuel hose clip from the fuel pump side of the fuel filter. Remove the hose bracket from the fuel pump bracket. civv Service Manual - Scrambler 1200 XC 509 of 640...
  • Page 510 Baffle housing Hose clip Remove the baffle housing hose clip over the inlet filter. Disconnect the fuel pump electrical connector. Remove the fuel pump securing bolt and strap. Service Manual - Scrambler 1200 XC 510 of 640...
  • Page 511 If removed, refit the connector hose to the fuel pump. Secure with the hose clip. Position the fuel pump to the bracket, ensuring the feet of the rubber isolator engage correctly in the fork. cevu Fork Isolator feet Service Manual - Scrambler 1200 XC 511 of 640...
  • Page 512 Note The fuel level sensor is located inside the fuel tank on the right hand side. Access to the fuel level sensor is through the aperture for the fuel pump. Service Manual - Scrambler 1200 XC 512 of 640...
  • Page 513 Align the two locating lugs into the holes in the bracket. Slide the fuel level sensor down the bracket for the locking device to engage and secure the sensor. Service Manual - Scrambler 1200 XC 513 of 640...
  • Page 514 Before the disconnection of any wiring, note the routing of all wiring and wiring connectors on both sides of the airbox. Release the fixing and detach the air temperature sensor from the airbox. Disconnect the ambient air pressure sensor connector. Service Manual - Scrambler 1200 XC 514 of 640...
  • Page 515 Remove the fixings and detach the connector bracket from the right hand side of the airbox. L0756 Fixings Connector bracket Detach the main fuse from the relay bracket. Disconnect the electrical connector from the keyless electronic control module Service Manual - Scrambler 1200 XC 515 of 640...
  • Page 516 Remove the fixings and detach the relay bracket from the left hand side of the airbox. L0916a Fixings Relay bracket Release the two hose clips and remove the engine breather hose. Service Manual - Scrambler 1200 XC 516 of 640...
  • Page 517 Remove the rear grommet for the left hand side panel for access to battery box lower fixing. Remove the two fixings securing the battery box to the frame. L0752 Grommet Fixings Service Manual - Scrambler 1200 XC 517 of 640...
  • Page 518 Release the fixing and carefully manoeuvre the battery box rearward for removal. L0753 Starter motor solenoid Fixing Battery box Remove the fixing and shouldered washer from both sides of the airbox. Service Manual - Scrambler 1200 XC 518 of 640...
  • Page 519 Check that the harnesses and hoses are routed as noted on removal. Tighten the intake hose clamp to 1.5 Nm. Fit the fixing and shouldered washer to both sides of the airbox, do not fully tighten at this stage. L0751 Service Manual - Scrambler 1200 XC 519 of 640...
  • Page 520 Main fuse Keyless ECM electrical connector Attach the relay bracket to the left hand side of the airbox, ensuring the harness is not trapped, and tighten the three fixings to 1.5 Nm. Service Manual - Scrambler 1200 XC 520 of 640...
  • Page 521 Carefully position the battery box to the rear of the airbox and secure to the frame. Tighten the fixings to 6 Nm. Tighten the airbox fixings to 6 Nm. L0751 Fixing Airbox Attach the starter motor solenoid to the right hand side of the battery box. Service Manual - Scrambler 1200 XC 521 of 640...
  • Page 522 Refit the engine breather hose and secure with the hose clips. L0758 Clips Engine breather pipe Attach the connector bracket to the right hand side of the airbox and tighten the fixings to 1.5 Nm. Service Manual - Scrambler 1200 XC 522 of 640...
  • Page 523 Battery - Installation Seat - 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 Service Manual - Scrambler 1200 XC 523 of 640...
  • Page 524 Remove the two fixings and remove the mountings for the air intake finisher. Service Manual - Scrambler 1200 XC 524 of 640...
  • Page 525 Note which spigot on the inlet manifold the MAP sensor hose is fitted to and, if fitted, which spigot the evaporative emissions hose is fitted to for installation. Disconnect the MAP hose and the evaporative emissions hose from the inlet manifold. Service Manual - Scrambler 1200 XC 525 of 640...
  • Page 526 Remove the four fixings securing the inlet manifold to the cylinder head and remove the inlet manifold. Remove the throttle body. cjdr Clamp Throttle body fixings (left hand side) Inlet manifold fixings (left hand side) Throttle body Inlet manifold Service Manual - Scrambler 1200 XC 526 of 640...
  • Page 527 The restriction is now controlled by the purge valve spigot on the inlet manifold. Fitting a new manifold with the purge valve restrictor in the spigot and using the Service Manual - Scrambler 1200 XC 527 of 640...
  • Page 528 Position the throttle body to the throttle body hose. Do not tighten the clamp at this stage. Fit the throttle body to the inlet manifold. Do not fully tighten the fixings at this Service Manual - Scrambler 1200 XC 528 of 640...
  • Page 529 Tighten the throttle body to inlet manifold fixings to 9 Nm. Ensure the throttle body hose is correctly fitted and tighten the clip to 1.5 Nm. cjdr Clamp Throttle body fixings (left hand side) Service Manual - Scrambler 1200 XC 529 of 640...
  • Page 530 Fit the mountings for the air intake finisher and tighten its new fixings to 3 Nm. L0859 Fixings Mounting (right hand side shown) Fit the air intake finishers and tighten the new fixing to 1.5 Nm. Service Manual - Scrambler 1200 XC 530 of 640...
  • Page 531 This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Perform the following operations: Seat - Removal Battery - Removal Fuel Tank - Removal Exhaust Silencer - Removal Service Manual - Scrambler 1200 XC 531 of 640...
  • Page 532 Remove the two fixings and remove the mountings for the air intake finisher. L0859 Service Manual - Scrambler 1200 XC 532 of 640...
  • Page 533 If the injectors require replacing continue from step 6. Note the position of the retaining clip for installation. Carefully remove the retaining clips securing the fuel injectors to the fuel rail. Service Manual - Scrambler 1200 XC 533 of 640...
  • Page 534 If the fuel injectors have not been removed, continue from step 3. Lightly lubricate the O-rings with clean engine oil and fit the new fuel injectors to the fuel rail. Fit the retaining clip for each fuel injector as noted for removal. Service Manual - Scrambler 1200 XC 534 of 640...
  • Page 535 For the USA and Canadian Markets only, there is an ignition master switch and bracket assembly secured to the left hand side of the throttle body by the finisher mounting and its fixings. Service Manual - Scrambler 1200 XC 535 of 640...
  • Page 536 Mounting (right hand side shown) Fit the air intake finishers and tighten the new fixing to 1.5 Nm. L0825 Fixing Air intake finisher (right hand side shown) Perform the following operations: Side Panels Service Manual - Scrambler 1200 XC 536 of 640...
  • Page 537 Remove the engine electronic control module (ECM) strap and detach it from the battery box. Disconnect the two electrical connectors and remove the engine ECM (see Electrical Connectors). L0747 Electrical connectors Engine ECM Strap Service Manual - Scrambler 1200 XC 537 of 640...
  • Page 538 This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Perform the following operations: Seat - Removal Battery - Removal Fuel Tank - Removal Remove the right hand handlebar end weight. Discard the fixing. Service Manual - Scrambler 1200 XC 538 of 640...
  • Page 539 Release the fixings and remove the clamp for the twist grip housing from the handlebar. L0422 Anti-tamper fixings Fixings Note Note the position and orientation of the twist grip to its housing for installation. Slide the twist grip off the handlebar. Service Manual - Scrambler 1200 XC 539 of 640...
  • Page 540 Locating lug Hole Twist grip clamp Fit the fixings and tighten, upper one first, to 2.5 Nm. Refit the right hand handlebar end weight and spacer. Tighten the new fixing to 5 Service Manual - Scrambler 1200 XC 540 of 640...
  • Page 541 Note the routing of the twist grip harness and its rubber bands for installation. Note the routing of the brake lines, clutch cable and harnesses through the headstock tidy for installation. Release the fixings and remove headstock tidy outer cover. Service Manual - Scrambler 1200 XC 541 of 640...
  • Page 542 Release the fixings and remove the headstock centre cover. L0813 Fixing M5 Fixing M4 Centre cover Disconnect the twist grip position sensor electrical connector from the main harness and route the harness to the twist grip. Service Manual - Scrambler 1200 XC 542 of 640...
  • Page 543 Twist grip position sensor electrical connector Position the harnesses to the headstock tidy as noted for removal. Fit the headstock centre cover and tighten the M5 fixing to 5 Nm and the M4 fixing to 3 Service Manual - Scrambler 1200 XC 543 of 640...
  • Page 544 Position the front brake lines and the clutch cable to the headstock tidy as noted for removal. Fit the headstock tidy outer cover and tighten the fixings to 3 Nm. L0713_1 Fixings Outer cover Front brake master cylinder brake line Service Manual - Scrambler 1200 XC 544 of 640...
  • Page 545 Crankshaft Position Sensor - Installation Removal and Installation - Exhaust System Components Exhaust Silencer - Removal Exhaust Silencer - Installation Left Hand Header Pipe - Removal Left Hand Header Pipe - Installation Service Manual - Scrambler 1200 XC 545 of 640...
  • Page 546 Fixing Electrical connector Airbox Exhaust Catalytic Converter - Removal Exhaust Catalytic Converter - Installation Evaporative System Components Evaporative Loss Control System – Certain Markets Only Evaporative Control System – Engine Off Service Manual - Scrambler 1200 XC 546 of 640...
  • Page 547 Water Pump - Inspection Coolant System Pressure Test Coolant Pressure Cap Test Thermostat - Removal Thermostat - Inspection Thermostat - Installation Radiator - Removal Radiator - Installation Coolant Expansion Tank - Removal Service Manual - Scrambler 1200 XC 547 of 640...
  • Page 548 Reconnect the electrical connector to the sensor. Perform the following operations: Refit the right hand Side Panels Battery - Installation Seat - Installation Perform the following operations: Seat - Removal Battery - Removal Service Manual - Scrambler 1200 XC 548 of 640...
  • Page 549 Note the routing of the coolant temperature harness for installation. Remove the rubber cover and using a suitable 19 mm slotted socket, remove the coolant temperature sensor from the cylinder head and discard the washer. Service Manual - Scrambler 1200 XC 549 of 640...
  • Page 550 Perform the following operations: Seat - Removal Battery - Removal Fuel Tank - Removal Ignition Coils - Removal Remove the fixing and remove the MAP sensor. Service Manual - Scrambler 1200 XC 550 of 640...
  • Page 551 Perform the following operations: Seat - Removal Battery - Removal Throttle Body and Inlet Manifold Assembly - Removal Disconnect the electrical connector from the sensor. Release the fixing and remove the sensor. Service Manual - Scrambler 1200 XC 551 of 640...
  • Page 552 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: Seat - Removal Service Manual - Scrambler 1200 XC 552 of 640...
  • Page 553 Electrical connector Connect the electrical connector to the fall detection switch. Fit the fall detection switch to the frame below storeage box and tighten the new fixings to 3 Nm. L0809 Service Manual - Scrambler 1200 XC 553 of 640...
  • Page 554 Right hand Side Panels Front Sprocket Cover - Removal On the right side of the airbox, disconnect the gear position sensor electrical connector from the main harness. L0810 Gear position sensor electrical connector Note Service Manual - Scrambler 1200 XC 554 of 640...
  • Page 555 Remove and discard the fixings and detach the harness guide from the crankcase. L0706 Fixings Harness guide Upper gap White tape Carefully remove the gear position sensor harness from the harness guide. Service Manual - Scrambler 1200 XC 555 of 640...
  • Page 556 Fit new O-rings to the sensor. Lubricate the O-rings with a smear of petroleum jelly. Position the sensor to the engine, ensuring that the lug on the sensor engages with the slot in the selector drum shaft. Service Manual - Scrambler 1200 XC 556 of 640...
  • Page 557 Secure the harness guide to the crankcase and tighten the new fixings to 4 Nm. L0706 Fixings Harness guide Upper gap White tape Service Manual - Scrambler 1200 XC 557 of 640...
  • Page 558 Note the position of the four wires connected to the ignition coils for installation. Disconnect the four wires from the ignition coils (two either side of the ignition Service Manual - Scrambler 1200 XC 558 of 640...
  • Page 559 Ignition coils Detach the coolant temperature connector from the ignition coils bracket. ciwk Coolant temperature sensor connector Remove the three fixings and detach the ignition coil bracket from the motorcycle frame. Service Manual - Scrambler 1200 XC 559 of 640...
  • Page 560 Detach the fuel pump harness from the ignition coils bracket. Disconnect the MAP sensor hose and the electrical connector from the MAP sensor. ciya Fuel pump harness MAP sensor electrical connector Service Manual - Scrambler 1200 XC 560 of 640...
  • Page 561 Position the ignition coils onto their bracket, secure with new fixings and tighten to 3 Nm. Connect the MAP sensor hose and the electrical connector to the MAP sensor. Attach the fuel pump harness to the ignition coil bracket, as noted for removal. Service Manual - Scrambler 1200 XC 561 of 640...
  • Page 562 The wires for the right hand side of the ignition coils are identified with the red tape. Connect the four wires from the ignition coils as noted for removal (two either side of the ignition coils). ciwj Ignition coil connections (right hand side shown) Ignition coils Service Manual - Scrambler 1200 XC 562 of 640...
  • Page 563 Disconnect the electrical connector from the keyless electronic control module (ECM). L0916_1 Keyless ECM electrical connector Remove the rear grommet for the left hand side panel for access to battery box Service Manual - Scrambler 1200 XC 563 of 640...
  • Page 564 The keyless ECM is attached to the underside of the battery box. Remove the two fixings securing the battery box to the frame and carefully manoeuvre the battery box rearward for removal. L0753 Service Manual - Scrambler 1200 XC 564 of 640...
  • Page 565 This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Fit the keyless ECM to the battery box as noted for and tighten the fixings to 3 Nm. Service Manual - Scrambler 1200 XC 565 of 640...
  • Page 566 Carefully position the battery box to the rear of the airbox and secure to the frame. Tighten the fixings to 6 Nm. Attach the starter motor solenoid to the right hand side of the battery box. Service Manual - Scrambler 1200 XC 566 of 640...
  • Page 567 Perform the following operations: Seat - Removal Battery - Removal Alternator Cover - Removal Remove and discard the fixings securing the crankshaft position sensor to the alternator cover. Service Manual - Scrambler 1200 XC 567 of 640...
  • Page 568 Position the stator to the alternator cover and route the harness as noted for removal. Secure the stator with new fixings and tighten to 12 Nm. Service Manual - Scrambler 1200 XC 568 of 640...
  • Page 569 Fit the harness cover and tighten the new fixing to 6 Nm. Note The air gap for the crankshaft position sensor is not adjustable. Fit the crankshaft position sensor with two new fixings and tighten to 6 Nm. civn Service Manual - Scrambler 1200 XC 569 of 640...
  • Page 570 To avoid skin damage, always allow the hot parts to cool before working on the exhaust system. Perform the following operations: Seat - Removal Release the two fixings and remove the silencer rear heat shield. L0723 Fixings Service Manual - Scrambler 1200 XC 570 of 640...
  • Page 571 Remove the fixing and move the heat shield bracket rearwards for removal. Collect the two rubber grommets. L0722 Fixing Rubber grommets Heat shield bracket Release the fixings and remove the centre heat shield. L0703 Service Manual - Scrambler 1200 XC 571 of 640...
  • Page 572 Lower silencer clamp Catalytic converter Note Note the position of the shouldered washers and rubber bushes in the silencer mountings for installation. Support the silencer assembly and remove the upper fixing. Service Manual - Scrambler 1200 XC 572 of 640...
  • Page 573 Collect the rubber bushes and the shouldered washer. L0718 Fixing Shouldered washer Rubber bushes Remove and discard the exhaust gaskets. Rear Suspension Exploded View – Rear Suspension Units Exploded View – Swinging Arm Service Manual - Scrambler 1200 XC 573 of 640...
  • Page 574 Fit the two rubber bushes and the shouldered washer to the lower mounting as noted for removal Position the exhaust clamps onto the silencer. Position the silencer assembly onto the catalytic converter. Fit the lower mounting fixing, do not fully tighten at this stage. Service Manual - Scrambler 1200 XC 574 of 640...
  • Page 575 Align the silencer upper mounting to the frame and fit the fixing but do not fully tighten at this stage. L0724 Fixing Position the exhaust gaskets into the silencer clamp area until flush with the end of the silencer clamp area. Service Manual - Scrambler 1200 XC 575 of 640...
  • Page 576 Tighten the silencer assembly lower fixing to 19 Nm. Position the inner and outer covers of the centre heat shield to the silencers, fit the fixings and tighten to 6 Nm. Service Manual - Scrambler 1200 XC 576 of 640...
  • Page 577 Fit the heat shield bracket to its locating lugs on the exhaust silencer. Fit and tighten the bracket rear fixing to 6 Nm. L0722 Fixing Rubber grommets Heat shield bracket Fit the rear heat shield and tighten its fixings to 6 Nm. Service Manual - Scrambler 1200 XC 577 of 640...
  • Page 578 Always note the position and orientation of exhaust clamps prior to releasing them, and return them to the noted position and orientation on assembly. Perform the following operations: Seat - Removal Battery - Removal Service Manual - Scrambler 1200 XC 578 of 640...
  • Page 579 Loosen the clamp securing the left hand header pipe to the catalytic converter. cjzs Exhaust clamp Left hand header pipe Catalytic converter Release the fixing and detach the connector bracket from the right hand side of the headstock. L0823 Fixing Connector bracket Service Manual - Scrambler 1200 XC 579 of 640...
  • Page 580 Disconnect the left hand oxygen sensor from the main harness. L0824 Left hand oxygen sensor connector Right hand oxygen sensor connector Remove the fixings and the finned clamps securing the exhaust header pipe to the cylinder head. Service Manual - Scrambler 1200 XC 580 of 640...
  • Page 581 Note To retain the gaskets during assembly, apply a smear of grease or petroleum jelly to the gasket faces in the head. Fit new gaskets to the cylinder head ports. cjcu Service Manual - Scrambler 1200 XC 581 of 640...
  • Page 582 Retighten the header pipe lower nut to 10 Nm. Header pipe lower nut Header pipe upper nut Stage 2: Header pipe lower nut to 19 Nm Header pipe upper nut to 19 Nm Service Manual - Scrambler 1200 XC 582 of 640...
  • Page 583 Start the engine and check for exhaust gas leaks. Rectify if necessary. 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. Service Manual - Scrambler 1200 XC 583 of 640...
  • Page 584 The oxygen sensors are NOT marked. Always ensure the right hand oxygen sensor harness is connected to the main harness connector with the red connector. Disconnect the right hand oxygen sensor from the main harness. L0824 Service Manual - Scrambler 1200 XC 584 of 640...
  • Page 585 To retain the gaskets during assembly, apply a smear of grease or petroleum jelly to the gasket faces in the head. Fit a new gasket to the cylinder head right hand port. Service Manual - Scrambler 1200 XC 585 of 640...
  • Page 586 Fit the fixings to the cylinder head studs and tighten in the sequence shown below. Stage 1: Header pipe lower nut to 10 Nm Header pipe upper nut to 10 Nm Retighten the header pipe lower nut to 10 Nm Service Manual - Scrambler 1200 XC 586 of 640...
  • Page 587 Fit the connector bracket to the right hand side of the headstock and tighten its fixing to 3 Nm. L0823 Fixing Connector bracket Perform the following operations: Left Hand Header Pipe - Installation Exhaust Silencer - Installation Fuel Tank - Installation Service Manual - Scrambler 1200 XC 587 of 640...
  • Page 588 These two conditions are explained overleaf. Component Locations Evaporative Canister - under the airbox. Purge Control Valve - (electronically controlled by the engine ECM) left hand side of the airbox behind the side panel. Service Manual - Scrambler 1200 XC 588 of 640...
  • Page 589 A to a carbon filled evaporative canister that stores the vapour. Once in the canister, vapour cannot return to the fuel tank because the purge valve is closed. ckjg_1 Service Manual - Scrambler 1200 XC 589 of 640...
  • Page 590 In order to control the speed at which vapour is purged from the canister, the engine management system regularly shuttles the purge control valve between open and closed positions. ckjg 2 Service Manual - Scrambler 1200 XC 590 of 640...
  • Page 591 Cut and remove the two cable ties securing the evaporative emissions canister to the frame and remove the evaporative canister. L0821 Hose to purge valve Hose to fuel tank vent Hose evaporative cannister vent Service Manual - Scrambler 1200 XC 591 of 640...
  • Page 592 Sump Guard - 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. Service Manual - Scrambler 1200 XC 592 of 640...
  • Page 593 L0917 Fixing Purge valve Disconnect the electrical connector from the purge control valve. Detach the two hoses and remove the purge control valve. Service Manual - Scrambler 1200 XC 593 of 640...
  • Page 594 Hose (from evaporative cannister) Hose (to inlet manifold) Connect the electrical connector to the purge control valve. Position the purge control valve to its mounting bracket and tighten the fixing to 3 Service Manual - Scrambler 1200 XC 594 of 640...
  • Page 595 L0917 Fixing Purge valve Perform the following operations: Fuel Tank - Installation Service Manual - Scrambler 1200 XC 595 of 640...
  • Page 596 Check the radiator hoses for cracks or deterioration, and hose clamps for tightness in accordance with scheduled maintenance requirements. Radiator CAUTION Service Manual - Scrambler 1200 XC 596 of 640...
  • Page 597 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. Service Manual - Scrambler 1200 XC 597 of 640...
  • Page 598 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.
  • Page 599 Position a container below the engine and radiator to collect the displaced coolant. Using T3880207 - Hose Clip Pliers, release the hose clamps then release the bottom hose from the radiator and allow the coolant to drain. Service Manual - Scrambler 1200 XC 599 of 640...
  • Page 600 Refit the bottom hose. Ensure the hose is positioned to the alignment mark and the clamp is positioned as noted for removal. cjfz Service Manual - Scrambler 1200 XC 600 of 640...
  • Page 601 Lower the motorcycle’s rear wheel to the ground. Refit the fuel tank (see Fuel Tank - Installation). Reconnect the battery, positive (red) lead first and tighten the battery terminals to 4.5 Nm. Service Manual - Scrambler 1200 XC 601 of 640...
  • Page 602 Contact with hot coolant will cause scalds and skin damage. Remove the fixing and position the coolant filler neck away from the immobiliser bracket. Service Manual - Scrambler 1200 XC 602 of 640...
  • Page 603 Carefully connect the hand pump (part of T3880147 - Radiator and Cap Tester Kit) to the T3880176 - Radiator Pressure Test (use with T3880147) ensuring an air tight seal is maintained. cjhr Coolant filler neck Service Manual - Scrambler 1200 XC 603 of 640...
  • Page 604 De-pressurise the coolant test kit using the pressure release valve. cjhr_1 Coolant filler neck Bayonet type connector Hand held pump Pressure release valve Service Manual - Scrambler 1200 XC 604 of 640...
  • Page 605 Allow the engine temperature to cool for at least 30 minutes. Remove the coolant pressure cap. Check the condition of the upper and lower seals of the coolant pressure cap. ccer Service Manual - Scrambler 1200 XC 605 of 640...
  • Page 606 Coolant cap type connector Select the correct test adapter and securely fasten to the pressure cap. Carefully connect the hand pump to the adapter ensuring an air tight seal is maintained. Service Manual - Scrambler 1200 XC 606 of 640...
  • Page 607 Rear Suspension Unit - Assembly Rear Suspension Units - Installation Swinging Arm - Removal Swinging Arm - Disassembly Swinging Arm - Inspection Swinging Arm - Assembly Swinging Arm - Installation Brakes Service Manual - Scrambler 1200 XC 607 of 640...
  • Page 608 Anti-lock Brake System (ABS) Management Anti-lock Brake System (ABS) ABS ECM Connector Pin Numbering Diagnostics and Testing System Diagnostics Triumph Diagnostic Software - ABS Diagnostic Trouble Codes ABS Electrical Connectors Pinpoint Tests Service Manual - Scrambler 1200 XC 608 of 640...
  • Page 609 Removal and Installation - Front Brakes Components Front Brake Pads - Removal Front Brake Pads - Inspection Front Brake Pads - Installation Front Brake Caliper - Removal Front Brake Caliper - Disassembly Service Manual - Scrambler 1200 XC 609 of 640...
  • Page 610 Rear Brake Caliper - Disassembly Rear Brake Caliper - Inspection Rear Brake Caliper - Assembly Rear Brake Caliper - Installation Rear Brake Disc - Wear Rear Brake Disc - Removal Rear Brake Disc - Installation Service Manual - Scrambler 1200 XC 610 of 640...

  • Page 611: Tyre Inflation Pressures

    ABS Hydraulic Modulator/ECM - Removal ABS Hydraulic Modulator/ECM - Installation Wheels and Tyres Exploded View – Front Wheel Exploded View – Rear Wheel and Cush Drive Tyre Inflation Pressures Minimum Recommended Tread Depth Service Manual - Scrambler 1200 XC 611 of 640...
  • Page 612 Rear Sprocket Carrier and Cush Drive - Inspection Rear Sprocket Carrier and Cush Drive - Installation Rear Sprocket Carrier Bearings - Disassembly Drive Pulley Flange Bearings - Inspection Rear Sprocket Carrier Bearings - Assembly Service Manual - Scrambler 1200 XC 612 of 640...
  • Page 613 Bank Angle Indicators Seat - Removal Seat - Installation Side Panels Mirrors - Removal Mirrors - Installation Steering Lock - Removal Steering Lock - Installation Front Mudguard - Removal Front Mudguard - Installation Service Manual - Scrambler 1200 XC 613 of 640...
  • Page 614 Exploded View – Direction Indicators Exploded View - Keyless Exploded View – Battery, Horn and Wiring Exploded View – Battery, Horn and Wiring (US only) Battery, Fuses and Relays Battery Battery Disposal Service Manual - Scrambler 1200 XC 614 of 640...
  • Page 615 Keyless ECM Diagnostic Trouble Codes Pinpoint Tests - Keyless ECM Power Supply Rail Overvoltage/Undervoltage Keyless ECM Internal Power Supply Malfunction Starter Motor Switch Malfunction Instrument Wake-up Signal Overcurrent Instrument Communication (CAN) Service Manual - Scrambler 1200 XC 615 of 640...
  • Page 616 Headlight Vertical Adjustment Headlight/Position Light LED Unit Replacement Rear Light Bulb Replacement - LED LED Direction Indicators LED Licence Plate Light Removal and Installation - Electrical Components Headlight - Removal Headlight - Installation Service Manual - Scrambler 1200 XC 616 of 640...
  • Page 617 An unexpected error has occurred error.message An unexpected error has occurred error.message An unexpected error has occurred error.message An unexpected error has occurred error.message An unexpected error has occurred error.message Service Manual - Scrambler 1200 XC 617 of 640...
  • Page 618 An unexpected error has occurred error.message Front Direction Indicators - Installation Rear Direction Indicators - Removal Rear Direction Indicators - Installation Rear Licence Plate Light - Removal Rear Licence Plate Light - Installation Service Manual - Scrambler 1200 XC 618 of 640...
  • Page 619 Service Manual - Scrambler 1200 XC 619 of 640...
  • Page 620 Remove the fixings and release the brake hose assembly from the lower yoke. L0730 Headlight brackets Headlight bracket fixings Brake hose fixings Brake hose assembly UseT3880023 - 50 mm Socket to remove the lock nut. Service Manual - Scrambler 1200 XC 620 of 640...
  • Page 621 Remove the inner race and dust seal from the lower yoke using a press or puller. 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 Service Manual - Scrambler 1200 XC 621 of 640...
  • Page 622 Protect the threads of the lower yoke when using a press or a puller as damaged threads may mean replacing the lower yoke completely. Press a new lower bearing inner race onto the steering stem of the lower yoke. Service Manual - Scrambler 1200 XC 622 of 640...
  • Page 623 Fit the bearing to the bearing inner race on the steering stem. Insert the lower yoke to the frame headstock, fit the upper bearing, inner race, dust seal and retain with the adjuster nut. Service Manual - Scrambler 1200 XC 623 of 640...
  • Page 624 Ensure the adjuster nut does not move as the lock nut is tightened. cjbu T3880023 - 50 mm Socket Lock nut Tab washer Adjuster nut Dust seal Fit the headlight brackets to the lower yoke and tighten the fixings to 3 Nm. Service Manual - Scrambler 1200 XC 624 of 640...
  • Page 625 Twist Grip - Removal Remove the fixings for the mirror brackets and release the brackets. If a non-heated left handgrip is installed, remove the top and bottom fixings and remove the grip. Service Manual - Scrambler 1200 XC 625 of 640...
  • Page 626 Release the fixings and remove the clamp from the clutch lever assembly. Without disconnecting the clutch cable, lay the lever aside. Remove the cable tie securing the switch housing wiring harness to the left hand switch housing. Service Manual - Scrambler 1200 XC 626 of 640...
  • Page 627 Note the position and orientation of the clip for installation. Insert T3880369 - Switch Housing Removal Tool into the opening on the left hand switch housing until a click is felt/heard. Service Manual - Scrambler 1200 XC 627 of 640...
  • Page 628 Slide the switch housing towards the end of the handlebar to free it from the retaining clip. Withdraw T3880369 - Switch Housing Removal Tool from the switch housing. L0386_2 Left hand switch housing T3880369 - Switch Housing Removal Tool Retaining clip Service Manual - Scrambler 1200 XC 628 of 640...
  • Page 629 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. L0879 Fixings Clamp Alignment mark Service Manual - Scrambler 1200 XC 629 of 640...
  • Page 630 Install the fixings that attach the two handlebar risers and torque the fixings to 38 Refit the upper yoke. Make sure that the two pins on the underside of the upper yoke are engaged into the grommets for the headlight bracket. Service Manual - Scrambler 1200 XC 630 of 640...
  • Page 631 Handlebar clamp Right riser Tighten the handlebar clamp fixings, front ones first, to 24 Nm. Put the instrument and bracket assembly in position. Install three new fixings and torque to 5 Nm. Service Manual - Scrambler 1200 XC 631 of 640...
  • Page 632 Connect the electrical connector to the instruments. Install the cover for the connector. Install and torque the fixing for the cover to 3 Nm. L0733 Fixing Cover Perform the following operations: Service Manual - Scrambler 1200 XC 632 of 640...
  • Page 633 Slide the twist grip position sensor onto the right hand side of the handlebar. Locate the handlebar onto the risers, fit the clamp and the fixings. Do not fully tighten at this stage. Service Manual - Scrambler 1200 XC 633 of 640...
  • Page 634 Use a new cable tie to secure the wiring harness to the switch housing. Do steps 1 and 2 again for the left switch housing. Note The left hand switch housing electrical connections are recessed into the switch housing body. Service Manual - Scrambler 1200 XC 634 of 640...
  • Page 635 Do not tighten the clamp bolts at this stage. Align the split line of the master cylinder clamp to the alignment mark on the top surface of the handlebar. Tighten the clamp fixings, upper one first, to 8 Nm. Service Manual - Scrambler 1200 XC 635 of 640...
  • Page 636 Torque the fixing to 1 Nm L0745 Fixing Switch cover Clutch switch If a non-heated left handgrip is installed, install the grip and tighten the top and bottom fixings to 2 Nm. Service Manual - Scrambler 1200 XC 636 of 640...
  • Page 637 Perform the following operations: Install the heated twist grip (see Twist Grip - Installation). Install the two mirrors (see Mirrors - Installation). Battery - Installation Seat - Installation Instruments - Removal Instruments - Disassemble Service Manual - Scrambler 1200 XC 637 of 640...
  • Page 638 Ignition Master Switch (US Markets Only) - Removal Ignition Master Switch (US Markets Only) - Installation Circuit Diagrams Glossary of Circuit Diagram Symbols Main Wiring Harness Electrical Connectors Power Distribution Circuit Keyless Control Circuit Service Manual - Scrambler 1200 XC 638 of 640...
  • Page 639 CAN and LIN Circuit Auxiliary Connection Circuit Alarm Circuit Diagnostic Connector Circuit Earth Circuit - 01 Earth Circuit - 02 Earth Circuit - 03 Electronic Systems Configuration and Setup General Information Service Manual - Scrambler 1200 XC 639 of 640...
  • Page 640 Pairing New or Replacement Keys Guidelines - Replacing a Lost Smart Key Guidelines - Adding a Second Smart Key All Keys Lost Pairing the Engine ECM Trouble Shooting Spares Kits Matrix - Keyless Ignition System Service Manual - Scrambler 1200 XC 640 of 640...

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