Table Of Contents - Triumph Scrambler 1200 XC Service Manual

Table of Contents

How To Use This Manual2
Warnings, Cautions And Notes2
Tampering With Noise Control System2
References3
Dimensions3
Force3
Edges3
Tightening Procedure4
Torque Tolerance4
Use Of Crow Foot Spanner Adapters With Torque Wrenches4
General Information5
Ignition System Safety Precautions5
Dangerous Substances6
Fluoroelastomers6
Warning On Oils7
Health Protection Precautions7
Environmental Precautions8
Brakes Warning8
Safety Instructions9
Safe Jacking And Lifting9
Precautions Against Damage10
Warnings On Coolant10
Cleaning Components11
Lubrication Note11
Joints And Joint Faces Note11
Gaskets, O-Rings Note12
Liquid Gasket, Non-Permanent Locking Agent Note12
Screw Threads Note12
Locking Devices Note13
Circlips, Retaining Rings13
Self-Locking Nuts13
Encapsulated Bolts13
Chassis Bearing Lubrication14
Press Note14
Ball Bearing14
New Bearings15
Lubrication And Checks While Servicing A Bearing15
Sealed Bearings16
Taper Bearings16
Fuel Handling Precautions17
Angular Contact And Ball Bearing17
Needle Roller Bearings17
Metal Bushes17
Electrical Precautions19
Fuel Tank Removal Note19
Warning On Chassis Repairs19
Battery Disconnecting20
Electrical Testing21
Disciplines21
Electrical Wires21
Circuit Diagrams23
Basic Electrical Circuits23
Basic Circuit Diagram23
Tracing Circuits24
Open Circuit24
Short Circuit24
To Check Continuity25
To Measure Voltage26
Splices27
Switches27
Relays27
Can (Controller Area Networking)28
Lin (Local Interconnect Network)29
Service Tools30
Specifications33
Engine Data33
Cylinder Head And Valves Data33
Camshafts Data35
Clutch And Primary Drive Data35
Piston Data36
Crankshaft Data37
Transmission Data38
Final Drive Data39
Lubrication Data39
Ignition System Data40
Fuel System Data40
Emissions Control System Data41
Cooling System Data41
Suspension Data42
Brakes Data42
Frame Data43
Wheels And Tyres Data44
Electrical Equipment Data45
Torque Wrench Settings45
Main Wiring Harness Routing66
Evaporative Hose Routing67
Clutch Cable Routing68
Abs Brake Hose Routing68
Scheduled Maintenance69
Scheduled Maintenance Table71
Service Symbol/General Warning Symbol71
Service Specifications77
Service Torque Wrench Settings79
Engine Check For Fluid Leaks81
Engine Oil - Level Inspection81
Engine Oil And Filter Renew83
Air Filter Element - Renew85
Fuel Filter - Renew88
Throttle Body Plate (Butterfly) - Check/Clean92
Fuel/Evaporative System - Check For Leaks, Routing, Chafing, Security92
Autoscan93
Spark Plugs - Check/Renew93
Spark Plugs - Inspection95
Dry And Wet Fouling96
Overheating96
Spark Plug Deposits97
Spark Plug Breakage97
Spark Plug Normal Life98
Spark Plug Melting99
Spark Plug Erosion, Corrosion And Oxidation99
Coolant Level Inspection100
Coolant Level Adjustment101
Coolant Renew102
Valve Clearance Adjustment102
Clutch Cable - Check/Adjust105
Rocker Shaft Tightening Sequence105
Tyres - Check For Wear/Damage106
Tread Wear Indicator107
Wheels - Check For Damage108
Tyre Pressures - Check/Adjust108
Wheel Bearings - Inspection109
Check Lights, Instruments And Electrical Systems110
Steering Check110
Fork Inspection110
Headstock Bearings - Check/Adjust111
Headstock Bearings - Lubricate112
Headstock Bearing - Inspection113
Brake Pad Wear Inspection114
Brake Fluid Level Inspection115
Front Brake Fluid Level Adjustment116
Rear Brake Fluid Level Adjustment116
Brake Calipers - Inspection118
Brake Master Cylinders - Inspection119
Final Drive Chain Adjustment119
Drive Chain Free Movement Inspection119
Drive Chain Free Movement Adjustment120
Drive Chain And Sprocket Wear Inspection121
Final Drive Chain Lubrication122
Drive Chain Rubbing Strip - Check123
Side Stand - Clean/Lubricate123
Rear Brake Pedal Grip - Lubricate125
Bank Angle Indicators126
Latest Calibrations Check127
Fasteners - General Inspection127
Road Test128
Service Indicator And Service Maintenance Book131
Post Road Test131
Engine Covers Exploded Views133
Sump - Removal137
Sump - Inspection139
Sump - Installation139
Clutch Cover - Removal141
Clutch Cover - Installation143
Alternator Cover - Removal146
Alternator Cover - Installation148
Camshaft Cover - Removal151
Camshaft Cover - Installation152
Front Sprocket Cover - Removal153
Front Sprocket Cover - Inspection155
Front Sprocket Cover - Installation156
Cylinder Head Exploded View158
Cylinder Head - Description160
Camshaft Drive Chain Tensioner - Removal160
Camshaft Drive Chain Tensioner - Inspection163
Camshaft Drive Chain Tensioner - Installation163
Camshaft Drive Chain Rubbing Blade - Removal168
Camshaft Drive Chain Rubbing Blade - Installation169
Camshaft Drive Chain And Idler Gear - Removal170
Camshaft Chain - Inspection173
Camshaft Drive Chain And Idler Gear - Installation175
Exhaust Decompressors177
Camshaft - Removal178
Camshaft Frame Release Sequence180
Camshaft - Identification182
Camshaft - Installation182
Cylinder One Camshaft Frame Tightening Sequence191
Valve Clearance192
Feeler Gauges193
Cylinder Head - Removal195
Cylinder Head Bolt Release Sequence196
Camshaft Drive Chain Tensioner Rubbing Blade196
Cylinder Head - Inspection197
Mounting Lugs197
Cylinder Head - Installation198
Head Gasket Markings199
Valves And Valve Stem Seals - Removal200
Valves And Valve Stem Seals - Installation202
Barrels And Pistons203
Valve Face Inspection203
Valve Stems203
Barrels - Removal204
Locating Dowels205
Barrels - Inspection206
Barrels - Installation206
Piston - Removal208
Piston - Wear Check209
Piston - Installation210
Piston Ring To Groove - Clearance212
Piston Rings - Removal213
Piston Ring - End Gap214
Piston Rings - Assembly215
Piston Ring Identification216
Piston Ring End Gap Locations216
Clutch217
Exploded View – Clutch Controls217
Exploded View – Clutch218
Clutch Cable - Removal218
Clutch Cable - Inspection221
Clutch Cable - Installation221
Clutch Lifter Arm - Removal223
Clutch Lifter Arm - Installation225
Clutch Lifter Arm226
Clutch Lifter Arm Plate226
Clutch - Removal227
Pressure Plate228
Friction Plate Inspection230
Steel Plate Inspection230
Clutch Pack - Height231
Clutch - Installation234
Clutch Anti-Rotation Jig237
Clutch Outer Drum237
Crankcase, Crankshaft And Connecting Rods239
Exploded View – Crankshaft And Connecting Rod239
Exploded View – Crankcase240
Crankcase - Disassembly240
Crankcase - Assembly243
Crankcase Fixing Release Sequence243
Sealer Areas245
Crankshaft - Removal252
Crankshaft - Installation252
Connecting Rods - Removal253
Connecting Rod - Installation254
Connecting Rod Big End Journal Checking, Measuring, Bearing Selection256
Checking The Big End Bearing/Crankshaft Journal Clearance257
Connecting Rod Bearing Selection257
Crankshaft Main Bearing/Journal Checking, Measuring, Bearing Selection258
Big End Bearing Selection Chart258
Checking The Crankshaft Journal Clearance259
Main Bearing Selection260
Coolant Manifold - Removal261
Coolant Manifold - Installation262
Breather Plate - Removal263
Breather Plate - Installation265
Balancer266
Exploded View – Balancers266
Rear Balancer Shaft - Removal267
Front Balancer Shaft - Removal269
Balancer Shafts - Inspection272
Front Balancer Shaft - Installation273
Rear Balancer Shaft - Installation278
Balancer Shafts Dynamic Adjustment281
Front Balancer Shaft Dynamic Adjustment282
Rear Balancer Shaft Dynamic Adjustment286
Transmission290
Exploded View – Input And Output Shafts290
Exploded View – Gear Selector291
Exploded View – Gear Change Lever292
Gear Change Shaft - Removal292
Gear Change Shaft - Inspection294
Gear Change Shaft - Installation294
Gear Change Detent Wheel - Removal296
Gear Change Detent Wheel - Installation297
Selector Forks And Drum - Removal298
Selector Forks And Drum Inspection301
Selector Forks And Drum - Installation301
Exploded View - Output Shaft304
Output Shaft - Disassembly305
Output Shaft - Inspection312
Output Shaft - Assembly312
Exploded View - Input Shaft320
Input Shaft - Disassembly321
Input Shaft - Inspection323
Input Shaft - Assembly323
Starter Drive And Sprag Clutch325
Exploded View - Starter And Sprag325
Starter Drive/Sprag Clutch - Removal325
Starter Sprag Gear328
Starter Drive/Sprag Clutch - Inspection329
Starter Drive/Sprag Clutch - Installation329
Sprag Clutch Housing Assembly331
Lubrication332
Exploded View – Oil Filter And Pump332
Oil Circuit Diagram333
Oil Circuit334
Triumph Engine Oil335
Engine Oil - Specification335
Oil Viscosity Temperature Range336
Disposal Of Used Engine Oil And Oil Filters336
Oil And Water Pump - Removal336
Oil Pump Inspection341
Oil Pump - Disassembly341
Oil Pump Rotor Tip Clearance343
Oil Pump Body Clearance343
Oil Pump End Clearance344
Oil Pump - Assembly345
Oil And Water Pump - Installation346
Oil Pressure Relief Valve - Removal349
Oil Pressure Relief Valve - Installation351
Low Oil Pressure Warning Light Switch - Removal351
Low Oil Pressure Warning Light Switch - Installation353
Engine - Removal354
Electrical Connector (Engine)361
Engine - Installation363
Fuel And Exhaust System And Engine Management373
Exploded View – Fuel Tank373
Exploded View – Fuel Pump374
Exploded View – Fuel Rail, Throttles And Injectors375
Exploded View - Engine Management376
Exploded View – Airbox376
Exploded View – Exhaust System377
Exploded View – Evaporative System378
Engine Management379
Fuel Requirements379
Oxygenated Gasoline379
Glossary Of Terms380
Engine Management System Description386
Engine Management System Sensors386
Actuators388
Immobiliser And Keyless Ignition System390
Keys391
Immobiliser Components Location392
Engine Management Adaption392
Adaption Status393
Typical Values Of A Correctly Adapted Motorcycle394
Forcing Adaption To Take Place394
Diagnostics And Testing395
Electrical Connectors395
Engine Management System Diagnostics398
Ecm Connector Pin Numbering399
System Diagnostic Tool Connection400
Triumph Diagnostic Software401
Current Data401
Sensor Voltages403
Sensor Readings403
Injector Data404
Ignition Data404
Idle Speed And Throttle Data405
Inputs405
Outputs406
Adaption Status Table406
Function Tests407
Freeze-Frame Data408
Gear Position Sensor Voltage Characteristics409
Neutral Position Adaption410
Cruise Control Switch Check411
Adaption Reset411
Re-Adaption411
Cruise Control Switch Check Function412
Engine Electronic Control Module - Diagnostic Trouble Codes413
Pinpoint Tests - Fuel423
Oxygen Sensor Heater423
Manifold Absolute Pressure (Map) Sensor425
Cooling Fan Relay428
Resistance Data429
Resistance Data Under Typical Conditions432
Cruise Control Prevented Due To Other Malfunction433
Engine Electronic Control Unit - Connector A440
Crankshaft Sensor441
Engine Electronic Control Module Connector A441
Cruise Control Disabled Until Button Press Sequence Completed465
Calibration Lock465
Instrument Id Incompatible465
Keyless Ecm Communication466
Fall Detection Switch466
Ems Ignition Voltage Input Circuit/Ems Main Relay Circuit466
Can Communication466
Removal And Installation - Fuel And Air Components478
Fuel Tank - Installation484
Fuel Pressure Checking491
Fuel Pump Assembly - Removal/Inspection/Installation499
Fuel Pressure Regulator - Removal/Inspection/Installation499
Fuel Pump - Removal/Inspection/Installation499
Fuel Level Sensor - Removal499
Fuel Level Sensor Installation501
Airbox - Removal/Installation501
Throttle Body And Inlet Manifold Assembly - Removal/Installation501
Removal And Installation - Engine Management Components504
Engine Electronic Control Module (Ecm) - Removal/Installation504
Twist Grip - Removal/Installation504
Intake Air Temperature Sensor - Removal504
Fuel Pump Plate Tightening Sequence507
Intake Air Temperature Sensor - Installation527
Coolant Temperature Sensor - Removal/Installation527
Manifold Absolute Pressure (Map) Sensor - Removal/Installation531
Ambient Air Pressure Sensor - Removal/Installation531
Fall Detection Switch - Removal/Installation531
Gear Position Sensor - Removal531
Twist Grip Position Sensor Electrical Connector543
Removal And Installation - Exhaust System Components545
Exhaust Silencer - Removal/Installation545
Left Hand Header Pipe - Removal/Installation545
Evaporative System Components546
Cooling547
Front Suspension548
Coolant Temperature Sensor550
Gear Position Sensor Electrical Connector558
Coolant Temperature Sensor Connector559
Keyless Ecm Electrical Connector563
Seat - Removal570
Rear Suspension573
Fuel Tank - Removal579
Left Hand Header Pipe - Installation587
Exhaust Silencer - Installation587
Evaporative Canister - Under The Airbox588
Sump Guard - Removal591
Sump Guard - Installation592
Radiator596
Cooling Fan597
Remove The Coolant Pressure Cap599
Disconnect The Bottom Hose600
Rear Suspension Units - Removal605
Brakes607
Front Fork619
Headstock623
Switch Housing Connectors627
Handlebars628
"Up" Arrow630
Switch Housing Electrical Connectors635