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Triumph Rocket 3 GT 2021 Service Manual

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Service Manual

Rocket 3 GT/R

2021

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Page 1 Service Manual Rocket 3 GT/R 2021...
Page 3: Table Of Contents
Table des matières Introduction..............................1 Introduction ..............................1 How to use this manual ........................... 2 Warnings, Cautions and Notes ......................3 Noise Control System ..........................3 References ..............................4 Dimensions ..............................4 Repairs and Replacements ........................4 Force ................................5 Edges ................................
Page 4 LIN (Local Interconnect Network) ...................... 39 Service Tools ..............................41 Service Tools and Garage Equipment ....................41 Specifications ..............................47 Engine ................................47 Cylinder Head and Valves ........................48 Camshafts ..............................50 Clutch and Primary Drive ........................51 Pistons ................................. 52 Connecting Rods .............................
Page 5 Starter Drive and Sprag Clutch ......................67 Lubrication ..............................68 Fuel System, Exhaust System and Airbox ..................68 Cooling ................................ 71 Front Suspension ............................. 73 Rear Suspension ............................74 Front Brakes ............................... 75 Rear Brakes ..............................76 ABS System ..............................76 Wheels and Tyres .............................
Page 6 Spark Plugs - Check/Renew ....................... 128 Coolant System - Check For Fluid Leaks ..................129 Coolant Level Inspection ........................130 Coolant Level Adjustment ........................132 Coolant System - Check Hoses for Chafing, Cracks, Damage..........134 Coolant Renew ............................135 Clutch Fluid Level Inspection ......................135 Changing Clutch Fluid .........................
Page 7 Rear Bevel Box Oil Change ........................ 201 Check Lights, Instruments and Electrical Systems ..............202 Latest Calibrations Check ........................203 Bank Angle Indicators ......................... 204 Side Stand – Clean ..........................204 Fasteners - General Inspection ......................207 Road Test ..............................207 Service Indicator and Service Maintenance Book ..............
Page 8 Exploded View - Cylinder Head......................270 Exploded View - Camshaft and Camshaft Drive ................ 271 Cylinder Head – Description ......................272 Camshaft Drive Chain Tensioner – Removal ................273 Camshaft Drive Chain Tensioner – Inspection ................277 Camshaft Drive Chain Tensioner – Installation ................277 Camshaft Drive Chain –...
Page 9 Piston Ring - End Gap ......................... 338 Piston Ring to Groove – Clearance....................340 Piston - Assembly ..........................341 Clutch ................................344 Exploded View - Clutch ........................344 Exploded View - Clutch Controls ....................345 Exploded View - Clutch Slave Cylinder ..................346 Clutch Description ..........................
Page 10 Crankcase – Assembly ......................... 414 Crankshaft – Removal .......................... 418 Crankshaft – Installation ........................422 Connecting Rod – Removal ....................... 425 Connecting Rod – Installation ......................426 Connecting Rod Big End Journal Checking, Measuring and Bearing Selection ..... 427 Crankshaft Main Bearing/Journal Checking, Measuring and Bearing Selection .... 430 Main Bearing Selection Chart ......................
Page 11 Selector Forks and Drum Inspection ..................... 487 Gear Selector Forks – Installation ....................488 Gear Change Shaft and Selector Drum – Removal ..............490 Gear Change Shaft Inspection ......................492 Gear Change Shaft and Selector Drum – Installation .............. 493 Gear Change Actuator Shaft –...
Page 12 System Diagnostics ..........................603 Engine ECM Connector Pin Numbering ..................... 606 System Diagnostic Tool Connection ....................607 Triumph Diagnostic Software - Engine ECM ..................608 Cruise Control Switch Check ......................617 Crankshaft Position Adaption (European Markets Only) ..............618 Engine Electronic Control Module - Diagnostic Trouble Codes ............623...
Page 13 Further Diagnosis ..........................637 Pinpoint Tests – Fuel..........................638 Manifold Absolute Pressure (MAP) Sensor ..................638 Intake Air Temperature Sensor ......................641 Coolant Temperature Sensor ......................644 Throttle Position Sensor ........................647 Oxygen Sensor Heater ........................650 Oxygen Sensor Heater ........................652 Oxygen Sensor ............................654 Oxygen Sensor - Slow Response ......................656 Fuel Injectors ............................658 Engine Misfire .............................662 Crankshaft Sensor ..........................658...
Page 14 EMS Main Relay Circuit ........................704 CAN Communication ......................... 706 Instrument Communication (CAN) ....................710 Shift Force Sensor Circuit (Triumph Shift Assist) ................711 EEPROM Error ............................ 713 Traction Control Disabled Due to ABS Malfunction ................713 ABS Modulator ID Incompatible ......................714 Engine ECM Tamper Detected ......................
Page 15 Fuel Pressure Checking........................746 Fuel Pump Assembly – Removal ......................750 Fuel Pump Assembly – Inspection ......................752 Fuel Pump Assembly – Installation ....................752 Fuel Pressure Regulator – Removal ....................754 Fuel Pressure Regulator – Inspection ....................756 Fuel Pressure Regulator – Installation ....................756 Fuel Pump – Removal .........................759 Fuel Pump –...
Page 16 Coolant Temperature Sensor – Removal ................... 806 Coolant Temperature Sensor – Installation ..................808 Manifold Absolute Pressure (MAP) Sensor – Removal ..............809 Manifold Absolute Pressure (MAP) Sensor – Installation ..............810 Ambient Air Pressure Sensor – Removal ................... 811 Ambient Air Pressure Sensor –...
Page 17 Radiator and Cooling Fan Inspection .................... 863 Coolant ..............................864 Coolant Replacement – Drainage ....................866 Coolant Replacement – Filling ......................868 Coolant Expansion Tank – Removal ....................870 Coolant Expansion Tank – Installation ..................874 Radiator – Removal ..........................878 Radiator –...
Page 18 Lower Yoke and Headstock Bearings - Installation ..............944 Rear Suspension and Swinging Arm ....................948 Exploded View - Rear Suspension Unit and Linkage ..............948 Exploded View - Swinging Arm ......................949 Rear Suspension Unit – Removal ..................... 950 Rear Suspension Unit –...
Page 19 Anti-lock Brake System (ABS) ......................1022 ABS ECM Connector Pin Numbering ....................1025 Diagnostics and Testing ........................1026 System Diagnostics .......................... 1026 Triumph Diagnostic Software – ABS ....................1028 Diagnostic Trouble Codes ........................ 1029 ABS Electrical Connectors ....................... 1031 Further Diagnosis ..........................1036 Pinpoint Tests ............................
Page 20 Front Brake Caliper – Installation ....................1068 Front Brake Disc – Removal ......................1071 Front Brake Disc – Installation ......................1073 Front Brake Lever – Removal ......................1074 Front Brake Lever – Installation....................... 1078 Front Brake Master Cylinder-Removal .................... 1083 Front Brake Master Cylinder-Disassembly ..................
Page 21 ABS Hydraulic Modulator/ECM - Installation .................. 1131 Wheels and Tyres ............................ 1134 Exploded View - Front Wheel ......................1134 Exploded View - Rear Wheel ......................1135 Tyres ................................ 1136 Tyre Inflation Pressures ........................1138 Minimum Recommended Tread Depth ..................1139 Important Tyre Information ......................
Page 22 Exploded View - Steering Lock, Lockset and Keyless ECM (All markets except US) .. 1187 Exploded View – Flyscreen ......................1188 Exploded View – Mirrors ........................1189 Exploded View – Seats ........................1190 Exploded View - Passenger Back Rest ..................1191 Exploded View –...
Page 23 Radiator Cowl – Installation ......................1234 Side Panels – Removal ........................1237 Side Panels – Installation ......................... 1240 Battery Box – Removal ........................1242 Battery Box – Installation ......................... 1248 Side Stand – Removal ........................1253 Side Stand – Installation ........................1256 Rear Mudguard –...
Page 24 Diagnostics - Starter and Charging Circuits ................1298 Starting Circuit ..........................1298 Diagnosis - Starter Circuit ........................ 1300 Alternator/Charging System ......................1301 Alternator Stator ..........................1303 Regulator/Rectifier .......................... 1306 System Diagnostics - Keyless ECM ....................1309 System Diagnosis - Keyless ECM ...................... 1309 Keyless ECM Diagnostic Trouble Codes ...................
Page 25 Headlight Adjustment ........................1341 Headlight/Position Light LED Unit – Removal ................. 1342 Headlight/Position Light LED Unit Installation ................1348 Rear Light Bulb Replacement – LED ....................1352 Direction Indicators LED ........................1352 LED Licence Plate Light ........................1352 Removal and Installation - Electrical Components ..............1353 Headlight Assembly –...
Page 26 Cooling Fan Controller – Installation ....................1418 Heated Grip - Removal (if fitted) ..................... 1420 Heated Grip - Installation (if fitted) ....................1421 Low Frequency (LF) Antenna – Removal ..................1423 Low Frequency (LF) Antenna – Installation ..................1425 Ignition Master Switch (US Markets Only) – Removal ..............1428 Ignition Master Switch (US Markets Only) –...
Page 27 Alarm Circuit ............................ 1470 Accessories Circuit ........................... 1471 Heated Accessories Circuit ......................1472 Rider Information Circuit ......................... 1473 Ground Circuit – Front ........................1474 Ground Circuit – Middle ........................1475 Ground Circuit - Rear ........................1476 Electronic Systems Configuration and Setup ................1477 General Information...........................
Page 28 Spares Kits Matrix - Keyless Ignition System ................... 1504 Gear Position Adaption and Triumph Shift Assist (if fitted) ..........1505 Gear Position Sensor ........................1505 Neutral Position Adaption ....................... 1506 Triumph Shift Assist System (if fitted) ..................... 1508 Shift Force Sensor (if fitted) ......................1510 Shift Force Sensor Adaption (if fitted) .....................
Page 29: Introduction
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: •...
Page 30: How To Use This Manual
• 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. • Use only approved lubricants, as specified in the Owner's Handbook, in the maintenance of the motorcycle.
Page 31: Warnings, Cautions And Notes
Warnings, Cautions and Notes Particularly important information is presented in the following form: A WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.
Page 32: References
Among those acts presumed to constitute tampering are the acts listed below: • Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases. • Removal of, or puncturing of any part of the intake system. •...
Page 33: Force
Triumph parts are used. Safety features and corrosion prevention treatments embodied in the motorcycle may be impaired if parts other than genuine Triumph parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification.
Page 34: Use Of Crow Foot Spanner Adapters With Torque Wrenches
Torque Tolerance Torque Tolerance 0 Nm to 25 Nm +/- 10% 26 Nm to 100 Nm +10% -0% 101 Nm to 200 Nm +10% -0% Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed.
Page 35: General Information
Example M1 = M2 x L1/L2 M2 is the required 90 Nm tightening torque to be applied L1 is the normal length of the torque wrench, measured from the centre of 300 mm the drive square to the centre of the handle L2 is the extended length of the torque wrench, measured from the centre of...
Page 36: Dangerous Substances
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 Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far as possible, be kept from contact with the skin.
Page 37: Fluoroelastomers
Fluoroelastomers Fluoroelastomer material is used in the manufacture of various seals in Triumph motorcycles. In fire conditions involving temperatures greater than 315°C this material will decompose and can then be potentially hazardous. Highly toxic and corrosive decomposition products, including hydrogen fluoride, carbonyl fluoride, fluorinated olefins and carbon monoxide can be generated and will be present in fumes from fires.
Page 38: Health Protection Precautions
Health Protection Precautions • Avoid prolonged and repeated contact with oils, particularly used engine oils. • Wear protective clothing, including impervious gloves where practicable. • Do not put oily rags in pockets. • Overalls must be cleaned regularly. Discard heavily soiled clothing and oil impregnated footwear.
Page 39: Environmental Protection Precautions
Environmental Protection Precautions Do not pour oil on the ground, down sewers or drains, or into water courses. To prevent pollution of water courses etc., dispose of used oil sensibly. If in doubt contact your local authority. Burning of used engine oil in small space heaters or boilers can be recommended only for units of approved design.
Page 40: Brakes
It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph dealer before riding the motorcycle. Failure to take remedial action may reduce braking efficiency leading to an accident.
Page 41 Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to an accident.
Page 42: Safety Instructions
Safety Instructions Diagnostic Trouble Codes If the motorcycle falls over or is involved in an accident, diagnostic trouble codes may be triggered and stored. If the motorcycle has fallen over or been involved in an accident, always clear any diagnostic trouble codes. If diagnostic codes reappear, address them immediately.
Page 43 Coolant Coolant mixture, which is blended with antifreeze and corrosion inhibitors contains toxic chemicals which are harmful to the human body. Never swallow antifreeze, corrosion inhibitors or any of the motorcycle coolant. Do not remove the radiator cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure.
Page 44 Cleaning Components A high flashpoint solvent is recommended to reduce fire hazard. Always follow container directions regarding the use of any solvent. Always use the recommended cleaning agent or equivalent. Do not use degreasing equipment for components containing items which could be damaged by the use of this process.
Page 45 Gaskets, O-rings Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. Liquid Gasket, Non-permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used.
Page 46 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...
Page 47 Self-locking nuts can be reused, provided resistance can be felt when the locking portion passes over the thread of the bolt or stud. DO NOT reuse self-locking nuts in critical locations, e.g. suspension components. Always use the correct replacement self-locking nut. Encapsulated Bolts An encapsulated bolt can be identified by a coloured section of thread which is treated with a locking agent.
Page 48: Chassis Bearing Lubrication
When pressing in a seal which has manufacturer's marks, press in with the marks facing out. Seals must be pressed into place using a suitable driver. Use of improper tools will damage the seal. Press A part installed using a press or driver, such as a wheel bearing, should first be coated with oil or grease on its outer or inner circumference so that it will locate smoothly.
Page 49 General For a bearing to be serviceable for its anticipated life span it must be checked, adjusted and lubricated at regular intervals, as specified in the service schedules given in the Owner's Handbook and this Service Manual. A correctly lubricated bearing will have a film of lubrication that separates the moving parts, disperses heat and protects the bearing surfaces from corrosion.
Page 50 Several common bearing types and the lubrication procedures for each are identified below: NOTICE Sealed bearings can be identified by their integrated seals. Sealed bearings are lubricated for life by the manufacturer. Any attempt to change the grease in a sealed bearing will damage the integrated seals.
Page 51 1. Grease must be forced between the inner race and the roller carrier. 2. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts. 3. Any excess grease should be smeared on the outside of the rollers. 1.
Page 52: Fuel Handling Precautions
1. Coat the needle rollers with grease. 2. Ensure the needle rollers turn so that the grease is distributed over the entire circumference of the internal parts. 3. Assemble the parts, adjust and check as necessary. Metal Bushes 1. Disassemble the parts as necessary to access the bush. 2.
Page 53 Petrol (gasoline) is highly flammable and can be explosive under certain conditions. When opening the fuel tank cap always observe all the following items: Turn the motorcycle ignition switch OFF. Do not smoke. Always have a suitable fire extinguisher close at hand when handling or draining fuel or fuel systems.
Page 54 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 55: Electrical Precautions
Electrical Precautions The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and electronic components fitted to the motorcycle. Where necessary, specific precautions are detailed in the relevant sections of this manual which should be referred to prior to commencing repair operations.
Page 56 High Voltage Circuits - Whenever disconnecting live H.T. circuits always use insulated pliers. Exercise caution when measuring the voltage on the coil terminals while the engine is running. High voltage spikes can occur on these terminals. Connectors and Harness - The engine of a motorcycle is a particularly hostile environment for electrical components and connectors.
Page 57: Electrical Testing
Disciplines Switch off the ignition prior to making any connection or disconnection in the system. An electrical surge can be caused by disconnecting 'live' connections which can damage electronic components. Ensure hands and work surfaces are clean and free of grease, swarf, etc. as grease collects dirt which can cause tracking or high- resistance contacts.
Page 58 Ohm's Law The relationship between voltage, current and resistance is defined by Ohm's Law. • The potential of a battery is measured in volts (V). • The flow of current in a circuit (1) is measured in amperes. • The power rating of a consumer is measured in watts (W). •...
Page 59 Basic Electrical Circuits Basic Circuit Diagram In the above circuit an electrical reservoir (the battery) is connected via a cable to a terminal on the controlling device (the switch) whose contacts are either open or closed. The other terminal on the switch is connected via a cable to the consumer (the bulb), and the other side of the bulb filament is connected to ground (earth) by another cable.
Page 60: Circuit Diagrams
Circuit Diagrams Circuit Diagrams Circuit diagrams are created to provide a 'picture' of the electrical system and to identify the route taken by each individual wire through the system, in order to identify which components it feeds and which connectors the wire runs through. Circuit diagrams are an essential tool for fault finding, as it is possible to locate start and finish points for a circuit without having to manually trace the wire through the motorcycle itself.
Page 61 Short Circuit A 'short cut' in an electrical circuit - current bypasses the intended circuit, either to ground or to another, different circuit. Often caused by failure of the cable insulation due to chafing or trapping of the wire. There are two different types of short circuit - short to ground and short to battery Voltage.
Page 62 To Check Continuity: Ensure the circuit being tested is switched off before measuring continuity. Damage to the Digital Multi Meter (DMM) may result from testing a 'live' circuit with the meter set to resistance (Q). In the example below, the ground circuit continuity is being tested from the battery to the frame.
Page 63 To Measure Voltage: In the example below, the circuit voltage is being measured at the bulb positive (+) terminal. • Turn the circuit to be tested 'ON'. • Set the Digital Multi Meter (DMM) to Voltage Check (V). Ensure the multi meter is set to DC Volts for direct current circuits (most circuits) or AC Volts for alternating current circuits (typically alternator output voltage tests).
Page 64 Splices Splices are probably the most common cause of wiring faults after connectors. Splices are made where two or more wires come together and diverge in different directions, usually to feed a different circuit. To locate a splice, it is necessary to peel back the insulation and examine the splice for its integrity.
Page 65: Can (Controller Area Networking)
CAN (Controller Area Networking) CAN (sometimes called CANbus) is a protocol for data communication between Electronic Control Modules (ECMs). Each ECM on the network is connected by a single pair of twisted wires (or bus) which are used for the transmission of vehicle sensor data. By using CAN, the overall number of system sensors, and the amount of cabling required to allow ECMs to communicate with each other is greatly reduced.
Page 66 ECM from clogging the network with incorrect data and preventing other messages from getting through. The fault would then be reported by a DTC (Diagnostic Trouble Code). Triumph currently uses CAN for communication between the following ECMs: • Engine ECM •...
Page 67: Lin (Local Interconnect Network)
LIN (Local Interconnect Network) LIN (Local Interconnect Network) is a serial network protocol used for communication between components in vehicles. The bus is a single master/multiple slave bus that uses a single wire to transmit data. By using LIN, the amount of cabling required to allow components to communicate with each other is greatly reduced.
Page 68 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 69: Service Tools
Where this is the case, the tools required will be described during the procedure. Special Service Tools: BatteryMate Battery Charger - See Latest Parts Catalogue for Part Number T3880001- Fuel Pressure Gauge Information T3880057 - Triumph Diagnostic Interface T3880053 - Wheel Bearing Extraction Kit...
Page 70 T3880070 - Bearing Installer T3880075 - Bearing Installer T3880085 - Fork Piston Holder T3880105-Torque Angle Gauge T3880176 - Radiator Pressure Test (use T3880147 - Radiator and Cap Tester Kit with T3880147)
Page 71 T3880181 - Wrench Frame Adjuster T3880183 - Fork Seal Tool, 47 mm T3880207 - Hose Clip Pliers T3880208 - Slide Hammer T3880215 - Fork Seal Cleaner, 35-45 mm T3880209 – Adaptor forks...
Page 72 T3880313 - Oil Filter Wrench T3880342 - 17 mm U-Spanner T3880365 - Alternator Housing Puller T3880377 - Engine Mounting Adjuster T3880501 Crankshaft Locking Pin T3880502 - Camshaft timing bar...
Page 73 T3880503 - Drop link alignment pin T3880504 - Oil spray jet protectors T3880505 - Main frame support T3880506 - Outrigger dowel removal T3880507 - Cable extension, fuel pump T3880518 - Spacer...
Page 74 T3880511 - Needle Bearing Installer T3880512 - Needle Bearing Installer 6.5mm 7.5mm T3880513 - Adaptor 12mm T3880609 - Timing Torque Limiter T3880629 - Bearing Installer Handle T3880636 - Kit, Brake Lever Pivot Sleeve...
Page 75: Specifications
T3880651 - Timing Chain Tensioner T3880750 - Headstock Service Tool Specifications Engine Engine Configuration Liquid cooled in-line 3 cylinder Arrangement Longitudinal in-line Displacement 2458 cc Bore x Stroke 110.2 x 85.9 Compression Ratio 10.9:1 Cylinder numbering Front to rear Firing order 1-3-2...
Page 76: Cylinder Head And Valves
Cylinder Head and Valves Cylinder head Flatness tolerance 0.030 mm Inlet 37.9 mm Valve Head Diameter Exhaust 32.3 mm Inlet 9.15 mm Valve Lift Exhaust 9.64 mm 5.475 – 5.490 mm (standard) Inlet 5.465 mm (service limit) Valve Stem Diameter 5.47- 5.48 mm (standard)
Page 77 0.010- 0.037 mm (standard) Inlet 0.075 mm (service limit) Valve Stem to Guide Clearance 0.020- 0.042 mm (standard) Exhaust 0.080 mm (service limit) 1.000 mm (standard) Inlet 1.500 mm (service limit) Valve Seat Width (in cylinder head) 1.200 mm (standard) Exhaust 1.700 mm (service...
Page 78: Camshafts
Camshafts Open 3.0º Close 57.0º Inlet ABDC Duration 234º Camshaft Timing (at 1mm lift) Open 53º BBDC Close 13º Exhaust ATDC Duration 246º 22.94 – Camshaft Journal Diameter 22.96 mm 0.040 – 0.081 mm (standard) Camshaft Journal Clearance 0.12 (service limit) 23.000 –...
Page 79: Clutch And Primary Drive
Clutch and Primary Drive Primary Drive Type Gear Reduction Ratio 1.246:1 (57/71) Clutch Type Wet multi-plate No. of Friction Plates Steel Plate Flatness Limit 0.15 mm Friction Plate Flatness Limit 0.2 mm Friction Plate Thickness (new) 3.8 mm Friction Plate Thickness (service limit) 3.6 mm Clutch Pack Height 56 mm +0.32/-0.68 mm...
Page 80: Pistons
Pistons 110.185 - 110.203 mm (standard) Cylinder Bore Diameter 110.293 mm (service limit) 110.17 - 110.18 mm (@ 42 mm down from crown) (standard) (standard) Piston Diameter (at 90° to gudgeon pin) 110.13 mm (service limit) Piston Ring to Groove Clearances 0.02-0.06 mm (standard) (standard) 0.075 mm (service limit) (service limit) 0.02-0.06 mm (standard) (standard)
Page 81: Connecting Rods
Connecting Rods 25.032 - 25.045 mm (standard) Connecting Rod Small End Diameter 25.055 mm (service limit) Connecting Rod Big End Diameter 55.500-55.518 mm (standard) 0.15 -0.30 mm (standard) Connecting Rod Big End Side Clearance 0.5 mm (service limit) Crankshaft 52.458 - 52.472 mm (standard) Crankshaft Big End Journal Diameter 52.434 mm (service limit) 0.034 -0.066 mm (standard)
Page 82: Transmission
Transmission 6 Speed, Constant Mesh Transmission Type (Helical 2nd, 3rd, 4th, 5th, 6th) 2.389:1 (43/18) 1.840:1 (46/25) 1.414:1 (41/29) Gear Ratios 1.121:1 (37/33) 0.972:1 (35/36) 0.838:1 (31/37) 5.90 - 6.00 mm (standard) Gear Selector Fork Thickness 5.8 mm 6.10 - 6.20 mm (standard) Gear Selector Groove Width 6.3 mm (service limit) 0.1 -0.3 mm (standard)
Page 83: Lubrication
Lubrication Oil Capacity (including filter, dry fill) 5.2 litres Oil and Filter Change 4.6 litres Oil Change only 4.4 litres Recommended Oil Approval Rating API SH (or higher) and JASO MA-2 Semi or fully synthetic 15W/50 motorcycle engine oil which meets specification API Oil Viscosity SH (or higher) and JASO MA, such as Castrol Power 1 4T.
Page 84: Fuel System
Fuel System Unleaded, 95 RON (CLC or AKI octane rating (R+M)/2 Fuel Type of 89 or higher) Fuel Tank Capacity 18.8 litres Low Level Warning Lamp 4.5 litres remaining Fuel Pump Type Submerged, electric Fuel Pressure (nominal) 3.5 bar Purge Control System Modulated, vacuum Fuel Injection System Type...
Page 85: Emissions Control
Solenoid controlled, reed valve type Evaporative Control Activated carbon canister Coolant system Coolant Mixture Premixed Anti-Freeze Type Triumph HD4X Hybrid OAT coolant Cooling System Capacity 2.6 litres Radiator Cap Opening Pressure 1.2 bar Thermostat Opening Temperature 88°C 10% fan speed at 91°C variable speed up Cooling Fan Switch On Temperature to 100% at 103°C...
Page 86: Suspension
Suspension Front Fork Travel 120 mm Recommended Fork Oil Grade Showa SS47G Oil Level (spring, spring seat and spacer 94 mm removed and fork fully compressed) Oil Volume (dry fill) 669 ml upper surface of the fork top cap flange is Front Fork Pull Through 55.7 mm above the lower surface of the upper yoke...
Page 87: Brakes
Brakes Four piston monobloc calipers acting on Front Brakes Type twin discs Front Caliper Piston Diameter 30 mm Front Disc Diameter 320 mm 4.5 mm (standard) Front Disc Thickness 4.0 mm (service limit) Front Disc Run-out Max. (installed) 0.25 mm Front Brake Master Cylinder Diameter 18 mm DOT 4 brake and clutch...
Page 88: Wheels And Tyres
Rear Wheel Rim Radial Run-out 0.5 mm A list of approved tyres specific to these models is available from your authorised Approved Tyres Triumph dealer, or on the Internet at www.triumph.co.uk. Frame Frame Type Modular cast aluminium frame Rake (headstock angle) 28°...
Page 89: Electrical
Electrical Battery Type YTX20CH-BS Battery Rating 12 V-18.9 Amp. Hour 25 Amps at 1000 rpm minimum Alternator Rating 46.5 Amps at 3000 rpm maximum Headlight Rear Light/Brake Light Licence Plate Light Directional Indicator Lights...
Page 90: Torque Wrench Settings
Torque Wrench Settings Engine Covers Torque Application Notes (Nm) Alternator cover Alternator Cover - Installation Alternator cover crankshaft Apply a thin smear of proprietary high 8 Nm inspection plug temp. copper-based grease to the threads Alternator cover face seal plug 6 Nm Camshaft cover Camshaft Cover - Installation...
Page 91: Cylinder Head
Cylinder Head Torque Application Notes (Nm) Camshaft caps bolts Camshaft - Installation Fit new fixing(s) if loosened or Camshaft caps bolts stage 1 5 Nm removed Camshaft caps bolts stage 2 10 Nm Camshaft Drive Chain Camshaft drive chain hydraulic tensioner 16 Nm Tensionner –...
Page 92: Clutch
Secondary air injection plugs completes turns Service tool 3880609 pre-set torque 0.6 Nm Service tool 3880651 16 Nm Spark plug 12 Nm Sprocket to camshaft Camshaft - Installation Clutch Torque Application Notes (Nm) Fit new fixing(s) if loosened or removed Clutch centre nut 160 Nm Fit new Belleville washer...
Page 93: Balancer, Crankshaft And Crankcase
Balancer, Crankshaft and Crankcase Torque Application Notes (Nm) Starter Drive/Sprag Alternator rotor to sprag clutch housing Clutch - Installation Fit new fixing(s) if loosened or Alternator rotor to sprag clutch housing 16 Nm removed Balancer adjuster plug 25 Nm Fit new fixing(s) if loosened or Camshaft sprocket to crankshaft 44 Nm removed...
Page 94 Crankcase tightening sequence Stage 2 32 Nm Transmission cover 1 to 4 Crankcase tightening sequence Stage 2 12 Nm Transmission cover 5 to 14 Crankcase tightening sequence - Lower Lower Crankcase - Crankcase Installation Crankcase tightening sequence Stage 1 10 Nm Lower Crankcase 1 to 27 Crankcase tightening sequence Stage 2 140º...
Page 95: Transmission
Transmission Torque Application Notes (Nm) Detent arm 10 Nm Fit new fixing(s) if loosened or removed Detent arm spring 10 Nm Fit new fixing(s) if loosened or removed Detent wheel 12 Nm Fit new fixing(s) if loosened or removed Gear change actuator knuckle 28 Nm Fit new fixing(s) if loosened or removed Gear change clamp pinch bolt...
Page 96: Lubrication
Lubrication Torque Application Notes (Nm) Engine oil filler tube 10 Nm Engine oil filter 10 Nm Apply clean engine oil to the seal(s) Engine oil filter adapter to Fit new oil filter adapter if loosened or 16 Nm crankcase removed Engine oil jet spray, piston 4 Nm Fit new fixing(s) if loosened or removed...
Page 97: Fuel Pump Assembly - Installation
Torque Application Notes (Nm) Catalytic converter clamp 11 Nm Catalytic converter left hand 5 Nm covers Catalytic converter right hand 5 Nm covers Coolant temperature sensor 18 Nm Fit new sealing washer(s) Engine ECM bracket 9 Nm Evaporative canister 5 Nm Evaporative canister bracket 22 Nm Fit new fixing(s) if loosened or removed...
Page 98 Torque Application Notes (Nm) Fuel tank front fixing to frame 8 Nm Fuel tank rear pivot 8 Nm Fuel tank right hand mounting 22 Nm bracket Fuel tank strap front hook 2.5 Nm Fuel tank strap rear fixing 1.5 Nm Fuel tank strap to front bracket 1.5 Nm Gear position sensor...
Page 99: Cooling
Torque Application Notes (Nm) Spark plug 12 Nm 2.5 Nm Throttle bodies clamps 1.5 Nm Throttle body T30 blanking screw 5 Nm Transition Piece 9 Nm Twist grip position sensor clamp Cooling Torque Application Notes (Nm) Clutch cover bracket to radiator 3 Nm mounting bracket Clutch cover bracket upper fixing...
Page 100 Torque Application Notes (Nm) Lower cowl upper fixing 6 Nm Radiator cowl side fixings 5 Nm Fit new fixing(s) if loosened or removed Radiator cowl upper fixings 3 Nm Radiator fan assembly to radiator 8 Nm Radiator fans control module 3 Nm Radiator filler cover bracket 5 Nm...
Page 101: Front Suspension
Front Suspension Torque Application Notes (Nm) Damping cylinder bolt 20 Nm Damping rod to top cap lock nut 20 Nm Fork top cap 35 Nm Handlebar end weights 5 Nm Handlebar riser 60 Nm Handlebar riser clamp 26 Nm Headstock bearing adjuster and Steering Head Bearing - Adjustement lock nut Tighten adjuster nut stage 1...
Page 102: Rear Suspension
Rear Suspension Torque Application Notes (Nm) Cable guide on swinging arm 3 Nm Rear Suspension Linkage - Drag link bracket Installation Drag link bracket lower fixing 48 Nm Drag link bracket to drag link Rear Suspension Linkage - fixing Installation Drag link bracket to drag link 48 Nm fixing...
Page 103: Front Brakes
Front Brakes Torque Application Notes (Nm) Brake caliper to front fork 45 Nm Brake disc to wheel 22 Nm Fit new fixing(s) if loosened or removed Brake lever pivot bolt 6 Nm Brake lever pivot bolt lock nut 6 Nm Brake line union to front brake 25 Nm Fit new fixing(s) if loosened or removed...
Page 104: Rear Brakes
Rear Brakes Torque Application Notes (Nm) Brake caliper bleed screw 6 Nm Brake pad retaining pin 6 Nm Brake line union to rear brake 25 Nm Fit new sealing washer(s) caliper Brake line union to rear master 25 Nm Fit new sealing washer(s) cylinder Brake pedal pivot bolt 22 Nm...
Page 105 Torque Application Notes (Nm) ABS modulator to bracket 9 Nm Fit new fixing(s) if loosened or removed ABS pulser ring to wheel 4 Nm Fit new fixing(s) if loosened or removed ABS rear pulser ring 4 Nm Fit new fixing(s) if loosened or removed ABS sensor 9 Nm Fit new fixing(s) if loosened or removed...
Page 106: Wheels And Tyres
Torque Application Notes (Nm) Front ABS sensor conduit 9 Nm Fit new fixing(s) if loosened or removed Rear brake caliper bleed screw 8 Nm Rear brake line to sump 4 Nm Rear brake line to swinging arm 5 Nm p-clip Wheels and Tyres Torque Application...
Page 107: Final Drive
Final Drive Torque Application Notes (Nm) Bevel box finisher 4 Nm Fit new fixing(s) if loosened or removed Bevel box oil drain plug 25 Nm Fit new sealing washer(s) Bevel box oil level plug 25 Nm Fit new sealing washer(s) Bevel box to swinging arm nuts Fit new fixing(s) if loosened or removed Bevel box to swinging arm stage...
Page 108 Torque Application Notes (Nm) Frame adjusters 3 Nm Frame mounting bolts stage 1 10 Nm Frame mounting bolts stage 2 80 Nm Frame rear lower mounting bolts 48 Nm Front bridge to sub frame Front bridge to sub frame 12 Nm Front mudguard bracket (front 6 Nm fixings)
Page 109 Torque Application Notes (Nm) Mirror pinch bolt 3.5 Nm Oil filler cap fixings 1.5 Nm Outrigger bolts 80 Nm Passenger seat backrest finisher 3 Nm Passenger seat backrest leg 32 Nm Passenger seat backrest lower tie 27 Nm bar front fixings Passenger seat backrest lower tie 27 Nm bar rear fixings...
Page 110 Torque Application Notes (Nm) Rear mudguard finisher 3 Nm Rear mudguard finisher bracket 1 Nm Rear mudguard under tray 3 Nm Rear mudguard upper moulding 3 Nm Rear reflector bracket (US 3 Nm markets) Rear splash guard 3 Nm Fit new fixing(s) if loosened or removed Rear subframe rear piece 48 Nm Fit new fixing(s) if loosened or removed...
Page 111: Electrical
Torque Application Notes (Nm) Side stand magnet 3 Nm Side stand switch 3 Nm Fit new fixing(s) if loosened or removed Steering lock fixings Steering lock fixings Fit new fixing(s) if loosened or removed Upper yoke harness cover 5 Nm Electrical Torque Application...
Page 112 Torque Application Notes (Nm) Battery box outer moulding side 3 Nm fixing Battery terminal 4.5 Nm Crankshaft position sensor 6 Nm Fit new fixing(s) if loosened or removed Engine ECM bracket 6 Nm Front direction indicator clamp 3 Nm Front direction indicator to clamp 3 Nm (all except UC and CA) Front direction indicator to clamp...
Page 113 Torque Application Notes (Nm) Instruments to mounting bracket 3 Nm Keyless ECM 3 Nm LF antenna, rear 3 Nm LF antenna, front 3 Nm Rear direction indicators 3 Nm Rear licence plate light 1.5 Nm Rear light 3 Nm Starter motor 9 Nm Starter motor power lead 5 Nm...
Page 114: Routing
Routing Main Wiring Harness Routing...
Page 115: Clutch Control Routing
Clutch Control Routing...
Page 116: Fuel Tank Evaporative Hose Routing
Fuel Tank Evaporative Hose Routing...
Page 117: Abs Routing
ABS Routing...
Page 118: Scheduled Maintenance
Incorrect or neglected maintenance can lead to a dangerous riding condition. Always have an authorised Triumph dealer carry out the scheduled maintenance of this motorcycle. All maintenance is vitally important and must not be neglected. Incorrect maintenance or adjustment may cause one or more parts of the motorcycle to malfunction.
Page 119 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. 1. Motorcycles travelling less than 10,000 miles (16,000 km) per year must be maintained annually.
Page 120: Scheduled Maintenance Table
Fuel System and Engine Management Autoscan - carry out a full Autoscan using the • • • • • Triumph diagnostic tool (print a customer copy) Fuel system - visually check fuel hoses for • • • • • chafing, cracks or damage. Replace if necessary Air filter - renew (replace more often if •...
Page 121 Engine Clutch - check operation • • • • • Clutch fluid levels – check • • • • • Clutch fluid renew Every 2 years, regardless of mileage Valve clearances - check/adjust • • Camshaft timing – check/adjust • •...
Page 122 Instruments, chassis ECM and engine ECM - check for latest calibration download using the • • • • • Triumph diagnostic tool Bank angle indicators - check for wear • • • • • Side stand check for smooth operation •...
Page 123: Engine Check For Fluid Leaks
Engine Check For Fluid Leaks Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Standard required: All engine components must be free from fluid leaks.
Page 124: Engine Oil - Level Inspection
Engine Oil - Level Inspection Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 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.
Page 125 If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries. Running the engine with insufficient oil will cause engine damage.
Page 126 NOTICE Do not operate the throttle while the engine is at idle. This will give an inaccurate oil level on the engine oil dipstick. • Stop the engine, then wait for at least three minutes to allow the oil to settle. •...
Page 127 1. Engine oil dipstick 2. Maximum limit 3. Minimum limit • If the level is near or below the minimum mark, add the recommended engine oil, a little at a time, up to the maximum mark on the engine oil dipstick. NOTICE Make sure no foreign matter or contamination enters the engine during an engine oil change or top up.
Page 128: Engine Oil And Filter Renew
Engine Oil and Filter Renew Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis.
Page 129 The engine oil and oil filter must be replaced in accordance with scheduled maintenance requirements. • Warm up the engine thoroughly, and then stop the engine. Secure the motorcycle on the side stand on level ground. • Place an oil drain pan beneath the engine. •...
Page 130 • Pivot the radiator lower surround and unscrew and remove the engine oil filter using the Triumph service tool T3880313. Dispose of the old filter in an environmentally friendly way. 1. Fixings 2. Bracket 3. Oil filter 4. Radiator lower surround •...
Page 131 NOTICE An accurate indication of the level of oil in the engine is only shown when the engine is cold and the motorcycle is on the side stand. This method of checking the engine oil is especially important to make sure the oil volume is distributed correctly because this model has a dry sump engine.
Page 132: Autoscan
Running the engine with low oil pressure will cause engine damage. 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 133: Air Filter - Renew
Check: Visually check fuel/evaporative system components for signs of fuel leakage. Visually check fuel/evaporative system components for signs of damage. Visually check fuel/evaporative system components for security (where accessible). Check the operation of the fuel filler cap and lock (if fitted). Visually inspect the fuel cap seal for signs of damage.
Page 134 1. Release the two fixings and remove the plenum cover finisher. Discard the fixings. 1. Fixings 2. Plenum cover finisher 2. Noting their orientation, release the three clips securing the air intake runner to the air filter element box. NOTICE Note the position of the four fixings securing the air intake runner to the plenum for installation.
Page 135 3. Release the four fixings and remove the air intake runner. Remove and discard the gasket and the four fixings. 1. Clips 2. Fixings 3. Air intake runner NOTICE Note the routing of the secondary air inject pipe to the reed covers for installation. Note the routing of the secondary air inject pipe to the air filter element box for installation.
Page 136 4. Release the four clips and detach the secondary air injection (SAI) pipe from the reed valve covers and the air filter element box. 1. Clips 2. SAI pipe to reed valves 3. SAI pipe to air filter box 5. Carefully manoeuvre the secondary air injection pipe to the front of the engine. NOTICE Note how the air filter element box is secured to the frame for installation.
Page 137 6. Release the three fixings, lower the air filter box and detach the rear of the box from the frame. Remove the air filter box and air filter element. 1. Fixings 2. Air filter element box 7. Remove the air filter element. 1.
Page 138 Installation 1. Clean the air filter element box and the interior of the frame air intake. 2. Locate the new filter element into the air filter element box, as noted for removal. 3. Fit the air filter element and box assembly to the frame as noted for removal, tighten its fixings to 1.5 Nm.
Page 139 6. Fit the SAI pipe to the air filter element box and secure with its clip. 1. Clips 2. SAI pipe to reed valves 3. SAI pipe to air filter box 7. Fit a new gasket to the plenum cover for the air intake runner. 8.
Page 140 11. Stage 3 • Retighten fixings one and two to 10 Nm. Remove the two fixings for the plenum cover finisher. Air Intake Runner Tightening Sequence 12. Position the three clips as noted for removal and tighten to 10 Nm. 13.
Page 141: Fuel Filter - Renew
Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. • Fit the left hand Side Panels – Removal •...
Page 142 Removal Perform the following operations: • Fuel Pump Assembly - Removal NOTICE Note the orientation of the hose bracket arall hose retaining clips for installation. 1. Release the fixing and remove the hose bracket from the fuel pump bracket. 1. Fixing 2.
Page 143 5. Detach the fuel hose from the fuel outlet pipe. 1. Cable ties 2. Hose clip (fuel outlet pipe) 3. Hose clips (fuel filter) 6. Remove the fuel filter from the fuel pump assembly. NOTICE Note the position and orientation of the dot alignment mark on the fuel filter outlet hose for installation.
Page 144 7. Remove the fuel hose from the outlet of the fuel filter. 1. Dot alignment mark 2. Fuel outlet pipe Inspection 1. Inspect all hoses for cracks, splits, fraying and other damage. Replace as necessary. 2. Check all hose clamps for cracks and signs of distortion. Replace as necessary. 3.
Page 145 5. Secure the fuel filter to the fuel pump bracket with two cable ties. 6. Fit the hose bracket to the fuel pump bracket as noted for removal and tighten its fixing to 4 Nm. 1. Fixing 2. Hose bracket...
Page 146: Throttle Body Balancing
3. Temporarily reconnect the battery, positive (red) lead first. 4. Attach exhaust extraction hoses to the silencers. 5. Attach the Triumph diagnostic tool, start the engine and navigate to ADJUST TUNE (see System Diagnostic Tool...
Page 147 6. Select BALANCE THROTTLES. Adjust Tune Procedure Adjust the throttle balance as described in the Service Manual until balanced Press cancel to cancel the adjustment process Press OK to finish Throttle Status: Throttles Balanced Cylinder 1 MAP Pressure: 480 mmHg Cylinder 2 MAP Pressure: 481 mmHg Cylinder 3 MAP Pressure:...
Page 148 Total cleanliness must be observed at all times whilst the throttle balance blanking screw is removed, and adjustment must take place in a dirt/dust-free environment. Dirt or dust ingress to the throttle motor housing will cause the throttles to stick, leading to loss of motorcycle control and an accident.
Page 149 8. Using a suitable Torx T20 screwdriver adjust the throttle adjusters until the words 'THROTTLES BALANCED' appear on the diagnostic tool. 1. Adjusters 9. When balanced, stop the engine and disconnect the diagnostic tool. 10. Refit the Torx T30 blanking screw to the throttle control motor housing and tighten to 5 Nm.
Page 150: Spark Plugs - Inspection
Spark Plugs – Inspection Assessing the condition of a spark plug can be a valuable aid to a technician, and a good source of information about the engines overall operating condition. In general, a light brown/grey colour tells you that the spark plug is operating at optimum temperature and that the engine is in good condition.
Page 151 Normal Condition An engines condition can be judged by the appearance of the spark plugs firing end. If the firing end of a spark plug is light brown or grey, the condition can be judged to be good and the spark plug is functioning optimally.
Page 152 Dry and Wet Fouling Although there are many different scenarios, if the insulation resistance between the centre electrode and the shell is over 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.
Page 153 Overheating When a spark plug overheats, deposits that have accumulated on the insulator tip melt and give the insulator a glazed or glossy appearance. Deposits The accumulation of deposits on the firing end is influenced by oil leakage, fuel quality and the engines operating duration.
Page 154 Breakage Breakage is usually caused by thermal expansion and thermal shock due to sudden heating or cooling. Normal Life 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).
Page 155 Melting Melting is caused by overheating. Mostly, the electrode surface is rather lustrous and uneven. The melting point of nickel alloy is 1200 to 1300 °C (2200 to 2400 °F). Erosion, Corrosion and Oxidation The material of the electrodes has oxidised, and when the oxidation is heavy, it will be green on the surface.
Page 156 Spark Plugs - Check/Renew Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 157 Coolant System - Check For Fluid Leaks Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 158 Coolant Level Inspection Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. If the coolant level is found to be low, or if coolant has to be added regularly, inspect the cooling system for coolant leaks.
Page 159 1. Position the motorcycle on level ground and in an upright position. 2. The coolant level must be between the MAX (upper line) and MIN (lower line) marks in the expansion tank. 1. MAX mark 2. MIN mark 3. Expansion tank cap Do not remove the expansion tank or coolant pressure cap when the engine is hot.
Page 160 Coolant Level Adjustment Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Do not remove the expansion tank or coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the cooling system will be hot and may also be under pressure.
Page 161 3. The coolant level must be between the MAX (upper line) and MIN (lower line) marks in the expansion tank. 1. MAX mark 2. MIN mark 3. Expansion tank cap 4. Remove the coolant expansion tank cap from the coolant expansion tank. 5.
Page 162 Coolant System - Check Hoses for Chafing, Cracks, Damage Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 163 1. Allow the engine to cool for a minimum of 30 minutes. 2. Drain the coolant (see Coolant Replacement - Drainage). 3. Refill the coolant with Triumph HD4X Hybrid OAT coolant (see Coolant Replacement - Filling). Clutch Fluid Level Inspection Make sure the motorcycle is stabilised and adequately supported.
Page 164 1. The clutch fluid level must be kept between the upper and lower level lines (reservoir held horizontal). Clutch Fluid Level Adjustment 1. Clean the reservoir cap before removing. 2. Remove the two fixings. 3. Remove the reservoir cap and the diaphragm seal. 4.
Page 165 Changing Clutch Fluid Clutch and brake fluid must be changed every two calendar years, irrespective of the mileage the motorcycle has covered in that time. (see Bleeding the Clutch). Bleeding the Clutch Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 166 To prevent body damage, do not spill brake and clutch fluid onto any area of the bodywork or the brake and clutch reservoirs. Perform the following operations: • Seat – Removal • Battery – Removal • Coolant Expansion Tank – Removal •...
Page 167 3. Release the three fixings and remove the lower radiator cowl bracket. 1. Fixings 2. Bracket NOTICE Note the position of the single fixing of the clutch cover finisher for installation. 4. Release the fixing and remove the clutch cover finisher. 1.
Page 168 5. Remove the dust cap from the bleed nipple on the slave cylinder. 6. Attach a transparent plastic tube to the bleed nipple. 1. Bleed nipple dust cap 2. Bleed nipple 3. Bleed tube 4. Container 7. Place the other end of the tube into a suitable receptacle containing new clutch fluid. 8.
Page 169 11. Release the bleed nipple. NOTICE During bleeding, do not allow the fluid level to fall below the lower level mark in the reservoir. If the level is allowed to fall below this mark, air may enter the system and the sequence of bleeding must be repeated.
Page 170 20. Fit the lower radiator cowl bracket and tighten the clutch cover fixings to 10 Nm. 21. Secure the radiator lower bracket to the lower radiator cowl bracket and tighten the fixing to 5 Nm. 1. Fixings 2. Bracket Always return the lever adjuster to the original setting as noted in step 1. Operating the motorcycle with lever settings which are unfamiliar may lead to loss of control or an accident.
Page 171 Valve Clearance Measurement Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. NOTICE Valve clearance measurement must be carried out with the engine cold. Perform the following operations: •...
Page 172 3. Using feeler gauges, measure and record the clearances for this pair of valves only. 4. Repeat the process until the valve clearances for all valves have been checked. NOTICE The correct valve clearances are in the range given below: Inlet 0.09-0.14 mm Exhaust...
Page 173: Installation
Perform the following operations: • If the measurement does not fall within the specified range see Valve Clearance Adjustment • If the measurement does fall within the specified range fit the Camshaft Cover – Installation • Refit the spark plugs and tighten to 12 Nm Valve Clearance Adjustment Make sure the motorcycle is stabilised and adequately supported.
Page 174 1. Remove the tappet bucket from the cylinder head. 2. Remove the shim. 1. Tappet bucket 2. Shim NOTICE The shim may withdraw with the tappet bucket. 3. Measure the original shim, using a micrometer and select the appropriate new shim as required.
Page 175 Perform the following operations: • Camshaft - Installation • Recheck all valve clearances. Repeat the procedure if the valves require further adjustment • Camshaft Cover - Installation • Refit the spark plugs and tighten to 12 Nm Camshaft Timing Check/Adjust Make sure the motorcycle is stabilised and adequately supported.
Page 176 Camshaft Timing Check 1. Remove the spark plugs to reduce compression resistance when turning the engine. 2. Remove the crankshaft locking pin plug from the crankcase. 3. At the front of the engine, rotate the crankshaft anticlockwise using the bolt fitted to the end of the crankshaft until the two gear teeth with an alignment mark on each is visible and central in the hole for the crankshaft locking pin.
Page 177 NOTICE The alignment mark on the flange of T3880501 - Crankshaft Locking Pin is in line with the gear tooth at the other end of the service tool. Use this alignment mark as a guide when inserting the service tool. 5.
Page 178 6. Insert service tool T3880502 into the camshaft slots. Make sure the tool is centrally located between the camshafts. 1. T3880502 - Camshaft timing bar 2. Camshaft slots With the camshaft alignment marks, at the sprocket end, pointing inwards and the camshaft timing bar in the slots of the camshaft, adjustment is not required.
Page 179 Camshaft Timing Adjustment (if required) 1. Loosen the two accessible camshaft sprocket fixings, do not remove at this stage. 1. Fixings 2. Remove service tool T3880501 from the crankcase.
Page 180 3. At the front of the engine, rotate the crankshaft anticlockwise 360 degrees using a suitable socket on the bolt fitted to the end of the crankshaft (do not use the water pump drive slot in the bolt to turn the engine). Loosen the two accessible camshaft sprocket fixings, do not remove at this stage.
Page 181 4. Turn the crankshaft anticlockwise 360 degrees until the two gear teeth with an alignment mark on each is visible in the hole for the crankshaft locking pin. 1. Crankshaft primary gear 2. Alignment marks 5. Check that the camshafts alignment marks on the sprocket end of the camshaft are pointing inwards.
Page 182 6. Insert service tool T3880501 through the hole in the crankcase. Make sure the gear tooth on the service tool fits between the two teeth with the alignment marks. 1. T3880501 - Crankshaft Locking Pin 2. Alignment mark 7. Place suitable wedges between the camshaft sprockets and the crankcase, to hold the camshaft drive chain taut during removal of camshaft drive tensioner and the fitting of service tool T3880651.
Page 183 10. Fit the service tool T3880651 and tighten to 16 Nm. T3880651 - Timing Chain Tensioner The torque value stated is very important to accurate timing. Always use the correct value of 0.6 Nm, as set using T3880609 - Timing Torque Limiter. Using an incorrect torque value will result in incorrect valve timing being set, or damage to the tensioner blade or other valve train components.
Page 184 12. Turn the camshafts only to allow service tool T3880502 to fit into the camshaft slots. 1. T3880502 - Camshaft timing bar 2. Camshaft slots 13. Check that the camshafts alignment marks on the sprocket end of the camshaft are pointing inwards.
Page 185 14. Tighten the two accessible (uppermost) camshaft sprocket fixings to 16 Nm. 1. Fixings 15. Remove the wedges between the camshaft sprockets and the crankcase. 16. Remove service tool T3880502 from the camshaft slots. 1. T3880502 Camshaft timing bar 2. Camshaft slots...
Page 186 17. Remove service tool T3880501 from the crankcase. 1. T3880501 - Crankshaft Locking Pin 2. Alignment mark Always check that service tool T3880502 has been removed before rotating the engine. Severe damage will result to the camshafts or service tool T3880502 if engine rotation is attempted with the tool installed.
Page 187 20. Make sure the two gear teeth with an alignment mark on each is visible in the hole for the crankshaft locking pin and install the service tool T3880501. 1. Crankshaft primary gear 2. Alignment marks NOTICE The alignment mark on the flange of T3880501 - Crankshaft Locking Pin is in line with the gear tooth at the other end of the service tool.
Page 188 21. Insert service tool T3880501 through the hole in the crankcase .Make sure the gear tooth on the service tool fits between the two teeth with the alignment marks. 1. T3880501 Crankshaft Locking Pin 2. Alignment mark NOTICE With the camshaft alignment marks pointing inwards and the camshaft timing bar in the slots of the camshaft, adjustment is not required.
Page 189: Installation
22. Insert service tool T3880502 into the camshaft slots. Make sure that the tool is centrally located between the camshafts. 1. T3880502 Camshaft timing bar 2. Camshaft slots NOTICE Make sure the camshaft drive chain remains on the crankshaft sprocket when removing service tool T3880651 and fitting the camshaft drive chain tensioner.
Page 190 Perform the following operations: • Camshaft Cover – Installation • Clutch Cover – Installation • Fuel Tank – Installation • Battery – Installation • Seat – Installation Wheel Bearings – Inspection Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 191 Rear Wheel Needle Roller Bearing – Lubricate Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 192 4. Release the fixings and remove the rear bevel box badge. Discard the fixings. 1. Fixings 2. Badge 5. Remove the bearing sleeve and oil seal. 6. Coat the needle rollers with Castrol grease. Make sure the needle rollers turn so that the grease is distributed over the entire circumference of the internal parts.
Page 193 Check the rims for dents or deformation. Operation with damaged or defective wheels or tyres is dangerous and loss of motorcycle control or an accident could result. Always consult your authorised Triumph dealer for tyre replacement, or for a safety inspection of the tyres.
Page 194 (90% worn). It is false economy and unsafe to use tyres until they are worn to their minimum. NOTICE Triumph recommends the use of a tyre depth gauge to measure the depth of the tread. For this model the part of the rear tyre tread pattern looks like a tyre wear indicator. The actual tyre wear indicator has the letters T.W.I on it, see illustration below.
Page 195 Measure the depth of the tread with a depth gauge, and replace any tyre that has worn to, or beyond the minimum allowable tread depth. Inspect tyres for cracks, splits and kerb damage. Always replace tyres that are suspected of having become damaged. Damaged tyres must be replaced.
Page 196 6. If it is greater than the recommended setting, slowly deflate the tyre checking the gauge regularly until the correct reading is achieved. 1. Tyre Valve 2. Tyre gauge (valve connector) 3. Tyre gauge 7. Repeat the process for the remaining tyre. 8.
Page 197 Fork Oil Renew – Draining Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Do not change the fork adjustment settings. If they are changed, this will change the handling of the motorcycle from those which the rider is used to.
Page 198 3. Holding the inner and outer tubes together, invert the fork and pour out the fork oil into a suitable container. 4. Return the fork to service tool T3880171. 5. Allow the outer tube to slide down the inner to allow access to the spring spacer. While compressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork.
Page 199 NOTICE During the step that follows, measure the length of the threads above the locknut for the installation procedure. 8. Loosen the damper locknut a small amount, then unscrew and remove the top cap and the rebound adjuster rod, taking care not to bend the rod. The top cap assembly cannot be dismantled.
Page 200 12. Remove the bump rubber (if not attached), nylon spacer, spring spacer and spring. 1. Nylon spacer 2. Spring spacer 3. Bump rubber 13. Invert the fork and pour out the remaining fork oil into a suitable container.
Page 201 Fork Oil Renew – Refilling The oil level is measured from the upper surface of the fork outer tube, with the fork fully compressed and the spring and spring spacer removed. Fork Oil Level (spring, spring seat and spacer removed, and the fork fully compressed) Fork Oil Level Chart Oil Level Oil Volume Oil Grade...
Page 202 3. Set the scale on service tool T3880160 to the level specified (see the fork oil table or illustration below for the correct level setting). 1. T3880160 - Fork Oil Filler/Evacuator 2. Adjustment plate 3. Scale area 4. Hole (zero position) NOTICE Zero level on the tool is set at the small exit hole in the side of the scale tube, NOT AT THE END TIP.
Page 203 Incorrect fork oil levels could result in an unsafe riding condition leading to loss of motorcycle control and an accident. 7. Position the fork assembly as for compression of the fork spring during disassembly. 8. Fit the fork spring in the orientation noted for disassembly. 9.
Page 204 10. Turn the damper rod lock nut until the length of threads to the end of the rod is equal to the length measured during disassembly. 1. Damper rod 2. Locknut 11. Attach service tool T3880085 to the threads of the damper rod and pull the damper upwards.
Page 205: Installation
15. Hold the top cap with service tool T3880342 and tighten the damper rod locknut to 20 Nm. 1. Damper lock nut 2. T3880067 - Fork Spring Compressor 3. Spring holder (part of T3880067 - Fork Spring Compressor) While compressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork.
Page 206 Steering Head Bearing – Check Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 12. Raise and support the motorcycle so that the front wheel is clear of the ground. 13.
Page 207 Headstock Bearings – Lubricate Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 208 Swinging Arm Spindle – Lubricate Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 209 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. Riding the motorcycle with defective or damaged suspension can cause loss of...
Page 210 Brake Calipers – Inspection Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Always renew caliper seals and pistons after removal from the caliper. An effective hydraulic seal can only be made if new components are used.
Page 211 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 calipers must be replaced simultaneously. Replacing individual pads will reduce braking efficiency and may cause loss of motorcycle control and an accident.
Page 212 Brake Fluid – Renew Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Make sure absolute cleanliness when adding brake fluid to the brake fluid reservoir. Do not allow moisture or debris to enter the cylinder, as this will adversely affect the fluid properties.
Page 213 Note the original setting of the brake lever adjuster in order that it can be returned to the same position when the bleeding operation is complete. 12. Turn the brake lever adjuster fully in to give maximum lever span. 1. Brake lever 2.
Page 214 3. Check the condition of the reservoir sealing diaphragm. Replace if necessary. 4. Remove the rubber cap from the bleed screw on the caliper. 5. Attach a transparent tube to the bleed screw and place the other end of the tube in a suitable receptacle containing new brake fluid.
Page 215 NOTICE Pressure applied to the brake lever during the brake fluid renew process must be applied and removed smoothly and slowly. It must take a minimum of five seconds between lever positions (from fully released to stop). Failure to do this slowly can allow air to be drawn in to the system through the bleed screw threads.
Page 216 17. Fit the fixings into the cap and diaphragm seal assembly. 1. Insert 2. Diaphragm seal 3. Locating lug 4. Hole for locating lug 5. Reservoir cap 6. Fixings If the master cylinder reservoir cap screws are over tightened this can result in a brake fluid leak.
Page 217 It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency...
Page 218 Rear Brake Fluid 1. Remove the cap from the rear bleed screw. 2. Attach a transparent tube to the bleed screw. 3. Place the other end of the tube in a suitable receptacle containing new brake fluid. 1. Bleed screw 2.
Page 219 1. MIN mark 2. MAX mark 3. Float 4. Seal 5. Reservoir cap 6. Fixings 5. Check the condition of the reservoir sealing diaphragm. Replace if necessary. NOTICE The bleed screws should only be opened by a small angle, just enough to allow system pressure to drop.
Page 220 10. Remove the bleed tube. 11. Replace the bleed screw cap. 12. Make sure the float for the brake fluid reservoir is in the reservoir. 13. Fit the insert to the diaphragm seal. 14. Fit the diaphragm and insert assembly to the reservoir cap. Make sure the holes for the fixings are correctly aligned.
Page 221 17. Check the operation of the rear brake. Rectify as necessary. It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency...
Page 222 Brake Fluid Level Inspection Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. In accordance with the Scheduled Maintenance chart, inspect the brake fluid level in the front and rear master cylinder reservoirs.
Page 223 Front Brake Fluid Level Adjustment 1. Remove the two fixings. 2. Remove the reservoir cap and the diaphragm seal. 3. Fill the reservoir to the upper level line using new DOT 4 fluid from a sealed container. 4. Fit the insert to the diaphragm seal. Make sure the locating lug on the insert fits into its hole in the diaphragm.
Page 224 7. Hold the assembly together and position the cap and diaphragm seal assembly onto the reservoir. Make sure the locating lug on the insert fits into its hole in the reservoir. Tighten the fixings to 1.5 Nm. 1. Reservoir cap 2.
Page 225 Rear Brake Fluid Reservoir 1. The brake fluid level must be kept between the upper and lower level lines (reservoir held horizontal). 1. MIN mark 2. MAX mark 3. Float 4. Seal 5. Reservoir cap 6. Fixings Rear Brake Fluid Level Adjustment NOTICE It is not necessary to remove the float when adding brake fluid to the rear brake master cylinder.
Page 226 7. Fit the fixings into the cap and diaphragm seal assembly. 1. Insert 2. Diaphragm seal 3. Reservoir cap 4. Fixings If the master cylinder reservoir cap screws are over tightened this can result in a brake fluid leak. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
Page 227 8. Hold the assembly together and position the cap and diaphragm seal assembly onto the reservoir. Tighten the fixings to 1.5 Nm. 1. Float 2. Reservoir cap assembly 3. Reservoir Rear Bevel Box Oil Specification Use of incorrect bevel box lubricant could result in a malfunction of the final drive unit causing lock-up of the rear wheel leading to loss of motorcycle control and an accident.
Page 228 Rear Bevel Box Oil Level Check Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1.
Page 229 Rear Bevel Box Oil Change Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. NOTICE Change the rear bevel box oil at the 600 mile (1,000 km) and 20,000 mile (32,000 km) services only.
Page 230 NOTICE The drain plug is magnetic. It is normal for metallic deposits to be attached to the drain plug magnet. 3. Wipe the drain plug clean, fit a new sealing washer then refit to the final drive and tighten to 25 Nm. 4.
Page 231 A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Check for the latest calibration download for the following using the Triumph Diagnostic Tool: •...
Page 232 Bank Angle Indicators 1. Inspect the bank angle indicators on the rider's footrests for wear. The bank angle indicators are worn out when 5 mm of the bank angle peg remains. 2. Bank angle indicators must be replaced when they have reached the maximum wear limit of 5.0 mm (service limit) in length.
Page 233 Removal 1. Raise and support the motorcycle. Wear hand, eye and face protection when unhooking the stand spring. Take great care to minimise the risk of personal injury and loss of components. 2. With the side stand in the up position, unhook the spring from the side stand and remove it from the motorcycle.
Page 234 Installation 1. Prior to fitting the side stand clean the pivot pin and the bushes in the side stand with a lint free cloth. Make sure the pivot pin and bushes are free from grease. 2. Fit the side stand to the motorcycle and insert the pivot pin. 3.
Page 235 Fasteners - General Inspection Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Check all visible fasteners for security. Make sure any encapsulated fasteners that have been loosened or removed are replaced.
Page 236 For the first 1,000 miles, the motorcycle should be ridden within the running in procedure (see Owner's Handbook), checking for abnormalities, unusual noises and for satisfactory operation. When checking the brakes on road test, a suitable safe place should be found to carry out the test.
Page 237 Standard required: Refer to the Owner's Handbook for further information regarding the ABS indicator light illumination sequence for the relevant model. The ABS indicator light should flash on and off and continue to flash after engine start up until the motorcycle first reaches a speed exceeding 6 mph (10 km/h). Clutch Standard required: The clutch should engage smoothly, without judder, slipping or noise.
Page 238 Instrument Panel Standard required: All instruments must operate correctly. Check: Check that the warning lights on the instruments operate correctly. Steering and Suspension Standard required: The motorcycle should be easy to steer and should not pull to one side. Cornering should be precise with the motorcycle leaning naturally into the corner and returning to the upright position upon exiting the corner.
Page 239 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 240 Certain components of the motorcycle will be hot immediately after road test. Care must be taken to avoid burn injuries caused by contact with hot components. Cooling Fan Operation (liquid cooled engines only) Standard required: NOTICE Some models are fitted with a cooling fan variable speed controller. This controls the speed of the cooling fan(s) at various speeds depending on the temperature of the coolant.
Page 241 Do not allow the engine temperature to rise too high. Serious damage may result if the engine is allowed to overheat. Check: Check the cooling fan for correct operation. Action: Switch off the engine. Hot Start NOTICE This test should be carried out when the engine is at normal operating temperature.
Page 242 Standard required: The fuel system must be free from leaks. Tyres Standard required: Front and rear tyres must be free from damage. Check the tyres for cuts, embedded nails or other sharp objects. Check the wheel rims for dents or deformation. Operation with damaged or defective wheels or tyres is dangerous and loss of motorcycle control or an accident could result.
Page 243: Engine Covers
Engine Covers Exploded View - Alternator Cover...
Page 244 Exploded View - Camshaft Cover...
Page 245 Exploded View - Clutch Cover...
Page 246 Exploded View - Oil Tank Cover...
Page 247 Exploded View - Starter Motor Cover...
Page 248 Exploded View – Sump...
Page 249 Alternator Cover – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. The rotor magnets are very strong. When handling the alternator cover the magnets may 'grab' the stator, causing injury to the hands or fingers.
Page 250 NOTICE To access the regulator/rectifier connectors, the radiator lower surround will need to be pivoted slightly forward. 1. Release the fixings, move the radiator lower cowl forward to disengage the upper retaining clips and remove the lower cowl. 1. Fixings 2.
Page 251 2. Release the two fixings securing the radiator lower surround to its bracket. 1. Fixings 2. Bracket 3. Radiator lower surround 3. Pivot the radiator lower surround forward and disconnect the alternator harness from the regulator/rectifier. 1. Alternator connector 2. Regulator/rectifier...
Page 252 4. Route the alternator harness to the rear of the engine. NOTICE Note the routing of the alternator, Triumph shift assist, side stand and gear position sensor harnesses around the wire guide and the location of the cable tie for installation.
Page 253 NOTICE The bushes for the torque limiter assembly may remain in the starter motor drive cover and in the alternator cover. 8. Place an oil catch tray beneath the alternator cover to collect any oil that may spill out on removal. 9.
Page 254 10. Remove the starter drive torque limiter assembly and collect its two washers. 1. Torque limiter assembly 11. Release the fixings securing the alternator cover to the crankcases. 1. Fixings 2. Alternator cover...
Page 255 12. Carefully withdraw the cover. Discard the gasket 13. Clean the surfaces of the crankcase and the alternator cover using a lint free cloth. The rotor magnets are very strong. When handling the alternator cover the magnets may 'grab' the stator, causing injury to the hands or fingers. When handling the alternator cover wear suitable gloves and only grip the alternator cover by the outside surfaces;...
Page 256 1. Silicone sealant 2. Grommet location 3. Fit the harness grommet to the alternator cover and apply two beads of silicone sealant, 2 mm (+/-0.5 mm), to the alternator cover to the harness rubber grommet, as shown in the diagram below. Make sure the sealant is a minimum of 2 mm away from any bolt holes.
Page 257 4. Position a new gasket to the crankcase dowels. 5. Fit the alternator cover and tighten the fixings in the following two stages: Stage 1 6. Tighten the fixings one to twelve in the sequence shown to 10 Nm. Stage 2 7.
Page 258 8. Make sure the two washers are fitted one each on both ends of the starter drive torque limiter assembly. 1. Washers 9. Fit the torque limiter assembly to the starter motor drive gear. 1. Torque limiter assembly...
Page 259 12. Secure the harnesses to the wire guide as noted for removal. 1. Alternator harness 2. Starter motor, Triumph shift assist, side stand and gear position sensor harnesses 3. Wire guide 4. Cable tie...
Page 260 13. Pivot the radiator lower surround forward and connect the alternator harness to the regulator/rectifier. 1. Alternator connector 2. Regulator/rectifier 14. Secure the radiator lower surround to its bracket and tighten the fixings to 4 Nm. 1. Fixings 2. Bracket 3.
Page 261 15. Engage the upper retaining clips of the radiator cowl into their slots, fit the fixings and tighten to 4 Nm. 1. Fixings 2. Lower cowl 3. Retaining clips Perform the following operations: • Starter Drive Cover - Installation • Starter Motor - Installation •...
Page 262 Camshaft Cover – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 263 3. Release the two fixings and remove the number one cylinder ignition coil. 1. Ignition coil connections 2. Fixings 3. Number one cylinder ignition coil 4. Detach the rear caliper brake line from the ignition coil bracket. Discard the fir tree clip.
Page 264 5. Release the four fixings and remove the ignition coil bracket. Discard the fixings. 1. Rear caliper brake line 2. Retaining fir tree clip 3. Fixings 4. Ignition coil bracket 6. Release the fixing and detach the rear brake master cylinder line from the evaporative canister bracket.
Page 265 NOTICE Note there are two M6 x 55 mm fixings with copper washers and are located between cylinders one and two spark plugs for installation. The remaining twelve fixings are M6 x 30mm. Note the position of the right hand side panel for installation. Note the position of the brackets on the front and rear of camshaft cover for installation.
Page 266 NOTICE Note the orientation of the camshaft cover and spark plug tower gaskets for installation. 10. Remove and discard the camshaft cover gasket and the spark plug tower gasket. 11. Remove any residual oil from the mating face of the cylinder head using a lint free cloth.
Page 267 Stage 1 6. Tighten the fixings in the sequence shown to 2 Nm. Stage 2 7. Tighten the fixings in the sequence shown to 10 Nm. Stage 3 8. Retighten fixings one and two to 10 Nm. Camshaft Cover Tightening Sequence 9.
Page 268 10. Attach the rear brake master cylinder line to the evaporative canister bracket and tighten the new fixing to 5 Nm. 1. Fixing 2. Rear brake master cylinder line 3. Fixings 4. Evaporative canister bracket 5. Fuel tank bracket 11. Position the number one cylinder bracket as noted for removal and tighten the new fixings to 9 Nm.
Page 269 12. Attach the rear caliper brake line to the ignition coil bracket and secure with a new fir tree clip. 1. Rear caliper brake line 2. Retaining fir tree clip 3. Fixings 4. Ignition coil bracket 13. Fit the number one cylinder ignition coil to its bracket and tighten the new fixings to 5 Nm.
Page 270 15. Route and connect the high tension cables to the spark plugs as noted for removal. Perform the following operations: • Fit the air filter Air Filter - Renew • Evaporative Canister - Installation • Fit the left hand Side Panels - Installation •...
Page 271 NOTICE Note the position of the single fixing of the clutch cover finisher for installation. 1. Release the three fixings and remove the lower radiator cowl bracket. 1. Fixings 2. Bracket 2. Release the fixing and remove the clutch cover finisher. 1.
Page 272 Do not allow the clutch slave cylinder to hang on the clutch hose as this may damage the hose and could impair clutch operation leading to loss of motorcycle control and an accident. 3. Release the three fixings and detach the slave cylinder from the clutch cover. Make sure the piston remains in its cylinder.
Page 273 4. Retain the piston to the slave cylinder using a retaining tie such as a rubber band or cable tie. 1. Clutch slave cylinder 2. Retaining tie 5. Tie the clutch slave cylinder aside. 6. Place an oil catch tray beneath the clutch cover to collect coolant that may spill out on removal.
Page 274 7. Release the fixings and remove the water pump cover. Discard the seal. 1. M6 x 70 mm fixings 2. M6 x 35 mm fixings 3. Water pump cover NOTICE For the clutch cover there are, five M6 x 50 mm and six M6 x 35 mm fixings. Note the position of the fixings for installation.
Page 275 9. Release the fixings and remove the clutch cover. Discard the gasket. 1. M6 x 35 mm fixings 2. M6 x 50 mm fixings 3. Radiator lower bracket Clutch Cover – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 276 6. Fit the six M6 x 35 mm and five M6 x 50 mm fixings as noted for removal. 1. M6 x 35 mm fixings 2. M6 x 50 mm fixings 3. Radiator lower bracket 7. Tighten the clutch cover fixings in the following three stages: Stage 1 8.
Page 277 9. Fit a new water pump cover seal to the water pump cover. 10. Fit the water pump cover and its four M6 x 70 mm and two M6 x 35 mm fixings as noted for removal. 1. M6 x 70 mm fixings 2.
Page 278 Stage 2 11. Tighten the fixings one to fourteen in the sequence shown to 10 Nm. Clutch Cover Tightening Sequence Stage 2 Stage 3 12. Retighten fixings one to four to 10 Nm. Clutch Cover Tightening Sequence Stage 3...
Page 279 13. Remove the cable tie or rubber band from the slave cylinder. 14. Fit a new gasket to the clutch slave cylinder. 15. Fit the slave cylinder to the clutch cover ensuring that the lifter piece locates correctly in the cylinder. Tighten the cylinder to clutch cover bolts to 10 Nm. 1.
Page 280 18. Fit the lower radiator cowl bracket and tighten the clutch cover fixings to 10 Nm. 19. Secure the radiator lower bracket to the lower radiator cowl bracket and tighten the fixing to 5 Nm. 1. Fixings 2. Bracket Perform the following operations: •...
Page 281 Oil Tank Cover – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 282 Oil Tank Cover – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Thoroughly clean the cover and crankcase mating faces. 2.
Page 283 Stage 2 7. Tighten the fixings one and two to 10 Nm. Oil Tank Cover Tightening Sequence Perform the following operations: • Cylinder Head – Installation • Throttle Body – Installation • Engine – Installation • Fuel Tank - Installation •...
Page 284 Starter Drive Cover – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 285 Starter Drive Cover – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Thoroughly clean the cover and alternator cover mating faces. 2.
Page 286 Sump – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Support the motorcycle on its side stand with access to the sump. 2.
Page 287 5. Release the five fixings and position the radiator lower surround bracket to one side. 1. Fixings 2. Radiator lower surround bracket NOTICE Note the routing of the brake line and the coolant expansion tank drain hose for installation. 6. Release the fixings and remove the rear brake line two rear brackets. 1.
Page 288 7. Release the fixings and remove the rear brake line front bracket. 1. Fixings 2. Brake line front bracket 3. Brake line Do not allow a brake component to hang unsupported on the brake hose or line. Brake hoses or lines that are not supported may become damaged or bent. Bent or damaged brake hoses or lines lead to reduced braking efficiency causing loss of motorcycle control and an accident.
Page 289 8. Release the fixings and detach the rider right hand control plate from the engine. support the control plate to prevent damage to the brake lines. 1. Fixings 2. Right hand control plate NOTICE For the sump there are, twenty six M6 x30 mm, two M6 x 130 mm and five M6 x 50 mm fixings.
Page 290 1. M6 x 130 mm fixings 2. M6 x 50 mm fixings 9. Release the fixings in the sequence shown and remove the sump. Remove and discard the sump gasket and the five M6 x 50mm fixings. Sump Release Sequence 10.
Page 291 NOTICE Note the orientation of the baffle plate, the two oil strainers and their O-rings for installation. Note the orientation of the oil pick-up and its retaining plate filter for installation. 11. Remove the baffle plate and the filters for cleaning. 1.
Page 292 Sump – Inspection Make sure the oil pick-up is clean and free of blockages or restrictions. If the oil flow is restricted, oil pressure will be reduced and may cause severe engine damage. 1. Check the oil pick-up for blockages or restrictions. Remove and clean if found to be blocked or restricted.
Page 293 1. Oil strainers 2. Baffle plate 3. Fixings 4. Pick up filter 5. Retaining plate 6. Fixing 3. Position a new gasket to the sump. 4. Make sure the four locating dowels are fitted to the sump as noted for removal. 5.
Page 294 Stage 1 9. Tighten the fixings one to thirty three in the sequence shown to 10 Nm. Stage 2 10. Retighten fixings one and two to 10 Nm. Sump Tightening Sequence Always return the rider control plates to their original positions. Operating the motorcycle with the control plates in a position which is unfamiliar may lead to loss of control or an accident.
Page 295 11. Fit the rider's right hand control plate to the engine as noted for removal and tighten the fixings to 36 Nm. 1. Fixings 2. Right hand control plate 12. Route the brake line and the coolant expansion tank hose as noted for removal. Fit the brake line two rear brackets and tighten the fixings to 5 Nm.
Page 296 13. Fit the rear brake line front bracket and tighten its fixings as shown in the illustration. 1. Fixings - tighten to 5 Nm 2. Fixing - tighten to 8 Nm 3. Brake line bracket 4. Rear brake line 14. Fit the radiator lower surround bracket to the radiator lower surround and the sump and tighten its fixings as shown in the illustration below.
Page 297 15. Fill the engine with the correct grade of engine oil (see Lubrication). Raising the engine speed above idle, before the oil reaches all parts of the engine can cause engine damage or seizure. Only raise engine speed after running the engine for 30 seconds to allow the oil to circulate fully.
Page 298: Cylinder Head
Cylinder Head Exploded View - Cylinder Head...
Page 299 Exploded View - Camshaft and Camshaft Drive...
Page 300 Cylinder Head – Description The engine is fitted with an aluminium alloy cylinder head, which carries the camshafts, valves and spark plugs. The cylinder head is cast as a single entity and various components are permanently added after machining. The camshafts run directly in the cylinder head without separate bearings. Valve clearances are adjusted by changing variable thickness shims which sit between the valve tappet bucket and the valves.
Page 301 Camshaft Drive Chain Tensioner – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. When turning the crankshaft at the front of the engine (clutch cover end) always turn anticlockwise.
Page 302 15. Remove the crankshaft locking pin plug from the crankcase. 1. Locking pin plug 2. At the front of the engine, rotate the crankshaft anticlockwise using the bolt fitted to the end of the crankshaft until the two gear teeth with an alignment mark on each is visible and central in the hole for the crankshaft locking pin.
Page 303 3. Check the alignment marks on the front end of the camshaft journals are pointing inwards. If they are pointing outwards, rotate the crankshaft anticlockwise one complete turn. 1. Camshaft alignment marks 2. Exhaust camshaft 3. Inlet camshaft NOTICE The alignment mark on the flange of T3880501 - Crankshaft Locking Pin is in line with the gear tooth at the other end of the service tool.
Page 304 4. Insert service tool T3880501 through the hole in the crankcase. Make sure the gear tooth on the service tool fits between the two teeth with the alignment marks. 1. T3880501 - Crankshaft Locking Pin 2. Alignment mark 5. Place suitable wedges between the camshaft sprockets and the crankcase, to hold the camshaft drive chain taut during removal of the tensioner.
Page 305 7. Remove the hydraulic tensioner and discard the O-rings. Camshaft Drive Chain Tensioner – Inspection 1. Inspect the camshaft drive chain tensioner spring for damage and deformation. Renew as necessary. 2. Inspect the tip of the camshaft drive chain tensioner plunger for wear and damage. Renew as necessary.
Page 306 3. Check the alignment marks on the front end of the camshaft journals are pointing inwards. 1. Camshaft alignment marks 2. Exhaust camshaft 3. Inlet camshaft 4. Check that service toll T3880501 is through the hole in the crankcase. 1. T3880501 - Crankshaft Locking Pin 2.
Page 307 The plunger of the camshaft drive chain tensioner is under spring tension. Always wear hand, eye and facial protection when removing the tensioner as unprotected areas of the body can be injured if the spring tension is released in an unexpected or uncontrolled way.
Page 308 7. While holding the resister ring in place, drain the engine oil into a suitable container. 8. Make sure the resister ring is correctly located as shown below. 1. Resister ring 9. Refit the spring. 10. Support the tensioner in a soft jawed vice. 11.
Page 309 12. When the snap ring aligns with the snap ring groove, release the vice and move one end of the snap ring into the groove. Slowly release the plunger to make sure it is held in place. 1. Snap ring groove 2.
Page 310 18. Continue to rotate the crankshaft anticlockwise to complete two revolutions and the two gear teeth with an alignment marks are visible and central in the hole for the crankshaft locking pin. 1. Crankshaft primary gear 2. Alignment marks 19. Check that there is tension in the camshaft drive chain and the slot at the camshafts end are correctly aligned.
Page 311 20. Check that the tensioner plunger is correctly located in the middle of the camshaft drive chain tensioner blade when viewed from above. 21. Rotate the engine through 4 full revolutions, and reset number 1 cylinder to TDC. Make sure that the two gear teeth with an alignment marks are visible in the hole for the crankshaft locking pin.
Page 312 24. Reheck that there is tension in the camshaft drive chain and the slot at the camshafts end are correctly aligned. 1. Camshaft timing slots 25. Recheck the tensioner plunger location against the camshaft drive chain tensioner blade. 26. Remove service tool T3880501. 1.
Page 313 27. Fit the crankshaft locking pin plug and tighten to 33 Nm. 1. Locking pin plug NOTICE After fitting to the engine, the hydraulic tensioner will be empty of engine oil. After starting the engine, the camshaft drive chain and tensioner blade will be noisy until full pressure is felt at the tensioner plunger.
Page 314 Camshaft Drive Chain – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 315 1. Remove the coolant exit pipe from the cylinder head. Discard the pipe and its four O- rings. 1. Coolant exit pipe 2. O-rings 2. The camshaft drive chain is removed from inside the camshaft drive chain chest, after first detaching the drive chain from the crankshaft gear. Camshaft Drive Chain –...
Page 316 For a more thorough check, proceed as follows: 1. Remove the drive chain from the engine. 2. Suspend the drive chain from a pin or hook with a 13 kg weight attached at the lower end. 3. Measure across 23 links as shown in the diagram below. If the drive chain is within limits, the measurement should be no longer than 147.14 mm.
Page 317 4. Check for severe wear of the inner surface of the outer plates at the side-contact points with the sprocket teeth. 5. Check for signs of stiffness or kinking. 6. Check for severe wear of the plates in the area shown below. 7.
Page 318 Camshaft Drive Chain – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Fit four new O-rings to the new coolant exit pipe. 1.
Page 319 3. Fit the coolant exit pipe as noted for removal with the camshaft drive chain links on both sides of the pipe. 1. Coolant exit pipe 2. Camshaft drive chain Perform the following operations: • Coolant Temperature Sensor – Installation •...
Page 320 Camshaft Drive Chain Tensioner Blade – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 321 2. Remove the fixing and raise the camshaft drive chain tensioner blade to remove it. Collect the hardened washer. 1. Fixing 2. Tensioner blade...
Page 322 Camshaft Drive Chain Tensioner Blade – Disassembly NOTICE For the purpose of this instruction, the top of the tensioner blade is where the pad is located. 2. Release the clips and remove the pad. 2. Pad 3. Clip (one side shown) 2.
Page 323 3. Release the two side locating devices. 1. Locating devices 2. Facing blade 4. Release the three hooks and remove the facing blade. 1. Hooks...
Page 324 Camshaft Drive Chain Tensioner Blade – Assembly NOTICE For the purpose of this instruction, the top of the tensioner blade is where the pad is located. 1. Align the three hooks and fit the facing blade. 1. Hooks 2. Align the two side locating devices. 1.
Page 325 3. Attach the top hook to the tensioner blade. 1. Top hook 2. Tensioner blade 4. Fit the pad and secure the clips. 1. Pad 2. Clip (one side shown)
Page 326 Camshaft Drive Chain Tensioner Blade – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 327 • Radiator - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation Camshaft – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 328 1. Remove the spark plugs to reduce compression resistance when turning the engine (see Spark Plugs - Check/Renew). 2. Remove the crankshaft locking pin plug from the crankcase. 1. Locking pin plug 3. At the front of the engine, rotate the crankshaft anticlockwise using the bolt fitted to the end of the crankshaft so any two camshaft sprocket fixings are accessible.
Page 329 4. Loosen the two accessible camshaft sprocket fixings. Do not remove the fixings at this stage. 1. Fixings 5. Rotate the crankshaft until the remaining two fixings are accessible. Do not rotate the crankshaft further once the four camshaft sprocket bolts have been loosened.
Page 330 8. Evenly and progressively release the bolts securing the camshaft caps to the cylinder head in the sequence shown below. Camshaft Caps Release Sequence 9. Remove the camshaft caps. Collect the dowels (if loose), 1. Dowel locations 10. Lift the camshaft drive chain from the exhaust camshaft sprocket and remove the exhaust camshaft.
Page 331 14. At the front of the engine, rotate the crankshaft anticlockwise using the bolt fitted to the end of the crankshaft until the two gear teeth with an alignment mark on each is visible and central in the hole for the crankshaft locking pin. 1.
Page 332 15. Insert service tool T3880501 through the hole in the crankcase. Make sure the gear tooth on the service tool fits between the two teeth with the alignment marks. 1. T3880501 - Crankshaft Locking Pin 2. Alignment mark NOTICE Note the orientation for each camshaft sprockets for installation. 16.
Page 333 Camshaft – Identification The inlet and exhaust camshafts are different. The exhaust camshaft has three decompressors fitted to it.. The mark on the camshaft boss is not a timing mark, it is used as a visual aid during the timing adjustment procedure. 1.
Page 334 When turning the crankshaft at the front of the engine (clutch cover end) always turn anticlockwise. When turning the crankshaft at the rear of the engine (alternator cover end) always turn clockwise. Turning the crankshaft in the wrong direction may cause the camshaft drive chain to slip on the camshaft sprockets resulting in incorrect camshaft timing.
Page 335 2. If removed, refit the camshaft sprockets in their noted orientation and secure using the new fixings. DO NOT tighten the bolts at this stage; the sprockets must be free to rotate. 3. If removed, refit the camshaft caps dowels. 1.
Page 336 11. Check the alignment marks on the front end of the camshaft journals are pointing inwards. 1. Camshaft alignment marks 2. Exhaust camshaft 3. Inlet camshaft 12. Fit service tool service tool T3880502 into the camshaft timing slots. 1. T3880502 - Camshaft timing bar 2.
Page 337 If the camshafts and camshaft caps are fitted without first aligning the timing marks on both the crankshaft and camshaft sprockets, the inlet and exhaust valves will contact each other causing damage to both the cylinder head and the valves. 13.
Page 338 If any components have been renewed, the valve clearances must be checked and adjusted. Running with incorrectly adjusted valve clearances may cause excess engine noise, rough running and engine damage. 18. Check that the camshaft drive chain is engaged around the camshaft drive sprocket on the crankshaft, the camshaft sprockets and the camshaft drive chain is positioned against the tensioner blade.
Page 339 21. Tighten the two accessible camshaft sprocket bolts to 16 Nm. 1. Fixings 22. Remove service tool T3880502 from the camshaft slots. 1. T3880502 - Camshaft timing bar 2. Camshaft slots...
Page 340 23. Remove service tool T3880501 from the crankcase. 1. T3880501 - Crankshaft Locking Pin 2. Alignment mark Always check that service tool T3880502 has been removed before rotating the engine. Severe damage will result to the camshafts or service tool T3880502 if engine rotation is attempted with the tool installed.
Page 341: Installation
25. Tighten the two accessible camshaft sprocket bolts to 16 Nm. 1. Fixings 26. Place suitable wedges between the camshaft sprockets and the crankcase, to hold the camshaft drive chain taut during removal of service tool T3880651. 27. Release the tension on service tool T3880651 and remove it. 28.
Page 342 NOTICE The alignment mark on the flange of T3880501 - Crankshaft Locking Pin is in line with the gear tooth at the other end of the service tool. Use this alignment mark as a guide when inserting the service tool. 30.
Page 343 33. Fit the crankshaft locking pin plug and tighten to 33 Nm. 1. Locking pin plug Perform the following operations: • Valve Clearance Measurement • Camshaft Cover - Installation • Plenum - Installation (All Markets Except US) Plenum - Installation (US Markets Only) •...
Page 344 damage to the valve and valve seat will take place. If the valve clearance becomes too great, the engine will become noisy and will not run correctly. Cylinder Head – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 345 • Clutch Cover - Removal Camshaft - Removal NOTICE To prevent the tappet buckets and shims from becoming mixed, place the shim and tappet together in a marked container. The components must be refitted in their original positions. 1. Note the position of all the tappet buckets and shims so that they can be refitted in the same positions.
Page 346 2. Remove the two fixings within the camshaft drive chain chest. 1. Fixings NOTICE Two of the cylinder head bolts are to be used with service tool T3880518 to secure the barrel. 3. Progressively release the cylinder head bolts in the sequence shown below. Cylinder Head Bolt Release Sequence...
Page 347 4. Lightly tap the cylinder head with a rubber mallet to break the seal of the gasket. 5. Remove the cylinder head and the camshaft drive chain assembly. Discard the cylinder head gasket. The gasket between the barrel and the crankcase must also be replaced if the cylinder head has been removed.
Page 348 When turning the crankshaft at the front of the engine (clutch cover end) always turn anticlockwise. When turning the crankshaft at the rear of the engine (alternator cover end) always turn clockwise. Turning the crankshaft in the wrong direction may cause the camshaft drive chain to slip on the camshaft sprockets resulting in incorrect camshaft timing.
Page 349 Tighten the cylinder head bolts in the steps and the correct sequence that follows. If you do not use the correct procedure or replace all of the bolts, engine damage can occur or the life of the cylinder head gasket can be reduced. 6.
Page 350 Stage 4 14. Carry out a torque over check of the bolts to 80 Nm Overcheck. Cylinder Head Bolt Tightening Sequence 15. Fit the two fixings within the camshaft drive chain chest and tighten to 25 Nm. 1. Fixings...
Page 351 16. Refit the tappet shims and buckets to their positions as noted for removal. 1. Tappet bucket 2. Shim Perform the following operations: • Camshaft - Installation • Clutch Cover - Installation • Engine - Installation • Fuel Tank - Installation •...
Page 352 Valves and Valve Stem Seals - Removal from the Cylinder Head 1. Remove each valve from the cylinder head using a valve spring compressor. The compressor must act on the top cup to allow removal of the valve collets. Valve Removal 2.
Page 353 1. Valve stem oil seal NOTICE Make sure inlet and exhaust valve components do not become mixed. 1. Collets 2. Valve spring retainer 3. Valve spring 4. Valve spring platform 5. Valve stem oil seal 6. Valve...
Page 354 Valves and Valve Stem Seals – Inspection Valve to Valve Guide Clearance If the valve guides are worn beyond the service limit given below, the cylinder head must be replaced. Valve Stem to Guide Clearance Inlet 0.010 -0.037 mm (standard) 0.075 mm (service limit) Exhaust 0.020 -0.042 mm (standard)
Page 355 6. Fit the valve collets ensuring correct collet location in the spring cap and valve as the spring compressor is released. Always check for correct location of the valve collets during and after assembly. If not fitted correctly, the collets may become dislodged when the engine is running allowing the valves to contact the pistons.
Page 356: Cylinders And Pistons
Cylinders and Pistons Exploded View - Barrels and Piston...
Page 357 Barrels – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 358 1. Piston alignment mark 2. T3880518-Spacer 2. Remove the spacers. 3. Lightly tap the barrels with a rubber mallet to break the seal of the gasket. Support the pistons as the barrels are removed to prevent piston damage. Note the position of the locating dowels for installation. 4.
Page 359 6. Discard the gasket. 1. Barrels 2. Locating dowels 3. Gasket 7. Pull the piston and connecting rod assemblies out of the barrels.
Page 360 Barrels – Inspection 1. Measure the diameter of each cylinder bore using an internal micrometer or similar accurate measuring equipment. 2. Measure the inside diameter 10 mm from the top of the bore as shown below. Cylinder Bore Diameter Measurement Points 3.
Page 361 Perform the following operations: • Check that the three oil spray jets are fitted and the three oil jet protectors from service tool T3880504 are also fitted. 1. Thoroughly clean the mating surfaces of the crankcase and barrels taking care not to damage the mating surfaces.
Page 362: Installation
6. Invert the engine and fit the crankshaft (see Crankshaft - Installation). Perform the following operations: • Cylinder Head - Installation • Clutch Cover - Installation • Engine - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation Piston –...
Page 363 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. 1. Remove and discard the gudgeon pin circlip from one side of the piston. Removing the Gudgeon Pin Circlip Never force the gudgeon pin through the piston.
Page 364 NOTICE If the piston rings are to be reused, note the orientation of the oil control rings prior to removal. 4. Remove the piston rings (see Piston rings - Removal). Piston - Wear Check 1. Remove any carbon build-up from the piston crown. Inspect the piston crown for signs of pitting and check the piston skirt and ring grooves for signs of wear or scuffing.
Page 365 Piston rings – Removal Do not expand the piston rings any more than is necessary to allow them to be removed from the piston. The rings are brittle and will break if expanded too much. NOTICE Prior to removing the rings, check the ring-to-groove clearance of each compression ring (see Piston Ring to Groove - Clearance).
Page 366 Piston Ring - End Gap NOTICE The piston ring end gap must be measured in the cylinder bore to which the piston ring will be fitted to on installation. Make sure all piston rings are fitted in their original locations (if original rings are being reused) or to the piston/bore which the end gaps were checked (if new rings are being installed).
Page 367 2. When checking the piston ring end gap, always refer to the specifications table (see Pistons). NOTICE If the end gap is too large, replace the piston rings with a new set. If the gap remains too large with new piston rings, both the pistons and barrels must be replaced.
Page 368 Piston Ring to Groove – Clearance 1. Prior to removing the rings, check the ring-to-groove clearance of each compression ring. Piston Ring-to-Groove Clearance Check 2. When checking the piston ring to groove clearance, always refer to the specifications table (see Pistons). NOTICE If the ring-to-groove clearance is too large, replace the piston rings with a new set.
Page 369 Piston - Assembly Do not expand the piston rings any more than is necessary to allow them to be installed on the piston. The rings are brittle and will break if expanded too much. NOTICE Make sure all piston rings are fitted in their original locations (if original rings are being reused) or to the piston/bore which the end gaps were checked (if new rings are being fitted).
Page 370 NOTICE Connecting rods may be fitted either way around. However, make sure all three are fitted the same way. 5. Lubricate the piston, small end and gudgeon pin with a 50/50 solution of engine oil and molybdenum disulphide grease. 6. Align the small end in the connecting rod with the gudgeon pin hole in the piston and fit the gudgeon pin.
Page 371 NOTICE The top compression ring gap should be in the 12 o'clock position. The second compression ring gap should be in the 6 o'clock position. The first oil control ring gap should be in the 12 o'clock position. The second oil control ring gap should be in the 6 o'clock position. The oil control ring expander gap should be in the 7 o'clock position.
Page 372 Clutch Exploded View - Clutch...
Page 373 Exploded View - Clutch Controls...
Page 374 Exploded View - Clutch Slave Cylinder...
Page 375 Clutch Description This model is fitted with a hydraulically operated, wet plate, torque assist clutch. The clutch is operated by a hydraulic master cylinder, which in turn operates a slave cylinder mounted on the clutch cover. The clutch has ten friction plates and nine steel plates located between the inner and outer drums.
Page 376 It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph dealer before riding the motorcycle. Failure to take remedial action may impair clutch operation leading to loss of motorcycle control and an accident.
Page 377 Clutch Master Cylinder – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. To prevent body damage, do not spill brake and clutch fluid onto any area of the bodywork or the brake and clutch reservoirs.
Page 378 4. Disconnect the clutch hose from the master cylinder and discard the two sealing washers. 1. Union bolt 2. Sealing washers 3. Clutch hose 5. Release the fixings, remove the clamp and remove the master cylinder.
Page 379 Clutch Master Cylinder – Disassembly NOTICE Note the order and orientation of each component as it is removed. It is essential for correct clutch operation that each component is installed in the correct order and orientation during reassembly. The following items can be replaced on the clutch master cylinder. •...
Page 380 5. Carefully detach the fluid reservoir from the master cylinder spigot. 1. Reservoir 2. Master cylinder 3. Spigot Clutch lever NOTICE Only disassemble the lever if it is to be replaced. If the lever is to be replaced, The pivot assembly and push rod for the master cylinder must be removed from the original lever and fitted to the new lever.
Page 381 T3880636 - Kit, Brake Lever Pivot Sleeve 1. Mandrel 2. Extractor 3. Installer piece 4. Support piece When removing the lever pivot sleeve, always wear overalls, eye, face and hand protection. The lever sleeve is hardened and liable to splinter if broken. Debris from broken components could cause injury to eyes, face and any unprotected parts of the body.
Page 382 5. Position the lever assembly to the support piece as shown. 1. Brake lever 2. Pivot 3. Support piece 6. Position the mandrel and extractor to the lever and press out the pivot sleeve from the lever assembly. 1. Mandrel 2.
Page 383 Always wear eye, hand and face protection when separating the lever components. Uncontrolled release of the lever components may cause the spring to become detached during dismantling. Flying springs may cause injury to eyes, face and any unprotected parts of the body. NOTICE Note the orientation of the return spring, push rod and pivot bush for installation.
Page 384 Clutch Master Cylinder – Assembly Clutch Lever NOTICE The service tool T3880636 is required to fit the lever pivot sleeve. T3880636 - Kit, Brake Lever Pivot Sleeve 1. Mandrel 2. Extractor 3. Installer piece 4. Support piece 1. Locate the pivot sleeve over the shank of the installer piece. 1.
Page 385 2. Screw the installer piece into the mandrel. 1. Mandrel 2. Pivot sleeve 3. Installer piece 3. Make sure the push rod is fitted to the pivot. 1. Pivot 2. Push rod 4. Align the lever to the pivot and push rod assembly ensuring the return spring is located as noted during removal.
Page 386 6. Place the lower surface of the lever onto the support piece, and then using a press push the pivot sleeve through the lever pivot until the mandrel touches the upper brake lever surface. 1. Mandrel 2. Support piece 3. Extractor 4.
Page 387 8. Visually check the pivot sleeve, return spring, brake lever pivot and push rod are installed as noted during removal. 9. Fit the dust cover to the push rod on the clutch lever. 1. Dust cover 2. Push rod 10. Line up the holes of the brake lever and master cylinder, and insert the pivot bolt. Tighten the pivot bolt to 6 Nm.
Page 388 13. Check lever operation and make sure the rubber seal is still correctly seated. Brake Fluid Reservoir 1. Check the condition of the spigot seal in the reservoir. Replace if damaged. 2. Fit the reservoir onto the master cylinder spigot. 1.
Page 389 6. Fit the clutch lever to the master cylinder. Tighten the pivot bolt to 6 Nm and tighten the lock nut to 6 Nm. 7. Fit the master cylinder (see Clutch Master Cylinder – Installation) 8. Bleed the clutch (see Bleeding the Clutch).
Page 390 2. Align the straight edge on the clamp to the alignment mark on the handlebar (as shown in the illustration below) and tighten the fixings (upper one first) to 8 Nm. 1. Alignment mark 2. Straight edge 3. Clamp 3. Connect the clutch hose to the master cylinder incorporating new sealing washers to each side of the union.
Page 391 4. Attach the clutch switch assembly to the master cylinder as noted for removal. 1. Clutch switch 2. Securing lugs 3. Location holes 5. If removed, refit the clutch lever. Tighten the pivot bolt to 6 Nm and the nut to 6 Nm. 6.
Page 392 If the clutch slave cylinder is found to be leaking, the engine oil must be replaced after repairs to the clutch slave cylinder have been carried out. Contamination of the engine oil with brake and clutch fluid may result in damage to engine and clutch components. To prevent body damage, do not spill brake and clutch fluid onto any area of the bodywork or the brake and clutch reservoirs.
Page 393 2. Release the fixing and remove the clutch cover finisher. 1. Fixings 2. Clutch cover finisher 3. Position a suitable container for the collection of brake and clutch fluid. 4. Release the union bolt from the clutch slave cylinder. Place the hose fitting into the container to collect the fluid.
Page 394 5. Release the three fixings and remove the slave cylinder from the clutch cover. Make sure the piston remains in its cylinder. Discard the slave cylinder gasket. 1. Union bolt 2. Sealing washers 3. Fixings 6. If the cylinder is not to be disassembled, retain the piston to the slave cylinder using a retaining tie such as a rubber band or cable tie.
Page 395 Clutch Slave Cylinder – Inspection The clutch slave cylinder contains no user serviceable parts and replacement piston and dust seals are not available. If disassembled, never attempt to reassemble the clutch slave cylinder using the original seals as this could cause a fluid leak. The clutch slave cylinder must be replaced If disassembled for any reason.
Page 396 5. Bleed the clutch (see Bleeding the Clutch). 1. Union bolt 2. Sealing washers 3. Fixings 6. Check the clutch for correct operation and fluid leaks. Rectify as necessary. 7. Fit the clutch cover finisher and secure with the single fixing as noted for removal. Do not fully tighten the fixing at this stage.
Page 397 8. Fit the lower radiator cowl bracket and tighten the clutch cover fixings to 10 Nm. 9. Secure the radiator lower bracket to the lower radiator cowl bracket and tighten the fixing to 5 Nm. 1. Fixings 2. Clutch cover finisher Perform the following operations: •...
Page 398 Clutch – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. When turning the crankshaft at the front of the engine (clutch cover end) always turn anticlockwise.
Page 399 2. Remove the crankshaft locking pin plug from the crankcase. 1. Locking pin plug 3. Turn the crankshaft anticlockwise until the two gear teeth with an alignment mark on each is visible in the hole for the crankshaft locking pin. 1.
Page 400 NOTICE The alignment mark on the flange of T3880501 - Crankshaft Locking Pin is in line with the gear tooth at the other end of the service tool. Use this alignment mark as a guide when inserting the service tool. 4.
Page 401 5. Remove the lifter piece and bearing carrier. 1. Lifter piece 2. Bearing carrier 6. Carefully de-stake the clutch centre nut. 7. Remove the centre nut, Belleville washer and a plain washer. Discard the nut and Belleville washer. 1. Centre nut 2.
Page 402 8. Remove the clutch centre and pressure plate. 1. Clutch centre and pressure plate assembly 9. Remove the thrust washer from the input shaft. 10. Slide the clutch outer drum assembly gently backwards and forwards to dislodge the inner bearing. Carefully remove the bearing while supporting the clutch drum. 1.
Page 403 Clutch – Disassembly 1. Evenly and progressively loosen the three fixings securing the release plate to the clutch centre and pressure plate assembly. 1. Fixings 2. Release plate 2. Remove the fixings and lift off the release plate. Collect the springs and their seats. 1.
Page 404 3. Remove the clutch centre. NOTICE The one outermost and two innermost friction plates differ from the seven centre plates and must not be fitted in any other positions. The innermost steel plate differs from the eight other steel plates and cannot be fitted in any other position. 4.
Page 405 Friction Plate Inspection Thickness NOTICE If any friction plate thickness is outside the service limit, replace the friction plates as a set. 1. Measure the thickness of the friction plate. 2. Clutch friction plate 2. For the clutch friction plate thickness, refer to Clutch and Primary Drive.
Page 406 Steel Plate Inspection Bend/warp Check all plates for bend and warp as follows: 1. Place the plate being checked on a clean surface plate and attempt to pass a feeler gauge of the maximum service limit thickness etween the steel plate and surface plate.
Page 407 Clutch – Assembly The outermost and two innermost friction plates differ from the seven centre friction plates. Identification is as follows: • The outermost and two innermost friction plates have a larger internal diameter to accommodate the anti-judder spring and pressure plate splines respectively. •...
Page 408 1. Clutch centre 2. Anti-judder spring 3. Steel plate 4. Curved edge 5. Outer friction plate 3. Assemble the following to the clutch centre in the same order and orientation as noted for removal: • Anti-judder washer • Anti-judder spring •...
Page 409 4. Assemble the innermost friction and steel plates to the pressure plate in the same order and orientation as noted for removal. 1. Pressure plate 2. Inner friction plates 3. Inner steel plate 5. While holding the innermost friction and steel plates in position, invert the pressure plate and locate it onto the clutch centre.
Page 410 6. Make sure the pressure plate ramps engage correctly with the clutch centre. 1. Pressure plate ramps NOTICE Do not allow the clutch centre and pressure plate to separate at this point as this may cause the innermost steel plate to disengage from the pressure plate splines. 7.
Page 411 NOTICE During the next instruction step, the release plate fixings should be tightened until a small amount of preload is applied to the springs. The amount of preload applied should be sufficient to prevent the clutch centre and pressure plate from separating, while allowing movement/rotation of the friction plates.
Page 412 Clutch - Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. NOTICE To aid installation, the clutch centre and pressure plate assembly should be temporarily fitted to the clutch outer drum while it is removed from the motorcycle.
Page 413 2. Remove the clutch centre and pressure plate assembly from the outer drum assembly. Take care not to disturb the friction plate tabs. 3. Position the clutch outer drum assembly to the input shaft. NOTICE When the bearing sleeve is correctly fitted, it will be a flush fit with the clutch drum face.
Page 414 5. Fit the clutch centre and pressure plate assembly, aligning the friction plate tabs with the clutch drum slots, noting that the outermost friction plate engages in its own (shallow) slot. Align the clutch centre splines with those of the input shaft and slide the assembly fully into position.
Page 415 1. Release plate 2. Chamfer edge 3. Fixing tower 4. Machined face 6. Evenly and progressively tighten the release plate bolts to 10 Nm, ensuring that the springs remain correctly located and that the release plate is correctly seated to the pressure plate fixing towers.
Page 416 9. Tighten the centre nut to 160 Nm. 10. Using a suitable pin punch, stake the nut to the shaft. 11. Fit the lifter piece and bearing carrier, ensuring they are correctly installed in the release plate. 1. Lifter piece 2.
Page 417 13. Fit the crankshaft locking pin plug and tighten to 33 Nm. 1. Locking pin plug Perform the following operations: • Clutch Cover - Installation • Battery - Installation • Seat - Installation...
Page 418 Crankcase, Crankshaft and Connecting Rods Exploded View – Crankcase...
Page 419 Exploded View - Crankshaft and Connection Rod...
Page 420 Lower Crankcase – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: NOTICE Before removing the lower crankcase, make sure that the transmission is in neutral and remains in neutral until the lower crankcase is refitted.
Page 421 1. If fitted, remove service tool T3880501 1. T3880501 - Crankshaft Locking Pin 2. Alignment mark NOTICE Note the orientation of the detent arm spring for installation. 2. Remove the detent arm spring. 1. Springs...
Page 422 3. If fitted, release the three fixings and remove the crankcase left hand protector with the rubber protector. 1. Fixings 2. Protector 3. Rubber protector 4. If fitted, release the fixings and remove the crankcase right hand protector. 1. Fixings 2.
Page 423 NOTICE For the lower crankcase there are, eight M11 x 128 mm, nine M6 x 30 mm, seven M6 x 55 mm and three M6 x 75 mm fixings. Note the position of the fixings for installation. Note the orientation of the crankshaft scraper for installation. 1.
Page 424 NOTICE Note the position of the hardened washers under bolts 20 to 27. 5. Progressively release the lower crankcase fixings in the sequence shown below. Lower Crankcase Release Sequence Do not use levers to separate the upper and lower sections of the crankcase as damage to the crankcases could result.
Page 425 NOTICE Always check that all fixings have been released before attempting to separate the lower crankcase. 6. Remove the crankshaft scraper. 7. Separate the lower crankcase from the upper crankcase noting the position of the three location dowels. Make sure that the crankshaft main bearing shells remain in their original location on the lower crankcase.
Page 426 Lower Crankcase – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 427 4. Make sure that the three locating dowels are in position in the upper crankcase. 1. Dowels 2. Upper crankcase 5. If fitted, remove service tool T3880504 retain the three fixings for the lower crankcase. 1. T3880504 - Oil spray jet protectors 2.
Page 428 Do not use excessive amounts of sealer. The extra sealer may become dislodged and could block the oil passages in the crankcases causing severe engine damage. 6. Apply a 2 mm diameter bead of silicone sealant (at the factory, ThreeBond 1216E is used) to the lower crankcase mating faces.
Page 429 1. Actuator knuckle 2. Actuator shaft 3. Return spring ends 4. Dowel 9. Position the crankshaft scraper as noted for removal. 10. Fit the bolts into the lower crankcase as noted for removal and hand tighten until the bolt heads are near contact with the crankcase. Hardened washers to be fitted to bolts 1 to 8.
Page 430 15. In the sequence shown below, tighten the crankcase bolts 1 to 8 to 85° of bolt rotation using service tool T3880105. T3880105 - Torque Angle Gauge Stage 3 16. Tighten the fixings 9 to 27 in the sequence shown to 12 Nm. Lower Crankcase Tightening Sequence...
Page 431 17. If removed, fit the crankcase right hand protector and tighten its fixings to 12 Nm. 1. Fixings 2. Protector 18. If removed, fit the crankcase left hand protector with the rubber protector and tighten its fixings to 12 Nm. 1.
Page 432 Perform the following operations: • Rear Balancer - Installation • Front Balancer - Installation • Sump – Installation • Engine - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation Transmission Cover – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 433 NOTICE For the transmission cover there are, six M6 x 30 mm, two M6 x 40 mm, one M6 x 75 mm, one M6 x 90 mm, three M8 x 45 mm and one M8 x 65 mm fixings. Note that the M8 x 65 mm fixing has a copper washer for installation. Note the position of the fixings for installation.
Page 434 2. Progressively release the transmission cover bolts in the sequence shown below. Transmission Cover Bolts Release Sequence Do not use levers to separate the upper and lower sections of the crankcase as damage to the crankcases could result. NOTICE Always check that all fixings have been released before attempting to separate transmission cover from the crankcase.
Page 435 4. If the oil dowel and O-ring is in the transmission cover, remove it and fit it to the bearing cap with the O-ring uppermost. 1. Dowels 2. Oil dowel 5. Remove any residual oil and sealant from the mating face of the transmission cover and the upper crankcase using a lint free cloth.
Page 436 1. Use high flash-point solvent to clean the crankcase mating faces. Wipe the surfaces clean with a lint-free cloth. 2. Make sure that the two locating dowels are in position in the upper crankcase and the oil dowel is fitted to the bearing cap with the O- ring uppermost. 1.
Page 437 Sealer Areas 4. Position the transmission cover to the upper crankcase. 5. Fit a new copper washer to the M8 x 65 mm fixing (item1 in the tightening sequence). 6. Fit the bolts into the transmission cover as noted for removal and hand tighten until the bolt heads are near contact with the crankcase.
Page 438 Perform the following operations: • Oil Tank Cover - Installation • Throttle Body - Installation • Engine - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation Crankcase – Disassembly Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 439 Remove the components from the original crankcase as described in the procedure below. Perform the following operations: • Engine - Removal • Clutch - Removal • Alternator Rotor - Removal • Output Shaft - Removal • Input shaft - Removal •...
Page 440 5. Remove the dead shaft clamp blanking plug. Discard the washer. 1. Hollow dowels 2. Solid dowel 3. Washer 4. Plug 6. Remove the three hollow dowels for the upper crankcase. 7. Remove the solid dowel for the clutch cover. 8.
Page 441 Transmission Cover 1. Remove and discard the two fixings securing the transmission oil spray bar. 2. Remove the spray bar from the transmission cover and discard its O-ring. 1. Fixings 2. Oil spray bar 3. O-ring (oil spray bar) 3. Remove the two solid dowels for the oil tank cover. 4.
Page 442 NOTICE Note the orientation of the crankcase breather hose for installation. 5. Release the clamp and remove the crankcase breather hose. Crankcase – Assembly Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 443 1. Fixings 2. Oil spray bar 3. O-ring (oil spray bar) 5. Fit the two original solid dowels for the oil tank cover to the transmission cover. 6. Fit the oil filler tube and tighten its fixing to 10 Nm. 1.
Page 444 Lower Crankcase 3. Fit the three hollow dowels for the upper crankcase. 4. Fit the solid dowel for the clutch cover. 5. Fit the crankshaft locking pin plug to the crankcase. 1. Hollow dowels 2. Solid dowel 3. Locking pin plug 6.
Page 445 1. Dowels 2. Lower crankcase...
Page 446: Installation
8. Fit the oil pump to the lower crankcase (see Oil Pump - Installation). Perform the following operations: • Barrels - Installation • Gear Change Shaft and Selector Drum - Installation • Input Shaft - Installation • Output Shaft - Removal •...
Page 447 • Alternator Rotor - Removal • Lower Crankcase - Removal Due to the weight and size of the crankshaft, the three protectors in service tool T3880504 must fitted to the crankcase to protect the oil spray jets. If service tool T3880504 is not used the oil spray jets may get damaged and require replacing.
Page 448 NOTICE The big end cap will only fit one way, note the orientation of the bearing cap for installation. 2. Mark each big end cap and connecting rod to identify both items as a matched pair and to identify the correct orientation of the bearing cap to the connecting rod. NOTICE It may be necessary to gently tap the big end cap with a rubber mallet to release the cap.
Page 449 NOTICE Between cylinders one and two the crankshaft has two thrust bearings fitted to the upper crankcase. Note their position and orientation for installation. Note the two cut outs on one face of the thrust bearings must face the crankshaft when fitted.
Page 450 Crankshaft – Installation Make sure the three piston cooling jets are installed and are protected by service tool T3880504. If the piston cooling jets are omitted or get damaged, oil pressure will be reduced. Running the engine with low oil pressure will cause severe engine damage. Always check the bearing journal clearance (see Connecting Rod Big End Journal Checking, Measuring and Bearing Selection...
Page 451 2. Lubricate all bearings with a 50/50 solution of engine oil and molybdenum disulphide grease. 3. Make sure that the crankshaft is clean, and that the oil ways within the crankshaft are clean and free from blockages and debris. 4. Fit crankshaft main bearing shells to the upper crankcase. 5.
Page 452 Stage 2 11. Tighten the big end cap fixings to 120° of bolt rotation using service tool T3880105. T3880105 - Torque Angle Gauge Perform the following operations: • Lower Crankcase - Installation • Alternator Rotor - Installation • Engine - Installation •...
Page 453 Connecting Rod – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 454 Connecting Rod – Installation Connecting rod bolts MUST only be used once. If the bolts are removed or undone for any reason, new bolts MUST always be used. Reusing bolts can cause connecting rods and their caps to detach from the crankshaft causing severe engine damage, loss of motorcycle control and an accident.
Page 455 NOTICE Do not turn the connecting rods and crankshaft during the clearance measurement as this will damage the Plastigauge. The crankshaft journal clearances are measured using Plastigauge (Triumph part number 3880150-T0301). 2. Remove the lower crankcase (see Lower Crankcase - Removal).
Page 456 10. Using the gauge provided with the Plastigauge kit, measure the width of the compressed Plastigauge. Checking the Measured Clearance 11. For specifications refer to Crankshaft. 12. If the clearance exceeds the service limit, measure the diameter of the crankshaft bearing journal.
Page 457 1. Select the correct bearing shell as follows: 2. Measure and record the diameter of each crankshaft bearing journal. 3. Measure and record each bearing bore diameter (bearings removed, journal caps fitted and all fixings fully torqued) (for torque sequence see Crankshaft - Installation).
Page 458 NOTICE Do not turn the connecting rods and crankshaft during the clearance measurement as this will damage the Plastigauge. The crankshaft journal clearances are measured using Plastigauge (Triumph part number 3880150-T0301). 2. Remove the lower crankcase (see Lower Crankcase - Removal).
Page 459 9. Using the gauge provided with the Plastigauge kit, measure the width of the compressed Plastigauge. Checking the Measured Clearance 10. For specifications refer to Crankshaft. 11. If the clearance exceeds the service limit, measure the diameter of the crankshaft bearing journal.
Page 460 Main Bearing Selection NOTICE Minor differences in dimensions are compensated for by using selective bearings. For further information on bearing part number to colour cross-references, see the latest parts information. Always confirm, using the Plastigauge method, that the running clearance is correct before final assembly.
Page 461 Main Bearing Selection Chart Crankcase Crankshaft Main Journal Diameter Bore 52,468 52,469 52,47 52,471 52,472 52,473 52,474 52,475 52,476 52,477 52,478 52,479 52,48 52,481 52,482 Diameter Blue Blue 50,510 Blue Blue Blue 50,511 Blue Blue Blue Blue 50,512 Blue Blue Blue Blue Blue...
Page 462 Balancer Exploded View – Balancers...
Page 463 Balancer Introduction Two balancers are fitted to the engine, one in front of the crankshaft and one behind it in the lower crankcase. Both balancers are driven by the crankshaft and the front balancer has an extra gear to drive the oil pump. It is only the rear balancer that can be adjusted.
Page 464 When turning the crankshaft at the front of the engine (clutch cover end) always turn anticlockwise. When turning the crankshaft at the rear of the engine (alternator cover end) always turn clockwise. Turning the crankshaft in the wrong direction may cause the camshaft drive chain to slip on the camshaft sprockets resulting in incorrect camshaft timing.
Page 465 3. At the front of the engine, rotate the crankshaft anticlockwise using the bolt fitted to the end of the crankshaft until the two gear teeth with an alignment mark on each is visible and central in the hole for the crankshaft locking pin. 1.
Page 466 NOTICE The oil pump drive gear is an integral part of the front balancer gear. 5. The two dot alignment marks on the front balancer gear should be aligned with the protruding rib on the crankcase. 1. Front balancer 2. Alignment marks 3.
Page 467 6. Release the fixing and remove the dead shaft keeper plate. Discard the fixing. 1. Fixing 2. Keeper plate 3. Dead shaft NOTICE The keeper plate end of the dead shaft has a M6 thread within it. Use a M6 bolt to assist the removal of the dead shaft.
Page 468 8. Hold the front balancer in position and remove the dead shaft. 1. M6 bolt 2. Dead shaft 9. Carefully raise the front balancer out. While raising the balancer, hold the two washers in their recess. 1. Front balancer 2. Washers 3.
Page 469 Rear Balancer – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. When turning the crankshaft at the front of the engine (clutch cover end) always turn anticlockwise.
Page 470 7. Remove the crankshaft locking pin plug from the crankcase. 1. Locking pin plug 8. At the front of the engine, rotate the crankshaft anticlockwise using the bolt fitted to the end of the crankshaft until the two gear teeth with an alignment mark on each is visible and central in the hole for the crankshaft locking pin.
Page 471 NOTICE The alignment mark on the flange of T3880501 - Crankshaft Locking Pin is in line with the gear tooth at the other end of the service tool. Use this alignment mark as a guide when inserting the service tool. 4.
Page 472 NOTICE Note that the rear balancer have washers that sit in the recess on both side of the gear. 6. Remove the fixing securing the clamp to the crankcase. Discard the fixing. 7. Hold the rear balancer in position and remove the dead shaft and clamp assembly. 4.
Page 473 8. Carefully manoeuvre the rear balancer out. While raising the balancer, hold the two washers in their recess. 1. Rear balancer 2. Washer (one of two shown) 9. Check the condition of the two O-rings on the dead shaft, replace if necessary. 1.
Page 474 Front Balancer – Installation NOTICE When fitting the balancer make sure the word OUT is facing outwards. 1. Make sure the needle bearing is fitted to the balancer and the two washers are in their recess. 1. Front balancer 2. Needle roller bearing 3.
Page 475 3. Align the two dot alignment marks on the balancer to the protruding rib on the crankcase. 1. Front balancer 2. Alignment marks 3. Protruding rib 4. Oil pump drive gear 4. While holding the balancer in position, fit the dead shaft. 5.
Page 476 6. Fit the keeper plate and tighten the new fixing to 10 Nm. 1. Fixing 2. Keeper plate 3. Dead shaft 7. Check that the rear balancer two alignment marks are aligned with the protruding rib on the crankcase. 1. Rear balancer 2.
Page 477 8. Remove service tool T3880501 1. T3880501 - Crankshaft Locking Pin 2. Alignment mark 9. Fit the crankshaft locking pin plug and tighten to 33 Nm. 1. Locking pin plug 10. Refit the spark plugs (see Spark Plugs - Check/Renew).
Page 478 Perform the following operations: • Clutch Cover - Installation • Engine - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation Rear Balancer – Installation 1. Make sure the needle bearing to the balancer and the two washers are their recess on both ends of the balancer.
Page 479 4. While holding the balancer in position, fit the dead shaft and clamp assembly. 5. Fit the clamp new fixing and tighten to 10 Nm. 6. Check that the front balancer two alignment marks are aligned with the protruding rib on the crankcase. 1.
Page 480 7. Remove the dead shaft clamp blanking plug and discard the washer. 1. Blanking plug 2. Washer 8. Loosen the dead shaft pinch bolt a maximum of two complete turns to allow smooth rotation of the balancer dead shaft in the clamp. 9.
Page 481 10. Rotate the dead shaft clockwise to 5 Nm. 11. Rotate the dead shaft anticlockwise 21.5° using service tool T3880105. T3880105 - Torque Angle Gauge 12. Tighten the dead shaft pinch bolt to 7 Nm. 13. Remove service tool T3880501 1.
Page 482 14. Fit the crankshaft locking pin plug and tighten to 33 Nm. 1. Locking pin plug 15. Refit the spark plugs (see Spark Plugs - Check/Renew). Perform the following operations: • Alternator Cover - Installation • Sump - Installation • Engine - Installation •...
Page 483 Rear Balancer Adjustment Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. If the engine has recently been running, the engine oil will be hot to the touch. Contact with the hot oils may cause damage to exposed skin.
Page 484 NOTICE Before dynamically adjusting rear balancer the engine coolant fan must have cycled once and the coolant temperature must be at least 103°C. 1. Start the motorcycle's engine and allow to run to operating temperature. The dead shaft is an eccentric shaft which runs inside the balancer shaft. When rotated the dead shaft therefore closes or opens the gap between the teeth of the balancer gear and the teeth of the crankshaft gear.
Page 485 2. Stop the engine. 3. Remove the dead shaft clamp blanking plug located on the lower crankcase above the side stand. Discard the washer. 1. Blanking plug 2. Side stand 4. Loosen the dead shaft pinch bolt a maximum of two complete turns to allow smooth rotation of the balancer dead shaft in the clamp.
Page 486 4. Remove the face seal plug from the alternator cover. 1. Face seal plug 2. Alternator cover When adjusting the balancer shaft do not allow the gears to whine or rattle for a prolonged period. Allowing the gears to mesh incorrectly for extended periods may cause damage to the gears and or bearings.
Page 487 7. If a whining can be heard, rotate the rear balancer dead shaft anticlockwise until the whining has stopped. 1. Dead shaft 8. Tighten the dead shaft pinch bolt to 7 Nm. 9. Stop the engine. 10. Fit a new washer and tighten the dead shaft clamp blanking plug to 25 Nm. 1.
Page 488 11. Fit the face seal plug to the alternator cover and tighten to 6 Nm. 1. Face seal plug 2. Alternator cover 12. Inspect the engine oil level (see Engine Oil - Level Inspection).
Page 489 Transmission Exploded View - Gear Change Pedal...
Page 490 Exploded View - Gear Selector...
Page 491 Exploded View - Input and Output Shafts...
Page 492 Exploded View - Torsional Damper Torsional Damper – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 493 NOTICE The torsional damper assembly is not to be disassembled. If an item of the torsional damper requires replacing, the complete torsional damper must be replaced. Perform the following operations: • Seat - Removal • Battery - Removal • Fuel Tank - Removal •...
Page 494 Torsional Damper – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 4. Fit the retaining plate Make sure the OUT marking on the retaining plate is facing towards the torsional damper.
Page 495 Perform the following operations: • Output shaft - Installation • Engine - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation Output Shaft – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 496 1. Remove the M22 sealing plug and its O-ring located below the torsional damper housing. 2. Carefully remove the fixing securing the output retaining plate to the upper crankcase. 1. M22 sealing plug 2. Torsional damper housing 3. Fixing NOTICE There could be one or more shims between the bearing cap and the output shaft retaining plate.
Page 497 3. Remove the fixings securing the output shaft retaining plate to the transmission bearing cap. Discard the fixings. 1. Fixings 4. If fitted, remove the shim(s) and retain for installation. NOTICE For the transmission bearing cap there are two M6 x 30 mm and two M8 x 65 mm fixings.
Page 498 5. Progressively release the transmission bearing cap fixings in the sequence shown below. Transmission Bearing Cap Release Sequence 6. Remove the transmission bearing cap. NOTICE Note there is a washer between the output shaft and the upper crankcase for installation. Note the position of the two gear selector forks for installation.
Page 499 8. Remove the torsional damper and the retaining plate from the output shaft. If necessary, use a soft faced mallet to gently tap the torsional damper off the output shaft. 1. Torsional damper 2. Retaining plate 3. Output shaft Output Shaft Bearing Measuring and Shim Selection The shim selection for the output shaft is only required if one of the following conditions are met: •...
Page 500 2. Fit the washer between the output shaft and the upper crankcase as noted for removal. 1. Washer 2. Selector forks 3. Output shaft 3. Make sure the output shaft bearing is flush against its stop in the crankcase. 1. Bearing 2.
Page 501 4. Fit the transmission bearing cap and tighten its fixings. NOTICE There is a raised edge on one side of the transmission cap. Make sure the straight edge is clear of the raised edge. 5. With a straight edge against the bearing face, use feeler gauges to measure the gap between the straight edge and the transmission bearing cap on both sides of the bearing.
Page 502 7. Remove the transmission cap and the output shaft. Shim Chart Shim Shim Thickness (mm) Measured Range 0.30 0.50 to 0.59 0.40 0.60 to 0.69 0.50 0.70 to 0.79 1 + 1 0.60 0.80 to 0.89 1 + 2 0.70 0.90 to 0.99 2 + 2 0.80...
Page 503 1. Assemble the retaining plate and torsional damper to the output shaft as noted for removal. Make sure the OUT marking on the retaining plate is facing towards the torsional damper. Make sure the oil seal is fitted and the there is a snap ring on either side of it.
Page 504 1. Washer 2. Selector forks 3. Output shaft 4. Make sure the snap rings on either side of the damper oil seal are located into the crankcase grooves. 1. Snap rings 2. Oil seals 3. Grooves...
Page 505 5. Fit the transmission bearing cap and tighten the fixings in the following two stages: Stage 1 6. Tighten the fixings 1 to 4 in the sequence shown to 10 Nm. Stage 2 7. Tighten the fixings 1 to 2 in the sequence shown to 32 Nm. 8.
Page 506 10. Secure the output retaining plate to the transmission bearing cap with new fixings and tighten to 16 Nm. 1. Fixings 11. Fit a new fixing to secure the retaining plate to the upper crankcase and tighten to 16 12. Fit the M22 sealing plug and its O-ring to the crankcase and tighten to 40 Nm. 1.
Page 507 Perform the following operations: • Transmission Cover - Installation • Throttle Body - Installation • Engine - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation Input shaft – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 508 NOTICE The input shaft bearing housing fixings may not be reused but should be retained for use during the removal and installation of the input shaft. The bearing housing and retaining plate fixing holes will only align in one position. Note the orientation of the bearing housing and retaining plate for installation.
Page 509 3. While supporting the input shaft, evenly and progressively tighten both bolts to draw the bearing housing and input shaft from the crankcase. 1. Fixings 2. Bearing housing NOTICE There is a needle roller bearing at the back end of the input shaft that may come out with the shaft or remain in the crankcase.
Page 510 4. When the bearing housing is released from the crankcase, carefully pull the input shaft out of the crankcase. Collect the needle roller bearing. 1. Needle roller bearing 2. Input shaft Input Shaft – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 511 1. Make sure the needle roller bearing is fitted to the back of the input shaft. 1. Needle roller bearing 2. Input shaft 2. Carefully fit the input shaft into the crankcase, make sure the back of the input shaft and needle roller bearing align to its recess in the crankcase.
Page 512 5. When the bearing housing is fully fitted to the crankcase, remove and discard the fixings. 6. Fit the retaining plate as noted for removal, make sure the OUT marking on the retaining plate is facing outwards, and tighten the new fixings to 12 Nm. 1.
Page 513 Gear Selector Forks – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 514 1. Spring 2. Fixing 3. Hardened washer 4. Detent arm NOTICE Note the orientation of the retaining plate for installation. 3. Release the fixing and remove the selector fork shaft retaining plate. Discard the fixing. 1. Fixing 2. Retaining plate NOTICE Prior to removal, mark, or make a note of the relative positions and orientation of each selector fork in the selector drum.
Page 515 4. Withdraw the selector fork shaft and noting their position and orientation, collect the three selector forks. 1. Selector fork shaft 2. Selector fork (input shaft) 3. Selector fork (output shaft) 4. Selector fork (output shaft) Selector Forks and Drum Inspection Inspect all bearings for damage or wear.
Page 516 Gear Selector Forks – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. NOTICE Make sure the input shaft is in neutral, as shown in the illustration below.
Page 517 2. Fit the selector fork shaft retaining plate, as noted for removal, and tighten the new fixing to 10 Nm. 1. Fixing 2. Retaining plate 3. Fit the detent arm, the hardened washer and tighten the new fixing to 10 Nm. 4.
Page 518 5. Check to make sure that the selector drum is in the neutral position. Perform the following operations: • Output shaft - Installation • Clutch - Installation • Engine - Installation • Fuel Tank - Installation • Battery - Installation •...
Page 519 NOTICE Note the position and orientation of the gear change knuckle for installation. Note the position of the E-clips and washers for installation. 1. Remove the fixing securing the gear change knuckle to the gear change shaft. Discard the fixing. 2.
Page 520 6. If required, release the fixing and remove the detent wheel from the selector drum. Discard the fixing. 1. Fixing 2. Retaining plate 3. Selector drum 4. Fixing 5. Detent wheel Gear Change Shaft Inspection Inspect the gear change shaft assembly and spring for damage or wear, the springs for overextension (i.e.
Page 521 Gear Change Shaft and Selector Drum – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 522 3. Fit the bearing retaining plate and tighten the new fixing to 10 Nm. 1. Selector drum 2. Retaining plate 3. Fixing 4. Fit the gear change shaft, two washers and the gear change knuckle to the upper crankcase as noted for removal. 5.
Page 523 6. Position the gear change knuckle as noted for removal, fit a new fixing and tighten to 28 Nm. 1. Fixing 2. E-clips 3. Washers 4. Gear change shaft 5. Gear change knuckle Perform the following operations: • Lower Crankcase - Installation •...
Page 524 Gear Change Actuator Shaft – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 525 2. Pull the gear change actuator shaft from the lower crankcase. NOTICE Note the position of the oil seal for installation. 3. Using a suitable tool, carefully remove the oil seal in the lower crankcase without damaging the lower crankcase. 4.
Page 526 1. Press a new actuator shaft oil seal to the lower crankcase as noted for removal, make sure the sealing lip is facing inwards. 2. Lubricate the seal lip with molybdenum disulphide grease and fit the actuator shaft into the lower crankcase as noted for removal. 3.
Page 527 Gear Change Linkage – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. NOTICE Note the orientation of the gear change linkage for installation.
Page 528 2. Remove the wire clip retaining the gear change link to the gear change pedal ball joint and remove the gear change link. 1. Wire clip 2. Gear change link Gear Change Linkage – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 529 1. If the gear change linkage has been disassembled, make sure the length between the two ball joints (not the lock nuts) has been set to 77.9 mm before tightening the lock nuts to 6 Nm. Gear change rod setting dimension 1.
Page 530 3. Fit the gear change link to the gear change knuckle ball joint and secure with the wire clip. 1. Wire clip 2. Gear change link 3. Gear change knuckle...
Page 531 Starter Drive and Sprag Clutch Exploded View - Starter and Sprag Starter Drive/Sprag Clutch – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 532 1. Withdraw the starter drive gear from the sprag clutch. 1. Starter drive gear 2. Sprag housing 3. Alternator rotor 2. Remove and discard the fixings in the sequence shown below. Alternator Rotor Tightening Sequence...
Page 533 3. Withdraw the sprag clutch housing and remove the sprag clutch from the housing. 1. Sprag clutch housing 2. Sprag clutch assembly Starter Drive/Sprag Clutch – Inspection 1. Check the sprag clutch bearings for overheating, wear and/or non-smooth operation. Replace the sprag clutch if overheating, wear and/or non-smooth operation is found. 2.
Page 534 1. Locate the sprag clutch to the sprag clutch housing as shown below. Push firmly until the lip seats in the recess provided in the housing. 1. Sprag clutch housing 2. Sprag clutch assembly 2. Fit the sprag clutch housing to the alternator rotor. 3.
Page 535 5. Once all six bolts have been tightened, go around again in sequence and recheck each bolt is correctly torqued, if any bolt moves, go around again. Repeatedly check the bolts in sequence until all are correctly torqued and do not move when checked, this will ensure the sprag clutch housing is correctly seated on the rotor.
Page 536 Starter Motor Drive Torque Limiter – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 537 Starter Motor Drive Torque Limiter - Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 538 2. Fit the torque limiter assembly to the starter motor drive gear. 1. Torque limiter assembly Perform the following operations: • Starter Motor - Installation • Starter Drive Cover - Installation...
Page 539 Lubrication Exploded View - Oil filter and Pump...
Page 540 Oil Circuit General Description The oil pump fitted to this model has three pumping rotors. Two of the rotors are for the scavenge system and the third is for the pressure system. The oil pressure relief valve is located inside the oil pump. If the oil pressure valve requires replacement, the oil pump and oil pressure valve assembly is to be replaced.
Page 541 Scavenge System The scavenge rotors collect oil from the front and rear of the sump and return it to the oil tank through oil ways within the sump then through a drilling in the lower and upper crankcases up to the oil tank. The oil pump pressure rotor gets its oil supply from the oil tank.
Page 542 Pressure System - Cylinder Head Filtered oil is fed to the rear of the cylinder head from the crankshaft number four main bearing to supply oil to the low oil pressure warning switch and the camshafts. After the oil pressure switch, the oil is divided into two drillings in the cylinder head to supply oil to both camshafts at the number four camshaft cap.
Page 543 Pressure System - Crankshaft and Pistons Filtered oil is fed to the main gallery located in the upper crankcase. Here it is delivered to the crankshaft main bearings and, through drillings in the crankshaft, to the big end bearings. Spray jets located in the upper crankcase, under the barrels, lubricate the pistons and connecting rod small ends.
Page 544 Pressure System - Transmission Oil is fed to the transmission through drilings to the transmission cover. At the transmission cover, oil is fed to the output shaft and its front bearing, spray bar and the transmission bearing cap. From the bearing cap, oil is fed to the input shaft rear bearing, input shaft and the selector fork shaft.
Page 545 Engine Oil – Specification Triumph's high performance fuel injected engines are designed to use 10W/40 or 10W/50 fully or semi synthetic motorcycle engine oil that meets specification API SH (or higher) and JASO MA. Triumph Performance fully synthetic engine oil is recommended.
Page 546 Disposal of Used Engine Oil and Oil Filters To protect the environment, do not pour oil on the ground, down sewers or drains, or into watercourses. Do not place used oil filters in with general waste. If in doubt contact your local authority.
Page 547 3. Remove the oil pump drive dowel. 1. Circlip 2. Hardened washer 3. Oil pump drive gear 4. Dowel 4. Invert the lower crankcase. While supporting the oil pump, remove its fixing and then manouevre the oil pump out of the crankcase. Discard the fixing and the oil pump gasket.
Page 548 5. Note the position of the location dowels for the oil pump. 1. Dowels 2. Lower crankcase 6. Remove the circlip for the oil pump seal in the lower case. Discard the circlip. NOTICE Note the position of the oil seal, just behind groove for circlip, for installation. 7.
Page 549 8. Remove any residual oil and gasket from the mating face of the lower crankcase and the oil pump using a lint free cloth. Oil Pump – Disassembly NOTICE The oil pump assembly consists of two scavenge pump assemblies at the rear and one pressure pump rotor assembly at the front.
Page 550 NOTICE There is a recess in one end of the two scavenge pump rotors and the pressure pump rotor, the recess is to hold a dowel in position on the oil pump drive shaft. 3. Withdraw the rear scavenge pump rotor assembly. Keep the components of the rotor assembly together for assembly.
Page 551 NOTICE Note there is a washer between the front scavenge pump dowel and the scavenge pump housing for installation. 6. Remove the front scavenge pump dowel and the washer from the oil pump drive shaft. 7. Remove the oil pump pressure housing from the oil pump drive shaft. NOTICE Note that the oil pressure outer and inner rotors have a dot mark on one face for identification as they are slightly narrower when compared to the two scavenge rotors.
Page 552 Oil Pump Rotor Tip Clearance NOTICE When measuring the rotor tip clearance, make sure the scavenge rotors are fitted to their housing and the pressure rotors are fitted to their pressure housing. 1. Measure the rotor tip clearance using feeler gauges. 2.
Page 553 Oil Pump Body Clearance NOTICE When measuring the oil pump body clearance, make sure the scavenge rotors are fitted to their housing and the pressure rotors are fitted to their pressure housing. 1. Measure the oil pump body clearance using feeler gauges. 2.
Page 554 NOTICE 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. 8. Apply a thin smear of grease to the outer rotor and a small quantity of silicone release agent to the face of the end plate.
Page 555 13. For specifications refer to Lubrication. 1. Rotor (outer) 2. Plastigauge 3. Gauge, in millimetres 14. If the clearance measured is within the specified tolerance, clean off all traces of Plastigauge from the outer rotor and oil pump cover. 10. If any clearance measured is outside the service limits, renew the complete pump.
Page 556 Oil Pump – Assembly 1. Fit the pressure rotor dowel to the second hole away from the E-clip recess in the oil pump drive shaft. 2. Fit the pressure inner rotor to the drive shaft from E-clip recess end, make sure the recess in the rotor fits over the dowel.
Page 557 5. Fit the washer and the front scavenge pump dowel to the drive shaft as noted for removal. 6. Fit the front scavenge pump inner rotor to the drive shaft, make sure the recess in the rotor fits over the dowel. 7.
Page 558 11. Fit the oil pump front end cap and the three bolts as noted for removal. 12. fit the locknuts and tighten to 5 Nm. 1. Fixings 2. Lock nuts 3. Front end cap Oil Pump – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 559 2. Make sure that the two locating dowels are in position in the lower crankcase. 1. Dowels 2. Lower crankcase 3. Fit a new oil pump gasket to the lower crankcase. 4. Fit the oil pump to the lower crankcase, make sure the oil pump fits onto the two locating dowels.
Page 560 6. Using a suitable tool, carefully fit a new oil seal without damaging the lower crankcase. 7. Secure the oil seal with a new circlip. 1. Circlip 2. Oil seal 3. Lower crankcase 8. Fit the oil pump drive dowel. 9.
Page 561 Perform the following operations: • Lower Crankcase - Installation • Engine - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation Oil Pressure Relief Valve The oil pressure relief valve is located inside the oil pump. If the oil pressure valve requires replacement, the oil pump and oil pressure valve assembly is to be replaced.
Page 562 Low Oil Pressure Warning Light Switch – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 563 Low Oil Pressure Warning Light Switch - Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 564: Engine Remove And Install
Engine Remove and Install Engine – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 565 1. Release the three fixings and remove the lower radiator cowl bracket. 2. Release the fixing and remove the clutch cover finisher. 1. Fixings 2. Clutch cover finisher...
Page 566 3. Release the three fixings and detach the slave cylinder from the clutch cover. Make sure the piston remains in its cylinder. Discard the slave cylinder gasket. 1. Fixings 2. Clutch slave cylinder 4. Retain the piston to the slave cylinder using a retaining tie such as a rubber band or cable tie.
Page 567 5. To drain the fluid from the master cylinder, attach a tube to the rear brake caliper bleed screw, loosen the screw and allow the fluid to drain into a suitable container. Operate the brake pedal until all fluid has been expelled (see Bleeding the Rear Brake).
Page 568 7. Detach the rear brake line from the union block at the front of the sump. 1. Rear brake line 2. Union block 8. Release the fixings and remove the rear brake line front bracket. 1. Fixings 2. Brake line front bracket 3.
Page 569 9. Release the fixing and detach the brake line from the sump. 1. Fixing 2. Brake line 10. Release the fixings and remove the rider right hand control plate from the engine. 1. Fixings 2. Right hand control plate...
Page 570 11. Release the fixings and detach the side stand assembly from the crankcase. 1. Fixings 2. Side stand assembly 12. Release the fixings, detach the side stand switch and remove the side stand assembly. Discard the fixings. 1. Fixings 2. Side stand switch...
Page 571 NOTICE Note the routing of the gear position sensor harness for installation. 13. Release the fixings and detach the gear position sensor from the crankcase. 1. Fixings 2. Gear position sensor 14. Route the gear position sensor to the rear of the engine. NOTICE Note the routing of the alternator and regulator/rectifier harnesses for installation.
Page 572 16. Release the fixings and remove the secondary air injection silencer box. 1. Fixings 2. Secondary air injection silencer box 17. Disconnect the ABS modulator multiplug (see ABS Electrical Connectors). NOTICE Note the routing of the brake line of the rear brake master cylinder for installation.
Page 573 18. Release the brake line union for the rear brake master cylinder at the ABS hydraulic modulator. Discard the sealing washers. 1. Brake line union 2. Brake line (rear master cylinder) 19. Release the fixings and detach the purge valve bracket from the camshaft cover. 1.
Page 574 20. Detach the brake line and its grommet from the purge valve bracket. Remove the brake line. 21. Disconnect the front ABS sensor connector. 22. Detach the hose from the purge valve, remove the purge valve and bracket assembly. 1. Brake line 2.
Page 575 26. Remove the fixing securing the left hand side panel moulding to the frame. 1. Fixing 2. Side panel moulding Make sure the engine and the motorcycle frame are stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 576 30. Remove the lock nut and washer securing the left hand outrigger to the rear of the cylinder head. 1. Bolt 2. Lock nut 3. Washers 4. Left hand outrigger 31. Remove the bolt and washer securing the right hand outrigger to the upper crankcase.
Page 577 33. Remove the bolt, lock nut and washer securing the frame to the left hand side of the crankcase. Discard the lock nut. 34. Remove the lock nut and washer securing the frame to the left hand side of the cylinder head.
Page 578 NOTICE There are six frame adjusters for this model. Four are on the left hand side and two on the right hand side. For the four adjusters on the left hand side and the cylinder head adjuster on the right hand side use T3880181 - Wrench Frame Adjuster.
Page 579 36. Engage service tool T3880181 into the slots of the left hand frame adjusters and rotate anticlockwise to fully loosen the frame adjusters. 37. Engage service tool T3880181 into the slots of the right hand cylinder head frame adjuster and rotate anticlockwise to fully loosen the frame adjuster. 38.
Page 580 41. Using service tool T3880506 remove the outrigger rear dowel. Leave service tool T3880506 in to support the outrigger. 1. Dowel 2. T3880506 - Outrigger dowel removal 42. With the aid of an assistant, remove service tool T3880506 and pivot the outriggers rearwards.
Page 581 46. Fit the support bar of service tool T3880505 to the frame through the swinging arm pivot mounting holes, as shown below. 1. T3880505 - Main frame support 2. Swinging arm mountings 3. Support bar 47. Remove the hoist supporting the rear of the motorcycle and remove the engine. Engine - Installation Make sure the motorcycle is stabilised and adequately supported.
Page 582 3. Using a suitable hoist, support the rear frame and outrigger assembly. 4. With the aid of an assistant, remove service tool T3880505 from the frame. 1. T3880505 - Main frame support 2. Swinging arm mountings 3. Support bar 5. With the aid of an assistant, remove service tool T3880506 and pivot the outriggers rearwards.
Page 583 Stage 1 7. Insert the cylinder head front mounting bolt from the right hand side with a washer between the bolt and the frame. 1. Bolt 2. Washers 8. Using service tool T3880181 tighten the cylinder head front frame adjuster to 3 Nm. 9.
Page 584 11. Insert the crankcase front mounting bolt from the left hand side with a washer between the bolt and the frame. 12. Fit the washer and new lock nut to the crankcase front mounting bolt. Do not fully tighten at this stage. 13.
Page 585 19. Fit the swinging arm spindle from the left hand side. 1. Pivot 2. Swinging arm 20. Fit the swinging arm bolt from the right hand side. Do not fully tighten at this stage. Stage 2 21. Counter hold the swinging arm spindle and tighten the bolt to 100 Nm. 1.
Page 586 22. Counter hold the lock nut and tighten the outrigger rear mounting bolt to 80 Nm. 23. Counter hold the lock nut and tighten the outrigger front mounting bolt to 80 Nm. 1. Rear lock nut 2. Front lock nut 24.
Page 587 26. Using service tool T3880181 tighten the crankcase left hand rear frame adjuster to 3 1. Frame adjuster 27. Fit the crankcase right hand rear mounting bolt with a washer between the bolt and the frame. Do not fully tighten at this stage. 28.
Page 588 30. Insert the cylinder head rear mounting bolt from the right hand side with a washer between the bolt and the outrigger. 31. Using service tool T3880181 tighten the cylinder head left hand rear frame adjuster to 3 Nm. 1. Frame adjuster 32.
Page 589 38. Secure the left hand side panel moulding to the frame, tighten the fixing to 3 Nm. 1. Fixing 2. Side panel moulding 39. Fit the engine oil dipstick. 40. Connect the cooling fan speed controller to the main harness. 41.
Page 590 1. Brake line 2. Grommet 3. Hose 4. Purge valve 5. Purge valve bracket 46. Attach the purge valve bracket to the cylinder head and tighten the fixings to 10 Nm. 1. Fixings 2. Purge valve bracket 47. Incorporating new sealing washers to either side of the union, fit the brake line to the ABS modulator as noted for removal.
Page 591 1. Brake line union 2. Brake line (rear master cylinder) 49. Connect the ABS modulator multiplug (see ABS Electrical Connectors). 50. Route the secondary air injection hoses as noted for removal, fit the silencer box and tighten the fixings to 5 Nm. 1.
Page 592 53. Fit two new O-rings to the gear position sensor. Lubricate the O-rings with a smear of petroleum jelly. 54. it the gear position sensor to the engine. Make sure that the locating pin on the sensor fits into the hole in the end of the gear selector drum. 1.
Page 593 57. Fit the side stand assembly to the crankcase and tighten the fixings to 41 Nm. 1. Fixings 2. Side stand assembly 58. Fit the rider right hand control plate to the engine and tighten the fixings to 25 Nm. 1.
Page 594 59. Attach the rear brake line to the sump and tighten the fixing to 4 Nm. 1. Fixing 2. Brake line 60. Fit the rear brake line front bracket and tighten its fixings as shown in the illustration. 1. Fixings - tighten to 5 Nm 2.
Page 595 61. Attach the rear brake line to the union block at the front of the sump and tighten to 5 Nm. 1. Rear brake line 2. Union block 62. Route the brake line and the coolant expansion tank hose as noted for removal. Fit the brake line two rear brackets and tighten the fixings to 5 Nm.
Page 596 63. Fit a new clutch slave cylinder gasket. 64. If fitted remove the rubber band or cable tie securing the piston to the slave cylinder. 65. Fit the clutch slave cylinder as noted for removal and tighten its fixings to 10 Nm. 66.
Page 597 70. Fit the lower radiator cowl bracket and tighten the clutch cover fixings to 10 Nm. 71. Secure the radiator lower bracket to the lower radiator cowl bracket and tighten the fixing to 5 Nm. 1. Fixings 2. Bracket 72. Attach the rear brake hose P-clip to the swinging arm with a new fir tree clip. 1.
Page 598 Perform the following operations: • Rear Bevel Box - Installation • Rear Suspension Linkage - Installation • Rear Suspension Unit - Installation • Rear Bevel Box - Installation with the final drive shaft. • Catalytic Converter - Installation • Rear Wheel - Installation •...
Page 599 Fuel and Exhaust System and Engine Management Exploded Views Exploded View - Fuel Tank...
Page 600 Exploded View - Fuel Pump...
Page 601 Exploded View – Airbox...
Page 602 Exploded View - Secondary Air Injection...
Page 603 Exploded View - Fuel Rail, Throttles and Injectors...
Page 604 Exploded View - Evaporative System...
Page 605 Exploded View - Engine Management System...
Page 606 Exploded View - Exhaust System Engine Management Fuel Requirements Fuel Requirements - all countries except USA This model must be run on 91 RON or higher unleaded fuel.
Page 607 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 different...
Page 608: Air Temperature
'gasohol', 'ethanol enhanced', or 'contains ethanol. This fuel may be used in Triumph motorcycles. Methanol Fuels containing methanol should not be used in Triumph motorcycles as damage to components in the fuel system can be caused by contact with methanol. MTBE (Methyl Tertiary Butyl Ether) The use of gasolines containing up to 15% MTBE (Methyl Tertiary Butyl Ether) is permitted in Triumph motorcycles.
Page 609: Coolant Temperature
Ambient air pressure Pressure of the air in the airbox. ATDC After Top Dead Centre. BBDC Before Bottom Dead Centre. Bottom Dead Centre. BTDC Before Top Dead Centre (TDC). Battery Voltage The voltage at the input to the Engine Electronic Control Module (ECM). Catalytic converter Device placed in the exhaust system which converts toxic gases and pollutants in exhaust gas into less-toxic pollutants by an oxidation and a reduction reaction.
Page 610 Coolant temperature sensor Sensor which detects coolant temperature. Cooling fan status The ON or OFF condition of the cooling fan. Cooling fan variable speed controller The cooling fan controller controls the cooling fans at various speeds depending on the temperature of the coolant. Cruise control cancel switch (if fitted) A switch located in the twist grip housing, used to cancel the cruise control.
Page 611 Engine speed The crankshaft revolutions per minute. Fall detection (if fitted) The fall detection switch will detect if the motorcycle is on its side and will cut power to the engine ECM immediately. If the fall detection switch is fitted, the inertial measurement unit (IMU) will not be fitted. Freeze-frame A data set captured at the time a Diagnostic Trouble Code (DTC) is set.
Page 612: Ignition Switch Position
Ignition advance The timing of ignition at the spark plug relative to Top Dead Centre. Ignition switch position The ON or OFF position of either or both the ignition switch and the engine stop switch. Ignition timing Same as ignition advance. Immobiliser and Tyre Pressure Monitoring System (TPMS) Control Module The control module for the immobiliser and TPMS system.
Page 613 The percentage above or below the nominal fuel requirement for the volume of air entering at engine speeds other than idle. This function is not currently used in the Triumph system. Open circuit A break in an electrical circuit - current cannot flow.
Page 614 Oxygen sensor The oxygen sensor measures the oxygen levels in the exhaust gases and feeds this information to the engine ECM. Based on this information, adjustments to air/fuel ratio are made. Primary throttle position sensor Sensor for the primary (lower) throttle position. Purge valve duty cycle (if fitted) The time the purge valve is open in an open/close cycle, expressed as a percentage of the cycle time.
Page 615: Throttle Position
Short term fuel trim A correction applied to the fuel mixture during closed loop operation. This, in turn, has an effect on the long term fuel trim in that if an engine constantly requires mixture correction, the long term fuel trim will adapt to this requirement thus reducing the need for constant short term adjustment.
Page 616 Twist grip position sensor The twist grip position sensor is used to relay twist grip position information to the engine ECM. The engine ECM uses this information to drive the throttle actuation motor to the correct position. Transponder A transponder-responder chip located in the ignition key. The transponder is activated by a radio signal sent out by the immobiliser control module, via an antenna located around the ignition switch.
Page 617 adjusted to suit the prevailing conditions. • Manifold Absolute Pressure (MAP) sensor - situated behind the airbox plenum, top right hand side, and is connected to each of the three throttle bodies by equal length tubes. The MAP sensor provides information to the engine ECM which is used at shallow throttle angles (very small throttle openings) to provide accurate engine load indications to the ECM.
Page 618 TFT instruments will show the selected gear. • Triumph Shift Assist (TSA) (if fitted) - situated on the gear change linkage. Triumph Shift Assist adjusts the engine torque to allow gears to engage, without closure of the throttle twist grip or operation of the clutch. This feature works for both up shifts and down shifts of gear.
Page 619 1. Triumph Shift Assist (TSA) (if fitted) 2. Throttle position sensor 3. Clutch switch 4. Side stand switch 5. MAP sensor 6. Intake air temperature sensor 7. Ambient air pressure sensor 8. Gear position sensor 9. Crankshaft position sensor Actuators...
Page 620 • Canister purge valve - situated in front of the cylinder head. The purge valve controls the return of vapour which has been stored in the carbon canister during the period when the engine is switched off. The valve is 'pulsed by the engine ECM to give control over the rate at which the canister is purged.
Page 621 NOTICE In this system, the starter lockout system (clutch switch, neutral switch, side stand switch) all operate through the engine management ECM. Actuator Locations 1. Ignition coils 2. Evaporative canister 3. Canister purge valve 1. Cooling fan speed controller 2. Secondary air injection solenoid 3.
Page 622 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. This stored data can then be recovered using the Triumph diagnostic tool (see System Diagnostics).
Page 623 A previously paired key must be present when pairing a new key. Make sure 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.
Page 624 Diagnostics To fully diagnose the immobiliser system it is necessary to check for fault codes in the keyless ECM using the Triumph diagnostic tool (see System Diagnostics). Further Diagnosis The diagnostic trouble code tables, if used correctly, help to pinpoint a fault in the system once a diagnostic trouble code has been stored (see System Diagnosis - Keyless ECM).
Page 625 Engine Management Adaption NOTICE After the engine management adaption has been reset on this model, the Cruise Control Switch Check Function Test must be performed (see Cruise Control Switch Check). After the adaptions have been reset, DTC 1575 (cruise control disabled until button press sequence completed) will be stored, and the cruise control disabled, until the function test is completed.
Page 626 Terminology Where the term 'status' is used, this indicates how far the present operating parameter is from the stored (baseline) value. The nearer these figures are to zero the better as it indicates the motorcycle has adapted to its current operating conditions. The term 'range' indicates how much (in percentage terms) of the adjustment range has been used to reach the current operating status.
Page 627 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 628 Fault Indications If 'range' figures at 100% are seen, then the adjustment has reached maximum indicating a mechanical fault exists on the motorcycle. This can be due to a number of faults but the most likely causes will be low/high fuel pressure, faulty injectors or air leaks at the throttle bodies or airbox.
Page 629 • Check for a security device that must be released before the connector can be separated, for example barb, hook and eye. When Inspecting a Connector: • Check that the individual pins have not been bent • Check for dampness/dirt/corrosion •...
Page 630 1. Turn the ignition to the OFF position and wait at least 1 minute for the ECM to complete its power down sequence. 2. Detach the engine ECM from its bracket and the frame (see Engine Electronic Control Module (Engine ECM) - Removal).
Page 631: Installation
System Diagnostics The engine management system has an on-board diagnostics feature which allows service technicians to retrieve stored data from the ECM using Triumph diagnostic software. Full details of the Triumph diagnostic software operation and how to interpret the results are given in the Triumph Diagnostic Tool User Guide.
Page 632 The MIL will be immediately extinguished if, after first rectifying the fault, the DTC (diagnostic trouble code) that caused the MIL illumination is erased from the ECM memory using the Triumph diagnostic software.
Page 633 Triumph Diagnostic tool. 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. Rectify the fault and clear the diagnostic trouble codes using the Triumph Diagnostic tool.
Page 634 Engine ECM Connector Pin Numbering The above illustration shows the pin numbering system used in the engine management circuit diagram. The smaller connector's pins are prefixed B and C and the larger connector pins A. Connector C is grey in colour. As viewed on the mating face with the ECM (as per the illustration), pins are numbered from right to left with number one in the top right corner.
Page 635 System Diagnostic Tool Connection 1. To connect the Triumph diagnostic interface to the motorcycle, remove the seat (see Seat - Removal) and release the diagnostic connector from its locating tang. 2. Diagnostic connector 2. Plug the Triumph diagnostic interface directly into the diagnostic connector.
Page 636 The tables indicate which tests are performed by the on-board system and what information can be retrieved by the Triumph diagnostic software. NOTICE Full details of how to operate the software can be found in the Triumph Diagnostic Tool User Guide, which can be downloaded by authorised Triumph dealers from www.triumphonline.net.
Page 637 Current Data The data available under Current Data is: Function Examined Result Reported (Scale) Fuel system status open or closed loop operation Calculated load value Engine coolant temperature °C Short term fuel trim Intake manifold absolute pressure mmHg Engine speed Vehicle speed km/h Ignition timing advance...
Page 638 Sensor Voltages The data available under Sensor Voltages is: Item Checked Result Unit Battery Voltage Volts Voltage from ignition switch to engine ECM Volts Air temperature sensor Voltage Volts Coolant temperature sensor Voltage Volts Atmospheric pressure sensor Voltage Volts Manifold absolute pressure sensor Voltage Volts Throttle position sensor Voltage Volts...
Page 639 Sensor Readings The data available under Sensor Readings is: Item Checked Result Unit Air temperature °C Coolant temperature °C Atmospheric (barometric) pressure mmHg Manifold absolute pressure (one reading per cylinder) mmHg Low fuel light on/off Oxygen sensor 1 short term fuel trim Oxygen sensor heater status on/off Injector Data...
Page 640 Ignition Data The data available under Ignition Data is: Item Checked Result Unit Ignition timing cyl 1 degrees BTDC Ignition timing cyl 2 degrees BTDC Ignition timing cyl 3 degrees BTDC Coil 1 dwell time milliseconds Coil 2 dwell time milliseconds Coil 3 dwell time milliseconds...
Page 641 Inputs The data available under Inputs is: Function Examined Result Unit Starter switch status switch on/off Side stand status up/down Fall detection status normal/over Clutch switch status release/grip Neutral switch gear/neutral Vehicle speed km/h Calculated load Brake switch 1 status on/off Brake switch 2 status on/off...
Page 642 Outputs The data available under Outputs is: Function Examined Result Unit EMS Main relay status relay on/off Fuel pump relay status on/off Starter relay status starter on/off Malfunction indicator light status MIL on/off Cooling fan status fan on/off Purge valve duty cycle Throttle actuator motor internal relay on/off Adaption Status...
Page 643 Operate the cruise control switches as instructed. Observe the relevant switch response and rectify as necessary *If a fault is detected. Adjust Tune Using the Triumph diagnostic software, it is possible to: • Reset the adaptions • Balance the throttle bodies.
Page 644 Freeze Frame Data Freeze frame data is stored at the time a DTC is recorded (confirmed) by the ECM. If multiple DTCs are recorded, the freeze frame data which is stored will relate to the first recorded DTC only. By calling up freeze frame data associated with the first recorded DTC, the technician can check the engine condition at the time the fault occurred.
Page 645 Cruise Control Switch Check The cruise control switch check is required after certain DTCs or defects have been repaired which relate to the ride by wire system or cruise control system, or after the adaptions have been reset. The switch check requires the user to operate the switches in order, following the instructions on screen.
Page 646 Cruise Control Switch Check Function If the engine is running you will be prompted to turn it off before the test will start. If the cruise control is turned on you will be prompted to turn it off before the test will start.
Page 647 Preliminary Steps 1. Make sure the transmission is in neutral. 2. Connect the Triumph diagnostic tool and turn the ignition ON. 3. Make sure the engine stop switch is in the RUN position. 4. Navigate to ENGINE DIAGNOSTICS - Sensor Data - Inputs.
Page 648 To Adapt the Crankshaft Position: Exhaust fumes are poisonous, always operate a motorcycle in the open-air or in an area with adequate ventilation. Do not operate a motorcycle in an enclosed area without adequate ventilation. Operating a motorcycle in an enclosed area without adequate ventilation can cause loss of consciousness and death within a short period of time.
Page 649 NOTICE Upon holding the throttle open, the engine speed will increase and decrease in cycles at approximately one cycle per second. The cycles are repeated until the crankshaft position adaption is complete. Adaption is typically completed after the fourth cycle. You will be prompted to close the throttle when adaption has completed.
Page 650: Troubleshooting
The diagnostic tool Mechanical fault. Investigate potential displayed an instruction to mechanical faults. Contact Crankshaft position signal close the throttle at the Triumph Service. out of range. expected time (after the forth engine revving cycle). Crankshaft trigger wheel out of tolerance.
Page 651 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 652 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Oxygen sensor P0053 heater resistance Oxygen Sensor Heater - bank 1 sensor 1 Manifold absolute pressure sensor Manifold Absolute...
Page 653 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Intake air temperature Intake Air P0112 sensor short Temperature Sensor circuit to ground Engine coolant temperature...
Page 654 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Oxygen sensor open circuit or P0130 short circuit to Oxygen Sensor battery positive - bank 1 sensor 1 Oxygen sensor...
Page 655 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Injector 3-2 circuit P0207 Fuel Injector malfunction Throttle position sensor 2 short Throttle Position P0220 circuit to battery...
Page 656 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Ignition coil 2 P0352 Ignition Coils malfunction Ignition coil 3 P0353 Ignition Coils malfunction...
Page 657 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Engine coolant temperature Engine Coolant sensor signal P050C Temperature Sensor high-too warm Signal High for cold start...
Page 658 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased 5V Sensor Circuit C-reference P06A8 5V Sensor Circuit C voltage out of range 5V Sensor Circuit D-reference...
Page 659 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Gear position sensor short P0914 Gear Position Sensor circuit to ground or open circuit Gear position sensor signal...
Page 660 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Unmatched ABS ABS Modulator ID P1520 Flashing module Incompatible CAN fault - lost communication ABS Modulator P1521...
Page 661 P16B0 adaption Position Adaption incomplete or unsuccessful ECM tamper Engine ECM Tamper P1604 detected - return Detected to Triumph ECM locked by Only if tune ECM locked by the P1605 the tune lock lock is Flashing Calibration Lock function unlocked...
Page 662 CAN fault – lost Instrument communication P1695 Communication with instrument (CAN) panel Shift Force Sensor Shift force sensor P1702 Circuit (Triumph Shift circuit low voltage Assist) Shift force sensor Shift Force Sensor P1703 circuit high Circuit (Triumph Shift voltage Assist) Throttle actuator...
Page 663 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Throttle valve Throttle Valve Drive P2111 drive error (stuck Error open) Throttle valve Throttle Valve Drive...
Page 664 Number of Number of Diagnostic no-fault no-fault Trouble cycles illuminated Pinpoint test page Fault Description cycles Code before when fault number before DTC (DTC) turning off is logged is erased Throttle position sensor 1 Throttle Position P2135 correlation error Sensor with throttle position sensor 2 Twist grip...
Page 665 Further Diagnosis Pinpoint Tests Pin point tests, if used correctly, help to diagnose a fault in the system once a diagnostic trouble code has been stored. Before Starting Pinpoint Tests: 1. Delete the stored DTCs. 2. Switch the ignition OFF and ON. 3.
Page 666 Pinpoint Tests – Fuel Manifold Absolute Pressure (MAP) Sensor NOTICE For Fault Code P0068, carry out the actions as listed in the action column for P0068. Only carry out the Camshaft Timing Check/Adjust if all the previous checks listed for P0068 do not clear the fault code.
Page 667 1 Open Locate and rectify wiring Engine ECM pin C29 to MAP Circuit fault, proceed to test 4 sensor pin 2 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine. Contact Triumph service present...
Page 668 1. MAP Sensor 2. Engine ECM Connector B 3. Engine ECM Connector C...
Page 669 Intake Air Temperature Sensor Fault Possible cause Action Code Intake air temperature sensor open View and note diagnostic software P0110 circuit or short circuit to 5 volt sensor 'freeze-frame' data if available. supply View and note diagnostic software 'sensor' data. Make sure sensor connector is secure.
Page 670 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present Resistance data: If engine is warm, remove the sensor and allow time to cool to ambient temperature prior to test.
Page 671 1. Inlet Air Temperature Sensor 2. Engine ECM Connector A 3. Engine ECM Connector B 4. Engine Subharness (main harness side) 5. Engine Subharness (engine harness side)
Page 672 Coolant Temperature Sensor Fault Possible cause Action Code Engine coolant temperature sensor P011B correlation error with intake air temperature sensor Engine coolant temperature sensor View and note diagnostic software P0115 open circuit or short circuit to 5 Volt freeze frame data if available sensor supply View and note diagnostic software Engine coolant temperature sensor...
Page 673 6 Data below Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present Resistance data: Resistance data under typical conditions: Temperature Resistance Value Warm engine 200 to 400 Ohms Cold engine: 20°C ambient...
Page 674 1. Engine ECM Connector B 2. Coolant Temperature Sensor...
Page 675 Throttle Position Sensor Fault Possible cause Action Code Throttle position sensor 1 short circuit P0120 to battery positive or open circuit Throttle position sensor 1 signal out P0121 of range View and note diagnostic software Throttle position sensor 1 short circuit P0122 freeze frame data if available.
Page 676 Engine ECM pin A26 to Ground Engine ECM pin A38 to Engine ECM pin A20 Engine ECM pin A38 to Ground Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present...
Page 677 1. Throttle Position Sensor 2. Engine ECM Connector A...
Page 678 - Engine ECM pin C22 to Engine Short Locate and rectify wiring ECM pin A08 Circuit fault, proceed to test 5 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine. Check adaption status. Contact Triumph service present...
Page 679 1. Oxygen Sensor 2. Engine Management System Relay 3. Engine ECM Connector A 4. Engine ECM Connector C...
Page 680 Check sensor resistance: - Oxygen sensor pin 3 to 4 Rectify fault, proceed to Faulty test 5 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present...
Page 681 1. Oxygen Sensor 2. Engine Management System Relay 3. Engine ECM Connector A 4. Engine ECM Connector C...
Page 682 -Engine ECM pin C32 EMS relay pin 5 Short Locate and rectify wiring Circuit fault, proceed to test 5 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present...
Page 683 1. Oxygen Sensor 2. Engine Management System Relay 3. Engine ECM Connector A 4. Engine ECM Connector C...
Page 684 Locate and rectify wiring Engine ECM pin A08 to oxygen Circuit fault, proceed to test 4 sensor pin 4 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine. Check adaption status. Contact Triumph service present...
Page 685 1. Oxygen Sensor 2. Engine Management System Relay 3. Engine ECM Connector A 4. Engine ECM Connector C...
Page 686 Fuel Injectors Fault Possible cause Action Code P0201 Injector 1-1 circuit malfunction View and note diagnostic software P0202 Injector 2-1 circuit malfunction 'freeze-frame' data if available. Make P0203 Injector 3-1 circuit malfunction sure relevant injector connector is secure. P0205 Injector 1-2 circuit malfunction Disconnect engine ECM and proceed P0206 Injector 2-2 circuit malfunction to pinpoint test 1:...
Page 687 Test Result Action Check cable for short circuit to ground: P0201 Engine ECM pin C23 to ground Proceed to test 3 P0202 Engine ECM pin C6 to ground P0203 Engine ECM pin C7 to ground P0205 Engine ECM pin B7 to ground Short Locate and rectify wiring P0206...
Page 688 Test Result Action Check cable continuity: For all fault codes, only the individual injector needs to be tested Relevant injector pin 2 to EMS relay pin 5 P0201 Proceed to test 5 Engine ECM pin C23 to injector 1-1 pin 1 P0202 Engine ECM pin C6 to injector 2-1 pin P0203...
Page 689 Action complete - quit test Reconnect harness, clear fault code and Fault run engine to verify fault cleared. still Contact Triumph service present 1. Engine ECM Connector A 2. Engine ECM Connector C 3. Engine ECM Connector B 4. Engine Subharness (main harness side) 5.
Page 690 Engine Misfire Fault Possible cause Action Code Random/Multiple Cylinder Misfire View and note diagnostic software P0300 Detected freeze frame data if available Make sure relevant injector and coil P0301 Cylinder 1 Misfire Detected connectors are secure. Disconnect P0302 Cylinder 2 Misfire Detected Engine ECM and proceed to pinpoint P0303 Cylinder 3 Misfire Detected test 1...
Page 691 Test Result Action Check cable for short circuit to ground integrity for the relevant fault code, P0300 will require all terminals/cables Proceed to test 3 listed to be checked: P0301 Engine ECM pin C23 to ground Engine ECM pin B7 to ground Engine ECM pin B33 to ground P0302 Engine ECM pin C6 to ground...
Page 692 Test Result Action Check cable continuity for the relevant fault code, P0300 will require all terminals/cables listed to be checked: P0301 EMS relay pin 5 to injector 1-1 pin 2 EMS relay pin 5 to injector 1-2 pin 2 Proceed to test 5 EMS relay pin 5 to ignition coil 1 pin 2 Engine ECM pin C23 to injector 1-1 pin 1...
Page 693 Ignition coil pin A-1 to ignition coil to 4.2 Ohms pin B-1 Renew relevant ignition Faulty coil, proceed to test 9 Action complete - quit test Reconnect harness, clear fault code and Fault run engine to verify fault cleared. still Contact Triumph service present...
Page 695 1. Engine Management System Relay 9. Fuel Injector 1-2 2. Engine ECM Connector A 10. Fuel Injector 3-1 3. Engine ECM Connector B 11. Fuel Injector 2-1 4. Engine ECM Connector C 12. Fuel Injector 1-1 5. Engine Subharness (main harness 13.
Page 696 Check crankshaft toothed wheel: Damage to teeth - magnetic debris Clean/renew toothed Faulty contamination wheel, proceed to test 6 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present...
Page 697 1. Crankshaft Position Sensor 2. Engine ECM Connector B Ignition Coils Fault Possible cause Action Code View and note diagnostic software P0351 Ignition coil 1 malfunction 'freeze-frame' data if available. Make sure relevant ignition coil connector is P0352 Ignition coil 2 malfunction secure.
Page 698 Pinpoint Tests Test Result Action Check cable and terminal integrity: Engine ECM pin B33 (fault code Proceed to test 2 P0351) Engine ECM pin B22 (fault code P0352) Engine ECM pin B11 (fault code Rectify fault, proceed to Faulty P0353) test 7 EMS relay pin 5 (all fault codes) Check cable for short circuit:...
Page 699 Ignition coil pin 1 to ignition coil Ohms pin 2 Renew relevant ignition Faulty coil, proceed to test 7 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present...
Page 700 1. Engine ECM Connector A 2. Engine ECM Connector B 3. Ignition Coils 4. Engine Management System Relay...
Page 701 Secondary Air Injection Valve Fault Possible cause Action Code View and note diagnostic tool sensor data. Secondary air injection short circuit to Make sure the SAI valve connector is P0412 ground or open circuit secure. Disconnect engine ECM and proceed to pinpoint test 1: Secondary air injection short circuit to Disconnect engine ECM and SAI valve...
Page 702 7 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present 1. Engine ECM Connector A 2. Engine ECM Connector B 3. Secondary Air Injection Valve...
Page 703 Purge Valve Fault Possible cause Action Code View and note diagnostic software 'sensor' data. Purge valve short circuit to ground or Make sure the purge valve connector P0443 open circuit is secure. Disconnect engine ECM and proceed to pinpoint test 1: Purge valve short circuit to battery Disconnect the purge valve and P0459...
Page 704 Reconnect harness, clear fault code Action complete - quit test and run diagnostic software function Fault still test to visually verify operation of Contact Triumph service present purge valve. 1. Engine ECM Connector A 2. Engine ECM Connector B 3. Secondary Air Injection Valve...
Page 705 Locate and rectify wiring Engine ECM pin B18 to sensor pin 1 Engine ECM pin B23 to sensor pin 2 Circuit fault, proceed to test 5 Action complete - quit test Reconnect harness, clear fault code. Fault still Contact Triumph service present...
Page 706 1. Engine ECM Connector C 2. Fuel pump subharness (main harness end) 3. Fuel pump subharness (subharness end) 4. Fuel pump subharness (at fuel pump mounting plate) 5. Fuel pump harness (inside fuel tank) 6. Fuel pump harness to fuel level sensor fly lead (inside fuel tank) 7.
Page 707 Cruise Control Fault Possible cause Action Code View and note 'freeze-frame' data if available. Twist grip cruise cancel switch circuit Perform throttle position sensor tests, P056C malfunction Throttle Position Sensor, If fault still present, disconnect engine ECM and proceed to pinpoint test 1: View and note 'freeze-frame' data if available.
Page 708 Test Result Action Check cable for short circuit: Disconnect the clutch Engine ECM pin A6 to Engine ECM switch from the switch pin A8 housing subharness see Engine ECM pin A6 to Engine ECM Clutch Switch - Removal, pin A21 proceed to test 4 Engine ECM pin C30 to Engine ECM Disconnect the two...
Page 709 Faulty connector pin 8 Expected result proceed to test 7 • RESET switch released - Open circuit • RESET switch operated - Short circuit Action complete - quit test Reconnect harness, clear fault code. Fault still Contact Triumph service present...
Page 710 1. Left Hand Switch Housing (two pin connector) 2. Engine ECM Connector C 3. Engine ECM Connector A 4. Switch Housing Subharness Connector (main harness side) 5. Switch Housing Subharness Connector (subharness side) 6. Clutch Switch Connector...
Page 711 Engine Coolant Temperature Sensor Signal High Fault Possible cause Action Code View and note 'freeze-frame' data if available. Check for associated DTCs and perform tests as required. Reset DTCs, if fault still present check the following: • Check/clean radiator cooling fins Engine coolant temperature sensor •...
Page 712 Engine Idle Higher than Expected Fault Possible cause Action Code View and note 'freeze-frame' data if available. Check for associated DTCs and perform tests as required. Reset DTCs, if fault still present check the following: Idle control system RPM higher than P0507 expected •...
Page 713 Test Result Action Reconnect harness, clear fault Action complete - quit test code and run engine to verify Fault still Contact Triumph service fault cleared. present 1. Engine Management System Relay 2. Engine ECM Connector A...
Page 714 Engine ECM Internal Error Fault Possible cause Action Code P0606 Engine ECM internal error Contact Triumph service. P1607 Engine ECM ride by wire internal error P1608 5V Sensor Circuit A Fault Possible cause Action Code 5V Sensor Circuit A - reference...
Page 715 5 position sensor connector pin 5 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present 1. Throttle Position Sensor 2. Engine ECM Connector A...
Page 716 Engine ECM pin B24 to twist grip Open Locate and rectify wiring position sensor pin 1 Circuit fault, proceed to test 5 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present...
Page 717 1. Engine ECM Connector B 2. Twist Grip Position Sensor...
Page 718 Locate and rectify fault, Engine ECM pin B13 to twist grip Circuit proceed to test 5 position sensor pin 6 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present...
Page 719 1. Engine ECM Connector B 2. Twist Grip Position Sensor...
Page 720 3 Engine ECM pin B23 to MAP sensor pin 1 Open Locate and rectify fault, Engine ECM pin B18 to Triumph Circuit proceed to test 5 shift assist sensor pin 3 Engine ECM pin B23 to Triumph shift assist sensor pin 2...
Page 721 2. Engine ECM Connector B 3. Ambient Air Pressure Sensor 4. Manifold Absolute Pressure (MAP) Sensor 5. Gear Position Sensor 6. Triumph Shift Assist Subharness (main harness side (If Fitted)) 7. Triumph Shift Assist Subharness (subharness side (If Fitted)) 8. Triumph Shift...
Page 722 Engine ECM pin A06 to left hand switch housing connector C pin 2 Open Locate and rectify fault, Circuit proceed to test 5 Action complete – quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present...
Page 723 1. Left Hand Switch Housing (two pin connector) 2. Engine ECM Connector C 3. Engine ECM Connector A 4. Switch Housing Subharness Connector (main harness side) 5. Switch Housing Subharness Connector (subharness side) 6. Clutch Switch Connector...
Page 724: Neutral Position
Engine ECM pin B30 to sensor pin 1 Circuit fault, proceed to test 5 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine to verify fault cleared. Contact Triumph service present • Reset the neutral position adaption (see Neutral Position Adaption)
Page 725 1. Engine ECM – Connector B 2. Gear position sensor Fuel Pump Relay Fault Possible cause Action Code Check if pump runs briefly when ignition is switched on Fuel pump relay short circuit to Make sure fuel pump relay connector P1231 ground or open circuit is secure...
Page 726 4 to fuel pump relay Circuit fault, proceed to test 5 pin 1 Action complete - quit test Reconnect harness, clear fault code and run diagnostic software function Fault still Contact Triumph service test to verify operation of fuel pump. present...
Page 727 1. Fuel Pump Relay 2. Engine ECM Connector A 3. Switch Housing Subharness (main harness side) 4. Switch Housing Subharness (engine harness side) 5. Right Hand Switch Housing Connector A...
Page 728 Pinpoint Tests Test Result Action Follow the Pair ECM and Immobiliser Action complete - quit test procedure as described in the Triumph Fault still Contact Triumph service Diagnostic Tool user guide present ABS Modulator Communication Fault Possible cause...
Page 729 Ignition Relay Pin 5 to ABS pin 4 Proceed to test 6 Check fuse box fuse 8 integrity. Renew fuse, proceed to test Faulty Action complete - quit test Reconnect harness, clear fault code Fault still and run engine. Contact Triumph service present...
Page 730 1. ABS Modulator 2. Fuse Box 3. Ignition Relay 4. Engine ECM Connector C...
Page 731 Cooling Fan Controller Fault Possible cause Action Code View and note diagnostic software 'sensor' data. Make sure fan relay Cooling fan controller short circuit to P1552 connector is secure. Disconnect ground or open circuit engine ECM and proceed to pinpoint test 1: Cooling fan controller short circuit to Disconnect engine ECM and fan relay...
Page 732 Fan speed controller connector pin 4 to Engine ECU connector pin C13 Action complete - quit test Reconnect harness, clear fault code and Fault run diagnostic software function test to still Contact Triumph service visually verify operation of cooling fan. present...
Page 733 1. Cooling Fan Speed Controller 2. Cooling Fan Speed Controller Connector 3. Cooling Fan Speed Controller Connector (main harness side) 4. Fuse Box Fuse 7 5. Ignition Relay 6. Engine ECM Connector C 7. Cooling Fan 1 8. Cooling Fan 2 9.
Page 734 Engine ECM detects Inertial Measurement Unit (IMU) circuit malfunction Fault Possible cause Action Code View and note 'freeze-frame' data if Engine ECM detects Inertial available. P16A1 Measurement Unit (IMU) circuit Make sure ABS modulator connector malfunction is secure. Proceed to pinpoint test 1: NOTICE For this model, the Inertial Measurement Unit (IMU) circuit is incorporated in the ABS module.
Page 735 Locate and rectify wiring present fault, proceed to test 6 Action complete - quit test Reconnect harness, clear fault code Fault still and run engine. Contact Triumph service present 1. ABS Modulator 2. Fuse Box 3. Ignition Relay 4. Engine ECM Connector C...
Page 736 Inertial Measurement Unit (IMU) Check for associated DTCs P16A0, malfunction P16A1, and P16A2, perform the tests for any DTC present. Reset DTCs, if problem persists contact Triumph service. Closed Throttle Position Adaption Fault Possible cause Action Code View and note 'freeze-frame' data if available.
Page 737 5 Circuit fault, proceed to test 5 Engine ECM pin A26 to throttle position sensor connector pin 3 Action complete - quit test Reconnect harness, clear fault code and Fault run engine. still Contact Triumph service present...
Page 738 1. Engine ECM 2. Engine ECM Connector A 3. Throttle Position Sensor Immobiliser Control Module Communication Fault Possible cause Action Code View and note 'freeze-frame' data if available. CAN fault - Lost communication with P1650 Make sure Keyless module connector Keyless module is secure.
Page 739 Fuse box fuse 1 to keyless module pin Proceed to test 6 Check fuse box fuse 1 integrity Replace Fuse, proceed to Faulty test 6 Action complete - quit test Reconnect harness, clear fault code and Fault run engine. still Contact Triumph service present...
Page 740 1. Engine ECM Connector C 2. Battery 3. Battery subharness 4. Fuse Box 5. Keyless Module EMS Ignition Voltage Input Circuit Fault Possible cause Action Code Disconnect engine ECM and proceed P1659 Ignition power supply malfunction to pinpoint test 1:...
Page 741 Reconnect harness, clear fault code and Action complete - quit test run engine to verify fault cleared. Fault Note that the engine stop switch must be still Contact Triumph service in the RUN position and any alarm fitted present must be disarmed...
Page 742 1. Fuse Box 2. Ignition Relay 3. Switch Housing Subharness (main harness side) 4. Switch Housing Subharness (subharness side) 5. Right Hand Switch Housing (black connector) 6. Engine ECM Connector A 7. Fuel Pump Relay EMS Main Relay Circuit Fault Possible cause Action Code...
Page 743 Action complete - quit test module, or place in a signal-blocking container for longer than 90 seconds. Fault Bring the key into range and check that still Contact Triumph service the EMS main relay operates. Start engine present as final check.
Page 744 1. Fuse box 2. Engine Management System Relay 3. Engine ECM Connector A CAN Communication Fault Possible cause Action Code View and note 'freeze-frame' data if available. View and note 'sensor' data. P1690 CAN Fault Make sure Instrument connector is secure. Disconnect the engine ECM and proceed to pinpoint test 1:...
Page 745 Pinpoint Tests Test Result Action Check cable and terminal integrity: Disconnect and proceed Engine ECM pin C24 to test 2 Engine ECM pin C25 Instrument pin 24 Instrument pin 25 ABS module pin 2 ABS module pin 11 Diagnostic connector pin 6 Rectify fault, proceed to Diagnostic connector pin 14 Faulty...
Page 746 5 - Engine ECM pin C24 to Bluetooth® module pin 4 Engine ECM pin C25 to Bluetooth® module pin 3 Action complete - quit test Reconnect harness, clear fault code and Fault run engine. still Contact Triumph service present Bluetooth is an optional accessory.
Page 747 1. Instruments 2. Engine ECM Connector C 3. Steering Lock Module 4. Bluetooth module Connector 5. Keyless Module 6. Diagnostic Connector 7. ABS Control Module...
Page 748 Engine ECM pin C25 to Instrument pin Open Locate and rectify wiring Engine ECM pin C24 to Instrument pin Circuit fault, proceed to test 5 Action complete - quit test Reconnect harness, clear fault code and Fault run engine. still Contact Triumph service present...
Page 749 1. Intrument 2. Engine ECM Connector C Shift Force Sensor Circuit (Triumph Shift Assist) Fault Possible cause Action Code Shift force sensor short circuit View and note diagnostic tool 'sensor' data to ground or open circuit P1702 Disconnect engine ECM and proceed to...
Page 750 B18 Circuit fault, proceed to test 5 Check cable continuity: Renew shift force sensor, Engine ECM pin B21 to Triumph shift proceed to test 5 assist connector pin 1 Engine ECM pin B23 to Triumph shift Open Locate and rectify wiring...
Page 751 1. Shift Force Sensor 2. Triumph Shift Assist Subharness (main harness side) 3. Triumph Shift Assist Subharness (subharness side) 4. Engine ECM Connector B EEPROM Error Fault Possible cause Action Code View and note 'freeze frame' data if available. P06B8 EEPROM error No tests available - contact Triumph service.
Page 752 If fault is still present contact Triumph Service. Engine ECM Tamper Detected Fault Possible cause Action Code P1604 Engine ECM tamper detected - return to Triumph Contact Triumph service ECM locked by the Calibration Lock Function Fault Possible cause Action...
Page 753 Proceed to test 4 Clear fault code, check for normal Fault still operation. present Action complete - quit test Contact Triumph service Fuel Pump Short Circuit to Ground or Open Circuit Fault Possible cause Action Code View and note diagnostic tool freeze frame data if available.
Page 754 5 Reconnect harness, clear fault code and Action complete - quit test run engine to verify fault Fault still cleared. Contact Triumph service present 1. Fuse Box 2. Fuel Pump 3. Battery 4. Battery Subharness 5. Fuel pump harness (inside fuel tank) 6.
Page 756 Locate and rectify wiring Engine ECM pin B04 to Throttle Circuit fault, proceed to test 4 actuator motor connector pin 1 Action complete - quit test Reconnect harness, clear fault code and Fault run engine. still Contact Triumph service present...
Page 757 1. Throttle Actuator Motor 2. Engine Subharness (subharness side) 3. Engine Subharness (main harness side) 4. Engine ECM Connector B 5. Engine ECM Connector A...
Page 758 Check throttle body for mechanical Throttle actuator control internal P2123 malfunctions. motor relay does not operate Clear fault code and contact Triumph Throttle actuator control internal P2126 service if fault is still present. motor relay operates continually Twist Grip Position 1...
Page 759 Engine ECM pin B28 to sensor pin 4 Circuit fault, proceed to test 5 Engine ECM pin B13 to sensor pin 6 Action complete - quit test Reconnect harness, clear fault code and Fault run engine to verify fault cleared. still Contact Triumph service present...
Page 760 1. Engine ECM Connector B 2. Twist Grip Position Sensor...
Page 761 Locate and rectify wiring Engine ECM pin B25 to sensor pin 2 Circuit fault, proceed to test 5 Action complete - quit test Reconnect harness, clear fault code and Fault run engine to verify fault cleared. still Contact Triumph service present...
Page 762 1. Engine ECM Connector B 2. Twist Grip Position Sensor...
Page 763 Engine ECM pin B27 to sensor pin 3 Engine ECM pin B28 to sensor pin 4 Open Rectify fault, proceed to circuit test 3 Action complete - quit test Reconnect harness, clear fault code and Fault run engine to verify fault cleared. still Contact Triumph service present...
Page 764 1. Engine ECM Connector B 2. Twist Grip Position Sensor...
Page 765 Engine ECM pin A5 to sensor pin 2 Open Locate and rectify wiring Engine ECM pin B18 to sensor pin 3 Circuit fault, proceed to test 4 Action complete - quit test Reconnect harness, clear fault code and Fault run engine. still Contact Triumph service present...
Page 766 1. Engine ECM Connector A 2. Engine ECM Connector B 3. Ambient Air Pressure Sensor...
Page 767 Pinpoint Tests - Immobiliser/TPMS L0001 - Front Wheel Unit Sensor Battery Alert NOTICE All the fault codes for the tyre pressure monitoring system and the immobiliser system can only be viewed in the Chassis section of the Triumph diagnostic software.
Page 768 Replace the front wheel pressure sensor alert following the procedure described in the L0003 Note: This DTC will Triumph diagnostic tool user guide. automatically be generated Record the new sensor's ID number into the if DTC L0007 occurs owner handbook before fitting.
Page 769 Fault Possible cause Action Code If the problem persists: Using the Triumph diagnostic tool, check that Front wheel sensor unit loss the correct ID number for the front wheel of communication error pressure sensor is registered to the Low battery voltage Immobiliser/TPMS control module.
Page 770 Fault Possible cause Action Code If the problem persists: Using the Triumph diagnostic tool, check that Rear wheel sensor unit loss the correct ID number for the front wheel of communication error pressure sensor is registered to the Low battery voltage Immobiliser/TPMS control module.
Page 771 Removal and Installation - Fuel and Air Components Fuel Tank – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 772 Perform the following operations: Seat - Removal • Battery - Removal • Flyscreen - Removal • • Using proprietary professional automotive workshop equipment approved for fuel handling, drain the fuel from the fuel tank. 1. Remove the fuel pump fuse from the fuse box. 1.
Page 773 NOTICE Because fuel stored in the fuel rail will be at 3.5 bar pressure, it is essential that the fuel pressure is reduced before any dismantling of the fuel rail takes place. To reduce pressure, briefly crank the engine with the fuel pump fuse removed. When disconnected, the fuel tank is self-sealing but a small amount of fuel may dribble from the hose.
Page 774 6. Loosen the instruments clamp fixings and tilt the instruments forward. 1. Fixings 2. Instruments clamp 7. Remove the fixing securing the front of the fuel tank to the frame. 1. Fixing...
Page 775 8. Raise the front of the fuel tank 50 - 100 mm and disconnect the fuel tank breather hose from the evaporative cannister. 1. Roll over valve hose 2. Purge valve haose 3. Evaporative canister 9. To release the double check clip, ease the latch away from the connector until the release buttons are exposed.
Page 776 Do not pull on the fuel hose to disconnect the connector from the fuel rail. Pulling on the fuel hose may damage the fuel hose connector. Disconnect from the fuel line by lifting up the fuel hose connector. 10. Press in the release buttons (one either side of the fuel hose connector) to release the locking device.
Page 777 14. Disconnect the electrical connector for the fuel pump. 1. Electrical connector 15. Remove the fixing securing the rear of the fuel tank to the frame. 1. Fixing 16. Remove the fuel tank's rear fixing sleeve and remove the fuel tank. Make sure the fuel tank is lifted over the ignition coils.
Page 778 Fuel Tank – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.
Page 779 1. With the aid of and assistant, lift the fuel tank over the ignition coils and position it onto the motorcycle. Connect the fuel hose to its spigot by gently pushing inwards until the hose engages with a click. 1. Fuel hose 2.
Page 780 3. Secure to the frame with its rear sleeve and fixing only. Do not fully tighten. Make sure the fuel tank is lifted over the ignition coils. 1. Fixing 4. Raise the front of the fuel tank 100 - 150 mm. 5.
Page 781 7. Lower the front of the fuel tank 50 - 100 mm. 8. Connect the roll over and purge valve hoses to the evaporative canister. 1. Roll over valve hose 2. Purge valve haose 3. Evaporative canister 9. Lower the front of the fuel tank and tighten the rear fixing to 8 Nm. 1.
Page 782 10. Fit the fixing securing the front of the fuel tank to the frame and tighten to 8 Nm. 1. Fixing 11. Tilt the instruments clamp to its original position and tighten the clamp fixings to 9 1. Fixings 2. Instruments clamp...
Page 783 12. Fit the headstock harness cover and tighten the fixings to 5 Nm. 1. Fixings 2. Harness cover 13. Fit the fuel pump fuse to the fuse box. 1. Fuel pump fuse location...
Page 784 • Refill the fuel tank with the fuel drained during removal, and check carefully for fuel leaks. • Flyscreen - Installation • Battery - Installation • Seat - Installation Fuel Pressure Checking Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.
Page 785 Always use the correct fuel pressure gauge adapter (adapter 'B' for Explorer models). Use of an incorrect adapter will result in a fuel leak. A fuel leak can result in a fire causing damage to property and injury to persons. 4.
Page 786 NOTICE To release the fuel pressure gauge from the adapter, slide the outer ferrule downwards. This will allow the gauge to spring upwards from the adapter. To insert the gauge to the adapter, push the gauge spigot into the adapter until a click can be heard.
Page 787: Installation
11. When fuel pressure checking is complete, turn the ignition to the OFF position and remove the fuel pump fuse from the fuse box. 1. Fuel pump fuse location NOTICE Because fuel stored in the fuel rail will be at 3.5 bar pressure, it is essential that the fuel pressure is reduced before any dismantling of the fuel rail takes place.
Page 788 Fuel Pump Assembly – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.
Page 789 4. Remove the ring of fixings securing the fuel pump mounting plate to the fuel tank. 1. Fixing 2. Fuel pump mounting plate 5. Detach the pump assembly from the fuel tank. 6. Disconnect the fuel level sensor from the fuel pump assembly harness. 1.
Page 790 Fuel Pump Assembly – Inspection 1. Inspect all hoses for cracks, splits, fraying and other damage. Replace as necessary. 2. Check all hose clamps for cracks and signs of distortion. Replace as necessary. 3. Check the mesh filter for damage and replace if necessary. Fuel Pump Assembly –...
Page 791 2. Connect the fuel level sensor fly lead connector to the fuel pump assembly harness as noted for removal. Make sure the fly lead is routed between the fuel pump harness and the fuel pump bracket. 1. Fuel level sensor fly lead 2.
Page 792 Perform the following operations: Fuel Tank - Installation • • Refill the fuel tank with the fuel drained during removal, and check carefully for fuel leaks. Battery - Installation • Seat - Installation • Fuel Pressure Regulator – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 793 3. Release the hose clamp and detach the hose from the fuel pressure regulator. 1. Clamp 2. Hose 2. Remove and discard the circlip securing the fuel pressure regulator in its housing. 1. Circlip 2. Fuel pressure regulator...
Page 794 3. Remove the fuel pressure regulator from the fuel pump plate. Discard the large O- ring from the fuel pressure regulator and the small 0- ring in the pressure regulator housing. 1. Large O-ting 2. Fuel pressure regulator 3. Small O-ring Fuel Pressure Regulator –...
Page 795 Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers. A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly. 1.
Page 796 4. Secure the fuel pressure regulator with a new circlip. 1. Circlip 2. Fuel pressure regulator 5. Refit the hose and secure with the hose clip. Check for any fuel leaks and rectify if necessary. 1. Clamp 2. Hose...
Page 797 Fuel Pump – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.
Page 798 NOTICE Note the orientation of the baffle housing for installation. It is not necessary to disconnect the baffle housing hose from the fuel pressure regulator unless it is to be removed at the same time as the fuel pump. 3. Release the hose clamp securing the baffle housing to the fuel pump. 4.
Page 799 Fuel Pump – Inspection 1. Inspect all hoses for cracks, splits, fraying and other damage. Replace as necessary. 2. Check all hose clamps for cracks and signs of distortion. Replace as necessary. 3. Check the mesh filter for damage and replace if necessary. Fuel Pump –...
Page 800 3. Reconnect the fuel pump electrical connector. 1. Hose clip 2. Electrical connector 4. Fit the fuel pump strap, ground cable as noted for removal, secure with a new fixing and tighten to 4 Nm. 5. Position the baffle housing hose clip loosely over the fuel pump body. 6.
Page 801 Fuel Delivery System Fuel is delivered to the injectors by a fuel pump. The fuel pump is a part of the pump assembly located on the underside of the fuel tank. The fuel pump assembly consists of the following components: •...
Page 802 Fuel Level Sensor – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.
Page 803 Fuel Level Sensor – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers.
Page 804 Plenum - Removal (All Markets Except US) Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 805 NOTICE Note that the crankcase breather pipe is attached to rear of the plenum base near the lower right hand corner. The air temperature sensor is also attached to the rear of the plenum base on the right hand side. 2.
Page 806 1. Connect the crankcase breather pipe and the air temperature sensor electrical connector to the plenum base. 2. Position the plenum base on to the throttle bodies. 3. Fit the four fixings and tighten to 8 Nm. 1. Fixings 2. Plenum base 3.
Page 807 Stage 2 7. Tighten the fixings one to ten in the sequence shown to 8 Nm. Plenum Cover Tightening Sequence Perform the following operations: • Fit the air intake runner Air Filter - Renew • Left hand Side Panels - Installation Fuel Tank - Installation •...
Page 808 Perform the following operations: Seat - Removal • Battery - Removal • Fuel Tank - Removal • • Left hand Side Panels - Removal Manifold Absolute Pressure (MAP) Sensor - Removal • • Remove the air intake runner Air Filter - Renew 1.
Page 809 2. Release the four fixings and detach the plenum base from the throttle bodies. 3. Disconnect the ignition master switch from the main harness. 1. Ignition master switch 2. Connector 4. Disconnect the crankcase breather pipe, the air temperature sensor electrical connector and remove the plenum base.
Page 810 Plenum - Installation (US Markets Only) Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1.
Page 811 4. Fit the four fixings and tighten to 8 Nm. 1. Fixings 2. Plenum base 3. Crankcase breather pipe 4. Air temperature sensor 5. Fit a new seal to the plenum base. 6. Fit the plenum cover to the base and tighten the plenum cover fixings in the following two stages: Stage 1 7.
Page 812 Stage 2 8. Tighten the fixings one to ten in the sequence shown to 8 Nm. Plenum Cover Tightening Sequence Perform the following operations: • Fit the air intake runner Air Filter - Renew • Left hand Side Panels - Installation •...
Page 813 Perform the following operations: Seat - Removal • Battery - Removal • Fuel Tank - Removal • Plenum - Removal (All Markets Except US) Plenum - Removal (US Markets • Only) NOTICE The fuel rail and injectors are removed from the cylinder head together. 1.
Page 814 NOTICE The fuel injectors are not to be removed from the fuel rail unless they are to be replaced. If the injectors require replacing continue from step 4. Note the position of the retaining clip for installation. 4. Carefully remove the retaining clips securing the fuel injectors to the fuel rail. 5.
Page 815 Fuel Injectors and Fuel Rail – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 816 3. Remove and discard the O-ring on the fuel injector. 4. Fit a new O-ring using finger pressure only. 5. Lightly lubricate the O-ring on the injectors and fit the injector/fuel rail assembly to the cylinder head, orientating each injector such that the electrical connection is facing upwards.
Page 817 Throttle Body – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: Seat - Removal •...
Page 818 To prevent damage to the manifold absolute pressure (MAP) sensor and purge valve hoses, care must be taken when removing and fitting the throttle bodies. NOTICE Note the orientation of the throttle body retaining clamps for installation. 3. Release the clamps and detach the throttle bodies from the transition piece. 1.
Page 819 4. Detach the purge valve hose and remove the throttle bodies. 1. Purge valve hose (yellow) 2. MAP sensor hose (green) 3. Throttle body 5. If required, release the fixings and remove the transition piece. 1. Fixings 2. Transition piece...
Page 820 Throttle Body – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. If removed, fit the transition piece and tighten the fixings to 9 Nm. 1.
Page 821 3. Attach the purge valve to the throttle bodies as noted for removal. 1. Purge valve hose (yellow) 2. MAP sensor hose (green) 3. Throttle body 4. Make sure the throttle bodies clamps are in the same orientation as noted for removal on the transition piece.
Page 822 1. Clips 2. Throttle body 6. Connect the throttle actuator motor multiplug. 7. Connect the throttle position sensor multiplug. 1. Throttle actuator multiplug 2. Throttle position sensor multiplug...
Page 823 Perform the following operations: Fuel Injectors and Fuel Rail - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation • Secondary Air Injection Solenoid – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 824 2. Detach the solenoid from the evaporative canister bracket. 3. Using service tool T3880207 release the clamp and detach the secondary air injection hose from the solenoid. 4. Disconnect the electrical connector and remove the secondary air injection solenoid. 1. Purge valve 2.
Page 825 1. Connect the electrical connector to the secondary air injection solenoid. 1. Purge valve 2. Evaporative canister bracket 3. Clamp 4. Electrical connector 2. Connect the secondary air injection hose to the solenoid and secure with its clamp. 3. Attach the solenoid to the evaporative canister bracket. 4.
Page 826 Perform the following operations: Evaporative Canister - Installation • Fuel Tank - Installation • Battery - Installation • Seat - Installation • Removal and Installation - Engine Management Components Engine Electronic Control Module (Engine ECM) – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 827 2. Manoeuvre the engine ECM rearwards and upward to access the last two electrical connectors. NOTICE Three connectors of two different size and colour are used for the engine ECM. Two connectors have 33 pins and one connector is coloured black and the other grey. One connector has 39 pins and is coloured black.
Page 828 Engine Electronic Control Module (Engine ECM) – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 829 3. Fit the engine ECM bracket and tighten its fixing to 9 Nm. 1. Fixing 2. Bracket 3. Engine ECM Perform the following operations: • Flyscreen - Installation • Battery - Installation • Seat - Installation Heated Twist Grip – Removal Make sure the motorcycle is stabilised and adequately supported.
Page 830 Perform the following operations: Seat - Removal • Battery - Removal • Mirrors - Removal • NOTICE The anti-tamper fixings on the twist grip housing must not be loosened or removed. If the anti-tamper fixings have been loosened or removed any warranty claims for the twist grip housing will not be honoured.
Page 831 2. Slide the heated twist grip off the handlebar while carefully feeding the heated grip subharness out of the handlebar. 3. Disconnect the electrical connector and remove the heated twist grip. 1. Electrical connector 2. Heated twist grip Heated Twist Grip – Installation Make sure the motorcycle is stabilised and adequately supported.
Page 832 2. Connect the electrical connector of the heated twist grip to the subharness. 1. Electrical connector 2. Heated twist grip 3. Fit the heated twist grip while carefully feeding the subharness into the handlebar. 4. Align the twist grip to the twist grip position sensor as noted for removal. 5.
Page 833 6. Fit and fixings and tighten, upper one first, to 2.5 Nm. Perform the following operations: Mirrors - Installation • Battery - Installation • Seat - Installation • Move the handlebars to left and right full lock while checking that the brake hose, clutch hose and electrical harnesses do not bind or that the steering feels tight or difficult to turn.
Page 834 1. Release the two fixings and remove the headstock harness cover. 1. Fixings 2. Harness cover NOTICE Note the routing of the twist grip position sensor harness for installation. 2. Disconnect the twist grip position sensor from the main harness at the front subframe and route to the handlebar.
Page 835 NOTICE Three locating lugs hold the plastic grommet in position. 3. Press in the sides of the plastic grommet to release two of the locating lugs and remove the grommet. 1. Plastic grommet (harness removed for clarity) 2. Locating lugs (two of three shown) NOTICE Note the routing of the twist grip position sensor harness through the handlebar for installation.
Page 836 Twist Grip Position Sensor – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1.
Page 837 3. Fit the headstock harness cover and tighten the fixings to 5 Nm. 1. Fixings 2. Harness cover 4. Fit the plastic grommet to the handlebar. 1. Plastic grommet (harness removed for clarity) 2. Locating lugs (two of three shown)
Page 838 Perform the following operations: Heated Twist Grip - Installation • Flyscreen - Installation • Battery - Installation • Seat - Installation • Throttle Position Sensor The fixings for the throttle position sensor must not be loosened or removed. If the throttle position sensor fixings have been loosened or removed, the throttle body assembly must be replaced as there are no means to reset throttle position sensor to its correct position.
Page 839: Throttle Body
Throttle Actuator Motor The fixings for the throttle actuator motor and the butterfly hard stop adjustment screws are marked with yellow paint and must not be loosened or removed. If the fixings or adjustment screws have been loosened or removed the throttle body assembly must be replaced as there are no means to reset the throttle actuator motor to its correct position.
Page 840 NOTICE 1. The ignition coil harnesses are identified by coloured tape as follows: White - Number one cylinder Red - Number two cylinder Blue - Number three cylinder 2. Note the routing and position of the six wires connected to the ignition coils for installation.
Page 841 4. If required, detach the electrical connector and brake line clamp from the ignition coils bracket. Discard the fixing. 5. Remove and discard the fixings on the right hand side of the ignition coils bracket. 1. Electrical connector 2. Fixing (brake in clamp) 3.
Page 842 Ignition Coils – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Fit the ignition coils bracket to the motorcycle frame. Fit a new fixing on the left hand side and tighten to 9 Nm.
Page 843 4. Attach the brake line clamp to the ignition coils bracket and tighten its new fixing to 5 Nm. 1. Electrical connector 2. Fixing (brake in clamp) 3. Fixing (bracket) 5. Route the high tension cables as noted for removal and connect them to the spark plugs.
Page 844 7. Connect the six wires to the ignition coils as noted for removal. 1. Ignition coil connections (Number one cylinder) 2. Ignition coil connections (Number two cylinder) 3. Ignition coil connections (Number three cylinder) 4. Fixings Perform the following operations: Evaporative Canister - Installation •...
Page 845 Perform the following operations: • Seat - Removal • Battery - Removal • Radiator - Removal NOTICE The coolant temperature sensor is located in front of the cylinder head. Note the routing of the coolant temperature harness for installation. 1. Press the wire locking device fully in and detach the coolant temperature sensor from the main harness.
Page 846 Coolant Temperature Sensor – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Fit a new sealing washer to the coolant temperature sensor and fit to the cylinder head.
Page 847 Manifold Absolute Pressure (MAP) Sensor – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 848 Manifold Absolute Pressure (MAP) Sensor – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 849 Ambient Air Pressure Sensor – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 850 3. Release the fixing and remove the ambient air temperature sensor. 1. Connector 2. Fixing 3. Ambient air temperature sensor 4. Bracket Ambient Air Pressure Sensor – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 851 2. Connect the electrical connector. 1. Connector 2. Fixing 3. Ambient air temperature sensor 4. Bracket 3. Fit the engine ECM bracket and tighten its fixing to 9 Nm. 1. Fixing 2. Bracket 3. Engine ECM...
Page 852 Perform the following operations: • Battery - Installation • Seat - Installation Intake Air Temperature Sensor – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 853 Intake Air Temperature Sensor – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1.
Page 854 Ambient Air Temperature Sensor – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: Seat - Removal •...
Page 855 3. Release the fixings and detach the flyscreen mounting from the front subframe. 1. Twist grip position sensor connector 2. Handlebar sub harness connectors 3. Low frequency antenna fixings 4. Low frequency antenna 5. Flyscreen mounting fixings NOTICE Note the routing of the hose connected to the temperature sensor for installation.
Page 856 4. Release the fixing, disconnect the electrical connector and remove the temperature sensor and hose assembly. 1. Fixing 2. Electrical connector 3. Hose 4. Temperature sensor 5. If required, remove the hose from the temperature sensor. Ambient Air Temperature Sensor – Installation Make sure the motorcycle is stabilised and adequately supported.
Page 857 2. Connect the electrical connector and position the temperature sensor with the hose routed as for removal. Fit and tighten the fixing to 3 Nm. 1. Fixing 2. Electrical connector 3. Hose 4. Temperature sensor 3. With harnesses as noted for removal, fit the fit the flyscreen mounting to the front subframe and tighten the fixings to 5 Nm.
Page 858 5. Fit the low frequency antenna to the flyscreen mounting and tighten the fixings to 3 1. Twist grip position sensor connector 2. Handlebar sub harness connectors 3. Low frequency antenna fixings 4. Low frequency antenna 5. Flyscreen mounting fixings Perform the following operations: Flyscreen - Installation •...
Page 859 Gear Position Sensor – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: Seat - Removal •...
Page 860 2. Disconnect the gear position sensor electrical connector from the main harness. 1. Gear position sensor connector 2. Oxygen sensor connector NOTICE Note the routing of the gear position sensor harness for installation. 3. Route the gear position sensor harness through the frame to the gear position sensor.
Page 861 5. Remove and discard the two O-rings from the gear position sensor. Gear Position Sensor – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 862 7. Tighten the M6 x 42 mm fixings to 7 Nm. 1. Fixings M6 x 20mm 2. Fixing M6 x 42mm 3. Starter motor cover Perform the following operations: • Battery Box - Installation • Right hand Side Panels - Installation •...
Page 863 Keyless ECM – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 864 3. While lifting up the starter motor relay bracket, detach the relays and starter motor solenoid from it. 1. Starter motor solenoid bracket 2. Relays 3. Starter motor solenoid 4. Disconnect the engine ECM connectors (see Engine Electronic Control Module (Engine ECM) - Removal).
Page 865 5. Release the fixings, remove the relay bracket and detach the keyless ECM from the battery box. Manoeuvre the keyless ECM upwards to allow extra harness into the engine area. 1. Fixings 2. Relay bracket 3. Keyless ECM 6. Detach the keyless ECM connector from its bracket and disconnect from the main harness.
Page 866 Keyless ECM – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Position the keyless ECM into the battery box and feed its harness to the top of the engine area, as noted for removal.
Page 867 4. Fit the relay bracket to the keyless ECM and tighten the fixings to 3 Nm. 1. Fixings 2. Relay bracket 3. Keyless ECM 5. Connect the engine ECM connectors (see Engine Electronic Control Module (Engine ECM) - Installation). 6. Fit the relays and starter motor solenoid to the starter motor relay bracket as noted for removal.
Page 868 7. Fit the starter motor solenoid bracket to the relay bracket and secure with the push release plastic rivet. 8. Fit the relay cover 1. Relay cover 2. Starter motor solenoid bracket 3. Push release plastic rivet Perform the following operations: •...
Page 869 Crankshaft Position Sensor – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. NOTICE If the crankshaft position sensor needs to be replaced, the alternator stator will also be replaced as they are one assembly.
Page 870 2. Remove and discard the fixings securing the stator to the alternator cover and remove the stator. 1. Fixings (position sensor and harness guide) 2. Position sensor 3. Harness guide 4. Fixings (alternator stator) 5. Alternator stator Crankshaft Position Sensor – Installation Make sure the motorcycle is stabilised and adequately supported.
Page 871 2. Fit crankshaft position sensor and the harness guide to the alternator cover as noted for removal. Secure with new fixings and tighten to 6 Nm. 1. Fixings (position sensor and harness guide) 2. Position sensor 3. Harness guide 4. Fixings (alternator stator) 5.
Page 872 Removal and Installation - Exhaust System Components Catalytic Converter – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 873 2. Move the cover forward to detach it from its locating lug and remove the cover. 1. Fixing 2. Shouldered washer 3. Cover 4. Locating lug NOTICE Count the number of turns to detach the oxygen sensor from the catalytic converter for installation.
Page 874 4. Release the clamp securing the catalytic converter to the hand header. 1. Clamp 2. Catalytic converter 3. Header pipe NOTICE Note the position of the shouldered washers and rubber bushes in the catalytic converter mountings for installation.
Page 875 5. From the left hand side, remove the centre fixing securing the catalytic converter to the left hand drag link bracket. Discard the captive nut. 1. Fixing 2. Catalytic converter bracket 3. Drag link bracket 6. Release the fixing securing the catalytic converter to the side stand bracket. Discard the lock nut.
Page 876 7. While supporting the catalytic converter release the fixing on the right hand side and remove the catalytic converter. Discard the lock nut. 1. Fixing 2. Lock nut 3. Catalytic converter bracket 8. Remove and discard the exhaust gasket from the header pipe. Catalytic Converter –...
Page 877 4. Position the catalytic converter clamp onto the header pipe. 5. Fit the catalytic converter to the header pipe and position to its mountings on the motorcycle. Fit the fixing and a new lock nut to the right hand mounting. Do not fully tighten at this stage.
Page 878 7. From the left hand side, fit the centre fixing securing the catalytic converter to the left hand drag link bracket. Do not fully tighten at this stage. 1. Fixing 2. Catalytic converter bracket 3. Drag link bracket 8. Fit the catalytic converter to the header pipe. Fit the clamp as noted for removal and tighten to 11 Nm.
Page 879 9. Tighten the catalytic converter centre fixing to 28 Nm 10. Hold the lock nut and tighten the catalytic converter left hand fixing to 28 Nm 11. Hold the lock nut and tighten the catalytic converter right hand fixing to 28 Nm 12.
Page 880 15. Fit the shouldered washer and tighten the fixing to 5 Nm. 1. Fixing 2. Shouldered washer 3. Cover 4. Locating lug Exhaust Headers – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 881 1. Remove the fixing and shouldered washer from the catalytic converter right hand cover. 2. Move the cover forward to detach it from its locating lug and remove the cover. 1. Fixing 2. Shouldered washer 3. Cover 4. Locating lug 3.
Page 882 4. Remove and discard the exhaust gasket from the header pipe. NOTICE It is not necessary to remove the heat shields to remove the exhaust headers. 5. If required, release the fixings and remove the three heat shields from the exhaust header.
Page 883 NOTICE Note the orientation of the three header gaskets for installation. 7. Remove and discard the three gaskets from the cylinder head. Exhaust Headers - Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 884 4. Fit the catalytic converter to the header pipe. Fit the clamp as noted for removal but do not fully tighten at this stage. 1. Clamp 2. Catalytic converter 3. Header pipe 5. Tighten the header pipe fixings in the following two stages: Stage 1 6.
Page 885 Stage 2 7. Retighten fixings one to three to 22 Nm. Exhaust Header Tightening Sequence (new illus required) 8. With the catalytic converter clamp in the position noted for removal, tighten it to 11 1. Clamp 2. Catalytic converter 3. Header pipe...
Page 886 9. Fit the catalytic converter right hand cover to its locating lug. 10. Fit the shouldered washer and tighten the fixing to 5 Nm. 1. Fixing 2. Shouldered washer 3. Cover 4. Locating lug 11. If removed, fit the three heat shields and tighten the new fixings to 5 Nm. 1.
Page 887 Evaporative System Components Evaporative Loss Control System This model is fitted with a system to control the evaporation of fuel vapour to the atmosphere. A carbon filled evaporative canister absorbs vapour while the engine is not running. When the engine is started, the vapour is returned to the engine and burnt. There are two distinct phases to the system's operation;...
Page 888 Evaporative Control System - Engine Off When the engine is stationary, any pressure increase in the fuel tank due to a rise in ambient temperature will cause the fuel vapour to pass down via breather pipe A to a carbon filled evaporative canister which stores the vapour. Once in the canister, vapour cannot enter the engine because the purge valve is closed.
Page 889 Evaporative Control System - Engine Running When the engine is started, a vacuum is applied to the purge hose from the throttle bodies. At certain times, the engine ECM opens the purge valve. The vacuum applied to the purge valve now begins to draw stored vapour from the carbon filled evaporative canister to the throttle bodies for burning in the engine.
Page 890 Evaporative Canister – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. NOTICE Note the routing and locations of the hoses connected to the evaporative canister for installation.
Page 891 2. Detach the purge valve hose from the evaporative canister. 3. Detach the brake line P-clip from the evaporative cannister bracket. NOTICE Not the position of the evaporative canister bracket to the fuel tank mounting for installation. 4. Release the lock nuts and detach the fuel tank mounting from the frame. Discard the lock nuts.
Page 892 6. Detach the evaporative canister from its rubber grommets to remove the canister. 1. Grommets 2. Bracket Evaporative Canister – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 893 1. Attach the evaporative canister to its rubber grommets on the ignition coil bracket. 1. Grommets 2. Bracket 2. Attach the evaporative canister bracket to the evaporative canister. Do not fully tighten the fixings at this stage. 3. Fit the evaporative canister bracket to the fuel tank mounting and tighten the new lock nuts to 22 Nm.
Page 894 6. Attach the purge valve hose to the evaporative canister as noted for removal. 1. Purge valve hose 2. Fixing (brake line) 3. Fixings (evaporative canister) 4. Lock nuts 5. Bracket 7. Attach the vent hose to the evaporative cannister as noted for removal. 1.
Page 895 Perform the following operations: • Fuel Tank - Installation • Battery - Installation • Seat - Installation Purge Control Valve – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 896 2. Detach the purge valve from the evaporative canister bracket. 3. Using service tool T3880207 release the clamp and detach the secondary air injection hose from the purge valve. 4. Disconnect the electrical connector and remove the purge valve. 1. Purge valve 2.
Page 897 1. Connect the electrical connector to the purge valve. 1. Purge valve 2. Evaporative canister bracket 3. Clamp 4. Electrical connector 2. Connect the secondary air injection hose to the purge valve and secure with its clamp. 3. Attach the purge valve to the evaporative canister bracket.
Page 898 4. Connect the secondary air injection silencer hose to the purge valve and secure with its clamp. 1. Camp 2. Silencer hose Perform the following operations: • Fuel Tank - Installation • Battery - Installation • Seat - Installation...
Page 899 Cooling Exploded View - Radiator Cowl and Coolant Expansion Tank...
Page 900 Exploded View – Radiator Radiator Hoses Check the radiator hoses for cracks or deterioration, and hose clamps for tightness in accordance with scheduled maintenance requirements.
Page 901 Radiator and Cooling Fan Inspection Radiator Using high pressure water, such as from a pressure-washer, can damage the radiator fins and impair the radiator's efficiency. Do not obstruct or deflect airflow through the radiator by installing unauthorised accessories in front of the radiator or behind the cooling fan. Interference with the radiator airflow can lead to overheating and consequent engine damage.
Page 902 From VIN AG0784 the coolant was changed from Triumph HD4X Hybrid OAT coolant to Triumph D2053 OAT coolant. If the Triumph HD4X Hybrid OAT coolant is drained the cooling system must be flushed through prior to filling the cooling system with the Triumph D2053 OAT coolant.
Page 903 Reduced cooling system efficiency may cause the engine to overheat and suffer severe damage. NOTICE 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.
Page 904 Coolant Replacement – Drainage Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Do not remove the expansion tank or coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the cooling system will be hot and may also be under pressure.
Page 905 2. Position a container below the engine and radiator to collect the displaced coolant. 3. Turn the radiator cap cover anticlockwise and remove. 4. Release the fixing and remove the coolant pressure cap. 1. Cover 2. Fixing 3. Coolant pressure cap 5.
Page 906 Coolant Replacement – Filling Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Fit a new sealing washer to the drain plug. Fit the drain plug and tighten to 8 Nm. 1.
Page 907 3. Refit the coolant pressure cap. 4. Start the motorcycle and allow the engine to idle. Briefly raise the engine speed several times to allow any air to be expelled from the system. 5. Stop the engine and allow it to cool. 6.
Page 908 10. Fit the radiator lower surround to its bracket and tighten the fixings to 4 Nm. 1. Fixings 2. Bracket 3. Radiator lower surround Coolant Expansion Tank – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 909 Perform the following operations: • Radiator Cowl - Removal NOTICE Note the routing of the coolant expansion hose and its retaining clips for installation. 1. Release the clamp and detach the coolant expansion hose from the radiator filler neck. 1. Clamp 2.
Page 910 2. Release the fixings, move the radiator lower cowl forward to disengage the upper retaining clips and remove the lower cowl. 1. Fixings 2. Lower cowl 3. Retaining clips 3. Release the two fixings securing the radiator lower surround to its bracket. 1.
Page 911 4. Release the lower cowl upper fixing and detach the lower cowl assembly from the motorcycle. 1. Fixing 2. Lower cowl assembly 5. Release the clamp and detach the coolant expansion hose from the top of the expansion tank. 6. Release the two fixings, lift the coolant expansion tank upwards to release the lower locating lugs and remove.
Page 912 Coolant Expansion Tank – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Make sure the grommets for the expansion tank lower locating lugs are fitted to the lower cowl assembly.
Page 913 3. Attach the coolant expansion hose to the top of the expansion tank and secure with its clamp. 1. Clamp 2. Hose 3. Fixings 4. Locating lugs position 4. Make sure the grommets and the spacer are fitted to the upper mounting of the laower cowl assembly 1.
Page 914 5. Position the lower cowl assembly to the motorcycle, fit the upper fixing and tighten to 6 Nm. 1. Fixing 2. Lower cowl assembly 6. Fit the radiator lower surround to its bracket and tighten the fixings to 4 Nm. 1.
Page 915 7. Engage the upper retaining clips of the radiator cowl into their slots, fit the fixings and tighten to 4 Nm. 1. Fixings 2. Lower cowl 3. Retaining clips 8. Route the coolant expansion hose to the radiator filler neck as noted for removal. Fit to the filler neck and secure with its clamp.
Page 916 9. Check and, if necessary, top up the coolant level in the expansion tank (see Coolant Level Adjustment). Perform the following operations: • Radiator Cowl - Installation Radiator – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 917 Perform the following operations: • Seat - Removal • Battery - Removal • Radiator Cowl - Removal • Coolant Replacement - Drainage • Coolant Expansion Tank - Removal NOTICE Note the positions and orientations of the grommets, flanged sleeves and washers for installation.
Page 918 3. Remove the fixings and the flanged sleeves securing the radiator assembly to the frame. 1. Fixing (left hand side shown) 2. Flanged sleeve 3. Frame 4. Grommet 4. Disconnect the lower coolant hose from the engine. 5. Support the radiator assembly and disconnect the cooling fans electrical connectors. 1.
Page 919 6. Disconnect the upper coolant hose and remove the radiator assembly. 7. If required, release the fixings and remove the cooling fan assembly from the radiator. 1. Fixings 2. Cooling fan assembly Radiator – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling.
Page 920 1. If removed, fit the cooling fan assembly to the radiator and tighten the fixings to 8 1. Fixings 2. Cooling fan assembly 2. Connect the upper coolant hose and secure with its clamp orientation as noted for removal. 3. Support the radiator assembly and connect the cooling fans electrical connectors. 1.
Page 921 5. Position the radiator assembly to the frame. Fit the grommets, flanged sleeves, washers and fixings as noted for removal. Do not fully tighten at this stage. 1. Fixing (left hand side shown) 2. Flanged sleeve 3. Frame 4. Grommet 6.
Page 922 7. Tighten the radiator upper fixings to 6 Nm (right hand side first). 8. Tighten the radiator lower fixings to 6 Nm. 9. Fit the horn to the radiator assembly and tighten its fixing to 9 Nm. 10. Connect the horn electrical connectors. Perform the following operations: •...
Page 923 Coolant System Pressure Test Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure.
Page 924 3. Securely fit service tool T3880176 to the coolant filler neck. 4. Carefully connect the hand pump (part of service tool T3880147) to the service tool T3880176 ensuring an air tight seal is maintained. 1. Coolant filler neck 2. T3880176 - Radiator Pressure Test (use with T3880147) 3.
Page 925 7. Remove the engine oil filler cap and check for contamination of the engine oil caused by coolant escaping into the engine sump. 8. Release the pressure from the coolant test kit using the pressure release valve. 9. Detach the service tool T3880176 bayonet type adapter from the coolant filler neck. 10.
Page 926 Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with hot coolant will cause scalds and skin damage. NOTICE It is recommended to carry out coolant pressure cap and cooling system pressure tests consecutively.
Page 927 4. Check the condition of the upper and lower seals of the coolant pressure cap. 1. Lower Seal 2. Upper Seal 3. Spring NOTICE If there is any sign of damage or deterioration replace the cap. 5. Select the correct test adapter and securely fasten to the pressure cap. 6.
Page 928 7. Pressure test the cap to it's 1.2 bar blow off pressure. If the coolant cap opens at a lower pressure, fails to open at the correct pressure or the seal leaks, replace the cap. 8. Release the pressure from the coolant test kit using the pressure release valve. 9.
Page 929 Thermostat – Inspection 1. Inspect the thermostat at room temperature. If the thermostat is open, it must be replaced. 2. To check the thermostat is opening at the correct temperature, suspend the thermostat in a suitable container of water and raise the temperature of the water until the thermostat opens.
Page 930 Thermostat - Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Thoroughly clean the thermostat cover and clutch cover mating faces. 2.
Page 931: Front Suspension And Steering
Front Suspension and Steering Exploded View - Front Fork, Lower Yoke and Steering Head Bearings...
Page 932 Exploded View – Handlebar...
Page 933 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. Riding the motorcycle with defective or damaged suspension can cause loss of...
Page 934 Front Fork Oil Seal – Clean Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1.
Page 935 5. Slide the cleaning hook carefully under the seal lip. Rotate service tool T3880216 360° in the direction shown then remove the cleaning hook from the oil seal. Direction of Rotation 6. Slide service tool T3880216 down to use the other cleaning hook to clean the dust seal.
Page 936 Front Forks – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Do not allow a brake component to hang unsupported on the brake hose or line. Brake hoses or lines that are not supported may become damaged or bent.
Page 937 1. Release the fixing and detach the ABS wheel speed sensor from the left hand fork leg, collect the shim. 1. Fixing 2. Shim 3. Clip (one of three) NOTICE Note the orientation and position of the direction indicators on the forks for installation.
Page 938 4. Remove the direction indicator bracket pinch bolt. 1. Fixings 2. Upper yoke 3. Fixing 4. Direction indicator 5. Remove the lower yoke pinch bolt and slide the fork down through the yokes. Discard the pinch bolt. 2. Fixings 6. As the fork is released, slide the direction indicator brackets off the fork and tie aside. Do not allow the direction indicators to hang on the wiring harnesses.
Page 939 7. Remove the forks from the lower yoke. Front Forks – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Page 940 Stage 2 3. Tighten the fixings in the sequence shown to 25 Nm. Lower Yoke pinch Bolts Tightening Sequence 4. If the fork top caps have been loosened, tighten them to 35 Nm. 5. Tighten the upper yoke clamp bolts to 25 Nm. 6.
Page 941 Move the handlebars to the left and right full lock while checking that cables and harnesses do not bind or that the steering feels tight or difficult to turn. A cable or harness that binds, or steering that is tight/difficult to turn will restrict the steering and may cause loss of control and an accident.
Page 942 1. If the damper rod is to be removed, loosen the damper fixing at the bottom of the fork by a half turn. 1. Damping cylinder fixing location 2. Drain the fork oil (see Fork Oil Renew - Draining). NOTICE The fork seals can be renewed without removal of the damping cylinder.
Page 943 3. Using service tool T3880171 clamp the fork outer tube. T3880171 - Fork Holding Tool 4. Raise the inner tube and remove the dust seal and circlip from the outer tube. 1. Dust seal 2. Circlip...
Page 944 5. Remove the fork from service tool T3880171 and, using a slide hammer action to release the oil seal and bushes from the outer tube. Separate the inner and outer tubes, leaving the seals and bushes in place on the inner tube. Note the relative positions and orientation of all bushes and seals before removal.
Page 945 7. Remove the damper fixing from the bottom of the fork. 1. Damping cylinder fixing location 8. Remove the damping cylinder from the inner tube. 1. Damping cylinder...
Page 946 Front Fork - Assembly The front forks comprise of many precision machined parts. Total cleanliness must be observed at all times and assembly must take place in a dirt/dust-free environment. Dirt ingress may cause damage to the fork parts, leading to incorrect operation, instability, loss of motorcycle control and an accident.
Page 947 4. Position the seals and bushes to the inner tube as noted during removal. Make sure the oil seal (item 3) is positioned with the text end facing the circlip (item 2). Use a new circlip. 1. Dust seal 2. Circlip 3.
Page 948 8. Install a new circlip to retain the oil seal. 9. Position the dust seal to the outer tube. 10. Use the wider end of service tool T3880183 with hand pressure only, to press the dust seal into position in the outer tube. 1.
Page 949 If the lower yoke fixings are also loosened, the forks will no longer support the weight of the motorcycle. Do not loosen the lower yoke fixings as, in this condition, the motorcycle could topple over causing damage and/or risk of injury. Perform the following operations: •...
Page 950 It is essential that the adjuster nut is not over-tightened. If the adjuster is over- tightened it will cause a pre-load on the headstock bearings. This will introduce tight steering, which could cause loss of motorcycle control and an accident. •...
Page 951 NOTICE Keep the torque wrench at 90 degrees to the centre line of the tool when you tighten the adjustment nut in the stage that follows. This will apply the correct torque to the adjustment nut. NOTICE The adjustment nut can turn up to 90 degrees when you tighten it anticlockwise. This is usual.
Page 952 Operation of the motorcycle with incorrectly adjusted steering head bearings, either too loose or too tight, may cause a dangerous riding condition leading to loss of motorcycle control and an accident. 2. Check that the free play has been eliminated and that the steering can be turned freely from lock-to-lock without any sign of tightness.
Page 953 • Twist Grip Position Sensor - Removal NOTICE The clutch switch is secured to its housing by two fixings. The clutch switch housing is a press fit to the clutch master cylinder. Note the orientation of the clutch switch for installation. 1.
Page 954 3. Release the fixings, lift off the clamp then detach and support the front brake master cylinder. 1. Fixings 2. Clamp 3. Master cylinder NOTICE Note the routing of the handlebar harnesses for installation. 4. Release the fixing and remove the cover on the left hand switch housing. 1.
Page 955 5. Remove the cable tie securing the switch housing wiring harness to the left hand switch housing. 6. Gently pull on the wiring harness to disconnect the switch housing connectors. NOTICE The service tool T3880369 is required to release the handlebar switch housings from their retaining clips.
Page 956 10. Slide the switch housing off the handlebar and collect the retaining clip. 1. Left hand switch housing 2. Retaining clip 11. Remove the cable tie securing the switch housing wiring harness to the right hand switch housing. 12. Gently pull on the wiring harness to disconnect the switch housing connectors. 13.
Page 957 17. Press in the sides of the left hand plastic grommet to release two of the locating lugs and remove the grommet. 1. Plastic grommet (harness removed for clarity) 2. Locating lugs (two of three shown) NOTICE If heated grips are not fitted, there is a plastic plug fitted both ends of the handlebar to retain the connector for heated grips.
Page 958 19. With the aid of an assistant, support the handlebar and release the fixings and remove the clamps. 1. Fixings 2. Handlebar clamps NOTICE Note the position of the instruments riser and clamp on the handlebar for installation. 20. If required, release the four fixings and remove the instruments mounting and friction rings assembly.
Page 959 NOTICE Note the routing of the switch housing and the twist grip position sensor harnesses for installation. 21. Carefully remove the handlebar while feeding the switch housing and the twist grip position sensor harnesses out the handlebar. 1. Harness (right hand switch housing) 2.
Page 960 2. Carefully fit the twist grip position sensor harness first into the handlebar as noted for removal. 3. Carefully fit the switch housing harnesses into the handlebar as noted for removal. 1. Harness (right hand switch housing) 2. Harness (left hand switch housing) 3.
Page 961 6. Position the handlebar to risers. Make sure the lug on the right hand riser is in the groove of the instruments riser. 1. Lug (handlebar riser) 2. Groove (instruments riser) 7. Fit the handlebar clamps and fixings. Do not fully tighten at this stage. 1.
Page 962 8. Position the handlebar so that the inside corner of the clamp is aligned with the alignment mark on the front of the handlebar, as shown below. 1. Alignment mark 2. Clamp 9. Tighten the handlebar clamp fixings, front ones first, to 26 Nm. 10.
Page 963 11. Fit the plastic grommet to the left hand side of the handlebar. 1. Plastic grommet (harness removed for clarity) 2. Locating lugs (two of three shown) 12. Position a new retaining clip into the handlebar in the orientation noted during removal and slide the left hand switch housing onto the handlebar.
Page 964 NOTICE The switch housing electrical connections are recessed into the switch housing body. To aid orientation, there are coloured dots on each connector. The coloured dots identify the bottom face of the connector. When inserting the connectors, carefully locate the connectors into their sockets, then use a suitable tool to push the connectors fully home.
Page 965 18. Slide over the retaining clip until it locks into position. 1. Right hand switch housing 2. Retaining clip 19. Fit the switch housing connectors. 20. Using a new cable tie, secure the switch housing wiring harness to the left hand switch housing.
Page 966 22. Align the straight edge on the clamp to the alignment mark on the handlebar (as shown in the illustration below) and tighten the fixings (upper one first) to 8 Nm. 1. Alignment mark 2. Straight edge 3. Clamp 23. Attach the clutch switch assembly to the master cylinder as noted for removal. 1.
Page 967 24. Locate the front brake master cylinder to the handlebars and fit the clamp, do not fully tighten at this stage. NOTICE When fitting the front brake master cylinder, care must be taken to avoid trapping switch housing harness between handlebar and reservoir clamp. 25.
Page 968 Upper Yoke – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Do not allow a brake component to hang unsupported on the brake hose or line. Brake hoses or lines that are not supported may become damaged or bent.
Page 969 1. Release the two fixings and remove the headstock harness cover. 1. Fixings 2. Harness cover NOTICE Note the routing of the instruments harness for installation. The instruments electrical connector cover is secured to the instruments with a fixing and a retaining lug. 2.
Page 970 3. Disconnect the electrical connector from the instruments. 4. Release the fixing and detach the brake and clutch line connector block from the upper yoke. Discard the fixing. 1. Fixing 2. Brake line connector 3. Clutch line connector NOTICE The clutch switch is secured to its housing by two fixings. The clutch switch housing is a press fit to the clutch master cylinder.
Page 971 5. Carefully detach the clutch switch assembly from the master cylinder. 1. Clutch switch 2. Securing lugs 3. Location holes 6. Release the fixings, lift off the clamp then detach and support the front brake master cylinder.
Page 972 7. Release the fixings, remove the clamp then detach and support the master cylinder. 1. Fixings 2. Clamp 3. Master cylinder NOTICE Note the routing of the handlebar harnesses for installation. 8. Release the fixings and washer for the handlebar risers and remove the handlebar assembly.
Page 973 NOTICE Note the positions of the compression limiters, rubber grommets and caps for installation. 9. Remove the cap, compression limiter and rubber grommets from upper yoke. 1. Cap 2. Compression limiter 3. Rubber grommet 10. Loosen the upper yoke pinch bolts. 11.
Page 974 Upper Yoke – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Fit the upper yoke to the motorcycle. 2.
Page 975 4. Fit the cap, compression limiter and rubber grommets to the upper yoke as noted for removal. 1. Cap 2. Compression limiter 3. Rubber grommet 5. Position the handlebar assembly onto the upper yoke. Fit the washer and fixings for the handlebar risers and tighten to 60 Nm.
Page 976 NOTICE When fitting the front brake master cylinder, care must be taken to avoid trapping switch housing harness between handlebar and reservoir clamp. 6. Locate the front brake master cylinder to the handlebars and fit the clamp. 7. Align the straight edge on the clamp to the alignment mark on the handlebar (as shown in the illustration below) and tighten the fixings (upper one first) to 8 Nm.
Page 977 9. Align the straight edge on the clamp to the alignment mark on the handlebar (as shown in the illustration below) and tighten the fixings (upper one first) to 8 Nm. 8. Alignment mark 9. Straight edge 10. Clamp 10. Attach the clutch switch assembly to the master cylinder as noted for removal. 10.
Page 978 11. Attach the brake and clutch line connector block to the upper yoke and tighten the new fixing to 9 Nm. 1. Fixing 2. Brake line connector 3. Clutch line connector 12. Connect the electrical connector to the instruments. 13. Fit the cover to as noted for removal and tighten the fixing to 3 Nm. 14.
Page 979 15. Fit the headstock harness cover and tighten the fixings to 5 Nm. 1. Fixings 2. Harness cover Perform the following operations: • Front Subframe - Installation • Flyscreen - Installation • Battery - Installation • Seat - Installation Lower Yoke and Headstock Bearings – Removal Make sure the motorcycle is stabilised and adequately supported.
Page 980 Perform the following operations: • Seat - Removal • Battery - Removal • Upper Yoke - Removal • Seat - Removal • Battery - Removal 1. Use service tool T3880750 to remove the lock nut. 2. Remove the tab washer. 3.
Page 981 Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries if suitable protective apparel is not worn. For this model there are two oil seals for the headstock bearings as shown in the illustration below.
Page 982 NOTICE When removing the bearing races from the headstock, the oil seals within the headstock will get damaged and must be replaced. Note the orientation of the dust seals for installation. 1. Remove the dust seal. 2. Remove the inner race and bearing from the headstock. 3.
Page 983 1. Fit a new dust seal to the steering stem on the lower yoke. 1. Dust seal 2. Press a new lower bearing inner race onto the steering stem of the lower yoke. 3. Fit the bearing to the inner race on the lower yoke. NOTICE The oil seal for the headstock upper bearing is to be flush with the seat for the bearing outer race.
Page 984 4. Fit a new seal to the lower end of the headstock with lip of the seal facing the bearing and is 3 mm past the seat for the bearing outer race. 1. Oil seal 2. Bearing outer race 3. Headstock 4.
Page 985 7. Evenly and progressively drive the new bearing outer race into the upper end of the headstock. Lower Yoke - Installation 1. Lubricate the headstock bearings using Castrol LCX 222 or an equivalent heavy duty lithium based grease. 2. Fit the bearing to the bearing inner race on the steering stem. 3.
Page 986 Rear Suspension and Swinging Arm Exploded View - Rear Suspension Unit and Linkage...
Page 987 Exploded View - Swinging Arm...
Page 988 Rear Suspension Unit – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the following operations: •...
Page 989 4. Release the fixings and detach rear suspension preload adjuster from the battery box. 1. Fixings 2. Preload adjuster 3. Retaining band 4. Rear suspension unit Part of the main harness is routed near the rear suspension unit upper fixing. Care must be taken not to damage the harness when removing or installing the rear suspension unit and its fixings.
Page 990 5. Remove the flanged lock nut from the upper mounting bolt. Discard the flanged lock nut. 1. Battery box (rear subframe removed for clarity) 2. Harness 3. Flanged lock nut 4. Engine ECU connectors (2 off) NOTICE Note there is a sleeve fitted to the right hand outrigger for the suspension unit upper mounting bolt.
Page 991 NOTICE Note there is a sleeve fitted to the right hand side of the drag link rocker for the suspension unit lower mounting bolt. 7. Remove the bolt securing the rear suspension unit to its lower mounting. Discard the flanged lock nut. 1.
Page 992 Rear Suspension Unit – Inspection Contents under pressure. Never attempt to open this rear suspension unit. Never attempt to service this rear suspension unit. Never incinerate, puncture, or disassemble this rear suspension unit. Opening this rear suspension unit may result in severe injuries or even death.
Page 993 Rear Suspension Unit – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Part of the main harness is routed near the rear suspension unit upper fixing. Care must be taken not to damage the harness when removing or installing the rear suspension unit and its fixings.
Page 994 3. Fit the new flanged lock nut. Do not fully tighten at this stage. 3. Battery box (rear subframe removed for clarity) 4. Harness 5. Flanged lock nut 6. Engine ECU connectors (2 off) 4. Fit the lower mounting bolt and sleeve as noted for removal. 1.
Page 995: Installation
5. Route the preload adjuster hose and secure to its retaining clip as noted for removal. 6. Fit the rear suspension preload adjuster to the battery box and tighten the fixings to 15 Nm. 1. Fixings 2. Preload adjuster 3. Retaining band 4.
Page 996 Rear Suspension Linkage – Removal Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. If the engine has recently been running, the exhaust components may be hot to the touch.
Page 997 2. Remove the sleeve from the right hand drag link bracket. 1. Fixing 2. Drag link brackets 3. Drag link 3. Detach the drag link and remove the sleeve from the lower mounting. 4. Remove the fixing securing the rocker to the swinging arm. 5.
Page 998 7. Draw back the slide part of the hammer swiftly to facilitate the removal of the swinging arm to rocker sleeve. 8. Manoeuvre the drag link and rocker assembly out of the swinging arm. NOTICE The drag link will only fit to one end of the rocker. Note that the drag link is fitted to the rocker with the letter L, on one side of the drag link, facing the left hand side of the motorcycle for installation.
Page 999 Drag Link Brackets 1. Remove the swinging arm (see Swinging Arm - Removal). 2. Remove the fixing securing the drag link brackets to the upper crankcase. Discard the flanged lock nut. 3. Remove the fixings securing the drag link brackets to the lower crankcase and remove the brackets.
Page 1000 If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid skin damage, always allow the hot parts to cool before working on the exhaust system. Perform the following operations: Seat - Removal •...
Page 1001 4. Repeat steps 1 to 3 for the other end Bearings Removal – Rocker NOTICE The rocker bearing cannot be removed undamaged. 1. Secure the rocker in a soft jawed vice. 2. Remove the two seals. 3. Drift out the needle roller bearing. 1.
Page 1002 Rear Suspension Linkage Bearings – Installation Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Bearing Installation - Rocker When using a press, always wear overalls, eye, face and hand protection.
Page 1003 4. Press in the new bearing until the service tool contacts the rocker. 1. T3880629 - Bearing Installer Handle 2. T3880512 - Needle Bearing Installer 7.5mm 3. Needle roller bearing 5. Using the same service tools, fit new seals to the rocker. Make sure the seals, when fitted, are below the chamfer edge.

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