Service Manual Tiger 900 Rally Pro

Service Manual - Tiger 900 Rally Pro
Introduction
Introduction
This manual is designed primarily for use by trained technicians in a properly equipped workshop. However, it contains enough detail and basic information to make it useful to
the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools
to complete the job.
A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessary in order to carry out maintenance and repair work satisfactorily.
Whenever the owner has insufficient experience or doubts regarding his ability to do the work, an authorised Triumph dealer must undertake all adjustments, maintenance, and
repair work.
In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work.
All work should be performed with great care and in a clean working area with adequate lighting.
Always use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of substitutes may adversely affect
safe operation.
Where accurate measurements are required, they can only be made using calibrated, precision instruments.
For the duration of the warranty period, an authorised Triumph dealer must perform all repairs and scheduled maintenance.
To maximise the life of your motorcycle:
Accurately follow the maintenance requirements of the periodic maintenance chart in the Service Manual.
Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the motorcycle. Rectify all problems as soon as possible
(immediately if safety related).
Use only genuine Triumph parts as listed in the electronic parts catalogue (EPC).
Follow the procedures in this manual carefully and completely. Do not take short cuts.
Keep complete records of all maintenance and repairs with dates and any new parts installed.
Use only approved lubricants, as specified in the Owner's Handbook, in the maintenance of the motorcycle.
How to use this manual
To assist in the use of this manual, the section title is given at the top.
Each major section starts with a contents page, listing the information contained in the section.
The individual steps comprising repair operations are to be followed in the sequence in which they appear.
Adjustment and repair operations include reference to service tool numbers and the associated illustration depicts the tool.
Where usage is not obvious, the tool is shown in use.
Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, specialist information and useful assembly details.
Warnings, Cautions and Notes
Particularly important information is presented in the following form:
WARNING
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.
CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.
Note
This note symbol indicates points of particular interest for more efficient and convenient operation.
Tampering with Noise Control System Prohibited
Owners are warned that the law may prohibit:

The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into
any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and
The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
References
References to the left hand or right hand side given in this manual are made when viewing the motorcycle from the rear.
Operations covered in this manual do not always include reference to testing the motorcycle after repair. It is essential that work is inspected and tested after completion and, if
necessary, a road test of the motorcycle is carried out particularly where safety related items are concerned.
Dimensions
The dimensions quoted are to design engineering specification with service limits where applicable.
During the period of running-in from new, certain adjustments may vary from the specification figures given in this manual. These will be reset by the dealer at the 500 mile/800
km service, and thereafter should be maintained at the figures specified in this manual.
Repairs and Replacements
Before removal and disassembly, thoroughly clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle.
Particular attention should be paid when installing a new part, that any dust or metal filings are cleared from the immediate area.
Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may
be causing the problem. Never lever a component as this will cause damage both to the component itself and to the surface being levered against.
Whenever tapping to aid removal of an item is necessary, tap lightly using a hide or plastic faced mallet.
Service Manual - Tiger 900 Rally Pro 1 of 527

Edges
Watch for sharp edges, especially during engine disassembly and assembly. Protect the hands with industrial quality gloves.
When replacement parts are required, it is essential that only genuine Triumph parts are used.
Safety features and corrosion prevention treatments embodied in the motorcycle may be impaired if parts other than genuine Triumph parts are fitted. In certain territories,
legislation prohibits the fitting of parts not to the manufacturer's specification.
Tightening procedure
Generally, when installing a part with several bolts, nuts or screws, they should all be started in their holes and tightened to a snug fit, evenly and in a cross pattern. This is to
avoid distortion of the part and/or gas or oil leakage. Conversely, bolts, nuts, or screws, should all be loosened (in sequence if specified) by about a quarter of a turn and then
removed.
Where there is a tightening sequence specified in this Service Manual, the bolts, nuts, or screws must be tightened in the order and by the method indicated.
Torque wrench setting figures given in this manual must be observed. The torque tools used must be of accurate calibration.
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. This applies particularly to micro-
encapsulated fixings which must always be replaced if disturbed. Where necessary, the text in this manual will indicate where such a fixing is used.
Use of Crow Foot Spanner Adapters with Torque Wrenches
The use of a crow foot spanner adapter will effectively lengthen the lever arm of a torque wrench. The amount of torque applied to a fastener is increased as the torque wrench
lever arm is extended, therefore the torque wrench setting must be adjusted in order to achieve the correct tightening torque.
Before tightening a fixing using a crow foot spanner adapter, measure the normal length of the torque wrench from the centre of the drive square to the centre of the handle
(dimension L1). Fit the crow foot spanner adapter to the torque wrench as shown below. Measure the extended length of the torque wrench from the centre of the crow foot
spanner head to the centre of the handle (dimension L2).
Use the following formula to calculate the correct torque wrench setting to achieve the required tightening torque.
Note
The example shown below is calculated using a crow foot spanner measuring 25 mm from the centre of the spanner head to the centre of the drive square.
L2
L1
L2
L1
L2
L1
M1 = M2 x L1 / L2 Example
M2 is the required tightening torque to be applied 90 Nm
L1 is the normal length of the torque wrench, measured from the centre of the drive square to the centre of the 300 mm
handle
L2 is the extended length of the torque wrench, measured from the centre of the crow foot spanner head to the 325 mm
centre of the handle
M1 is the calculated torque wrench setting 83 Nm
General Information
Ignition System Safety Precautions
WARNING
The ignition system produces extremely high voltages. Do not touch any part of the ignition system or any cables while the engine is running.
An electric shock caused by contact with the ignition system may lead to illness, injury or death.
WARNING

WARNING
Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and or diagnostic equipment.
The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death.
Dangerous Substances
WARNING
Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far as possible, be kept from
contact with the skin. These substances among others include acid, antifreeze, asbestos, brake fluid, fuel, lubricants, and various adhesives. Always pay close attention to
the instructions printed on labels and obey the instructions contained within. These instructions are included for your safety and well-being.
NEVER DISREGARD THESE INSTRUCTIONS!
Third Party Products
WARNING
Many proprietary products, such as chemicals, solvents and cleaning agents, will cause damage to components if used incorrectly or inappropriately. Always follow the
manufacturer’s instructions printed on the product container’s labels and obey the instructions given. These instructions are included for your safety and well-being.
Damage to the motorcycle components caused by the incorrect or inappropriate use of chemicals, solvents and cleaning agents may reduce the components efficiency,
resulting in loss of motorcycle control and an accident.
Fluoroelastomers
WARNING
Fluoroelastomer material is used in the manufacture of various seals in Triumph motorcycles.

In fire conditions involving temperatures greater than 315°C this material will decompose and can then be potentially hazardous. Highly toxic and corrosive decomposition
products, including hydrogen fluoride, carbonyl fluoride, fluorinated olefins and carbon monoxide can be generated and will be present in fumes from fires.
In the presence of any water or humidity, hydrogen fluoride may dissolve to form extremely corrosive liquid hydrofluoric acid.
If such conditions exist, do not touch the material and avoid all skin contact. Skin contact with liquid or decomposition residues can cause painful and penetrating burns
leading to permanent, irreversible skin and tissue damage.
Oils
WARNING
The engine oil may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned.
WARNING
Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which
can cause cancer. Wear suitable clothing and avoid skin contact.
Health Protection Precautions
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.
First aid treatment should be obtained immediately for open cuts and wounds. Always be aware of who your nearest First Aider is and where the medical facilities are kept.
Use barrier creams, applying before each work period to protect the skin from the effects of oil and grease and to aid removal of the same after completing work.
Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have
been removed.
Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.
If skin disorders develop, obtain medical advice without delay.
Where practicable, degrease components prior to handling.
WARNING
Any risk of eye injury must be avoided. Always wear eye protection when using a hammer, air line, cleaning agent or where there is ANY risk of flying debris or chemical
splashing.
Environmental Protection Precautions
CAUTION
Do not pour oil on the ground, down sewers or drains, or into water courses. To prevent pollution of water courses etc., dispose of used oil sensibly. If in doubt contact your
local authority.
Burning of used engine oil in small space heaters or boilers can be recommended only for units of approved design. If in doubt, check with the appropriate local authority and/or
manufacturer of the approved appliance.
Dispose of used oil and used filters through authorised waste disposal contractors, to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact
your local authority for advice on disposal facilities.

Brakes
WARNING
Brake fluid is hygroscopic which means it will absorb moisture from the air. Any absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction
in braking efficiency.
Replace brake fluid in line with the routine maintenance schedule. A dangerous riding condition could result if this important maintenance item is neglected!
Do not spill brake fluid onto any area of the bodywork as this will damage any painted or plastic surface.
Always use new brake fluid from a sealed container and never use fluid from an unsealed container or from one that has been previously opened.
Do not mix different brands of fluid. Check for fluid leakage around brake fittings, seals and joints.
Check regularly for brake hose damage.
FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING EFFICIENCY LEADING TO AN ACCIDENT.
WARNING
If there has been an appreciable drop in the level of the fluid in either brake fluid reservoir, consult your authorised Triumph dealer for advice before riding.
If the brake lever or pedal feels soft when it is applied, or if the lever/pedal travel becomes excessive, there may be air in the brake lines or the brake may be defective.
It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph dealer before riding the motorcycle.
Failure to take remedial action may reduce braking efficiency leading to an accident.
WARNING
Use only DOT 4 specification brake fluid as listed in the General Information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the
General Information section may reduce the efficiency of the braking system leading to an accident.
Failure to change the brake fluid at the interval specified in the routine maintenance schedule may reduce braking efficiency resulting in an accident.
WARNING
Never use mineral-based grease in any part of the braking system or in any area where contact with the braking system is possible. Mineral-based grease will damage the
hydraulic seals in the calipers and master cylinders.
Damage caused by contact with mineral-based grease may reduce braking efficiency resulting in an accident.
WARNING
Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid.
Never use solvents, petrol (gasoline), engine oil or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the
calipers and master cylinders.
A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
Safety Instructions
Diagnostic Trouble Codes
WARNING
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.
Jacking and Lifting
WARNING
Always ensure that any lifting apparatus has adequate load and safety capacity for the weight to be lifted. Ensure the motorcycle is well supported to prevent any possibility
of the machine falling prior to lifting or jacking or while repairs and servicing are carried out.
Never rely on a single means of support when working with the motorcycle. Use additional safety supports and straps to prevent toppling.
Do not leave tools, lifting equipment, spilled oil, etc. in a place where they could become a hazard to health. Always work in a clean, tidy area and put all tools away when
the work is finished.
Precautions Against Damage
Avoid spilling brake fluid or battery acid on any part of the bodywork. Wash spillages off with water immediately.
Disconnect the battery earth lead before starting work, see ELECTRICAL PRECAUTIONS.
Always use the recommended service tool where specified.
Protect exposed bearing and sealing surfaces, and screw threads from damage.
Coolant
WARNING
Coolant mixture, which is blended with antifreeze and corrosion inhibitors contains toxic chemicals which are harmful to the human body. Never swallow antifreeze,
corrosion inhibitors or any of the motorcycle coolant.

WARNING
Do not remove the radiator cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised
coolant will cause scalds and skin damage.
CAUTION
The coolant antifreeze contains a corrosion inhibitor which helps prevent damage to the metal surfaces inside the cooling system. Without this inhibitor, the coolant would
'attack' the metals and the resulting corrosion would cause blockages in the cooling system leading to engine overheating and damage. Always use the correct antifreeze as
specified in the Owner's Handbook. Never use a methanol based antifreeze as this does not contain the required corrosion inhibition properties.
CAUTION
Distilled water must be used with the antifreeze (see specification for antifreeze) in the cooling system.
If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Reduced cooling
system efficiency may lead to the engine overheating and engine damage.
Cleaning Components
A high flashpoint solvent is recommended to reduce fire hazard.

Always follow container directions regarding the use of any solvent.
Always use the recommended cleaning agent or equivalent.
Do not use degreasing equipment for components containing items which could be damaged by the use of this process. Whenever possible, clean components and the area
surrounding them before removal. Always observe scrupulous cleanliness when cleaning dismantled components.
Lubrication
The majority of engine wear occurs while the engine is warming up and before all the rubbing surfaces have an adequate lubrication film. During assembly, oil or grease
(whichever is more suitable) should be applied to any rubbing surface, which has lost its lubrication film. Old grease and dirty oil should be cleaned off. This is because used
lubricants will have lost some lubrication qualities and may contain abrasive foreign particles.
Use recommended lubricants. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are
not intended. This manual makes reference to molybdenum disulphide grease in the assembly of certain engine and chassis parts. Always check manufacturer
recommendations before using such special lubricants.
Joints and Joint Faces
Assemble joints dry unless otherwise specified in this manual.

If gaskets and/or jointing compound is recommended for use; remove all traces of old jointing material prior to reassembly. Do not use a tool which will damage the joint faces
and smooth out any scratches or burrs on the joint faces using an oil stone. Do not allow dirt or jointing material to enter any tapped holes.
Gaskets, O-rings
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or
compression leaks.
Liquid Gasket, Non-permanent Locking Agent
Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly as excessive amounts of sealer may block engine
oil passages and cause serious damage.
Prior to reassembly, blow through any pipes, channels or crevices with compressed air.
WARNING
To prevent injury, always use eye, face and ear protection when using compressed air. Always wear protective gloves if the compressed air is to be directed in proximity to
the skin.
Screw Threads
Metric threads to ISO standard are used.

Damaged nuts, bolts and screws must always be discarded.
Castellated nuts must not be loosened back to accept a split pin, except in those recommended cases when this forms part of an adjustment.
Do not allow oil or grease to enter blind threaded holes. The hydraulic action on screwing in the bolt or stud could split the housing.
Always tighten a nut or bolt to the recommended torque figure. Damaged or corroded threads can affect the torque reading.
Unless specified, threaded fixings must always be fitted dry (no lubrication).
WARNING
Never lubricate a thread unless instructed to do so.

When a thread of a fixing is lubricated, the thread friction is reduced. When the fixing is tightened, reduced friction will cause over tightening and possible fixing failure.
A fixing which fails in service could cause component detachment leading to loss of control and an accident.
Locking Devices
Always release locking tabs and fit new locking washers. Do not reuse locking tabs.
Fitting a Split Pin
Always fit new split pins of the correct size for the hole in the bolt or stud. Do not loosen back castle nuts when fitting a split pin, except in those recommended cases when this
forms part of an adjustment.
Always fit new roll pins of an interference fit in the hole.

Circlips, Retaining Rings
Replace any circlips and retaining rings that are removed. Removal weakens and deforms circlips causing looseness in the circlip groove. When installing circlips and retaining
rings, take care to compress or expand them only enough to install them.
Always use the correct replacement circlip as recommended in the Triumph parts catalogue.
Self-Locking Nuts
Self-locking nuts can be reused, provided resistance can be felt when the locking portion passes over the thread of the bolt or stud.
DO NOT reuse self-locking nuts in critical locations, e.g. suspension components. Always use the correct replacement self-locking nut.
Encapsulated Bolts
An encapsulated bolt can be identified by a coloured section of thread which is treated with a locking agent.
Unless a specified repair procedure states otherwise, encapsulated bolts cannot be reused and MUST be replaced if disturbed or removed.
WARNING
Failure to replace an encapsulated bolt could lead to a dangerous riding condition. Always replace encapsulated bolts.
Oil and Grease Seals
Replace any oil or grease seals that are removed. Removal will cause damage to an oil seal which, if reused, would cause an oil leak.
Ensure the surface on which the new seal is to run is free of burrs or scratches. Renew the component if the original sealing surface cannot be completely restored.
Protect the seal from any surface which could cause damage over which it has to pass when being fitted. Use a protective sleeve or tape to cover the relevant surface and
avoid touching the sealing lip.
Lubricate the sealing lips with a recommended lubricant. This will help to prevent damage in initial use. On dual lipped seals, smear the area between the lips with appropriate
grease.
When pressing in a seal which has manufacturer's marks, press in with the marks facing out.
Seals must be pressed into place using a suitable driver. Use of improper tools will damage the seal.
Press
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil or grease on its outer or inner circumference so that it will locate smoothly.
Ball Bearing
When installing a ball bearing, the bearing race which is an interference fit should be pushed by a suitable driver. This prevents severe stress or damage to the load carrying
components. Press a ball bearing until it touches the shoulder in the bore or on the shaft.
With the sealing lip facing the lubricant, press or drift a seal to the depth of its housing, if the housing is shouldered, or flush with the face of the housing where no shoulder is
provided.
Chassis Bearing Lubrication
Note
This information relates only to bearing lubrication. For the procedures necessary to replace a bearing, always refer to the relevant section of this Service
Manual.
Bearings installed in engine and transmission applications are not covered by this information. Refer to the Lubrication chapter or the relevant engine chapter
for additional information.
General
For a bearing to be serviceable for its anticipated life span it must be checked, adjusted and lubricated at regular intervals, as specified in the service schedules given in the
Owner’s Handbook and this Service Manual.
A correctly lubricated bearing will have a film of lubrication that separates the moving parts, disperses heat and protects the bearing surfaces from corrosion.
Note
In all cases, use the lubricant recommended.
Grease the bearing, not the cavity where it is located.
A bearing that is not regularly checked and lubricated will have a reduced life span.
New Bearings
New bearings are typically protected with an oil preservative to prevent corrosion etc. during storage. This is NOT the lubrication for the bearing but DOES NOT need to be
washed off prior to assembly and in-service lubrication.
When lubricating a new bearing with grease the following steps should be taken:
1. Do not clean off the oil preservative.
2. Grease must be forced between the roller elements and the roller cage.
3. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts.
4. Any excess grease should be smeared on the outside of the rollers.
Lubrication and Checks While Servicing a Bearing
1. Disassemble parts as necessary to access the bearing.

2. Inspect the old grease covering the bearing, looking for signs of bearing damage, i.e. flakes or specks of metal.
3. Remove the old grease.
4. Check the bearing for smooth operation and visually check for corrosion, dents and flaking in the bearing race, rollers or cage. Replace if necessary.
Several common bearing types and the lubrication procedures for each are identified below:

ceon
Sealed Bearings
Note
Sealed bearings can be identified by their integrated seals.
Sealed bearings are lubricated for life by the manufacturer.
Any attempt to change the grease in a sealed bearing will damage the integrated seals. If the seals are damaged, dirt and water will ingress and the life of the
bearing will be greatly reduced.
ceon
Taper Bearings
1. Grease must be forced between the inner race and the roller carrier.
ceon
Angular Contact and Ball Bearing
1. Grease the bearing races and the ball bearing carrier.

ceop
Needle Roller Bearings
1. Coat the needle rollers with grease.

2. Ensure the needle rollers turn so that the grease is distributed over the entire circumference of the internal parts.
3. Assemble the parts, adjust and check as necessary.
Metal Bushes

1. Disassemble the parts as necessary to access the bush.
2. Remove the old grease.
3. Apply fresh grease to the metal bush.
Fuel Handling Precautions
General
The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled safely. It also outlines other areas of risk which must not be
ignored. This information is issued for basic guidance only and, if in doubt, appropriate enquiries should be made to your local Fire Officer.
Petrol – Gasoline
When petrol (gasoline) evaporates it produces 150 times its own volume in vapour which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than
air and will always fall to the lowest level. It can readily be distributed throughout any indoor environment by air currents, consequently, even a small spillage of petrol (gasoline)
is potentially very dangerous.
WARNING
Petrol (gasoline) is highly flammable and can be explosive under certain conditions. When opening the fuel tank cap always observe all the following items:
Turn the motorcycle ignition switch OFF.
Do not smoke.
Always have a fire extinguisher containing FOAM, CO2, HALON or POWDER close at hand when handling or draining fuel or fuel systems. Fire extinguishers must also be
present in areas where fuel is stored.
Always disconnect the vehicle battery, negative (black) lead first, before carrying out, dismantling or draining work on a fuel system.
Whenever petrol (gasoline) is being handled, drained, stored or when fuel systems are being dismantled, make sure the area is well ventilated. All potential forms of ignition
must be extinguished or removed (this includes any appliance with a pilot light). Any lead-lamps must be flame-proof and kept clear of any fuel spillage.
Warning notices must be posted at a safe distance from the site of the work to warn others that petrol (gasoline) is being openly handled. The notice must instruct the reader
of the precautions which must be taken.
Failure to observe any of the above warnings may lead to a fire hazard which could result in personal injury.
WARNING
No one should be permitted to repair components associated with petrol (gasoline) without first having specialist training on the fire hazards which may be created by
incorrect installation and repair of items associated with petrol (gasoline).
Repairs carried out by untrained personnel could bring about a safety hazard leading to a risk of personal injury.
WARNING
Draining or extraction of petrol (gasoline) from a vehicle fuel tank must be carried out in a well ventilated area.
The receptacle used to contain the petrol (gasoline) must be more than adequate for the full amount of fuel to be extracted or drained. The receptacle should be clearly
marked with its contents, and placed in a safe storage area which meets the requirements of local authority regulations.
When petrol (gasoline) has been extracted or drained from a fuel tank, the precautions governing naked lights and ignition sources should be maintained.
Failure to observe any of the above warnings could bring about a safety hazard leading to a risk of personal injury.
Fuel Tank Removal
Fuel tanks should have a 'PETROL (GASOLINE) VAPOUR' warning label attached to them as soon as they are removed from the vehicle. In all cases, they must be stored in a
secured, marked area.
Chassis Repairs
WARNING
If the motorcycle is involved in an accident or collision it must be taken to an authorised Triumph dealer for repair or inspection. Any accident can cause damage to the
motorcycle, which if not correctly repaired, may cause a second accident which may result in injury or death.
The frame must not be modified as any modification to the frame such as welding or drilling may weaken the frame resulting in an accident.
Electrical Precautions
The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and electronic components fitted to the motorcycle. Where
necessary, specific precautions are detailed in the relevant sections of this manual which should be referred to prior to commencing repair operations.
Equipment - Prior to commencing any test procedure on the motorcycle ensure that the relevant test equipment is working correctly and any harness or connectors are in good
condition, in particular mains leads and plugs.
WARNING
The ignition system produces extremely high voltages. Do not touch any part of the ignition system or any cables while the engine is running.
An electric shock caused by contact with the ignition system may lead to illness, injury or death.
WARNING
Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and/or diagnostic equipment.
The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death.
WARNING
The battery contains harmful materials. Always keep children away from the battery whether or not it is fitted in the motorcycle.
Do not jump start the battery, touch the battery cables together or reverse the polarity of the cables as any of these actions may cause a spark which would ignite battery

WARNING
gases causing a risk of personal injury.
High Voltage Circuits - Whenever disconnecting live H.T. circuits always use insulated pliers. Exercise caution when measuring the voltage on the coil terminals while the
engine is running. High voltage spikes can occur on these terminals.
Connectors and Harness - The engine of a motorcycle is a particularly hostile environment for electrical components and connectors. Always ensure these items are dry and
oil-free before disconnecting and connecting test equipment. Never force connectors apart either by using tools or by pulling on the wiring itself. Always ensure locking
mechanisms are disengaged before removal and note the orientation to enable correct reconnection. Ensure that any protective covers and substances are replaced if
disturbed.
Having confirmed a component to be faulty, switch off the ignition and disconnect the battery negative (black) lead first. Remove the component and support the disconnected
harness. When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking mechanism becomes fully
engaged.
Battery Disconnecting
Before disconnecting the battery, switch off all electrical equipment.
WARNING
To prevent the risk of a battery exploding and to prevent damage to electrical components ALWAYS disconnect the battery negative (black) lead first. When reconnecting the
battery, always connect the positive (red) lead first, then the negative (black) lead. Always disconnect the battery when working on any part of the electrical system.
Failure to observe the above warnings may lead to electrical damage and a fire hazard which could cause personal injury.
Always ensure that battery leads are routed correctly and are not close to any potential chafing points.
Disciplines
Switch off the ignition prior to making any connection or disconnection in the system. An electrical surge can be caused by disconnecting 'live' connections which can damage
electronic components.
Ensure hands and work surfaces are clean and free of grease, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts.
Prior to commencing any test, and periodically during any test, touch a good earth to discharge body static. This is because some electronic components are vulnerable to
static electricity.
Electrical Wires
All the electrical wires are either single-colour or two-colour and, with only a few exceptions, must be connected to wires of the same colour. On any of the two-colour wires
there is a greater amount of one colour and a lesser amount of a second colour. A two-colour wire is identified by first the primary colour and then the secondary colour. For
example, a yellow wire with thin red stripes is referred to as a 'yellow/red' wire; it would be a 'red/yellow' wire if the colours were reversed to make red the main colour.
Glossary of Circuit Diagram Symbols
The following is a description of the symbols found in the circuit diagrams used in all Triumph Service Manuals.
Connector
1
2
3
4
This illustration is used to show all multiplug type electrical connectors on Triumph circuit diagrams. The numbers in the box relate to the terminal numbers of the connector
pins. On ECMs with two connectors, the number would be prefixed with the letters 'A' or 'B' to identify each connector. An additional number outside the box will identify the
component.
Diode
An electrical one-way valve. Diodes allow current to flow in one direction but will not allow it to return. The arrow, which forms part of the diode symbol, indicates the direction of
current flow.
Electromagnetic Winding (solenoid)
An electromagnetic winding (or solenoid) is used to convert an electrical current into a lateral movement. This can then be used to operate switches (as used in relays) or other
components such as fuel injectors or secondary air injection solenoids.
Fuse
3
2
A fuse is a device which protects a circuit in the event of a fault. The fuse will 'blow' should a short circuit occur, protecting that circuit from further damage. The number next to
the fuse on the circuit diagram indicates the position of the fuse in the fuse box.
Ground Point

This symbol is used to show ground points. This is the negative connection to either the frame or engine, and is a common cause of intermittent faults due to loose or corroded
connections.
Lamp or Bulb
3 2
This symbol is used to show all types of light bulbs. The numbers in the box relate to the terminal numbers of the connector pins. An additional number outside the box will
identify the component.
LED (Light Emitting Diode)
Triumph use LEDs for the alarm warning light, instrument illumination and warning lights, gear change lights and rear light/brake lights on various models.
Motor
An electric motor. This could be the starter motor or a motor within an actuator, for example within the ABS modulator.
Relay
1 6 4 8
A relay is effectively an electromagnetic switch. To close the relay contacts and complete the circuit, an electromagnet in the relay is energised which causes the relay contacts
to close, making the circuit complete.
Relays are used when the electrical current is too great for a mechanical switch, usually when the switching must be done quickly to prevent arcing across the switch contacts.
If a mechanical switch were used, the mechanical switch contacts would quickly burn away.
Resistor
A device placed in a cable to reduce a voltage or restrict the maximum current a device can draw.
Splice
A hard cable joint where two or more cables are joined in the wiring harness. A potential source of both open and short circuits.
Switches
A mechanical device for completing or breaking a circuit. There are three common types of switch: normally open, normally closed and changeover.
Electrical Testing
For any electrical system to work, electricity must be able to flow in a complete circuit from the power source (the battery) via the components and back to the battery. No circuit
means no electrical flow. Once the power has left the positive side of the battery and run through the component it must then return to the battery on its negative side (this is
called earth or ground). To save on wiring, connections and space, the negative side of the battery is connected directly to the frame or engine. Around the frame and engine
will be various other ground points to which the wiring coming from components will be connected. In the case of the starter motor it bolts directly to the engine, which is bolted
to the frame. Therefore the frame and engine also form part of the earth return path.
Ohm’s Law

The relationship between voltage, current and resistance is defined by Ohm’s Law.
The potential of a battery is measured in volts (V).
The flow of current in a circuit (I) is measured in amperes.
The power rating of a consumer is measured in watts (W).
The resistance (R) of a circuit is measured in Ohms.
Ohm’s law, for practical work can be described as -
Power is calculated by multiplying Volts x Amps -
By transposing either of these formulae, the value of any unit can be calculated if the other two values are known.
For example, if a battery of 12 V is connected to a bulb of 60 W:
the current flowing in the circuit can be calculated by using -
the bulb resistance can be calculated by using -
To use either of the following triangles, put your finger over the value you want to find. Multiply the remaining values if side by side, or divide if one is over the other.
Basic Electrical Circuits
Basic Circuit Diagram
In the above circuit an electrical reservoir (the battery) is connected via a cable to a terminal on the controlling device (the switch) whose contacts are either open or closed.
The other terminal on the switch is connected via a cable to the consumer (the bulb), and the other side of the bulb filament is connected to ground (earth) by another cable.
The ground point is usually a part of the frame or engine, to which the battery negative terminal is also connected.
When the switch contacts are open (as shown in the diagram), the circuit is broken and no current flows. When the switch contacts are closed, the circuit is made and current
flows from the battery positive terminal through the switch contacts and bulb filament to ground. The frame completes the circuit to the battery negative terminal and the bulb
illuminates.
Although some circuits on the circuit diagram may at first seem more complicated, it will generally be found that they can be broken down into sections which do not differ
greatly from the basic circuit above.
Circuit Diagrams
Circuit diagrams are created to provide a 'picture' of the electrical system and to identify the route taken by each individual wire through the system, in order to identify which
components it feeds and which connectors the wire runs through. Circuit diagrams are an essential tool for fault finding, as it is possible to locate start and finish points for a
circuit without having to manually trace the wire through the motorcycle itself. Circuit diagrams may look confusing at first but when they are studied closely they soon become
logical.
Circuit diagrams also depict the inner workings of a switch housing (i.e. which wire connects to which when a switch is turned from one position to another) so that a test of that
switch can be made using the wire terminals in the connector instead of disassembling the switch itself.
More information can be found in Circuit Diagrams, in the Electrical section of the Service Manual.
Tracing Circuits
The following is a description of two types of common electrical failures, and some of the methods which may be used to find them.
Open Circuit

A break in an electrical circuit - current cannot flow. Usually caused by a break in a wire or cable or by a loose connection. Open circuits can often be intermittent, making
diagnosis difficult.
Short Circuit
A 'short cut' in an electrical circuit - current bypasses the intended circuit, either to ground or to another, different circuit. Often caused by failure of the cable insulation due to
chafing or trapping of the wire. There are two different types of short circuit - short to ground and short to battery Voltage.
A short to ground means that the current is going to ground before it reaches the component it is supposed to feed. These are often caused by chafing of the harness to the
frame or wires trapped between a bolted component, and will often blow the fuse on that circuit.
A short to battery voltage (12 Volts) is caused by a live power supply wire contacting an adjacent cable. Note that it is also possible for a 5 Volt sensor reference voltage to short
to an adjacent circuit, which can also cause electrical failures and DTCs (Diagnostic Trouble Code) to be stored.
When tracing a wire that is suspect, carefully check the circuit diagram before starting. Remember:
a wire may diverge at a splice and go off to feed other circuits. If these circuits are working, check for wiring faults from the splice onwards.
the circuit diagram is not an accurate guide to the actual location of the parts when fitted on the motorcycle. It is a schematic diagram of the circuits.
particularly where engine management items are concerned, the circuit is only completed by the ECM. If the ECM is not connected, the circuit may register as open.
To Check Continuity:
CAUTION
Ensure the circuit being tested is switched off before measuring continuity. Damage to the Digital Multi Meter (DMM) may result from testing a 'live' circuit with the meter set
to resistance (Ω).
In the example below, the ground circuit continuity is being tested from the battery to the frame.
0.0
Locate each end of the wire.

Set the Digital Multi Meter (DMM) to resistance check Ohms.
Probe each end of the wire.
If there is continuity, the meter will usually bleep or register the resistance of the cable.
A high resistance figure could indicate a dirty or corroded connection.
If there is a break in the wire, the meter will not bleep or register a resistance.
By probing the wire in various places, the position of a high resistance or break in the wire (open circuit) can be narrowed down until it is found.
To Measure Voltage:
In the example below, the circuit voltage is being measured at the bulb positive (+) terminal.
12.7
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).

Set the range of the DMM to the range best suited to the voltage of the circuit being tested (typically 20 Volts for most DMMs). Refer to the DMM manufacturers instructions.
Connect the black (ground) lead of the DMM to a reliable ground connection (usually the battery or frame ground).
Locate the positive terminal of the wire or component to be tested.
Connect the red (positive) lead of the DMM to the positive terminal.
Read the voltage from meter.
Splices
Splices are probably the most common cause of wiring faults after connectors. Splices are made where two or more wires come together and diverge in different directions,
usually to feed a different circuit.
To locate a splice, it is necessary to peel back the insulation and examine the splice for its integrity. The most common fault is where one of the wires at the joint has come adrift
usually causing the circuit it feeds or grounds to become 'dead'.
Switches
To check a switch, set the multimeter to resistance/continuity and probe the two pins that form a closed circuit when the switch is pushed. If the switch is working correctly, the
resistance should register or the meter will bleep.
Relays
All relay cases have a circuit path engraved on them showing the circuit path across the electromagnet and the switch. Before making any checks, first note the pin
designations, current paths, and whether or not there is a diode in either circuit path.
Make continuity checks across the electromagnet first, usually from pin 86 (positive) to pin 85 (negative). If a diode appears in the circuit use the diode check on the multimeter
(Volts scale) in the direction of current flow. If there is no diode, use the resistance check facility. An open circuit or unusually high resistance value indicates a faulty relay.
To check the switch side, apply a 12 Volt supply between pins 86 and 85. With the supply connected, the relay should be heard to click and there should be continuity between
pins 30 and 87. An open circuit indicates a faulty relay.
CAN (Controller Area Networking)
CAN (sometimes called CANbus) is a protocol for data communication between Electronic Control Modules (ECMs). Each ECM on the network is connected by a single pair of
twisted wires (or bus) which are used for the transmission of vehicle sensor data. By using CAN, the overall number of system sensors, and the amount of cabling required to
allow ECMs to communicate with each other is greatly reduced.
This saves cost, weight and space, and makes the system more reliable, as the physical number of wires and connections is reduced.
R
B28 4
U
B27 5
16
1
KY
A34 3
2
B
CAN works by each ECM sending out 'packets' of information (such as engine speed or fuel consumption information) on to the network bus (note that the network must be free
of data before any ECM is allowed to transmit). This data is given a priority according to its importance (for example 'engine speed' may have a higher priority than 'low fuel
level'), so that even if two ECMs send data at the same time, high priority information is always sent first. Lower priority data is then resent after the high priority data has been
received by all ECMs on the network.
The receiving ECM confirms the data has been received correctly and that the data is valid, and this information is then used by the ECM as necessary. Specific data not
required by an ECM will still be received and acknowledged as correct but then disregarded (for example if an ECM does not require 'clutch switch position' information, this
data packet would be ignored).
This allows for a very high speed system of communication, which is also very reliable. Should one ECM fail or transmit corrupted or otherwise incorrect messages, none of the
other ECMs on the network will be affected, and after a certain time that ECM will be prevented from transmitting further messages until the fault is rectified. This stops the
ECM from clogging the network with incorrect data and preventing other messages from getting through. The fault would then be reported by a DTC (Diagnostic Trouble Code).
Triumph currently uses CAN for communication between the following ECMs:
Engine ECM
Instruments
ABS ECM
Immobiliser or Chassis ECM
Diagnostic connector
Inertial Measurement Unit (if fitted)
Audio system (if fitted)
Electronic steering lock (if fitted)

LED Headlights (if fitted).
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. This saves cost, weight and space, and makes the
system more reliable, as the physical number of wires and connections is reduced.
The instruments use some of this data internally and also broadcasts it on the CANbus (Controller Area Networking) for use on the motorcycle as necessary.
Information (such as headlight main beam) is being requested continuously by the Instruments, once a confirmation of the request is recognised the instruments will react
accordingly.
9 1 3 1
17 10
25 18
34 26
6 4
1 2
7 4
1. Instruments
2. Switch housing (left hand side)
Example
Pressing the headlight main beam button on the switch housing (left hand handlebar) confirms to the instruments that headlight main beam is required.
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
Heated seat
Dip beam/Daytime running lights (DRL) switch (if equipped)
Mode button
Turn signal switch
Joystick button
Horn button
High beam button
Service Tools
Service Tools
Service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical components in a practical manner without causing damage. Some
operations in this Service Manual cannot be carried out without the aid of the relevant service tools. Where this is the case, the tools required will be described during the
procedure.
Service Tools
T3880001 - Fuel Pressure Gauge T3880023 - 50 mm Socket
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T3880053 - Wheel Bearing Extraction Kit T3880057 - Triumph Diagnostic Interface

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T3880065 - Bearing Installer T3880067 - Fork Spring Compressor
T3880070 - Bearing Installer T3880085 - Fork Piston Holder
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T3880102 - Wrench, Camshaft Turning T3880104 - Swinging Arm Adjuster Wrench
T3880105 - Torque Angle Gauge T3880123 - Extension Cable
T3880147 - Radiator and Cap Tester Kit T3880156 - Holder, Balancer Gear

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T3880157 - Fork Seal Installer T3880160 - Fork Oil Filler/Evacuator
ccha
T3880166 - Wrench, Engine Mounting Adjuster T3880171 - Fork Holding Tool
cdoa cjix
T3880207 - Hose Clip Pliers T3880216 - Fork Seal Cleaner, Large
T3880306 - Clutch Anti Rotation Jig T3880313 - Oil Filter Wrench
T3880315 - Extractor, Cylinder Liner T3880342 - 17 mm U-Spanner

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T3880365 - Alternator Housing Puller T3880369 - Switch Housing Removal Tool
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T3880375 - Alternator Rotor Holder T3880601 - Camshaft Timing Pin
T3880607 - Camshaft Timing Tensioner T3880609 - Timing Torque Limiter
T3880636 - Kit, Brake Lever Pivot Sleeve T3880640 - Camshaft Timing Plate
T3880800 - Octagonal Spanner, 49mm BatteryMate Battery Charger - See Latest Parts Catalogue for Part Number
Information

Specifications
Engine
Engine Configuration 3 Cylinder 12 valve DOHC
Arrangement Transverse in-line
Displacement 888 cc
Bore x Stroke 77.99 x 61.94 mm
Compression Ratio 11.266:1
Cylinder numbering Left to Right (no.3 adjacent to camshaft drive chain)
Cylinder Sequence Number 1 at left
Firing order 1-3-2
Cylinder Head
Valve Head Diameter Inlet 30.50 mm
Exhaust 25.50 mm
Valve Lift Inlet 7.7 mm
Exhaust 7.8 mm
Valve Stem Diameter Inlet 3.975 - 3.990 mm
Service Limit 3.965 mm
Valve Stem Diameter Exhaust 3.955 - 3.970 mm
Valve Guide Bore Diameter Inlet 4.000 - 4.015 mm
Valve Guide Bore Diameter Exhaust 4.000 - 4.015 mm
Valve Stem to Guide Clearance Inlet 0.010 - 0.040 mm
Service Limit 0.010 - 0.040 mm
Valve Stem to Guide Clearance Exhaust 0.030 - 0.060 mm
Valve Seat Width (in head) Inlet 0.80 - 1.20 mm
Valve Seat Width (in head) Exhaust 1.00 - 1.40 mm

Valve Seat Width (valve) Inlet 0.99 - 1.86 mm
Exhaust 1.06 - 1.93 mm
Valve Seat Angle 45.25°
Inlet/Exhaust Valve Spring Load at Length 538 N +/-25 N at 27.5 mm
Valve Clearance Inlet 0.10 - 0.20 mm
Exhaust 0.325 - 0.375 mm
Valve Bucket Diameter Inlet 25.385 - 25.399 mm
Valve Bucket Diameter Exhaust 25.421 - 25.431 mm
Valve Bucket Bore Diameter Inlet 25.421 - 25.431 mm
Valve Bucket Bore Diameter Exhaust 25.421 - 25.431 mm
Camshafts
Camshaft Timing Inlet Open 2.5° BTDC @ 1.0 mm lift
Close 22.5° ABDC @ 1.0 mm lift
Duration 205.0°
Exhaust Open 27.5° BBDC @ 1.0 mm lift
Close 2.5° BTDC @ 1.0 mm lift
Duration 205.0°
Camshaft Journal Diameter 23.940 - 23.960 mm
Camshaft Journal Clearance 0.040 - 0.081 mm
Camshaft Journal Bore Diameter 24.000 - 24.021 mm
Camshaft End Float 0.23 - 0.33 mm
Camshaft Run-out 0.015 mm max.
Clutch / Primary Drive
Primary Drive Type Gear
Reduction Ratio 1.652:1 (76/46)
Clutch Type Wet multi-plate
No. of Friction Plates 9
Plate Flatness Within 0.2 mm
Friction Plate Thickness 3.00 mm
Clutch Actuation Method Cable

Clutch Pack Height 43.00 mm (+0.34/-0.66)
Cable Free Play (at lever) 2.0 - 3.0 mm
Pistons
Cylinder Bore Diameter 77.985 - 78.003 mm
Piston Diameter (at 90° to gudgeon pin) 77.970 - 77.980 mm
Piston Ring to Groove Clearances
Top 0.02 - 0.06 mm
Second 0.02 - 0.06 mm
Piston Ring End Gaps
Top 0.15 - 0.30 mm
Second 0.35 - 0.50 mm
Oil 0.10 - 0.40 mm
Gudgeon Pin Bore Diameter in Piston 16.994 - 17.001 mm
Gudgeon Pin Diameter 16.984 - 16.989 mm
Connecting Rods
Connecting Rod Small End Diameter 17.014 - 17.027 mm
Connecting Rod Big End Side Clearance 0.15 - 0.30 mm
Crankshaft
Crankshaft Big End Journal Diameter 32.994 - 33.010 mm
Crankshaft Big End Bearing Clearance 0.032 - 0.064 mm
Crankshaft Main Bearing Journal Diameter 32.972 - 32.998 mm
Crankshaft Main Bearing Clearance 0.020 - 0.046 mm

Crankshaft End Float 0.15 - 0.30 mm
Crankshaft Run-out 0.02 mm or less
Transmission
Type 6 Speed, Constant Mesh
Gear Ratios 1st 2.615:1 (34/13)
2nd 1.857:1 (39/21)
3rd 1.500:1 (36/24)
4th 1.285:1 (27/21)
5th 1.107:1 (31/28)
6th 0.967:1 (29/30)
Gear Selector Fork Thickness 5.9 - 6.0 mm
Gear Selector Groove Width 6.10 - 6.17 mm
Gear Selector Fork to Groove Clearance 0.47 mm max.
Lubrication
Type Pressure Lubrication, Wet Sump
Oil capacity (dry fill) 3.65 litres
Oil Capacity (wet fill including filter) 3.15 litres
Oil Capacity (wet fill excluding filter) 2.95 litres
Recommended Oil Approval Rating API SH (or higher) and JASO MA
Viscosity 10W/40 or 10W/50
Type Semi or fully synthetic
Oil Pressure (in main gallery) 3.4 bar (49 lb/ft2) min. @ 80°C oil temperature @ 5,000 rpm
Oil Pump Rotor Tip Clearance 0.15 mm
Oil Pump Body Clearance 0.15 - 0.22 mm
Oil Pump Rotor End Float 0.04 - 0.09 mm
Ignition System
Type Digital Inductive
Electronic Rev Limiter 10,000 (rpm)
Pick-up Coil Resistance 1.4 Ohms +/-15% @ 20°C
Ignition Coil Type Plug-top

Spark Plug Type NGK CR9EK
Spark Plug Gap 0.7 mm
Fuel System
Fuel Type Unleaded, 91 RON (U.S. 87 CLC/AKI)
Fuel Tank Capacity (motorcycle upright) 20 litres
Low Level Warning Lamp 4 litres remaining
Fuel Pump Type Submerged
Fuel Pressure (nominal) 3.5 bar
Purge Control System Electronic, via fuel system ECU
Fuel Injection System
Type Electronic, sequential
Idle Speed 1,200 rpm
Injector Type Twin jet, solenoid operated plate valve
Throttle Electronically controlled throttle bodies
Control Sensors Atmospheric air pressure, throttle position, twist grip

position, coolant temperature, crankshaft position,
oxygen sensor, intake air temperature, gear position,
MAP, vehicle speed (from ABS), Fuel Level, Fall
Detection
Emissions Controls
Catalysts 2, in down pipe
Oxygen sensor Heated, in down pipe
Evaporative Control Activated carbon canister
Secondary Air Injection Solenoid controlled, reed valve type
Coolant System
Coolant Mixture 50/50 (pre-mixed as supplied by Triumph)
Anti-Freeze Type Triumph HD4X Hybrid OAT coolant
Freezing point -35°C
Cooling System Capacity 2.25 litres
Radiator Cap Opening Pressure 1.1 bar
Thermostat Opening Temperature 88°C (nominal)
Cooling Fan Switch On Temperature 103°C
Temperature Gauge Sensor Resistance 2.3 - 2.6 K Ohms @ 20°C
Suspension
Front Fork Travel 240 mm
Recommended Fork Oil Grade Showa SS47G
Oil Level (spring removed and fork fully compressed) 90 mm
Front Fork Oil Volume (dry fill) 650 +/- 2.5 cc

Front Fork Pull Through 3 mm
Rear Wheel Travel 230 mm
Rear suspension Bearing Grease Grease to NLGI 2 specification
Frame
Frame Type Steel trellis
Overall Length 2,258 mm (100.7 in)
Overall Width 950 mm (37.4 in)
Overall Height 1,450 mm (57.1)
Wheelbase 1,552 mm (61.1 in)
Seat Height 850 mm / 870 mm (33.5 in / 34.3 in )
Rake 24.4°
Trail 115.9 mm
Maximum Payload (rider, passenger, luggage and accessories) 223 kg (491 lb)
Brakes
Front Type Two hydraulically actuated twin piston sliding calipers acting on twin
discs
Caliper Piston Diameter 2 x 30.00 mm
Disc Diameter 320 mm
Disc Thickness 4.5 mm
Disc Run-out (Installed) 0.15 mm max.
Master Cylinder Diameter 18.0 mm
Recommended Fluid DOT 4 Brake and Clutch Fluid
Rear Type Hydraulically actuated single piston caliper, single disc
Caliper Piston Diameter 34.0 mm
Disc Diameter 255 mm
Disc Thickness 5.5 mm
Disc Run-out (Installed) 0.5 mm max.
Master Cylinder Diameter 12.7 mm
Recommended Fluid DOT 4 Brake and Clutch Fluid
Wheels and Tyres
Front Wheel Size WM 2.15 x 21
Front Tyre Size 90/90 - 21 M/C 54V
Front Tyre Pressure - All Tyres 2.34 bar (34 lb/in²)
Recommended Front Tyre A list of approved tyres specific to these models is available from your
authorised Triumph dealer, or on the Internet at www.triumph.co.uk.
Front Wheel Rim Axial Run-out 1.0 mm

Front Wheel Rim Radial Run-out 1.0 mm
Rear Wheel Size MT 4.25x 17
Rear Tyre Size 150/70 R 17 M/C 69V
Rear Tyre Pressure - All except Pirelli Scorpion™ Rally 2.9 bar (42 lb/in²)
Rear Tyre Pressure - Pirelli Scorpion™ Rally 2.62 bar (38 lb/in²)
Recommended Rear Tyres A list of approved tyres specific to these models is available from your
authorised Triumph dealer, or on the Internet at www.triumph.co.uk.
Rear Wheel Rim Axial Run-out 1.0 mm
Rear Wheel Rim Radial Run-out 1.0 mm
Front Tyre Minimum Tread Depth 2 mm (0.08 mm)

Under 80 mph (130km/h)
Rear Tyre Minimum Tread Depth 2 mm (0.08 mm)

Under 80 mph (130km/h)
Front Tyre Minimum Tread Depth 2 mm (0.08 mm)

Over 80 mph (130km/h)
Rear Tyre Minimum Tread Depth 3 mm (0.12 inch)

Over 80 mph (130km/h)
Final Drive
Final Drive Chain
Final Drive Ratio 3.125:1 (50/16)
Chain Type RK O-ring
Number of Links 122
20 Link Length 317 mm
Drive Chain Play 30 - 40 mm
Chain Lubrication Chain spray suitable for O-ring chains
Torque Wrench Settings

Engine Covers
Application Torque (Nm) Notes
Front sprocket cover 9 Nm
Alternator cover (25 mm bolts) to crankcase 10 Nm
Alternator cover (35 mm bolts) to crankcase 10 Nm Fit new fixing(s) if loosened or removed
Wire retainer on alternator cover 6 Nm Fit new fixing(s) if loosened or removed
Crank cover (25 mm bolts) 10 Nm
Crank cover (35 mm bolts) 10 Nm Fit new fixing(s) if loosened or removed
Balancer cover to crankcase 8 Nm
Crankcase breather cover 10 Nm
Cylinder Head Area
Camshaft cover to cylinder head 10 Nm

Camshaft drive chain tensioner to head 9 Nm
Camshaft bearing ladder to head * Refer to Cylinder Head Section

Fit new fixing(s) if loosened or removed
Camshaft sprocket to camshaft 16 Nm Fit new fixing(s) if loosened or removed
Camshaft drive chain rubbing blade to crankcase 9 Nm Fit new fixing(s) if loosened or removed
Camshaft drive chain top pad to cylinder head * Refer to Cylinder Head Section
Cylinder head to crankcase (M6 screws) 10 Nm Fit new fixing(s) if loosened or removed
Cylinder head to crankcase bolts * Refer to Cylinder Head Section
Camshaft cap and ladder to cylinder head * Refer to Cylinder Head Section
Cylinder head dry seal plug 25 Nm Fit new fixing(s) if loosened or removed
Sound suppression bolt in head 12 Nm
Spark plugs 12 Nm
Cylinder head exhaust stud 10 Nm Fit new fixing(s) if loosened or removed
Coolant bypass spigot 15 Nm Fit new if loosened or removed
Clutch
Clutch cover to crankcase (28 mm bolts) 10 Nm Fit new fixing(s) if loosened or removed
Clutch cover to crankcase (35 mm bolts) 10 Nm Fit new fixing(s) if loosened or removed
Clutch centre nut 98 Nm Fit new fixing(s) if loosened or removed
Clutch pressure plate to centre drum 10 Nm
Clutch lever clamp bolts 9 Nm
Clutch lever nut 3.5 Nm
Clutch cable adjuster bracket to crankcase 12 Nm
Switch cover screws 2 Nm
Clutch cover protector 5 Nm
Crankshaft, Crankcase and Sprag
Crankcase upper to lower (M8 fixings) * Refer to Crankshaft Section
Crankcase upper to lower (M6 fixings) * Refer to Crankshaft Section
Crankcase dry seal plug 33 Nm Apply ThreeBond 1305 to the threads
Breather cover to crankcase 10 Nm
Connecting rod big end nut * Refer to Crankshaft Section
Camshaft drive sprocket gear to crankshaft 27 Nm Fit new fixing(s) if loosened or removed
Sprag clutch to alternator rotor * Refer to Transmission Section
M6 Stud 4 Nm Replace if removed
Transmission

Output sprocket to output shaft 85 Nm Fit new tab washer(s)
Detent wheel to selector drum 12 Nm Fit new fixing(s) if loosened or removed
Detent arm bolt 12 Nm Fit new fixing(s) if loosened or removed
Input shaft bearing carrier/retainer 12 Nm Fit new fixing(s) if loosened or removed
Selector shaft retainer 12 Nm Fit new fixing(s) if loosened or removed
Spring abutment bolt 15 Nm Fit new fixing(s) if loosened or removed
Gear position sensor 5 Nm
Gear pedal crank pinch bolt 12 Nm
Gear pedal pivot bolt 22 Nm Fit new fixing(s) if loosened or removed
Gear change rod adjuster nuts 6 Nm
Sprag housing to rotor 16 Nm Fit new fixing(s) if loosened or removed
Lubrication System
Sump to crankcase 12 Nm
Sump drain plug to sump 25 Nm Fit new sealing washer(s)
Oil pressure relief valve to crankcase 15 Nm Apply ThreeBond 1305 to the threads
Low oil pressure warning light switch to crankcase 13 Nm Fit new sealing washer(s)
Oil filter to adaptor 10 Nm
Oil filter adaptor 16 Nm Fit new fixing(s) if loosened or removed
Heat exchanger to crankcase 10 Nm Fit new fixing(s) if loosened or removed
Oil pump drive chain retainer plate 12 Nm Fit new fixing(s) if loosened or removed
Oil pump to crankcase 12 Nm Fit new fixing(s) if loosened or removed
Oil pump drive sprocket to pump shaft 12 Nm Apply ThreeBond 1374 to the threads
Oil pump rotor cover to pump body bolts 12 Nm
Oil pump pick up pipe 12 Nm Fit new fixing(s) if loosened or removed
Oil transfer pipe 12 Nm Fit new fixing(s) if loosened or removed
Water pump cover to oil pump body bolts 12 Nm
Transmission oil feed pipes to crankcase 12 Nm Fit new fixing(s) if loosened or removed
Breather drain tube 12 Nm Fit new fixing(s) if loosened or removed
Frame, Footrests, Control Plates and Engine Mountings
Lower crankcase to frame 48 Nm Refer to Engine Remove/Refit Section
Cylinder head to frame 48 Nm Refer to Engine Remove/Refit Section
Heel guard to control plate 10 Nm
Side stand mounting bracket 55 Nm
Side stand switch 3 Nm Fit new fixing(s) if loosened or removed
Seat lock to frame 6 Nm Fit new fixing(s) if loosened or removed

Lower rear engine mounting frame adjuster 10 Nm
Engine bars to engine 15 Nm
Engine bar centre to engine bar 6 Nm
Centre stand spring pin 7 Nm Fit new if loosened or removed
Rear subframe 58 Nm
Bank angle indicators 9 Nm Fit new if loosened or removed
Control plates to frame 30 Nm
Rear footrest hanger 27 Nm
Rear footrest rubber 4 Nm
Fuel System, Exhaust System and Airbox
Fuel tank to frame (rear fixing) 10 Nm Fit new fixing(s) if loosened or removed
Fuel tank rear brackets to fuel tank 6 Nm
Fuel cap to fuel tank 4 Nm
Fuel pump mounting plate to fuel tank 9 Nm
Throttle body transition piece to cylinder head 8 Nm Fit new fixing(s) if loosened or removed
Throttle body adaptor clip 1.5 Nm
Fuel rail to throttle body 3.4 Nm
Exhaust header to cylinder head * Refer to Fuel Section
Exhaust header to frame 19 Nm
Silencer heat shield 5 Nm Torque every service
Silencer to subframe 15 Nm
Silencer rear finisher 5 Nm Fit new fixing(s) if loosened or removed
Silencer front finisher 5 Nm Fit new fixing(s) if loosened or removed
Silencer clamp to header assembly 10 Nm
Oxygen sensor 25 Nm Apply anti-seize compound to threads
Catalytic converter heat shield 5 Nm
Air filter cover to housing 1.5 Nm
Airbox to breather cover 9 Nm Fit new fixing(s) if loosened or removed
Airbox top to airbox bottom 1.5 Nm
Airbox to throttle bodies 6 Nm
Air temperature sensor 1.5 Nm
Manifold air pressure (MAP) sensor 1.5 Nm
Ambient air pressure sensor 1.5 Nm
Fall detection switch 3 Nm Fit new fixing(s) if loosened or removed
Crankshaft position sensor 6 Nm Fit new fixing(s) if loosened or removed
Evaporative canister to fuel tank 6 Nm Fit new fixing(s) if loosened or removed

Gear position sensor 5 Nm
Secondary air injection reed covers 9 Nm
Purge valve to bracket 3 Nm
Cooling System
Radiator to frame bottom bolts 6 Nm
Radiator to frame top nuts 9 Nm
Radiator guard to radiator 3 Nm
Coolant by-pass to cylinder head 15 Nm
Thermostat housing to cylinder head 9 Nm
Water elbow to crankcase 8 Nm
Fan shroud to radiator 8.5 Nm
Water temperature sensor 18 Nm Apply ThreeBond 1374 to the threads
Expansion tank to frame 3 Nm Fit new fixing(s) if loosened or removed
Water pump outlet pipe 12 Nm Fit new fixing(s) if loosened or removed
Water pump inlet pipe 12 Nm Fit new fixing(s) if loosened or removed
Front Suspension
Upper yoke pinch bolt 25 Nm
Lower yoke pinch bolt 25 Nm
Upper yoke centre nut 120 Nm
Fork top cap to damper rod 20 Nm
Fork top cap 35 Nm
Damping cylinder bolt 20 Nm Fit new sealing washer(s)
Handlebar clamp and riser to upper yoke (10 mm bolt) 35 Nm
Handlebar upper clamp to riser (8 mm bolt) 26 Nm Apply clean engine oil to the thread(s)
Handlebar end weights 6 Nm Fit new if loosened or removed
Mirror 25 Nm
Left hand heated grip 3 Nm If fitted
Left hand heated grip housing 0.5 Nm
Yoke wire guide, lower 5 Nm Fit new if loosened or removed
Rear Suspension
Swinging arm spindle nut 110 Nm Fit new fixing(s) if loosened or removed
Chain rubbing strip to swinging arm 9 Nm
Rear suspension unit upper mounting nut 60 Nm Apply torque to the nut, counter hold the bolt
Rear suspension unit lower mounting to drop link nut 80 Nm Apply torque to the nut, counter hold the bolt

Drag link pivot at frame 80 Nm Apply torque to the nut, counter hold the bolt
Drop links to swinging arm nut 80 Nm Apply torque to the nut, counter hold the bolt
Chain guard (upper) 9 Nm
Chain guard (lower) 7 Nm
Front Brakes
Front brake caliper to fork 45 Nm
Front brake caliper bleed screw 10 Nm
Front brake hose to caliper 25 Nm Fit new sealing washer(s)
Front brake master cylinder to handlebar 9 Nm Apply torque to the top fixing first
Front brake hose to master cylinder 25 Nm Fit new sealing washer(s)
Front brake disc to wheel 22 Nm Fit new fixing(s) if loosened or removed
Brake lever pivot bolt 1.5 Nm
Brake lever pivot bolt lock nut 5.5 Nm
Master cylinder brake hose clamp to fork leg 4 Nm
Brake hose wire guide 6 Nm
Front brake light switch 2.5 Nm
Front brake fluid reservoir cap 0.7 Nm
Front brake reservoir to bracket 3.5 Nm Hold the nut to allow the bolt to torque
Tension adjuster for the front brake lever angle 5.5 Nm
Front brake fluid reservoir bracket to master cylinder 2.5 Nm
Front brake master cylinder bleed screw 8 Nm
Rear Brakes
Rear brake caliper sliding pin into caliper 22.5 Nm
Rear brake caliper sliding pin into carrier 14 Nm
Rear brake caliper bleed screw 14 Nm
Rear brake hose to caliper 25 Nm Fit new sealing washer(s)
Rear brake master cylinder to frame 16 Nm
Rear brake master cylinder reservoir to mounting 7 Nm Fit new fixing(s) if loosened or removed
Rear brake master cylinder reservoir cap fixings 1 Nm
Rear brake master cylinder push rod lock nut 18 Nm
Rear brake hose to master cylinder 25 Nm Fit new sealing washer(s)
Brake pedal pivot bolt 22 Nm Fit new fixing(s) if loosened or removed
Brake hose P-clip bolt 5 Nm
Rear brake disc to wheel 22 Nm Fit new fixing(s) if loosened or removed
ABS System

ABS bracket to frame 9 Nm Fit new fixing(s) if loosened or removed
ABS lines to modulator 25 Nm
ABS module to bracket 9 Nm Fit new fixing(s) if loosened or removed
ABS pulser ring to brake disc 22 Nm Fit new fixing(s) if loosened or removed
ABS sensor to bracket 9 Nm
Brake pressure switch 15 Nm
Brake pressure switch manifold 9 Nm
Wheels
Front wheel spindle/axle bolt 65 Nm
Front wheel spindle pinch bolts 22 Nm
Rear wheel spindle 110 Nm
Chain adjuster lock nut 15 Nm
Rear sprocket to cush drive 33 Nm Fit new fixing(s) if loosened or removed. Apply torque
to the nut, counter hold the bolt
Final Drive
Rear sprocket to cush drive 33 Nm Hold the nut to allow the bolt to torque
Chain rubbing strip to swinging arm 9 Nm
Bodywork
Front mudguard to forks 3 Nm
Front fork protectors to front mudguard TBA
Handguard to bracket 5 Nm Fit new fixing(s) if loosened or removed
Handguard to handlebar spacer 5 Nm Fit new fixing(s) if loosened or removed
Sump guard screws to sump 6 Nm
Sump guard bracket to sump 15 Nm
Sump guard side bolts 6 Nm
Engine protection bars to engine 15 Nm If fitted
Centre bar to engine protection bar 6 Nm If fitted

Fit new fixing(s) if loosened or removed
Front subframe to frame 30 Nm Apply torque to the nut, counter hold the bolt
Cable tidy to front subframe 20 Nm Fit new fixing(s) if loosened or removed
Beak and support assembly to front subframe 3 Nm
Beak to beak support moulding 1.5 Nm
Front licence plate bracket (India and Indonesia only) 5 Nm
Front licence plate bracket spacer (India and Indonesia only) 3 Nm

Screen bracket 5 Nm
Screen 3 Nm
Screen adjuster mount boss 3 Nm
Side screens to screen support 3 Nm
Cockpit side panel to head light 3 Nm
Cockpit side panel to side blade bracket 3 Nm
Cockpit side panel brackets to fuel tank 5 Nm
Cockpit side panel infill to side blade 3 Nm
Cockpit side panel infill to side blade sliding joint shouldered bolt 3 Nm Fit new fixing(s) if loosened or removed
Ignition switch cover 5 Nm
Fuel tank panel, front 3 Nm
Fuel tank panel end to side blade infill 3 Nm
Radiator cowl finisher 3 Nm
Radiator rear lower cowl to fuel tank 3 Nm
Radiator rear lower cowl to front lower cowl 3 Nm
Lower rear radiator cowl to radiator 6 Nm
Rear mudguard to rear mudguard bracket 1 Nm
Rear mudguard bracket to rear subframe 6 Nm Fit new fixing(s) if loosened or removed
Phone tray to rear mudguard bracket 3 Nm
Phone tray to rear seat hook 3 Nm
Rear mudguard to frame 6 Nm Fit new fixing(s) if loosened or removed
Rear frame infill panels to rear mudguard 1 Nm
Seat lock bracket to rear mudguard support 6 Nm
Seat lock bracket to left rear frame infill panel 1 Nm
Inner mudguard cover 6 Nm
Licence plate centre hanger to licence plate side hanger 6 Nm
Licence plate hanger side to rear subframe 25 Nm
Grab rail bracket to rear infill panel and side licence plate hangers 6 Nm
Rear infill panel to licence plate centre hanger 1.5 Nm
Grab rail to subframe bolts 25 Nm
Grab rail bracket to grab rail 6 Nm
Grab rail to licence plate centre hanger 6 Nm
Grab rail finisher fixings 3 Nm
Front seat bridge 5 Nm
Rear seat bracket fixing 5 Nm
Seat panels to seat bridge 3 Nm
Seat panels to fuel tank 3 Nm

Saree guard top fixings - India only 25 Nm
Saree guard front fixing - India only 12 Nm
Electrical
Alternator rotor to crankshaft 130 Nm See Electrical Section
Alternator VR sensor cable guide 3 Nm Fit new fixing(s) if loosened or removed
Alternator stator to cover 12 Nm Fit new fixing(s) if loosened or removed
Alternator regulator/rectifier to bracket 9 Nm
Alternator cover 25 mm fixings 10 Nm
Alternator cover 35 mm fixings 10 Nm Fit new fixing(s) if loosened or removed
Battery terminal fixings 4.5 Nm
Starter motor to crankcase 10 Nm
Starter motor power lead connection 3 Nm
Starter motor solenoid lead connection 5 Nm
Spark plug to cylinder head 12 Nm
Horn 12 Nm
Inertial measurement unit (IMU) 6 Nm Fit new fixing(s) if loosened or removed
Immobiliser ECM 9 Nm Fit new fixing(s) if loosened or removed
Ignition switch 16 Nm Fit new fixing(s) if loosened or removed
Instrument assembly to instrument mount 3.5 Nm
Instrument mount to front subframe 3 Nm
Headlight 4 Nm
Rear light 3 Nm
Front and rear direction indicator 3 Nm
Negative battery lead to upper crankcase 9 Nm
Auxiliary power socket fixing 2 Nm
Ambient air temperature sensor 5 Nm
Fog light bracket to front subframe 20 Nm Fit new fixing(s) if loosened or removed
Fog light and shroud to bracket 6 Nm
Routings
Clutch Cable Routing

ckqp
ABS Hose Routing
ckqq

Main Wiring Harness Routing
ckqu
Fuel Tank Breather Hose Routing

ckqr
Routine Maintenance
Scheduled Maintenance
WARNING
Triumph Motorcycles cannot accept any responsibility for damage or injury resulting from incorrect maintenance or improper adjustment carried out by the owner.
Incorrect or neglected maintenance can lead to a dangerous riding condition.
Always have an authorised Triumph dealer carry out the scheduled maintenance of this motorcycle.
WARNING
All maintenance is vitally important and must not be neglected. Incorrect maintenance or adjustment may cause one or more parts of the motorcycle to malfunction. A
malfunctioning motorcycle may lead to loss of control and an accident.
Weather, terrain and geographical location affect maintenance. The maintenance schedule should be adjusted to match the particular environment in which the motorcycle
is used and the demands of the individual owner.
Special tools, knowledge and training are required in order to correctly carry out the maintenance items listed in the scheduled maintenance chart. Only an authorised
Triumph dealer will have this knowledge and equipment.
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.
To maintain the motorcycle in a safe and reliable condition, the maintenance and adjustments outlined in this section must be carried out as specified in the schedule of daily
checks, and also in line with the scheduled maintenance chart. The information that follows describes the procedures to follow when carrying out the daily checks and some
simple maintenance and adjustment items.
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 6,000 miles (10,000 km) per year must be maintained annually. In addition to this, mileage based items require maintenance at their
specified intervals, as the motorcycle reaches this mileage.
2. Motorcycles travelling approximately 6,000 miles (10,000 km) per year must have the annual maintenance and the specified mileage based items carried out together.
3. Motorcycles travelling more than 6,000 miles (10,000 km) per year must have the mileage based items maintained as the motorcycle reaches the specified mileage. In
addition to this, annual based items will require maintenance at their specified annual intervals.
In all cases maintenance must be carried out at or before the specified maintenance intervals shown. Consult an authorised Triumph dealer for advice on which maintenance
schedule is most suitable for your motorcycle.
Triumph Motorcycles cannot accept any responsibility for damage or injury resulting from incorrect maintenance or improper adjustment.
Service Symbol/General Warning Symbol
The service symbol will illuminate for five seconds after the motorcycle start up sequence as a reminder that a service is due in approximately 60 miles (100 km). The
service symbol will illuminate permanently when the mileage is reached, it will remain permanently illuminated until the service interval is reset using the Triumph Diagnostic
tool.
The general warning symbol will flash if an ABS or engine management fault has occurred and the ABS and/or MIL warning lights are illuminated. Contact an authorised
Triumph dealer as soon as possible to have the fault checked and rectified.

Scheduled Maintenance Table
Operation Description Odometer Reading in Miles (km) or Time Period, whichever comes first
First Service Annual Service Mileage Based Service
Every 600 (1000) Year 6,000 and 12,000 24,000
6 Months 18,000 (20,000) (40,000)
(10,000 and
30,000)
Lubrication
Engine oil – renew - • • • • •
Engine and oil filter – renew - • • • • •
Engine and oil cooler – check for leaks Day • • • • •
Fuel System and Engine Management
Fuel system – check for leaks, chafing etc. Day • • • • •
Throttle body plate (butterfly) - check/clean - • •
Autoscan – carry out a full Autoscan using the Triumph diagnostic - • • • • •

tool (print a customer copy)
ABS modulator – check for stored DTCs - • • • • •
Secondary air injection system - check/clean - • •
Air cleaner – renew - • •
Throttle bodies – balance - • • •
Ignition System
Spark plugs – renew - • •
Cooling System
Cooling system – check for leaks Day • • • • •
Coolant level – check/adjust Day • • • • •
Coolant – renew Every three years, regardless of mileage
Engine
Clutch cable – check/adjust Day • • • • •
Clutch lever pivot - clean/grease • • • •
Valve clearances – check/adjust - • •
Camshaft timing - adjust First 12,000 mile (20,000 km) service only
Wheels and Tyres
Wheels – inspect for damage Day • • • • •
Wheel bearings – check for wear/smooth operation - • • • • •
Wheels – check wheels for broken or damaged spokes and check Day • • • • •
spoke tightness (if fitted)
Tyre wear/tyre damage – check Day • • • • •
Tyre pressures – check/adjust Day • • • • •
Electrical
Lights, instruments and electrical systems – check Day • • • • •
Steering and Suspension
Steering – check for free operation Day • • • • •
Forks – check for leaks/smooth operation Day • • • • •
Fork oil – renew - •

Operation Description Odometer Reading in Miles (km) or Time Period, whichever comes first
First Service Annual Service Mileage Based Service
Every 600 (1000) Year 6,000 and 12,000 24,000
6 Months 18,000 (20,000) (40,000)
(10,000 and
30,000)
Headstock bearings – check/adjust - • • • •
Headstock bearings – lubricate - • •
Rear suspension linkage – check/lubricate - • •
Brakes
Brake pads – check wear levels Day • • • • •
Brake master cylinders – check for fluid leaks Day • • • • •
Brake calipers – check for fluid leaks and seized pistons Day • • • • •
Brake fluid levels – check Day • • • • •
Brake fluid – renew Every two years, regardless of mileage
Drive Chain
Drive chain slack – check/adjust Day • • • • •
Drive chain – wear check Every 500 miles (800 km)
Drive chain – lubricate Every 200 miles (300 km)
Drive chain rubbing strip – check Day •
Drive chain rubbing strip – renew - • • •
General
Fasteners – inspect visually for security Day • • • • •
Bank angle indicators – inspect visually for wear Day • • • • •
Accessory rack sliding carriage – check for correct operation ‡ - • • • •
Side stand – check operation Day • • • • •
Side stand pivot – clean/grease - • • •
Centre stand – check operation Day • • • • •
Centre stand – clean/grease - • • • •
Accessory pannier link mechanism – check for correct operation - • • • •

and adjustment ‡
Carry out all outstanding service bulletin and warranty work - • • • • •
Carry out road test - • • • • •
Complete the service record book and reset the service indicator - • • • • •
* Evaporative system fitted to models for certain markets only.

‡ Only if fitted.
Service Specifications
Engine Oil Type Semi or fully synthetic
Engine Oil Capacity (Wet Fill Including Filter) 3.15 litres
Spark Plug Type NGK CR9EK
Spark Plug Gap 0.7 mm
Coolant Type Triumph HD4X Hybrid OAT coolant

Coolant Capacity 2.25 litres
Cutch Lever Free Play 2.0 - 3.0 mm
Valve Clearances - Inlet 0.10 - 0.20 mm
Valve Clearances - Exhaust 0.325 - 0.375 mm
Front Tyre Pressure 2.34 bar (34 lb/in²)
Rear Tyre Pressure - All except Pirelli Scorpion™ Rally 2.9 bar (42 lb/in²)
Rear Tyre Pressure - Pirelli Scorpion™ Rally 2.62 bar (38 lb/in²)
Fork Oil Grade Showa SS47G
Fork Oil Level - Left Hand Fork 90 mm
Fork Oil Level - Right Hand Fork 90 mm
Fork Oil Volume - Left Hand Fork 650 +/- 2.5 cc
Fork Oil Volume - Right Hand Fork 650 +/- 2.5 cc
Front Fork Pull Through 3 mm
Front Brake Disc Maximum Run Out 0.15 mm max.
Rear Brake Disc Maximum Run Out 0.5 mm max.
Front Brake Disc Minimum Thickness 4.0 mm
Rear Brake Disc Minimum Thickness 5.0 mm
Brake Fluid Type DOT 4 Brake and Clutch Fluid
Drive Chain Type RK O-ring
Drive Chain Slack 30 - 40 mm
Drive Chain 20 Link Limit 317 mm
Drive Chain Lubrication Chain spray suitable for O-ring chains
Service Torque Wrench Settings
Oil Filter 10 Nm Apply clean engine oil to the seal(s)
Sump Plug 25 Nm Fit new sealing washer(s)
Air Filter Housing Fixings 1.5 Nm
Spark Plugs 12 Nm
Camshaft Cover 10 Nm See Camshaft Cover - Installation

Apply clean engine oil to the seal(s)
Front Wheel Spindle 65 Nm
Front Wheel Spindle Pinch Bolts 22 Nm
Upper Yoke Centre Nut 120 Nm
Swinging Arm Spindle Nut 110 Nm
Front Brake Master Cylinder Reservoir Cap 0.7 Nm
Front Brake Master Cylinder Bleed Screw 8 Nm
Front Brake Hose to Caliper 25 Nm Fit new sealing washer(s)
Front Brake Hose to Master Cylinder 25 Nm Fit new sealing washer(s)
Front Brake Caliper 45 Nm

Front Brake Caliper Bleed Screw 10 Nm
Rear Brake Master Cylinder Reservoir 7 Nm Fit new fixing(s) if loosened or removed
Rear Brake Hose to Master Cylinder 25 Nm Fit new sealing washer(s)
Rear Brake Master Cylinder to Control Plate 16 Nm
Rear Brake Caliper Bleed Screw 14 Nm
Fuel Tank to Frame (Rear Fixing) 10 Nm
Battery Terminals 4.5 Nm
Engine Check For Fluid Leaks
WARNING
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.
Check:
Check the visible areas of the crankcase, cylinder head and transmission for fluid leaks.
Visually inspect the oil hoses (if fitted) for fluid leaks and signs of damage or chafing (where accessible).
Rectification if required:
A leaking or damaged component must be replaced.
Engine Oil - Level Inspection
In order for the engine, transmission, and clutch to function correctly, maintain the engine oil at the correct level, and change the oil and oil filter in accordance with scheduled
maintenance requirements.
WARNING

WARNING
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.
WARNING
Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated engine wear resulting in engine or transmission seizure. Seizure of the
engine or transmission may lead to loss of motorcycle control and an accident.
CAUTION
Running the engine with insufficient oil will cause engine damage. If the low oil pressure indicator remains on, stop the engine immediately and investigate the cause.
1. Start the engine and run at idle for approximately five minutes.
2. Stop the engine, then wait for at least three minutes to allow the oil to settle.
3. Note the oil level visible in the sight-glass.
3
4

B00531
1. Filler
2. Sight-glass
3. Oil level (correct level shown)
4. Crankcase oil level lines
4. When correct, oil should be visible in the sight-glass at a point midway between the two horizontal lines marked on the crankcase.
Note
An accurate indication of the level of oil in the engine is only shown when the engine is at normal operating temperature and the motorcycle is upright (not on
the side stand).
5. If it is necessary to top up the oil level, remove the filler plug and add oil, a little at a time, until the level registered in the sight glass is correct.
6. Once the correct level is reached, fit and tighten the filler plug.
Oil and Oil Filter - Renew
WARNING

WARNING
Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contamination which
The engine oil and filter must be replaced in accordance with scheduled maintenance requirements.
Perform the following operations:

Aluminium Sump Guard - Removal
1. Warm up the engine thoroughly, and then stop the engine.
2. Place an oil pan beneath the engine.
WARNING
The oil may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned.
3. Remove the oil drain plug.
1
B00530
1. Oil drain plug

2. Oil filter
4. With the motorcycle on level ground, and on the side stand, allow the oil to completely drain.
5. Unscrew and remove the oil filter using Triumph service tool T3880313.
6. Dispose of the old filter in an environmentally friendly way.
7. Apply a smear of clean engine oil to the sealing ring of the new oil filter.
8. Fit the oil filter and tighten to 10 Nm using T3880313 - Oil Filter Wrench.
9. After the oil has completely drained out, fit a new sealing washer to the drain plug. Fit and tighten the plug to 25 Nm.
10. Fill the engine with new oil of the type and grade listed (see Lubrication).
11. Start the engine and allow it to idle for a minimum of 30 seconds.
CAUTION
Raising the engine speed above idle before the oil reaches all parts of the engine can cause engine damage or seizure. Only raise engine speed after running the engine for
30 seconds to allow the oil to circulate fully.
12. Ensure that the oil pressure warning light extinguishes shortly after starting.
CAUTION
If the engine oil pressure is too low, the low oil pressure warning light will illuminate. If this light stays on when the engine is running, stop the engine immediately and
investigate the cause. Running the engine with low oil pressure will cause engine damage.

13. Stop the engine and check the oil level. Adjust if necessary.
14. Install the sump guard (see Aluminium Sump Guard - Installation).
Fuel/Evaporative System - Check For Leaks, Routing, Chafing and Security
Standard required:
Fuel/evaporative hoses must be secure and routed in such a way that they do not chafe against moving parts of the motorcycle.
Fuel/evaporative hoses must not be routed around sharp curves. This could cause restrictions in the flow of fuel.
Fuel/evaporative system components must be free from damage.
The fuel tank cap must be easy to open and close.
The fuel tank cap seal must be free from damage.
The fuel cap lock barrel and key (if fitted) must operate easily and smoothly.
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.
Fuel/evaporative leaks must be rectified.

Damaged fuel/evaporative system components must be replaced.
An incorrectly fitting fuel cap must be replaced.
Throttle Body Plate (butterfly) - Check/Clean
WARNING


Throttle Bodies/Injectors - Removal
1. Using a lint free cloth and a suitable degreaser such as Castrol Motorcycle Parts Cleaner, remove any residue from the internal surfaces and throttle plate (butterfly).
2. Check for any signs of damage and ensure the butterfly moves correctly.
Throttle Bodies/Injectors - Installation
Throttle Body Balancing
CAUTION
The fixings for the throttle position sensor, throttle butterfly adjustment screws and the throttle hard stop blanking screw are marked with yellow paint and must not be
loosened or removed.
If the fixings, adjustment screws or blanking screw have been loosened or removed the throttle body assembly must be replaced as there are no means to reset these items
to their correct positions.
Note
The fixings for the throttle position sensor, throttle butterfly adjustment screws and the throttle hard stop blanking screw are marked with yellow paint and
must not be loosened or removed. If the fixings, adjustment screws or blanking screw have been loosened or removed any warranty claims for the throttle
bodies will be rejected.
The three air bypass adjustment screws on the throttle bodies also have the yellow paint on them, these three screws can be moved for throttle balance only.
2
1
1. Throttle position sensor fixings

2. Throttle butterfly adjustment screws
3. Throttle hard stop blanking screw
The throttle body balance adjustment is made with the air bypass adjustment screws only. This adjustment alters the amount of air that can flow through the air bypass drilling.
DO NOT remove the throttle hard stop blanking screw to adjust the throttle balance.

1
cipo_1
1. Air bypass drilling (throttle bodies shown removed

for clarity)
2. Air bypass adjustment screws
Adjust the air bypass screws such that there is a minimum amount of adjustment used on each adjustment screw to achieve throttle balance. For example, if MAP pressures
were as follows and were shown to be out of balance:
Cylinder 1 MAP Pressure: 490 mmHg
Each cylinder should be adjusted to 450 mmHg, this will help minimise the amount of adjustment at each adjustment screw.
Note
The throttles cannot be balanced using equipment to measure vacuum in each throttle. Instead, the Triumph diagnostic software must be used.
Rider's Seat - Removal/Installation
Fuel Tank - Removal
Airbox - Removal
WARNING
If the engine has recently been running, the components beneath the fuel tank may be hot to the touch.
1. Turn the ignition to the OFF position.

2. Using T3880123 - Extension Cable carefully connect the fuel pump connection on the main harness to the fuel tank. Connect the other end of the harness extension to the
motorcycle main harness.
3. Select the fuel pressure gauge adaptor marked B from T3880001 - Fuel Pressure Gauge.
WARNING
Always use the correct fuel pressure gauge adaptor (adaptor B for all Tiger 900 models). Use of an incorrect adaptor will result in a fuel leak. A fuel leak can result in a fire
causing damage to property and injury to persons.
4. Connect the adaptor hose to the fuel pump plate outlet as shown in the illustration below.
cdve_5
1. Adaptor hose B
2. Fuel pump plate outlet
3. T3880123 - Extension Cable
5. Connect the fuel hose to the adaptor hose as shown in the illustration below.

3 2
B00603
1
1. Motorcycle fuel hose

2. Adaptor hose B
3. T3880123 - Extension Cable
4. Fuel pump connection
5. Fuel pump plate outlet
Note
If disconnected, temporarily reconnect the immobiliser multiplug.
6. Attach exhaust extraction hoses to the silencer.
7. Attach the Triumph diagnostic tool to the dedicated plug, refer to the Triumph Diagnostic Tool User Guide. Start the engine, and allow to idle.
8. On the diagnostic software navigate to ADJUST TUNE.
9. Select BALANCE THROTTLES.
10. Click the Adjust button.
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

Adjusting parameter - Balance Throttles
Balance Throttles Screen
Note
The balance throttles screen will show the vacuum value of each throttle in mmHg. In addition, when the throttles are balanced to an acceptable range of each
other the words THROTTLES BALANCED in green text will appear on the right of the screen. At this point, no further adjustment is necessary or productive.
If the throttles are not balanced to each other the word THROTTLES UNBALANCED in red text will appear on the right of the screen. At this point adjustment
will be necessary.
There is an air bypass adjustment screw on each of the three cylinders.
DO NOT attempt to adjust the throttle hard stop screw, located below the throttle hard stop blanking screw. The stop screw is set at the factory during
manufacture, and must not be adjusted.
11. Using the air bypass adjustment screws, make adjustments to the three cylinders until the word THROTTLES BALANCED in green text appears.
1
cipr
1. Air by-pass adjustment screws
12. When balanced, stop the engine and disconnect the diagnostic tool.
13. Disconnect the fuel pressure gauge adaptor and wiring extension.
14. Remove the exhaust extraction hoses from the silencer.
Airbox - Installation
Fuel Tank - Installation
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.
Print a customer copy.
Air Filter - Renew
WARNING

Removal

Battery - Terminal Disconnect
1. Remove the left and right seat panels.
2. Remove the six fixings that secure the air filter housing into the airbox.
B00514
1. Air filter housing fixings

2. Air filter housing
3. Remove the air filter housing, with the air filter element, from the airbox.
B00515
1. Air filter
2. Air filter housing
4. Remove and discard the old air filter element.
Installation
1. Install a new air filter element into the air filter housing.
2. Install the air filter housing and air filter into the airbox.
3. Install the six fixings and tighten to 1.5 Nm.
Battery - Terminal Connect
Secondary Air Injection Reed Valves - Inspection
1. Check for cracks, bending or other damage to the valve flaps. Replace as necessary.
2. Check for damage to the seal areas. Replace as necessary.
3. Check the valve body to camshaft cover seal for damage.
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.
Dark colouring, such as heavy wet or dry deposits, can indicate:
an overly rich condition

too cold a heat range spark plug
a possible vacuum leak
low compression
overly retarded timing
too large a spark plug gap.
If the deposits are wet, it can be an indication of:
a breached head gasket
poor oil control from the piston rings
valve train problems
an extremely rich condition - depending on the actual liquid present at the firing tip.
Signs of fouling or excessive heat must be traced quickly to prevent further deterioration of performance and possible engine damage.
Normal Condition
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.
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.
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.
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).
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. The surface of the electrodes will also be fretted and rough.
Spark Plugs - Check/Renew
WARNING


Fuel Tank - Removal
1. Detach the electrical connections from the ignition coils.
2. Remove the ignition coils from the cylinder head.
3. Use a suitable tool to remove the spark plugs from the cylinder head.
4. Check the condition of the spark plug cap seal for wear and/or damage. Replace as necessary.
5. Check for signs of abnormal discolouration or deposits (see Spark Plugs - Inspection).
6. Check and, if necessary, adjust the spark plug gap to 0.7 mm.
7. Refit the spark plugs or, if required, fit new spark plugs and tighten to 12 Nm.
8. Inspect the seals for the ignition coils for damage and replace if necessary.
9. Refit the ignition coils and reconnect the electrical connections to the ignition coils .
Coolant System - Check For Fluid Leaks
WARNING

WARNING
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. Contact with hot coolant will cause scalds and skin damage.
CAUTION
If the coolant level is found to be low, or if coolant has to be added regularly, inspect the cooling system for coolant leaks. If necessary, pressure test the system to locate the
source of the leak and rectify as necessary. Loss of coolant may cause the engine to overheat and suffer severe damage.
All cooling system components must be free from fluid leaks.

Check the visible areas of the radiator heat exchanger/oil cooler (if fitted) for fluid leaks.
Visually inspect the coolant hoses for fluid leaks.
A leaking or damaged cooling system component must be replaced.
Coolant System - Check Hoses Check For Chafing, Cracks, Damage

WARNING

WARNING
CAUTION
1. Visually inspect the coolant hoses for cracks, damage, leaks or splits .
2. Check the coolant hoses for correct routing, they are secured by the relevant brackets and are not chafing.
3. Check the hose clamps for damage and corrosion.
4. If necessary, pressure test the system to locate the source of the leak and rectify as necessary.
5. Replace any defective components as required.
6. If the level of coolant is low, see Coolant Level - Adjustment.
Coolant Level - Inspection
WARNING

WARNING
Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with hot
CAUTION
Note
Only inspect the coolant level when the engine is cold.
The coolant within the expansion tank can be inspected without removing any covers. The expansion tank can be viewed from the right hand side of the
motorcycle, below and towards the front of the fuel tank.
1. Position the motorcycle on level ground and in an upright position.
2. The coolant level should be between the MAX and MIN marks.
2
3
B00550
1. Expansion tank (fuel tank end panel shown

removed for clarity)
2. MAX mark
3. MIN mark
3. If the level of coolant is low, remove the cap from the expansion tank and add coolant mixture as necessary to bring the level up to the MAX mark. Refit the cap.

B00525
1. Expansion tank cap
Coolant Level - Adjustment
WARNING

WARNING
Note
If the coolant level is being checked because the coolant has overheated, also check the level in the right radiator and top up if necessary.
In an emergency, distilled water can be added to the cooling system. However, the coolant must then be drained and replenished with HD4X Hybrid OAT coolant
as soon as possible.
1. Allow the engine to cool for a minimum of 30 minutes.
2. Position the motorcycle on level ground and in an upright position.
3. The expansion tank can be viewed from the right hand side of the motorcycle, below and towards the front of the fuel tank. The coolant level should be between the MAX
and MIN marks.
2
3
B00550
1. Expansion tank (fuel tank end panel shown

removed for clarity)
2. MAX mark
3. MIN mark
4. If the level of coolant is low, remove the cap from the expansion tank.
B00525
1. Expansion tank cap
5. Add coolant mixture as necessary to bring the level up to the MAX mark.
6. Refit the coolant expansion tank cap.
Coolant Renew
WARNING

WARNING

WARNING
Allow the engine to cool for a minimum of 30 minutes.

Drain the coolant (see Coolant Replacement - Drainage).
Refill the coolant with Triumph HD4X Hybrid OAT coolant(see Coolant Replacement - Filling).
Clutch Cable - Check/adjust
WARNING

Standard required:
It should be possible to pull the clutch lever easily and smoothly towards the handlebar grip.
The clutch cable must be routed such that it does not chafe against moving parts of the motorcycle.
When the clutch lever is released, check for correct clutch free play at the lever is as described in the Clutch Free Play C*7
Check:
Check the action of the clutch by pulling the clutch lever towards the handlebar grip in order to disengage the clutch.
Check that the clutch cable is correctly routed and free from sharp bends or twists along its length.
Check that the clutch lever returns to the fully forward position when released (allowing for the specified free-play).
Check the operation of the clutch lever span adjuster.
If necessary, adjust the clutch cable as described in the Owner’s Handbook.

If undue resistance is felt when pulling the clutch lever towards the handlebar grip, check that the clutch cable is correctly routed. Twists or sharp bends in the cable will result in
increased friction between the inner and outer cables.
Valve Clearance - Measurement
WARNING

Note
Valve clearance measurement must be carried out with the engine cold.
Camshaft Cover - Removal
1. Remove the spark plugs to reduce compression resistance when turning the engine.
2. Select a high gear and, using the rear wheel, turn the engine until a pair of camshaft lobes are positioned pointing away from the valves.
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.
Note
If the measurement does not fall within the specified range, adjustment must be made, (see Valve Clearance - Adjustment.
The correct valve clearances are in the range given below:
Inlet 0.10 - 0.20 mm
Exhaust 0.325 - 0.375 mm
CAUTION
If the valve clearances are not checked and corrected, wear could cause the valves to remain partly open, which lowers performance, burns the valves and valve seats and
may cause serious engine damage.
5. Record the measured valve clearances on a chart similar to the example shown.
Typical Valve Clearance Chart

Inlet Valve No. Gap Measured
1 as measured (mm)
2 as measured (mm)
3 as measured (mm)
4 as measured (mm)
5 as measured (mm)
6 as measured (mm)
Exhaust Valve No. Gap Measured
1 as measured (mm)
2 as measured (mm)
3 as measured (mm)
4 as measured (mm)
5 as measured (mm)
6 as measured (mm)
Valve Clearance - Adjustment
WARNING

Note
To adjust the valve clearances the camshafts must be removed. Follow the camshaft removal procedure.
1. Remove the camshafts (see Camshafts - Removal).
2. Remove the tappet bucket from the cylinder head.
3. Remove the shim from the valve head.
1
2
cdrb
1. Tappet bucket
2. Shim
Note
The shim may withdraw with the tappet bucket.
4. Measure the original shim, using a micrometer and select the appropriate new shim as required.
Clearance too small - Fit a thinner shim.
Clearance too large - Fit a thicker shim.
Note
Shims are available ranging from 1.70 mm to 3.00 mm in increments of 0.025 mm.
5. Fit the new shim to the valve head.
6. Lubricate the tappet bucket(s) with a solution of engine oil and molybdenum disulphide grease in the proportions of 60 grammes of grease mixed with 930 cc of engine oil.
7. Refit the tappet bucket.
8. Refit the camshafts (see Camshafts - Installation).
9. Recheck all valve clearances.
10. Repeat the procedure if the valves require further adjustment.
11. Refit the camshaft cover, (see Camshaft Cover - Installation).

12. Refit the spark plugs, tightening to 12 Nm.
Camshaft Timing - Adjustment
WARNING


Crankshaft Cover - Removal
Note
After the initial camshaft timing has been completed and T3880640 - Camshaft Timing Plate removed, it will not be possible to refit it without first loosening the
camshafts.
CAUTION
The camshaft sprockets are attached to the camshafts using slotted bolt holes. This allows for very accurate valve timing and therefore improved performance and fuel
economy.
Never fit the camshaft sprockets without correctly setting the valve timing using the service tools and timing procedure described below. Severe engine damage will result
from incorrect camshaft adjustment.
Note
The camshaft sprocket fixings need only be loosened sufficiently to allow the sprockets to rotate on the camshafts.
Removing the spark plugs reduces compression resistance when turning the engine
Note
While rotating the crankshaft, ensure that the front camshaft drive chain rubbing blade remains in its mounting.
Before inserting the timing pin, ensure the dot on the primary gear is aligned with the line on the crankcase.
2. Using the bolt fitted to the end of the crankshaft, rotate the crankshaft clockwise (the normal direction of rotation). Stop rotation when the camshaft alignment marks are
positioned outwards as shown below and the dot mark on the primary gear aligns with the line on the crankcase.
1
gaaa 14
1. Camshaft alignment marks

2. Fixings
3. Insert T3880601 - Camshaft Timing Pin into the timing holes in the crankcase and crankshaft.
3
4
1
chwh
1. DOT alignment mark

2. Marker line
3. T3880601 - Camshaft Timing Pin
4. Timing hole in crankcase
4. Evenly release the camshaft drive chain tensioner mounting bolts until the plungers spring tension has been released.
5. Remove the tensioner and discard the O-ring and gasket.

2
1. Tensioner
2. Fixings
6. Fit the T3880607 - Camshaft Timing Tensioner using the original fixings and tighten to 9 Nm.
chwf
1. T3880607 - Camshaft Timing Tensioner
CAUTION
The torque value stated is very important to accurate timing. Always use the correct value of 0.6 Nm, as set using the T3880609 - Timing Torque Limiter.
Using an incorrect torque value will result in incorrect valve timing being set, or damage to the tensioner blade or other valve train components.
Either condition may result in serious damage to the engine, reduced engine performance, or reduced fuel economy.
7. Using the T3880609 - Timing Torque Limiter and a 6 mm Ball Ended Allen Key, tighten the T3880607 - Camshaft Timing Tensioner to 0.6 Nm preset by the T3880609 -
Timing Torque Limiter.
chwe

2. T3880609 - Timing Torque Limiter
3. 6 mm Ball Ended Allen Key
Note
Loosen the camshaft sprocket fixings just enough to allow the sprocket and camshaft to be able to move independently.
8. Make sure there is no slack in the chain between the crankshaft and the sprockets.
9. Loosen but do not remove the two accessible fixings.

chei_1
1. Fixings
10. Remove T3880601 - Camshaft Timing Pin from the crankcase and crankshaft.
3
4
1
chwh

2. Marker line
11. Using the bolt fitted to the end of the crankshaft, rotate the crankshaft 360° clockwise (the normal direction of rotation). Stop rotation when the camshaft alignment marks
are positioned inwards as shown below and the dot mark on the primary gear aligns with the line on the crankcase.
12. In addition to the crankshaft alignment mark, at TDC, the alignment marks on the camshaft bosses will point inwards.
gaaa_12
CAUTION
Do not rotate the engine further once the four camshaft sprocket bolts have been loosened.
Rotation of the engine with the four sprocket bolts loose will result in valve to piston contact.
Valve to piston contact will cause serious engine damage.
3
4
1
chwh

2. Marker line
Note
Loosen the camshaft sprocket fixings just enough to allow the sprocket and camshaft to be able to move independently.
14. Loosen but do not remove the remaining two fixings.
chei_1
1. Fixings
15. Note the orientation of the camshaft ladder in relation to the cylinder head.
16. Progressively release the fixings securing the camshaft ladder to the cylinder head in the sequence shown below.
6 14 16 10 12 2
4
8
7
3
5 13 15 9 11 1
cdqs
Camshaft Ladder Fixing Release Sequence
17. Remove the camshaft ladder, top pad, dowels and spark plug tower O-rings, noting their orientation for installation.
Note
Adjust the valve clearances as required using the data collected prior to removal of the camshafts (see Valve Clearance - Adjustment).
CAUTION
Make sure the T3880640 - Camshaft Timing Plate removal screw is unscrewed fully.
The T3880640 - Camshaft Timing Plate must be positioned so that it is located centrally between the camshafts.
Failure to fit the T3880640 - Camshaft Timing Plate correctly may lead to the irreparable damage to the camshafts.
18. Insert the T3880640 - Camshaft Timing Plate into the camshaft slots as shown below.
3
choj
1. T3880640 - Camshaft Timing Plate

2. Camshaft slots
3. Removal screw

Note
Make sure the alignment marks on the camshaft bosses are pointing inwards.
19. Rotate both sprockets on the camshafts until the fixings are positioned centrally within the slots.
2
gaaa_15
1. Elongated slots
2. Fixings
20. Check that the chain is correctly located around the crankshaft, and both camshaft sprockets.
21. Assemble the dowels, spark plug tower O-rings, camshaft ladder and top pad in the same location and orientation as prior to removal.
Note
The bolts for the camshaft cap ladder are tightened in two stages.
22. Stage 1 - Fit and evenly tighten the fixings to 5 Nm, in the sequence shown below.
11 3 1 7 5 15
13
9
10
14
cdqr
12 4 2 8 6 16
Camshaft Cover Fixings Tightening Sequence
23. Stage 2 - Fit and evenly tighten the fixings to 10 Nm, in the sequence shown below.
11 3 1 7 5 15
13
9
10
14
cdqr
12 4 2 8 6 16
Camshaft Cover Fixings Tightening Sequence
CAUTION
The torque value stated is very important to accurate timing. Always use the correct value of 0.6 Nm, as set using the T3880609 - Timing Torque Limiter.
Using an incorrect torque value will result in incorrect valve timing being set, or damage to the tensioner blade or other valve train components.
Either condition may result in serious damage to the engine, reduced engine performance, or reduced fuel economy.
24. Using the T3880609 - Timing Torque Limiter and a 6 mm Ball Ended Allen Key, tighten the T3880607 - Camshaft Timing Tensioner to 0.6 Nm preset by the T3880609 -

1
chwe

25. Tighten the two accessible (uppermost) camshaft sprocket fixings to 16 Nm.
chei_1
1. Uppermost fixings
26. Remove the T3880640 - Camshaft Timing Plate by rotating the removal screw clockwise as shown below.
2
choj_1

2. Removal screw
27. Remove T3880601 - Camshaft Timing Pin from the crankcase and crankshaft.
3
4
1
chwh

2. Marker line
28. Rotate the crankshaft until the remaining two fixings are accessible.
29. Make sure there is no slack between the crankshaft and exhaust sprocket when the sprocket fixings are centrally located within the slotted holes and the alignment marks
on the end of the camshaft journals are pointing inwards.

1
gaaa_12
Camshaft Alignment Marks
30. Tighten the two remaining (uppermost) camshaft sprocket fixings to 16 Nm.
chei_1
1. Uppermost fixings
31. Check that the chain is correctly located around the crankshaft, and both camshaft sprockets.
CAUTION
Always check that the T3880640 - Camshaft Timing Plate has been removed before rotating the engine. Severe damage will result to the camshafts or T3880640 -
Camshaft Timing Plate if engine rotation is attempted with the tool installed.
32. Set the hydraulic tensioner onto the first tooth of the ratchet (minimum extension) carry out the following:
Note
If installing a new hydraulic tensioner, do not release the plunger before fitting.
If installing the original hydraulic tensioner, the engine oil must be drained out of the tensioner to enable the plunger to be set onto the first tooth of the ratchet.
Prior to installation the hydraulic tensioner must be set to the first tooth on the ratchet (minimum extension).
33. Hold the resister ring ends together and pull out the plunger.
2
1
cfei_2
1. Resister ring ends

2. Plunger
34. Remove the spring.

cfhp
1. Spring
35. While holding the resister ring in place, pour out the engine oil into a suitable container.
36. Make sure the resister ring is correctly located as shown in the illustration below.
cfho
1. Resister ring
37. Refit the spring.
CAUTION
When resetting the tensioner, care must be taken to avoid activating the tensioner when there is no resistance on the plunger.
Activating the tensioner when there is no resistance on the plunger may cause internal damage to the tensioner housing.
It is recommended that the plunger is pushed into the tensioner housing in a controlled manner using a suitable soft jawed vice. Once the snap ring is located into its
groove, the vice should be released slowly to ensure that the plunger is held in place.
38. Hold the resister ends together and insert the plunger into the tensioner housing.
39. Place the tensioner in a soft jawed vice.
40. While holding the resister ends together, use the vice to push the plunger through the resister ring until the groove for the snap ring aligns with the snap ring.
2 3
1
cfei_3
4
1. Resister ring
2. Plunger
3. Groove for snap ring
4. Snap ring
41. When the groove aligns with the snap ring, release the resister ring and move one end of the snap ring into the groove. Slowly release the vice to ensure that the plunger is
held in place.
cfej

2. Snap ring

42. Place a suitable wedge between the camshaft drive chain tensioner blade and crankcase, to hold the camshaft drive chain taut during removal of the T3880607 - Camshaft
Timing Tensioner.
chwh
1. Wedge
2. Crankcase
3. Tensioner blade
43. Release the tension on Camshaft Timing Tensioner T3880607and remove the T3880609 - Timing Torque Limiter .

44. Remove the T3880607 - Camshaft Timing Tensioner.
chwf
45. Fit the timing chain tensioner, incorporating a new gasket and O-ring. Tighten the fixings to 9 Nm.
1. tensioner

2. Fixings
46. Remove the wedge from between the camshaft drive chain tensioner blade and crankcase.
47. To release the hydraulic tensioner, rotate the crankshaft 1/4 of a turn anticlockwise using the bolt fitted to the end of the crankshaft. Then rotate the crankshaft clockwise
two revolutions until the 'dot' mark on the primary gear aligns with the line on the crankcase.
Note
Before inserting the timing pin, make sure the 'dot' on the primary gear is aligned with the line on the crankcase.
48. Insert the T3880601 - Camshaft Timing Pin into the timing holes in the crankcase and crankshaft.
3
4
1
chwh
1. Dot mark
2. Marker line
49. Check that the timing marks are still approximately aligned (to check that the camshaft timing has not moved during T3880607 - Camshaft Timing Tensioner removal).
50. Remove the T3880601 - Camshaft Timing Pin.
Camshaft Cover - Installation
Crankshaft Cover - Installation
Crankshaft Position Adaption (European Markets Only)
Tyres - Check For Wear/Damage
WARNING

WARNING
Operation with excessively worn tyres is hazardous and will adversely affect traction, stability and handling which may lead to loss of control and an accident.
When tubeless tyres, used without a tube, become punctured, leakage is often very slow. Always inspect tyres very closely for punctures. Check the tyres for cuts,
embedded nails or other sharp objects. Operation with punctured or damaged tyres will adversely affect motorcycle stability and handling which may lead to loss of control
or an accident.
Check the rims for dents or deformation. Operation with damaged or defective wheels or tyres is dangerous and loss of motorcycle control or an accident could result.
Always consult your authorised Triumph dealer for tyre replacement, or for a safety inspection of the tyres.
As the tyre tread wears down, the tyre becomes more susceptible to puncture and failure. It is estimated that 90% of all tyre failures occur during the last 10% of tread life (90%
worn). It is false economy and unsafe to use tyres until they are worn to their minimum.
All tyres are fitted with tread wear indicators. When the tyre becomes worn down as far as the top of a tread wear indicator, the tyre is worn beyond its service life and must be
replaced.
1. Tread wear indicator
Attention must also be paid to the legal limits for tread wear, which differ from country to country. Tyres that have worn to the legal limit in the country or region in which the
motorcycle is operated must be replaced, even if tread wear has not yet reached the level of the tread wear indicators.
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.
Tyre Pressures - Check/Adjust
WARNING

Note
Always check the tyre pressures when they are cold.
Checking tyre pressures when they are cold will achieve a more accurate reading on the tyre pressure gauge.
1. Remove the caps from the tyre valves.
2. Position the tyre pressure gauge onto the end of the valve body making sure the tyre valve is in contact with the tyre inflator.
3. Momentarily deflate the tyre to equalise the pressure in the tyre and the gauge.
4. Check that the correct pressure is displayed on the gauge.
5. If the air pressure is below the recommended setting, inflate the tyre until the correct pressure is achieved.
6. If it is greater than the recommended setting, slowly deflate the tyre checking the gauge regularly until the correct reading is achieved.
2 3
ckie
1. Tyre Valve
2. Tyre gauge (valve connector)
3. Tyre gauge
7. Repeat the process for the remaining tyre.

8. Refit the caps to the tyre valves.
Wheels - Check For Damage
WARNING

WARNING
Check the wheel rims for dents or deformation.

Operation with damaged or defective wheels is dangerous and loss of motorcycle control or an accident could result.
Always consult your authorised Triumph dealer for a safety inspection of the wheels, or for wheel replacement.
Wheel Bearings - Inspection
WARNING


Position the motorcycle on level ground and place on a paddock stand.
1. Hold the wheel at the top and bottom and rock the wheel checking for movement when a force is applied.
2. Check the wheel bearings spin smoothly with no signs of play.
3. If the bearings do not spin smoothly or there is excessive play in the wheel bearings, replace all bearings in that wheel.

Bearing check
Steering Check
WARNING

1. Move the handlebars to left and right full lock while checking that the brake hose, clutch cable and electrical harnesses do not bind or that the steering feels tight or difficult
to turn. Rectify as necessary.
Fork Inspection
WARNING

Examine each fork for any sign of damage or scratching of the slider surface or for oil leaks.
If any damage or oil leakage is found, strip and repair as described in this section or consult an authorised Triumph dealer.
Check for smooth operation of the forks as follows:
Place the motorcycle on level ground.
While holding the handlebars and applying the front brake, pump the forks up and down several times.
If roughness or excessive stiffness is detected, repair as described in the Front suspension section of this service manual or consult an authorised Triumph dealer.
WARNING
Riding the motorcycle with defective or damaged suspension can cause loss of motorcycle control and an accident. Never ride with damaged or defective suspension.
Fork Oil - Renew
WARNING


Drain the fork oil (see Fork Oil Change).
Refill the fork with Showa SS47G) oil (see Fork Oil Change).
Rear Suspension Unit - Inspection
1. Fully clean all components and inspect for damage or wear to:
The rear suspension unit upper and lower mountings
The suspension unit damper body and spring
The bottom needle bearing and seals
2. Replace as necessary.
3. Check the swinging arm drop link bearings and seals for wear or damage. Replace as necessary.
4. Examine the drop and drag link bearings (see Drag Link and Drop Links - Inspection).
WARNING
Never attempt to disassemble the rear suspension unit or preload motor (where installed). It contains fluid under pressure and serious injury could result if any part of the
system is disturbed.
Headstock Bearing - Check/Adjustment
Check
1. Raise and support the front of the motorcycle.
WARNING

WARNING
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the
motorcycle.
cgjt_25
Checking Headstock Bearing Adjustment
2. Hold the lower end of the front forks as illustrated and rock with a front-to-rear motion. If free play can be detected, the headstock bearings require adjustment.
Adjustment
WARNING
Always return the handlebars and risers to their original position as noted in paragraph 1. Operating the motorcycle with a handlebar position that is unfamiliar may lead to
loss of motorcycle control and an accident.
1. Note the original position of the handlebars, in order that they can be returned to the same position when the repair operation is complete.
3. Release the fixings securing the handlebar clamps to the risers. Detach the clamps and release the handlebars.
4. As an assembly, raise the handlebars until clear of the upper yoke. Rest the assembly forward of the steering stem to give access to the headstock top nut and the
adjustment nuts. Make sure that the front brake master cylinder remains in an upright position.
5. Loosen the upper yoke pinch bolts.
WARNING
If the lower yoke fixings are also loosened, the forks will no longer support the weight of the motorcycle.
Do not loosen the lower yoke fixings as, in this condition, the motorcycle could topple over causing damage and/or risk of injury.
CAUTION
Care must be taken when removing the headstock top nut, to make sure that the top nut and upper yoke do not become scratched. Protect the surfaces with a suitable cloth
or tape to prevent scratching.
6. Remove the headstock top nut and washer. Discard the washer.
1. Headstock top nut
7. Ease the upper yoke from the forks and support while detached.
8. Adjust the bearing free-play as follows, all using T3880023 - 50 mm Socket:
Remove the tab washer, lock nut, rubber washer and adjuster nut.
Fully clean the threads on the steering stem.
Refit the adjuster nut and tighten to 40 Nm.
Loosen the adjuster nut, then re-tighten to 38 Nm.
Fit the rubber washer. Make sure that the washer is fully pressed down in contact with the adjuster nut.
Fit the lock nut and tighten by hand until the locknut touches the rubber washer.
WARNING

WARNING
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.
Turn the lock nut clockwise until the slots align with the slots of the adjuster nut.
Fit the tab washer.
B00994
1. Tab washer
2. Lock nut
3. Rubber washer
4. Adjuster nut
T3880023 - 50 mm Socket
2 1
3
4
B00993
1. Tab washer
2. Lock nut
3. Rubber washer
4. Adjuster nut
9. Refit the upper yoke assembly to the forks.

10. Fit a new washer and the original top nut.
11. Tighten the top nut to 120 Nm.
12. Tighten the upper yoke clamp bolts to 25 Nm.
13. Locate the handlebar assembly into the risers. Fit the upper clamps and the 10 mm bolts.
14. Rotate the handlebar so that the alignment mark on the handlebar aligns with the split line between the upper clamp and riser.
2 3

ceic_3
1. Upper clamp
2. Clamp split line
3. Alignment mark
15. Tighten the 10 mm bolts to 35 Nm.

16. Refit the 8 mm bolts and tighten to 26 Nm.
17. Recheck the bearing adjustment.
Headstock Bearings - Lubricate
WARNING


Headstock Bearing - Removal
1. Inspect the headstock bearings for damage/wear (see Headstock Bearing - Inspection).
2. Lubricate the headstock bearings, using finger pressure, force five grammes of Castrol LCX 222 or an equivalent heavy duty lithium based grease between the inner race
and the carrier.
3. Rotate the ball bearing to ensure that the grease is distributed over the entire circumference of the internal parts.
1
2
ckid
1. Roller bearing
2. Inner carrier face
3. Outer carrier face

Headstock Bearing - Installation
Headstock Bearing - Inspection
WARNING
Only remove raised witness marks from within the frame. Removal of material below any raised areas will reduce the level of interference between the frame and the
bearings. Loss of interference could cause the bearing to become loose in the frame leading to loss of motorcycle control and an accident.
1. Examine the frame for any raised witness marks caused by the removal process. Remove any such marks with fine emery paper or a suitable file.
Brake Wear Inspection
In accordance with the Scheduled Maintenance chart, inspect the brake pads for wear. The minimum thickness of lining material for any front or rear brake pad is 1.5 mm. If
any pad has worn to the bottom of the groove in the pad centre, replace all the brake pads on that wheel.

cbmz_1
1. Brake pads
2. Minimum thickness line
WARNING
Do not replace individual brake pads; replace both pads in the brake caliper. On the front where two calipers are mounted on the same wheel, all the pads in both calipers
must be replaced simultaneously. Replacing individual pads will reduce braking efficiency and may cause loss of motorcycle control and an accident.
Brake Master Cylinders - Inspection
WARNING

Inspect both the front and rear master cylinders for fluid leaks. Rectify as necessary.
Brake Calipers - Inspection
WARNING

WARNING
Always renew caliper seals and pistons after removal from the caliper. An effective hydraulic seal can only be made if new components are used.
A dangerous riding condition leading to loss of control of the motorcycle or an accident could result if this warning is ignored.
1. Check for correct brake operation and that the caliper pistons are not seized. Rectify as necessary.
2. Inspect the brake calipers for fluid leaks. Rectify as necessary.
Front Brake Fluid Level - Inspection
WARNING

WARNING
Ensure absolute cleanliness when adding brake fluid to the brake fluid reservoir. Do not allow moisture or debris to enter the cylinder, as this will adversely affect the fluid
properties. Always use fluid from a sealed container and do not use fluid from a container that has been opened for any period of time. Always check for fluid leakage
around hydraulic fittings and for damage to hoses. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
WARNING
Do not allow the fluid level to fall below the LOWER level mark in the reservoir. If the fluid level is allowed to fall below this mark, air can enter the system cause the brakes
to malfunction. A dangerous riding condition leading to loss of motorcycle control and an accident could result.
CAUTION
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.
1. Turn the handlebars to bring the fluid reservoir to a level position.

2. Check that the level of brake fluid is between the UPPER and LOWER section of the reservoir.

1. Reservoir cap retaining screws
2. Front reservoir upper level
3. Front reservoir lower level
3. If the level is not at the UPPER line, do the following steps to add brake fluid to the reservoir:
4. Remove the screws from the brake reservoir cover.
5. Carefully remove the reservoir cover taking care not to spill any fluid.
6. Fill the reservoir to the UPPER level line using new DOT 4 brake fluid from a sealed container.
7. Check the condition of the sealing diaphragm for the reservoir. Replace if necessary.
8. Install the fixings into the cap and diaphragm seal assembly.
9. Hold the assembly together and position the cap, diaphragm seal and fixings onto the reservoir.
10. Tighten the fixings to 0.7 Nm.
11. Check the operation of the front brake. Rectify as necessary.
WARNING
It is dangerous to operate the motorcycle with defective brakes. You must have your authorised Triumph dealer take remedial action before you attempt to ride the
motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Rear Brake Fluid Level - Inspection
WARNING

WARNING
WARNING
Do not allow the fluid level to fall below the LOWER level mark in the reservoir. If the fluid level is allowed to fall below this mark, air can enter the system cause the brakes
to malfunction. A dangerous riding condition leading to loss of motorcycle control and an accident could result.
CAUTION
1. Check that the level of brake fluid is between the UPPER and LOWER section of the reservoir.
1. Cover screws
2. Rear reservoir upper level
3. Rear reservoir lower level
2. If the level is not at the UPPER line, do the following steps to add brake fluid to the reservoir:
3. Remove the screws and remove the rear brake reservoir cover, taking care not to spill any fluid.
4. Fill the reservoir to the UPPER level line using new DOT 4 brake fluid from a sealed container.
5. Check the condition of the sealing diaphragm. Replace the diaphragm as necessary.
6. Refit the reservoir cap ensuring that the diaphragm seal is correctly positioned between the cap and the reservoir body.
7. Tighten the reservoir cap fixings screws to 1 Nm.
8. Check the operation of the rear brake. Rectify as necessary.
WARNING

WARNING
Brake Fluid - Renew
WARNING

WARNING
CAUTION
Do not allow the fluid level to fall below the LOWER level mark in the reservoir. If the fluid level is allowed to fall below this mark, air may enter the system and the sequence
of bleeding must be repeated.
CAUTION
Front Brake Fluid
1. Note the number of clicks required to turn the lever span adjuster fully clockwise.
1 2
B00566
1. Span adjuster
2. Brake lever
1. Screws

6. Remove the rubber cap from the bleed screw on the right hand caliper.
7. Attach a transparent tube to the caliper bleed screw.

1
2
3
B00941
1. Bleed screw
2. Bleed tube
3. Container
8. Place the other end of the tube in a suitable container that contains new brake fluid. Keep the tube end below the level of fluid.
Note
The bleed screws should only be opened by a small angle, just enough to allow system pressure to drop. When pulling the brake lever or pushing the caliper
pistons in, some resistance should be felt indicating that the screw is not opened too much.
9. Partially open the bleed screw.
Note
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.
10. Get an assistant to slowly pull the brake lever to the handlebar and then slowly release the brake lever.
11. Repeat step 10 until fresh brake fluid appears in the bleed tube.
12. When fresh brake fluid is in the system, apply pressure to the brake lever, close the bleed screw and tighten it to 10 Nm.
13. Remove the bleed tube and replace the bleed screw cap.
14. Fill the reservoir to the upper level with new DOT 4 fluid.
15. Repeat steps 6 to 14 for the other front brake caliper.
16. When the brake fluid has been renewed, make sure the brake lever operation has a firm resistive feel to it, does not feel spongy and that the lever cannot be pulled directly
back to the handlebar. Take remedial action as necessary.
17. Refit the reservoir cap ensuring that the diaphragm seal is correctly positioned between the cap and the reservoir body. Tighten the fixings to 0.7 Nm.
WARNING
Always return the lever adjuster to the original setting as noted in paragraph 1. Operating the motorcycle with lever settings that are unfamiliar may lead to loss of control or
an accident.
WARNING
It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the
Rear Brake Fluid
1. Remove the cap from the rear bleed screw.

2. Attach a transparent tube to the bleed screw.
B00802
1. Bleed screw
2. Bleed tube
3. Container
3. Place the other end of the tube in a suitable container that contains new brake fluid.
CAUTION
To prevent body damage, do not spill brake fluid onto any area of the bodywork.

4. remove the screws and remove the rear brake reservoir cover taking care not to spill any fluid.
1. Cover screws
WARNING
Ensure absolute cleanliness when adding brake fluid to the brake fluid reservoir. Do not allow moisture or debris to enter the cylinder as this will adversely affect the fluid
properties. Always use fluid from a sealed container and do not use fluid from a container which has been opened for any period of time. Always check for fluid leakage
around hydraulic fittings and for damage to hoses.
A dangerous riding condition leading to an accident could result if this warning is ignored.
5. Check the condition of the sealing diaphragm. Replace the diaphragm as necessary.
Note
The bleed screws should only be opened by a small angle, just enough to allow system pressure to drop. When pressing the brake pedal or pushing the caliper
6. Partially open the bleed screw.
Note
Pressure applied to the brake pedal 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.
7. Get an assistant to slowly depress the brake pedal and then slowly release the brake lever.
8. Repeat step 7 until fresh brake fluid appears in the bleed tube.
9. When fresh brake fluid is in the system, apply pressure to the brake pedal, close the bleed screw and tighten it to 14 Nm.
10. Remove the bleed tube and replace the bleed screw cap.
11. Refit the reservoir cap ensuring that the diaphragm seal is correctly positioned between the cap and the reservoir body.
12. Tighten the reservoir cap fixings screws to 1 Nm.
13. Check the operation of the rear brake. Rectify as necessary.
WARNING
Final Drive Chain Free-Movement - Adjustment
WARNING

Drive Chain Free-movement Inspection
1. Maximum movement position

1. Place the motorcycle on a level surface and hold it in an upright position with no weight on it.
2. Rotate the rear wheel by pushing the motorcycle to find the position where the chain has least slack. Measure the chains vertical movement, mid-way between sprockets.
3. If correct, the vertical movement of the drive chain midway between the sprockets should be 30 - 40 mm.
Drive Chain Free-movement Adjustment
1. Loosen the wheel spindle nut.

2. Loosen the lock nuts on both the left hand and right hand chain adjuster bolts.
1 2 3 4 5
1. Adjuster bolt
2. Adjuster bolt lock nut
3. Rear wheel spindle nut
4. Chain adjuster block
5. Graduation marks
3. Moving both adjusters by an equal amount, turn the adjuster bolts clockwise to increase chain free movement and anti-clockwise to reduce drive chain free movement.
4. When the correct amount of chain free movement has been set, push the wheel into firm contact with the adjusters.
Note
Check for equal adjustment on both sides using the graduation marks on the swinging arm.
5. Tighten both adjuster lock nuts to 15 Nm and the rear wheel spindle nut to 110 Nm.
6. Repeat the drive chain adjustment check. Re-adjust if necessary.
WARNING
Operation of the motorcycle with insecure adjuster lock nuts or a loose wheel spindle may result in impaired stability and handling of the motorcycle. This impaired stability
and handling may lead to loss of motorcycle control and an accident.
7. Check the rear brake effectiveness. Rectify if necessary.
WARNING
Final Drive Chain and Sprocket Wear - Inspection
WARNING

10-20
KG
2
1. Measurement across 20 links

2. 10 - 20 kg weight
1. Remove the upper and lower chain guards from the swinging arm.
2. Stretch the drive chain taut by hanging a 10 - 20 kg (20 - 40 lb) weight on the chain.
3. Measure a length of 20 links on the straight part of the drive chain from pin centre of the 1st pin to pin centre of the 21st pin. Repeat the test at various sections of the chain

to establish an average reading. This is because the chain may wear unevenly.
4. If the length exceeds the service limit of 317 mm, the drive chain must be replaced.
WARNING
A drive chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing loss of
motorcycle control and an accident.
5. Examine the whole length of the drive chain. If there are any excessively tight or loose sections, loose pins or damaged rollers, the drive chain should be replaced.
6. Inspect sprockets for unevenly or excessively worn teeth. Also examine the sprockets for damaged teeth.
Note
Sprocket wear is exaggerated for illustration purposes.
WARNING
The use of non-approved chains may result in a broken chain or may cause the chain to jump off the sprockets.
Use a genuine Triumph supplied chain as specified in the Triumph Parts Catalogue.
Never neglect chain maintenance and always have chains installed by an authorised Triumph dealer.
7. If there is any irregularity found in any of the components, replace the drive chain and/or any other damaged components.
8. Refit the lower drive chain guard, tightening the fixings to 7 Nm.
9. Refit the upper drive chain guard, tightening the fixings to 9 Nm.
Final Drive Chain Lubrication
Lubrication is necessary every 200 miles (300 km) and also after riding in wet weather, on wet roads, or any time that the chain appears dry.
Use the special drive chain lubricant as recommended in the specification section.
Correct application is critical for drive chain lubrication. Apply the lubricant for one full drive chain revolution only, then leave for eight hours before riding. This allows the
lubricant’s solvent (used to thin the oil) to evaporate and the oil to 'soak' into all parts of the drive chain. If the lubricant is applied and the motorcycle is ridden shortly
afterwards, the lubricant is unlikely to reach all parts and the majority will be flung off and wasted. Applying excessive amounts is not helpful under any circumstances.
It should be noted that the lubricant is applied to the drive chain to lubricate its action across the sprockets. In an O-ring chain, external lubrication does not penetrate to the
bushes and rollers as the O-ring seals prevents this from happening.
CAUTION
Do not use a power jet washer to clean the chain as this may cause damage to the chain components.
Drive Chain Rubbing Strip - Check
WARNING

Inspect the drive chain rubbing strip for cracks, damage or excessive wear. Replace if necessary.
Check Lights, Instruments and Electrical Systems
WARNING

Check the instruments, lights and electrical systems for functionality. Rectify if necessary.
Latest Calibrations Check
WARNING

WARNING

Check for the latest calibration download for the following using the Triumph Diagnostic Tool:
Instruments (if applicable)
Chassis ECM (if fitted)
Keyless ECM (if fitted)
Engine ECM
See the Triumph Diagnostic Tool User Guide for more information.
Fasteners - General Inspection
WARNING

Check all visible fasteners for security. Make sure any encapsulated fasteners that have been loosened or removed are replaced.
Side Stand - Clean/Lubricate

Side Stand - Removal
1. Thoroughly clean all mating faces.
2. Smear the upper and lower contact surfaces of the side stand and side stand carrier bracket with multi-purpose grease to NLGI 2 specification.
3. Smear the shank of the side stand pivot pin with multi-purpose grease to NLGI 2 specification.
5 1 2
B00992
1. Side stand carrier bracket

2. Side stand
3. Pivot pin
4. Circlip
5. Spring anchor pin
6. Spring
7. Lubrication areas (shaded)

Side Stand - Installation
Rear Brake Pedal Grip - Lubricate
WARNING

1. Use Castrol Motorcycle Parts Cleaner, or an equivalent, to clean all dirt and contamination from the pivot joint on the pedal grip of the rear brake pedal.
2. Fully dry the cleaned area.
3. Apply Castrol Chain Spray O-R, or an equivalent lubricant, to the shaded area shown below.

1
L0897
1. Lubrication area
4. Operate the pivoting action of the pedal grip to distribute the lubricant.
L0896
1. Pedal grip
5. Clean all surplus lubricant off the rear brake pedal and grip assembly.
Bank Angle Indicators - Inspect
WARNING
Always replace the bank angle indicators before they are worn to their maximum limit.
Use of a motorcycle with bank angle indicators worn beyond the maximum limit will allow the motorcycle to be banked to an unsafe angle.
Banking to an unsafe angle may cause instability, loss of motorcycle control and an accident.
WARNING
The bank angle indicators must not be used as a guide to how far the motorcycle may be safely banked.
This depends on many various conditions including, but not limited to, road surface, tyre condition and weather.
Bank angle indicators are located on the riders footrests.
1
2
1. Bank angle indicator

2. Maximum wear limit groove
Bank angle indicators must be replaced when they have worn down to the maximum wear limit. The maximum wear limit is shown by a groove on the bank angle indicator.
Regularly check the bank angle indicators for wear.
Additional Work
Standard required:
Check Triumph Online for all additional work required by relevant Triumph issued Service Bulletins, Recalls and Technical News Bulletins. These must be completed prior to the
road test.
Road Test
WARNING
When riding the motorcycle the rider must always wear a safety helmet, eye protection, gloves, boots, trousers (close fitting around the knee and ankle) and a brightly
coloured jacket. Brightly coloured clothing will considerably increase a rider's visibility to other operators of road vehicles. Although full protection is not possible, wearing
correct protective clothing can reduce the risk of injury when riding.

WARNING
A safety helmet is one of the most important pieces of riding gear as it offers protection against head injuries. Your safety helmet should be carefully chosen and should fit
your head comfortably and securely. A brightly coloured safety helmet will increase a rider's visibility to other operators of road vehicles. An open face helmet offers some
protection in an accident though a full face helmet will offer more. Always wear a visor or approved goggles to help vision and to protect your eyes.
Note
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.
WARNING
Do not attempt to test the ABS function of the motorcycle’s braking system during road test. The ABS function is for use in emergency situations only. Any attempt to
artificially create an emergency situation is extremely hazardous and could lead to a collision with a following vehicle or loss of motorcycle control and an accident.
Note
Faults detected during road test or post road test inspection, must be rectified before the motorcycle is released to the customer.
The distance covered on the road test should be long enough to allow a satisfactory check to be made in the following areas:
Engine Cold Start Performance
Standard required:
The engine must start quickly and idle smoothly.

Note
This check is to be carried out when the engine is cold.
Action:
Turn the ignition switch to the ON position.

Start the engine and allow to idle.
ABS (anti-lock brake system) indicator light (models fitted with ABS only)
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.
Gear Change
Standard required:
Changing between gears must be smooth and easily accomplished.
Throttle Response
Standard required:
The engine should be quick to respond to any movement of the throttle.

There should be no pronounced misfires.
The idle speed must not change when the handlebars are turned from lock to lock.
Brakes
Standard required:
The brakes should have a firm, responsive feel.

The brakes should act smoothly and silently without judder.
Upon activation of the brakes, the motorcycle should come to rest without deviating from a straight line.
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.

The front and rear suspension operation should be smooth with no excessive stiffness, roughness or tight spots.
Check:
Check the correct action of the front suspension, including the damper action.
Check the correct action of the rear suspension, including the damper action.
Cruise Control (if fitted)
Standard required:
All cruise control switches must operate correctly. All functions and displays must operate as described in the Owner’s Handbook.
Check:
Once the relevant conditions have been met as described in the Owner’s Handbook, turn the cruise control ON and OFF.
Check the functionality of all following actions:
SET the speed
Resume the SET speed
Increase the SET speed
Decrease the SET speed
Throttle cancel - twist the throttle fully forward to cancel the cruise control
Brake cancel - ensure the cruise control is cancelled by use of the front brake, then the rear brake
Clutch cancel - ensure the cruise control is cancelled by pulling the clutch lever in
Gear change cancel - ensure the cruise control is cancelled when changing gear
Sixty second overtake cancel - ensure the cruise control is cancelled after increasing the speed with the throttle for more than sixty seconds.
Post Road Test
Note
The following tests should be carried out immediately after the motorcycle returns from the road test.
Faults detected during road test or post road test inspection, must be rectified before the motorcycle is released to the customer.
WARNING
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:
Note
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.
The fan(s) may come on earlier and at a slower speed. Depending on the ambient temperature, it is possible the fan(s) may not reach 100% speed.
The fan should operate when the coolant temperature rises above normal operating temperature. It will stop automatically.
The blades of the cooling fan must not come into contact with the radiator or the guard which surrounds the cooling fan blades.
There must be no abnormal noises when the cooling fan is operating.
WARNING
The cooling fan operates automatically, even with the ignition switched off. To prevent injury, keep hands and clothing away from the fan blades at all times.
Action:
With the engine idling, allow the engine temperature to rise to above normal operating temperature.
CAUTION
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
Note
This test should be carried out when the engine is at normal operating temperature.
Standard required:
The engine should start easily when at normal operating temperature and run smoothly at idle.
Action:
Switch off the engine (if running) and wait thirty seconds.

Start the engine and allow to idle.
Switch off the engine.
Engine
Standard required:
The engine must be free from fluid leaks.
Fuel System
Standard required:
The fuel system must be free from leaks.
Tyres
Standard required:
Front and rear tyres must be free from damage.
WARNING
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.
Bodywork
Standard required:
The motorcycle bodywork must be clean and free from damage.
Check:
Check the motorcycle bodywork for new damage.

Check the motorcycle bodywork for cleanliness.
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.
Engine Covers
Exploded View - Camshaft Cover

Exploded View - Sump
Exploded View - Engine Breather Cover

Exploded View - Alternator Cover

Exploded View - Clutch Cover
Exploded View - Crankshaft Cover

Exploded View - Balancer Shaft Cover
Exploded View - Sprocket Cover

WARNING


Fuel Tank - Removal
Airbox - Removal
Secondary Air Injection Solenoid Valve - Removal
Secondary Air Injection Reed Valves - Removal
1. Remove the ignition coils from the camshaft cover.
cgyp

cgyp
1. Ignition coils
2. Progressively release the camshaft cover bolts in the sequence shown in the following illustration.
Note
Two shorter bolts are fitted at the end adjacent to the camshaft drive chain.
3 1 6
cdra 5 2 4
Camshaft Cover Bolt Release Sequence
3. Remove the camshaft cover from the motorcycle.
CAUTION
Never use a lever to remove the camshaft cover from the cylinder head.
Using a lever will cause damage to the cylinder head and camshaft cover, which could lead to an oil leak.
4. Remove the camshaft cover gasket. If necessary, recover the three dowels from the camshaft ladder (these may come away in the camshaft cover or gasket).
5. Discard the camshaft cover gasket and bolt seals.
6. Remove any residual oil from the front of the cylinder head using a syringe or lint free cloth.
WARNING

1. Refit the three dowels to the camshaft ladder.
cdqu
1. Dowels
2. Fit a new camshaft cover seal to the cylinder head. Ensure the groove in the gasket is correctly seated to the head. Ensure the plug tower seals and the dowels are
correctly located.
1 2
cdqv 3
1. Camshaft cover seal

2. Dowels
3. Plug tower seals
3. Fit the camshaft cover, ensuring that the gasket remains in the correct position.
4. Lubricate the new camshaft cover bolt seals with clean engine oil. Fit the camshaft cover bolts and bolt seals and tighten until finger tight.
5. Tighten the camshaft cover bolts, in the sequence below to 10 Nm.
3 1 6
cdqz_3 5 2 4
Camshaft Cover Bolt Tightening Sequence
6. Re-tighten fixings 1 and 2 to 10 Nm.

7. Inspect the ignition coils seal for damage and replace if necessary.
8. Fit the ignition coils and reconnect the electrical connectors.
cgyp
1. Coils

Secondary Air Injection Reed Valves - Installation
Secondary Air Injection Solenoid Valve - Installation
Alternator Cover - Removal
Note
The removal of the starter motor and alternator stator electrical connector is only required if replacement of the alternator cover or stator is required. Removal
is not required for access to the alternator rotor only.
Starter Motor - Removal
1. Disconnect the alternator stator electrical connector.
2. Remove the fixings that attach the alternator cover. Collect the coolant hose bracket from under the front two fixings.
3. Remove the alternator cover fixings. Note the positions of the two 35 mm fixings. Discard the 35 mm fixings.

B00516_1
1. Alternator cover
2. Coolant hose bracket
4. Withdraw the alternator cover from the crankcase against the pull of the alternator rotor magnet.
Alternator Cover - Installation
1. If the alternator stator and crankshaft sensor assembly has been removed from the cover, clean all traces of silicone sealer from the grommet, grommet opening and the
cover.
2. Apply a 3.5 +/- 1 mm diameter bead of silicone sealer across the opening for the grommet in the position shown below.
B00966
1. Silicone sealant
2. Minimum 2 mm from bolt hole
3. Minimum 2 mm each side of grommet opening
3. Push the grommet with the electrical harness into the opening.
4. Apply a 3.5 +/- 1 mm diameter bead of silicone sealer across the grommet in the position shown below.
3
1
B00965
1. Silicone sealant
2. Minimum 2 mm from bolt hole
3. Minimum 2 mm each side of grommet
5. Position a new gasket to the crankcase dowels then refit the alternator cover.
6. Refit the bottom hose bracket to the front two fixings. Install the fixings, using new 35 mm fixings positioned as noted during removal (the 25 mm fixings may be reused).
B00516_1
1. Alternator cover
2. Coolant hose bracket
7. Tighten the fixings to 10 Nm, in the sequence shown below.
7 11
3 1

3 1
10
6
5
2
9
12 4
8
B00516
Tightening Sequence
8. Retighten fixings one and two to 10 Nm.

9. If removed, refit the alternator stator electrical connector.
10. If removed, refit the starter motor (see Starter Motor - Installation).
Clutch Cover - Removal
WARNING


Release the clutch cable from the actuating arm (see Clutch Cable - Removal).
1. Remove the clutch cover. Discard the clutch cover gasket.
B00520
1. Clutch cover
Clutch Cover - Installation
WARNING

1. Clean and refit the clutch cover incorporating a new gasket.

2. Fit new clutch cover fixings and tighten them to 10 Nm in the sequence shown below.
3
7
10
1
6
5
2
9
11
B00519 8 4

Clutch Cover Tightening Sequence

4. Refit the clutch cable to the actuating arm at the clutch end and set the clutch adjustment (see Clutch Cable - Installation).
Balancer Shaft Cover - Removal
WARNING

1. Release the fixings and remove the balancer shaft end cover.
2
cipg
1. Cover
2. Fixings
Balancer Shaft Cover - Installation
WARNING

1. Clean and refit the balancer shaft cover incorporating a new gasket.
2. Tighten the balancer shaft cover fixings to 8 Nm in the sequence shown below.
3 1
4
2
cipg
Tightening Sequence
Sump - Removal
WARNING

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

WARNING
touch hot oil.
WARNING

Exhaust Header Assembly Removal
WARNING
The exhaust system will be hot if the engine has recently been running. Always allow sufficient time for the exhaust to cool before working on or near the exhaust system.
Contact with a hot exhaust could result in burn injuries.
1. Remove the three fixings and remove the sump guard bracket.
B00552
1. Fixings
2. Sump guard bracket
2. Remove the fixings securing the sump to the lower crankcase.
2
B00559
1. Sump
2. Fixings
3. Detach the sump and collect the water pump drain tube. Remove and discard the four drain tube O-rings.
Note
The water pump drain tube may remain attached to the water pump or become detached with the sump.
1
2
2

B00543
1. Water pump drain tube

2. O-rings
Sump - Installation
WARNING

1. Incorporating new O-rings (two each end of the tube), position the water pump drain tube to the oil pump.
1
2
2
B00543
1. Water pump drain tube

2. O-rings
2. Incorporating a new sump gasket/baffle, position the sump to the lower crankcase.
3. Tighten the sump fixings to 12 Nm in the sequence shown below.
6 10 14
2
3
12
7
8
11
4
13 1
B00542 9 5
Sump Fixings Tightening Sequence
4. Tighten fixings one and two again to 12 Nm.

5. Refit the sump guard bracket and secure with the three fixings. Tighten to 15 Nm.
B00552
1. Fixings
2. Sump guard bracket
Note
Use new exhaust gaskets at the exhaust header connections with the cylinder head.
Exhaust header Assembly Installation

Aluminium Sump Guard - Installation
Fill the engine with the correct grade of engine oil (see Engine Oil - Specification).
Start the engine and ensure that the low oil pressure warning light goes out shortly after starting.
Stop the engine and check the engine oil level. Adjust if necessary (see Engine Oil - Level Inspection).
WARNING

1. Release the fixings and remove the crankshaft end cover.

2. Discard the two encapsulated 35 mm fixings, retaining the 25 mm fixings for reuse.
B00524
1. Cover
2. 35 mm Fixings
WARNING

1. Clean and refit the crankshaft cover incorporating a new gasket.

2. Fit new encapsulated 35 mm fixings to position one and seven.
3. Refit the remaining 25 mm fixings.
4. Tighten the crankshaft cover fixings to 10 Nm in the sequence shown below.
8
3
4
7
6
1
B00523
Tightening Sequence
5. Tighten fixings one and two again to 10 Nm.
Engine Breather Cover - Removal
WARNING



Fuel Tank - Removal
Airbox - Removal
Note
Note that the grey connector on the fuel hose connects to the fuel rail for installation.
1. Remove the breather hose from the breather cover.
3 2
1
B00511
1. Breather hose
2. Fuel pipe latch
3. Fuel hose
2. Do the following steps to release the fuel hose.

3. Ease the latch away from the connector until the release buttons are exposed.
1 2
cekp
1. Locked position
2. Unlocked position
4. Disconnect the fuel hose by squeezing the sides of the connector and pulling the hose free from its spigot on the fuel rail.
Note
Note the position of the hose and connector bracket that is mounted to the engine breather cover, for installation.
The hose and connector bracket can remain in position.
5. Release the 12 fixings and move the starter motor cable aside. Remove the engine breather cover.
4
3
B00512
Electrical harness and purge valve are shown

removed for clarity.
1. Engine breather cover
2. Fixings
3. Hose brackets
4. Cable clip
6. Discard the gasket.
Engine Breather Cover - Installation

1. Fit a new engine breather cover gasket to the crankcase.
2. Fit the engine breather cover. Make sure that the gasket remains in the correct position.
3. Install the fixings into positions 1 and 2 and tighten to 10 Nm.
11 12
4
8
2
5 10
7
9
3 6
B00518 1
Breather Cover Torque Sequence

4. Install the fixings in positions 3 to 9 and tighten in ascending numerical order to 10 Nm.
5. Position the hose and connector bracket to the engine breather cover as noted during removal.
6. Install the fixings and tighten to 10 Nm.
4
3
B00512
1. Fixings
2. Engine breather cover
3. Hose brackets
4. Cable clip
7. Locate the fuel hose into the hose and connector bracket.
8. Reconnect the grey connector of the fuel hose to the fuel rail by gently pushing inwards until the hose engages with a click.
9. Slide the double check latch to the locked position until the release buttons are covered. If the latch will not slide into position, then the fuel hose is not fully home on its
spigot and must be fitted again correctly.
1 2
cekp
1. Locked Position
2. Unlocked Position

Sprocket Cover - Removal
WARNING

WARNING

1. Note the position and orientation of the gear linkage crank in relation to the selector shaft. Remove the pinch bolt then remove the crank.
2. Move the gear change linkage away to give access to the sprocket cover.
3. Remove the two fixings and remove the sprocket cover.
1
2
B00541
1. Gear linkage crank

2. Pinch bolt
3. Fixings
4. Sprocket cover
Sprocket Cover - Installation
WARNING

1. Clean and refit the sprocket cover.

2. Install the two fixings and tighten to 9 Nm.
1
2
B00541
1. Gear linkage crank

2. Pinch bolt
3. Fixings
4. Sprocket cover
3. Fit the gear linkage crank to the shaft in the same orientation as noted prior to removal. Make sure that the alignment mark on the shaft aligns with the split line on the gear
linkage crank.
4. Tighten the pinch bolt to 12 Nm.
Cylinder Head
Exploded View - Cylinder Head and Valves

Exploded View - Camshaft and Camshaft Drive

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.
The camshafts are driven by a silent-type chain. The chain is guided by two blades and is tensioned by a hydraulic tensioner.
The hydraulic tensioner is fed oil via a gallery in the cylinder head. The combination of oil pressure and spring pressure pushes the plunger against the tensioner blade which
tensions the camshaft drive chain. The hydraulic tensioner has an oil pressure relief valve located in the plunger. It is set to open between 19 and 23 bar. When open it sprays
oil through a drilling in the tensioner blade onto the camshaft drive chain.
Oil is supplied to the cylinder head by an internal gallery. Once supplied to the cylinder head, the oil is distributed along internal drilling’s within the head casting and camshaft.
Single valve springs are used to close both the inlet and exhaust valves. These valve springs have close wound coils at one end to assist in the prevention of valve bounce at
high engine speed and to give a smooth valve actuation. When assembling the cylinder head it is important that the close wound, colour coded ends of the springs are fitted
downwards (towards the piston). The tip of the inlet and exhaust valves are hardened to give a long service life.
Due to the methods used to assemble the valve seat and valve guides to the head, these parts cannot be replaced.
CAUTION
In any of the following operations which necessitate the removal or disconnection of the camshaft drive chain, NEVER turn the engine without the camshaft drive chain and
tensioner correctly fitted and adjusted. In the disassembled condition, the pistons will contact the valves if the crankshaft is turned, causing severe engine damage.
Camshaft Drive Chain Tensioner - Removal
WARNING


2. Rotate the engine using the bolt fitted to the end of the crankshaft so that any two camshaft sprocket fixings are accessible.
Note
Before inserting the timing pin, ensure the DOT alignment mark on the primary gear is aligned with the line on the crankcase.
4
2
3
cidu
1. Dot mark
2. Marker line
4. In addition to the dot mark, at TDC, the alignment marks on the camshaft bosses will point inwards.

gaaa_2
5. Place a suitable wedge between the camshaft drive chain tensioner blade and crankcase, to hold the camshaft drive chain taut during removal of the tensioner.
WARNING
The hydraulic tensioner is under spring tension. Always wear hand, eye, and face protection when withdrawing the tensioner mounting bolts and take great care to minimise
the risk of injury and loss of components.
Note
Note the orientation of the hydraulic tensioner.
6. Evenly release the hydraulic tensioner mounting fixings until the plunger spring tension has been released.
7. Remove the hydraulic tensioner and discard the O-ring and gasket.
Camshaft Drive Chain Tensioner - Installation
WARNING

1. Check that the dot mark on the primary gear is still aligned with the line on the crankcase and T3880601 - Camshaft Timing Pin is installed. Ensure the crankshaft cannot
rotate.
2. Ensure that the wedge fitted earlier is still holding the camshaft drive chain tensioner blade in contact with the camshaft drive chain.
3. Check that the camshaft alignment marks point inwards.
4. To set the hydraulic tensioner onto the first tooth of the ratchet (i.e. minimum extension) carry out the following:
Note
If installing a new hydraulic tensioner, do not release the plunger before fitting.
If installing the original hydraulic tensioner, the engine oil must be drained out of the tensioner to enable the plunger to be set onto the first tooth of the ratchet.
5. Hold the resister ring ends together and pull out the plunger.
2
1
cfei_2
1. Resister ring ends

2. Plunger
6. Remove the spring.
cfhp
1. Spring
7. While holding the resister ring in place, pour out the engine oil into a suitable container.
8. Make sure that the resister ring is correctly located as shown in the illustration below.

1
cfho
1. Resister ring
9. Refit the spring.
CAUTION
When resetting the tensioner, care must be taken to avoid activating the tensioner when there is no resistance on the plunger.
Activating the tensioner when there is no resistance on the plunger may cause internal damage to the tensioner housing.
It is recommended that the plunger is pushed into the tensioner housing in a controlled manner using a suitable soft jawed vice. Once the snap ring is located into it’s
groove, the vice should be released slowly to ensure that the plunger is held in place.
10. Hold the resister ends together and insert the plunger into the tensioner housing.
11. Place the tensioner in a soft jawed vice.
12. While holding the resister ring ends together, use the vice to push the plunger through the resister ring until the groove for the snap ring aligns with the snap ring.
2 3
1
cfei_2 4
1. Resister ring
2. Plunger
4. Snap ring
13. When the groove aligns with the snap ring, release the resister ring and move one end of the snap ring into the groove. Slowly release the vice to make sure that the
plunger is held in place.
cfej

2. Snap ring
14. Fit a new O-ring and gasket to the hydraulic tensioner.

15. Fit the tensioner to the cylinder head as noted for removal. Tighten the bolts to 9 Nm.
16. Remove the wedge, taking care not to move or damage the tensioner blade.
17. Remove the camshaft drive chain tensioner blade wedge, taking care not to move or damage the tensioner blade.
18. Remove the T3880601 - Camshaft Timing Pin.
19. To release the hydraulic tensioner, rotate the crankshaft 1/4 of a turn anticlockwise using the bolt fitted to the end of the crankshaft. Then rotate the crankshaft clockwise
until the dot alignment mark on the primary gear aligns with the line on the crankcase.
20. Check that there is tension in the camshaft drive chain and the timing marks at the camshaft sprockets are correctly aligned.
Note
After fitting to the engine, the hydraulic tensioner will be empty of engine oil. After starting the engine, the camshaft drive chain and tensioner blade will be
noisy until full pressure is felt at the tensioner plunger. This could take up to 5 seconds.
21. Check that the tensioner plunger is correctly located in the middle of the camshaft drive chain tensioner blade when viewed from above.

22. Rotate the engine through 4 full revolutions, and reset number 1 cylinder to TDC. Make sure that the dot mark on the primary gear aligns with the line at the bottom of the
cover.
cdga
1. Dot mark
2. Marker line
23. Check that the camshaft timing marks align as illustrated below.
gaaa_2
Camshaft to Cylinder Head Alignment Marks
24. Recheck the tensioner plunger location against the camshaft drive chain tensioner blade.
Refit the spark plugs and tighten to 12 Nm.
Camshaft Drive Chain Tensioner Blade - Disassembly
Note
For the purpose of this instruction, the top of the tensioner blade is where the pad is located.
1. Release the clips and remove the pad.
2
1
cfee
1. Pad
2. Clip (one side shown)
2. Detach the top hook from the tensioner blade.

1
cfef
1. Top hook
2. Tensioner blade
3. Release the three side locating devices.
cfeg
1. Locating devices
2. Facing blade
4. Release the three hooks and remove the facing blade.
cfeh
1. Hooks
Camshaft Drive Chain Tensioner Blade - Assembly
Note
For the purpose of this instruction, the top of the tensioner blade is where the pad is located.
1. Engage the three hooks to attach the facing blade.
cfeh
1. Hooks
2. Engage the three side locating devices.

1
cfeg
1. Locating devices
2. Facing blade
3. Attach the top hook to the tensioner blade.
cfef
1. Top hook
2. Tensioner blade
4. Engage the clips to attach the pad.
2
1
cfee
1. Pad
2. Clip (one side shown)
Camshaft Drive Chain - Removal
WARNING


Camshafts - Removal
1. Remove the sound suppression bolt from the centre of the camshaft drive chain housing in the cylinder head.
cdrc
1. Sound suppression bolt
2. Remove the fixing and raise the front camshaft drive chain rubbing blade and detach the camshaft drive chain from the crankshaft gear.
3. The camshaft drive chain is removed from inside the cylinder head space.
Camshaft Drive Chain - Inspection

Visual in situ checks can also be made as follows:
1. Check for significant blue discolouration of the drive chain plates indicating excessive heat build-up.
2. Examine all of the pins for signs of rotation.
3. Check for cracking or deep scratching of the drive chain plates.
4. Check for severe wear of the inner plates as indicated in the diagram below.
ccrv
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.
cajs
3. Measure across 23 link pins as shown in the diagram below. If the drive chain is within limits, the measurement should be no longer than 149.48 mm. Measurements
beyond 149.48 mm indicate that the drive chain must be replaced.
1 2 3 4 22 23
cajt
4. Check for severe wear of the inner surface of the outer plates at the side-contact points with the sprocket teeth.
ccru
5. Check for signs of stiffness or kinking.

6. Check for severe wear of the plates in the area shown below.

caju
7. If any of these symptoms are evident, the camshaft drive chain must be replaced.
Camshaft Drive Chain - Installation
WARNING

1. Fit the camshaft drive chain and locate the lower end around the crankshaft gear.
2. Incorporating a new seal, refit the sound supression bolt to the centre of the camshaft drive chain housing in the cylinder head, tightening to 12 Nm.
3. Refit the camshafts (see Camshafts - Installation).
Camshafts - Removal
WARNING


Camshaft Drive Chain Tensioner - Removal
2. Rotate the engine using the bolt fitted to the end of the crankshaft so any two camshaft sprocket fixings are accessible.
Note
The camshaft sprocket fixings need only be loosened sufficiently to allow the sprockets to rotate on the camshafts.
The camshaft sprocket fixings must never be reused if loosened or removed; however new fixings should only be installed during final tightening after the
timing procedure has been completed.
If the sprockets are to be removed from the camshafts, temporarily refit the sprockets for timing adjustment using the old fixings, and only install new fixings
during final tightening.
3. Loosen the two camshaft sprocket fixings. Do not remove the fixings at this stage.
chei
1. Fixings
4. Rotate the crankshaft until the remaining two fixings are accessible.
CAUTION
Do not rotate the crankshaft further once the four camshaft sprocket bolts have been loosened. Rotation of the crankshaft with the four sprocket bolts loose will result in
valve to piston contact and serious engine damage.
5. Loosen the two remaining camshaft sprocket fixings.

6. Evenly release the hydraulic tensioner mounting bolts until the plunger spring tension has been released.
7. Remove the hydraulic tensioner and discard the O-ring and gasket.
8. Note the orientation of the camshaft ladder in relation to the cylinder head.
9. Progressively release the bolts securing the camshaft ladder to the cylinder head in the sequence shown below.
6 14 16 10 12 2
4
8

7
3
cdqs 5 13 15 9 11 1
Camshaft Ladder Bolt Release Sequence
10. Remove the top pad and camshaft ladder. Collect the dowels (if loose), spark plug tower O-rings and the secondary air injection O-rings. Discard the O-rings.
11. Lift the camshaft drive chain from the exhaust camshaft sprocket and remove the exhaust camshaft.
12. Repeat the procedure for the inlet camshaft.
carv1
1. Camshaft drive chain

2. Inlet camshaft
13. Noting its orientation for installation remove the camshaft drive chain.
14. Rotate the crankshaft clockwise (the normal direction of rotation), using the bolt fitted to the end of the crankshaft. Stop rotation when number 1 cylinder is at top dead
centre (TDC), that is when the dot alignment mark on the primary gear aligns with the line on the crankcase.
15. Insert T3880601 - Camshaft Timing Pin into the timing hole in the crankcase and crankshaft.
4
2
3
cidu
1. Dot mark
2. Marker line
16. At this stage the camshafts and sprockets can be separated if required.
Note
The inlet and exhaust camshafts are different. They can be identified by a raised feature in the centre of the exhaust camshaft, which is machined off on the
inlet camshaft.
The mark on the camshaft boss is not a timing mark, it is used as a visual aid during the timing adjustment procedure.
2 1
gabo1 4
1. Inlet camshaft

2. Machined section
3. Exhaust camshaft
4. Raised section
Note
Identical sprockets are used for both inlet and exhaust camshafts, and are attached to the camshaft using slotted bolt holes. The same holes are used when
fitting the sprocket to either camshaft.
Camshaft and Bearing - Inspection
1. Inspect the camshaft sprockets for damaged and worn teeth. Replace as necessary.
CAUTION
Identical sprockets are used for both inlet and exhaust camshafts, and are attached to the camshaft using slotted bolt holes. The same holes are used when fitting the
sprocket to either camshaft.
1. Camshaft bolt holes

2. Sprocket
2. Measure the camshaft journals with a micrometer. If any journal is outside the specified tolerance, replace the camshaft.
Standard Journal Diameters 23.940 - 23.960 mm
1. Standard journal
3. Examine the camshaft and camshaft ladder for excessive wear and damage.
4. Check the journal-to-cylinder head clearances, using Plastigauge (Triumph part number 3880150-T0301) as follows:
Ensuring that the camshaft sprocket alignment marking is located as for removal, assemble one camshaft to the cylinder head and progressively tighten the camshaft
ladder in the correct sequence, (see Camshafts - Installation).
Remove the camshaft ladder using the bolt release sequence given earlier. Wipe the exposed areas of both the camshaft journal and a single cap area of the ladder.
Apply a thin smear of grease to the journal and a small quantity of silicone release agent to the camshaft cap area of the ladder.
Size a length of the Plastigauge to fit across the camshaft journal. Fit the Plastigauge to the camshaft journal using the grease to hold the strip in place.
Refit the camshaft ladder then evenly and progressively tighten all the camshaft ladder bolts in the correct sequence, (see Camshafts - Installation).
Release the bolts and remove the camshaft ladder. Using the gauge provided with the Plastigauge kit, measure the width of the now compressed Plastigauge.
Note
The camshaft ladder is unique to each cylinder head and is, therefore, not available individually. If the camshaft ladder is worn or damaged, the complete
cylinder head must be replaced.

ccrw
Measuring the Compressed Plastigauge
5. Calculate the journal clearance using the Plastigauge chart supplied with the Plastigauge kit.
Camshaft journal clearance
Standard 0.040 - 0.081 mm
Service limit 0.130 mm
6. If the clearance measured is within the specified tolerance, remove the ladder and clean off all traces of Plastigauge. Assemble the camshafts, (see Camshafts -
Installation).
Note
If the measured clearance is outside the tolerance, and the camshaft journals are within tolerance, the cylinder head must be replaced.
CAUTION
Although Plastigauge is oil soluble, all traces of the material must be removed to prevent blockage of the oil drillings and resultant engine damage.
Camshafts - Installation
WARNING

Accurate camshaft timing can only be obtained using the correct timing method and service tools as described below.
CAUTION
The camshaft sprockets are attached to the camshafts using slotted bolt holes. This allows for very accurate valve timing and therefore improved performance and fuel
economy.
Never fit the camshaft sprockets without correctly setting the camshaft timing using the service tools and timing procedure described below. Severe engine damage will
result from incorrect valve timing adjustment.
1. Check that the dot alignment mark on the primary gear is still aligned with the line on the crankcase and the Crankshaft Timing Pin T3880601 is installed.
2. Thoroughly clean the camshafts and journals. Inspect the ends of the camshafts for correct fitment of the sealing plugs. Lubricate the camshafts with clean engine oil before
fitting to the cylinder head.
3. If removed, refit the camshaft drive chain.
4. If removed, refit the camshaft sprockets noting their orientation, and secure using the original bolts. DO NOT tighten the bolts at this stage; the sprockets must be free to
rotate.
5. Locate each camshaft to the cylinder head ensuring the camshafts are correctly identified (inlet and exhaust) and are also correctly located over their respective valve
banks.
6. Refit the exhaust camshaft to the cylinder head, hooking the camshaft drive chain over the sprocket as you do so.
7. Ensure there is no slack between the crankshaft and exhaust sprocket when the sprocket bolts are centrally located within the slotted holes. Ensure alignment marks on the
end of the camshaft journals are pointing inwards.
8. Refit the inlet camshaft to the cylinder head, hooking the chain over the sprocket as you do so.
9. Ensure the bolts on the inlet sprocket are also centrally located within the slotted holes when there is no slack between the exhaust and inlet sprockets.
10. Check that the camshaft drive chain is correctly located around the crankshaft and both camshaft sprockets.
11. Rotate the camshafts until the alignment marks on the end of the camshaft journals are pointing inwards.
gaaa_12
12. Insert T3880640 - Camshaft Timing Plate into the camshaft slots, ensuring the removal screw is unscrewed fully, as shown below. Ensure that the tool is centrally located
between the camshafts.

1
3
choj

2. Camshaft slots
3. Removal screw
CAUTION
If the camshafts and ladder 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. Lubricate the camshaft bearing areas of the camshaft ladder with a 50/50 solution of engine oil and molybdenum disulphide grease.
14. Assemble the dowels, camshaft ladder, top pad, new spark plug tower O-rings and new secondary air injection O-rings in the same location and orientation as prior to
removal.
Note
The bolts for the camshaft cap ladder are tightened in stages.
15. Stage 1 - Lubricate the threads of the camshaft cap ladder bolts with clean engine oil, then fit and evenly tighten the bolts to 5 Nm, in the sequence shown below.
11 3 1 7 5 15
13
9
10
14
cdqr 12 4 2 8 6 16
Camshaft Cap Ladder Bolt Tightening Sequence
16. Stage 2 - In the sequence shown in the previous illustration, tighten the bolts to 10 Nm.
CAUTION
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.
17. Fit T3880607 - Camshaft Timing Tensioner using the original bolts and tighten to 9 Nm.
chwf
CAUTION
The torque value stated is very important to accurate timing. Always use the correct value of 0.6 Nm, as set using the Torque Limiter T3880609. Using an incorrect torque
value will result in incorrect valve timing being set, or damage to the tensioner blade or other valve train components. Either condition may result in serious damage to the
engine, reduced engine performance, or reduced fuel economy.
18. Using T3880609 - Timing Torque Limiter, and the 6 mm Ball Ended Allen Key supplied, tighten T3880607 - Camshaft Timing Tensioner to 0.6 Nm preset by T3880609 -

chwe

3. 6 mm Ball End Allen key
19. Tighten the two accessible (uppermost) camshaft sprocket bolts to 16 Nm.
chei
1. Uppermost bolts
20. Remove the T3880640 - Camshaft Timing Plate by rotating the removal screw clockwise as shown below.
3
choj

2. Removal screw
21. Remove T3880601 - Camshaft Timing Pin.
CAUTION
Always check that T3880640 - Camshaft Timing Plate has been removed before rotating the engine. Severe damage will result to the camshafts or T3880640 - Camshaft
Timing Plate if engine rotation is attempted with the tool installed.
22. Rotate the engine until the remaining two sprocket bolts are accessible.
23. Tighten the two remaining camshaft sprocket bolts to 16 Nm.
24. Place a suitable wedge between the camshaft drive chain tensioner blade and crankcase, to hold the camshaft drive chain taut during removal of T3880607 - Camshaft
Timing Tensioner.
25. Release the tension on T3880607 - Camshaft Timing Tensioner and remove it.
26. Refit the timing chain tensioner, incorporating a new gasket and O-ring (see Camshaft Drive Chain Tensioner - Installation).
27. Rotate the crankshaft clockwise two complete turns, using the bolt fitted to the end of the crankshaft. Stop rotation when number 1 cylinder is at top dead centre (TDC), that
is when the dot alignment mark on the primary gear aligns with the line on the crankcase.
Note
Before inserting the timing pin, ensure the dot on the primary gear is aligned with the line on the crankcase.

4
2
3
cidu
1. Dot mark
2. Marker line
29. Check that the timing marks are still approximately aligned (to check that the camshaft timing has not moved during T3880607 - Camshaft Timing Tensioner removal).
30. Remove T3880601 - Camshaft Timing Pin.
Camshaft Drive Chain Tensioner - Installation
Valve Clearances
Camshaft, valve, valve shim and valve seat wear affects the valve clearances. The effect of this wear is to change the gap between the camshaft and tappet bucket, causing
engine noise and improper running. If the valve clearances become too small, permanent damage to the valve and valve seat will take place. If the valve clearance becomes
too great, the engine will become noisy and will not run correctly.
Cylinder Head - Removal
WARNING

Note
Removal of the cylinder head is not possible with the engine in the frame.
Engine - Removal
Camshafts - Removal
1. Remove the camshaft drive chain tensioner blades.
Note
Note the position of all tappet buckets and shims during removal.
To prevent the tappet buckets and shims from becoming mixed, place the shim and tappet bucket together in a marked container.
2. Remove all the tappet buckets and shims.
1
2
cdrb
1. Tappet bucket
2. Shim
3. Disconnect the coolant bypass hose from the rear of the cylinder head.
4. Release the screws securing the outside of the cylinder head to the upper crankcase.

cdra
1. Cylinder head to upper crankcase screws
5. Progressively release the cylinder head bolts in the order shown below.
7 3 1 5
B00697 6 2 4 8
Cylinder Head Bolt Release Sequence
6. Lightly tap the cylinder head with a rubber mallet to break the seal of the gasket.
7. Remove the cylinder head. Discard the cylinder head bolts and gasket.
Cylinder Head - Inspection
1. Thoroughly clean the surface of the cylinder head and check for damage and pitting of the combustion chambers.
2. Using a straight edge, check the cylinder head gasket face for warp which could lead to gasket failure. Replace the cylinder head if warped.
1. Cylinder head gasket face

2. Straight edge
3. Check the camshaft drive chain tensioner blades. Renew if worn or damaged.
Cylinder Head - Installation
WARNING

1. Thoroughly clean the upper faces of the crankcase, taking care not to damage the mating surfaces.
2. Fit a new cylinder head gasket. Make sure that the cylinder head to crankcase location dowels are correctly in place.

cart_3
1. Cylinder head gasket
3. Ensure that the cylinder head face is completely clean.

4. Carefully lower the cylinder head over the camshaft drive chain and locate the head onto the dowels.
CAUTION
Using the correct procedure to fit and tighten the cylinder head bolts will ensure the long term reliability of the cylinder head gasket.
Clean each new bolt, paying particular attention to the threads and under the bolt head areas. If any of the threads or bolt head areas are damaged, replace the bolt(s).
Tighten the bolts using the fiver-stage procedure given below.
Failure to observe these important items may lead to engine damage through a damaged head gasket.
5. Apply a thin layer of clean engine oil to the threads and under the heads of the new cylinder head bolts.
6. Fit the new bolts and washers to the cylinder head and tighten until finger tight.
Note
The cylinder head bolts are tightened in five stages, in the sequence shown below. This is to make sure that the cylinder head gasket seals correctly to the
cylinder head and crankcase.
For stages one, two and five of the bolt tightening operation, a torque wrench of known, accurate calibration must be used.
For stages three and four the bolts must be turned through a set number of degrees to reach the final setting. To accurately gauge the turn, T3880105 - Torque
Angle Gauge must be used.
Stage 1
Tighten the cylinder head bolts, to 20 Nm in the sequence shown below.
7 3 1 5
B00697 6 2 4 8
Cylinder Head Bolt Tightening Sequence
Stage 2
Tighten the cylinder head bolts to 27 Nm in the sequence shown above.
Stage 3
Tighten the cylinder head bolts again to 27 Nm in the sequence shown above.
Stage 4
Fit T3880105 - Torque Angle Gauge between the Torx socket and the drive handle and locate the Torx drive to the bolts. Pick an increment point on the torque turn gauge
which aligns with a suitable reference point on the cylinder head.
cbxt
T3880105 - Torque Angle Gauge
Tighten the cylinder head bolts to 100° of bolt rotation as measured using T3880105 - Torque Angle Gauge.
Stage 5
Tighten the cylinder head bolts again to 40 Nm in the sequence shown above.

1. Fit the cylinder head to upper crankcase screws located at the side of the cylinder head and tighten to 10 Nm.
cdra
1. Cylinder head to upper crankcase screws
2. Install the camshaft drive chain tensioner blades. Install a new bolt to the front tensioner blade and tighten to 9 Nm.
Note
The tappet buckets and shims must be refitted in their original positions as noted during removal.
3. Clean and lubricate the tappet bucket(s) with a solution of engine oil and molybdenum disulphide grease in the proportions of 60 grammes of grease mixed with 930 cc of
engine oil. Refit the tappet buckets and shims into their original positions.
4. Refit the coolant bypass hose to the rear of the cylinder head.
Engine - Installation
Valves and Valve Stem Seals - Removal
1. Remove each valve from the head using a valve spring compressor. The compressor must act on the valve spring retainer to allow removal of the valve collets.
Valve removal
2. Once the collets are released, remove the following items:

Valve spring retainer
Valve spring
Valve stem oil seal
Valve (deburr before removal).
ca rr
1. Valve stem seal
Note
Ensure the inlet and exhaust valve components do not become mixed.

2
ccrx
5
1. Collets
2. Valve spring retainer
3. Valve spring
4. Valve stem oil seal
5. Valve
Valve Face - Inspection
Remove any carbon build-up from the valve head area. Examine the valve seat face, checking in particular for signs of cracking or pitting.
Valves and Valve Stem Seals - Installation
1. Lubricate the valve stems with a solution of engine oil and molybdenum disulphide grease in the proportions of 60 grammes of grease mixed with 930 cc of engine oil.
2. Install the valve into the valve guide.
3. Fit the valve stem seal over the valve stem and, using a suitable tool, press down fully until the seal is correctly seated over the valve guide.
Note
During fitment of the valve stem seal, two distinctly different degrees of resistance will be noted when the seal is correctly fitted.
Firstly, press the seal down the valve stem until the lower side of the seal comes into contact with the valve guide. Greater resistance is felt at this contact point
and further gentle pressure is then required to locate the seal over the top end of the valve guide.
On application of this pressure, the seal can be felt to positively locate over the top face of the valve guide. Once correctly positioned, the seal cannot be
pushed down any further.
CAUTION
Incorrect fitment of the valve stem oil seals could lead to high oil consumption and blue smoke emissions from the exhaust system. Do not use excessive force in fitting the
seal as this may break the seal ring.
4. Install the valve spring over the valve stem. Ensure the close wound, colour coded ends of the springs are fitted downwards (towards the piston).
5. Fit the valve spring retainer.
6. Compress the valve spring ensuring that the spring is compressed squarely to prevent damage to the valve stem and cylinder head.
7. Fit the valve collets ensuring correct collet location in the spring retainer and valve as the spring compressor is released.
CAUTION
Always check for correct location of the valve collets during and after assembly. If not fitted correctly, the collets may become dislodged when the engine is running allowing
the valves to contact the pistons. Any such valve to piston contact will cause severe engine damage.
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 - 0.040 mm
Exhaust 0.030 - 0.060 mm
Valve Guides
If a valve guide is found to be worn beyond the service limit, the complete cylinder head must be renewed.
Clutch
Exploded View - Clutch Assembly

Exploded View - Clutch Controls

Clutch Switch
WARNING
The clutch switch is an integral part of the cruise control system. To ensure the clutch switch functions correctly after a replacement, the cruise control switch test must be
carried out (see Cruise Control Switch Check).
Failure to carry out the cruise control switch test may result in loss of motorcycle control and an accident.
The clutch switch is an integral part of the left hand handlebar switch housing. If the clutch switch requires replacement, the left hand handlebar switch housing and clutch
switch assembly must be replaced.
Clutch Lever Assembly - Partial Removal
1. Release the fixings and remove the clamp from the clutch lever assembly.
L0513
1. Fixings
2. Handlebar marking
3. Clamp split line
2. Position the assembly aside.
Clutch Lever Assembly - Installation
1. Fit the clamp and align the split line to the marking on the handlebars.
2. Tighten the fixings upper first and then the lower to 9 Nm.
L0513
1. Fixings
3. Clamp split line
3. Set the lever adjuster to a point where an equal adjustment is possible in both directions.
4. Set the adjuster at the clutch end to give a preliminary setting of 2 - 3 mm of free play as measured at the lever. Tighten the lock nuts.
5. Operate the clutch lever several times and check the amount of free play present.
6. Set the final adjustment of the cable to give 2 - 3 mm of free play at the lever by turning the adjuster nut and lock nut at the lever end.

2
1
cinn_3
1. Clutch lever
2. Correct setting, 2 - 3 mm

Handguards - Installation
Clutch Cable - Removal
WARNING


Handguards - Removal
1. Loosen the cable lock nut and release the adjuster at the clutch cover end to give maximum play in the cable.
2. Release the clutch cable from the actuating arm by pushing the inner cable nipple through the arm and sliding the cable out of the slot. Detach the cable from the bracket.
4 3
1
2
cglc
1. Clutch cable
2. Adjuster
3. Inner cable nipple
4. Actuating arm
3. Align the cable adjuster and lever bracket slots.

4. Pull in the clutch lever and turn the inner cable, anticlockwise through the slots in the adjuster, until the cable can be detached from the lever by pushing downwards.
B00696
1. Cable adjuster/lever bracket slots

2. Cable release point
5. Remove the cable from the motorcycle noting the cable routing and retaining clips.
Clutch Cable - Inspection
1. Check the inner cable for free movement through the outer cable.
2. Examine the inner cable for frayed strands.

3. Examine the two inner cable nipples for signs of looseness and damage. Replace the cable if necessary.
Clutch Cable - Installation
WARNING

1. Position the cable to the motorcycle using the same routing and retaining clips as noted during removal.
2. Attach the inner cable to the clutch lever and actuating arm using a reversal of the removal process.
3. Refit the outer cable to the adjuster bracket at the clutch end.
Note
Ensure that the two adjuster nuts are positioned one either side of the bracket.
4. Set the lever adjuster to a point where an equal adjustment is possible in both directions.
5. Set the adjuster at the clutch end to give a preliminary setting of 2 - 3 mm of free play as measured at the lever. Tighten the lock nuts.
6. Operate the clutch lever several times and check the amount of free play present.
7. Set the final adjustment of the cable to give 2 - 3 mm of free play at the lever by turning the adjuster nut and lock nut at the lever end.
1
cinn_3
1. Clutch lever
2. Correct setting, 2 - 3 mm

Clutch - Disassembly
WARNING


Release the clutch cable from the actuating arm (see Clutch Cable - Removal).
Note
Note that the stopper plate has an OUT mark. This must face outwards when fitted.
There are spring seats located in the pressure plate. Ensure the seats are in the pressure plate prior to fitting the springs.
1. Release the 3 bolts, remove the stopper plate, springs, pressure plate and spring seats.
OU
T
3
2
1. Bolts

2. Stopper plate
3. Springs
4. Spring seats
5. Pressure Plate
2. Remove the clutch pull-rod.
cdoo_3
2
1. Clutch pull-rod
2. Clutch pressure plate
3. Remove the clutch friction plates and steel plates together with the anti-judder spring and anti-judder seat washer.
Note
Record the orientation of all components as they are removed. The plates must be assembled in the same order.
Note
The inner and the two outermost friction plates are different to the other friction plates. They must be fitted in their noted positions.
The outer steel plate is different to the other plates. It must be fitted in its noted position.
4
1
5
3
1. Outer friction plate

2. Steel plate
3. Anti-judder spring
4. Anti-judder seat washer
5. Clutch inner drum
Note
Store all plates in their correct fitted order to avoid confusion on installation.
Refer to the following page of this section for details of clutch friction plate checking.
It is not normally necessary to disassemble the clutch further, but if the clutch inner and outer drums are to be removed, proceed as follows:
4. Engage second gear and lock the inner and outer clutch drums together using T3880307 - Clutch Anti-rotation Jig.
gaaz_1
1. T3880307 - Clutch Anti-rotation Jig
5. Depress the rear brake pedal to prevent the engine from turning, then release the clutch centre nut.

6. Remove the centre nut, Belleville washer, flat washer, clutch inner drum and thrust washer. Discard the nut and Belleville washer.
4
3
1. Centre nut
2. Belleville washer
3. Flat washer
4. Inner drum
5. Thrust washer
7. Slide the clutch outer drum assembly gently backwards and forwards to dislodge the inner bearing sleeve. Carefully remove the bearing sleeve while supporting the clutch
outer drum.
1
2
kaio1
1. Outer drum
2. Bearing sleeve
8. Remove the clutch outer drum leaving the oil pump drive sprocket, bearing and sleeve in place on the input shaft.
Friction Plate - Inspection
Thickness
Note
If any friction plate thickness is outside the service limit, replace the friction plates as a set.
1. Measure the thickness of the friction plate.
cbvy
1. Clutch friction plate
2. For the clutch friction plate thickness, refer to Clutch / Primary Drive
Steel Plate - Inspection
Bend/warp
Check all plates for bend and warp as follows:

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

2 1
cbvz
1. Steel plate
2. Feeler gauge
3. Surface plate
2. For specifications refer toClutch / Primary Drive
Clutch Pack Height
The clutch pack height should only be measured if the friction plates and the steel plates have been replaced.
The clutch pack height is critical for a smooth operation of the gear change and needs to be measured prior to installation.
If used steel plates are being fitted, the clutch pack height measurement is not necessary, as the plates may not be worn to the service limit (and are therefore still serviceable),
but could fall outside the clutch pack height tolerance when measured.
If building a new clutch pack, its height must be correct. To achieve this, build the new clutch pack with the following:
2 x new outer friction plate
6 x new friction plates
1 x new inner friction plate
7 x steel plates, 2.0 mm thick
1 x outer steel plate, 2.0 mm thick.
Friction plate and steel plate arrangement
1. Arrange the new friction and new steel plates in a stack as shown below.
1. Outer friction plates

2. Friction plates
3. Inner friction plate
4. Steel plate, 2.0 mm thickness
5. Outer steel plate, 2.0 mm thickness
2. Place the assembled clutch pack on a flat surface and measure its height as shown below.
T0943_1
1. Clutch pack height
3. For the correct clutch pack height for this clutch assembly see Clutch / Primary Drive.
4. If the clutch pack is too high, continue from step 5, omit step 6 then continue from step 7. If the clutch pack is too low, continue from step 6.

Note
1.6 mm and 2.3 mm steel plates are available, refer to the Parts Catalogue for part numbers.
No more than one 1.6 mm thick steel plate is to be used in the clutch pack.
5. If the clutch pack height is too high, replace the 2.0 mm steel plate indicated below with a new 1.6 mm steel plate.
1. 2.0 mm steel plate to be replaced
Note
No more than one 2.3 mm thick steel plate is to be used in the clutch pack.
6. If the clutch pack height is too low, replace the 2.0 mm steel plate indicated below with a new 2.3 mm steel plate.
1. 2.0 mm steel plate to be replaced
7. Re-check the clutch pack height as described earlier.
Clutch - Assembly
WARNING

1. Position the clutch outer drum assembly to the input shaft and align the oil pump drive pegs with the corresponding holes in the rear of the clutch outer drum.
2 3
1. Clutch outer drum

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

1
2
kaio1
1. Outer drum
2. Bearing sleeve
Note
When the bearing sleeve is correctly fitted, it will be a flush fit with the clutch drum face.
3. Fit the thrust washer to the shaft.
4. Fit the clutch inner drum.
5. Fit the flat washer, ensuring it is centralised on the shaft and not resting in the relief groove on the gearbox input shaft.
2
1
ckej
1. Gearbox input shaft

2. Flat washer
3. Relief groove
6. Fit a new Belleville washer (OUT mark facing outwards), and fit a new centre nut.
O
4
U
T
2 3
1. Centre nut
2. Belleville washer
3. Flat washer
4. Inner drum
5. Thrust washer
7. Lock the inner and outer drums together using T3880307 - Clutch Anti-rotation Jig. Depress the rear brake pedal to prevent the engine turning, and tighten the centre nut to
98 Nm. Remove the clutch anti-rotation tool.

gaaz_1
1. T3880307 - Clutch Anti-rotation Jig
8. Disengage second gear and check for free rotation of the clutch inner drum.
9. Using a suitable pin punch, stake the nut to the shaft.
10. Coat all clutch friction plates in clean engine oil before fitting the friction plates, steel plates, anti-judder spring and anti-judder seat washer to the clutch basket in the same
order and orientation as noted during removal.
Note
The inner and the two outermost friction plates are different to the other friction plates. They must be fitted in their noted positions.
The outer steel plate is different to the other plates. It must be fitted in its noted position.
4
1
5
3
1. Outer friction plate

2. Steel plate
3. Anti-judder spring
4. Anti-judder seat washer
5. Clutch inner drum
11. Refit the clutch pull-rod.

12. Fit the pressure plate. Ensure that the spring seats are fitted into the pressure plate as noted for removal.
13. Fit the springs and stopper plate, ensure that the OUT mark on the stopper plate is facing outwards. Secure with the bolts and tighten to 10 Nm.
OU
T
3
2
1. Bolts
2. Stopper plate
3. Springs
4. Spring seats
5. Pressure plate
Note
The pull-rod should be free to move in and out and also it should be free to turn.
Refit the clutch cable to the actuating arm at the clutch end (see Clutch Cable - Installation).
Set the clutch adjustment (see Clutch Cable - Installation).
Clutch Lifter Arm - Removal
WARNING



Note
If the clutch lifter arm is removed, the oil seal for the lifter arm in the clutch cover must be replaced.
Note the orientation of the clutch lifter arm for installation.
Note the position and orientation of the lifter arm spring for installation.
1. Remove the clutch lifter arm spring.
B00551
1. Spring
2. Pull out the lifter arm from the clutch cover.
B00528
1. Clutch lifter arm

2. Washer
3. Oil seal
4. Needle roller bearings
3. Using a suitable tool, carefully remove the oil seal in the clutch cover without damaging the clutch cover.
4. Check the condition of the needle roller bearings and the lifter arm for damage. If necessary renew the needle roller bearings and clutch lifter arm.
Clutch Lifter Arm - Installation
WARNING

1. Press a new clutch lifter rod oil seal to the clutch cover. Make sure that the sealing lip is facing inwards.
2. Lubricate the seal lip with molybdenum disulphide grease and fit the clutch lifter arm into the clutch cover as noted for removal.
B00528
1. Clutch lifter arm

2. Washer
3. Oil seal
4. Needle roller bearings

3. Before fitting the spring, ensure the lifter arm plate is positioned as shown in the following illustration.
B00551
1. Spring
4. Fit the spring as noted for removal.

5. Check the operation of the clutch lifter arm before installing the clutch cover.
Crankcase, Crankshaft, Connecting Rods and Pistons

Exploded View - Crankshaft, Connecting Rod, Piston and Liner
Exploded View - Crankcase

Crankcases - Disassembly
CAUTION
Failure to follow the correct bolt release sequence may result in permanent crankcase damage.

Engine - Removal
Balancer Shaft Cover - Removal
Sump - Removal
Starter Drive Gears/Sprag Clutch - Removal
Oil and Coolant Pump - Removal
1. Invert the engine to give access to the lower crankcase bolts.
2. Release the lower crankcase bolts in the sequence shown in the diagram below. Note the position of the hardened washers under bolts 19 to 26.
1 3 4 2
15 17
16 18
22 24
20
26
19
21
23
25
9 8
12 14
11
5 7 6 13 10

Crankcase Bolt Release Sequence
3. Separate the lower and upper crankcases. Make sure that the three locating dowels remain in the upper crankcase.
CAUTION
Do not use levers to separate the upper and lower sections of the crankcase or damage to the crankcases could result.
Note
The position of each individual bearing shell.
At this point the transmission shafts, balancer, crankshaft, bearings etc. can be removed.
4. Collect the piston cooling jets from below the upper main bearings, noting that the piston cooling jet for number 3 cylinder is longer and has a larger diameter drilling than
the piston cooling jets for number 1 and 2 cylinders. It can also be identified by its smaller outside diameter and a groove around its circumference.
Crankcases - Assembly
1. Use high flashpoint solvent to clean the crankcase mating faces. Wipe the surfaces clean with a lint-free cloth.
2. Fit the gearbox shafts (if removed), ensuring the locating ring and dowels on the output shaft bearings are positioned correctly in the crankcase.
3. Ensure that the transmission is in neutral.
4. Ensure that the three locating dowels are in position in the upper crankcase.
cdmx
1. Locating dowels
5. Apply a thin bead of silicone sealer (at the factory, ThreeBond 1216E is used) to the lower crankcase mating faces.
cdmy
Sealer Areas
CAUTION
Do not use excessive amounts of sealer. The extra sealer may become dislodged and could block the oil passages in the crankcases causing severe engine damage.
6. If removed, insert the three piston cooling jets into the main bearing housings in the upper crankcase.
cdjk
1. Piston cooling jet

CAUTION
Ensure the three piston cooling jets are installed. If the piston cooling jets are omitted, oil pressure will be reduced. Running the engine with low oil pressure will cause
severe engine damage.
Note
The piston cooling jet for number three cylinder is longer and has a larger diameter drilling than the piston cooling jets for number one and two cylinders. It can
also be identified by its smaller outside diameter and a groove around its circumference. Piston cooling jets must not be installed incorrectly.
CAUTION
Always check the bearing journal clearance (see Checking the Measured Clearance), before final assembly of the crankshaft. Failure to correctly select crankshaft bearings
will result in severe engine damage.
7. Install and lubricate the crankshaft bearing shells with clean engine oil (see bearing selection on page Checking the Measured Clearance before proceeding).
8. Lubricate the crankshaft journals with clean engine oil.
9. Position the lower crankcase to the upper. An assistant may be required to support the crankcase during alignment.
10. Fit the bolts into the lower crankcase and hand tighten until the bolt heads are near contact with the crankcase. Note the position of the hardened washers under bolts one
to eight.
Note
The crankcase bolts are tightened in stages.
Two different sizes of crankcase bolts are used. All bolts are tightened through the first stage of the tightening procedure but only the M8 size bolts are
tightened at the second stage.
CAUTION
Failure to follow the correct bolt tightening sequence may result in permanent crankcase damage.
Stage 1 - all fixings
1. In the sequence shown below, tighten only the M8 size crankcase fixings numbered 1 to 8 to 10 Nm.
2. In the sequence shown below, tighten only the crankcase fixings numbered 9 to 26 to 12 Nm.
26 24 23 25
17 15
16 14
5 3
7
1
8
6
4
2
12 13
9 18
10
11
22 20 21 19
Crankcase Fixing Tightening Sequence
Stage 2 - M8 fixings only
1. In the sequence shown below, loosen only the M8 size crankcase fixings numbered 1 to 8 then retighten to 10 Nm.
2. In the sequence shown below, tighten only the M8 size crankcase fixings numbered 1 to 8 through 70° of bolt rotation as measured using T3880105 - Torque Angle Gauge.
3. In the sequence shown below, tighten only the M8 size crankcase fixings numbered 9 to 14 to 32 Nm.
12 10
11 9
5 3
7
1

1
8
6
4
2
13
14
M8 Crankcase Fixing Tightening Sequence
4. Rotate the crankshaft clockwise. Check for tight spots and rectify as necessary.
Oil and Coolant Pump - Installation
Clutch - Assembly
Starter Drive Gears/Sprag Clutch - Installation
Sump - Installation
Balancer Shaft Cover - Installation
Crankshaft - Removal

Engine - Removal
Alternator Rotor - Removal
Connecting Rods - Removal
1. Release and remove the crankshaft from the upper crankcase.
Note
Identify the location of each bearing shell.
Remove all bearings and inspect for damage, wear, overheating (blue discolouration) and any other signs of deterioration. Replace the bearings as a set if
necessary.
Collect the piston jets from below the upper main bearings.
If the camshaft drive chain sprocket is removed from the crankshaft, always install a new fixing. Tighten to 27 Nm.
2. Remove the balancer (see Balancer - Removal).
Crankshaft - Installation
CAUTION
Always check the bearing journal clearance (see Checking the Measured Clearance), before final assembly of the crankshaft. Failure to correctly select crankshaft bearings
will result in severe engine damage.
1. If removed, insert the three piston cooling jets into the main bearing housings in the upper crankcase, as noted for disassembly.
cdjk
1. Piston cooling jet
CAUTION
Ensure the three piston cooling jets are installed. If the piston cooling jets are omitted, oil pressure will be reduced. Running the engine with low oil pressure will cause
severe engine damage.
Note
The piston cooling jet for number three cylinder is longer and has a larger diameter drilling than the piston cooling jets for number one and two cylinders. It can
also be identified by its smaller outside diameter and a groove around its circumference. Piston cooling jets cannot be installed incorrectly.
2. Select and fit new main and big end shell bearings (see Checking the Measured Clearance).

cdmx
1. Big end shell bearings
3. Lubricate all bearings with a 50/50 solution of engine oil and molybdenum disulphide grease.
4. Ensure that the crankshaft is clean, and that the oil ways within the crankshaft are clean and free from blockages and debris.
5. Refit the balancer (see Balancer - Installation).
6. Install the crankshaft ensuring that the crankshaft journals align with the big ends and that the crankshaft and balancer gear markings align as shown in the next illustration.
cdmz_4
1. Balancer gear markings

2. Crankshaft gear markings

Connecting Rods - Installation
If removed, refit the transmission shafts.
Alternator Rotor - Installation
Connecting Rods - Removal

Engine - Removal
Cylinder Head - Removal
1. Mark each big end cap and connecting rod to identify both items as a matched pair and to identify the correct orientation of the bearing cap to the connecting rod.
2. Release the connecting rod bolts and remove the big end cap. Make sure that the bearing shell remains in place in the cap.
cdur
1
1. Big end cap

2. Connecting rod bolt
Note
It may be necessary to gently tap the big end cap with a rubber mallet to release the cap.
3. Push the connecting rod up through the crankcase and collect the piston and connecting rod from the top.
4. Label the assembly to identify the cylinder from which it was removed.
CAUTION
Never reuse connecting rod bolts. If the connecting rod cap is disturbed, always renew the bolts. Using the original bolts may lead to severe engine damage.

5. Remove the cylinder liner assembly (see Cylinder Liner - Removal).
6. Detach the piston from the connecting rod (see Pistons - Disassembly).
Connecting Rods - Installation
Note
Connecting rod bolts are treated with an anti-rust solution which must not be removed.
Clean the connecting rod with high flashpoint solvent.
Remove all bearings and inspect for damage, wear and any signs of deterioration and replace as necessary.
WARNING
Connecting rod bolts MUST only be used once. If the bolts are removed or undone for any reason, new bolts MUST always be used.
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.
Note
Make sure that the piston is fitted correctly to the connecting rod.
If a previously run engine is being rebuilt, always make sure that the piston and connecting rod are assembled in the same orientation, and to the same
cylinder, as prior to disassembly.
1. Fit the piston onto the connecting rod (see Pistons - Assembly).
2. Install the pistons into the liner assembly and install the liner assembly (see Cylinder Liner - Installation).
Note
Ensure that the piston/liner/connecting rod assembly aligns correctly with the crankshaft journal during assembly into the crankcase.
3. Select the big end bearing shells (see Connecting Rod Big End Bearing Selection/Crankshaft Journal Wear Check).
4. Fit the bearing shells to the connecting rod and big end cap and lubricate with a 50/50 solution of engine oil and molybdenum disulphide grease.
5. Align the connecting rod to the crankshaft and fit the big end cap.
cdur
1
1. Big end cap

2. Connecting rod bolt
CAUTION
The torque characteristics of the connecting rod bolts are sensitive to the correct lubrication being applied. If the threads and under-head areas are not lubricated with
molybdenum disulphide grease, the bolts may be stretched and may become loose when in service resulting in an expensive engine failure.
6. Lubricate the threads and under-head area of the new bolts with molybdenum disulphide grease. Tighten the bolts evenly and progressively in five stages as follows:
CAUTION
The torque characteristics of the connecting rod bolts are sensitive to the rate at which they are tightened. If all the torque is applied in one action, the bolt may be stretched
and may become loose when in service resulting in an expensive engine failure.
Tighten to 14 Nm.
Tighten through 210° of bolt rotation as measured using T3880105 - Torque Angle Gauge.

Cylinder Head - Installation

Connecting Rod Big End Bearing Selection/Crankshaft Journal Wear Check
1. Measure the bearing and crankshaft journal clearance as follows.

Note
The crankshaft journal clearances are measured using Plastigauge (Triumph part number 3880150-T0301).
Do not turn the connecting rod and crankshaft during the clearance measurement as this will damage the Plastigauge.
Remove the big end cap from the journal to be checked.
Wipe the exposed areas of the crankshaft journal, and the bearing face inside the cap.
Apply a thin smear of grease to the journal and a small quantity of silicone release agent to the bearing.
Size a length of the Plastigauge to fit across the crankshaft journal. Fit the Plastigauge to the journal using the grease to hold the strip in place.
Lubricate the threads and under-head of the bolt with molybdenum disulphide grease. Refit the bearing and cap and tighten the big end bolts (see Connecting Rods -
Installation).
Remove the big end cap from the journal being checked. Using the gauge provided with the Plastigauge kit, measure the width of the compressed Plastigauge.
Checking the Measured Clearance
Connecting Rod Big End Bearing/Crankshaft Journal Clearance
Note
If the measured clearance exceeds the service limit, measure the crankshaft journal diameter.
Crankshaft Journal diameter
Standard 32.994 - 33.010 mm
Note
If any crankshaft journal has worn beyond the service limit, the crankshaft must be replaced.
Due to the advanced techniques used during manufacture, the crankshaft cannot be re-ground and no oversize bearings are available.
Connecting Rod - Bearing Selection
Minor differences in crankshaft dimensions are compensated for by using selective bearings. For further information on bearing part number to colour cross-references, see the
latest parts information.
1. Select the correct big end bearing shell as follows:
Measure each crankshaft journal diameter.
Select the correct bearings by matching the information found with the chart below.
Note
All dimensions in millimetres.
Big end bearing selection chart
Shell Colour White Red
Connecting Rod Big End Bore Dia. 36.009 36.009

36.000 36.000
Crankshaft Journal Dia. 33.010 33.002

33.003 33.994
Running Clearance Range 0.064 0.061

0.036 0.032
Running Clearance Nominal 0.049
For instance:

Connecting Rod Big End Dia. 36.002
Crankshaft Journal Diameter 32.987
Required Bearing Red
Note
Repeat the measurements for all connecting rods and their respective crankshaft journals.
It is normal for the bearings selected to differ from one connecting rod to another.
1. Install the new bearings in the connecting rod.
cdmx
1. Big end bearings
CAUTION
Always confirm, using the Plastigauge method, that the running clearance is correct before final assembly. Severe engine damage could result from incorrect clearance.
Crankshaft Main Bearing/Journal Checking, Measuring and Bearing Selection
Minor differences in crankshaft dimensions are compensated for by using selective bearings. For further information on bearing part number to colour cross-references, see the
latest parts information.
Note
All dimensions in millimetres.
CAUTION
Always confirm, using the Plastigauge method, that the running clearance is correct before final assembly. Severe engine damage could result from incorrect clearance.
Crankshaft Main Bearing/Journal Wear
Minor differences in crankshaft and crankcase dimensions are compensated for by using selective bearings. For further information on bearing part number to colour cross-
references, see the latest parts catalogue information.
1. Measure the bearing to crankshaft journal clearance as follows:
2. Measure the bearing to crankshaft main journal clearance using Plastigauge (Triumph part number 3880150-T0301).
Note
Do not turn the connecting rods and crankshaft during the clearance measurement as this will damage the Plastigauge.
3. Separate the crankcase halves (see Crankcases - Disassembly).
4. Wipe the exposed areas of the crankshaft journal, and the bearing faces inside the crankcase halves.
5. Apply a thin smear of grease to the journal and a small quantity of silicone release agent to the bearing.
6. Trim a length of the Plastigauge to fit across the crankshaft journal.
7. Fit the Plastigauge to the journal using the grease to hold the strip in place.
Note
The original fixings may be reused for bearing selection. Do not use new fixings as they may only be used once, even if the single use is related to bearing
selection.
8. Lubricate the threads and the face of the fixings with molybdenum disulphide grease.
Note
It is not necessary to apply silicone sealer to the crankcase mating faces during the bearing selection process.
Only apply silicone sealer during final assembly.
9. Refit the crankcase and tighten the original fixings (see Crankcases - Assembly).
10. Release the fixings and remove the crankcase.
11. Using the Plastigauge kit, measure the width of the compressed Plastigauge.

Checking Crankshaft Journal Clearance
using Plastigauge
12. For specifications refer toCrankshaft.

13. If the clearance exceeds the service limit, measure the diameter of the crankshaft bearing journal.
Note
If any journal has worn beyond the service limit, the crankshaft must be replaced. Due to the techniques used during manufacture, the crankshaft cannot be re-
ground and no oversize bearings are available.
Main Bearing Selection
Note
Minor differences in dimensions are compensated for by using selective bearings. For further information on bearing part number to colour cross-references,
see the latest parts information.
Select the bearings as follows:
1. Measure and record the diameter of each crankshaft main bearing journal.
2. Measure and record each main bearing bore diameter in the crankcase (bearings removed, crankcase halves assembled and all fixings fully torqued).
3. Select and install the correct bearings by matching the information found in the Main Bearing Selection Chartmain bearing selection chart.
For example:
Crankcase Bore 35.990 mm
Crankshaft Journal Diameter 32.978 mm
Required Bearing Blue
Note
It is normal for the bearings selected to differ from one journal to another.
It is also normal for there to be two options of bearing shell colour. In such cases, pick the shell size that gives the greater running clearance.
4. Install the new bearings.
Crankshaft End Float
Note
Crankshaft end float is controlled by the tolerances in crankshaft and crankcase machining. No thrust washers are used. If the crankshaft end float is outside
the specified limit, the crankshaft and/or the crankcases must be replaced.
Main Bearing Selection Chart
Crankcase Crankshaft Main Journal Diameter

Bore
Diameter 32.972 32.973 32.974 32.975 32.976 32.977 32.978 32.979 32.980 32.981 32.982 32.983 32.984 32.985 32.986 32.987 32.988
35.980 Blue Blue Blue Blue Red Red Red Red Red Red Red Red Red Red Red Red Red
35.981 Blue Blue Blue Blue Blue Red Red Red Red Red Red Red Red Red Red Red Red
35.982 Blue Blue Blue Blue Blue Blue Red Red Red Red Red Red Red Red Red Red Red
35.983 Blue Blue Blue Blue Blue Blue Blue Red Red Red Red Red Red Red Red Red Red
35.984 Blue Blue Blue Blue Blue Blue Blue Blue Red Red Red Red Red Red Red Red Red
35.985 Green Blue Blue Blue Blue Blue Blue Blue Blue Red Red Red Red Red Red Red Red
35.986 Green Green Blue Blue Blue Blue Blue Blue Blue Blue Red Red Red Red Red Red Red
35.987 Green Green Green Blue Blue Blue Blue Blue Blue Blue Blue Red Red Red Red Red Red
35.988 Green Green Green Green Blue Blue Blue Blue Blue Blue Blue Blue Red Red Red Red Red
35.989 Green Green Green Green Green Blue Blue Blue Blue Blue Blue Blue Blue Red Red Red Red
35.990 Green Green Green Green Green Green Blue Blue Blue Blue Blue Blue Blue Blue Red Red Red
35.991 Green Green Green Green Green Green Green Blue Blue Blue Blue Blue Blue Blue Blue Red Red
35.992 Green Green Green Green Green Green Green Green Blue Blue Blue Blue Blue Blue Blue Blue Red

35.993 Green Green Green Green Green Green Green Green Green Blue Blue Blue Blue Blue Blue Blue Blue
35.994 Green Green Green Green Green Green Green Green Green Green Blue Blue Blue Blue Blue Blue Blue
35.995 Green Green Green Green Green Green Green Green Green Green Green Blue Blue Blue Blue Blue Blue
35.996 Green Green Green Green Green Green Green Green Green Green Green Green Blue Blue Blue Blue Blue
35.997 Green Green Green Green Green Green Green Green Green Green Green Green Green Blue Blue Blue Blue
35.998 Green Green Green Green Green Green Green Green Green Green Green Green Green Green Blue Blue Blue
For instance:
Crankcase Bore 35.990
Crankshaft Journal Diameter 32.978
Required Bearing Blue
WARNING
Always confirm, using the Plastigauge method, that the running clearance is correct before final assembly. Severe engine damage could result from incorrect clearance
resulting in loss of motorcycle control and an accident.
Note
Repeat the measurements for all respective journals.
It is normal for the bearings selected to differ from one journal to another.
Pistons - Disassembly
Note
It is not necessary to remove the connecting rods from the crankshaft.
1. Remove the cylinder liner assembly (see Cylinder Liner - Removal).
2. Remove and discard the gudgeon pin circlip from one side of the piston.
B00638
Removing the Gudgeon Pin Circlip
3. Remove the gudgeon pin by pushing the pin through the piston and rod toward the side from which the circlip was removed.
CAUTION
Never force the gudgeon pin through the piston. This may cause damage to the piston which may also damage the liner when assembled.
Note
If the gudgeon pin is found to be tight in the piston, check the piston for a witness mark caused by the circlip. Carefully remove the mark to allow the pin to be
removed.
4. Piston rings must be removed from the piston using hand pressure only. Do not overextend the piston rings during removal.
Note
If the piston rings are to be reused, note the orientation of the oil control rings prior to removal.
Piston - Wear Check
1. Measure the piston outside diameter, 8 mm up from the bottom of the piston and at 90° to the direction of the gudgeon pin.

3 2
1
capf_1
1. Piston outside diameter

2. Measurement point
3. Circlip removal groove
All Pistons 77.970 - 77.980 mm
Replace the piston if the measured diameter falls outside the specified limit.
Pistons - Assembly
1. Clean the piston ring grooves and fit the piston rings to the piston.
Note
The top ring upper surface is marked N and can be identified by a chamfer on the inside edge.
The second ring upper surface is marked N2, and is plain on the inside edge.
When new, the oil control rings can be fitted with either face upward. Used oil control rings must be refitted in the same orientation as noted prior to removal.
Piston Ring Identification
2. Fit the piston onto the connecting rod.

Note
Connecting rods may be fitted either way around. However, ensure all three are fitted the same way.
3. Lubricate the piston, small end and gudgeon pin with a 50/50 solution of engine oil and molybdenum disulphide grease.
4. Align the small end in the connecting rod with the gudgeon pin hole in the piston and fit the gudgeon pin.
5. Fit new circlips on both sides of the gudgeon pin ensuring the circlips are correctly fitted in the grooves.
WARNING
Failure to use new gudgeon pin circlips could allow the pin to detach from the piston. This could seize the engine, resulting in loss of motorcycle control and an accident.
6. The piston ring gaps must be arranged as shown in the diagram below.
1. Top ring
2. Second ring
3. First steel oil control ring
4. Oil control ring expander
5. Second steel oil control ring

Note
The top ring gap should be positioned in the 12 o'clock position, and the second ring gap in the 6 o'clock position. The first steel oil control ring gap should be
in the 12 o'clock position and the second steel oil control ring should be in the 6 o'clock position. The oil control ring expander should be in the 7 o'clock
position.
7. Fit the piston into the liner from below using a gentle rocking motion to engage the rings in the bore.
Piston Rings/Ring Grooves
Check the pistons for uneven groove wear by visually inspecting the ring grooves.
If all the rings do not fit parallel to the groove upper and lower surfaces, the piston must be replaced.
Clean the piston ring grooves.
Fit the piston rings to the pistons. Check, using feeler gauges, for the correct clearance between the ring grooves and the rings. Replace the piston and rings if outside the
specified limit.
B00640
Piston Ring to Ring Groove Clearance Check
Piston Ring/Groove Clearance
Top ring 0.02 - 0.06 mm
Second 0.02 - 0.06 mm
Piston Ring Gap
Note
The piston ring gap, with the piston ring fitted in the liner, must be checked before final assembly.
1. Place the piston ring inside the liner.
2. Push the ring into the top of the cylinder, using the piston to hold the ring square with the inside of the bore. Continue to push the ring into the bore until the third groove of
the piston is level with the cylinder top, around the full circumference of cylinder.
B00639
1. Piston
2. Cylinder liner assembly
3. Piston ring groove
3. Remove the piston and measure the gap between the ends of the piston ring using feeler gauges.
Piston Ring End-Gap Tolerances
Top 0.15 - 0.30 mm
Second 0.35 - 0.50 mm

Oil Control 0.10 - 0.40 mm
Note
If the end-gap is too large, replace the piston rings with a new set.
If the gap remains too large with the new piston rings, both the pistons and barrels must be replaced.
If the gap is too small, check the cylinder bore for distortion, replacing as necessary. DO NOT FILE PISTON RINGS!
Cylinder Liner - Removal
Note
You will need two sets of T3880315 - Extractor, Cylinder Liner to remove the cylinder liner assembly.
1. Assemble the two sets of T3880315 - Extractor, Cylinder Liner.
1
gakh_2
1. T3880315 - Extractor, Cylinder Liner

2. Extractor bung and guide assembly
2. Turn the crankshaft until the pistons number one and three are at the middle point of their stroke.
3. Check that the locking nuts on each T3880315 - Extractor, Cylinder Liner are loose, then gradually fully unscrew the extraction nut on each tool.
4. Carefully fit one tool fully into cylinder bore number one, positioning the tool legs on the crankcase. Turn the locking nut clockwise until the rubber sleeve on the tool tightly
grips the bore of the liner.
2 2 1
1
3
B00636
1. T3880315 - Extractor, Cylinder Liner

2. Extraction nuts
3. Locking nuts
5. Repeat step 4 with the second tool into cylinder bore number three.
6. Check that the tool legs are positioned to allow withdrawal of the liner.
7. Turn the two extraction nuts clockwise in alternate steps to evenly extract the liner.
CAUTION
Take care to make sure that the piston/connecting rods do not fall against the crankcase when you install or remove them from the liner assembly.
The pistons can be easily damaged if they hit the crankcases.
Note
The tools must be used to release the seal between the liner and the crankcase.
It is not intended that the tools are used to fully extract the liner. Once the seal is released, the tools must be removed and the liner extracted by hand.
8. Turn the locking nuts anticlockwise to release the tools from the liner.
Cylinder Liner - Installation
1. Fully clean the cylinder liner assembly and remove all traces of old silicone sealer.
1
2
3

B00637 4
1. Cylinder liner assembly

2. Dowel location holes
3. Sealer area
4. Chamfer
2. Remove all traces of sealer from the mating surfaces in the crankcase bores.
3. Apply silicone sealer to the mating face between the cylinder liner assembly and the crankcase (at the factory, ThreeBond 1216E is used).
4. Make sure that the two locating dowels for the cylinder liner assembly are correctly installed in the crankcase.
CAUTION
Take care to make sure that the piston/connecting rods do not fall against the crankcase when you install or remove them from the cylinder liner assembly.
The pistons can be easily damaged if they hit the crankcases.
5. Fit the cylinder liner assembly over the pistons using a gentle rocking motion to allow compression of the piston rings.
Note
The cylinder liner assembly has a large chamfer at the bottom of each bore to enable the fitting of the pistons without need for a piston ring compressor.
CAUTION
Fit the cylinde liner assembly over whichever piston is at TDC. When you turn the engine, do not allow the pistons to contact the inside of the crankcase.
6. Continue fitting the cylinder liner assembly over each piston until the cylinder liner assembly is fully fitted and sealed.
Note
When the cylinder liner assembly has been fitted, it should not be disturbed. If it is necessary to remove the cylinder liner assembly after fitting, the sealer must
be reapplied.
Cylinder Wear
Measure the inside diameter of each cylinder using an internal micrometer or similar accurate measuring equipment.
Cylinder bore diameter
Standard 77.985 - 78.003 mm
10 mm
Test Position For Bore Wear Check (bore shown in

section)
1. Measure the inside diameter 10 mm from the top of the bore as shown above.
2. If the reading is outside the specified limits, replace the liner assembly and all piston and ring assemblies.
Crankcase Breather
The upper crankcase is fitted with a labyrinth type breather system, which requires no maintenance. During engine disassembly and overhaul, check the oil drain tube for
blockage and contamination.
Balancer
Exploded View - Balancer Shaft

abxc
Balancer
The balancer is fitted to control 'pulsing' within the engine. Without any form of balancer, the engine would 'pulse' each time the crankshaft rotated. This 'pulsing' would be felt
as a vibration which would amplify as the engine speed was increased.
The balancer has the effect of a pair of counterbalance weights which create an equal amount of energy in the opposite direction, and at the same time as that produced by the
crankshaft, pistons and connecting rods. Because the opposing pulses occur at the same point of crankshaft rotation, and are of an equal magnitude, a state of equilibrium or
balance is reached.
Balancer - Removal
1. Separate the crankcase halves (see Crankcases - Disassembly).

2. With the crankcase halves separated, lift out the balancer shaft complete with the shaft bearings, washer and circlips.
3. To remove the needle roller bearing, slide the bearing, circlip and bearing sleeve from the balancer shaft. Note the orientation of the bearing prior to removal.
WARNING
When using a press, always wear overalls, eye face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up
may cause damage and injury to unprotected parts of the body.
Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.
4. To remove the roller ball bearing, remove the circlip and washer, then using a press and press bars remove the bearing race from the shaft, ensuring the inner bearing race
is supported. Discard the bearing.
CAUTION
Do not remove the drive gear from the balancer shaft. The drive gear is aligned to the shaft. If the balancer and drive gear are not correctly aligned, severe engine vibration
will occur leading to damage to components.
Balancer - Inspection
1. Inspect the balancer gear for chipped or missing teeth.

2. Inspect all bearings for signs of overheating (blue discolouration), seized or damaged rollers, and any other damage.

3. Inspect the gear teeth for overheating (blue discolouration).
Balancer - Assembly
Note
Ensure the inner race of the roller ball bearing is supported when installing the bearing.
1. Position a new roller ball bearing to the balancer shaft, ensuring the circlip is positioned nearest to the drive gear.
WARNING
2. Using a press and press bars, fit the roller ball bearing to the balancer shaft.
3. Refit the washer and a new circlip to the shaft.
4. Lubricate and fit the needle roller bearing and install a new circlip in the same orientation as noted prior to removal.
Balancer - Installation
CAUTION
If the balancer and crankshaft are not correctly aligned, severe engine vibration will occur leading to damage to components.
1. Locate the balancer shaft to the upper crankcase.

2. Align the balancer gears to the crankshaft as shown in the illustration below.
cdmz_4
1. Balancer gear markings

2. Crankshaft gear marking
3. Ensure that the roller ball bearing circlip and dowel locate correctly in the corresponding groove in the crankcase.
2
1
3
cdol_3
4
1. Balancer shaft
2. Balancer shaft (roller ball bearing)
3. Circlip
4. Dowel
4. Ensure that the needle roller circlip and dowel locate correctly in the corresponding groove in the crankcase.

2
cdok
1. Balancer shaft
2. Circlip
3. Dowel
5. Check that the balancer and crankshaft are correctly aligned before continuing to assemble the crankcase halves.
6. Assemble the crankcase halves (see Crankcases - Assembly).
Transmission
Exploded View - Input and Output Shafts
Exploded View - Gear Selectors and Drum

Exploded View - Gear Change Mechanism

Exploded View - Input Shaft
17
16
15
8
7
5 14
4
3 13
2 12
11
1
10
1. Thrust washer
2. Second gear
3. Lock washer
4. Splined washer
5. Splined bush
6. Sixth gear
7. Splined thrust washer
8. Circlip
9. Third/fourth gear
10. Circlip
12. Fifth gear
13. Plain bush
14. Input shaft
15. Bearing housing
16. Bearing
17. Bearing retainer
Exploded View - Output Shaft

17
18
1 19
2 20
3 21
4
5
6
22
7
9 23
10 24
11
25
12
26
13
14 27
15
16 28
29
1. Bearing
2. Thrust washer
3. First gear
4. Plain bush
5. Thrust washer
6. Fifth gear
7. Circlip
9. Fourth gear
10. Splined bush
11. Lock washer
12. Splined washer
13. Splined bush
14. Third gear
15. Splined washer
16. Circlip
17. Sixth gear
18. Circlip
20. Plain bush
21. Second gear
22. Output shaft
23. Snap ring
24. Bearing
25. Sprocket spacer
26. Output shaft seal
27. Output sprocket
28. Tab washer
29. Output sprocket nut
Selector Shaft - Removal
WARNING

WARNING

1. Note the position and orientation of the gear pedal crank in relation to the shaft, then remove the crank.
2. Remove the E-clip and washer from the gear pedal end of the gear change shaft.
kakh1
1. Gear change shaft

2. E-clip
3. Washer
3. Remove the clutch (see Clutch - Disassembly.

4. Unhook the detent arm spring from the detent arm.
5. Withdraw the gear change shaft and detent arm from the clutch end of the crankcase.
3
2
cglt

2. Detent arm
3. Detent arm spring
6. Collect the detent arm spring.
Selector Shaft - Installation
WARNING

1. Rotate the selector drum to the neutral position.
1
2
cglv

1. Detent wheel
2. Neutral position
2. Using grease to NLGI 2 specification, lubricate the lip of the seal on the gear change shaft.
cglw
1. Gear change shaft seal

2. Gear change shaft bearing
CAUTION
Take care to avoid damaging the lip of the seal when inserting the gear change shaft into the crankcase. A damaged seal will lead to oil loss and could result in engine
damage.
3. Carefully insert the gear pedal end of the shaft through the bearings and lip seal in the crankcase. Support the detent arm bearing clear of the selector drum as the selector
shaft is fully installed, and ensure the selector shaft spring fits either side of the abutment bolt.
cglt

2. Spring
3. Abutment bolt
4. Fit the washer and E-clip to the gear pedal end of the gear change shaft.
kakh1

2. E-clip
3. Washer
5. Fit the gear pedal crank to the shaft in the same orientation as noted prior to removal. Make sure that the alignment mark on the shaft aligns with the split line on the gear
pedal crank. Tighten the fixing to 12 Nm.
6. Refit the detent arm spring to the detent arm.
7. Refit the clutch (see Clutch - Assembly).
Selector Forks and Drum - Removal

Engine - Removal
Input and Output Shaft Assemblies - Removal
Selector Shaft - Removal
1. Remove and discard the two selector fork shaft retaining fixings, selector drum keeper plate fixing, noting the position of the two washers and the selector drum keeper
plate.
3
2
cglv_2
1. Selector drum keeper plate

2. Selector drum keeper plate fixing
3. Output selector fork shaft fixing and washer
4. Input selector fork shaft fixing and washer
CAUTION
The two output shaft selector forks can be fitted incorrectly. Ensure the position and orientation of the selector forks are marked prior to removal. Incorrect fitting of the
selector forks will cause gearbox damage.
2. Noting the positions of the selector forks, slide the output selector shaft from the crankcase in the direction of the clutch. Collect the two selector forks as they are released
by the selector fork shaft.
2
3
cdme
1. Output selector shaft

2. Sixth gear selector fork
3. Fifth gear selector fork
3. Noting the position of the selector fork, remove the input selector shaft, leaving the selector fork in the gearbox.
cdmd
1. Input selector shaft

2. Selector fork
4. Remove the gear position sensor.

1
cglw
1. Gear position sensor

2. Fixings
5. Withdraw the selector drum from within the crankcase.
cdmc
1. Selector drum removal
6. Collect the input shaft selector fork from the crankcase.
Selector Forks and Drum - Inspection
1. Examine all components for damage and/or wear, paying particular attention to the selector forks and selector drum. Replace any parts that are damaged and/or worn.
2. Examine the gear change shaft seal for damage and/or wear. Replace the seal if damaged and/or worn.
Gear selector fork thickness
Gear selector groove width
Selector fork to groove clearance
Service limit 0.47 mm max.
Selector Forks and Drum - Installation
1. Position the input shaft selector fork into the crankcase, locating the fork into the selector groove on the input shaft. Ensure the fork is fitted in the position noted during
removal.
cdny
2
1. Input shaft selector fork

2. Input shaft
2. Using clean engine oil, lubricate the selector drum bearings. Lubricate the selector drum tracks with a 50/50 solution of engine oil and molybdenum disulphide grease.
3. Position the selector drum into the crankcase.
cdmc
1. Selector drum
4. Refit the gear position sensor, ensuring the pin on the sensor engages in the hole in the selector drum. Tighten the fixings to 5 Nm.
5. Rotate the selector drum and ensure a smooth movement. Rectify as necessary.
CAUTION
The selector forks can be fitted incorrectly. Ensure the position and orientation of the selector forks are the same as noted during removal. Incorrect fitting of the selector
forks will cause gearbox damage.
6. Push the input selector shaft into the crankcase from the clutch end. As the shaft is inserted locate the selector fork onto the shaft. Ensure the fork is fitted in the position
noted during removal, and the pin on the fork engages in the track in the drum.
cdmd
1. Input selector shaft

2. Selector fork
7. Push the output selector shaft into the crankcase from the clutch end. As the shaft is inserted, locate the selector forks. Ensure the fork is fitted in the position noted during
removal, and the pin on the fork engages in the track in the drum.
2
3
cdme
1. Output selector shaft

2. Sixth gear selector fork
3. Fifth gear selector fork
8. Fit the two selector shaft retaining washers and two new fixings as noted for removal. Tighten the fixings to 12 Nm.
9. Fit the selector drum keeper plate and its new fixing as noted for removal. Tighten the fixing to 12 Nm.

1
3
2
cglv_2
1. Selector drum keeper plate

2. Selector drum keeper plate fixing
3. Output selector fork shaft fixing and washer
4. Input selector fork shaft fixing and washer

Selector Shaft - Installation
Input and Output Shaft Assemblies - Installation
Input and Output Shaft Assemblies - Removal
Note
The input and output shafts may be removed from the upper crankcase after first separating the lower crankcase from the upper.
Note
The rear needle roller bearing on the input shaft remains in the crankcase after removal of the shaft.
Engine - Removal
Remove the output shaft from the upper crankcase, noting the orientation of each bearing, their circlips and dowels.
Selector Forks and Drum - Removal
Note
The input shaft bearing housing fixings may not be reused but should be retained for use during installation of the input shaft.
1. Release the three fixings and remove the retaining plate.
1
1
1
cdmb_4
1. Fixings
2. Retaining plate
3. Bearing housing
2. Insert two M6 bolts into the two threaded holes at the periphery of the bearing housing. Evenly and progressively tighten both bolts to draw the bearing housing and input
shaft from the crankcase.
3
2
2
cdmb_3
1. Bearing housing
2. M6 threaded holes
3. Transmission oil tube
3. If required, the transmission oil tube can now be removed. Remove and discard the three oil tube O-rings.

Input and Output Shaft Assemblies - Installation
1. If removed, check the transmission oil tube for blockages and contamination. Carefully fit new O-rings to the transmission oil tube and insert the tube into the crankcase,
ensuring the tag on the tube locates in the slot in the crankcase.
2. Locate the input shaft to the upper crankcase, installing it through the aperture for the bearing housing.
3. Fit the bearing housing into the aperture, by hand, as deeply as possible.
4. Using the old fixings, evenly and progressively tighten them to draw the bearing housing into the upper crankcase until fully home. Remove and discard the fixings.
4
3 2
2 3
cdmb
1. Bearing housing
2. Fixings
3. M6 threaded holes
4. Transmission oil tube
5. Fit the retaining plate. Install new fixings and tighten to 12 Nm.
1
1
1
cdmb_4
1. Fixings
2. Retaining plate
3. Bearing housing
6. Refit the selectors and shafts (see Selector Forks and Drum - Installation).
7. Refit the output shaft to the crankcase ensuring the snap ring locates in the corresponding groove in the crankcase, and the dowel locates in the slot in the upper
crankcase.
8. Ensure the output shaft seal aligns with its recess in the crankcase.
3
2
4
kaix_1 1
1. Groove in crankcase
2. Snap ring
3. Seal
4. Bearing
9. Ensure the hole in the output shaft needle roller bearing outer race is positioned to locate onto the dowel provided in the upper crankcase. Ensure the selector forks are
located in the grooves in the output gears.

1
cdqj
1. Roller bearing
2. Dowel

Input Shaft - Disassembly
Note
The numbers in brackets in the following text refer to the exploded view (Exploded View - Input Shaft).
Working from the opposite end to where the clutch assembly is fitted, dismantle the input shaft as follows:
1. Slide off the plain thrust washer (1).
2. Mark one side of second gear to denote its correct orientation. Remove second gear (2).
3. Remove the splined lock washers (3 and 4), noting their position.
4. Mark one side of sixth gear to denote its correct orientation. Remove sixth gear (6), complete with the splined bush (5) which runs inside the gear.
5. Remove the splined thrust washer (7) from in front of the circlip between sixth and third/fourth gear.
6. Remove and discard the circlip (8) from the shaft.
7. Mark one side of the combined third/fourth gear to denote its correct orientation. Remove the combined third/fourth gear (9).
8. Remove and discard the circlip (10) from in front of fifth gear.
9. Remove the splined thrust washer (11) adjacent to fifth gear.
10. Mark one side of fifth gear to denote its correct orientation. Remove fifth gear (12), complete with the plain bush (13) which runs inside the gear.
Note
Unless the bearing at the clutch end of the input shaft is damaged or worn, it is not normally necessary to remove it from the shaft. The bearing is pressed onto
the shaft and is also pressed into its housing. The bearing and housing are removed from the shaft together and are then separated.
WARNING
Never wear loose clothing, which could become trapped in the press and cause crushing injuries to the hand, arms or other parts of the anatomy.
11. Support the bearing and housing (15 and 16) on press bars, then press the shaft (14) through the bearing and housing as shown below.
2
1 1
ccbl
1. Press bars
2. Bearing/housing
12. Support the outer circumference of the bearing housing on press bars, then press the bearing through the housing.
Pressing out the Bearing

Input Shaft - Inspection
1. Examine all gears, bearings and bushes and thrust washers for damage, distortion, chipped teeth and wear beyond the service limits. Replace all defective components
and always use new circlips to assemble the shaft.
2. Thoroughly clean the bearing housing and inspect for damage, scoring and cracks. Replace the housing if necessary.
Input Shaft - Assembly
Note
The numbers in brackets in the following text refer to the exploded view (Exploded View - Input Shaft).
Lubricate each gear, thrust washer and bush with clean engine oil during assembly.
WARNING
CAUTION
Bushes and gears with oil holes must always be MISALIGNED with the corresponding oil holes in the input shaft. Reduced oil pressure and gear lubrication may result from
alignment of the oil holes, which would cause premature wear of engine and transmission components.
CAUTION
Removing the input shaft bearing from the shaft and its housing will damage the bearing. Never use removed bearings as use of damaged or weakened components could
lead to engine and transmission damage. Also, check for damage to the housing itself.
1. Position the bearing to the housing.
CAUTION
Press only on the bearing outer race to prevent bearing damage.
2. Support the housing on press bars as shown below and press the bearing fully into the housing in the direction of the arrow.
1. Bearing housing
2. Bearing
CAUTION
Press only on the bearing inner race to prevent bearing damage.
3. Locate the bearing and housing to the input shaft. Carefully support the shaft on the press bed, and using a suitable sleeve over the input shaft to ensure the bearing is
pressed only on the inner race, press the bearing onto the shaft.
2 1
3 3
ccbo
1. Sleeve
2. Bearing/housing

3. Press bars
4. Input shaft
4. Fit the plain bush (13) to the shaft.

5. Fit fifth gear (12) to the input shaft as noted during disassembly, with the dog teeth pointing away from the input shaft bearing.
6. Slide on the splined thrust washer (11).
7. Fit a new circlip (10) to the input shaft ensuring that the circlip is located in the circlip groove as shown below.
2
3
cdmo
1. Fifth gear
2. Thrust washer
3. Circlip
8. Fit the combined third/fourth gear (9) as noted during disassembly, with the larger gear facing toward fifth gear. Ensure that the oil hole in the input shaft DOES NOT align
with the oil hole in the gear.
WARNING
If the oil hole in the third/fourth gear is aligned with the corresponding hole in the input shaft, engine oil pressure and gear lubrication will be reduced.
Reduced oil pressure and gear lubrication will cause engine damage and could also lead to engine seizure resulting in loss of motorcycle control and an accident.
9. Fit a new circlip (8) to the input shaft ensuring that the circlip is located in the circlip groove as shown below.
2
3
cdmp
1. Sixth gear
2. Thrust washer
3. Circlip
10. Fit the splined thrust washer (7) to the input shaft and slide up the shaft until in contact with the circlip.
11. Fit the splined bush (5) from sixth gear. Ensure that the oil hole in the input shaft DOES NOT align with the oil hole in the bush.
12. Fit sixth gear (6) as noted during disassembly, with the dog teeth facing third/fourth gear.
13. Fit the splined and lock washers (4 and 3), ensuring the tabs in the smaller washer (3) locate in the slots in the larger (4) washer.
2 3
cdmq
1. Second gear
2. Large splined lock washer
3. Small splined lock washer
14. Fit second gear (2) to the shaft as noted during disassembly.
15. Fit the plain thrust washer (1) adjacent to second gear.

Output Shaft - Disassembly
Note
The numbers in brackets in the following text refer to the exploded view (Exploded View - Output Shaft).
Working from the opposite end to the drive sprocket, dismantle the output shaft as follows.
1. Remove the output shaft bearing (1) and plain thrust washer (2).
2. Mark one side of first gear to denote its correct orientation. Remove first gear (3) from the shaft, complete with the plain bush (4) which runs inside the gear.
3. Remove the plain thrust washer (5).
4. Mark one side of fifth gear to denote its correct orientation. Remove fifth gear (6) from the shaft.
5. Remove the circlip (7) and splined thrust washer (8) from in front of fourth gear.
6. Mark one side of fourth gear to denote its correct orientation. Remove fourth gear (9) complete with the splined bush which runs inside the gear (10).
7. Remove the splined lock washers (11 and 12) noting their positions.
8. Mark one side of third gear to denote its correct orientation. Remove third gear (14) off the shaft complete with the splined bush (13) which runs inside the gear.
9. Remove the splined thrust washer (15).
10. Remove the circlip (16) from in front of sixth gear.
11. Mark one side of sixth gear to denote its correct orientation. Remove sixth gear (17) from the shaft.
12. Remove the circlip (18) from in front of second gear.
13. Remove the splined thrust washer (19).
14. Mark one side of second gear to denote its correct orientation. Remove second gear (21) from the shaft, complete with the plain bush (20) which runs inside the gear.
15. Position the output shaft (22) in a vice with soft jaws fitted. Tighten the vice to prevent the shaft from turning and release the tab washer (28) from the output sprocket nut
(29), then release the nut.
16. Remove the output sprocket nut (29), tab washer (28) and sprocket (27).
17. Collect the output shaft seal (26).
18. If it is found necessary to replace the large bearing (24) at the end of the shaft, use a press to remove both the bearing and output shaft sprocket spacer (25) together.
WARNING
When removing the output shaft bearing, always wear overalls, eye, face and hand protection. The bearing races are hardened and are liable to splinter if broken. Debris
from broken bearings could cause injury to eyes, face and any unprotected parts of the body.
Output Shaft - Inspection
1. Examine all gears, bearings and bushes and thrust washers for damage, distortion, chipped teeth and wear beyond the service limits. Replace all defective components
and always use new circlips, a new output shaft seal and a new sprocket tab washer to assemble the shaft.
Output Shaft - Assembly
Note
The numbers in brackets in the following text refer to the exploded view (Exploded View - Output Shaft).
Lubricate each gear and bush with clean engine oil during assembly.
WARNING
CAUTION
Bushes and gears with oil holes must always be MISALIGNED with the corresponding oil holes in the output shaft. Reduced oil pressure and gear lubrication may result
from alignment of the oil holes, which would cause premature wear of engine and transmission components.
CAUTION
Removing the output shaft bearing from the shaft will damage the bearing and snap ring. Never reuse removed bearings or snap rings as use of damaged or weakened
components could lead to engine and transmission damage.
CAUTION
Press only on the bearing inner race to prevent bearing damage.
1. If removed, working from the output sprocket end of the shaft, fit a new bearing (24) and a new sprocket spacer (25) to the shaft using a press and press bars. Fit the
sleeve with the large chamfer facing outwards.
1
2
3 3
ccbo
1. Output shaft
2. Bearing

3. Press bars
2. Lubricate and fit a new output shaft seal (26).

3. If removed, transfer the shaft to the vice and secure between soft jaws. Fit the output sprocket (27), new tab washer (28) and nut (29). Tighten the nut to 85 Nm. Close the
tab washer.
4. Withdraw the shaft from the vice and continue to assemble from the opposite end to the output sprocket.
5. Fit the plain bush (20) to the shaft.
6. Locate second gear (21) to the shaft as noted during disassembly, with the large step side facing towards the output sprocket end. Fit the splined thrust washer (19) and
retain with a new circlip (18) as shown below.
2 3
cdmr
1. Second gear
2. Thrust washer
3. Circlip
7. Fit sixth gear (17) as noted during disassembly, with the selector fork groove facing away from the output sprocket end. Ensure that the oil holes in the gear DO NOT align
with the corresponding oil hole in the output shaft.
8. Fit a new circlip (16) to retain third gear. Fit the splined thrust washer (15) to the rear of third gear as shown below.
2
3
1
cdms
1. Third gear
3. Circlip
9. Fit the splined bush (13) for third gear. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft. Fit third gear (14) to the shaft
with the large step side facing away from the output sprocket.
10. Fit the splined lock washers (12 and 11), ensuring the tabs in the smaller washer (11) locate in the slots in the larger washer (12) as shown below.
2 3
cdmt
1. Third gear
2. Large splined lock washer
3. Small splined lock washer
11. Fit the splined bush (10) from fourth gear. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft.
12. Fit fourth gear (9) as noted during disassembly, with the larger step side facing towards the output sprocket.
13. Fit the splined thrust washer (8) and retain with a new circlip (7) as shown below.
2
3
1

1
cdmu
1. Fourth gear
3. Circlip
14. Fit the fifth gear (6) to the shaft with the groove facing towards the output sprocket. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the
output shaft.
15. Fit the first gear thrust washer (5) and plain bush (4).
16. Fit first gear (3) to the shaft as marked during disassembly as shown below.
2
3
cdmv
4
1. First gear
2. Thrust washer
3. Thrust washer
4. Needle roller bearing
17. Finally fit the thrust washer (2) and needle roller bearing (1) to the end of the shaft.
Gear Change Linkage - Removal
WARNING


Note
Note the routing and cable tie securing locations of the shift force sensor cable for installation.
1. Remove the airbox (see Airbox - Removal).
2. Release the cable for the shift force sensor from the connector bracket on the breather cover.
3. Disconnect the shift force sensor multiplug from the main harness.
Note
Note the position of the shift force sensor harness for installation.
4. Remove the wire clips retaining the shift force sensor linkage top and bottom ball joints, as shown below.
2
1
B01018
1. Wire clip

2. Bottom ball joint
5. Pull each balljoint socket off its ball.

6. Remove the shift force sensor linkage.
7. If necessary, unscrew the ball for each balljoint. Collect the seals and the washers.
8. If you need to remove the lever from the gear change shaft, note the position for the installation process.
9. Remove the pinch bolt and remove the lever.
Gear Change Rod - Setting
Note
The gear change rod setting dimension is the same for a standard gear change rod and for Triumph Shift Assist (TSA).
If the gear change linkage needs to be removed, make sure that the setting dimension and alignment are as described below when refitting.
Make sure the alignment mark on the gear change shaft is aligned with the lower edge of the linkage clamp slot.
Make sure that the distance between the centres of the ball joints is 211.8 +/- 1 mm as shown below.
3
1
2
1. Left hand thread marker

2. Linkage setting length
3. Gear change shaft alignment mark
The length of exposed thread at each end of the gear change rod should be equal.
Tighten the gear change rod lock nuts to 6 Nm.
Make sure that the gear change mechanism is free to operate, without any excessive play.
Gear Change Linkage - Installation
1. If removed, install the balljoints, seals and washers. Tighten the balljoints to 8 Nm.
2. Make sure the gear change rod length is set correctly (see Gear Change Rod - Setting).
3. If removed, install the lever onto the gear change shaft in the position noted during removal.
4. Install a new pinch bolt and tighten to 12 Nm.
5. Attach the top ball joint to the lever on the gear change shaft.
6. Attach the bottom ball joint to the gear change pedal.
7. Refit the wire clips to retain the ball joints. Make sure the wire clips locate correctly in the ball joints before rotating the clips to lock in place.
1. Ball joint
2. Wire clip
8. Route the cable for the shift force sensor as noted during removal and connect the multiplug to the main harness.
3
1
2

B01019
1. Shift force sensor

2. Sprocket cover cable clip
3. Rubber band
4. Breather cover cable bracket
9. Install the airbox (see Airbox - Installation).

Starter Drive and Sprag Clutch

Exploded View - Sprag Clutch and Starter Gears
Starter Drive Gears/Sprag Clutch - Removal
WARNING

Note
The sprag clutch may be detached after first removing the rider's seat and the battery (disconnect the negative (black) lead first). The alternator must also be
removed. Refer to the relevant sections for removal procedures.

1. Withdraw the starter idler gear and shaft, noting the fitted position of the components.
1
2
cduq
1. Idler gear
2. Idler shaft
2. Remove the alternator rotor (see Alternator Rotor - Removal).

3. Withdraw the starter drive gear from the sprag clutch.
1 3
B00557
1. Starter drive gear

2. Sprag clutch/housing
3. Alternator rotor
4. Remove and discard the fixings securing the sprag clutch housing to the alternator rotor. Withdraw the sprag clutch housing.
5. Remove the sprag clutch from the housing.
1 2
1. Sprag clutch housing

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


WARNING
1. Locate the sprag clutch to the housing as shown below. Push firmly until the lip seats in the recess provided in the housing.
1 2
1. Sprag clutch housing

2. Sprag clutch assembly
2. Fit the housing to the alternator rotor.

3. Make sure that the housing is squarely seated and is not jammed on the rotor. Install new fixings.
4. Working in the sequence shown, tighten the bolts to 16 Nm. When 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 make sure that
the sprag clutch housing is correctly seated on the rotor.
1 3
6 5
4 2
B00558
Bolt Tightening Sequence
5. Fit the starter drive gear to the sprag clutch.
1 3
B00557
1. Starter drive gear

2. Sprag clutch/housing
3. Alternator rotor
6. Refit the alternator rotor (see Alternator Rotor - Installation).

7. Lubricate the idler gear shaft with a 50/50 solution of engine oil and molybdenum disulphide grease.
8. Fit the starter idler gear and shaft to the crankcase.
1
2

cduq
1. Idler gear
2. Idler shaft
9. Thoroughly clean the left hand engine cover.

Lubrication
Exploded View - Oil Pump/Water Pump, Gears and Heat Exchanger
Engine Oil - Specification
Use semi or fully synthetic 10W/40 or 10W/50 motorcycle engine oil which meets specification API SH (or higher) and JASO MA, such as Castrol Power 1 Racing 4T, sold as
Castrol Power RS Racing 4T in some countries.
Triumph recommends the fully synthetic 10W/40 motorcycle engine oil for most conditions. The oil viscosity may need to be changed to accommodate the ambient
temperatures in your riding area.
Refer to the chart below for the correct oil viscosity (10W/40 or 10W/50) to be used in your riding area.

Oil Viscosity Temperature Range
CAUTION
Triumph high performance fuel injected engines are designed to use semi or fully synthetic motorcycle engine oil which meets specification API SH (or higher) and JASO
MA.
Do not add any chemical additives to the engine oil. The engine oil also lubricates the clutch and any additives could cause the clutch to slip.
Do not use mineral, vegetable, non-detergent oil, castor based oils or any oil not conforming to the required specification. The use of these oils may cause instant, severe
engine damage.
Ensure no foreign matter enters the crankcase during an oil change or top up.
Triumph Engine Oil
Your Triumph motorcycle is a quality engineered product which has been carefully built and tested to exacting standards. Triumph Motorcycles are keen to ensure that you
enjoy optimum performance from your motorcycle and with this objective in mind have tested many of the engine lubricants currently available to the limits of their performance.
Disposal of Used Engine Oil and Oil Filters
To protect the environment, do not pour oil on the ground, down sewers or drains, or into watercourses. Do not place used oil filters in with general waste. If in doubt contact
your local authority.
Engine Oil Circuit Description
Oil is collected from the sump and is drawn through a mesh strainer into the oil pump rotor. The oil pump is fitted with a single pumping rotor which supplies pressurised oil to
the lubrication circuit via the oil pressure relief valve. The relief valve is set to open at 5.1 bar (75 lb/in ²) and when open, returns high pressure oil directly to the sump.
Pressurised oil is delivered to the outside rim of the oil filter, where it is filtered by passing through the filter membrane.
Filtered oil is then delivered to the oil-to-water heat exchanger (mounted on the front of the engine), where it is cooled.
The cooled oil is then fed into the lower crankcase gallery. From here it is distributed around the engine:
Oil is delivered to the crankshaft main bearings and, via drillings in the crankshaft, to the big end bearings.
Spray jets located in the upper crankcase, behind the main bearing shells, lubricate the pistons and connecting rod small ends. These jets are fed oil from the crankshaft oil
feed. A low oil pressure warning light switch is also located in the upper crankcase gallery.
Some oil is sent directly to the cylinder head via an internal gallery. Oil that arrives at the cylinder head is fed to both camshafts via a gallery in the cylinder head casting that
delivers oil directly to the sprocket end of the camshafts. Oil is then fed through the hollow camshafts to the other camshaft bearings, the tappet buckets and the valves.
Oil is fed to the gearbox via internal oil pipes and drillings that supply oil directly to the end of each shaft. Oil is circulated along the gearbox shafts to exit holes that feed
directly to the bearings, gears and selectors.
Engine Oil Circuit

Heat Exchanger
The heat exchanger is used to transfer heat from the engine oil into the coolant.
Filtered oil is delivered to the heat exchanger via an opening (3) where it is circulated through the heat exchanger core. Coolant is pumped through spigot (1) into the heat
exchanger core to cool the oil. The cooled oil then exits the heat exchanger (4) and flows to the main oil gallery. The coolant then flows out of the heat exchanger (2) and
through the rest of the cooling system.
2 1
3
4
2 1
L0457 3 4
1. Coolant in
2. Coolant out
3. Oil in
4. Oil out
An additional benefit of the heat exchanger is that, as the engine coolant reaches its operating temperature more quickly than the engine oil, the oil is heated by the engine
coolant at lower engine temperatures; this allows the engine oil to reach its optimum operating temperatur¿ more quickly, thereby helping to improve engine oil life, reduce
exhaust emissions and reduce engine wear.
Oil and Coolant Pump - Removal
WARNING

WARNING
WARNING
touch hot oil.
WARNING
CAUTION
Do not pour engine oil on the ground, down sewers or drains, or into watercourses. To prevent pollution of watercourses etc., dispose of used oil sensibly. If in doubt contact
your local authority.
Note
The oil pump and water pump are supplied as an assembly and cannot be separated. This procedure covers the removal of the oil and water pump assembly.
Coolant Replacement - Drainage
Sump - Removal
Clutch - Disassembly

1. Release and discard the two fixings and remove the oil transfer pipe. Remove and discard the two O-ring seals.
1 2
B00538
1. Oil transfer pipe

2. Fixings
2. Release and discard the two fixings and remove the oil pick-up. Remove and discard the O-ring seal.
2 1
B00532
1. Oil pick-up
2. Fixings
3. Remove and discard the bolt securing the coolant inlet elbow to the crankcase and withdraw the elbow. Remove and discard the O-ring from the elbow.
2
1
B00521
1. Coolant inlet elbow

2. Fixing
4. Remove and discard the bolt securing the coolant outlet pipe to the crankcase and withdraw the pipe. Remove and discard the three O-rings from the pipe.
B00522
1. Coolant outlet pipe

2. Fixing

5. Release the fixings securing the drive chain guide to the crankcase and remove the guide.
2
1
B00537
B00137
1. Oil pump drive chain guide (engine shown

inverted)
2. Fixings
6. Slide the oil pump drive sprocket gently backwards and forwards to dislodge the inner needle roller bearing.
B00535
B00137
1. Oil pump drive sprocket (engine shown inverted)

7. Carefully remove the bearing while supporting the oil pump drive sprocket.
2
1
B00555
1. Needle roller bearing (engine shown inverted)

2. Oil pump drive sprocket
Note
Note the position of the washer under the oil pump fixing for the oil pump dowel for installation.
8. Release the fixings securing the oil pump. Remove the fixings and collect the washer.
1
2
B00533

1. Oil pump
2. Fixings
3. Washer
9. Using a suitable tool, slide the dowel upwards to release the oil pump from the crankcase. It is not necessary to remove the dowel completely from the oil pump.
B00534
1. Oil pump
2. Dowel
10. Detach the drive chain from the oil pump.
B00536
1. Oil pump
2. Drive chain
11. Carefully withdraw the oil pump from the crankcase.

12. Remove and discard the O-ring from the inlet sleeve on the water pump body.
Oil and Coolant Pump - Installation
Oil Pump - Inspection
WARNING

CAUTION
Before fitting the oil pump to the crankcase ensure the pump internal surfaces have been wetted with clean engine oil. The pump may fail to pick up oil from the sump if the
surfaces have not been wetted. This will cause the engine to run without engine oil pressure and will lead to severe engine damage.
1. Install a new O-ring to the inlet sleeve on the water pump body.
2. Fill the oil pump with new engine oil, turning the pump rotor as the oil is poured in to make sure that all surfaces are coated with oil.
3. Position the oil pump to the crankcase and insert the water pump inlet sleeve into the opening in the crankcase.
4. Fit the oil pump to the crankcase. Make sure that the oil pump dowel correctly locates into the fixing hole in the crankcase.
CAUTION
Do not use excessive force to insert the dowel into the crankcase. Severe dowel or crankcase damage may result from the use of excessive force.
5. Using a suitable pin punch, gently tap the dowel downwards into the crankcase until it seats.
6. Feed the drive chain over the transmission input shaft and fit to the sprocket.
7. Fit the drive chain to the sprocket on the oil pump.
8. Support the oil pump drive sprocket and carefully refit the needle roller bearing.

2
1
B00555
1. Needle roller bearing (engine shown inverted)

2. Oil pump drive sprocket
9. Refit the washer and fixings as noted for removal. Tighten the fixings to 12 Nm.
1
2
B00533
1. Oil pump
2. Fixings
3. Washer
10. Refit the oil pump drive chain guide. Install new fixings and tighten to 12 Nm.
11. Install a new O-ring onto the coolant inlet elbow and position the elbow to the water pump inlet. Fit a new fixing and tighten to 12 Nm.
2
1
B00521
1. Coolant inlet elbow

2. Fixing
12. Install three new O-rings to the coolant outlet pipe and position the pipe through the crankcase. Locate the pipe to the water pump outlet. Install a new fixing and tighten to
12 Nm.
B00522
1. Coolant outlet pipe

2. Fixing
13. Install a new O-ring to the oil pick-up and refit the oil pick-up. Fit new fixings and tighten to 12 Nm.
14. Install two new O-rings to the oil transfer pipe and refit the oil transfer pipe. Fit new fixings and tighten to 12 Nm.

Clutch - Assembly
Sump - Installation
Coolant Replacement - Filling
1. Release the fixing and remove the drive sprocket and spacer washer.
2
3
1. Oil pump
2. Spacer washer
3. Drive sprocket
4. Fixing
2. Release the three fixings and withdraw the oil pump body.
2 1
cdpn
1. Oil pump body

2. Fixings
CAUTION
If any part of the oil pump is found to be outside the service limit, the complete pump must be replaced. Severe engine damage may result from the continued use of a faulty
oil pump.
3. Measure the rotor tip clearance using feeler gauges.
Rotor Tip Clearance
Standard 0.15 mm
cdqh
Rotor Tip Clearance

4. Measure the pump body clearance using feeler gauges.
cdqh
Pump Body Clearance
Pump Body Clearance
5. Measure the pump end clearance.
Pump End Clearance
Oil Pump - Assembly
1. If all clearances are within service limits, liberally apply clean engine oil to all internal components and refit the oil pump body to the oil pump rotor. Refit the fixings and
tighten to 12 Nm.
2. If any clearance measured is outside the service limits, renew the complete pump.
3. Inspect the sprockets and chain for wear and/or damage. Replace the sprockets and chain if wear and/or damage is found.
4. Check the water pump shaft and shaft bearings for side and end float. Renew if necessary.
5. Check for corrosion and scale build-up around the impeller and in the pump body. Renew if necessary.
6. Check the oil pump location dowel for damage. Renew if necessary.
7. Refit the spacer washer and drive sprocket. Apply ThreeBond 1374 to the fixing and tighten to 12 Nm.
2
3
1. Oil pump
2. Spacer washer
3. Drive sprocket
4. Fixing
Low Oil Pressure Warning Light Switch - Removal
WARNING

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

1. Disconnect the electrical connection to the switch.
2. Remove the switch and collect the copper washer.
cdpj
1
1. Low oil pressure warning light switch

2. Electrical connection
Low Oil Pressure Warning Light Switch - Installation
WARNING

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

WARNING
WARNING
touch hot oil.
WARNING
Note
Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and
orientation on assembly.
Position the motorcycle on level ground on the side stand.
1. Noting their orientation, disconnect the coolant hoses from the heat exchanger using service tool T3880207 - Hose Clip Pliers.
2. Remove the three fixings from the heat exchanger and withdraw it from the crankcase.
1 3 4

3 2
B00526
1. Heat exchanger
2. Fixings
3. Hose clips
4. Coolant hoses
3. Remove and discard the O ring from the lower crankcase.
Heat Exchanger - Inspection
1. Check the heat exchanger body for corrosion and/or damage.
Heat Exchanger - Installation
WARNING

1. Fit a new heat exchanger O-ring to the lower crankcase.

2. Fit the heat exchanger to the crankcase and tighten the bolts in the sequence shown to 10 Nm.
3. Retighten fixing 1 to 10 Nm.
B00526_1
Tightening Sequence
4. Fit the coolant hoses to the heat exchanger in the orientation noted during removal.
5. Using service tool T3880207 - Hose Clip Pliers, fit the coolant hose clips in the orientation noted during removal.
1 3 4
3 2
B00526
1. Heat exchanger
2. Fixings
3. Hose clips
4. Coolant hoses

Adjust the engine oil level (see Engine Oil - Level Inspection).

Engine Remove and Install
Engine - Removal
WARNING


Raise and support the motorcycle.
Passenger Seat - Removal/Installation
Battery - Removal
Fuel Tank - Removal
Airbox - Removal
Right Radiator - Removal
Silencer Removal
Left Radiator - Removal
Engine Bars - Removal
Drain the engine oil (see Oil and Oil Filter - Renew).
WARNING
The engine assembly is very heavy.

Get the help of an assistant and use the correct lifting equipment when you move the engine and transmission.
WARNING
Make sure that the engine assembly is secured and cannot fall during removal or installation.
If the engine assembly is not secured, it can fall and cause injury.
CAUTION
To prevent damage to the sump, position wooden blocks between the jacks and the sump.
Note
Secure the coolant hoses to prevent damage as the engine is removed.
1. Support the engine on proprietary lifting jacks, at the front and rear. Use wooden blocks to prevent damage to the sump.
2. Secure the engine to the jacks, using suitable straps, to prevent it from moving or falling as it is removed.
3. Note the position of the gear change crank on the gearbox shaft.
4. Disconnect the gear change linkage at the gearbox shaft. If Triumph Shift Assist (TSA) is fitted, temporarily tie the shift force sensor aside.
5. Remove the sprocket cover (see Sprocket Cover - Removal).
6. Set the drive chain adjustment to allow maximum free play in the chain, (see Final Drive Chain Free-Movement - Adjustment).
7. Disconnect the electrical connector for the oxygen sensor, located near the front sprocket.
5
6
4
3
2 7
B01031
1. Oxygen sensor connector

2. Rubber band
3. Oxygen sensor harness
4. Alternator harness
5. Cable guide
6. Shift assist sensor harness(where fitted)
7. Coolant hose
8. Remove the exhaust header assembly (see Exhaust Header Assembly Removal).
9. Detach the drive chain from the front sprocket and remove it.

10. Remove the two fixings and the left heel guard.
11. Remove the two fixings and the right heel guard.
WARNING
Do not fully remove the swinging arm spindle.

If the swinging arm spindle is fully removed, the swinging arm can drop and cause injury or damage to the motorcycle.
12. Partly remove the swinging arm spindle sufficiently to release the engine.
13. Remove the three fixings that attach the right control plate and tie the control plate aside.
14. Slacken the cable lock nut and release the adjuster at the clutch cover end to give maximum play in the cable.
15. Release the clutch cable from the actuating arm by pushing the inner cable nipple through the arm and sliding the cable out of the slot. Detach the cable from the bracket.
4 3
1
2
cglc
1. Clutch cable
2. Adjuster
3. Inner cable nipple
4. Actuating arm
16. Remove the two fixings that attach the left control plate and remove the control plate.
17. Disconnect the hose from the purge valve to the throttle bodies.
18. Remove the two fixings that attach the connector bracket and the connector tab to the breather cover.
19. Remove the rubber band that attaches the harness from the alternator to the regulator rectifier, to the fuel hose.
20. Release the fuel hose from the connector bracket and remove the hose.
21. Release the connectors from the connector bracket.
22. Disconnect the electrical connectors for the alternator and the side stand switch.
23. Disconnect the electrical connectors from the oil pressure switch and the coolant temperature sensor.
2 3
1 6
5
B01030
Some wires and hoses shown removed for clarity.

1. Connector bracket
2. Main harness connector
3. Temperature sensor connector
4. Oil pressure sensor connector
5. Crank position sensor connector
6. Connector tab
24. Release the electrical connector for the crank position sensor from the bracket on the starter motor.
25. Disconnect the crank position sensor.
26. Disconnect the engine harness from the main harness and remove the engine harness.
27. Remove the nut that attaches the ground cable to the rear of the crankcase and move the ground cable aside.
28. Release the rubber band that holds the cables together at the left side of the engine.
29. Where fitted, disconnect the electrical connector for the shift assist sensor and remove the shift assist sensor.
30. Note the routing of the cable for the gear position sensor.
1 3

B01012

2. Harness
3. Cable tie
4. Electrical connector
31. Remove the cable tie that holds the harness for the gear position sensor to the electrical connector.
32. Remove the top fixing that attaches the wire guide for the gear position sensor harness.
4
cifq
1. Wire guide
2. Fixings
4. Harness, gear position sensor
33. Disconnect the electrical connector for the gear position sensor.
34. Disconnect the positive cable from the starter solenoid, to the starter motor (see Starter Solenoid - Removal).
35. Use the jacks to support the weight of the engine .
36. Note the positions of the spacers at the engine mounting points.
37. Remove the rear lower bolt and collect the chain guide.
38. Loosen the left and right frame adjusters at the lower rear engine mountings.
39. Loosen but do not remove the left and right rear cylinder head fixings.
40. Remove the two front cylinder head fixings and washers. Collect the spacer from the right side.
41. Use the jacks to pivot the rear of the engine down. When the front cylinder head mountings are clear, remove the rear cylinder head fixings and lower the engine down.
WARNING

CAUTION
To prevent damage to the sump in the stage that follows, position wooden blocks between the jacks and the sump.
1. Support the engine on proprietary lifting jacks, at the front and rear. Position the jacks under the sump on wooden blocks.
2. Secure the engine to the jacks, using suitable straps, to prevent it from moving or falling as it is installed.
3. Raise the engine into the frame. Rotate it to align the rear cylinder head mountings.
3 2
4
2 4 5
1
6
8
B01010
Engine not shown for clarity

1. Swinging arm spindle
2. Rear right cylinder head bolt
3. Front right cylinder head bolt
4. Spacer
5. Front left cylinder head fixing
6. Bottom rear crankcase bolt
7. Rear left cylinder head fixing
8. Drive chain guide
4. Loosely install the left rear cylinder head fixing.

5. Loosely install the right rear cylinder head fixing with the spacer positioned between the frame and the cylinder head.
6. Loosely install the two front cylinder head fixings and washers.
7. Install the lower rear engine mounting bolt with its washer from the right side.
8. Rotate the engine to align the swinging arm spindle with the rear upper crankcase mounting. Loosely install the swinging arm spindle from the right side.
9. Fit the washer and nut onto the swinging arm spindle.
10. Hold the swinging arm spindle and tighten the nut to 110 Nm.
11. Tighten the right rear cylinder head fixing to 48 Nm.
12. Tighten the left front cylinder head fixing to 48 Nm.
13. Tighten the left rear cylinder head fixing to 48 Nm.
14. Remove the right front cylinder head fixing and install the spacer between the cylinder head and the frame. If either the frame or engine has been replaced, you will need to
select the correct spacer as supplied with the engine or frame. Try to install the thickest spacer. If this will not fit, try the middle thickness spacer. If this will not fit, install the
thinnest spacer.
15. Install the right front cylinder head fixing and washer. Tighten to 48 Nm.
16. Remove the lower rear engine mounting bolt with its washer.
17. Loosely turn the left and right bottom frame adjusters with T3880166 - Wrench, Engine Mounting Adjuster until the adjusters touch the engine.
18. Use T3880166 - Wrench, Engine Mounting Adjuster to tighten the left frame adjuster to 10 Nm.
19. Use T3880166 - Wrench, Engine Mounting Adjuster to tighten the right frame adjuster to 10 Nm.
20. Install the lower rear engine mounting bolt with its washer from the right side.
21. Insert the chain guide between the engine and the frame at the left side.
22. Fit the nut to the lower rear engine mounting bolt and tighten to 48 Nm.
23. Connect the electrical connector for the crank sensor and position the connector on the bracket on the starter motor.
2 3
1 6
5
B01030
Some wires and hoses shown removed for clarity.

2. Main harness connector
3. Temperature sensor connector
4. Oil pressure sensor connector
5. Crank position sensor connector
6. Connector tab
24. Connect the electrical connector to the oil pressure switch.

25. Connect the electrical connector to the coolant temperature sensor.
26. Connect the engine harness connector to the main harness connector.
27. Attach the connector to the connector tab for the breather cover.
28. Position the connector tab and install the breather cover fixing. Tighten to 10 Nm.
29. If shift assist is fitted, connect the electrical connector for the shift assist sensor. Attach the connector to the front of the breather cover connector bracket
30. Temporarily tie the shift assist sensor aside.
1 2
B01029
1. Side stand switch connector

2. Main harness to engine harness connector
3. Main harness
31. Connect the electrical connector for the side stand switch.
32. Attach the connector to the rear of the connector bracket.
33. Route the cables that follow, through the connector bracket for the breather cover:
Oxygen sensor cable
Alternator cable
Side stand switch cable
Shift force sensor cable (where fitted).
34. Position the fuel hose into the cable bracket with the grey connector at the fuel rail end.
35. Fit the rubber band that attaches the harness from the alternator to the regulator rectifier to the fuel hose.
36. Position the connector bracket and install the breather cover fixing. Tighten to 10 Nm.
37. Position the earth cable onto the stud at the rear of the crankcase. Fit and tighten the nut to 4 Nm.
38. Connect the starter motor cable to the starter solenoid (see Starter Solenoid - Installation).
39. Position the drive chain over the front and rear sprockets.
40. Adjust the drive chain tension (see Final Drive Chain Free-Movement - Adjustment).
41. Install the exhaust header assembly (see Exhaust header Assembly Installation).
42. Install the rubber band that holds the cables at the left side of the engine together.
5
6
4
3
2 7
B01031
1. Oxygen sensor connector

2. Rubber band
3. Oxygen sensor harness
4. Alternator harness
5. Cable guide
6. Shift assist sensor harness (where fitted)
7. Coolant hose
43. Connect the electrical connector for the oxygen sensor.

44. Route the coolant hose and cables through the cable guide of the sprocket cover and install the sprocket cover (see Sprocket Cover - Installation).
45. Connect the electrical connector for the gear position sensor.
1 3
B01012

2. Harness
3. Cable tie
46. Route the harness for the gear position sensor as noted during removal.
47. Use a new cable tie to attach the harness to the connector.
48. Position the wire guide onto the gear position sensor and install the fixing. Tighten to 5 Nm.

3
4
cifq
1. Wire guide
2. Fixings
49. Install the gear change linkage (see Gear Change Linkage - Installation).
50. Install the left control plate. Tighten the two fixings to 30 Nm.
51. Install the left heel guard. Tighten the two fixings to 10 Nm.
52. Install the right control plate. Tighten the two bottom fixings to 30 Nm. Tighten the top fixing to 16 Nm.
53. Install the right heel guard. Tighten the two fixings to 10 Nm.
54. Adjust the clutch cable (see Clutch Cable - Installation).
Fill the engine oil (see Oil and Oil Filter - Renew).
Silencer Installation
Left Radiator - Installation
Right Radiator - Installation
Engine Bars - Installation
Battery - Installation
Reset the neutral position adaption (see Neutral Position Adaption)
Fuel and Exhaust System and Engine Management

Exploded Views
Exploded View - Fuel Tank and Fuel Pump

Exploded View - Fuel Rail, Throttles and Injectors
Exploded View - Airbox

Exploded View - Exhaust System

Exploded View - Evaporative System
Exploded View - Secondary Air Injection

Exploded View - Engine Management System
Engine Management
Glossary of Terms
The following terms and abbreviations will be found in this section. Below is given a brief explanation of what some of the more common terms and abbreviations mean.
ABDC

After Bottom Dead Centre.
Air temperature
The air temperature in the airbox and intake hose.
Air temperature sensor
Sensor to detect the temperature of the incoming air.
Ambient air pressure
Pressure of the air in the airbox.
ATDC
After Top Dead Centre.
BBDC
Before Bottom Dead Centre.
BDC
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.
Closed throttle position
Throttle position at idle, measured as a voltage and expressed as a percentage.
Coolant temperature
The coolant temperature in the cylinder head.
Coolant temperature sensor
Sensor which detects coolant temperature.
Cooling fan status
The ON or OFF condition of the cooling fan.
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. The switch is operated by the over-closing of the twist grip.
DTC
Diagnostic Trouble Code.
Electronic steering lock (if fitted)
The electronic steering lock operated by a switch.
EMS main relay
Engine Management System Main Relay. When the ignition is switched on, the EMS main relay is powered up to provide a stable Voltage supply for the engine ECM.
Engine ECM
Engine Electronic Control Module.
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.

Gear position sensor
Gearbox mounted sensor which delivers information to the engine ECM. This is converted to the gear position value that is displayed on the instrument’s gear position indicator
and/or neutral lamp.
Idle fuel trim
The percentage above or below the nominal fuel requirement for the volume of air entering at idle.
Idle fuelling
Adjustment of fueling at idle to suit the actual air inducted.
Idle reference speed
The target idle speed as determined by the engine Electronic Control Module (ECM). (It should be the same as the actual idle speed if the motorcycle is operating correctly).
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.
IMU (if fitted)
The Inertial Measurement Unit measures the following:

Longitudinal acceleration
Vertical acceleration
Lateral acceleration
Pitch rate
Yaw rate
Roll rate
From these measurements the IMU calculates the motorcycle's lean angle.
The IMU outputs are used for multiple systems, for example, optimised cornering ABS (OCABS) and fall detection.
If the IMU is fitted, the fall detection switch will not be fitted.
Injector pulse time
The time during which an injector remains open (i.e. delivering fuel).
Keyless ECM (if fitted)
Keyless Electronic Control Module.
Long term fuel trim
Fueling after adapting to the engine's long term fueling requirements (closed loop only). See also short term fuel trim.
MAP sensor
Manifold Absolute Pressure (the air pressure in the intake system).
MIL
Malfunction Indicator Lamp.

Illuminates when most Diagnostic Trouble Codes (DTCs) are set.
Neutral switch status
The NEUTRAL or IN GEAR status of the transmission.
Off idle fuel trim
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.
Over temperature
High temperature within the engine Electronic Control Module (ECM) caused by an internal or external failure.
Oxygen sensor
The oxygen sensor measures the oxygen levels in the exhaust gases and feeds this information to the 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.
Road speed sensor
The rear wheel speed sensor is used to supply road speed data to the engine ECM.
Secondary air injection (if fitted)
A small amount of air injected into the exhaust port to reduce the levels of pollutants in the exhaust gases.
Sensor supply Voltage
Supply voltage to the system sensors (nominally 5 volts).
Short circuit
A short cut in an electrical circuit - current bypasses the intended circuit (usually to ground).
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.
Side stand status
The 'up' or 'down' position of the side stand.
Target dwell time
The actual time from coil ON to coil OFF.
TDC
Top Dead Centre.
Throttle actuator motor
Motor used to open/close the throttle.
Throttle position
The position of the throttle butterfly given as a percentage of the movement range. When the data is displayed on the diagnostic software, fully open need not be 100% nor fully
closed 0%.
Throttle Voltage
Voltage at the throttle potentiometer.
TPMS (if fitted)
Tyre Pressure Monitoring System.
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. If the immobiliser control module does not receive the correct code signal from the transponder, the immobiliser will remain active and the engine will
not start.
Fuel Requirements
Fuel Requirements - all countries except USA
This model must be run on 91 RON or higher unleaded fuel.
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 way, the following information may be applied:
This model is designed to run on unleaded gasoline with a CLC or AKI octane rating (R+M)/2 of 87 or higher.
Note
If 'Knocking' or 'Pinking' occurs at a steady engine speed under normal load, use a different brand of gasoline or a higher octane rating.
CAUTION
The use of leaded gasoline is illegal in some countries, states or territories and will invalidate the vehicle and emissions control warranties. Additionally, leaded gasoline will

CAUTION
cause damage to emissions control components.
Oxygenated Gasoline
To help in meeting clean air standards, some areas of the U.S. use oxygenated gasoline to help reduce harmful emissions. This model will give best performance when using
unleaded gasoline. However, the following should be used as a guide to the use of oxygenated fuels.
CAUTION
Because of the generally higher volatility of oxygenated fuels, starting, engine response and fuel consumption may be adversely affected by their use. Should any of these
difficulties be experienced, run the motorcycle on normal unleaded gasoline.
Ethanol
Ethanol fuel is a mixture of 10% ethanol and 90% gasoline and is often described under the names 'gasohol', 'ethanol enhanced', or 'contains ethanol'. This fuel may be used in
Triumph motorcycles.
Methanol
CAUTION
Fuels containing methanol should not be used in Triumph motorcycles as damage to components in the fuel system can be caused by contact with methanol.
MTBE (Methyl Tertiary Butyl Ether)
The use of gasolines containing up to 15% MTBE (Methyl Tertiary Butyl Ether) is permitted in Triumph motorcycles.
Triumph Diagnostic Software
Described on the following pages is the range of information which can be retrieved from the ECM’s memory and the adjustments which can be performed using the Triumph
diagnostic software.
The tables indicate which tests are performed by the on-board system and what information can be retrieved by the Triumph diagnostic software.
Note
Full details of how to operate the software can be found in the Triumph Diagnostic Tool User Guide, which can be downloaded by authorised Triumph dealers
from www.triumphonline.net.
Build Data
The Build Data screen will display the following information:

Motorcycle model;
Vehicle Identification Number (VIN);
ECM type;
ECM ID;
ECM serial number;
Calibration number;
Date of last calibration download;
Total calibration downloads since manufacture;
The lock status of the engine ECM (ECM Locked, Unlocked or Not Applicable).
Current Data
The data available under Current Data is:
Function Examined Result Reported (Scale)
Fuel system status open or closed loop operation
Calculated load value %
Engine coolant temperature °C
Short term fuel trim %
Intake manifold absolute pressure mmHg
Engine speed rpm
Vehicle speed km/h
Ignition timing advance degrees
Intake air temperature °C
Absolute throttle position %
Oxygen sensor Volts

Sensor Data
When using this function it is possible to check the status of various sensors and actuators.
The data sets are divided into seven groups - Sensor Voltages; Sensor Readings; Injector Data; Ignition Data; Idle Speed, Throttle Data and Inputs and Adaption Status. Each
of these screens is described on the following pages.
Sensor Voltages
The data available under Sensor Voltages is:
Item Checked Result Unit
Battery voltage Volts
Voltage from ignition switch to engine ECM Volts
Air temperature sensor voltage Volts
Coolant temperature sensor voltage Volts
Atmospheric pressure sensor voltage Volts
Manifold absolute pressure sensor voltage Volts
Fuel level sensor voltage Volts
Oxygen sensor output voltage Volts
Throttle position sensor 1 voltage Volts
Throttle position sensor 2 voltage Volts
Twist grip position sensor 1 voltage Volts
Twist grip position sensor 2 voltage Volts
Sensor Readings
The data available under Sensor Readings is:
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
The data available under Injector Data is:
Injector 1 pulse time milliseconds
Ignition Data
The data available under Ignition Data is:
Ignition timing cyl 1 degrees BTDC

Coil 1 dwell time milliseconds
Idle Speed and Throttle Data
The data available under Idle Speed and Throttle Data is:
Engine speed rpm
Idle reference speed rpm
Idle speed control current steps numeric
Idle speed control target steps numeric
Throttle position 1 % open
Throttle position 2 % open
Secondary air injection status SAI on/off
Twist grip position %
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 %
Outputs
The data available under Outputs is:
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
Calculated load %
Purge valve duty cycle %
Engine Adaption Status
Because the fuel system is adaptive, the engine management system is able to automatically adjust to new working conditions, such as changes in fuel quality, component
wear, air leaks etc. This screen displays information on the adaption status of the vehicle which will show if it has adapted or not.
Function Examined Report Method
Closed throttle position adapted adapted/not adapted

Twist grip adapted yes/no
Oxygen sensor adaption range (off idle) %
Oxygen sensor adaption range (idle) %
Oxygen sensor adaption status (off idle) %
Oxygen sensor adaption status (idle) %
Neutral Gear Position Adaption Status
The data available under Gear Position Adaption Status is:
Neutral position adapted adapted/not adapted
Function Tests
The system allows the diagnostic software to perform a series of function tests on various actuators in the engine management system. In some cases it is necessary to make
a visual observation of a component and in others, if faults are present, DTCs will be logged.
The Function Tests available are:
Instrument panel Observe instrument panel, refer to service manual
Idle air control stepper motor Observe throttle position/Stored fault code*
Purge valve Listen for valve operation/Stored fault code*
Fuel pump - priming Listen for fuel pump operation/Stored fault code*
Fuel pump - continuous operation Fuel pressure test/Listen for fuel pump operation/Stored fault code*
Cooling Fan Control Observe the cooling fan/Stored fault code*
Secondary air injection Listen for valve operation/Stored fault code*
* If a fault is detected.
Adjust Tune
Using the Triumph diagnostic software, it is possible to:

Reset the adaptions (see Engine Adaption)
Balance the throttle bodies (see Throttle Body Balancing).
Freeze Frame Data
Freeze frame data is stored at the time a DTC is recorded (confirmed) by the ECM. If multiple DTCs are recorded, the freeze frame data which is stored will relate to the first
recorded DTC only.
By calling up freeze frame data associated with the first recorded DTC, the technician can check the engine condition at the time the fault occurred. The data available is:
DTC Diagnostic Trouble Code (DTC) number
Fuel system status open or closed loop operation
Calculated load %
Coolant temperature °C
Short term fuel trim %
Intake manifold absolute pressure mmHg
Engine speed rpm
Vehicle speed km/h
Ignition advance degrees
Intake air temperature °C
Throttle position %

Oxygen sensor output voltage Volts
Oxygen sensor short term fuel trim %
Electrical Connectors
Before beginning any diagnosis, the following connector related information should be noted:
Note
A major cause of hidden electrical faults can be traced to faulty electrical connectors. For example:
Dirty/corroded terminals
Damp terminals
Broken or bent cable pins within multiplugs.
For example, the electronic control module (ECM) relies on the supply of accurate information to enable it to plan the correct fuelling and ignition timing. One dirty terminal will
cause an excessive voltage drop resulting in an incorrect signal to the ECM.
If, when carrying out fault diagnosis, a fault appears to clear by simply disconnecting and reconnecting an electrical plug, examine each disconnected plug for the following.
Before Disconnection:
If testing with a voltmeter, the voltage across a connector should be virtually battery Volts (unless a resistor is fitted in the circuit). If there is a noticeable change, suspect
faulty/dirty connections.
When Disconnecting a Connector:
Check for a security device that must be released before the connector can be separated, e.g. barb, hook and eye etc.
When Inspecting a Connector:
Check that the individual pins have not been bent

Check for dampness/dirt/corrosion
Check cables for security
Check cable pin joints for damage.
When Connecting a Connector:
Ensure there is no dirt around the connector/seal

Push together squarely to ensure terminals are not bent or incorrectly located
Push the two halves together positively.
Disconnection of ECM Connectors
CAUTION
When disconnecting a connector, never pull directly on the wires as this may result in cable and connector damage.
CAUTION
Never disconnect an ECM when the ignition switch is in the ON position as this may cause multiple fault codes to be logged in the ECM memory.
Always disconnect an ECM after disconnecting the battery negative (black) lead first.
1. Turn the ignition to the OFF position and wait at least 1 minute for the ECM to complete its power down sequence.
2. Press down on the locking device and gently pull back on the connector to release it from the ECM.
Reconnection of ECM Connectors
CAUTION
Damage to the connector pins may result if an attempt to fit the connectors incorrectly is made.
System Diagnostics
The engine management system has an on-board diagnostics feature which allows service technicians to retrieve stored data from the ECM using Triumph diagnostic software.
Full details of the Triumph diagnostic software operation and how to interpret the results are given in the Triumph Diagnostic Tool User Guide.
The software is connected, via an interface cable, to the motorcycle using a dedicated diagnostic plug situated beneath the seat. By using a dedicated plug, no electrical
connectors associated with the system are disturbed, reducing potential connector damage.
The software allows the user to retrieve data associated with the system sensors and actuators, test various component functions, read build data and make minor adjustments
to the set-up of the system. The data and tests available are described on the following pages.
On-board Fault Detection System
The on-board diagnostic system has two stages to fault detection. When a fault is detected, the DSM (Diagnostic Status Manager) raises a flag to indicate that a fault is present
and increments a counter. The counter checks the number of instances that the fault is noted. For example, if there is a fault in the crankshaft position sensor, the counter will
increment its count each time the crankshaft turns through 360°, provided the fault is still present.
When the count begins, the fault is detected but not confirmed. If the fault continues to be detected and the count reaches a predetermined threshold, the fault becomes
confirmed. If the fault is an emissions related fault or a serious malfunction affecting engine performance, a DTC (Diagnostic Trouble Code) and freeze-frame data will be
logged in the ECM's memory and the MIL (Malfunction Indicator Lamp) on the motorcycle instrument panel is illuminated. Once a fault is confirmed, the number of warm-up
cycles made by the engine is counted. If the fault clears, the warm-up cycle counter will extinguish the MIL (Malfunction Indicator Lamp) at a predetermined count, and erase
the DTC and freeze-frame data from the ECM memory at another (higher) count.
A single warm-up cycle is deemed to have taken place when the following criteria have been met:
The coolant temperature must be raised to 72°C or more.

The coolant temperature must have risen by 23°C or more from its start temperature, when 72°C is reached.
A controlled power down sequence must take place.
Note
When a fault has been rectified, the MIL will remain illuminated until sufficient non-fault warm-up cycles have taken place to turn it off. The MIL will be
immediately extinguished if, after first rectifying the fault, the DTC (diagnostic trouble code) that caused the MIL illumination is erased from the ECM memory
using the Triumph diagnostic software.
Note
In some cases, when a fault is detected, the engine management system will revert to a limp-home mode. In this mode, the engine will still function though the
performance and fuel economy may be marginally affected. In some cases, the rider may not notice any appreciable difference from normal operation.
Service Symbol/General Warning Symbol
The service symbol will illuminate for five seconds after the motorcycle start up sequence as a reminder that a service is due in approximately 60 miles (100 km). The
service symbol will illuminate permanently when the mileage is reached, it will remain permanently illuminated until the service interval is reset using the Triumph Diagnostic
tool.
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.
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.
Engine Adaption
General Information
The engine management system fitted to this model is adaptive. This means that the system is able to learn about new or changing operating conditions. The fuelling and
throttle system can continuously adapt itself without needing to constantly make major adjustments from a fixed baseline setting.
Adaptive changes can become necessary because of different fuels, changes in the region in which the motorcycle is operated (i.e. operation at high altitude where it was
previously used at sea level) or because a new part may have been fitted which has slightly different characteristics to the old part. Fuelling and throttle system adaptive
changes are automatic and require no intervention by rider or dealer.
Adaption Status and Range
To see if a motorcycle has fully adapted, a facility named is provided on the diagnostic tool under Engine Diagnostics - Sensor Data - Engine Adaption. The following adaption
details can be examined:
Function Examined Report Method Range/Status Description
Closed throttle position reference status Adapted/not adapted N/A
Twist grip adapted Adapted/not adapted N/A
Idle speed control adaption status % N/A
Oxygen sensor 1 adaption status (off idle) % Status off idle
Oxygen sensor 1 adaption range (off idle) % Range off idle
Oxygen sensor 1 adaption status (idle) % Status idle
Oxygen sensor 1 adaption range (idle) % Range idle
Oxygen sensor 2 adaption status (off idle) % Status off idle
Oxygen sensor 2 adaption range (off idle) % Range off idle
Oxygen sensor 2 adaption status (idle) % Status idle
Oxygen sensor 2 adaption range (idle) % Range idle
Terminology

Where the term 'status' is used, this indicates how far the present operating parameter is from the stored (adapted) value. The nearer these figures are to zero the better as it
indicates the motorcycle has adapted to its current operating conditions.
The term 'range' indicates how much (in percentage terms) of the adjustment range has been used to reach the current operating status.
Typical Values
In a correctly adapted motorcycle, the following will be typical:
Function Examined Read Out Range/Status Description
Closed throttle position reference status Adapted N/A
Twist grip adapted Adapted N/A
Idle speed control adaption status Between +100 and -100% N/A
Oxygen sensor 1 adaption status (off idle) 0% +/- 10% Status off idle
Oxygen sensor 1 adaption range (off idle) Between +100 and -100% Range off idle
Oxygen sensor 1 adaption status (idle) 0% +/- 10% Status idle
Oxygen sensor 1 adaption range (idle) Between +100 and -100% Range idle
Oxygen sensor 2 adaption status (off idle) 0% +/- 10% Status off idle
Oxygen sensor 2 adaption range (off idle) Between +100 and -100% Range off idle
Oxygen sensor 2 adaption status (idle) 0% +/- 10% Status idle
Oxygen sensor 2 adaption range (idle) Between +100 and -100% Range idle
Forcing Adaption to Take Place
If the read out indicates that the motorcycle is not adapted, the following will force the system to make adaptions:
WARNING
Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short
time. Always operate the motorcycle in the open-air or in an area with adequate ventilation.
Note
Resetting adaptions with the motorcycle connected to an exhaust extraction system may cause incorrect values to be set, causing poor engine running.
Always reset the adaptions with the engine disconnected from any exhaust extraction system whilst ensuring the motorcycle is positioned in a well ventilated
area.
1. Ensure the engine is cold.
2. WITHOUT TOUCHING THE THROTTLE, start the engine and allow it to warm up until the cooling fan comes on.
3. Turn the ignition OFF for at least 60 seconds to allow the adaption settings to be stored in ECM memory.
Resetting the Adaptions
A reset engine adaptions facility is provided in the diagnostic tool. This function can be used to:
Force fast fuelling and throttle adaption.
Reset (erase) current adaptions.
Fast Fuelling and Throttle Adaption
To force the fuelling and throttle system to quickly adapt to the current operating conditions:
1. Connect the diagnostic tool and turn the ignition ON.

2. Start the engine.
3. Allow the engine to reach normal operating temperature (90°C for liquid cooled models, 60°C for air cooled models).
4. Make sure the system is in closed loop control mode.
5. Navigate to Engine Diagnostics - Adjust.
6. Select 'RESET ENGINE ADAPTIONS' and click 'ADJUST'.
Note
This will force a fast adaption routine to take place in around five seconds. For this to happen, the engine MUST be running, it must be at normal operating
temperature and in closed loop control mode. Under any other conditions fast adaption will not take place and the current adaption settings may be erased as
described below.
Reset (Erase) Current Adaptions
To reset the currently stored adaptions:
1. Connect the diagnostic tool and turn the ignition ON. Do NOT start the engine.
2. Navigate to Engine Diagnostics - Adjust.
3. Select 'RESET ENGINE ADAPTIONS' and click 'ADJUST'.
The following adaptions will be reset:
Fuelling
Throttle
Twist Grip
Crankshaft Position (Euro 5 Motorcycles in Applicable Markets Only)
Note
The following adaptions will not be reset:
- Neutral Position
- Gear Position
- Shift Force Sensor (TSA)
To Re-Adapt
1. Connect the diagnostic tool and turn the ignition ON.
3. Allow the engine to reach normal operating temperature (90°C for liquid cooled models, 60°C for air cooled models).
4. Adapt the crankshaft position (Euro 5 Motorcycles in Applicable Markets Only).
5. If applicable, perform a cruise control switch check as described in the Service Manual.
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
possible causes will be incorrect fuel pressure, incorrectly connected oxygen sensors, faulty injectors or air leaks at the throttle bodies or airbox.
In these circumstances, locate and rectify the fault, and reset the adaptions as described above.
Engine Management System Description
These models are fitted with an electronic engine management system which encompasses control of both ignition and fuel delivery. The engine Electronic Control Module
(ECM) is electronically paired to the immobiliser/TPMS control module to help prevent theft of the motorcycle (see Immobiliser System Description). The engine ECM draws
information from sensors positioned around the engine, cooling and air intake systems and precisely calculates ignition advance and fuelling requirements for all engine speeds
and loads.
In addition, the system has an on-board diagnostic function. For additional information, see System Diagnostics.
Engine Management System Sensors
Intake air temperature sensor - situated in the top of the airbox. As the density of the air (and therefore the amount of oxygen available to ignite the fuel) changes with
temperature, an intake air temperature sensor is fitted. Changes in air temperature (and therefore air density) are compensated for by adjusting the amount of fuel injected
to a level consistent with clean combustion and low emissions.
Ambient air pressure sensor - situated below the battery. The ambient air pressure sensor measures atmospheric air pressure. With this information, the amount of fuel
injected is adjusted to suit the prevailing conditions.
Manifold Absolute Pressure (MAP) sensor - situated to the front of the airbox, 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 very small throttle openings to provide accurate engine load indications to the engine ECM. This degree of engine
load accuracy allows the engine ECM to make very small adjustments to fuel and ignition which would otherwise not be possible from throttle angle data alone.
Clutch switch - situated on the clutch lever. The clutch must be pulled in for the starter motor to operate. With the cruise control on and active, the operation of the clutch
will cancel cruise control.
Crankshaft position sensor - situated in the alternator cover. The crankshaft position sensor detects movement of teeth attached to the alternator rotor. The toothed rotor
gives a reference point from which the actual crankshaft position is calculated. The crankshaft position sensor information is used by the engine ECM to determine engine
speed and crankshaft position in relation to the point where fuel is injected and ignition of the fuel occurs.
Engine coolant temperature sensor - situated at the rear of the cylinder head. Coolant temperature information, received by the engine ECM, is used to optimise fuelling
at all engine temperatures and to calculate hot and cold start fuelling requirements.
Throttle position sensors 1 and 2 - the two sensors are located in the same housing which is situated at the right hand end of the throttle body. Used to relay throttle
position information back to the engine ECM.
Twist grip position sensors 1 and 2 - the two sensors are located in the same housing which is situated in the right hand switch housing. The twist position sensor is used
to relay twist grip position information to the engine ECM. The engine ECM uses this information to drive the throttle actuator motor to the correct position.
Oxygen sensor - situated in the exhaust header pipe system upstream of the catalyst. The oxygen sensor constantly feeds information to the engine ECM on the content
of the exhaust gases. Based on this information, adjustments to the air/fuel ratio are made.
Side stand switch - situated at the top of the side stand leg. If the side stand is in the down position, the engine will not run unless the transmission is in neutral.
Gear position sensor - situated in the upper crankcase, behind the front sprocket cover, on the left hand side of the engine. The gear position sensor provides the engine
ECM with selected gear information. This is used to prevent the engine from starting if the transmission is in gear. The sensor also provides information to the gear position
indicator and the neutral lamp in the instruments.
Fall detection switch (where fitted) - situated on the frame crossmember behind the airbox. The fall detection switch will detect if the motorcycle is on its side and will cut
power to the engine ECM immediately. This prevents the engine from running and the fuel pump from delivering fuel. In the event of a fall, the switch is reset by returning
the bike to an upright position and switching the ignition off then back on again.
Brake switches - situated at the front brake lever and in a manifold in the pipework from the rear master cylinder. With cruise control on and active, the operation of the
front or rear brakes will cancel cruise control.
Rear ABS wheel speed sensor - situated on the rear brake caliper carrier. The rear ABS wheel speed sensor provides the engine ECM with data from which road speed is
calculated and displayed on the speedometer.
Shift Force Sensor (Triumph Shift Assist) - situated on the gear change linkage. The shift force sensor 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. The clutch must be used for stopping and pulling
away.

Engine Management System Sensor Locations
1 2 3 4 5
9 8 7 6
1. Ambient air pressure sensor

2. Inertial Measurement Unit (IMU)
3. Intake air temperature sensor
4. Throttle position sensor
5. Front brake switch
6. Oxygen sensor
7. Coolant temperature sensor
8. Rear brake switch
9. ABS Rear wheel speed Sensor
1 2
5 4 3
1. Clutch switch
2. Manifold absolute pressure sensor (MAP sensor)
4. Side stand switch
5. Crankshaft position sensor
Engine Management System Actuators
In response to signals received from the sensors, the engine ECM controls and directs messages to a series of electronic and electromechanical actuators. The function and
location of the actuators is given below.
Throttle actuator motor - situated on the front of the throttle bodies. The throttle actuator motor opens and closes the throttle plates in the throttle bodies, in response to
commands from the ECM. The throttle actuator motor is an integral part of the throttle bodies.
Canister purge valve (certain markets only) - situated in the vapour return line between the carbon canister and the throttle bodies. 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.
Fuel injectors - located on the throttle body. The engine is fitted with three fuel injectors. The spray pattern of the injector is fixed but the length of time each injector can
remain open is variable according to operating conditions. The duration of each injection is calculated by the engine ECM using data received from the various sensors in
the system.
Ignition coils - plug-top coils are located in the camshaft cover. There are three coils fitted, one for each spark plug. The engine ECM controls the point at which the coils
are switched on and off. In calculating the switch-on time, the engine ECM allows sufficient time for the coils to charge to a level where a spark can be produced. The coils
are switched off at the point of ignition, the timing of which is optimised for good engine performance.
Engine Management System (EMS) main relay - situated behind the battery. When the ignition is switched on, the EMS main relay is powered up to provide a stable
Voltage supply for the engine ECM. When the ignition is turned off, the engine ECM carries out a power down sequence during which the EMS main relay remains powered
by the engine ECM for 1 minute. The engine ECM power down sequence includes: writing the adaption data to engine ECM memory and referencing the position of the
throttle stepper motor.
Fuel pump - located inside the fuel tank. The electric pump delivers fuel into the fuel system, via a pressure regulator, at a constant 3.5 bar pressure. The pump is run
continuously when the engine is operating and is also run briefly when the ignition is first switched on to ensure that full pressure is available to the system as soon as the
engine is cranked. Fuel pressure is controlled by a regulator also situated inside the fuel tank.
Cooling fans - located behind the radiators. The engine ECM controls switching on and off of the cooling fans in response to a signal received from the coolant
temperature sensor. When the coolant temperature rises to a level where the cooling effect of natural airflow is insufficient, the cooling fans are turned on by the engine

ECM. When the coolant temperature falls sufficiently, the engine ECM turns the cooling fans off. The fans only becomes operational when the engine is running. It will not
operate at any other time.
Secondary air injection solenoid - located above the camshaft cover. The secondary air injection solenoid controls airflow through the secondary air injection system.
Note
In this system, the starter lockout system (clutch switch, gear position sensor, side stand switch) all operate through the engine ECM.
Engine Management System Actuator Locations
Immobiliser System Description
Immobiliser System Components and Operation
Immobiliser System Components Location
Immobiliser System Keys
Immobiliser System Diagnostics
Tyre Pressure Monitoring System (TPMS) Description
Tyre Pressure Monitoring System (TPMS) Component Locations
Tyre Pressure Monitoring System (TPMS) Components and Operation
Tyre Pressure Monitoring System (TPMS) Diagnostics
Diagnostics and Testing
System Diagnostics
Engine ECM Connector Pin Numbering
Build Data
Current Data
Sensor Data
Adaption Status
Function Tests
Cruise Control Switch Check
Instrument Panel Function Test
Adjust Tune
Freeze frame Data
Diagnostic Tool Connection
Further Diagnosis
Pinpoint Tests - Fuel
Oxygen Heater Bank 1
Cruise Control
Manifold Absolute Pressure (MAP) Sensor
Intake Air Temperature Sensor
Coolant Temperature Sensor
Throttle Position Sensor
Oxygen Sensor
Oxygen Sensor 1
Fuel Injectors
Engine Misfire
Crankshaft Sensor
Ignition Coils

Secondary Air Injection Valve
Purge Valve
Fuel Level Sensor Circuit
Vehicle Speed Sensor
Engine Idle Lower than Expected
Engine Idle Higher Than Expected
System Voltage
EEPROM Error
Engine ECM Internal Error
Fault Code Possible Cause Action
P0606 Engine ECM internal error Contact Triumph service.
P1607 Engine ECM ride by wire internal error

P1608
5V Sensor Circuit A
Fault Code Possible cause Action
P0642 5V Sensor Circuit A - reference voltage low View and note diagnostic software 'freeze-frame' data if available.
Disconnect engine ECM and proceed to pinpoint test 1:
P0643 5V Sensor Circuit A - reference voltage high
P06A6 5V Sensor Circuit A - reference voltage out of range
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect sensor and proceed to test 2
- Engine ECM pin A32
- Engine ECM pin A20 Faulty Rectify fault, proceed to test 6
2 Check cable for short circuit: OK Proceed to test 3

- Engine ECM pin A32 to ground
- Engine ECM pin A32 to Engine ECM pin A20 Short circuit Locate and rectify wiring fault, proceed to test 6

- Engine ECM pin A32 to EMS relay pin 5
OK Locate and rectify wiring fault, proceed to test 5
4 Check cable for short to battery positive: OK Proceed to test 5

- With the battery disconnected check for short circuit ECM pin A32 to
harness battery positive connector OK Locate and rectify wiring fault, proceed to test 5
5 Check cable continuity: OK Proceed to test 5

- Engine ECM pin A32 to throttle position sensor connector pin 2
- Engine ECM pin A20 to throttle position sensor connector pin 5 Open circuit Locate and rectify wiring fault, proceed to test 5
6 Reconnect harness, clear fault code and run engine to verify fault OK Action complete - quit test
cleared.
Fault still present Contact Triumph service
13 1
26 14
39 27
3
1
5 1 A20 B 5
A38 U 4
2 3 A32 R 2
A26 K 3
A21 NK
A08 NK
1 2 3 4 5 6
3 1 2 5
NK

1. Engine electronic control module
2. Engine ECM - Connector A
3. Throttle position sensor
4. EMS relay
5V Sensor Circuit B
P0652 5V Sensor Circuit B - reference voltage low View and note diagnostic tool freeze frame data if available.
View and note diagnostic tool sensor data.
P0653 5V Sensor Circuit B - reference voltage high Disconnect twist grip position sensor and proceed to pinpoint test 1:
P06A7 5V Sensor Circuit B - reference voltage out of range
Pinpoint Tests
Test Result Action
1 Check terminal and cable integrity: Ok Proceed to test 2

- Engine ECM pin B26
- Engine ECM pin B24 Faulty Rectify fault, proceed to test 6

- Engine ECM pin B26 to ground
- Engine ECM pin B26 to Engine ECM pin B24 Short circuit Rectify fault, proceed to test 6

- Engine ECM pin B26 to EMS relay pin 5
Short circuit Locate and rectify fault, proceed to test 6

- With the battery disconnected check for short circuit ECM pin B26 to
harness battery positive connector Short circuit Locate and rectify fault, proceed to test 6

- Engine ECM pin B26 to twist grip position sensor pin 5
- Engine ECM pin B24 to twist grip position sensor pin 1 Open circuit Locate and rectify fault, proceed to test 6
cleared.
3 4
11 1
22 12
33 23
B26 R 5 5 R
B24 B 1 1 B
B27 S 3 3 W
B25 R 2 2 R
B13 B 6 6 B
B28 S 4 4 W
A21 NK
A08 NK
5 1
5
1 2
2 3
5 6
3 1 2 5
NK

2. Engine ECM - Connector B
3. Twist grip position sensor connector
4. Twist grip position sensor
5. EMS relay
5V Sensor Circuit C

P0698 5V Sensor Circuit C - reference voltage low View and note diagnostic tool freeze frame data if available.
P0699 5V Sensor Circuit C - reference voltage high Disconnect twist grip position sensor and proceed to pinpoint test 1:
P06A8 5V Sensor Circuit C - reference voltage out of range
Pinpoint Tests
Test Result Action


- Engine ECM pin B25 to Engine ECM pin B13 Short circuit Rectify fault, proceed to test 6

- Engine ECM pin B25 to EMS relay pin 5


- Engine ECM pin B13 to twist grip position sensor pin 6 Open circuit Locate and rectify fault, proceed to test 6
cleared.
3 4
11 1
22 12
33 23
B26 R 5 5 R
B24 B 1 1 B
B27 S 3 3 W
B25 R 2 2 R
B13 B 6 6 B
B28 S 4 4 W
A21 NK
A08 NK
5 1
5
1 2
2 3
5 6
3 1 2 5
NK

3. Twist grip position sensor connector
5. EMS relay
5V Sensor Circuit D
P06A4 5V Sensor Circuit D - reference voltage low View and note diagnostic tool freeze frame data if available.
P06A5 5V Sensor Circuit D - reference voltage high Disconnect twist grip position sensor and proceed to pinpoint test 1:
P06A9 5V Sensor Circuit D - reference voltage out of range
Pinpoint Tests
Test Result Action

Test Result Action
Faulty Rectify fault, proceed to test 6

Short circuit Rectify fault, proceed to test 6

- Engine ECM pin B18 to Engine ECM relay pin 5


- Engine ECM pin B18 to ambient pressure sensor pin 3
- Engine ECM pin B23 to ambient pressure sensor pin 1
- Engine ECM pin B18 to MAP sensor pin 3
- Engine ECM pin B23 to MAP sensor pin 1
- Engine ECM pin B18 to gear position sensor pin 3
- Engine ECM pin B23 to gear position sensor pin 4 Open circuit Locate and rectify fault, proceed to test 6
- Engine ECM pin B18 to side stand switch pin 1
- Engine ECM pin B23 to side stand switch pin 2
- Engine ECM pin B18 to quick shifter pin 3
- Engine ECM pin B23 to quick shifter pin 2
cleared.
13 1
26 14
39 27
3
1
A05 KP KP 2
B18 K K 3
B23 KB KB 1
4
1 2 3
KB 1
K 3
C29 KO KO 2
5
1 2 3
6
K 3 3 R
KB 4 4 B
B30 GK GK 1 1 U
2 1
4 3
7
8
K 3 3 R
KB 2 2 U
B21 RB RB 1 1 G
1 3 9
K 1 1 U
KB 2 2 B
A18 BR BR 3 3 P
11 1 11 1 2 1
22 12 22 12
33 23 33 23
10
12 11 3

4. Manifold absolute pressure (MAP) sensor
5. Gear position sensor connector
7. Quick shifter connector
8. Quick shifter connector
9. Side stand
10. Side stand connector
11. Engine ECM - connector C
Clutch Switch
P0704 Clutch switch 1 input circuit malfunction View and note diagnostic tool freeze frame data if available.
Disconnect Engine ECM and proceed to pinpoint test 1:

Pinpoint Tests
Test Result Action

- Engine ECM pin A06

- Engine ECM pin A06 to ground
- Engine ECM pin A06 to B12 Short circuit Rectify fault, proceed to test 5

- Engine ECM pin A06 to B18
- Engine ECM pin A06 to A08
- Engine ECM pin A06 to A21

- Engine ECM pin A06 to left hand switch housing connector A (six pin)
pin 3 Open circuit Locate and rectify fault, proceed to test 5
cleared.
3 1
13 1
26 14
6 4
39 27
5 4
R 3 3 BO A06
A08
A21
B12
B18
11 1
22 12
33 23

4. Left hand switch housing - Connector A (six pin)
5. Left hand switch housing
Gear Position Sensor
P0914 Gear position sensor short circuit to ground or open View and note 'freeze-frame' data if available.
circuit View and note 'sensor' data.
Make sure the sensor connector is secure.
P0915 Gear position sensor signal error - correlation error Disconnect the engine ECM and proceed to pinpoint test 1:
with vehicle speed
P0917 Gear position sensor short circuit to 5 Volt sensor

supply
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect sensor and proceed to test 2

Test Result Action

Short circuit Locate and rectify wiring fault, proceed to test 5
- Engine ECM pin B30 to Engine ECM pin B23

- Engine ECM pin B30 to Engine ECM pin A08
4 Check cable continuity: OK Renew gear position sensor and contact pin and proceed to test
- Engine ECM pin B18 to sensor pin 3 5
- Engine ECM pin B23 to sensor pin 4
- Engine ECM pin B30 to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed to test 5
5 Reconnect harness, clear fault code and run engine. OK Action complete - quit test
2 1
4 3
1 PU B30
2
3 RP B18
4 BK B23
2
11 1
22 12
33 23

Traction Control Prevented Due to ABS Malfunction
P1135 Traction Control prevented due to ABS malfunction Check that there is no other DTC linked to the ABS
system or CAN communication stored.
Contact Triumph service.
Cornering Traction Control and Roll Over Detection Disabled
P1136 Cornering Traction Control disabled due to Inertial View and note 'freeze-frame' data if available.
Measurement Unit (IMU) malfunction Make sure ABS modulator connector is secure.
Check for associated DTC C1713, perform tests for this DTC.
P16A2 Engine ECM detects IMU present but with signal error Reset DTCs, if problem persists contact Triumph service.
P1640 Roll Over detection disabled due to Inertial View and note 'freeze-frame' data if available.
Measurement Unit (IMU) malfunction Make sure ABS modulator connector is secure.
Check for associated DTCs P16A0, P16A1, and P16A2, perform the
tests for any DTC present.
Reset DTCs, if problem persists contact Triumph service.
Immobiliser and TPMS Control Module ID Incompatible

P1508 Unmatched Immobiliser/chassis ECM, causing the This is also identified by a fast flashing MIL indication and a disabled
engine ECM to be disabled to prevent the motorcycle engine management system.
from being operated
Pinpoint Tests
Test Result Action
1 Follow the Pair ECM and Immobilise procedure as described in the OK Action complete - quit test
Triumph Diagnostic Tool User Guide
ABS Modulator ID Incompatible
P1520 Unmatched ABS This is also identified by ABS warning light indication.
Proceed to pinpoint test 1:
P16A0 Unmatched IMU Proceed to pinpoint test 1:
Pinpoint Tests
Test Result Action
1 Check ABS modulator part number is correct for the motorcycle OK Proceed to test 2
Incorrect Replace ABS modulator with correct part and proceed to test 3
2 Check that the engine ECM calibration is correct for the motorcycle, OK Proceed to test 3
using the diagnostic tool.
Incorrect Update calibration using service tool, proceed to test 3
3 Clear fault code, check for normal operation OK Action complete - quit test
ABS Modulator Communication
P1521 CAN fault - lost communication with ABS module or View and note 'freeze-frame' data if available.
ABS system status error Make sure ABS modulator connector is secure.
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect ECM and proceed to test 2
- Engine ECM pin C25
- ABS modulator pin 2
- ABS modulator pin 10 Faulty Rectify fault, proceed to test 6
2 Check cable for short circuit: OK Disconnect ABS modulator and proceed to test 3
- Engine ECM pin C25 to ground
- Engine ECM pin C24 to ground Short circuit Locate and rectify wiring fault, proceed to test 5

- ABS pin 2 to ground
- ABS pin 11 to ground Short circuit Locate and rectify wiring fault, proceed to test 5

- Engine ECM pin C25 to ABS pin 2
- Engine ECM pin C24 to ABS pin 11
- ABS pin 10 to ground
Faulty Locate and rectify wiring fault, proceed to test 5
- Fuse box 1, fuse 5 to ABS pin 7
- Fuse box 1, fuse 7 to ABS pin 18
5 Check fuse box 1, fuse 8 integrity. OK Proceed to test 6

Check fuse box1, fuse 7 integrity.
Faulty Renew fuse, proceed to test 6

Test Result Action
1 2 3 4 5 6
8
7 9
7 5
R GP
18 R
7 GP
2 R R C25
11 U U C24
10 B
B 3
9 1
11 1
18 10 22 12
33 23
1. ABS modulator
2. Fuse box 1
3. Engine ECM - Connector C
Cruise Control Prevented Due to Other Malfunction
P1574 Cruise control prevented due to other malfunction Check that there is no other DTC linked to the engine
management system stored.
Check front and rear brake switches, cruise control
cancel switch and the rear wheel speed sensor.
Cruise Control Disabled Until Button Press Sequence Completed
P1575 Cruise control disabled until button press sequence Carry out the button press sequence as described in
completed Cruise Control Switch Check.
After certain DTCs have been stored and subsequently
repaired, the cruise control will be disabled until a test
of the systems various switches has been performed
Brake Switches
P1576 Brake 1 switch correlation error with brake switch 2 View and note freeze frame data if available.
Make sure the brake switches connectors are secure.
Make sure the battery voltage is greater than 10V.
P1577 Brake 2 switch correlation error with brake switch 1
Disconnect engine ECM and proceed to pinpoint test 1:
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2

- Front brake switch pin 1
- Front brake switch pin 2
- Front brake switch pin 3 Faulty Rectify fault, proceed to test 6
- Rear brake switch pin 1

Test Result Action

- Front brake switch pin 3 to ground Faulty Locate and rectify wiring fault, proceed to test 6
- Rear brake switch pin 2 to ground

- Front brake switch pin 1 to pin 3
- Rear brake switch pin 1 to pin 2 Open Circuit Locate and rectify wiring fault, proceed to test 6
- Rear brake switch pin 1 to pin 3

- Engine ECM pin C14 to Front brake switch pin 1
- Engine ECM pin C14 to Rear brake switch pin 1
- Engine ECM pin C26 to Front brake switch pin 2 Open Circuit Locate and rectify wiring fault, proceed to test 6
- Front brake switch pin 3 to Ignition switch pin 2
5 Check switch continuity, component side of connector: OK Proceed to test 6

- Front brake switch pin 3 to pin 2 with brake inactivated
- Front brake switch pin 3 to pin 1 with brake activated
- Rear brake switch pin 3 to pin 2 with brake inactivated Open Circuit Replace faulty switch, proceed to test 6
- Rear brake switch pin 2 to pin 1 with brake activated
6 Check fuse integrity: OK Proceed to test 7

- Fuse box 1, fuse 8
Faulty Replace fuse, proceed to test 7
Circuit Diagram
3
1 2
3 4
2
2
G
10 1
20 11
1
1 3
B6 GP GP 1 1 PG
B19 GP
B18 GU
8 2
9 1
18 10 2 1
9 17 11 3
2 2 3
B R U
G 2 2 6
7 GP GP 1 1
GN 3 3
8
11 1
22 12
33 23
7
3 2 1
1 2 3
B R U
C14 GP
G 3 3
C26 GU GP 1 1
GU 2 2
1. Chassis electronic control module

2. Chassis ECM - Connector B
3. Ignition switch
4. Rear light
9. ABS modulator
Engine ECM detects Inertial Measurement Unit (IMU) circuit malfunction
Chassis ECM Communication Error/Malfunction
Closed Throttle Position Adaption

ECM Tamper Detected
ECM locked by the Calibration Lock function
Instrument ID Incorrect
Fall Detection Switch
EMS Ignition Voltage Input Circuit
Immobiliser Control Module Communication
EMS Main Relay Circuit
CAN Communication
Instrument Communication (CAN)
Shift Force Sensor Circuit (Triumph Shift Assist)
Throttle Actuator Motor
Throttle Valve Drive Error
P2111 Throttle valve drive error (stuck open) View and note 'freeze-frame' data if available.
View and note 'sensor' data.
P2119 Throttle valve drive error Check throttle body for mechanical malfunctions. Clear fault code and
contact Triumph service if fault is still present.
P2102 Throttle actuator control internal motor relay does not
operate
P2103 Throttle actuator control internal motor relay operates

continually
Twist Grip Position 1
P2120 Twist grip position sensor 1 short circuit to ground or View and note 'sensor' data. Note ECM sensors requiring a power
open circuit supply will not be active.
Make sure the twist grip position sensor is secure.
P2121 Twist grip position sensor 1 signal out of range Disconnect the engine ECM and proceed to pinpoint test 1:
P2123 Twist grip position sensor 1 short circuit to battery

positive
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect twist grip position sensor and proceed to test 2
- Twist grip position sensor pin 5 Faulty Rectify fault, proceed to test 5
- Twist grip position sensor pin 3

- Engine ECM pin B26 to B24
- Engine ECM pin B27 to ground Short circuit Locate and rectify wiring fault, proceed to test 5

- Engine ECM pin B27 to Engine ECM pin B25 Short circuit Locate and rectify wiring fault, proceed to test 5
4 Check cable continuity: OK Renew twist grip position sensor, proceed to test 5
Open circuit Locate and rectify wiring fault, proceed to test 5
cleared.

2
3 4
11 1
22 12
33 23
B26 R 5 5 R
B24 B 1 1 B
B27 S 3 3 W
B25 R 2 2 R
B13 B 6 6 B
B28 S 4 4 W
1 2
5 6

3. Twist grip position sensor connector (main harness
side)
Twist Grip Position 2
P2125 Twist grip position sensor 2 short circuit to ground or View and note 'sensor' data. Note ECM sensors requiring a power
open circuit supply will not be active.
Make sure the twist grip position sensor is secure.
P2128 Twist grip position sensor 2 short circuit to battery Disconnect the engine ECM and proceed to pinpoint test 1:
positive
P2126 Twist grip position sensor 2 signal out of range
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect twist grip position sensor and proceed to test 2
- Twist grip position sensor pin 2 Faulty Rectify fault, proceed to test 5

- Engine ECM pin B25 to ground Short circuit Locate and rectify wiring fault, proceed to test 5

- Engine ECM pin B28 to Engine ECM pin B26 Short circuit Locate and rectify wiring fault, proceed to test 5
4 Check cable continuity: OK Renew twist grip position sensor, proceed to test 5
cleared.
3 4
11 1
22 12
33 23
B26 R 5 5 R
B24 B 1 1 B
B27 S 3 3 W
B25 R 2 2 R
B13 B 6 6 B
B28 S 4 4 W

1 2
5 6

side)
Twist Grip Position Sensor 1 Correlation Error with Twist Grip Position 2
P2138 Twist grip position sensor 1 correlation error with twist View and note diagnostic tool freeze frame data if available.
grip position sensor 2 View and note diagnostic tool sensor data.
Disconnect twist grip position sensor and proceed to pinpoint test 1:
Pinpoint Tests
Test Result Action
1 Turn the ignition on and measure the Voltage between: Ok - 5V DC Proceed to test 2
- Sensor pin 4 and sensor pin 6
- Sensor pin 1 and sensor pin 3 Faulty Rectify fault, proceed to test 3
2 Check cable continuity: OK Renew the twist grip and proceed to test 3
- Engine ECM pin B28 to sensor pin 4 Open circuit Rectify fault, proceed to test 3
cleared.
3 4
11 1
22 12
33 23
B26 R 5 5 R
B24 B 1 1 B
B27 S 3 3 W
B25 R 2 2 R
B13 B 6 6 B
B28 S 4 4 W
1 2
5 6

side)
Ambient Air Pressure Sensor
P2228 Ambient air pressure sensor circuit short circuit to View and note 'freeze-frame' data if available.
ground View and note 'sensor' data.
Make sure sensor connector is secure.
P2226 Ambient air pressure sensor circuit open circuit or Disconnect the engine ECM and proceed to pinpoint test 1:
short circuit to 5 Volt sensor supply
Pinpoint Tests
Test Result Action

Test Result Action
1 Check cable and terminal integrity: OK Disconnect ambient pressure sensor and proceed to test 2
- Engine ECM pin A5
- Sensor pin 1, 2, 3

- Engine ECM pin B23 to Engine ECM pin A5 Short circuit Locate and rectify wiring fault, proceed to test 4
3 Check cable for continuity: OK Renew ambient pressure sensor and proceed to test 4
- Engine ECM pin A5 to sensor pin 2
Circuit Diagram
13 1
26 14
39 27
3 1
1 KB B23
2 KP A5
3 K B18
11 1
22 12
33 23
1 2 3

Fault Finding – Non Electrical
Symptom Possible cause(s)
Poor throttle response at low rpm Low fuel pressure caused by filter blockage/leaks
Low fuel pressure caused by loose fuel pipes to the fuel pump and filter
Cutting out at idle Throttle bodies out of balance
Low fuel pressure caused by loose fuel pipes to the fuel pump and filter
Low fuel pressure
Weak mixture caused by air leak at the throttle body/transition piece to cylinder head
face
Idle speed too low/high Incorrect closed throttle position setting
Diagnostic software malfunctions during tune download procedure Low battery voltage
Throttle hang-up Incorrect closed throttle position setting
Motorcycle will start but cuts out immediately Low fuel pressure caused by loose fuel pipes to the fuel pump and filter

Low fuel pressure caused by filter blockage/leaks
Abnormally high fuel pressure Fuel pressure regulator inoperative
Temperature gauge reads cooler than normal Cooling system air–locked resulting in coolant temperature sensor operating in air
instead of coolant
Thermostat fault
Motorcycle will not start Check the immobiliser system for faults
Make sure that the keys, Engine ECM and Chassis ECM are all correctly paired
Pinpoint Tests - Immobiliser/TPMS
L0001 - Front Wheel Unit Sensor Battery Alert
Note
All the fault codes for the tyre pressure monitoring system and the immobiliser system can only be viewed in the Chassis section of the Triumph diagnostic
software.
L0001 Low battery voltage Replace the front wheel pressure sensor following the
or procedure described in the Triumph diagnostic tool
user guide.
The TPMS tyre symbol in the instrument pack will be
on for 8 seconds with the 'F' symbol with 'lo bAtt' shown Record the new sensor's ID number into the owner
in the display screen handbook before fitting.
L0002 - Rear Wheel Unit Sensor Battery Alert
L0002 Low battery voltage Replace the rear wheel pressure sensor following the
or procedure described in the Triumph diagnostic tool
user guide.
The TPMS tyre symbol in the instrument pack will be
on for 8 seconds with the 'R' symbol with 'lo bAtt' Record the new sensor's ID number into the owner
shown in the display screen handbook before fitting.
L0003 - Front Wheel Unit Sensor Fault Alert
L0003 Front wheel sensor unit fault alert If the problem persists:
Note: This DTC will automatically be generated if DTC Replace the front wheel pressure sensor following the
L0007 occurs procedure described in the Triumph diagnostic tool
user guide.
Record the new sensor's ID number into the owner
handbook before fitting.
L0004 - Rear Wheel Unit Sensor Fault Alert
L0005 - Front Wheel Unit Sensor Loss of Communication
L0006 - Rear Wheel Unit Sensor Loss of Communication
L0007 - Immobiliser/TPMS Control Module Fault
Invalid Key: Key Authentication Unsuccessful
Immobiliser and TPMS Control Module ID Incompatible
Removal and Installation - Fuel and Air Components
Fuel Tank - Removal
Fuel Pump and Filter Assembly - Removal
Fuel Pump and Filter Assembly - Installation
Fuel Level Sender Assembly - Removal
Fuel Level Sender Assembly - Installation
Fuel Pressure Checking
Fuel Delivery System
Airbox - Removal

Airbox Inspection
Throttle Bodies/Injectors Inspection
1. Check all joints and seals for splits, cuts and damage.
2. Check the throttles for sticking, loose or damaged throttle plates.
3. Check the transition piece rubber bead for damage, replace the transition piece if necessary.
1. Thoroughly clean the transition piece to cylinder head mating faces.

2. Refit the transition pieces to the cylinder head. Tighten the transition piece fixings to 8 Nm.
1
2
3
cdvt
1. Transition piece
2. Rubber bead
3. Fixings
3. If the injectors have been removed from the fuel rail, fit a new O-ring and seal to each injector.
Note
The injector will only fit one way in the fuel rail. Do not force fit the injector.
4. Refit injectors to the rail.
2
1
3
4
cipq
1. Injector
2. Fuel rail
3. O-ring
4. Seal
Note
The internal drilling in the MAP sensor spigot is much smaller than the evaporative emissions spigot.
5. If removed, refit the MAP sensor and evaporative emission hoses as noted for removal. Make sure that the MAP hoses are fitted to the spigot with smaller internal drilling.
1
1 2
cipn

1. MAP hose spigot
2. Evaporative emissions hose spigot
6. Refit the injectors and fuel rail to the throttle bodies. Tighten the fuel rail fixings to 3.4 Nm.
1
cipo
1. Fuel rail
2. Fuel rail fixings
WARNING
The throttle body clips must be positioned as shown below. If the clips are not positioned as shown this could cause the throttle to stick, leading to loss of motorcycle control
and an accident.
7. Refit the throttle bodies to the transition pieces and secure with the clips.
1
B00604
Electrical harness is removed for clarity

1. Transition piece (one per cylinder)
2. Clip location
8. Reconnect the throttle actuator motor multiplug.

9. If fitted, reconnect the evaporative emissions hose at the connection under the throttle body, as noted for removal.
10. Reconnect the fuel injector multiplugs.
11. Reconnect the throttle position sensor multiplug.
Throttle Position Sensor
CAUTION
The fixings for the throttle position sensor, throttle butterfly adjustment screws and the throttle hard stop blanking screw are marked with yellow paint and must not be
loosened or removed.
If the fixings, adjustment screws or blanking screw have been loosened or removed the throttle body assembly must be replaced as there are no means to reset these items
to their correct positions.
Note
The fixings for the throttle position sensor, throttle butterfly adjustment screws and the throttle hard stop blanking screw are marked with yellow paint and
must not be loosened or removed. If the fixings, adjustment screws or blanking screw have been loosened or removed any warranty claims for the throttle
bodies will be rejected.

2
1
1. Throttle position sensor fixings

2. Throttle butterfly adjustment screws
The throttle position sensor can not be removed, replaced or adjusted in service. If necessary, the throttle bodies and throttle position sensor must be replaced as an assembly.
Throttle Actuator Motor
The throttle actuator motor is an integral part of the throttle bodies and cannot be replaced separately.
Secondary Air Injection
System Purpose and Operation
B00605
The secondary air injection system is an aid to reducing levels of pollutants in the exhaust gases. It does this by introducing a small amount of air into each exhaust port as the
exhaust valve opens. The introduced air helps promote further combustion of the fuel mixture in the exhaust system after it has left the combustion chamber.
At certain specific engine speeds (determined by the factory programming of engine management system), the secondary air injection control valve is opened by the ECM and
allows an air feed into the secondary air system where, each time a pair of exhaust valves open, the exhaust gases in the exhaust port create a depression which causes reed
valves in the secondary air injection system to open. When open, the depression in the exhaust port draws air from the control valve, through the open reed valves, into the
exhaust port. This air promotes secondary combustion of the exhaust gases in the ports and the exhaust header system.
At other engine speeds, the system is disabled by closing the control valve in the system. This allows an oxygen sensor to control air to fuel ratios.

Fuel Tank - Removal
1. Release the spring hose clip and detach the secondary air injection feed hose from the camshaft cover.
2. Release the spring hose clip and detach the airbox hose from the secondary air injection solenoid.
2 2
B00609
1. Secondary air injection hose

2. Spring hose clips
3. Airbox hose
4. Secondary air injection solenoid
3. Detach the secondary air injection solenoid from its bracket.

4. Disconnect the electrical connector from the secondary air injection solenoid.
Note
Note the orientation of the secondary air injection feed hose on the solenoid for installation.
5. Release the spring hose clip and remove the secondary air injection feed hose from the secondary air injection solenoid.

1
3
cipw
3. Secondary air injection solenoid
1. Refit the secondary air injection feed hose to the secondary air injection solenoid as noted for removal and secure with the spring hose clip.
2. Connect the electrical connector to the secondary air injection solenoid.
3. Attach the secondary air injection solenoid to its mounting bracket.
4. Attach the airbox hose to the secondary air injection solenoid and secure with the spring hose clip.
5. Attach the secondary air injection feed hose to the camshaft cover and secure with the spring hose clip.
Secondary Air Injection Reed Valves - Removal

Fuel Tank - Removal
Note
Note the position of the mounting bracket for the secondary air injection solenoid valve for installation.
1. Release the fixings and remove the secondary air injection valve covers.
1
2
2
3
cipu
1. Mounting bracket
2. Fixings
3. Valve covers
2. Ease the valve covers from the valves.

3. Note the orientation of the valves and remove them from the camshaft cover.
cipt

1. Valves
Secondary Air Injection Reed Valves Inspection
1. Check for cracks, bending or other damage to the valve flaps. Replace as necessary.
2. Check for damage to the seal areas. Replace as necessary.
3. Check the valve body to cylinder head seal for damage.
Secondary Air Injection Reed Valves - Installation
1. Fit the reed valves to the camshaft cover as noted for removal.
2. Refit the valve covers and the mounting bracket for the secondary air injector solenoid valve as noted for removal. Tighten the fixings to 9 Nm.
Removal and Installation - Engine Management Components
Engine Electronic Control Module (ECM) Removal
Turn the ignition to the OFF position and wait at least 1 minute for the engine ECM to complete its power down sequence.
1. Remove the battery.
2. Disconnect the three electrical connectors from the ECM.
B00618
Rear side panel shown removed for clarity.

1. Engine Control Module (ECM)
2. Electrical connectors
3. Slide the ECM upwards to release it from the battery tray.

4. Remove the engine ECM from the motorcycle.
Engine Electronic Control Module (ECM) Installation
1. Slide the ECM into the battery tray.
B00618
Rear side panel shown removed for clarity.

1. Engine Control Module (ECM)
2. Connect the three electrical connectors to the engine ECM.

3. Install the battery.

Immobiliser/TPMS Control Module Removal

Fuel Tank - Removal
1. Remove the two fixings that attach the immobiliser/TPMS control module to the mounting bracket.
B00614 2
1. Immobiliser/TPMS control module

2. Fixings
2. Tilt the immobiliser/TPMS control module backwards to give access to the electrical connector.
B00615 1

3. Disconnect the electrical connector.

4. Remove the immobiliser/TPMS control module.
Immobiliser/TPMS Control Module Installation
1. Connect the electrical connector to the immobiliser/TPMS control module.
B00615 1

2. Position the immobiliser/ TPMS control module onto the mounting bracket.
3. Install and tighten the fixings for the immobiliser/TPMS control module to 9 Nm.
Intake Air Temperature Sensor Removal

Fuel Tank - Removal
1. Disconnect the electrical connector from the air temperature sensor.
B00612
2. Air temperature sensor
3. Fixing
2. Remove the fixing and the air temperature sensor.
Intake Air Temperature Sensor Installation
1. Install the air temperature sensor.
B00612
1. Spring hose clip

4. Air temperature sensor
2. Install the fixing and tighten it to 1.5 Nm.

3. Connect the electrical connector to the air temperature sensor.
MAP Sensor Removal

Fuel Tank - Removal
1. Disconnect the electrical connector from the MAP sensor.
2. Release the hose from the MAP sensor.
2
1
3
B00599

1. MAP sensor
3. Hose
3. Remove the fixing and remove the MAP sensor.
MAP Sensor Installation
1. Install the MAP sensor and tighten the fixing to 1.5 Nm.
2. Reconnect the hose and the electrical connector to the MAP sensor.
2
1
3
B00599
1. MAP sensor
3. Hose

Ambient Air Pressure Sensor - Removal
WARNING

Note
The ambient air pressure sensor is located on the battery tray, under the battery.
Battery - Removal
1. Remove the fixing securing the ambient air pressure sensor to the battery tray.
2. Disconnect the electrical connector and remove the sensor.
3
1
2
B00927
1. Fixing
Ambient Air Pressure Sensor - Installation
WARNING

WARNING

1. Reconnect the electrical connector to the ambient air pressure sensor.

2. Fit the sensor to the battery tray and tighten its fixing to 1.5 Nm.
3
1
2
B00927
1. Fixing

Ambient Air Temperature Sensor - Removal

1. Remove the beak (see Beak - Removal and Disassembly).
3. Release the fixing that attaches the ambient air temperature sensor to the Cable tidy and remove the sensor.
2 3
B00613
1. Ambient air temperature sensor

3. Fixing
4. Cable tidy
Ambient Air Temperature Sensor - Installation
1. Fit the sensor to the cable tidy, tightening the fixing to 3 Nm.
2 3
B00613

3. Fixing
4. Cable tidy
2. Connect the electrical connector.

Crankshaft Position Sensor Removal
Note
The crankshaft position sensor and the alternator stator are an assembly and cannot be replaced separately. If either component becomes faulty, both must be
replaced.
Note
Note the routing of the harnesses for installation.
1. Remove and discard the fixings securing the two cable brackets to the alternator cover.
2. Remove and discard the fixings securing the crankshaft position sensor to the alternator cover.
2 3 3 1
3
3
B00617
1. Crankshaft position sensor

2. Cable brackets
3. Fixings
3. Remove and discard the three fixings that attach the alternator stator to the alternator cover.
4. Noting the routing of the wiring for the crankshaft position sensor and the alternator stator.
5. Remove the crankshaft position sensor and alternator stator assembly from the alternator cover.
Crankshaft Position Sensor Installation
1. Clean all traces of silicone sealer from the aperture for the grommet in the alternator cover.
2. Position the crankshaft position sensor to the alternator cover and route the wiring as noted for removal.
Note
The air gap for the crankshaft position sensor is not adjustable.
3. Retain the crankshaft position sensor with new fixings and tighten to 6 Nm.
4. Position the alternator stator and route the wiring as noted for removal.
5. Install new fixings and tighten to 12 Nm.
6. Install the two cable brackets with new fixings. Tighten to 6 Nm.
Gear Position Sensor Removal

Note
Note the routing of the harnesses that are secured by the wire guide for installation.
Note the position of the wire guide secured by the upper fixing of the gear position sensor for installation.
1. Remove the top fixing to release the cable guide.
2. Release the cables from the cable guide.
3. Remove the bottom fixing and detach the gear position sensor from the engine.

1
4
cifq
1. Wire guide
2. Fixings
Note
Note the routing of the harness for the gear position sensor for installation.
4. Cut and remove the cable tie that attaches the harness to the electrical connector.
1 3
B01012

2. Harness
3. Cable tie
5. Disconnect the electrical connector and remove the gear position sensor.
Gear Position Sensor Installation
1. Fit two new O-rings to the gear position sensor. Lubricate the O-rings with a smear of petroleum jelly.
2. Route the harness of the gear position sensor as noted for removal.
Note
Make sure that the harnesses are routed through the wire guide as noted for removal.
3. Position the sensor to the engine. Fit the two screws and the wire guide as noted for removal and tighten the fixings to 5 Nm.
4
cifq
1. Wire guide
2. Fixings
4. Connect the multiplug for the gear position sensor to the main harness.

1 3
B01012

2. Harness
3. Cable tie
5. Use a new cable tie to secure the harness to electrical connector.
WARNING
Install the cable tie with the latch block on the inside, facing towards the rear of the motorcycle.

Ignition Switch and Immobiliser Antenna
Note
The immobiliser antenna is integral to the ignition switch and cannot be serviced separately.
Ignition Switch and Immobiliser Antenna Removal

Fuel Tank - Removal
1. Remove the two screws and remove the ignition switch cover.
CAUTION
Only drill out the head of the shear bolts securing the ignition switch to the frame. Take care not to drill into any other part of the ignition switch or frame as this will result in
irreparable damage.
2. Without damaging the ignition switch and using a suitable drill, carefully drill out the head of the shear bolts securing the ignition switch to the frame.
B00930
1. Ignition switch and immobiliser antenna

2. Shear bolts
3. Multiplug
3. Disconnect the ignition switch multiplug.

4. Noting the harness routing, remove the ignition switch.
5. Remove the remainder of the shear bolt from the frame.
Ignition Switch and Immobiliser Antenna Installation
1. Fit the ignition switch multiplug.

2. Fit the ignition switch, installing the harness as noted during removal.
3. Install new shear bolts and tighten until the heads shear off.

1
B00930
1. Ignition switch and immobiliser antenna

2. Shear bolts
3. Multiplug
4. Position the ignition switch cover. Install the fixings and tighten to 5 Nm.
Coolant Temperature Sensor - Removal
WARNING


Airbox - Removal
1. Detach the evaporation hose for the right throttle body.
1 2
B00928
1. MAP sensor hose

2. Right throttle body evaporation hose
2. Press the wire locking device fully in and disconnect the electrical connector from the coolant temperature sensor.
2 1
B00929
1. Coolant sensor
2. Wire locking device
3. Remove the coolant temperature sensor.

Coolant Temperature Sensor - Installation
1. Thoroughly clean the threads of the coolant temperature sensor and the cylinder head.
2. Apply ThreeBond 1374 to the threads of the coolant temperature sensor.
3. Fit the coolant temperature sensor into the cylinder head and tighten to 18 Nm.
Note
Make sure that the wire locking device is located correctly into the slot on the coolant temperature sensor.
4. Refit the electrical connector to the coolant temperature sensor.
2 1
B00929
1. Coolant sensor
2. Wire locking device
5. Reposition the MAP sensor hose.

6. Install the evaporation hose for the right throttle body.
1 2
B00928
1. MAP sensor hose

2. Right throttle body evaporation hose

Twist Grip - Removal
WARNING


Note
The anti-tamper fixings on the twist grip housing must not be loosened or removed.
If the anti-tamper screws have been loosened or removed any warranty claims for the twist grip housing will not be honoured.
1. Release the fixings and remove the clamp for the twist grip housing from the handlebar.

2
1
L0422
1. Anti-tamper fixings
2. Fixings
Note
Note the position and orientation of the twist grip to its housing for installation.
Note the routing of the heated grip harness for installation.
2. Slide the heated twist grip off the handlebar while carefully feeding the heated grip subharness into the hole on the left hand side of the handlebar between the switch
housing and the clutch lever clamp.
3. Disconnect the electrical connector and remove the heated twist grip.
ciqg
2. Heated twist grip
Twist Grip - Installation
WARNING

1. Connect the electrical connector of the heated twist grip to the subharness.
ciqg
2. Heated twist grip
2. Fit the heated twist grip while carefully feeding the subharness out from the hole on the left hand side of the handlebar.
3. Align the twist grip to the twist grip position sensor as noted for removal.
4. Fit the twist grip clamp. Ensure the locating lug fits into its hole on the handlebar.
1
2

3
L0421
1. Locating lug
2. Hole
3. Twist grip clamp
5. Fit and tighten the fixings, upper one first, to 2.5 Nm.
WARNING
Check the throttle opens and closes smoothly during operation.

Make sure the bar end mirrors or handguards (if fitted) do not interfere with the smooth operation of the twist grip.
A twist grip that does not close fully, operate smoothly or stick in any position will result in a dangerous riding condition leading to loss of motorcycle control and an accident.
WARNING
Heated grips (if fitted) will expand during operation.

When hot, the clearance between the heated twist grip and the bar end mirror or handguard will decrease.
Always test the heated grips when switched off (cold) and on (hot) to make sure the throttle opens and closes smoothly during operation.
A heated twist grip that does not close fully, operate smoothly or stick during operation will result in a dangerous riding condition leading to loss of motorcycle control and an
accident.
Check for correct operation of the twist grip. Rectify if necessary.
Twist Grip Position Sensor - Removal
WARNING


Fuel Tank - Removal
1. Remove the two plastic rivets and release the left headstock infill panel.
2. Note the routing of the wiring harness from the twist grip position sensor.
WARNING
The connector for the twist grip position sensor is to the front of the ABS modulator bracket in front of the immobiliser module.
3. Disconnect the electrical connector for the twist grip position sensor.
3 2
1
B01028
Only frame and harness shown for clarity.

1. Twist grip position sensor harness
3. Frame bracket
4. Remove the twist grip position sensor.
Twist Grip Position Sensor - Installation
WARNING

WARNING

1. Slide the twist grip position sensor onto the handlebar in the orientation noted for removal.
2. Route the electrical harness for the twist grip position sensor as noted during removal.
3 2
1
B01028
Only frame and harness shown for clarity.

1. Twist grip position sensor harness
3. Frame bracket
3. Connect the electrical connector for the twist grip position sensor to the main harness.
4. Position the left headstock infill panel and install the two plastic rivets.
WARNING

WARNING

accident.
Removal and Installation - Exhaust System Components
WARNING
If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool
as touching any part of a hot exhaust system could cause burn injuries.

Silencer Removal
1. Disconnect the oxygen sensor from the main harness.
2. Release the fixings securing the exhaust header pipe joints to the cylinder head. Discard the fixings.
2 2 2

B00545
1. Exhaust header pipes

2. Fixings
3. Remove the fixing from the exhaust header pipe rear mounting point.
B00544
1. Fixing
4. Detach the exhaust header pipe assembly and collect the seals from the cylinder head ports.
5. If necessary, remove the oxygen sensor.
1. If removed, apply a thin smear of anti-seize compound to the threads of the oxygen sensor, install the oxygen sensor and tighten to 25 Nm.
2. Position the header assembly under the motorcycle.
3. Raise the rear of the header assembly and align the rear mounting point.
4. Loosely install the rear fixing.
5. Fit new seals to the cylinder head. Make sure that the face of the seal with the tab is facing the cylinder head.
Note
A smear of grease may be used to retain the seals in the cylinder head during assembly.
cdoy
1. Cylinder head
2. Seal
3. Seal tab
6. Locate the exhaust header pipes and align the exhaust header pipe flanges to the fixing points. Fit new nuts and hand tighten.
7. Assemble the rear mounting point fixing but do not tighten at this stage.
8. Tighten the exhaust header pipe to cylinder head nuts in the sequence shown below:
Stage 1: Tighten the exhaust header pipe nuts to 2 Nm.
Stage 2: Tighten the exhaust header pipe nuts to 19 Nm.
5 1 3
6 2 4
B00545_1

Exhaust Header Pipe Tightening Sequence
9. Tighten the rear mounting point fixing to 19 Nm.

10. Reconnect the oxygen sensor and route the harness under the sump guard as noted on disassembly.
11. Position and engage the silencer to the exhaust header pipe. Do not tighten the clamp at this stage.
12. Reconnect the battery, positive (red) lead first and tighten the battery terminals to 4.5 Nm.
CAUTION
Do not install the exhaust system or run the engine without the exhaust heat shields fitted. Components protected by the exhaust heat shields may suffer severe damage or
a fire if the motorcycle is operated without the heat shields being fitted.
13. Start the engine and check for exhaust gas leaks. Rectify if necessary.
Silencer Removal
WARNING
If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool
as touching any part of a hot exhaust system could cause burn injuries.

1. Release the clamp securing the silencer to the exhaust header pipe.
2 1 3
B00931_1
1. Clamp
2. Header pipe
3. Silencer
2. Support the silencer and release the fixing and nut securing the silencer mounting bracket to the rear frame.
1 2
B00932
1. Fixing
2. Nut
3. Silencer
3. Move the silencer rearwards to disengage it from the exhaust header pipe.
4. Remove the silencer.
1. Position and engage the silencer to the exhaust header pipe. Do not tighten the clamp at this stage.
2. Align the silencer mounting bracket to the rear frame bracket. Refit the nut. Do not tighten the nut at this stage.
1 2

1 2
B00932
1. Silencer mounting bracket fixing

2. Nut
3. Silencer
3. Align the clamp for the silencer to exhaust header pipe joint as shown below and tighten to 10 Nm.
WARNING
Make sure that the overlap of the clamp aligns with the weld line of the header pipe assembly.
1 2 3
4
B00931
1. Header pipe
2. Weld line
3. Clamp alignment
4. Silencer
4. Tighten the fixing that attaches the silencer to the frame to 15 Nm.
5. Measure the clearance between the silencer and the licence plate hanger as shown below. The gap "A" must be 11.9 mm minimum.
B00995
1. Licence plate hanger

2. Silencer
CAUTION
Do not install the exhaust system or run the engine without the exhaust heat shields fitted. Components protected by the exhaust heat shields may suffer severe damage or
a fire if the motorcycle is operated without the heat shields being fitted.
6. Start the engine and check for exhaust gas leaks. Rectify if necessary.
Evaporative System Components
Evaporative Emissions Control System
All models are fitted with a system to control the evaporation of fuel vapour to the atmosphere.

A carbon filled canister absorbs vapour while the engine is not running. When the engine is started, the vapour is returned to the engine and burnt.
There are two distinct phases to the system's operation, engine off and engine running. These two conditions are explained overleaf.
Evaporative Emissions Control System Component Locations
Carbon Filled Canister (2) - under the fuel tank at the left side.
Purge Control Valve (3) - attached to the frame under the fuel tank (electronically controlled by the engine ECM).
5 2
4 1
1. Breather hoses
2. Carbon filled canister
3. Purge valve
4. Purge hose to throttle bodies
5. Fuel tank filler drain
Evaporative Emissions Control System - Engine Off
When the engine is stationary any pressure increase in the fuel tank due to a rise in ambient temperature will cause the fuel vapour to pass down the breather hose (1) to a
carbon filled canister (2) which stores the vapour.
Once in the canister, vapour cannot enter the engine because the purge valve is closed.

5 2
4 1
1. Breather hoses
3. Purge valve (closed)
Evaporative Emissions Control System - Engine Running
When the engine is running, engine vacuum is applied to the purge hose (4) from the throttle bodies.
At certain times, the engine ECM opens the purge valve. The vacuum applied to the purge hose (4) now begins to draw stored vapour from the carbon filled area of the canister
and returns it to the throttle bodies for burning in the engine.
In order to control the speed at which vapour is purged from the canister, the engine management system shuttles the purge control valve between open and closed positions.
5 2
4 1

1. Breather hoses
3. Purge valve (open under engine ECM control)
Purge Control Valve Removal

Fuel Tank - Removal
Note
Note the orientation of the sub harness and connectors for installation.
1. Disconnect the electrical connector from the purge control valve.
2 1 6 5
3
4
B00611
1. Purge control valve

3. Purge hose to evaporative canister
5. Fixing
6. Locating tab
2. Note the routing of the hoses on the purge control valve for installation.
3. Disconnect the hose to the evaporative cannister from the purge control valve.
4. Disconnect the hoes from the throttle bodies from the purge control valve.
5. Remove the fixing that attaches the purge control valve to the bracket.
Purge Control Valve Installation
1. Reconnect the hoses to the purge control valve as noted for removal.
2 1 6 5
3
4

B00611
1. Purge control valve

3. Purge hose to evaporative canister
5. Fixing
6. Locating tab
Note
Make sure the purge valve locating tab is correctly engaged in the mounting bracket.
2. Position the purge control valve to its mounting bracket and tighten the fixing to 3 Nm.
Note
Ensure the locking device is fully engaged when refitting electrical connectors
3. Reconnect the electrical connector to the purge control valve. Ensure the locking device is fully engaged.
Evaporative Canister Removal

1. Remove the fuel tank end panel at the left side (see Fuel Tank End Panel - Removal).
2. Disconnect the vacuum and purge hoses from the evaporative canister.
B00606
1. Evaporative canister
2. Vacuum hose
3. Purge hose
3. Remove the two plastic rivets that attach the left radiator cowl duct and move the cowl to give access to the evaporative canister.
B00977 2 1
1. Radiator cowl duct

2. Plastic rivet
4. Remove and discard the fixing from the front of the evaporative canister.

B00607
1. Fixing
5. Disconnect the vent hose from the evaporative canister.

6. Release the two locating lugs at the rear from the mounting bracket and remove the evaporative canister. Make sure that the rubber grommets remain in the mounting
bracket.
2
3
B00608
Radiator cowl lower cover not shown for clarity.

1. Evaporative cannister
2. Vent hose
3. Rubber grommets
Evaporative Canister Installation
1. Fit the locating lugs on the evaporative canister into the rubber grommets in the mounting bracket.
2
3
B00608
Radiator cowl lower cover not shown for clarity.

2. Vent hose
3. Rubber grommets
2. Connect the vent hose to the rear of the evaporative canister.

3. Install a new fixing and tighten to 6 Nm.
B00607
1. Fixing
2. Evaporative cannister
4. Position the radiator cowl duct and install the two plastic rivets.

2
B00977 2 1

2. Plastic rivet
5. Connect the vacuum and purge hoses to the evaporative canister.
B00606
2. Vacuum hose
3. Purge hose

Fuel Tank End Panel - Installation
Cooling
Exploded View - Cooling System

Coolant
A year-round, Hybrid Organic Acid Technology (known as Hybrid OAT or HOAT) coolant is installed in the cooling system when the motorcycle leaves the factory. It is coloured
green, contains a 50% solution of ethylene glycol based antifreeze, and has a freezing point of -35°C (-31°F).
Always change the coolant at the intervals specified in the Scheduled Maintenance chart.
WARNING
The standard coolant mixture contains toxic chemicals that are harmful to the human body. Never swallow neat antifreeze or any of the coolant mixture.
CAUTION
The antifreeze incorporated in the coolant mixture contains a corrosion inhibitor that helps prevent damage to the cooling system and engine. Without this inhibitor, the
coolant would 'attack' the metals and the resulting corrosion would cause blockages in the cooling system leading to engine overheating and damage.
Always use the antifreeze listed in the Specification section and never use a methanol based antifreeze as this does not contain the required corrosion inhibition properties.
CAUTION
If hard water is used in the cooling system, it will cause scale accumulation in the engine and radiator and considerably reduce the efficiency of the cooling system. Reduced
cooling system efficiency may cause the engine to overheat and suffer severe damage.
Note
HD4X Hybrid OAT coolant, as supplied by Triumph, is premixed and does not need to be diluted prior to filling or topping up the cooling system.
WARNING


Fuel Tank - Removal
WARNING
CAUTION
Do not remove the coolant pressure cap if the expansion tank contains coolant.
If you remove the coolant pressure cap, the coolant in the expansion tank will be released and can spill over the motorcycle.
Note
Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help make sure that they are returned to the same positions
and orientation on assembly.
Use T3880207 - Hose Clip Pliers for removal and installation of the coolant hose constant tension hose clips.
Note
To fully drain the coolant, place the motorcycle on its side stand so that it is angled to the left side.
1. Remove the right fuel tank end panel (see Fuel Tank End Panel - Removal).
2. Position a container to collect the drained coolant.
3. Loosen the clip and loosen the top hose on the right radiator to allow air into the system.
4. Loosen the hose clip then release the bottom hose from the radiator and allow the coolant to drain.
2 1

B00591
1. Hose clip
2. Bottom hose
5. Loosen the hose clips then release the heat exchanger hoses from the heat exchanger and allow the coolant to drain.
B00593
1. Heat exchanger
2. Heat exchanger hoses
3. Coolant hose clips
6. If the coolant system needs to be fully drained, remove and drain the coolant expansion tank (see Coolant Expansion Tank - Removal).
1. If removed, install the coolant expansion tank (see Coolant Expansion Tank - Installation).
2. Reconnect the top hose to the right radiator. Make sure that the hose clip is positioned as noted for removal.
3. Reconnect the bottom hose. Make sure that the hose clip is positioned as noted for removal.
2 1
B00591
1. Hose clip
2. Bottom hose
4. Reconnect the heat exchanger hoses. Make sure that the hose clips are positioned as noted for removal.
B00593
1. Heat exchanger
2. Heat exchanger hose
3. Coolant hose clip

Note
During filling, squeezing the bottom hose with both hands will help to pump coolant around the system and remove trapped air.
5. Slowly add coolant mixture to the system, through the filler opening in the radiator, until the system is full (see Coolant SystemCoolant System Specifications).
6. If the system has filled correctly and fully, there should be coolant visible through the radiator filler opening.
7. If necessary, top up the system through the filler and refit the coolant pressure cap.
8. Fill the expansion tank to the "MAX" line.
9. With the aid of an assistant, lean the motorcycle fully over to the right hand side, and then the left hand side, to release air trapped in the cooling system. Repeat as
necessary.
10. Install the fuel tank (see Fuel Tank - Installation).
11. Start the motorcycle and allow to run for approximately 20 to 30 seconds. Briefly raise the engine speed several times to allow any air to be expelled from the system.
12. Stop the engine. Check and top up the coolant level as necessary.
13. With the aid of an assistant, lean the motorcycle fully over to the right hand side, and then the left hand side, to release air trapped in the cooling system.
14. Start the motorcycle. Briefly raise the engine speed several times to allow any air to be expelled from the system.
15. Allow the engine to run until the cooling fan operates.
16. Stop the motorcycle and allow the engine to cool.
WARNING
Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the cooling system is hot and also under pressure. Contact with
the pressurised coolant will cause scalds and skin damage.
17. Check and top up the coolant level as necessary.

18. Check the expansion tank level and top up if necessary.
Coolant Level - Inspection
Water Pump
Note
The oil pump and water pump are supplied as an assembly and cannot be separated. For additional information, refer to Oil Pump (see Oil and Coolant Pump -
Removal and Oil and Coolant Pump - Installation).
Coolant Pressure Cap and Coolant System - Testing
Inspection and Testing
WARNING
Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the
pressurised coolant will cause scalds and skin damage.
WARNING
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the
motorcycle.
1. Allow the engine temperature to cool for at least 30 minutes.

2. Remove the coolant pressure cap.
3. Check the condition of the upper and lower seals of the coolant pressure cap.
2 3
cdbu
1. Lower seal
2. Upper seal
3. Spring
Note
If there is any sign of damage or deterioration replace the cap.
4. Pressure test the cap and cooling system to the blow off pressure of 1.1 bar as described below using T3880147 - Radiator and Cap Tester Kit. If the cap opens at a lower
pressure or fails to open at 1.1 bar, replace the cap.
Note
It is recommended to carry out coolant pressure cap and cooling system pressure tests consecutively.

Coolant Pressure Cap Test
1
3
4
2
cgwp
1. Hand held pump

2. Bayonet type connector
3. Pressure cap test adaptor 44 mm
4. Pressure cap test adaptor 46 mm
1. Select the correct test adaptor and securely fasten to the pressure cap.
2. Carefully connect the hand pump to the adaptor ensuring an air tight seal is maintained.
1
2
cgwq_5
1. Pressure cap
2. Test adaptor
3. Hand held pump
3. Pressure test the coolant cap to the blow off pressure. If the coolant cap opens at a lower pressure, fails to open at the correct pressure or the seal leaks, replace the cap.
Coolant System Pressure Test
1. Select the bayonet type adaptor and securely fasten to the radiator.
2. Carefully connect the hand pump to the bayonet connector ensuring an air tight seal is maintained.
3
1
cgwr
1. Radiator filler
3. Hand held pump
3. Pressurise the cooling system to the operating pressure, using the hand pump taking care not to exceed the maximum cap pressure.
4. Hold the pressure for a minimum of 10 minutes, whilst visually inspecting the external components of the coolant system for leaks.
5. Remove the engine oil filler cap/dipstick and check for contamination of the engine oil caused by coolant escaping into the engine sump.
Note
If the engine oil is contaminated further exploratory investigation will be required.
If the engine oil is contaminated rectify the cause of the problem and then renew the oil and filter.
6. Depressurise the coolant test kit using the pressure release valve.

4
3
1
cgwr_1
1. Radiator filler
3. Hand held pump
4. Pressure release valve
7. Refit the coolant pressure cap.

8. Fill the coolant to the maximum mark (see Coolant Replacement - Filling).
Thermostat - Removal
WARNING
Note
Fuel Tank - Removal
Airbox - Removal
1. Detach the coolant hose from the thermostat elbow.
2. Release the fixings securing the thermostat elbow to the cylinder head.
3. Remove the thermostat housing.
2
cduf
1. Thermostat housing
2. Fixings
4. Remove the thermostat from the cylinder head. Discard the seal.
cdug

1. Thermostat
2. Bleed valve
Thermostat - Installation
WARNING

1. Fit a new seal to the thermostat.

2. Locate the thermostat into the cylinder head. Ensure the bleed valve is uppermost as shown below.
cdug
1. Thermostat
2. Bleed valve
3. Refit the thermostat housing and tighten the fixings to 9 Nm.

4. Reconnect the top hose. Ensure the hose clip is positioned as noted for removal.
Left Radiator - Removal
WARNING

Note
Fuel Tank - Removal
WARNING

1. Pull the centre radiator panel forwards to release it from the three attachment grommets.

1
B00787
1. Centre radiator panel

2. Attachment grommets
CAUTION
Be careful when the radiator cowl panel is removed. With the radiator cowl panel removed, the radiator is only supported at one side and the radiator mounting brackets can
be easily broken.
2. Remove the left radiator cowl panel (see Radiator Cowl Panel - Removal).
3. Remove the two plastic rivets that attach the left radiator cowl duct and remove the duct.
B00978 2 1

2. Plastic rivet
4. Disconnect the cooling fan electrical connector.

5. Release the clips from the top and bottom hoses, and the radiator link hose.
B00789
2
1. Radiator
2. Bottom hose clip
3. Top hose clip
4. Link hose clip
6. Remove the alternator regulator/rectifier (see Regulator/Rectifier - Removal).
B00790 2 3 1

1. Left radiator
2. Right radiator
3. Link hose clips
4. Regulator/rectifier
5. Lower fixings
7. Remove the lower fixing for the left radiator.

8. Carefully release the radiator assembly from the upper mounting stud and disconnect the three hoses.
9. Remove the radiator assembly.
10. Collect the flanged washers from the mounting grommets.
Disassembly of the Radiator Assembly (if necessary)
CAUTION
Complete this procedure on a workbench that has a protective surface to prevent damage to the components.
1. Remove the three fixings that attach the cooling fan to the radiator and remove the cooling fan.
1
6 5 4
B00788 6 4
1. Cooling fan fixings

2. Cooling fan
3. Radiator
4. Radiator guard fixings
5. Radiator guard
6. Grommets
2. Remove and discard the two fixings that attach the radiator guard to the radiator.
3. Remove the two grommets from the radiator.
Right Radiator - Removal
WARNING

Note
Fuel Tank - Removal
WARNING

1. Pull the centre radiator panel forwards to release it from the three attachment grommets.

1
B00787

CAUTION
be easily broken.
2. Remove the right radiator cowl panel (see Radiator Cowl Panel - Removal).
3. Remove the two plastic rivets that attach the right radiator cowl duct and remove the duct.
B00978 2 1
Note that the left cowl duct is shown. The right side
is similar.
2. Plastic rivet
4. Disconnect the cooling fan electrical connector.

5. Release the clip from the expansion tank hose.
2 4
1 5
3
B00791
1. Radiator
2. Expansion tank hose clip
3. Link hose clip
4. Top hose clip
5. Regulator/Rectifier
6. Lower fixing
6. Release the clips from the top hose and the radiator link hose.
7. Release the radiator assembly lower fixing.
8. Remove the alternator regulator/rectifier (see Regulator/Rectifier - Removal).
9. Carefully release the radiator assembly from the upper mounting stud and disconnect the three hoses.
10. Remove the radiator assembly.
11. Collect the flanged washers from the grommets.
Disassembly of the Radiator Assembly (if necessary)
CAUTION
Note
The illustration shows the left radiator assembly. Disassembly of the right radiator assembly is the same.
1. Remove the three fixings that attach the cooling fan to the radiator and remove the cooling fan.

3
1
6 5 4
B00788 6 4

2. Cooling fan
3. Radiator
5. Radiator guard
6. Grommets
2. Remove and discard the two fixings that attach the radiator guard to the radiator.
3. Remove the two grommets from the radiator.
Inspection
1. Check the radiator for stone damage.

2. Check the radiator core for damage to the fins or obstructions to air flow.
3. Repair any damage and clear all obstructions.
CAUTION
To avoid overheating and consequent engine damage, replace the radiator if the cores are blocked or if the fins are badly deformed or broken.
4. Check that the fan spins freely and without tight spots.
5. Check the fan blades for signs of heat distortion.
Left Radiator - Installation
WARNING

Assemble the Radiator Assembly (if necessary)
1. Fit the two grommets into the radiator mounting brackets.
1
6 5 4
B00788 6 4

2. Cooling fan
3. Radiator
5. Radiator guard
6. Grommets
2. Put the radiator guard into position and install two new fixings. Tighten to 3 Nm.
3. Put the cooling fan in position. Install the three fixings and tighten to 8.5 Nm.
Radiator Assembly Installation
CAUTION

CAUTION
be easily broken.
1. Support the radiator and connect the three hoses.

2. Install the flanged washers into the grommets.
3. Align the radiator grommet to the upper mounting stud.
B00790 2 3 1
1. Radiator
2. Bottom hose clip
3. Bottom hose
4. Lower fixing
5. Upper mounting stud
4. Install the regulator/rectifier (see Regulator/Rectifier - Installation).

5. Install the lower fixing and tighten to 6 Nm.
6. Position the clips from the top and bottom hoses, and the radiator link hose.
B00789
2
1. Radiator
2. Bottom hose clip
3. Top hose clip
4. Link hose clip
7. Connect the electrical connector for the cooling fan.

8. Position the radiator cowl duct and install the two plastic rivets that attach the duct.
9. Install the left radiator cowl panel (see Radiator Cowl Panel - Installation).
10. Align the attachment pins on the radiator centre panel with the three frame grommets and push the radiator centre panel until it is correctly attached.
1
B00787



Right Radiator - Installation
WARNING

Assemble the Radiator Assembly (if necessary)
Note
The illustration shows the left radiator assembly. Assembly of the right radiator assembly is the same.
1. Fit the two grommets into the radiator mounting brackets.
1
6 5 4
B00788 6 4

2. Cooling fan
3. Radiator
5. Radiator guard
6. Grommets
2. Put the radiator guard into position and install two new fixings. Tighten to 3 Nm.
3. Put the cooling fan in position. Install the three fixings and tighten to 8.5 Nm.
Radiator Assembly Installation
CAUTION
be easily broken.
1. Support the radiator assembly and connect the top hose and the link hose.
2. Install the flanged washers into the grommets.
3. Align the radiator grommet to the upper mounting stud.
2 4
1 5
3
B00791
1. Radiator
2. Expansion tank hose clip
3. Link hose clip
4. Top hose clip
5. Upper mounting stud
6. Lower fixing
4. Install the regulator/rectifier (see Regulator/Rectifier - Installation).

5. Install the lower fixing and tighten to 6 Nm.

6. Position the clips from the top hose and the radiator link hose.
7. Connect the expansion tank hose.
8. Position the clip for the expansion tank hose.
9. Connect the electrical connector for the cooling fan.
10. Position the radiator cowl duct and install the two plastic rivets that attach the duct.
11. Install the right radiator cowl panel (see Radiator Cowl Panel - Installation).
12. Align the attachment pins on the radiator centre panel with the three frame grommets and push the radiator centre panel until it is correctly attached.
1
B00787


Coolant Expansion Tank - Removal
WARNING


Fuel Tank - Removal
1. Disconnect the expansion overflow hose
2. Remove the fixings that attach the coolant expansion tank to the frame. Discard the fixings.
B00594
1. Coolant expansion tank

2. Expansion overflow hose
3. Fixings
4. Hose clamp
Note
Note the position of the coolant expansion tank hoses for installation.
3. Position a container to collect the displaced coolant.
4. Release the hose clip and disconnect the radiator overflow hose from the coolant expansion tank.
5. Drain the coolant from the coolant expansion tank.
6. Remove the coolant expansion tank.
Coolant Expansion Tank - Installation
1. Connect the bypass hose to the coolant expansion tank and secure with the hose clips.
2. Position the coolant expansion tank to the frame, as noted for removal. Fit the two new fixings and tighten to 3 Nm.

2
B00594
1. Coolant expansion tank

2. Overflow hose
3. Fixings
4. Hose clamp
3. Connect the overflow pipe.

4. Top up the coolant level in the expansion tank (see Coolant Replacement - Filling).
Front Suspension
Exploded View - Front Forks

Exploded View - Handlebars
Front Suspension
This model is equipped with hydraulic, telescopic front forks.

Periodic inspection for damage and fluid leaks is essential for safe riding. Always follow the inspection instructions at the intervals stated in the scheduled maintenance chart.
Fork Inspection
Examine each fork for any sign of damage or scratching of the slider surface or for oil leaks.
If any damage or oil leakage is found, strip and repair as described in this section or consult an authorised Triumph dealer.
Check for smooth operation of the forks as follows:
Place the motorcycle on level ground.
While holding the handlebars and applying the front brake, pump the forks up and down several times.
If roughness or excessive stiffness is detected, repair as described in this section or consult an authorised Triumph dealer.
WARNING
Riding the motorcycle with defective or damaged suspension can cause loss of motorcycle control and an accident. Never ride with damaged or defective suspension.
Front Fork Oil Seal - Clean
WARNING


Front Mudguard - Removal

1. Clean the area around the dust seal then carefully detach the dust seal from the fork outer tube.
2. Wipe away any visible dirt or water from the oil seal.
Note
T3880216 - Fork Seal Cleaner, Large has two cleaning hooks. The one with the OIL SEAL text is for the oil seal, the other cleaning hook is for the dust seal.
When cleaning the oil seal with T3880216 - Fork Seal Cleaner, Large it is possible that a small amount of fork oil may seep out.
3. Clean T3880216 - Fork Seal Cleaner, Large
4. Fit T3880216 - Fork Seal Cleaner, Large to the fork inner tube. Make sure that the cleaning hook, with the text OIL SEAL below it, is pointing towards the oil seal.
ckpd
1. Cleaning hook
2. OIL SEAL text
3. Oil seal location
5. Slide the cleaning hook carefully under the seal lip. Rotate T3880216 - Fork Seal Cleaner, Large 360° in the direction shown then remove the cleaning hook from the oil
seal.
ckpd_1
Direction of Rotation
6. Slide T3880216 - Fork Seal Cleaner, Large down to use the other cleaning hook to clean the dust seal. Rotate T3880216 - Fork Seal Cleaner, Large 360° in the direction
shown then remove the cleaning hook from the dust seal.
2
1
ckpd_1
Direction of Rotation
1. Dust seal
2. Cleaning hook
7. Use the wider end of T3880183 - Fork Seal Tool, 47 mm, with hand pressure only, to press the dust seal into position in the outer tube.
Front Mudguard - Installation
Front Fork - Removal
WARNING


WARNING

Raise and support the front of the motorcycle.
Front Wheel - Removal
WARNING
Do not allow a brake component to hang unsupported on the brake hose or line.
Brake hoses or lines that are not supported may become damaged or bent.
Bent or damaged brake hoses or lines lead to reduced braking efficiency causing loss of motorcycle control and an accident.
Note
If the forks are to be dismantled, loosen the fork top cap.
Release the fixing and detach the brake hose from the clip on the fork leg.
3
cgyi
1. Brake hose
2. Brake hose clip
3. Fixing
1. Remove the fixing for the front wheel speed sensor from the left fork. Move the sensor aside and collect the spacer.
B00799
1. Upper yoke pinch bolts
CAUTION
Care must be taken when removing the forks, to ensure that the outer surfaces do not become scratched.
3. Loosen the lower yoke pinch bolts.
B00801

1. Lower yoke pinch bolts
4. Using a downward, twisting action, withdraw the forks from between the yokes.
Front Fork - Disassembly
WARNING


WARNING
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. Riding with unfamiliar
fork settings may cause unexpected handling characteristics leading to loss of control and an accident.
Fork Spring and Top Cap Removal
CAUTION
Never tightly clamp the outer tube as this will cause the tube to permanently distort. A distorted tube is not serviceable and must be replaced.
1. Clamp T3880171 - Fork Holding Tool in a vice and mount the fork vertically in the service tool.
4
3
1
cjiw_3
1. Vice
2. T3880171 - Fork Holding Tool
3. Fork
4. Top cap
2. Unscrew the top cap until it is released from the fork outer tube.
3. Remove the fork from T3880171 - Fork Holding Tool.
Note
The preload spacer seat, preload spacer and the spring can fall out of the fork when you invert the fork in the stage that follows.
4. Holding the fork inner and outer tubes together, invert the fork and pour out the fork oil into a suitable container. Pump the damper rod to remove all of the oil.
5. Return the fork to T3880171 - Fork Holding Tool.
6. Allow the outer tube to slide down the inner to allow access to the spring spacer.
WARNING
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. If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to
the user.
7. Fit T3880067 - Fork Spring Compressor over the top cap. Position the two adjustable arms to the holes in the spring spacer. Screw in the arms until they positively engage
in the spring spacer holes.
8. Using T3880067 - Fork Spring Compressor, manually compress the fork spring and insert the spring holder as shown, below the damper locknut.
1
3

ccut_4
1. Damper locknut
2. T3880067 - Fork Spring Compressor
3. Spring holder (part of T3880067 - Fork Spring
Compressor)
9. Loosen the lock nut for the top cap a small amount.
10. Carefully count the number of turns necessary and unscrew the top cap until the top cap is released from the damper.
CAUTION
Keep the top cap and damping adjuster rod assembly aligned with the fork tube to prevent damage to the adjuster rod during the stage that follows.
11. Remove the top cap and damping adjuster rod assembly.
12. Compress the fork spring again and remove the spring holder and T3880067 - Fork Spring Compressor.
13. Remove the bump rubber (if not attached), nylon spacer, spring spacer and spring.
1
2
ccwz_1
1. Nylon spacer
2. Spring spacer
3. Bump rubber
Fork Seal and Bearing Bush Removal
1. Invert the fork assembly and mount it in T3880171 - Fork Holding Tool.
2. Raise the inner tube and remove the dust seal from the outer tube.
cgrc_4
1. Inverted fork
2. Dust seal
3. Remove the circlip.
cetn_3

1. Circlip
4. Remove the fork from T3880171 - Fork Holding Tool 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.
ccuw
1. Inner tube
2. Outer tube
5. To allow the removal of the seals and bushes, carefully remove the upper bush from the inner tube.
5
4
3
2
1
ccup_7
1. Upper bush
2. Washer
3. Oil seal
4. Spring clip
5. Dust seal
6. Fork inner tube
6. Remove the seals and bushes.
Front Fork - Inspection
1. Inspect the fork inner tube for stone chips, scoring, scratches, excessive wear and any other damage. Renew as necessary.
Note
Small inclusions in the inner tube may be removed using a fine grade stone or similar.
2. Inspect the spring for damage, cracks and deformation. Renew the spring if necessary.
3. Inspect all the bushes and seals for damage. Renew any damaged items if necessary.
Front Fork - Assembly
WARNING
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.
Fork Seal and Bearing Bush Installation
1. Secure the fork outer tube and damper assembly in T3880171 - Fork Holding Tool in the inverted orientation.
2. Apply a smear of fork oil to the bushes and new seals.
3. Position the seals and bushes to the fork inner tube as noted during removal. Make sure that the oil seal (item 3) is positioned with the text end facing the circlip (item 2).
Use a new circlip.
1
2
3
4 5
6

ccup_2
1. Dust seal
2. Circlip
3. Oil seal
4. Washer
5. Lower bush
6. Upper bush
4. Using a suitable tool, fit the upper bush to the fork inner tube.
5. Position the inner tube assembly to the outer. Make sure that the oil and dust seal lips do not become damaged.
6. Use the narrow end of T3880157 - Fork Seal Installer to drive the lower bush, washer and oil seal into position. Make sure that the circlip groove is fully visible.
4 3
1
ccuq_7
1. T3880157 - Fork Seal Installer

2. Oil seal
3. Washer
4. Lower bush
7. Install a new circlip to retain the oil seal.
ccuv_6
1. Dust seal
2. Circlip
8. Position the dust seal to the outer tube.

9. Use the wider end of T3880157 - Fork Seal Installer with hand pressure only, to press the dust seal into position in the outer tube.
Note
It is much easier to torque the top cap when the fork has been refitted.
Fork Spring and Top Cap Installation
1. Invert the fork leg in T3880171 - Fork Holding Tool.

2. Fill the fork with oil (see Fork Oil Change).
3. Position the fork assembly as for compression of the fork spring during strip down.
4. Refit the fork spring spacer, spring, nylon spacer and the bump rubber.
2 4

3
ccuu_2_1
1. Spring spacer
2. Spring
3. Nylon spacer
4. Bump rubber
5. Attach T3880085 - Fork Piston Holder to the threads of the damper rod and pull the damper upwards.
CAUTION
If removed, the damping rod locknut must be fitted with the flat face facing to the top of the fork. The slightly tapered face must face the fork spring. Incorrect orientation may
lead to a loosening of the locknut.
6. Turn the damper rod locknut until the length of threads to the end of the rod is equal to the length measured during disassembly.
cdep_3
1. Damper rod
2. Locknut
WARNING
While re-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
the user.
7. Refit T3880067 - Fork Spring Compressor as previously described. Compress the fork spring and refit the spring holder.
1
3
ccut_4
1. Damper locknut
2. T3880067 - Fork Spring Compressor
3. Spring holder (part of T3880067 - Fork Spring
Compressor)
8. Inspect the O-ring for the top cap for any damage, replace if necessary.
9. Carefully install the top cap and rebound adjuster rod into the damper rod. Slowly turn the cap until it touches the locknut.
10. Hold the top cap while tightening the damper rod locknut to 20 Nm.
WARNING
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
the user.
11. Recompress the spring to remove the spring holder.

12. Lubricate the O-ring on the top cap with a smear of fork oil then screw the top cap into the outer tube. Do not fully tighten at this stage.

13. Fit the fork (see Front Fork - Installation) but do not fully tighten the top yoke clamp fixings at this stage.
14. Tighten the top cap to 35 Nm.
15. Tighten the top yoke clamp fixings to 25 Nm.
Front Fork - Installation
WARNING

1. Position the forks within the yokes so that the lip of the outer tube, not the top cap, is 3 mm above the upper surface of the upper yoke:
3 mm
2. Tighten the pinch bolts of the lower yoke pinch bolts, upper first, to 25 Nm. Retighten the upper bolts of the lower yoke again to 25 Nm.
3. Tighten the upper yoke pinch bolts, upper first, to 25 Nm.
Note
If the forks have been dismantled, tighten the fork top caps to 35 Nm, and if removed, the lower damper cylinder bolt to 20 Nm.
Refit the front mudguard (see Front Mudguard - Installation).
Position the brake hose to the fork leg clip and secure with its fixing, tightening to 4 Nm.
3
cgyi
1. Brake hose
2. Brake hose clip
3. Fixing

Front Wheel - Installation
Front Brake Caliper - Installation
Front ABS Wheel Sensor - Installation
Lower the motorcycle to the ground and park it on the side stand.
Fork Oil Change
Draining
WARNING


1. Remove the fork top cap and spring (see Front Fork - Disassembly.
2. Holding the inner and outer tubes together, invert the fork and pour out the fork oil into a suitable container. Pump the damper rod to remove all the oil.
Oil Refilling
The oil level is measured from the upper surface of the fork outer tube, with the fork fully compressed and the spring removed.

Fork Oil Level (fully compressed)
Oil Level 90 mm
1. Fill the fork with the grade of oil specified in the fork oil table, to a level above that which will finally be required.
2. Pump the fork assembly and damper several times to expel any trapped air then fully compress the fork and support it in an upright position. Leave the fork for a few
minutes to allow the oil to stabilise.
3. Refer to the fork oil level chart below and set the scale on T3880160 - Fork Oil Filler/Evacuator to the relevant distance, as shown below.
1. T3880160 - Fork Oil Filler/Evacuator

2. Adjustment plate
3. Scale area
4. Hole (zero position)
Note
Zero level on the tool is set at the small exit hole in the side of the scale tube, NOT AT THE END TIP. Do not attempt to block this side hole as this will cause the
final fluid level to be incorrect.
4. Insert the scale end of the tool into the fork inner tube.
5. Hold the tool adjuster plate level with the upper surface of the fork outer tube and draw fluid into the syringe until fluid flow ceases (empty the syringe if the body becomes
full before fluid flow stops).
6. The fluid level in the fork is now set to the height set on the tool scale. Check the tool scale setting and repeat the process if incorrectly set.
WARNING
Incorrect fork oil levels could result in an unsafe riding condition leading to loss of motorcycle control and an accident.
7. Assemble the fork (see Front Fork - Assembly).

8. Refit the fork (see Front Fork - Installation).
Fork Oil Level Chart
Oil Level* Oil Volume Oil Grade Fork Pull Through
90 mm 650 +/- 2.5 cc Showa SS47G Top of the outer tube 3 mm above the upper
face of the upper yoke
* Fork Fully Compressed
Upper Yoke - Removal
WARNING


1. Support the handlebars and remove the handlebar clamp fixings.
3 3
2
1 2
B00800
1. Alignment mark
2. Fixings M10
3. Fixings M8
2. As an assembly, raise the handlebars until they are clear of the upper yoke. Rest the assembly forward of the steering stem so that access to the headstock top nut is not
restricted. Make sure that the master cylinder stays upright.
B00799
1. Pinch bolts
4. Loosen and remove the top nut from the steering stem.
1. Top nut
5. Remove the upper yoke.
Upper Yoke - Installation
WARNING

1. Refit the upper yoke.

2. Fit and tighten the top nut to 120 Nm.
3. Tighten the upper yoke pinch bolts to 25 Nm.

1
B00799
1. Pinch bolts
4. With the aid of an assistant, support the handlebars and refit the clamps to the risers.
5. Align the split line to the marking on the handlebars and tighten the M10 fixing to 35 Nm and then the M8 fixings to 26 Nm.
3 3
2
1 2
B00800
1. Alignment mark
2. Fixings M10
3. Fixings M8

Headstock Bearing - Removal
WARNING

1. Note the original position of the handlebars, in order that they can be returned to the same position when the repair operation is complete.
3. Release the fixings securing the handlebar clamps to the risers. Detach the clamps and release the handlebars.
4. As an assembly, raise the handlebars until clear of the upper yoke. Rest the assembly forward of the steering stem to give access to the headstock top nut and the
adjustment nuts. Make sure that the front brake master cylinder remains in an upright position.
5. Remove both front forks (see Front Fork - Removal).
CAUTION
Care must be taken when removing the headstock top nut to make sure that the top nut and headstock do not become scratched. Protect the surfaces with a suitable cloth
or tape to prevent scratching.
6. Remove the headstock top nut and washer. Discard the washer.
1. Headstock top nut
7. As an assembly, raise the upper yoke and handlebars until clear of the steering stem. Rest the assembly forward of the steering stem such that access to the adjustment

nuts is unrestricted. Make sure that the front brake master cylinder remains in an upright position.
8. Using T3880023 - 50 mm Socket, remove the lock nut and tab washer.
T3880023 - 50 mm Socket
2 1
3
4
B00993
1. Tab washer
2. Lock nut
3. Rubber washer
4. Adjuster nut
9. Use T3880023 - 50 mm Socket to remove the adjuster nut.

10. Remove the bearing cover and dust seal.
11. Remove the bottom yoke from below the frame headstock.
WARNING
Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could
cause eye and soft tissue injuries if suitable protective apparel is not worn.
12. Use a suitable drift to evenly and progressively drive the bearing races from the frame headstock.
13. Remove the inner race and dust seal from the bottom yoke using a press or puller.
Headstock Bearing - Installation
1. Fit a new dust seal to the steering stem on the bottom yoke.
cdgo_2
1 2
1. Steering stem
2. Dust shield
CAUTION
Protect the threads of the bottom yoke when using a press or puller as damaged threads may mean replacing the yoke completely.
2. Press a new lower bearing inner race onto the steering stem of the bottom yoke.

1
3 2
cdnu_3
1. Bottom yoke
2. Inner bearing race
3. Press bed
3. Evenly and progressively drive a new complete upper outer bearing race into the frame headstock.
4. Install and lubricate the lower bearing using a heavy duty, lithium based, NLGI 2 specification grease such as Castrol SpheerolTM LCX 222.
5. Drive a new lower outer bearing race into the frame headstock.
6. Lubricate the lower bearing using a heavy duty, lithium based, NLGI 2 specification grease such as Castrol SpheerolTM LCX 222.
7. Insert the lower yoke to the frame, fit the upper bearing and race.
8. Fit a new upper dust seal and bearing cover, and retain with the adjuster nut.
9. Adjust the headstock bearings (see Headstock Bearing - Check/Adjustment).
10. Locate the upper yoke to the steering stem.
11. Fit a new washer and the original top nut. Do not fully tighten the top nut at this stage.
12. Fit the forks (see Front Fork - Installation).
13. Tighten the headstock top nut to 120 Nm.
14. Check that no free play exists in the headstock bearings. Adjust as necessary (see Headstock Bearing - Check/Adjustment).
15. Locate the handlebar assembly into the risers. Fit the upper clamps and the 10 mm bolts.
16. Rotate the handlebar so that the alignment mark on the handlebar aligns with the split line between the upper clamp and riser.
2 3
ceic_3
1. Upper clamp
2. Clamp split line
3. Alignment mark
17. Tighten the 10 mm bolts to 35 Nm.

18. Refit the 8 mm bolts and tighten to 26 Nm.
19. Recheck the bearing adjustment.
Handlebar - Removal
WARNING


Heated Grip (Left Hand) - Removal
Clutch Lever Assembly - Partial Removal
Front Brake Master Cylinder Assembly - Partial Removal
Left Hand Switch Housing - Removal
Right Hand Switch Housing - Removal
1. With the aid of an assistant, support the handlebar and release the fixings securing the handlebar clamps to the risers. Remove the handlebar clamps.
3 3

2
1 2
B00800
1. Alignment mark
2. Fixings M10
3. Fixings M8
2. Noting it’s orientation, carefully remove the heated grip wiring harness from the handlebar.
3. Remove the handlebar.
Handlebar - Installation
WARNING

Note
Install the heated grip wiring harness with the longer harness to the right hand side and the shorter harness to the left hand side.
1. As noted during removal, refit the heated grip wiring harness to the handlebar.
2. With the aid of an assistant, support the handlebar and refit the clamps to the risers.
3. Align the split line to the marking on the handlebar and tighten the M10 fixing to 35 Nm and then the M8 fixings to 26 Nm.
3 3
2
1 2
B00800
1. Alignment mark
2. Fixings M10
3. Fixings M8

Right Hand Switch Housing - Installation
Left Hand Switch Housing - Installation
Front Brake Master Cylinder Assembly - Partial Installation
Clutch Lever Assembly - Installation
Left Hand Grip - Installation
Left Hand Grip - Removal
WARNING



Note
Note the orientation of the heated grip wires prior to removal of the heated grips.
1. Release the two fixings and remove the heated grips switch housing cover from the left hand grip. Collect the two fixings.
L0734_4
1. Left hand handlebar grip

2. Fixings
3. Heated grip wire
Note
The heated grip switch is an integral part of the heated grip and is not available as a separate assembly.
2. Release the two fixings, collect the washers and remove the heated grip.
2
3
1
L0518
1. Heated grip
2. Heated grip switch
3. Fixings
Left Hand Grip - Installation
WARNING

1. Connect the electrical connector to the grip.

2. Route the heated grip harness as noted during removal.
3. Position the grip onto the handlebar.
4. Fit the two fixings and washers. Tighten the fixings to 3 Nm.

1. Fixings
2. Left hand grip

Rear Suspension
Exploded Views
Exploded View - Rear Suspension Unit

Exploded View - Drop Link and Drag Link
Exploded View - Swinging Arm

Removal and Installation - Rear Suspension Components
Swinging Arm - Removal
WARNING

WARNING
If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid
skin damage, always allow the hot parts to cool before working on the exhaust system.
WARNING
Raise the rear of the motorcycle and support under the frame and engine.
Support the swinging arm to allow for removal of the rear wheel and rear suspension unit.

Silencer Removal
Rear Wheel - Removal
1. Remove the fixings and the upper and lower chain guards.
2. Support the swinging arm and remove the drop link to swinging arm lock nut and bolt. Discard the lock nut.
B00807
1. Drop links
2. Fixing
3. Detach the chain from the output sprocket.
WARNING
Do not allow the caliper to hang on the brake hose as this may damage the hose and could lead to an accident.
4. Release the brake hose clips from the swinging arm and tie the rear brake caliper to one side.

2
B00797
1. Rear brake hose clips

2. Fixings
5. Remove the fixings and the finisher plates from both sides of the frame.
B00796
1. Fixing
2. Finisher plate
6. Remove the swinging arm spindle nut. Discard the nut.

7. Withdraw the swinging arm spindle from the right hand side and remove the swinging arm. Pass the swinging arm through the drive chain.
Note
Support the drive chain while the swinging arm is being removed to protect it from contamination.
Swinging Arm - Disassembly
1. Remove the dust covers from both sides.

2. Remove the bearing sleeves from both sides.
3. Remove the four seals.
4. Use a press or similar to remove the bearings by pushing through from the outside.
1
2
3
4
3
3
4
3
2
1
1. Dust cover
2. Bearing sleeve
3. Seal
5. Remove the three fixings and remove the drive chain rubbing strip assembly. Recover the flanged sleeves for the fixings.
Note
The drive chain rubbing strip can be removed without removing the swinging arm.

2
B00795
1. Drive chain rubbing strip

2. Fixings
6. Release the upper and lower dampers from the rubbing strip.
Swinging Arm - Inspection
1. Check all swinging arm bearings for damage, pitting, and cracks. Replace as necessary.
2. Check the swinging arm for damage. Replace as necessary.
3. Replace all bearing seals.
4. Check the drive chain for wear, damage, etc. Replace as necessary.
5. Check both sprockets for wear, damage, etc. Replace as necessary.
6. Check the drive chain rubbing strip for wear and damage. Replace as necessary.
7. Check the upper and lower dampers for the rubbing strip, for wear and damage. Replace as necessary.
Swinging Arm - Assembly
1. Install the bearings (marked faces outwards), sleeves, new seals and new dust covers into the swinging arm in the reverse order of disassembly.
1
2
3
4
3
3
4
3
2
1
1. Dust cover
2. Bearing sleeve
3. Seal
2. Install the upper and lower dampers into the chain rubbing strip. Make sure that the dampers are correctly located onto all of the attachment pins on the chain rubbing strip.
1 4
4
3
B00798
1. Chain rubbing strip

2. Upper damper
3. Lower damper
4. Attachment pins
3. Install the flanged sleeves into the drive chain rubbing strip, with the wide face against the swinging arm.
4. Fit the drive chain rubbing strip and tighten the fixing to 9 Nm.

2
B00795
1. Drive chain rubbing strip

2. Fixings
5. Fit the drive chain to the output sprocket.
Swinging Arm - Installation
WARNING

1. Position the swinging arm to the frame ensuring the drive chain is in position on the rubbing strip.
2. Refit the swinging arm spindle from the right hand side.
3. Fit a new swinging arm spindle nut and tighten to 110 Nm.
4. Refit the finishers, tightening the fixings to 10 Nm.
B00796
1. Fixing
2. Finisher plate
5. Position the rear caliper and refit the rear brake hose clips to the swinging arm. Tighten the fixings to 5 Nm.
B00797
1. Rear brake hose clips

2. Fixings
6. Position the drop link to the swinging arm.

7. Install the bolt from the right side. Fit a new nut then hold the bolt and tighten the nut to 80 Nm.
8. Install the upper chain guard. Tighten the fixings to 9 Nm.
9. Install the lower chain guard. Tighten the fixings to 7 Nm.
Rear Wheel - Installation
Pump the rear brake pedal several times to position the brake pads in the caliper. Rectify as necessary if correct brake operation is not restored (see Bleeding the Rear
Brakes).

WARNING
Drag Link and Drop Links - Removal
WARNING

WARNING

Raise and support the rear of the motorcycle beneath the frame or engine. Position a block to support the rear wheel.
1. Remove the bolts and lock nuts attaching the drop links to the swinging arm, drag links and rear suspension unit. Discard the lock nuts and remove the drop link plates.
2. Remove the bolt and lock nut securing the drag links to the frame. Discard the lock nut
3. Remove the drag links and recover the bearing sleeve.
4
3
2
3 1 3
B00807_1
1. Drag links
2. Drop links
3. Fixings
4. Rear suspension unit
4. Recover the bearing sleeve from the rear suspension unit.
Drag Link and Drop Links - Inspection
1. Clean all components and inspect the drag link and bearings for damage/wear.
2. Check the rear suspension unit lower bearings for wear.
3. Check the drop link bearings for wear.
4. Renew as necessary.
Drag Link and Drop Links - Installation
WARNING

1. Pack the bearings of the drag links and the rear suspension unit with multi-purpose grease to NLGI 2 specification.
2. Remove the swinging arm drop link bearing sleeve and pack the bearings with multi-purpose grease to NLGI 2 specification. Refit the sleeve.
3. Refit the drag links and the bearing sleeve into the frame. Install the bolt from the right side.
4. Align the drag links with the rear suspension unit and install the bearing sleeve.
5. Assemble the bolt and drop link plates onto the drag links and rear suspension unit. Install the bolt from the right side.
6. Fit new nuts and tighten to 80 Nm.
7. Align the drop link plates with the swinging arm pivot. Install the bolts from the right side.
8. Fit new a nut and tighten to 80 Nm.
Rear Suspension Unit - Removal

WARNING

WARNING

Raise and support the rear of the motorcycle under the frame or engine. Position a block to support the rear wheel.
1. Remove the drag link to rear suspension unit fixing. Discard the nut.
2. Remove the sleeve from the drag links and rear suspension unit to release the drag links.
3. Reposition the drop link plates and position the drag links clear of the rear suspension unit.
4
3
2
3 1 3
B00807_1
1. Drag links
2. Drop links
3. Fixings
4. Remove the plastic blanking plug that covers the upper fixing for the rear suspension unit.
1 2
B00808
1. Blanking plug
2. Rear suspension unit top fixing
WARNING
Never attempt to disassemble the rear suspension unit or remote reservoir. It contains fluid under pressure and serious injury could result if any part of the system is
disturbed.
5. Remove the upper mounting nut and bolt that attaches the rear suspension unit.
6. Use T3880104 - Swinging Arm Adjuster Wrench to loosen the frame adjuster for the rear suspension unit.
7. Manoeuvre the unit downwards through the swinging arm and clear of the motorcycle.
Rear Suspension Unit - Installation
WARNING

1. Pack the drag link bearings with multi-purpose grease to NLGI 2 specification.

2. Refit the rear suspension unit to the motorcycle by raising the unit upwards through the hole in the swinging arm.
3. Locate the drag links to the rear suspension unit and refit the sleeve.
4. Locate the rear suspension unit and insert the upper mounting bolt from the left side to hold the rear suspension unit.
5. At the right side, use T3880104 - Swinging Arm Adjuster Wrench to tighten the frame adjuster to 10 Nm.
6. Fit the washer and loosely fit a new nut.
7. Reposition the drop link plates and, from the right hand side, loosely fit the bolt and a new nut.
4
3
2
3 1 3
B00807_1
1. Drag link
2. Drop links
3. Fixings
8. Tighten the drag link to rear suspension unit fixing to 80 Nm.

9. With the weight of the motorcycle on its wheels, tighten the rear suspension unit upper mounting to 60 Nm.
10. Refit the plastic blanking plugs at the left and right sides that cover the rear suspension unit upper mounting fixing.
Brakes
Exploded Views
Exploded View - Front Brake Caliper

Exploded View - Front Brake Master Cylinder
Exploded View - Rear Brake Caliper

Exploded View - Rear Brake Master Cylinder

Exploded View - ABS System
Braking System Maintenance and Safety
Braking System Maintenance Safety Precautions
WARNING
Brake fluid is hygroscopic which means it will absorb moisture from the air. The absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction
in braking efficiency.
Replace brake fluid in line with the scheduled maintenance chart. A dangerous riding condition could result if this important maintenance item is neglected.
Do not spill brake fluid onto any area of the bodywork as this will damage any painted or plastic surface.
Always use new brake fluid from a sealed container and never use fluid from an unsealed container or from one which has been previously opened.
Do not mix different brands of fluid. Check for fluid leakage around brake fittings, seals and joints.
Check regularly for brake hose damage.
FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING EFFICIENCY LEADING TO AN ACCIDENT.
WARNING
If there has been an appreciable drop in the level of the fluid in either brake fluid reservoir, consult your authorised Triumph dealer for advice before riding.
If the brake lever or pedal feels soft when it is applied, or if the lever/pedal travel becomes excessive, there may be air in the brake lines or the brake may be defective.
It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph dealer before riding the motorcycle. Failure
to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
WARNING

WARNING
General Information section may reduce the efficiency of the braking system leading to an accident.
Failure to change the brake fluid at the interval specified in the scheduled maintenance chart may reduce braking efficiency leading to loss of motorcycle control and an
accident.
WARNING
Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible.
Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may
reduce braking efficiency leading to loss of motorcycle control and an accident.
WARNING
A magnetised brake disc and/or a magnetised ABS pulser ring may cause problems with the ABS sensor which will illuminate the ABS warning light and disable the ABS.
To prevent these parts becoming magnetised, we strongly recommend that magnets, and items that contain magnets, must not be stored near or placed on brake discs or
ABS pulser rings.
This includes parts fitted to motorcycles, parts removed during motorcycle service and new parts in dealer stores.
Examples of items that may contain magnets, are listed below:
∙Alternator rotor
∙Magnetic fuel tank bags
∙Audio speakers
∙Magnetic dial test indicator stand
∙Magnetic parts tray.
If the ABS is not functioning, the brake system will continue to function as a non-ABS braking system. Do not continue to ride for longer than is necessary with the indicator
light illuminated. Ride with extreme caution when performing diagnostic troubleshooting on a non-functioning ABS system. In this situation braking too hard will cause the
wheels to lock resulting in loss of motorcycle control and an accident.
Brake Pads Wear
Front and rear brake pad wear is automatically compensated for and has no effect on brake lever or pedal action.
Front Brake Discs - Wear
WARNING

Wear
1. Replace any brake disc if it is worn beyond the service limit or exceeds the disc run-out limit.
Front Brake Disc Thickness
Standard 4.5 mm
Front Brake Disc Run-out
Service Limit: 0.15 mm max.
Measure disc run out using an accurate dial gauge mounted on a surface plate.
1. Disc
2. Dial gauge

Rear Brake Disc - Wear
WARNING

1. Replace any brake disc worn beyond the service limit or that exceeds the disc run-out limit.
Rear Brake Disc Thickness
Standard 5.5 mm
Rear Brake Disc Run-out
Service Limit 0.5 mm max.
Measure brake disc run-out using an accurate dial gauge mounted on a surface plate.
1
2
ciaq
1. Disc
2. Dial gauge
Breaking-in New Brake Pads and Discs
After replacement brake discs and/or pads have been fitted to the motorcycle, we recommend a period of careful breaking-in that will optimise the performance and longevity of
the discs and pads. The recommended distance for breaking in new pads and discs is 200 miles (300 km).
After fitting new brake discs and/or pads avoid extreme braking, ride with caution and allow for greater braking distances during the breaking-in period.
Bleeding the Front Brakes
Brake Fluid Replacement - Routine Maintenance
Braking performance reduces as brake fluid ages, Repeated stops cause brake fluid to heat and cool rapidly reducing braking performance.
Brake fluid absorbs moisture over a period of time and becomes contaminated as it ages.
Therefore brake fluid should be replaced at specified intervals as instructed in the routine maintenance schedule, see Brake Fluid - Renew.
Brake Bleeding
When removing or replacing brake components and the brake line is opened air will enter as fluid escapes.
If the brake bleed procedure is not carried out air can become trapped in the brake fluid.
A consequence of air being trapped in the brake system is that the brake can feel soft/spongy and the performance of the brakes will be reduced.
WARNING
Brake fluid is hygroscopic which means it will absorb moisture from the air.
Only use new DOT 4 brake fluid from a sealed container, do not mix different brands of brake fluid and never use brake fluid from an unsealed container or from one that
has been previously opened.
Any absorbed moisture will greatly reduce the boiling point of the brake fluid.
Moisture in the braking system may a cause a reduction in braking efficiency leading to loss of motorcycle control and an accident.
WARNING
Do not allow dirt or debris to enter the braking system when adding brake fluid to the brake fluid reservoir.
Always maintain absolute cleanliness as this will adversely affect the brake fluid's properties.
Contaminated brake fluid may cause a reduction in brake performance leading to loss of motorcycle control and an accident.
WARNING
During bleeding, do not allow the brake fluid level to fall below the lower level mark in the reservoir.
If the fluid level is allowed to fall below this mark, air may enter the system and the sequence of bleeding must be repeated.

WARNING
Trapped air in the braking system may a cause a reduction in braking efficiency leading to loss of motorcycle control and an accident.
WARNING
Check for fluid leakage around brake fittings, seals and joints.
Leaks around fittings and joints may allow air to enter the brake system.
Air entering the braking system may a cause a reduction in braking efficiency leading to loss of motorcycle control and an accident.
CAUTION
Do not attempt to maintain brake fluid pressure by securing the brake lever to the handlebar or the brake pedal using a band or strap.
Banding or strapping the brake lever or pedal may deform the piston seals in the caliper.
Lever or pedal travel that is increased or reduced may a cause a reduction in braking efficiency leading to loss of motorcycle control and an accident.
CAUTION
To prevent paint damage, do not spill brake fluid onto any area of the bodywork.
Close the brake reservoir and wash any spilled brake fluid immediately with warm soapy water.
Spilled brake fluid, if left, will damage painted and plastic surfaces.
CAUTION
Pressure applied to the brake lever or caliper pistons during the bleeding 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 follow these instructions can allow air to be drawn in to the system through the bleed screw threads.
Note
An additional technician is required to monitor the fluid level and operate the brake lever or pedal when bleeding the brakes.
The following table indicates the procedure to follow when carrying out repairs or replacement of the following brake components.
Brake Bleed Procedure Table
When Bleed the brakes as follows:

replacing/fitting
the
ABS Modulator Front Brake Fluid Back bleed Brake master Bleed brake Final bleed Brake caliper Front Brake Brake Fluid
Brake Cap master cylinder caliper(s) procedure conditioning Lever Setting Cap
Lever Removal cylinder bleed1 Installation
Setting
Master Cylinder Front Brake Fluid Back bleed Brake master Final bleed Brake caliper Front Brake Brake Fluid -
Brake Cap master cylinder procedure conditioning Lever Setting Cap
Lever Removal cylinder bleed1 Installation
Setting
Brake Caliper(s) Front Brake Fluid Bleed brake Final bleed Brake caliper Front Brake Brake Fluid - -
Brake Cap caliper(s) procedure conditioning Lever Setting Cap
Lever Removal Installation
Setting
Brake Front Brake Fluid Brake master Bleed brake Final bleed Brake caliper Front Brake Brake Fluid -
Hose/line(s) Brake Cap cylinder caliper(s) procedure conditioning Lever Setting Cap
Lever Removal bleed1 Installation
Setting
1 For models with a front brake master cylinder bleed screw only.
Front Brake Lever Setting
1. Note the number of clicks required to turn the lever span adjuster fully clockwise.
1 2

B00566
1. Span adjuster
2. Brake lever
2. When the bleeding operation is complete, reset the brake lever adjuster to the rider's preferred setting as noted prior to setting the maximum adjustment.
Front Brake Fluid Cap Removal
1. Screws

Master Cylinder Back Bleed
CAUTION
When disconnecting the brake hose from the master cylinder it is necessary to keep the open end of the hose above the handlebars.
Allowing the brake hose to fall below the handlebar height will allow an excessive amount of air to enter into the brake system.
Trapped air may cause the brake lever to feel spongy and contribute to reduced braking efficiency.
Note
When back bleeding the master cylinder it is only necessary to remove one brake caliper.
1. Remove the caliper mounting fixings and slide the caliper off the disc.
B00943_1
1. Caliper mounting fixings

2. Caliper
3. Attach a transparent tube to the caliper bleed screw.

B00950
1. Bleed screw
2. Bleed tube
3. Container
4. Place the other end of the tube in a suitable container that contains new brake fluid. Keep the tube end below the level of fluid.
WARNING
Make sure no damage is made to the brake pad material when moving the brake pads.
Allowing the brake pads to come into contact with each other or sharp objects may cause the material to crack or break.
Damage to the brake pads may result in reduced braking efficiency leading to loss of motorcycle control and an accident.
5. Using a suitable flat metal plate approximately 2 mm thick and 30 to 50 mm wide (for example a gasket scraper) between the brake pads, pump the front brake lever slowly
until the plate is held by the brake pads. Do not allow the pistons to fall out.
6. Pump the brake lever slowly to pump the caliper pistons out to allow a reasonable amount of travel. Do not allow the pistons to fall out.
7. Depress the brake lever to the handlebar. This will make sure that the reservoir port is closed and brake fluid flows to the bleed screw and not the reservoir.
8. Being careful not to damage the brake pad material, use the metal plate against the brake pads to push the caliper pistons in evenly and apply pressure to the system.
Note
The master cylinder bleed screw should only be opened by a small angle, just enough to allow system pressure to drop. When pulling the brake lever or
pushing the caliper pistons in, some resistance should be felt indicating that the screw is not opened too much.
WARNING
9. Open the master cylinder bleed screw slightly to let fluid flow but still feel resistance to pushing the caliper pistons in.
10. With pressure still applied in the caliper, close the bleed screw.
11. Repeat steps 9 and 10 until no more air appears in the bleed tube.
12. Tighten the bleed screw to 10 Nm.
13. Refit the front brake caliper (see Front Brake Caliper - Installation).
Front Master Cylinder Bleed
1. Remove the rubber cap from the bleed screw on the master cylinder.
B00950
1. Bleed screw
2. Bleed tube
3. Container
3. Place the other end of the tube in a suitable container that contains new brake fluid.
4. Slowly apply then slowly release pressure to the brake lever five times, maintaining pressure on the final application.
Note
5. Open the bleed screw slightly.
6. Apply pressure to the brake lever and close the bleed screw once the lever has come to a stop against the handlebar.
7. Slowly apply and slowly release pressure to the brake lever another five times, maintaining pressure on the final application.
8. Open the bleed screw slightly to allow fluid to flow out but to still feel resistance in the brake lever.
9. Leave the bleed screw slightly open and slowly release the brake lever.
10. Slowly apply and release pressure to the brake lever another five times, closing the bleed screw on the final application.
11. Repeat steps 4 to 10 until no more air appears in the bleed tube.
12. With the brake lever still under pressure, tighten the master cylinder bleed screw as specified in the Service Manual.
13. Remove the transparent bleed tube.
14. Refit the bleed screw cap.
Front Brake Caliper Bleed

1
2
3
B00941
1. Bleed screw
2. Bleed tube
3. Container

3. Place the other end of the tube in a suitable receptacle containing new brake fluid.
Note
4. Slowly apply and slowly release pressure to the brake lever five times, maintaining pressure on the final application.
5. Counter hold the brake hose union bolt and open the bleed screw slightly to allow fluid to flow out but to still feel resistance in the brake lever.
6. Counter hold the brake hose union bolt and close the bleed screw.
7. Slowly apply and slowly release pressure to the brake lever another five times, maintaining pressure on the final application.
8. Counter hold the brake hose union bolt and open the bleed screw slightly to allow fluid to flow out but to still feel resistance in the brake lever.
9. Leave the bleed screw slightly open and slowly release the brake lever.
10. Slowly apply and slowly release pressure to the brake lever five times.
11. Counter hold the brake hose union bolt and close the bleed screw.
12. Repeat steps 4 to 11 until no more air appears in the bleed tube.
13. With pressure to the brake lever still applied, counter hold the brake hose union bolt and tighten the bleed screw to the 10 Nm.
15. Repeat the front brake caliper bleed for the left hand caliper.
Final Bleed Procedure
1. Repeat the bleed procedure as detailed in Front Brake Caliper Bleed.

2. If brake lever travel is unacceptably high, repeat Front Master Cylinder Bleed.
3. If the brake lever travel is acceptable, refit the front brake reservoir cover and tighten the screws to 0.7 Nm.
WARNING
Always return the lever adjuster to the original setting. Operating the motorcycle with lever settings which are unfamiliar may lead to loss of control or an accident.
4. Check that the brakes operate correctly. Rectify as necessary.
WARNING
It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you ride the motorcycle again.
Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.
Front Brake Caliper Conditioning
WARNING
1. On the right hand side caliper, using a suitable tool, push the caliper pistons 1-2 mm into the caliper body by forcing the brake pads apart.

B00943_2
2. Complete the piston movement for the other piston pair within the same caliper.
3. Operate the brake lever to pump the pistons back out until the brake pads come into contact with the brake disc.
4. Repeat steps 1 to 3 on the same caliper until the pistons have been pushed in and out three times.
5. Repeat steps 1 to 4 on the left hand side caliper.
6. Slowly apply front brake lever to the handlebar and maintain that pressure for approximately five seconds. Slowly release the lever, and leave for 30 seconds. Repeat three
times.
Brake Fluid Cap - Installation
1. Fit the diaphragm to the reservoir cap. Make sure the holes for the fixings are correctly aligned.
WARNING
Do not over tighten the brake reservoir cap fixings

Over tightening the master cylinder reservoir fixings may damage the diaphragm, cap or reservoir.
Damage to the brake fluid reservoir may result in loss of brake fluid, reduced braking efficiency leading to loss of motorcycle control and an accident.
1. Reservoir cap fixings

2. Reservoir upper level
3. Reservoir lower level
2. Tighten the fixings to 0.7 Nm.
Bleeding the Rear Brakes
Brake Light Switches
Brake Fluid Replacement - Routine Maintenance
Braking performance reduces as brake fluid ages, Repeated stops cause brake fluid to heat and cool rapidly reducing braking performance.
Brake fluid absorbs moisture over a period of time and becomes contaminated as it ages.
Therefore brake fluid should be replaced at specified intervals as instructed in the routine maintenance schedule, see Brake Fluid - Renew.
Brake Bleeding
When removing or replacing brake components and the brake line is opened air will enter as fluid escapes.
If the brake bleed procedure is not carried out air can become trapped in the brake fluid.
A consequence of air being trapped in the brake system is that the brake can feel soft/spongy and the performance of the brakes will be reduced.
WARNING

WARNING
Brake fluid is hygroscopic which means it will absorb moisture from the air.
Only use new DOT 4 brake fluid from a sealed container, do not mix different brands of brake fluid and never use brake fluid from an unsealed container or from one that
has been previously opened.
Any absorbed moisture will greatly reduce the boiling point of the brake fluid.
Moisture in the braking system may a cause a reduction in braking efficiency leading to loss of motorcycle control and an accident.
WARNING
Do not allow dirt or debris to enter the braking system when adding brake fluid to the brake fluid reservoir.
Always maintain absolute cleanliness as this will adversely affect the brake fluid's properties.
Contaminated brake fluid may cause a reduction in brake performance leading to loss of motorcycle control and an accident.
WARNING

WARNING
WARNING
Check for fluid leakage around brake fittings, seals and joints.
Leaks around fittings and joints may allow air to enter the brake system.
Air entering the braking system may a cause a reduction in braking efficiency leading to loss of motorcycle control and an accident.
CAUTION
Do not attempt to maintain brake fluid pressure by securing the brake lever to the handlebar or the brake pedal using a band or strap.
Banding or strapping the brake lever or pedal may deform the piston seals in the caliper.
Lever or pedal travel that is increased or reduced may a cause a reduction in braking efficiency leading to loss of motorcycle control and an accident.
CAUTION
CAUTION
Pressure applied to the brake lever or caliper pistons during the bleeding 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 follow these instructions can allow air to be drawn in to the system through the bleed screw threads.
Note
An additional technician is required to monitor the fluid level and operate the brake lever or pedal when bleeding the brakes.
Note
Always renew the brake fluid at the interval specified in the routine maintenance schedule.
The following table indicates the procedure to follow when carrying out repairs or replacement of the following brake components.
Rear Brake Bleed Procedure Table
When replacing/fitting Bleed the brakes as follows:

the
ABS Modulator Brake Fluid Cap Back bleed master Bleed brake Final bleed procedure Brake caliper Brake Fluid Cap
Removal cylinder caliper(s) conditioning Installation
Master Cylinder Brake Fluid Cap Back bleed master Bleed brake Final bleed procedure Brake caliper Brake Fluid Cap
Brake Caliper(s) Brake Fluid Cap Bleed brake caliper(s) Final bleed Brake caliper Brake Fluid Cap -
Removal procedure conditioning Installation
Brake Hose/line(s) Brake Fluid Cap Back bleed master Bleed brake Final bleed procedure Brake caliper Brake Fluid Cap
Brake Fluid Cap Removal
1. Remove the fixings and the rear brake reservoir cover, taking care not to spill any fluid.
2. Carefully remove the diaphragm seal.
3. Check the condition of the diaphragm seal. Replace if necessary.

1. Rear reservoir cover fixings
Rear Brake Master Cylinder Back Bleed

CAUTION
When disconnecting the brake hose from the master cylinder it is necessary to keep the open end of the hose above the height of the rear brake master cylinder.
Allowing the brake hose to fall below the rear brake master cylinder height will allow an excessive amount of air to enter into the brake system.
Trapped air may cause the brake lever to feel spongy and contribute to reduced braking efficiency.
1. Release the fixing and remove the rear ABS wheel speed sensor. Collect the shim from between the sensor and rear caliper carrier and discard the fixing.
2
B00939 1
1. Rear ABS wheel speed sensor

2. Fixing
3. Shim
4. Bleed screw cover
2. Release the cable for the sensor from the bleed screw cover.
Note
Note the position of the rear brake caliper for installation.
3. Remove the brake caliper and carrier assembly.
3 2
1
B00803 4
1. Caliper and carrier assembly

2. Caliper carrier boss
3. Swinging arm slot
4. Swinging arm
WARNING
4. Using a suitable flat metal plate approximately 2 mm thick and 30 to 50 mm wide (for example a gasket scraper) between the brake pads, pump the rear brake pedal slowly
until the plate is held by the brake pads. Do not allow the pistons to fall out.
5. Depress the brake pedal to its stop. This will ensure the reservoir port is closed and brake fluid flows to the fluid reservoir.
6. Being careful not to damage the brake pad material, use the metal plate against the brake pads to push the caliper pistons in evenly.
7. Push the pistons into the caliper to apply pressure to the system.
8. Position the caliper and carrier assembly to the swinging arm as noted for removal. Align the boss on the carrier with the slot on the swinging arm.

3 2
1
B00803 4

4. Swinging arm
9. Position the wheel speed sensor to the caliper carrier with its shim between the sensor and caliper carrier. Fit a new bolt and tighten to 9 Nm.
2
B00939 1

2. Fixing
3. Shim
10. Retain the cable for the sensor with the bleed screw cover.
Rear Brake Caliper Bleed
1. Remove the rubber cap from the caliper bleed screw.

3. Place the other end of the tube in a suitable container containing new brake fluid.
B00802
1. Bleed screw
2. Spanner
3. Bleed tube
Note
The bleed screw should only be opened by a small angle, just enough to allow system pressure to drop. When pulling the brake pedal or pushing the caliper
4. Slowly apply and slowly release pressure to the brake pedal five times, maintaining pressure on the final application.
5. Open the bleed screw slightly to allow fluid to flow out but to still feel resistance in the brake pedal.
6. Close the bleed screw.
7. Slowly apply and slowly release pressure to the brake pedal five times, maintaining pressure on the final application.
8. Open the bleed screw slightly to allow fluid to flow out but to still feel resistance in the brake pedal.
9. Leave the bleed screw slightly open and slowly release the brake pedal.
10. Slowly apply and slowly release pressure to the brake pedal five times.

11. Close the bleed screw.
12. Repeat steps 4 to 11 until no more air appears in the bleed tube/container.
13. With the brake pedal still applied tighten the bleed screw to 14 Nm.
Rear Brake Final Bleed Procedure
1. Repeat the bleed procedure as detailed in Rear Brake Caliper Bleed C*7.
2. If brake pedal travel is unacceptably high, bleed the rear brake as detailed in Rear Brake Master Cylinder Back Bleed C*7.
3. If brake pedal travel is acceptable, refit the rear brake reservoir cover.
Brake Caliper Conditioning
1. Using a suitable tool, push the rear brake caliper pistons 1-2 mm into the caliper body by forcing the brake pads apart.
chzr_2
1. Brake pads
2. Operate the brake pedal to pump the pistons back out until the brake pads come into contact with the brake disc.
3. Repeat steps 1 and 2 on the caliper until the pistons have been pushed in and out three times.
4. Slowly apply the rear brake pedal to the stop and maintain that pressure for approximately five seconds. Slowly release the pedal, and leave for 30 seconds. Repeat three
times.
Brake Fluid Cap Installation
CAUTION
1. Check that the brake fluid level is at the upper level line on the reservoir body. Adjust the level if necessary.
2. Check the condition of the brake fluid cap sealing diaphragm. Replace the diaphragm as necessary.
3. Refit the rear brake reservoir cap and fixings. Tighten the fixings to 1 Nm.
1. Rear reservoir cover fixings

WARNING
The front and rear brake light switches are an integral part of the cruise control system. To ensure the brake light switches and brake light functions correctly after a
replacement of adjustment, the cruise control switch test must be carried out as described in Cruise Control Switch Check.
Failure to carry out a cruise control switch test may result in loss of motorcycle control and an accident.
The front brake light switch is an integral part of the right hand switch housing. If the front brake light switch requires replacement, the right hand switch housing and brake light
switch assembly must be replaced.
For the removal and installation of the rear brake light switch see Rear Brake Light Pressure Switch - Removal and Rear Brake Light Pressure Switch - Installation.
Air Gap Measurement - Front and Rear ABS Wheel Speed Sensors

WARNING

1. Using feeler gauges, measure the air gap between the wheel speed sensor and the ABS pulser ring.
1. ABS wheel speed sensor

2. Shim
3. ABS pulser ring
4. Fixing
2. Rotate the wheel and repeat the measurement in several places to ensure the ABS pulser ring is not distorted or bent. Renew a damaged ABS pulser ring.
3. Adjust the air gap using the correct shim(s) to achieve an air gap between 0.1 - 1.5 mm.
Note
Shims are available in the following sizes: 0.5 mm, 1.0 mm, 1.5 mm and 2.0 mm.
Do not install more than two shims. If the required air gap cannot be achieved using two shims, investigate and rectify the cause before proceeding.
4. If necessary, remove the wheel speed sensor, fit the correct thickness shim(s) and refit the wheel speed sensor.
5. If removed, install a new fixing and tighten to 9 Nm.
6. Repeat the air gap measurement. Re-adjust as necessary.
Changing Brake Fluid
Brake fluid must be changed every two calendar years, irrespective of the mileage the motorcycle has covered in that time.
Anti-lock Brake System (ABS) Management
ABS System Description
This model is fitted with an electronic anti-lock brake system (ABS) which is designed to prevent the wheels from locking or skidding by reducing braking effort to the front or
rear brake caliper when wheel-lock is detected.
The system consists of a hydraulic modulator and ECM assembly mounted to a bracket located on the frame, under the front of the fuel tank, a front wheel speed sensor
mounted to the front fork, and a rear wheel speed sensor mounted to the rear brake caliper carrier.
Both front and rear wheels have a pulser ring. The front pulser ring is mounted onto the front left brake disc, and the rear mounted to the rear brake disc.
The front and rear master cylinders are connected via lines to the modulator and from the modulator the pipes connect to the brake calipers.
The front and rear brake circuits operate as separate systems. The front and rear brakes are not connected in any way inside the modulator.
The modulator ECM continuously calculates the front and rear wheel speeds, and from these inputs the ECM calculates the estimated motorcycle speed, wheel
deceleration/acceleration, the wheel speed difference and the wheel slip (skid) rate. This is calculated by comparing the calculated wheel speeds with the calculated vehicle
speed, so that if one wheel speed deviates significantly from the other two readings, this wheel is determined to be skidding.
Under braking, if the modulator detects that either wheel is about to slip, due to the brake force exceeding the available traction between the tyre and road surface (the wheel
will begin to slip or skid), the ECM very rapidly releases and re-applies the brake pressure to prevent the wheel from skidding.
This is felt through the brake pedal or lever as a rapid pulsing.
If the rider reduces braking effort, or traction increases (so that traction exceeds braking force, the wheel will rotate once more) the wheel will no longer lock up. The ABS
system will detect this and stop controlling brake pressure, and return to its monitoring state.
The system has a self diagnostic function built-in which monitors the fail safe relay, solenoid valves, motor relay, wheel speed sensors, power supply and ground, as well as
internal ECM functions. In the event of a malfunction being detected, the ECM will illuminate the ABS warning light, and store a diagnostic trouble code in the system memory.
This stored data can then be recovered using a special service tool which is mandatory for all Triumph dealers. In this way, precise diagnosis of a fault can be made and the
fault quickly rectified.
Under normal operation, the ABS warning light will flash on and off after ignition on until the vehicle speed exceeds 6 mph (10 km/h). If a trouble code is stored the ABS
warning light will stay illuminated and the ABS will not function, however the brakes will operate normally. If the ABS warning light does not extinguish, or illuminates whilst the
motorcycle is being ridden, refer to the ABS system diagnostics (see System Diagnostics).
ABS Hydraulic Circuit Layout

Diagnostics and Testing
ABS System - Component Location
3 2
1. ABS Modulator
2. Front Wheel Speed Sensor
3. Front Pulser Ring
1 2
4 3
1. Rear Brake Switch

2. Front Brake Switch
3. Rear Pulser Ring
4. Rear Wheel Speed Sensor
System Diagnostics

The ABS system has an on-board diagnostics feature which allows service technicians to retrieve stored data from the ECM using Triumph diagnostic software. Full details of
the Triumph diagnostic software operation and how to interpret the results are given in the Triumph Diagnostic Tool User Guide.
Triumph Diagnostic Tool
Described on the following pages is the range of information which can be retrieved from the ABS modulator's memory and the adjustments, which can be performed using the
Triumph diagnostic software.
Note
Build Data
Function Examined
ECM type
ECM ID number
Software version number
Current Data
The Current Data screen will display the following information:
Function Examined Result Reported (Scale)
Front wheel speed km/h
Rear wheel speed km/h
Brake switch status On/Off
ABS warning light status On/Off
Bleed System
Note
There is no specific ABS modulator bleed procedure. The ABS modulator bleed is part of the front and rear brake system bleed procedures. Full details of these
procedures are provided in Bleeding the Front Brakes for front brakes or Bleeding the Rear Brakes for rear brakes.
Dependent on the DTC stored, the ABS ECM will act in one of two ways:
Inhibit ABS operation immediately, irrespective of the ABS operating mode
or
Allow the ABS operation to complete before inhibiting the ABS.
Once the ABS ECM has inhibited ABS function, the ECM will act in one of three ways:
Allow the ABS to resume operation if the fault clears
or
Allow ABS operation after an ignition cycle if the fault clears
or
Inhibit the ABS function until the fault is rectified and the DTC erased.
The ABS system will act on the DTC stored according to the tables on the following pages:
Fault Description ABS warning light ABS operation is ABS continues to ABS will resume operation if fault clears
illuminated when fault inhibited when fault operate when fault is
is logged is logged logged
(Only when ABS is
active. When ABS is no
longer active, operation
is inhibited)
Front wheel sensor short circuit to ground or Yes Yes - No

open circuit
Front wheel sensor abnormal input or Yes Yes Yes Yes, if after ignition cycle, no fault is
dropping out detected. DTC remains stored
Rear wheel sensor short circuit to ground or Yes Yes - No

open circuit

Fault Description ABS warning light ABS operation is ABS continues to operate ABS will resume operation if fault clears
illuminated when fault inhibited when fault when fault is logged
is logged is logged (Only when ABS is
active. When ABS is no
longer active, operation
is inhibited)
Rear wheel sensor abnormal input or Yes Yes Yes Yes, if after ignition cycle, no fault is
dropping out detected. DTC remains stored
Front wheel pulser gear missing teeth Yes - Yes Yes, if after ignition cycle, no fault is
detected for 1 second and speed exceeds
30 km/h. DTC remains stored
Rear wheel pulser gear missing teeth Yes - Yes Yes, if after ignition cycle, no fault is
detected for 1 second and speed exceeds
30 km/h. DTC remains stored
Front wheel input solenoid short circuit to Yes Yes - No

ground or open circuit
Front wheel output solenoid short circuit to Yes - Yes No

Rear wheel input solenoid short circuit to Yes Yes - No

Rear wheel output solenoid short circuit to Yes - Yes No

Front wheel speed signal error; simulated Yes - Yes Yes, if after ignition cycle, no fault is
wheel lock detected. DTC remains stored
Rear wheel speed signal error; simulated Yes - Yes Yes, if after ignition cycle, no fault is
wheel lock detected. DTC remains stored
Motor - Lock Yes - Yes No
Motor - Stick at OFF Yes - Yes No
Motor - Stick at ON Yes - Yes No
Solenoid relay - Stick at OFF and ON Yes Yes - No
Power source Voltage drop Yes, light will Yes - Yes, if Voltage rises above a preset
extinguish if fault threshold for more than 10 seconds
clears
Power source Voltage rise Yes, light will Yes - Yes, if Voltage drops below a preset
extinguish if fault threshold for more than 10 seconds
clears
Different tyre diameter Yes Yes - No
Abnormal ECU Yes Yes - No
Diagnostic Trouble Codes - List
Diagnostic trouble codes (DTCs) are logged in the ABS ECM memory when there is a confirmed fault in the system.
The codes are reported to the Triumph diagnostic tool as a four digit code.
DTCs can be removed at any time using the Triumph diagnostic tool.
The system will log the diagnostic trouble codes listed below:
Diagnostic Trouble Code Fault Description Pinpoint test location

(DTC)
- ABS Warning Light ON (No DTCs Stored) ABS Warning Light ON (No DTCs Stored)
- ABS Warning Light Does Not Illuminate (No DTCs Stored) ABS Warning Light Does Not Illuminate (No DTCs
Stored)
C1611 Front wheel sensor short circuit to ground or open circuit Front Wheel Sensor Open Circuit/Short Circuit
C1612 Front wheel sensor abnormal input or dropping out Front Wheel Sensor Abnormal Input/losing Contact
C1613 Rear wheel sensor short circuit to ground or open circuit Rear Wheel Sensor Open Circuit/Short Circuit
C1614 Rear wheel sensor abnormal input or dropping out Rear Wheel Sensor Abnormal Input/Losing Contact
C1621 Front wheel pulser gear missing teeth Front Wheel Pulser Ring Missing Teeth

C1623 Rear wheel pulser gear missing teeth Rear Wheel Pulser Ring Missing Teeth
C1631 Front wheel input solenoid short circuit to ground or open circuit Front or Rear Input/Output solenoid Open/Short
Circuit
C1632 Front wheel output solenoid short circuit to ground or open circuit
C1633 Rear wheel input solenoid short circuit to ground or open circuit
C1634 Rear wheel output solenoid short circuit to ground or open circuit
C1641 Front wheel speed signal error; simulated wheel lock Wheel Speed Signal Error; Simulated Wheel Lock
C1643 Rear wheel speed signal error; simulated wheel lock
C1651 Motor - Lock Motor - Lock; Motor Does Not Run; Motor Runs
Continually
C1652 Motor does not run
C1653 Motor runs continually
C1661 Power source Voltage drop Power Source Voltage Drop/Voltage Rise
C1662 Power source Voltage rise
C1671 Different tyre diameter Different Tyre Diameter
C1681 Abnormal ECU Abnormal ECU
C1682 CAN fault - lost communication with engine ECM CAN Fault
C1683 CAN fault - lost communication with instrument panel
C1684 CAN lost fault - all communication
C1692 Modulator output (wheel) pressure sensor malfunction Modulator output (wheel) pressure sensor
malfunction
C1700 EEPROM error ABS Variant Coding Error
C1701 Sensor box internal error
C1702 Sensor box internal error
C1703 Yaw rate internal error
ABS Electrical Connectors
Note
A major cause of hidden electrical faults can be traced to faulty electrical connectors.
For example:
Damp terminals
Broken or bent cable pins within multiplugs.
For example, the ABS electronic control module (ABS ECM) relies on the supply of accurate information to enable it to monitor and control the brake system. One dirty terminal
will cause an excessive voltage drop resulting in an incorrect signal to the ECM.
Before Disconnection:
If testing with a voltmeter, the voltage across a connector battery supply and ground pins should be virtually battery volts with a small deviation allowable for usual voltage
drop within wiring circuits. If there is a noticeable change, suspect faulty/dirty connections. Refer to the ABS circuit diagram within this Service Manual for pin numbers.
Check for a security device that must be released before the connector can be separated e.g. barb, hook and eye etc.
Check that the individual pins have not been bent.

Check for dampness/dirt/corrosion.
Check cables for security.

Ensure there is no dirt around the connector/seal.

Push together squarely to ensure terminals are not bent or incorrectly located.
Disconnection of ABS ECM Connector
CAUTION
CAUTION
Never disconnect the ABS ECM when the ignition switch is in the ON position as this may cause multiple fault codes to be logged in the ECM memory.
1. Press the locking device and move the lever to the rear of the connector while disconnecting it from the ABS ECM.
2. When disconnected, ensure the lever is fully to the rear of the connector. An audible click can be heard when it is locked in position.
1
2
cjec
3
1. ABS modulator (shown removed for clarity)

2. Connector
3. Locking device
4. Lever
CAUTION
The ABS ECM is an integral part of the ABS modulator. Under no circumstances should the ECM be removed from the ABS modulator. If a new ECM is required, repair is
by replacement of the ABS modulator and ECM as an assembly only.
Reconnection of the ABS ECM Connector
CAUTION
CAUTION
If the lever is not fully over to the rear position, it is possible that the connector may not fully engage into its socket.
1. Ensure the lever on the connector is fully over to the unlocked position, as shown below:
ciar
1. Lever
2. Connector
2. Align the connector to its socket on the ABS modulator such that the end of the lever aligns with the lug on the socket.

1
cjfb
1. Lever end
2. Lug
3. Release the lever by pushing it towards the front of the connector. At the same time, push the connector into its socket until the lever is fully forward and locked in position.
An audible click can be heard when locked.
1
2
cjec
3
1. ABS modulator (shown removed for clarity)

2. Connector
3. Locking device
4. Lever
Pinpoint Tests
Before starting pinpoint tests
1. Delete the stored DTCs.

2. Switch the ignition OFF and ON.
WARNING
3. Ride the motorcycle at a road speed in excess of 30 km/h. If the DTC is repeated proceed to the relevant pinpoint test.
4. If the DTC is not repeated this indicates the DTC may have been stored due to external influences such as bad road surfaces or electrical interference.
After completion of the pinpoint tests

3. Ride the motorcycle at a road speed in excess of 30 km/h. If the DTC is repeated proceed to the relevant pinpoint test.
4. If a DTC is stored there is a further fault. Read the stored DTC and refer to the relevant pinpoint test.
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:

WARNING
3. Ride the motorcycle at a road speed in excess of 30 km/h. If the DTC is repeated, proceed to the relevant pinpoint test.
4. If the DTC is not repeated, this indicates the DTC may have been stored due to external influences such as bad road surfaces or electrical interference.

After Completion of Pinpoint Tests:

4. If a DTC is stored, there is a further fault. Read the stored DTC and refer to the relevant pinpoint test.
Pinpoint Tests
ABS Warning Light ON (No DTCs Stored)
ABS Warning Light ON (No DTCs Stored) ABS Ignition supply fuse/circuit fault Make sure the ABS ECM connector is secure.
ABS Warning light circuit fault Disconnect ABS ECM connector and proceed to
pinpoint test 1:
Pinpoint Tests
Test Result Action

- ABS ECM connector pin 4
- ABS ECM connector pin 10 Faulty Rectify fault, proceed to test 5
2 Check cable continuity of the ABS ignition supply circuit: With Voltage greater than 10 V Proceed to test 3
Ignition ON, check Voltage between:
- ABS ECM connector pin 4 and pin 10 Voltage less than 10 V Locate and rectify wiring fault, proceed to test 3
3 Reconnect ABS ECM harness, clear fault code and test ABS to OK Action complete - quit test
verify fault cleared
Circuit Diagram
2
9 8 2 1
7
R
1 2 3 4 5 6 1 2
3 4
18 17 11 10
8
1 7 9
3
18 R
4 G G 2
10 1
20 11 4
7 GP GP 19
6 5
1 2
17 BG B 1 1 B
8 UW GB 2 2 W
1 2 8 7
15 BG GR 1 1 B
6 UR UR 2 2 W
1 8
9 16
13 OG OG 1
5 BG BG 7
10 B 11 B
9
11
10
1. ABS ECM
2. Fuse box 1
3. Ignition switch
5. Front wheel speed sensor
6. Front wheel speed sensor connector
7. Rear wheel speed sensor
8. Rear wheel speed sensor connector
9. Diagnostic connector
10. Battery negative connector
11. Battery subharness
ABS Warning Light Does Not Illuminate (No DTCs Stored)
ABS Warning Light OFF (No DTCs Stored) ABS ECM ground circuit fault Make sure the ABS ECM connector is secure.
Make sure the ABS ECM ground connection is secure.
Disconnect ABS ECM connector and proceed to
pinpoint test 1:
Warning light circuit fault Refer to CAN Fault see CAN Fault

Pinpoint Tests
Test Result Action
1 Check the ABS warning light circuit and ignition fuses - fuse OK Proceed to test 2
box 1, fuse 7 and fuse 8

- ABS ECM connector pin 4 and pin 10
3 Check cable for short to Voltage: With Ignition OFF, check 0V Proceed to test 4
Voltage between:
- ABS ECM connector pin 4 and ground Above 3 V Locate and rectify wiring fault, proceed to test 5
4 Check cable for continuity: OK Proceed to test 5

- ABS ECM connector pin 10 and ground
Faulty Locate and rectify fault, proceed to test 5
5 Reconnect ABS ECM harness, check for fault code and test OK Action complete - quit test
ABS
Circuit Diagram
9 8 2 1
7
R
2 1 2 3 4 5 6 1 2
3 4
18 17 11 10
8
1 7 9
3
18 R
4 G G 2
10 1
20 11 4
7 GP GP 19
6 5
1 2
17 BG B 1 1 B
8 UW GB 2 2 W
1 2 8 7
15 BG GR 1 1 B
6 UR UR 2 2 W
1 8
9 16
13 OG OG 1
5 BG BG 7
10 B 11 B
9
11
10
1. ABS ECM
2. Fuse box 1
3. Ignition switch
Front Wheel Sensor Open Circuit/Short Circuit
C1611 Front wheel sensor short circuit to ground or open Make sure the ABS ECM connector is secure.
circuit Make sure the wheel speed sensor connector is
secure.
pinpoint test 1:
Pinpoint Tests
Test Result Action

- Sensor connector pin 1 Faulty Rectify fault, proceed to test 9
- Sensor connector pin 2

Test Result Action

Short circuit Proceed to test 3
3 Disconnect the front wheel speed sensor connector. Check OK Replace the wheel speed sensor, proceed to test 9
cable for short circuit:
- Wheel speed sensor connector pin 2 (motorcycle harness
side) and ground Short circuit Locate and rectify wiring harness fault, proceed to test 9

5 Check cable for short circuit: OK Replace the wheel speed sensor, proceed to test 9

- ABS ECM connector pin 17 and wheel speed sensor
connector pin 1 (motorcycle harness side) Open circuit Locate and rectify wiring harness fault, proceed to test 9

8 Reconnect the front wheel speed sensor connector. Check the 1.8 mA to 16.8 mA Proceed to test 9
wheel speed sensor operation:
- Connect a suitable voltage supply between 10 V and 16 V
between ABS ECM connector pin 8 (positive) and pin 17
(negative), and measure the current consumption of the wheel Faulty Replace the wheel speed sensor, proceed to test 9
speed sensor
verify fault cleared.
Circuit Diagram
Wheel speed sensor current consumption data under typical conditions:
Supply Voltage Min Typical Max
10 - 16 V 1.8 mA 7.5 mA 16.8 mA
2
9 8 2 1
7
R
1 2 3 4 5 6 1 2
3 4
18 17 11 10
8
1 7 9
3
18 R
4 G G 2
10 1
20 11 4
7 GP GP 19
6 5
1 2
17 BG B 1 1 B
8 UW GB 2 2 W
1 2 8 7
15 BG GR 1 1 B
6 UR UR 2 2 W
1 8
9 16
13 OG OG 1
5 BG BG 7
10 B 11 B
9
11
10
1. ABS ECM
2. Fuse box 1
3. Ignition switch
Front Wheel Sensor Abnormal Input/losing Contact

C1612 Front wheel sensor abnormal input or dropping out Ensure ABS modulator connector is secure.
Incorrect wheel speed sensor air gap Ensure wheel speed sensor connector is secure.
Damaged or dirty pulser ring Proceed to pinpoint test 1:
Loose or incorrectly installed wheel speed sensor
Pinpoint Tests
Test Result Action
1 Measure the air gap of the front wheel speed sensor between OK Proceed to test 2
the sensor and the pulser ring:
See Air Gap Measurement - Front and Rear ABS Wheel
Speed Sensors Faulty Rectify the fault and proceed to test 5
2 Check the pulser ring for damage or contamination by road OK Proceed to test 3
grime or ferrous metal filings
Faulty Clean or replace the ABS pulser ring, proceed to test 5
3 Check the wheel speed sensors for correct installation, and the OK Proceed to test 4
fixings for correct torque
Faulty Rectify the fault and proceed to test 5
4 Check the wheel speed sensor circuit (see Front Wheel Sensor OK Contact Triumph service
Open Circuit/Short Circuit)
5 Clear fault code and test ABS to verify fault cleared OK Action complete - quit test
Rear Wheel Sensor Open Circuit/Short Circuit
C1613 Rear wheel sensor short circuit to ground or open Make sure the ABS ECM connector is secure.
circuit Make sure the wheel speed sensor connector is
secure.
pinpoint test 1:
Pinpoint Tests
Test Result Action

- Sensor connector pin 1 Faulty Rectify fault, proceed to test 9
- Sensor connector pin 2

3 Disconnect the rear wheel speed sensor connector. Check OK Replace the wheel speed sensor, proceed to test 9
cable for short circuit:

5 Check cable for short circuit: OK Replace the wheel speed sensor, proceed to test 9


Test Result Action
connector pin 1 (motorcycle harness side)
Open circuit Locate and rectify wiring harness fault, proceed to test 9
8 Reconnect the front wheel speed sensor connector. Check the 1.8 mA to 16.8 mA Proceed to test 9
wheel speed sensor operation:
- Connect a suitable voltage supply between 10 V and 16 V
between ABS ECM connector pin 6 (positive) and pin 15
(negative), and measure the current consumption of the wheel Faulty Replace the wheel speed sensor, proceed to test 9
speed sensor
verify fault cleared.
Circuit Diagram
Wheel speed sensor current consumption data under typical conditions:
Supply Voltage Min Typical Max
10 - 16 V 1.8 mA 7.5 mA 16.8 mA
2
9 8 2 1
7
R
1 2 3 4 5 6 1 2
3 4
18 17 11 10
8
1 7 9
3
18 R
4 G G 2
10 1
20 11 4
7 GP GP 19
6 5
1 2
17 BG B 1 1 B
8 UW GB 2 2 W
1 2 8 7
15 BG GR 1 1 B
6 UR UR 2 2 W
1 8
9 16
13 OG OG 1
5 BG BG 7
10 B 11 B
9
11
10
1. ABS ECM
2. Fuse box 1
3. Ignition switch
Rear Wheel Sensor Abnormal Input/Losing Contact
C1614 Rear wheel sensor abnormal input or dropping out Make sure the ABS modulator connector is secure.
Incorrect wheel speed sensor air gap Proceed to pinpoint test 1:
Damaged or dirty pulser ring
Pinpoint Tests
Test Result Action
1 Measure the air gap of the rear wheel speed sensor between OK Proceed to test 2

4 Check the wheel speed sensor circuit (see Rear Wheel Sensor OK Contact Triumph service
Open Circuit/Short Circuit)
Front Wheel Pulser Ring Missing Teeth
C1621 Front wheel pulser ring missing teeth Make sure the ABS modulator connector is secure.
Damaged/incorrect wheels
Pinpoint Tests
Test Result Action
1 Measure the air gap of the front wheel speed sensor between OK Proceed to test 2
4 Check the motorcycle wheel for damage/incorrect size OK Proceed to test 4
Rear Wheel Pulser Ring Missing Teeth
C1623 Rear wheel pulser ring missing teeth Make sure the ABS modulator connector is secure.
Damaged/incorrect wheels
Pinpoint Tests
Test Result Action
1 Measure the air gap of the rear wheel speed sensor between OK Proceed to test 2
4 Check the motorcycle wheel for damage/incorrect size OK Proceed to test 4

Front or Rear Input/Output solenoid Open/Short Circuit
C1631 Front wheel input solenoid short circuit to ground or Make sure the ABS ECM connector is secure.
open circuit Disconnect ABS ECM connector and proceed to
pinpoint test 1:
C1632 Front wheel output solenoid short circuit to ground or
open circuit
C1633 Rear wheel input solenoid short circuit to ground or

open circuit
C1634 Rear wheel output solenoid short circuit to ground or

open circuit
Pinpoint Tests
Test Result Action
1 Check fuse box 1, fuse 7 integrity OK Proceed to test 3
Faulty Proceed to test 2
2 Check cable and terminal integrity: OK Replace fuse, proceed to test 5

- ABS ECM connector pin 18 and ground pin 10
Faulty Rectify fault, replace fuse, proceed to test 5
3 Check cable continuity: With ignition 'ON', check voltage Voltage greater than 11 V Proceed to test 4
between:
- ABS ECM connector pin 18 and ground pin 10 Voltage less than 11 V Locate and rectify fault, proceed to test 5

5 Clear fault code and test ABS to verify fault cleared. OK Action complete - quit test
Circuit Diagram
2
9 8 2 1
7
R
1 2 3 4 5 6 1 2
3 4
18 17 11 10
8
1 7 9
3
18 R
4 G G 2
10 1
20 11 4
7 GP GP 19
6 5
1 2
17 BG B 1 1 B
8 UW GB 2 2 W
1 2 8 7
15 BG GR 1 1 B
6 UR UR 2 2 W
1 8
9 16
13 OG OG 1
5 BG BG 7
10 B 11 B
9
11
10
1. ABS ECM
2. Fuse box 1
3. Ignition switch

Wheel Speed Signal Error; Simulated Wheel Lock
C1641 Front wheel speed signal error; simulated wheel lock Make sure the ABS modulator connector is secure.
Binding front brake Proceed to pinpoint test 1:
Incorrect wheel speed sensor air gap
An abnormal manoeuvre was performed (a very long
'wheelie' or 'stoppie' with the wheel stopped)
C1643 Rear wheel speed signal error; simulated wheel lock

Binding rear brake
Incorrect wheel speed sensor air gap
An abnormal manoeuvre was performed (a very long
'wheelie' or 'stoppie' with the wheel stopped)
Pinpoint Tests
Test Result Action
1 Check the relevant wheel for brake bind caused by caliper or OK Proceed to test 2
master cylinder faults, or other mechanical causes
2 Measure the air gap of the wheel speed sensor between the OK Proceed to test 3
sensor and the pulser ring:
Motor - Lock; Motor Does Not Run; Motor Runs Continually
C1651 Motor circuit fault Make sure the ABS modulator connector is secure.
Turn the ignition ON.
C1652 Motor does not run Proceed to pinpoint test 1:
C1653 Motor runs continually
Pinpoint Tests
Test Result Action
1 Check fuse box 1, fuse 7 integrity OK Proceed to test 2
Motor runs continually Replace fuse and proceed to test 5
2 Check the motor function: OK Proceed to test 3

Check that with the motorcycle stationary and the ABS ECM
connected, the motor does not operate Faulty Contact Triumph service
3 Check cable continuity: Battery Voltage Proceed to test 4

With ignition ON, check Voltage between:
- ABS ECM connector pin 18 and pin 10 Less than across battery Locate and rectify wiring fault, proceed to test 5
Voltage

5 Reconnect ABS modulator harness, clear fault code and test OK Action complete - quit test

ABS to verify fault cleared
Circuit Diagram
2
9 8 2 1
7
R
1 2 3 4 5 6 1 2
3 4
18 17 11 10
8
1 7 9
3
18 R
4 G G 2
10 1
20 11 4
7 GP GP 19
6 5
1 2
17 BG B 1 1 B
8 UW GB 2 2 W
1 2 8 7
15 BG GR 1 1 B
6 UR UR 2 2 W
1 8
9 16
13 OG OG 1
5 BG BG 7
10 B 11 B
9
11
10
1. ABS ECM
2. Fuse box 1
3. Ignition switch
Power Source Voltage Drop/Voltage Rise
C1661 Power source Voltage drop Make sure the ABS modulator connector is secure.
Disconnect ABS modulator connector and proceed to
C1662 Power source Voltage rise pinpoint test 1:
Pinpoint Tests
Test Result Action

ABS ECM connector pin 4 and pin 10
2 Check the cable for continuity: OK Proceed to test 3

ABS ECM connector pin 10 and ground
Faulty Rectify wiring harness fault, proceed to test 5
3 Check battery Voltage: Voltage greater than 10 V Proceed to test 4

With ignition ON, check the Voltage between:
- ABS ECM connector pin 4 and pin 10 Voltage less than 10 V Locate and rectify fault, proceed to test 5
4 Check battery Voltage: Voltage between 10 V and 16 V Proceed to test 5

Reconnect ABS modulator connector and start the engine.
Check the Voltage between: Voltage greater than 16 V Check the battery charging circuit. Locate and rectify fault,
- Battery positive (red) terminal and negative (black) terminal proceed to test 5
Circuit Diagram
2
9 8 2 1
7
R
1 2 3 4 5 6 1 2
3 4
18 17 11 10
8
1 7 9

3
18 R
4 G G 2
10 1
20 11 4
7 GP GP 19
6 5
1 2
17 BG B 1 1 B
8 UW GB 2 2 W
1 2 8 7
15 BG GR 1 1 B
6 UR UR 2 2 W
1 8
9 16
13 OG OG 1
5 BG BG 7
10 B 11 B
9
11
10
1. ABS ECM
2. Fuse box 1
3. Ignition switch
Different Tyre Diameter
C1671 Different tyre diameter Ensure ABS modulator connector is secure.

Pinpoint Tests
Test Result Action
1 Check for installation of wheels and tyres of the correct size OK Proceed to test 2
2 Check the tyre pressures OK Proceed to test 3
4 Measure the air gap of the wheel speed sensors between the OK Proceed to test 5
- Air gap between 0.1 mm to 1.5 mm Faulty Rectify the fault and proceed to test 5
Abnormal ECU
C1681 Abnormal ECU Ensure ABS modulator connector is secure.

Pinpoint Tests
Test Result Action
1 Measure the air gap of the wheel speed sensors between the OK Proceed to test 2

2 Check the pulser rings for damage or contamination by road OK Proceed to test 3
CAN Fault
C1682 CAN fault - lost communication with engine ECM Make sure ABS ECM connector is secure.
C1683 CAN fault - lost communication with instrument panel
C1684 CAN lost fault - all communication
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect instruments and proceed to test 2
- ABS ECM connector pin 11 Faulty Rectify fault, proceed to test 5
2 Check the cable for short circuit: OK Proceed to test 3

- ABS ECM pin 2 to ground
- ABS ECM pin 11 to ground Short circuit Rectify wiring harness fault, proceed to test 5

- ABS ECM pin 2 to Engine ECM pin C25
- ABS ECM pin 11 to Engine ECM pin C24
- ABS ECM pin 2 to Instruments pin 10
- ABS ECM pin 11 to Instruments pin 4
- ABS ECM pin 2 to Diagnostic connector pin 6 Open circuit Rectify wiring harness fault, proceed to test 5
- ABS ECM pin 11 to Diagnostic connector pin 14
- ABS ECM pin 2 to Immobiliser connector pin 6
- ABS ECM pin 11 to Immobiliser connector pin 1

- ABS ECM pin 2 to ABS ECM pin 11
Short circuit Rectify wiring harness fault, proceed to test 5
5 Clear fault code and test ABS to verify fault cleared. OK Action complete - quit test
Circuit Diagram
Chassis ECM connectors are referenced as letters in the circuit diagram -

Chassis ECM connector 1 = Chassis ECM connector A
Chassis ECM connector 2 = Chassis ECM connector B
Chassis ECM connector 3 = Chassis ECM connector C
1
1 8
14 U
6 R
9 16 2
4 U
1 4 3 R
3
A9 R
8 1
16 9 A10 U
12
4
11 1 C25 R
22 12
33 23 C24 U
11
5
9 8 2 1
11 U
2 R
18 17 11 10 6
6 R
5 1
10 6 1 U
7
3 R
2 U
4 6
1 2 3
8 1 3
10 R
4 U
6 1
1 R 4
12 7
9
4 6 6 R 6
1 3
10

2. Connectivity module
5. ABS modulator
6. Immobilser/TPMS electronic control module
7. Inertial measurement unit
8. Instruments
9. Right hand switch housing - connector grey
10. Left hand switch housing - six pin connector
12. Chassis ECM - Connector A
Modulator output (wheel) pressure sensor malfunction
Modulator output (wheel) pressure sensor malfunction Modulator output (wheel) pressure sensor malfunction Contact Triumph service
ABS Variant Coding Error
C1700 EEPROM error Contact Triumph service
C1711 Sensor box internal error Contact Triumph service
C1712 Sensor box internal error Contact Triumph service
C1713 Yaw rate internal error Contact Triumph service
Removal and Installation - Front Brake Components
Front Brake Pads - Removal
WARNING

WARNING
Do not allow a brake component to hang unsupported on the brake hose or line.
Brake hoses or lines that are not supported may become damaged or bent.
Bent or damaged brake hoses or lines lead to reduced braking efficiency causing loss of motorcycle control and an accident.
1. Remove the caliper mounting fixings and slide the caliper off the disc.
B00943_1

2. Caliper
2. Release the brake pad retaining lugs from the slots in the caliper and remove the brake pad.
3. Repeat for the other brake pad.
Note
Note the position and orientation of the anti-rattle spring for installation.

Note
Note that the arrow on the anti-rattle spring is pointing in the direction of forward rotation of the disc.
B00943_3
1. Arrow, anti-rattle spring

2. Front caliper
Note
Complete the installation of the brake pads to one caliper (see Front Brake Pads - Installation) before removing the pads from the other caliper.
Front Brake Pads - Inspection
1. Check the pad retainer and anti-rattle spring. Renew any component which shows signs of damage or corrosion.
2. Check that there is no sign of leakage from the caliper piston seals. Rectify any problems before installing the pads.
Note
Complete the assembly of the brake pads to one caliper (see assembly for details) before removing the pads from the other caliper.
Front Brake Pads - Installation
WARNING
Always have replacement brake pads supplied and fitted by your Triumph dealer.
The ABS calibration is optimised for use with the friction material provided on brake pads supplied by Triumph.
The use of proprietary brands of brake pads is not recommended as differing friction material specifications will affect the performance of the ABS, potentially causing loss
of motorcycle control and an accident.
WARNING
Brake pads for this model supplied by Triumph are specifically designed for use with the brake calipers fitted to your motorcycle.
The use of proprietary brands of brake pads is not recommended as these may have a reduced carrier plate thickness when compared with the Triumph genuine parts.
Brake pads with an incorrect carrier plate thickness can potentially become dislodged from the caliper body as they wear, leading to brake failure, loss of motorcycle control
and an accident.
WARNING
Never use mineral-based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible.
Mineral-based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders.
Damage caused by contact with mineral-based grease may reduce braking efficiency resulting in loss of motorcycle control and an accident.
CAUTION
Never lever directly against the disc, caliper or the pad lining material as this will damage these components. Always use a levering tool made from a soft material which will
not cause damage to the load bearing surfaces.
Brake fluid will be displaced as the caliper pistons are compressed. To prevent body damage, make sure that the displaced fluid does not come into contact with any part of
the bodywork.
1. If new pads are being installed, push the pistons fully back into the caliper body. Keep an eye on the fluid level in the reservoir whilst retracting the pistons to prevent fluid
spillage.
2. Make sure that the anti-rattle spring position and orientation is as noted for removal.
3. Fit one of the brake pad's retaining lugs into its mounting in the caliper with its friction material surfaces facing the other side of the caliper.
4. Using finger pressure only, fit the pad's other retaining lug into its mounting of the caliper. Ensure that both retaining lugs are fully fitted into their mounting slots.
5. Repeat steps 2 to 4 for the other brake pad.
6. Thoroughly clean the threaded fixing holes for the front fork brake caliper fixings.
7. Thoroughly clean the threaded part of the brake caliper fixings and smear the first four threads with a proprietary copper based grease.
8. Position the brake caliper over the disc.
9. Secure the brake caliper with the fixings and tighten sufficiently to bring the caliper into contact its mounting points, while allowing a small amount of lateral movement. Do
not fully tighten at this stage.

2
B00943_1

2. Caliper
Note
Before tightening, the brake caliper should be positioned such that it is aligned as centrally as possible over the brake disc.
10. Visually check the clearances between the caliper body and brake disc in the four locations shown below.
L0310_1
1. Caliper body
2. Brake disc
11. Slide the caliper body inwards or outwards against its fixings as required to achieve the most equal clearances possible on either side of the brake disc.
12. Holding the caliper in position against its mounting fixings, tighten the fixings to 45 Nm.
Note
When the brake caliper is fitted, there must be a minimum gap of 0.3 mm between the caliper and brake disc.
13. Using feeler gauges, measure the gap between the front brake caliper and the brake disc at the four measurement points shown in the following illustration. Minimum gap
to be 0.3 mm.
1. Front brake caliper

2. Front brake disc
14. If necessary, loosen the caliper bolts and adjust the caliper alignment to achieve the minimum gap of 0.3 mm on all four measurement points. Re-tighten the bolts to 45 Nm.
15. Pump the brake lever to correctly position the caliper pistons.
16. Repeat the removal, inspection and installation process for the other caliper.
WARNING
General Information section may reduce the efficiency of the braking system leading to an accident. Observe the brake fluid handling warnings given in the General
Information section (see Brakes).
CAUTION

17. Check the front brake fluid level and top up as required with new DOT 4 fluid.
18. Check for correct brake operation. Rectify as necessary.
WARNING
Front Brake Caliper - Removal
WARNING

CAUTION
1. Carefully note the positions of all of the clips that attach the hoses and the ABS wheel speed sensor cable, for the installation procedure.
2. Noting its orientation, disconnect the brake hose at the caliper (two hoses on right hand caliper), and place the free end of the hose(s) in a suitable container to collect the
brake fluid.
3. Retain the brake union bolt for reuse and discard the sealing washers.
4. Remove the two fixings securing the brake caliper to the front fork
3
2
B00943
1. Caliper fixings
2. Sealing washers
3. Brake hose (to ABS modulator)
4. Brake union bolt
5. Brake hose (to left hand brake caliper)
5. Remove the brake caliper.
Front Brake Caliper - Disassembly
WARNING
To prevent injury, never place fingers or hands inside the caliper opening when removing the pistons. Always wear eye, hand and face protection when using compressed
air. Eye, face and skin damage will result from direct contact with compressed air.
WARNING
Make sure the seal grooves in the caliper bores are not damaged during the removal of the seals. Damage to the seal grooves may allow brake fluid to leak past the seals
resulting in a dangerous riding condition leading to loss of motorcycle control and an accident.
1. Cover the caliper opening with a clean heavy cloth and using either compressed air or by reconnecting the master cylinder and pumping the brake lever, remove the pistons
one at a time.
3 2 1

1. Dust seal
2. Piston seal
3. Pistons
4. Caliper
2. Extract the dust seals and piston seals, taking care not to damage the caliper bores. Discard the old seals, these must not be reused.
Note
The piston seals are slightly thicker than the dust seals.
chbc
2
1. Piston seals
2. Dust seals
3. Check the pistons, caliper and mounting bracket for signs of damage, paying particular attention to the caliper bores and pistons. If damage is present, renew the worn
component or the complete caliper assembly.
Front Brake Caliper - Inspection
WARNING
1. Check the pistons and caliper bores for corrosion, scoring and damage. Renew as necessary.
2. Inspect the brake pads for damage and wear beyond the service limit. Renew as necessary.
Front Brake Caliper - Assembly
If all components are serviceable, obtain a piston seal kit and reassemble the caliper as follows:
WARNING
WARNING
Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the
WARNING
Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible.
Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may
reduce braking efficiency resulting in loss of motorcycle control and an accident.
1. Ensure all components are clean, then fit the new seals to their grooves in the caliper bores.
2. Lubricate the fluid seals, caliper bore and the outside of the pistons with clean DOT 4 brake fluid.
3. Ease the pistons squarely back into the bores, taking care not to displace the seals.
Front Brake Caliper - Installation
WARNING

1. If removed, install the brake pads (see Front Brake Pads - Installation).
2. Thoroughly clean the threaded fixing holes for both front fork brake caliper fixings.
3. Thoroughly clean the threaded part of the fixings and smear the first four threads with a proprietary copper based grease.

4. Position the left and right hand calipers over the disc.
5. Secure the brake calipers with the fixings and tighten sufficiently to bring the calipers into contact their mounting points, while allowing a small amount of lateral movement.
Do not fully tighten at this stage.
Note
When fitting the front brake hoses, make sure the left hand brake hose (loop hose) is fitted to the caliper first.
6. Connect the brake hose(s) to the caliper incorporating new sealing washers on each side of all hose connections.
7. Make sure the orientation of the brake hoses are as noted for removal and tighten the union bolt to 25 Nm.
3
2
B00943
1. Caliper fixings
2. Sealing washers
3. Brake hose (to left hand brake caliper)
4. Brake union bolt
5. Brake hose (to ABS modulator)
8. Refit the hose and cable clips in the positions noted during removal.
WARNING
General Information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident.
Observe the brake fluid handling warnings given earlier in this section of the manual.
9. Fill the master cylinder with new, DOT 4 brake fluid from a sealed container.
10. Bleed the front brake calipers (see Bleeding the Front Brakes).
Brake Caliper to Disc Clearance Adjustment
1. Visually check the clearances between the calipers body and brake disc in the four locations shown below.
L0310_1
1. Caliper body
2. Brake disc
2. Slide the calipers body inwards or outwards against their fixings as required to achieve the most equal clearances possible on either side of the brake disc.
3. Holding the calipers in position against their mounting fixings, tighten the fixings to 45 Nm.
4. Using feeler gauges, measure the gap between the front brake calipers and the brake disc at the four measurement points shown in the following illustration. The minimum
gap must be 0.3 mm.

1. Front brake caliper
2. Front brake disc
5. If necessary, loosen the caliper bolts and adjust the caliper alignment to achieve the minimum gap of 0.3 mm on all four measurement points. Retighten the bolts to 45 Nm.
6. Check the operation of the front brake. Rectify as necessary.
WARNING
Front Brake Discs - Removal
WARNING

WARNING
Do not renew front brake discs individually. Discs must always be renewed in pairs even if one of a pair is serviceable.
1. Remove the front wheel (see Front Wheel - Removal).

2. Support the wheel on blocks as illustrated to avoid damage to the wheel centre.
1. Wheel
2. Support blocks
3. Remove and discard the bolts.

4. Detach the disc. Collect the ABS pulser ring from the left hand disc.
5. Repeat for the other disc.
Front Brake Discs - Installation
WARNING

1. Locate the left disc onto the wheel. Refit the ABS pulser ring.
2. Fit new bolts and tighten to 22 Nm.
3. Fit the right disc in the same way.
4. Refit the front wheel (see Front Wheel - Installation).
WARNING
1. If hand guards are installed, remove the mirror (see Mirror - Removal).
2. Release the fixings and remove the clamp from the brake master cylinder assembly.

3
2 1
B00944
1. Fixings
3. Clamp split line
4. UP arrow
CAUTION
3. Taking care not to invert the brake fluid reservoir, lay the assembly aside.
CAUTION
1. Taking care not to invert the brake fluid reservoir, position the master cylinder assembly to the handlebar.
2. Fit the clamp with the UP arrow pointing upwards and align the split line to the marking on the handlebars.
3. Tighten the fixings upper first and then the lower to 9 Nm.
2 1
B00944
1. Fixings
3. Clamp split line
4. UP arrow
4. If hand guards are installed, fit the mirror (see Mirror - Installation).
Front Brake Master Cylinder - Removal
WARNING

CAUTION

1. To drain the fluid from the master cylinder, attach a tube to the right hand caliper bleed nipple, loosen the bleed nipple and allow the fluid to drain into a suitable container.
Operate the brake lever until all fluid has been expelled.
2. Note the setting of the brake lever adjuster to ensure it is returned to the same position when the overhaul operation is complete.

3. Remove the pivot lock nut and bolt securing the brake lever to the master cylinder, and remove the lever.
2
1
B00945 3
1. Master cylinder bleed nipple

2. Lever pivot locknut
3. Brake hose union
4. Handlebar clamp fixings
4. Noting it’s orientation, disconnect the brake hose from the master cylinder.
5. Release the fixing and detach the brake light switch from the master cylinder.
2 1
B00942
1. Brake light switch assembly

2. Fixing
6. Release the clamp screws from the handlebar to remove the master cylinder.
Front Brake Master Cylinder - Disassembly
Service Kits
Service kits for the master cylinder are available that are listed below:
Reservoir kit
Bracket kit
Brake lever kit
Piston kit
Bleeder kit
The procedures that follow describe the disassembly and replacement of the components in the kits.
Brake Fluid Reservoir and Bracket
1. Remove the two fixings and remove the reservoir cap.
2 3
4
5
B00949
1. Fixing
2. Cap
3. Diaphragm seal
4. Clip

5. Hose
2. Remove the diaphragm seal from the cap.

3. Remove the nut and fixing that attach the reservoir to the mounting bracket. Discard the nut.
4. Release the wire clips and disconnect the hose from the reservoir and the master cylinder.
5. Remove the two fixings and remove the reservoir bracket from the master cylinder.
Brake Lever
Note
The lever kit includes the pivot screw, bush, nut and lever span adjuster assembly. To replace the lever, you will need to transfer the pivot assembly from the
old lever.
Note the setting of the lever span adjuster to make sure it is returned to the same position on installation.
The master cylinder does not need to be removed from the motorcycle for removal of the brake lever.
The push rod and rubber boot will be released when the lever is separated from the master cylinder.
Turn the span adjuster fully clockwise to set the brake lever to maximum span.
1
5
2 4
B00953
1. Master cylinder
2. Lever assembly
3. Span adjuster
4. Lock nut
5. Pivot bolt
Note
The T3880636 - Kit, Brake Lever Pivot Sleeve is required to remove the pivot sleeve for front brake lever.
3 4
cjug
T3880636 - Kit, Brake Lever Pivot Sleeve

1. Mandrel
2. Extractor
3. Installer piece
4. Support piece
WARNING
When removing the brake lever pivot sleeve, always wear overalls, eye, face and hand protection. The brake lever sleeve is hardened and liable to splinter if broken. Debris
from broken components could cause injury to eyes, face and any unprotected parts of the body.
1. Remove the lock nut from the lever pivot bolt.

2. Remove the lever pivot bolt.
3. Release the lever from the master cylinder assembly.
Note
The push rod and rubber boot will be released when the lever is separated from the master cylinder.
Note the orientation of brake lever pivot assembly and its spring for installation.
4. Adjust the span adjuster clockwise fully into the brake lever.
5. Protect the pivot assembly painted surfaces from damage, using a suitable self-adhesive tape such as masking tape.
6. Fit the extractor to the mandrel as shown.

1
cjug
1. Mandrel
2. Extractor
7. Position the brake lever assembly inverted, with the brake switch lever facing upwards as shown.
8. Position the mandrel and extractor to the brake lever and press out the pivot sleeve from the brake lever assembly.
3
6
4
5
2
B00946
1. Mandrel
2. Support piece
3. Extractor
4. Front brake lever
5. Lever pivot assembly
6. Return spring
WARNING
Always wear eye, hand and face protection when separating brake lever components. Uncontrolled release of the brake lever components may cause the spring to become
detached during dismantling. Flying springs may cause injury to eyes, face and any unprotected parts of the body.
9. Carefully remove the extractor from the brake lever assembly.

10. Discard the brake lever pivot sleeve from the support piece.
Note
Note the orientation of the lever pivot assembly for installation.
Note the position of the spring for installation.
11. Carefully detach the lever pivot assembly and its spring from the lever.
1 2
B00948
1. Lever
2. Spring
3. Lever pivot assembly
12. Remove the circlip that retains the span adjuster.
4 3 1

5
2
B00137
1. Lever
2. Detent assembly
3. Circlip
4. Span adjuster
5. Span adjuster pivot
13. Remove the detent assembly for the span adjuster.

14. Remove the span adjuster and the span adjuster pivot.
2
1
1. Brake lever
2. Span adjuster
Bleed Screw
1. Remove the cover from the bleed screw. Release the bleed screw and remove from the master cylinder assembly.
2
3
B00947
1. Master cylinder
2. Bleed screw
3. Cover
Piston and Seals
CAUTION
The hose spigot seal and the paint finish on the master cylinder can be easily damaged.
Do not use sharp tools to remove the seal.
1. Pull the hose inlet spigot and its seal out of the master cylinder.

2
1
B00951
1. Hose inlet spigot

2. Seal
3. Master cylinder
2. Carefully use an applicable tool (long nosed pliers or similar) to remove the piston retaining pin.
1
B00955
1. Piston retaining pin

2. Master cylinder
3. Remove the piston, seals and springs assembly.
Front Brake Master Cylinder - Inspection
1. Check the following for wear, damage, cracks or deterioration:

Cylinder bore
Rubber boot
Spring
Piston
Pivot bolt.
2. Always renew the piston and seal set if the cylinder is dismantled.
3. Check that the two ports in the master cylinder bore are not blocked.
B00955_1
1. Ports
Front Brake Master Cylinder - Assembly
WARNING
WARNING
Piston and Seals

WARNING
Ensure that the piston and piston seals are fitted facing the same way as noted during removal. A dangerous riding condition leading to loss of motorcycle control and an
accident could result from incorrect assembly of the master cylinder.
1. Assemble the seals onto the piston.
9 10
8
6
4 5
2 3
1
B00954
1. Spring
2. Valve cap
3. Valve spring
4. Valve
5. Primary cup seal
6. Piston
8. Secondary cup seal
9. Rubber boot
10. Push rod
2. If removed, install the valve, valve spring and valve cover.

3. Lubricate the piston, seals and cylinder with new, clean brake fluid.
4. Fit the new spring and piston assembly into the master cylinder, aligning the retaining pin hole with the hole in the master cylinder body.
5. Install the piston retaining pin.
1
B00955

2. Master cylinder
6. Lubricate the seal for the hose inlet spigot with new, clean brake fluid. Install the seal and the hose inlet spigot.
1
B00951
1. Hose inlet spigot

2. Seal
3. Master cylinder
Bleed Screw

1. Assemble the cover onto the bleed screw thread.
2. Install the bleed screw and tighten to 8 Nm.
2
3
B00947
1. Master cylinder
2. Bleed screw
3. Cover
Brake Lever
1. Install the span adjuster pivot and the span adjuster into the lever.
4 3 1
5
2
B00137
1. Lever
2. Detent assembly
3. Circlip
4. Span adjuster
2. Install the circlip to retain the span adjuster.
WARNING
Do not install the detent assembly at this stage as there is insufficient clearance on the support piece ofT3880636 - Kit, Brake Lever Pivot Sleeve.
3. Position the lever pivot assembly and the spring as noted during disassembly.
4. Locate the pivot sleeve over the shank of the installer piece of T3880636 - Kit, Brake Lever Pivot Sleeve.
2
3
cjug
1. Pivot sleeve
2. Installer piece
3. Mandrel
5. Screw the installer piece into the mandrel.

6. Align the brake lever to the brake lever pivot assembly ensuring the return spring is located as noted during removal.
7. Using the service tool, align the installer piece to the brake lever and gently push down on the mandrel to locate the installer piece, through the lever and pivot.
8. Place the lower surface of the brake lever onto the support piece, and then using a press, push the pivot sleeve through the brake lever pivot until the mandrel touches the

upper brake lever surface.
3 2
cjue_4
1. Mandrel
2. Support piece
3. Lever
9. Support the brake lever, hold the mandrel and turn the installer piece anticlockwise to release it from the mandrel.
10. Visually check that the pivot sleeve, return spring and brake lever pivot are installed as noted during removal.
11. Install the span adjuster detent assembly.
12. Fit the new rubber boot to the push rod.
13. Apply brake grease to the two ends of the push rod.
14. Put the push rod and rubber boot assembly in position and align the holes of the brake lever and master cylinder.
2 1
4
B00956
1. Push rod
2. Rubber boot
3. Pivot bolt
4. Lock nut
15. Insert the pivot bolt and tighten to1.5 Nm.

16. Fit the pivot bolt lock nut and tighten to 5.5 Nm.
17. Check lever operation and make sure that the rubber boot is still correctly seated.
Brake Fluid Reservoir and Bracket
1. Install the diaphragm seal into the reservoir cap. Make sure that the holes in the diaphragm are correctly aligned with the screw holes in the cap.
2. Install the two wire clips onto the hose.
3. Connect the hose between the reservoir and the hose inlet spigot.
4. Position the wire clips to secure the hose.
5. Position the reservoir onto the bracket.
2 1
B00957

1. Fluid reservoir
2. Reservoir fixing
3. Lock nut
4. Bracket
5. Bracket fixings
6. Install the fixing and a new locknut.

7. Tighten the locknut to 3.5 Nm.
8. Make sure that the hose is not kinked or twisted.
9. Position the reservoir and bracket assembly onto the master cylinder body.
10. Install the two fixings and tighten to 2.5 Nm.
Front Brake Master Cylinder - Installation
Bleeding the Front Brakes
Front Brake Master Cylinder - Installation
WARNING

1. Locate the master cylinder to the handlebars and position the clamp with the UP arrow pointing upwards.
2 1
B00944
1. Handlebar clamp fixings

2. Alignment mark
3. Split line
4. UP Arrow
2. Align the master cylinder/clamp split line with the alignment mark on the handlebar.
3. Tighten the clamp bolts, upper first and then the lower to 9 Nm.
4. Using new sealing washers, connect the brake hose to the master cylinder in the orientation noted during removal.
5. Tighten the union bolt to 25 Nm.
6. Install the brake light switch. Make sure that the locating lug is in the recess in the master cylinder. Tighten the fixing to 2.5 Nm.
2 1
B00942
1. Brake light switch

2. Fixing
7. Position the brake lever ensuring that the pivot boss is correctly aligned to the push rod. Fit and tighten the pivot bolt to 1.5 Nm, and the lock nut to 5.5 Nm.
WARNING
8. Fill and bleed the front brakes (see Bleeding the Front Brakes).

WARNING
Always return the lever adjuster to the original setting noted during removal. Operating the motorcycle with lever settings which are unfamiliar may lead to loss of motorcycle
control and an accident.
9. Reset the brake lever adjuster to the original setting.

10. Examine the system for correct operation and fluid leaks. Rectify as necessary.
WARNING
Removal and Installation - Rear Brakes Components
Rear Brake Pads - Removal
WARNING

Note
Before removing the brake pads, note the relationship of the pads to the caliper and ensure that, on assembly, they are fitted in the same way.
1. Push the brake caliper inwards towards the wheel in order to displace the caliper piston.
Note
Note the orientation of the R-clip for installation.
2. Remove the R-clip from the pad retaining pin.
3. Using a suitable pin punch, tap the pad retaining pin out in the direction towards the wheel.
chzr
1. R-clip
2. Pad retaining pin
4. Remove the brake pads.
chzs
1. Brake pad
5. For inspection and replacing the anti-rattle springs, remove the caliper (see Rear Brake Caliper - Removal).
Rear Brake - Wear Inspection
If the thickness of any pad (carrier plate and lining) is less than that specified in the table, replace all the pads on the wheel.

Minimum lining and carrier plate thickness
4.3 mm
WARNING
WARNING
and an accident.
Brake pads supplied by Triumph will have the carrier plate at the correct thickness. Always have replacement brake pads supplied and fitted by your Triumph dealer.
1
2
1. Carrier plate
2. Brake pad lining
Rear Brake Pads - Installation
WARNING
WARNING
and an accident.
WARNING
CAUTION
1. If fitting new pads, use hand pressure to compress the caliper piston fully into its bore. Keep an eye on the fluid level in the reservoir whilst retracting the pistons to prevent
fluid spillage.
2. Fit the brake pads to the caliper in the positions noted during removal.
WARNING
Do not apply more than a minimum coating of grease to the pad retaining pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced
braking efficiency and an accident.
3. Lubricate the pad retaining pin using a minimum amount of proprietary high temperature brake grease.
4. Install the brake pad retaining pin.
5. Install the R-clip to the brake pad retaining pin, as noted for removal.

6. Pump the brake pedal to correctly position the caliper pistons.
7. Check the brake fluid level in the rear reservoir and top-up as required with new DOT 4 fluid.
WARNING
WARNING
Rear Brake Caliper - Removal
WARNING

CAUTION
1. Remove the brake pads (see Rear Brake Pads - Removal).

2. Release the fixing and remove the rear ABS wheel speed sensor. Collect the shim from between the sensor and rear caliper carrier and discard the fixing.
2
B00939 1

2. Fixing
3. Shim
4. Disconnect the rear brake hose at the caliper and place the free end of the hose in a suitable container to collect the brake fluid. Discard the sealing washers.
Note
Note the position of the rear brake caliper for installation.
5. Remove the rear wheel (see Rear Wheel - Removal).
6. Remove the brake caliper and carrier assembly.
3 2
1
B00803 4

4. Swinging arm
Rear Brake Caliper - Disassembly
The following items can be replaced on the rear brake caliper:

Anti-rattle springs
Pad retaining pin and clip
Sliding pin gaiters
Piston, piston seal and dust seal
Bleed screw
Bleed screw boot.
1. Slide the caliper off the carrier.
2
4
3
B00804
1. Caliper
2. Caliper carrier
3. Anti-rattle springs
4. Sliding pin gaiters
2. Remove the anti-rattle springs.

3. Cover the caliper opening with a clean, heavy cloth and, using either compressed air, or by reconnecting the master cylinder and pumping the brake lever, eject the piston
from the caliper.
WARNING
Ensure the seal grooves in the caliper bore are not damaged during the removal of the seals. Damage to the seal grooves may allow brake fluid to leak past the seals
resulting in a dangerous riding condition leading to loss of motorcycle control and an accident.
4. Extract the dust seal and piston seal, taking care not to damage the caliper bore.
Rear Brake Caliper - Inspection
1. Examine the piston, caliper, sliding pins and carrier for wear or damage. If the caliper, sliding pins or mounting bracket are worn or damaged, the complete caliper must be
replaced.
WARNING
2. Examine the anti-rattle springs. Replace if necessary.

3. Inspect the sliding pin gaiters for damage. Replace if necessary.
2
4
3
B00804

1. Caliper
2. Caliper carrier
3. Anti-rattle springs
4. Sliding pin gaiters
Rear Brake Caliper - Assembly
WARNING
WARNING
Ensure that the caliper bores do not become scratched during piston removal and assembly. Ensure that the pistons remain square to their bores during fitment otherwise
damage to the caliper could result. Loss of motorcycle control and an accident could result if this warning is ignored.
WARNING
1. Fit new fluid seals to the caliper. Apply brake fluid to the outside of the caliper piston and fluid seal.
2
3
4
B00805
1. Caliper
2. Piston seal
3. Dust seal
4. Piston
WARNING
Ensure that the piston does not tip during assembly as this could damage the caliper.
2. Carefully push the piston into the caliper by hand.

3. Install the anti-rattle spring into the caliper.
4. If removed, install the anti-rattle spring into the caliper carrier.
5. Apply a thin layer of proprietary high temperature copper based grease to the sliding pins.
6. Assemble the caliper onto the carrier.
Rear Brake Caliper - Installation
Rear Brake Pads - Installation
Rear Brake Caliper - Installation
WARNING

1. Position the caliper and carrier assembly to the swinging arm as noted for removal. Align the boss on the carrier with the slot on the swinging arm.
3 2

1
B00803 4

4. Swinging arm
2. Fit the rear wheel (see Rear Wheel - Installation).

3. Connect the brake hose to the caliper incorporating new washers on each side of the union bolt.
4. Tighten the union bolt to 25 Nm.
5. Position the wheel speed sensor to the caliper carrier with its shim between the sensor and caliper carrier. Fit the bolt and tighten to 9 Nm.
6. Check, and if necessary, adjust the air gap (see Air Gap Measurement - Front and Rear ABS Wheel Speed Sensors).
2
B00939 1

2. Fixing
3. Shim
7. Secure the cable for the sensor with the bleed screw cover.
8. Fit the brake pads (see Rear Brake Pads - Installation).
WARNING
9. Fill the master cylinder with new, DOT 4 brake fluid from a sealed container.
10. Bleed the rear brake (see Bleeding the Rear Brakes).
WARNING
Rear Master Cylinder - Removal
WARNING

CAUTION
1. Remove the two fixings and remove the heel guard.

2. Drain the fluid from the master cylinder by bleeding the system at the rear caliper until all fluid has been expelled.
3. Remove the clip from the clevis pin at the lower end of the brake push rod.

2 1
B01033
5
1. Master cylinder fixings

2. Master cylinder
3. Hose union
4. Clevis pin
5. Clip
4. Remove the clevis pin.

Note
Note the orientation of the rear brake hose to the master cylinder for installation.
5. Disconnect the rear brake hose from the master cylinder, noting its orientation. Discard the two sealing washers.
6. Remove the screws that attach the master cylinder to the control plate and detach the master cylinder.
7. Disconnect the reservoir hose and remove the master cylinder.
Rear Master Cylinder - Installation
WARNING

1. Fit the reservoir hose to the master cylinder.

2. Position the master cylinder on the control plate. Install and tighten the securing screws to 16 Nm.
3. Connect the push rod to the brake pedal using a new clevis pin and clip.
4. Incorporating new sealing washers, fit the brake hose to the master cylinder. Ensuring correct orientation of the brake hose, as noted for removal, and tighten the brake
hose union to 25 Nm).
WARNING
5. Fill and bleed the rear brake system (see Bleeding the Rear Brakes.
6. Refit the heel guard, tightening the fixings to 10 Nm.
Check the operation of the rear brake. Rectify as necessary.
WARNING
Rear Master Cylinder - Disassembly
1. Remove the boot from the cylinder and push rod.

2. Remove the circlip retaining the push rod to the cylinder.
3. Remove the push rod and piston set from the master cylinder bore, noting the relative position of the seals and piston components.
Rear Master Cylinder - Inspection
1. Visually inspect the master cylinder bore for wear, scratches or corrosion. Replace as necessary.
2. Check the piston and cylinder bore for damage, wear or deterioration. Replace as necessary.
3. Always renew the piston and seal set if the cylinder is dismantled.
4. Examine the push rod for bends and damage. Replace as necessary.
Rear Master Cylinder - Assembly
WARNING
WARNING

WARNING
1. Clean the master cylinder bore, piston and seals, with new brake fluid.
2. Ensure all ports are clear of obstruction.
WARNING
Ensure that the piston and piston seal are fitted facing the same way as noted during removal. A dangerous riding condition leading to loss of motorcycle control and an
accident could result from incorrect assembly of the master cylinder.
3. Install the spring and piston set together.

4. Apply a small amount of brake grease to the push rod.
5. Install the push rod in the master cylinder and retain with a new circlip.
6. Refit the boot.
4 5
3
6
1
2
cdlu1
1. Reservoir hose
2. Piston set
3. Dust boot
4. Push rod
5. Clevis pin
6. Clip
7. Circlip
7. If the push rod has been disassembled, adjust the length of the push rod as shown below:
1. Push rod
2. Lock nut
8. Set the push rod free length to 75.0 mm.

9. Tighten the lock nut to 18 Nm.
Rear Brake Disc - Removal
WARNING


2. Support the wheel on blocks to avoid damage to the wheel centre.
3. Remove and discard the four screws and remove the ABS pulser ring and brake disc.
1 2

3
B01034
1. Brake disc
2. Fixing
3. ABS pulser ring
Note
The fixings securing the rear brake disc to the wheel also secure the ABS pulser ring. Note the orientation of the brake disc and the ABS pulser ring for
installation.
Rear Brake Disc - Inspection
WARNING

Brake Disc Wear
Replace any brake disc worn beyond the service limit or that exceeds the disc run-out limit.
Rear Brake Disc Thickness
Standard: 5.5 mm
Service Limit: 5.0 mm
Rear Brake Disc Run-out
Service Limit: 0.5 mm max.
Measure disc run-out using an accurate dial gauge mounted on a surface plate.
1. Disc
2. Dial gauge
Rear Brake Disc - Installation
WARNING

1. Locate the brake disc and ABS pulser ring to the rear wheel as noted during removal.
3. Refit the rear wheel (see Rear Wheel - Installation).
4. Check, and if necessary, adjust the air gap between the wheel speed sensor and the ABS pulser ring (see Air Gap Measurement - Front and Rear ABS Wheel Speed
Sensors).

WARNING
Rear Brake Light Pressure Switch - Removal
WARNING

CAUTION

1. Drain the fluid from the master cylinder by bleeding the system at the rear caliper until all fluid has been expelled.
2. Disconnect the rear brake switch from the main harness, noting the routing of the cable for installation.
3. Using a suitable tool, release the rear brake pressure switch and remove from the motorcycle.
B00806
2. Rear brake pressure switch
Rear Brake Light Pressure Switch - Installation
WARNING

CAUTION
WARNING
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general
information section may reduce the efficiency of the braking system leading to an accident.
1. Fit the rear brake pressure switch and use a suitable tool to tighten to 15 Nm.

B00806
2. Rear brake pressure switch
2. Reconnect the rear brake pressure switch to the main harness, routing the cable as noted during removal.
3. Fill and bleed the rear brake system (see Bleeding the Rear Brakes).
WARNING
Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.

Removal and Installation - ABS Components
ABS Hydraulic Modulator - Removal
WARNING


Fuel Tank - Removal
1. Remove the two fixings and remove the ignition switch cover.
CAUTION
2. Drain the brake fluid from the front and rear master cylinders (for front brake master cylinder see Bleeding the Front Brakes, and for rear brake master cylinder see Bleeding
the Rear Brakes.
WARNING
Before the disassembly of any brake lines in the ABS hydraulic circuit, always mark their position so that they can be returned to the same position when assembled.
If the brake lines are incorrectly assembled the performance of the ABS system will be seriously compromised, leading to loss of motorcycle control and an accident.
3. Remove the rubber heat shield.

4. Disconnect the ABS modulator multiplug (see ABS Electrical Connectors).
4
3
B00935
1. Brake lines
2. ABS modulator
4. Rear fixings
5. Loosen the four brake lines at the ABS modulator.
WARNING
Do not allow the brake hard lines to become bent or kinked during ABS modulator removal. If the brake lines are bent or kinked the performance of the ABS system will be
seriously compromised, leading to loss of motorcycle control and an accident.
6. Noting their orientation, disconnect the four brake line unions and, taking care not to bend the brake lines, detach them from the ABS modulator.
7. Remove the front fixing for the ABS modulator.
8. Remove the two rear fixings for the ABS modulator.

9. Remove the ABS modulator.
10. Release the two fixings and remove the bracket from the ABS modulator.
1 2
B00936
1. ABS modulator bracket

2. Fixings
3. Flanged bushes
11. Collect the flanged bushes from the grommets.
ABS Hydraulic Modulator - Installation
WARNING

1. Align the ABS modulator to its bracket, fit the fixings and tighten to 9 Nm.
1 2
B00936
1. ABS modulator bracket

2. Fixings
3. Flanged bushes
2. Install the flanged bushes into the grommets.

3. Take care not to bend the brake lines and connect the four brake line unions to the ABS modulator as noted for removal. Tighten the four unions to 25 Nm.
4. Carefully manoeuvre the ABS modulator and bracket assembly to its fitted position on the frame. Make sure that the brake hoses are routed as noted during disassembly.
4
3
B00935
1. Brake lines
2. ABS modulator
4. Rear fixings
5. Fit the front fixing for the ABS modulator and tighten to 9 Nm.
6. Install the two rear fixings for the ABS modulator and tighten to 9 Nm.

7. Reconnect the ABS modulator multiplug, and make sure that the locking device is fully engaged (see ABS Electrical Connectors).
8. Install the rubber heat shield.
WARNING
9. Bleed the front brakes (see Bleeding the Front Brakes).

10. Bleed the rear brakes (see Bleeding the Rear Brakes).
WARNING
Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Check that the brakes operate correctly.
Front ABS Wheel Sensor - Removal
WARNING


Fuel Tank - Removal
Note
Note the routing of the harness and its retaining clips for installation.
1. Remove the fixings that attach the expansion tank to the frame. Move the expansion tank to get access to the fixings for the right frame infill panel .
2. Release the clutch cable clip from the infill panel and move the clutch cable aside.
3. Remove the two plastic rivets that attach the right frame infill panel and remove the infill panel.
3
B00938
1. Connector
2. Sensor harness
3. Clutch cable clip
4. Disconnect the electrical connector for the wheel speed sensor, identified as the white connector located in front of the ABS modulator.
5. Release the wheel speed sensor harness from the brake hose clips.
6. Release the bolt and remove the wheel speed sensor. Collect the shim from between the sensor and the fork leg.
B00937

1. Front ABS wheel speed sensor
2. Bolt
Front ABS Wheel Sensor - Installation
WARNING

Note
Check the condition of the shim before use. Do not use a shim which is bent or damaged.
1. Position the wheel speed sensor to the fork leg with its shim between the sensor and fork leg. Temporarily fit the original bolt and tighten to 9 Nm.
2. The air gap between the wheel speed sensor and the pulser ring must be between 0.1 mm and 1.5 mm. Check and adjust the wheel speed sensor air gap as described in
Air Gap Measurement - Front and Rear ABS Wheel Speed Sensors.
3. Once the wheel speed sensor air gap measurement is correct, install the bolt (if not already replaced during air gap adjustment) and tighten to 9 Nm.
4. Route the harness and secure it to the brake hose clips as noted during removal.
5. Connect the wheel speed sensor multiplug.
3
B00938
1. Connector
2. Sensor harness
3. Clutch cable clip
6. Position the right frame infill panel and install the plastic rivets.
7. Reposition the clutch cable and install the cable clip into the frame infill panel.
8. Position the expansion tank and install the fixings. Tighten the fixings to 3 Nm.
WARNING
ABS Pulser Ring - Inspection
1. Check the ABS pulser ring for damaged, missing or cracked teeth or distortion. Renew the ABS pulser ring as necessary.
Rear ABS Wheel Speed Sensor - Removal
WARNING


1. Remove the fixings and the seat bridge.
2
1

1
B00625
1. Fixings
2. Seat bridge
2. Release the electrical connector for the wheel speed sensor from the tab on the right rear side panel. The connector is white and located under the seat bridge, on the right
side.
B00940
1. Rear side panel

2. Connector
3. Connector attachment tab
3. Disconnect the electrical connector for the wheel speed sensor.

Note
Note the routing of the ABS wheel speed sensor harness for installation.
4. Release the wheel speed sensor cable from the brake hose clips.
6. Release the fixing securing the wheel speed sensor to the rear brake caliper carrier and remove the sensor. Collect the shim(s).
2
B00939 1
1. ABS wheel speed sensor

2. Fixing
3. Shim(s)
Rear ABS Wheel Speed Sensor - Installation
WARNING

Note
Check the condition of the shim before use. Do not use a shim which is bent or damaged.
1. Route the ABS sensor cable as noted during removal.
2. Retain the cable for the sensor with the bleed screw cover.
3. Measure the length of the cable from the bleed screw cover to the cable entry on the ABS sensor. The length must be 170 mm.
170mm

170mm
B00982
4. Position the shim between the wheel speed sensor and the brake caliper carrier.
5. Fit the wheel speed sensor and shim to the brake caliper carrier as noted during removal. Route the cable in a smooth arc.
6. Temporarily fit the bolt and tighten to 9 Nm.
7. The air gap between the wheel speed sensor and the pulser ring must be between 0.1 mm and 1.5 mm. Check and, if necessary, adjust the wheel speed sensor air gap as
described on page Air Gap Measurement - Front and Rear ABS Wheel Speed Sensors.
8. Once the wheel speed sensor air gap measurement is correct, install the bolt and tighten to 9 Nm.
9. Attach the ABS sensor cable to its clips on the brake hose.
10. Connect the electrical connector for the wheel speed sensor.
11. Attach the connector to the tab on the right rear side panel.
B00940
1. Rear side panel

2. Connector
12. Position the seat bridge and install the fixings. Tighten to 5 Nm.
2
1
B00625
1. Fixings
2. Seat bridge

Rear ABS Pulser Ring - Removal
WARNING


2. Support the wheel on blocks to avoid damage to the wheel centre.
3. Remove and discard the four screws and remove the ABS pulser ring and brake disc.
1 2
3

3
B01034
1. Brake disc
2. Fixing
3. ABS pulser ring
ABS Pulser Ring - Inspection
1. Check the ABS pulser ring for damaged, missing or cracked teeth or distortion. Renew the ABS pulser ring as necessary.
Rear ABS Pulser Ring - Installation
WARNING

1. Locate the brake disc and ABS pulser ring to the rear wheel as noted during removal.
3. Refit the rear wheel (see Rear Wheel - Installation.
4. TCheck, and if necessary, adjust the air gap between the wheel speed sensor and the ABS pulser ring (see Air Gap Measurement - Front and Rear ABS Wheel Speed
Sensors).
5. Check that the brakes operate correctly.
WARNING
Wheels and Tyres

Exploded View - Front Wheel

Exploded View - Rear Wheel
Wheels - Inspection
WARNING
Only remove raised witness marks from within the wheel. Removal of material below any raised areas will reduce the level of interference between the wheel and the
bearings. Loss of interference could cause the bearing to become loose in the wheel leading to loss of motorcycle control and an accident.
1. Examine the wheel for any raised witness marks caused by the bearing removal process. Remove any such marks with fine emery paper or a gentle file.
Wheel Bearings - Inspection
1. Check the wheel bearings spin smoothly with no signs of play. If not, renew the bearings.
Tyres

This model is equipped with tubeless tyres, valves, and wheel rims. Only tyres marked TUBELESS and tubeless type tyre valves mounted on rims marked SUITABLE FOR
TUBELESS TYRES can be used.
Typical Wheel Marking (front wheel shown)
ccom
Typical Tyre Marking
WARNING
Tyres that have been used on a rolling road dynamometer may become damaged. In some cases, the damage may not be visible on the external surface of the tyre.
Tyres must be replaced after such use as continued use of a damaged tyre may lead to instability, loss of control and an accident.
Important Tyre Information
All Triumph motorcycles are carefully and extensively tested in a range of riding conditions to ensure that the most effective tyre combinations are approved for use on each
model. It is essential that approved tyre combinations are used when purchasing replacement tyres as the use of non-approved tyres or approved tyres in non-approved
combinations may lead to motorcycle instability. A list of approved tyres specific to this model is available from your authorised Triumph dealer, or on the internet at
www.triumph.co.uk.
WARNING
The ABS computer operates by comparing the relative speed of the front and rear wheels. Use of non-recommended tyres can affect wheel speed and cause the ABS
function not to operate, potentially leading to loss of motorcycle control and an accident in conditions where the ABS would normally function.
WARNING
Always check tyre pressures before riding when the tyres are cold. Operation with incorrectly inflated tyres may affect handling leading to loss of control and an accident.
WARNING
Operation with excessively worn or damaged tyres will adversely affect handling and control leading to loss of control or an accident.
WARNING
Inner tubes must only be used on motorcycles fitted with spoked wheels and with tyres marked 'TUBE-TYPE' unless marked otherwise.
Use of an inner tube with a tyre marked 'TUBELESS' without appropriate marking and/or on an alloy wheel can lead to loss of motorcycle control and an accident.
All Triumph motorcycles are carefully and extensively tested in a range of riding conditions to ensure that the most effective tyre combinations are approved for use on each
model. It is essential that approved tyre combinations are used when purchasing replacement tyres as the use of non-approved tyres or approved tyres in non-approved
combinations may lead to motorcycle instability. A list of approved tyres specific to this model is available from your authorised Triumph dealer, or on the internet at
www.triumph.co.uk.
WARNING
If a tyre or inner tube sustains a puncture, the tyre and inner tube must be replaced together. Failure to replace a punctured tyre and inner tube together, or operation with a
repaired tyre or inner tube can lead to instability, loss of motorcycle control or an accident.
If tyre or inner tube damage is suspected, such as after striking the kerb, ask your authorised Triumph dealer to inspect the tyre both internally and externally and to also
inspect the inner tube. Remember, tyre damage may not always be visible from the outside. Operation of the motorcycle with damaged tyres could lead to loss of motorcycle

WARNING
When replacing a 'TUBE-TYPE' tyre on a spoked wheel, always inspect the rim tape (rim protection band) to ensure that it is correctly protecting the tube from the spoke
threads. A damaged rim tape may lead to rapid tyre deflation causing loss of control and an accident.
WARNING
Do not install tube-type tyres on tubeless rims. The bead will not seat and the tyres could slip on the rims, causing tyre deflation that may result in a loss of motorcycle
Do not install an inner tube inside a tubeless tyre unless it is clearly marked on the side wall that you can do so. This may cause instability and excessive heat build-up may
cause the tube to burst resulting in rapid tyre deflation, loss of vehicle control and an accident.
WARNING
The use of tyres other than those listed at your authorised Triumph dealer, or on the internet, at www.triumph.co.uk, may adversely affect handling leading to loss of
motorcycle control or an accident. Use the recommended tyre options only in the combinations listed at your authorised Triumph dealer, or on the internet at
www.triumph.co.uk. Do not mix tyres from different manufacturers or tyres from the same manufacturer but from another option.
WARNING
Accurate wheel balance is important for safe, stable handling of the motorcycle. Do not remove or change any wheel balance weights. Incorrect wheel balance may cause
instability leading to loss of motorcycle control and an accident.
When wheel balancing is required, such as after tyre replacement, see your authorised Triumph dealer.
Only use self-adhesive weights. Clip-on weights will damage the wheel and tyre potentially resulting in tyre deflation, loss of motorcycle control and an accident.
WARNING
When replacement tyres are required, consult your authorised Triumph dealer who will arrange for the tyres to be fitted according to the tyre manufacturer’s instructions.
When tyres are replaced, allow time for the tyre to seat itself to the rim (approximately 24 hours). During this seating period, ride cautiously as an incorrectly seated tyre
could cause loss of motorcycle control or an accident. Initially, the new tyre will not produce the same handling characteristics as the worn tyre and the rider must allow
adequate riding distance (approximately 100 miles/160 km) to become accustomed to the new handling characteristics.
After both 24 hours and 100 miles (160 km), the tyre pressures should be checked and adjusted and the tyre examined for correct seating and rectified as necessary.
Use of a motorcycle when not accustomed to its handling characteristics, with incorrect tyre pressures or an incorrectly seated tyre is dangerous and may lead to loss of
Tyre Wear/Wheel Inspection
As the tyre tread wears down, the tyre becomes more susceptible to puncture and failure. It is estimated that 90% of all tyre failures occur during the last 10% of tread life (90%
worn). It is false economy and unsafe to use tyres until they are worn to their minimum.
All tyres are fitted with tread wear indicators. When the tyre becomes worn down as far as the top of a tread wear indicator, the tyre is worn beyond its service life and must be
replaced.
1. Tread wear indicator
Attention must also be paid to the legal limits for tread wear, which differ from country to country. Tyres that have worn to the legal limit in the country or region in which the
motorcycle is operated must be replaced, even if tread wear has not yet reached the level of the tread wear indicators.
In accordance with the scheduled maintenance chart, measure the depth of the tread with a depth gauge, and replace any tyre that has worn to, or beyond the minimum
allowable tread depth.
Inspect wheels for cracks, splits and kerb damage. Always replace wheels that are suspected of having become damaged.
WARNING
Operation with excessively worn tyres is hazardous and will adversely affect traction, stability and handling which may lead to loss of control and an accident.
When tubeless tyres, used without a tube, become punctured, leakage is often very slow. Always inspect tyres very closely for punctures. Check the tyres for cuts,
embedded nails or other sharp objects. Operation with punctured or damaged tyres will adversely affect motorcycle stability and handling which may lead to loss of control
or an accident.
Check the rims for dents or deformation. Operation with damaged or defective wheels or tyres is dangerous and loss of motorcycle control or an accident could result.
Always consult your authorised Triumph dealer for tyre replacement, or for a safety inspection of the tyres.
Tyre Pressures
Correct inflation pressure will provide maximum stability, rider comfort and tyre life.
Always check tyre pressures before riding when the tyres are cold. Check tyre pressures daily and adjust if necessary.
For details of the correct tyre inflation pressures refer to www.triumph.co.uk.

WARNING
Incorrect tyre inflation will cause abnormal tread wear and instability problems which may lead to loss of control and an accident.
Under-inflation may result in the tyre slipping on, or coming off the rim. Over-inflation will cause instability and accelerated tread wear.
Both conditions are dangerous as they may cause loss of control leading to an accident.
Tyre Pressure Monitoring System (TPMS) - (if fitted)
WARNING
Incorrect tyre inflation will cause abnormal tread wear and instability problems that may lead to loss of control and an accident.
Underinflation may result in the tyre slipping on, or coming off the rim. Overinflation will cause instability and accelerated tread wear.
Both conditions are dangerous as they may cause loss of control leading to an accident.
WARNING
The tyre pressure monitoring system is not to be used as a tyre pressure gauge when adjusting the tyre pressures. For correct tyre pressures, always check the tyre
pressures when the tyres are cold and using an accurate tyre pressure gauge.
Use of the TPMS system to set inflation pressures may lead to incorrect tyre pressures leading to loss of motorcycle control and an accident.
CAUTION
Do not use anti puncture fluid or any other item likely to obstruct air flow to the TPMS sensor’s orifices. Any blockage to the air pressure orifice of the TPMS sensor during
operation will cause the sensor to become blocked, causing irreparable damage to the TPMS sensor assembly. Damage caused by the use of anti puncture fluid or incorrect
maintenance is not considered a manufacturing defect and will not be covered under warranty. Always have your tyres fitted by your authorised Triumph dealer and inform
them that tyre pressure sensors are fitted to the wheels.
Wheels fitted with a tyre pressure sensor can be identified with the letters TPMS on the side of the tyre valve and/or with a warning label near the tyre valve, as shown in the
illustration below.
2
T0907_1
1. TPMS on tyre valve

2. Warning label
Function
Tyre pressure sensors are fitted to the front and rear wheels. These sensors measure the air pressure inside the tyre and transmit pressure data to the instruments. These
sensors will not transmit the data until the motorcycle is travelling at a speed greater than 12 mph (20 km/h). Two dashes will be visible in the display area until the tyre
pressure signal is received.
When the battery voltage in a pressure sensor is low, BATTERY LOW FRONT/REAR TYRE will be displayed and a message will indicate which wheel sensor has the low
battery voltage. If the batteries are completely flat, only dashes will be shown in the display screen, the red TPMS warning light will be on and the TPMS symbol will flash
continuously.
The tyre pressure warning light works in conjunction with the tyre pressure monitoring system.
It will illuminate for the following conditions:
A tyre pressure sensor battery is completely flat.
The front and/or the rear tyre pressure drops to or below the pressures listed in the table below.
Tyre Pressure Monitor - Low Pressure Warning Light Activated
Front Tyre Pressure Rear Tyre Pressure
2.00 bar (29 lb/in²) 2.55 bar (37 lb/in²)
When the warning light is illuminated, the TPMS symbol will indicate which is the deflated tyre and its pressure will automatically be visible in the display area.
Minimum Recommended Tread Depth
In accordance with the periodic maintenance chart, measure the depth of the tread with a depth gauge, and replace any tyre that has worn to, or beyond the minimum legally
allowable tread depth specified (see Wheels and Tyres C*7).
WARNING
Triumph motorcycles must not be operated above the legal road speed limit except in authorised closed-course conditions.

WARNING
Only operate this Triumph motorcycle at high speed in closed-course, on-road competition or on closed-course racetracks. High-speed operation should only then be
attempted by riders who have been instructed in the techniques necessary for high speed riding and are familiar with the motorcycle's characteristics in all conditions. High-
speed operation in any other circumstances is dangerous and may lead to loss of motorcycle control and an accident.
Tyre Pressure Sensor - Removal - (if fitted)
WARNING

Note
The method for the removal of the tyre pressure sensor is the same for the front and rear wheels.
Wheels fitted with a tyre pressure sensor can be identified with the letters TPMS on the side of the tyre valve and/or with a warning label near the tyre valve, as shown in the
illustration below.
2
T0907_1
1. TPMS on tyre valve

2. Warning label
If fitting new wheels and using the original tyre pressure sensors, make a note of the front and rear pressure sensor serial numbers to make sure they are fitted to the correct
wheel.
1
2
T0912
1. Tyre pressure sensor

2. ID number

1. For the removal of the tyre note the following:
The tyre lever/removal tool must start 30° away from the tyre valve and move away from the tyre valve.
4
30°
1
2
3
T0913

1. Position for tyre lever/removal tool
2. Tyre valve
4. Direction of wheel rotation
Note
Note the orientation of the tyre valve for installation.
2. Release the fixing and remove the tyre pressure sensor and the tyre valve.
T0910

2. Tyre valve
3. Fixing
Tyre Pressure Sensor - Installation - (if fitted)
Note
If fitting the original tyre pressure sensors, make sure they are fitted to the correct wheel using the serial number on the sensor as noted for removal.
If fitting new tyre pressure sensors, record the serial numbers of the front and rear tyre pressure sensors in the spaces provided on the relevant page of the
Owner’s Handbook.
Note
The method for the installation of the tyre pressure sensor is the same for the front and rear wheels.
1. Make sure that the mounting hole on the wheel rim and the area around it is free from any dirt or grease.
2. Make sure that the seal is fitted to the tyre valve.
2
1
T0909_2
1. Tyre valve
2. Seal
3. Align the tyre valve to its mounting hole in the wheel rim. Make sure that the tyre valve orientation is the same as noted for removal.
2
T0909_3
1. Tyre valve
2. Hole

CAUTION
The edges of the tyre pressure sensor must be parallel to the walls of the wheel well. Damage to the sensor may result if the sensor is not correctly installed.
4. Fit the sensor to the tyre valve and tighten the fixing of the sensor to 4.5 Nm. Make sure that the sensor is not forced against the walls of the wheel well while tightening.
T0910

2. Tyre valve
3. Fixing
5. Ensure that the position of the sensor is parallel to the walls of the wheel rim, as shown in the illustration below.
T0911

2. Fixing
6. When secure, the gap between the sensor and the wheel rim must be a minimum of 0.8 mm and must have a limited twist movement around its fixing.
1. Wheel rim
2. Fixing
7. Refit the tyre noting the following:

The tyre lever/installation tool must start 30° away from the tyre valve and move away from the tyre valve.
4
30°
1
2

3
T0913
1. Position for tyre lever/installation tool

2. Tyre valve
4. Direction of wheel rotation
8. Check and, if necessary, adjust the balance of the wheel.

Wheel Spoke Tensioning
WARNING

WARNING
Do not replace more than two spokes on each wheel. If a wheel requires more than two spokes replacing, the wheel must be rebuilt by a specialist wheel builder.
Incorrectly built wheels will adversely affect traction, stability and handling which may lead to loss of control and an accident.
Note that some parts are not shown in the illustrations to provide more clarity.
Wheel Spoke Nipple Torques
Front Wheel Spoke Nipple 3 Nm
Rear Wheel Spoke Nipple 3 Nm

1. Starting at the tyre valve, check that the torque of each wheel spoke nipple is a minimum of 3 Nm.
If three or more front wheel spoke nipples were less than 3 Nm continue to Front Wheel Run-out.
If three or more rear wheel spoke nipples were less than 3 Nm continue to Rear Wheel Run-out.
4
1
ckql
1. Wheel spoke nipple

2. Wheel spoke
3. Tyre valve
4. Wheel rim
5. Wheel hub (brake disc removed for clarity)
Front Wheel Run-out
WARNING


Front Wheel Run-Out Limit
Frontr Wheel Rim Axial Run-Out 1.0 mm

Front Wheel Run-Out Limit
Front Wheel Rim Radial Run-Out 1.0 mm
1. Remove the tyre.

2. Install the wheel to a suitable wheel balance stand or wheel truing stand, or to the motorcycle but do not install the brake calipers.
3. Use a suitable dial test indicator gauge to measure the front wheel rim axial and radial run-out in the areas shown.
If the run-out is more than the provided specifications, the wheel must be rebuilt by a specialist wheel builder.
1. Front wheel rim axial run-out

2. Front wheel rim radial run-out
4. Refit the tyre.

Rear Wheel Run-out
WARNING

1. Position the motorcycle on a paddock stand.

WARNING
Do not allow the brake calipers to hang on the brake hoses as this may damage the hoses.
Damaged brake hoses could cause brake failure leading to loss of motorcycle control and an accident.
3. Detach and support the front brake calipers (see Front Brake Caliper - Removal).
Note
It is not necessary to disconnect the brake hoses.
4. Loosen both pinch bolts at the lower end of the right hand fork.
B00996
1. Fork pinch bolts

2. Wheel spacers (right hand shown)
5. Release and remove the wheel spindle, which is threaded into the left hand fork.
6. Remove the wheel and the wheel spacers.
7. Place the wheel on wooden blocks.
WARNING

WARNING
Do not allow the wheel to rest on either brake disc as this may damage the disc and could lead to loss of motorcycle control and an accident.
CAUTION
To prevent wheel and bearing damage, observe absolute cleanliness and ensure there is no dirt ingress to the wheel bearings while the wheel is removed.
8. Thoroughly clean all components and inspect for wear or damage.
WARNING

WARNING
Check the wheel rims for dents or deformation.


Raise and support the rear of the motorcycle.
Rear Wheel Run-Out Limit
Rear Wheel Rim Axial Run-Out 1.0 mm
Rear Wheel Rim Radial Run-Out 1.0 mm
1. Remove the tyre.

2. Install the wheel to a suitable wheel balance stand or wheel truing stand, or to the motorcycle but do not install the brake caliper.
3. Use a suitable dial test indicator gauge to measure the rear wheel rim axial and radial run-out in the areas shown.
If the run-out is more than the provided specifications, the wheel must be rebuilt by a specialist wheel builder.
The tyre is shown removed for clarity.
1. Rear wheel rim radial run-out

2. Rear wheel rim axial run-out
4. Refit the tyre.

WARNING

1. Lightly smear the wheel spacers with grease and locate in the hubs.
2. Position the wheel between the forks ensuring the spacers remain in position on both sides.

B00996
1. Fork pinch bolts

2. Wheel spacers (right hand shown)
3. Refit the wheel spindle from the right hand side and tighten to 65 Nm.
4. Lower the motorcycle to the ground and pump the front suspension to allow the left hand fork to float to its natural position on the wheel spindle.
5. Check that the brake disc is centrally located to the caliper on the left hand side. If not, apply gentle pressure to the fork to ensure the disc is centred with the caliper.
6. Maintaining the above position, tighten the fork pinch bolts to 22 Nm.
7. Fully clean and degrease the brake discs.
8. Refit the front brake calipers (see Front Brake Caliper - Installation).
WARNING
9. Check the operation of the front brake.
WARNING

WARNING
1. Raise and support the rear of the motorcycle to allow removal of the rear wheel.
2. Remove and discard the nut from the rear wheel spindle. Collect the left hand chain adjuster block.
3. Support the wheel and withdraw the wheel spindle. Collect the right hand chain adjuster block from the spindle.
4. Roll the wheel forward until the chain can be detached from the rear sprocket.
5. The rear brake caliper and brake caliper carrier will remain in position on the swinging arm when the wheel is removed.
WARNING
Do not allow the brake caliper to hang on the brake hose as this may damage the hose.
Damaged brake hoses could cause brake failure leading to loss of motorcycle control and an accident.
6. Withdraw the wheel and collect the flanged spacer from the right hand side and the plain spacer from the left hand side.
7. Place the wheel on wooden blocks with the drive sprocket uppermost.
8. Remove the final drive (see Rear Sprocket Carrier and Cush Drive - Removal).
9. Reposition the wheel on wooden blocks with the rear brake disc uppermost.
10. If required, remove the rear brake disc and discard the disc bolts.
11. If required, remove the rear brake caliper and brake caliper carrier from the swinging arm.
WARNING


WARNING
1. Thoroughly clean and degrease the brake disc.

2. Fit the brake disc and tighten new disc bolts to 22 Nm.
3. Refit the final drive assembly (see Rear Sprocket Carrier and Cush Drive - Installation.
CAUTION
The contact area between the swinging arm and the chain adjuster blocks must be free from accumulated dirt, grit, road salt and corrosion.
Thoroughly clean the contact areas on the swinging arm and the chain adjuster blocks before fitting the chain adjuster blocks.
If the contact areas are not clean, damage to the chain adjuster blocks may result when the rear wheel spindle is tightened.
4. Thoroughly clean the contact areas on the swinging arm and the chain adjuster blocks.
5. Position the wheel within the swinging arm and refit the chain to the final drive sprocket.
Fitting the Chain
6. Position the rear brake caliper and brake caliper carrier to the swinging arm as noted prior to removal. Align the boss on the swinging arm with the slot on the brake caliper
carrier.
3 2
1
B00803 4

4. Swinging arm
7. Refit the wheel spacers, flanged spacer to the right hand side (flange facing outwards) and plain spacer to the left.
1. Wheel spacer (right hand shown)
8. Lift the rear wheel into position, aligning the wheel, brake caliper carrier and swinging arm.

WARNING
Check that the spacers are still correctly positioned. Incorrectly fitted wheel spacers will cause a dangerous riding condition leading to loss of motorcycle control and an
accident.
9. Make sure the right hand chain adjuster block is installed on the wheel spindle.
10. Fit the wheel spindle with the threaded end facing to the left.
11. Fit the left hand chain adjuster block and a new rear wheel spindle nut.
12. Keeping the chain adjuster blocks in contact with the adjuster bolts, tighten the wheel spindle nut to 110 Nm.
13. Lower the motorcycle to the ground.
WARNING
14. Check the operation of the rear brake.

15. Check and, if necessary, adjust the chain (see Final Drive Chain Free-Movement - Adjustment ).
Front Wheel Bearings - Removal
CAUTION
Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc
is raised above the ground.
1. Remove the front wheel (see Front Wheel - Removal).

2. Place the wheel on wooden blocks to prevent damage to the brake discs.
3. Remove and discard the seals and the bearing circlip.
WARNING
CAUTION
To prevent wheel damage and to aid bearing removal, always apply force evenly on both sides of the bearing to prevent it from tipping and becoming stuck. Application of
uneven force will lead to difficulty in removing the bearing and to a damaged wheel.
4. Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect the centre sleeve.
cdgd
Wheel Bearing Removal
Front Wheel Bearings Inspection

WARNING
1. Examine the wheel for any raised witness marks caused by the removal process. Remove any such marks with fine emery paper or a gentle file.
Front Wheel Bearings - Installation
Note
Bearings are inserted by means of a draw bolt acting on the insertion tool. A support tool is located on the opposite side of the wheel to the insertion tool and
as the bolt is tightened, the bearing is drawn into the wheel.
Always fit a new bearing circlip and seals.
1. Assemble the wheel bearing to the side of the wheel with the circlip groove and the installation tools as noted in the diagram below.
2. Support the wheel and tighten the nut (3) drawing in the bearing until it is fully located against the inner face of the wheel.
3 1
cdgd
4 2
1. T3880075 - Bearing Installer

2. T3880053 - Wheel Bearing Extraction Kit
3. Nut and washer
4. Wheel
Note
Check that the spacer is centrally positioned against the inner wheel bearing race.
3. Support the previously installed wheel and bearing using T3880053 - Wheel Bearing Extraction Kit and fit the spacer.
2
cdgd
1. Spacer
CAUTION
Do not allow the spacer to become misaligned.

A misaligned spacer may cause the wheel bearings inner and outer races to be misaligned during installation.
Premature wear and irreparable damage to components may be caused by incorrectly installed wheel bearings.
4. Support the previously installed wheel bearing using T3880053 - Wheel Bearing Extraction Kit and using T3880065 - Bearing Installer, tighten the nut to draw the remaining
wheel bearing into the wheel until it is fully seated.

3 1
cdgd
1. Nut and washer

4. Wheel bearing
5. Fit a new circlip into the groove on the opposite side of the wheel.
2 1
cdgd
1. Circlip
2. Circlip groove
Note
Circlip side: Install the seal until it touches the circlip.
Opposite to circlip side: Install the dust seal until its outer face is 2.2 mm +/- 0.5 mm below the outer face of the hub. The seal must not touch the bearing.
6. Lubricate and fit new dust seals to the front wheel. Lubricate the seal's knife-edge with high-temperature grease to NLGI 2 specification.
1
2.2 mm
±0.5mm
1
cdgd
1. Dust seal

Front Brake Discs - Installation
Rear Wheel Bearings - Removal
CAUTION

2. Place the wheel on wooden blocks to prevent damage to the brake disc.
3. Remove and discard the seals and the bearing circlip.
WARNING
CAUTION
To prevent wheel damage and to aid bearing removal, always apply force evenly on both sides of the bearing to prevent it from tipping and becoming stuck. Application of
uneven force will lead to difficulty in removing the bearing and to a damaged wheel.
4. Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect the centre sleeve.

Rear Wheel Bearing Removal
Rear Wheel Bearings Inspection
WARNING
1. Examine the wheel for any raised witness marks caused by the removal process. Remove any such marks with fine emery paper or a gentle file.
Rear Wheel Bearings - Installation
Note
Bearings are inserted by means of a draw bolt acting on the insertion tool. A support tool is located on the opposite side of the wheel to the insertion tool and
as the bolt is tightened, the bearing is drawn into the wheel.
Always fit a new bearing circlip and seals.
1. Assemble the wheel bearing to the side of the wheel with the circlip groove and the installation tools as noted in the diagram below.
2. Support the wheel and tighten the nut (3) drawing the bearing until it is fully located against the inner face of the wheel.
3 1
cdgd
4 2

3. Nut and washer
4. Wheel
Note
Check that the spacer is centrally positioned against the inner wheel bearing race.
3. Support the previously installed wheel and bearing using T3880053 - Wheel Bearing Extraction Kit and fit the spacer.
2
cdgd
1. Spacer
CAUTION

CAUTION
Do not allow the spacer to become misaligned.

A misaligned spacer may cause the wheel bearings inner and outer races to be misaligned during installation.
Premature wear and irreparable damage to components may be caused by incorrectly installed wheel bearings.
4. Support the previously installed wheel bearing using T3880053 - Wheel Bearing Extraction Kit and using T3880065 - Bearing Installer, tighten the nut to draw the remaining
wheel bearing into the wheel until it is fully seated.
3 1
cdgd
1. Nut and washer

4. Wheel bearing
5. Fit a new circlip into the groove on the opposite side of the wheel.
2 1
cdgd
1. Circlip
2. Circlip groove
Note
Circlip side: Install the seal until its outer face is 2 mm +/- 0.5 mm below the outer face of the hub.
6. Lubricate and fit a new dust seal to the rear wheel. Lubricate the seal's knife-edge with grease to NLGI 2 specification.
1
cdgd
1. Dust seal

Rear Sprocket Carrier and Cush Drive - Installation
Final Drive
Exploded View – Final Drive

Final Drive Chain
For safety and to prevent excessive wear, the drive chain must be checked, adjusted and lubricated in accordance with scheduled maintenance requirements. Checking,
adjustment and lubrication must be carried out more frequently for extreme conditions such as salty or heavily gritted roads.
If the drive chain is badly worn or incorrectly adjusted (either too loose or too tight) the drive chain could jump off the sprockets or break.
WARNING
A drive chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing an accident.
Never neglect chain maintenance.
Note
Lubrication of the drive chain should ideally be carried out with the motorcycle set up so that the rear wheel is free to rotate.
The drive chain must be adjusted with the motorcycle in an upright position, resting on its wheels, and with no additional weight on it.
Final Drive Chain Lubrication
Lubrication is necessary every 200 miles (300 km) and also after riding in wet weather, on wet roads, or any time that the chain appears dry.
Use the special drive chain lubricant as recommended in the specification section.
Correct application is critical for drive chain lubrication. Apply the lubricant for one full drive chain revolution only, then leave for eight hours before riding. This allows the
lubricant’s solvent (used to thin the oil) to evaporate and the oil to 'soak' into all parts of the drive chain. If the lubricant is applied and the motorcycle is ridden shortly
afterwards, the lubricant is unlikely to reach all parts and the majority will be flung off and wasted. Applying excessive amounts is not helpful under any circumstances.
It should be noted that the lubricant is applied to the drive chain to lubricate its action across the sprockets. In an O-ring chain, external lubrication does not penetrate to the
bushes and rollers as the O-ring seals prevents this from happening.
CAUTION
Do not use a power jet washer to clean the chain as this may cause damage to the chain components.
Final Drive Chain and Sprocket Wear - Inspection

WARNING

10-20
KG
2
1. Measurement across 20 links

2. 10 - 20 kg weight
1. Remove the upper and lower chain guards from the swinging arm.
2. Stretch the drive chain taut by hanging a 10 - 20 kg (20 - 40 lb) weight on the chain.
3. Measure a length of 20 links on the straight part of the drive chain from pin centre of the 1st pin to pin centre of the 21st pin. Repeat the test at various sections of the chain
to establish an average reading. This is because the chain may wear unevenly.
4. If the length exceeds the service limit of 317 mm, the drive chain must be replaced.
WARNING
A drive chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing loss of
5. Examine the whole length of the drive chain. If there are any excessively tight or loose sections, loose pins or damaged rollers, the drive chain should be replaced.
6. Inspect sprockets for unevenly or excessively worn teeth. Also examine the sprockets for damaged teeth.
Note
Sprocket wear is exaggerated for illustration purposes.
WARNING
The use of non-approved chains may result in a broken chain or may cause the chain to jump off the sprockets.
Use a genuine Triumph supplied chain as specified in the Triumph Parts Catalogue.
Never neglect chain maintenance and always have chains installed by an authorised Triumph dealer.
7. If there is any irregularity found in any of the components, replace the drive chain and/or any other damaged components.
8. Refit the lower drive chain guard, tightening the fixings to 7 Nm.
9. Refit the upper drive chain guard, tightening the fixings to 9 Nm.
Drive Chain - Replacement (Rivet link type)
The following instructions for the replacement of rivet link type drive chains requires the use of T3880027 - Chain Link Tool Kit.
WARNING

1. Support the motorcycle on a stand so the rear wheel is clear of the ground.
2. Insert the hollow chain cutting tail piece into the tool body so its larger diameter end is facing towards the large pressure screw as shown.

3
cdqk1
1. T3880027 - Chain Link Tool Kit

2. Large pressure screw
3. Chain cutting tail piece
3. Position the chain to the tool ensuring that the chain link pin which is to be removed is aligned with the holes in the chain cutting tail piece and the large pressure screw.
Tighten the large pressure screw by hand to grip the chain.
cdqm_1

3. Chain
4. Chain cutting tail piece
4. Insert the small pressure screw into the larger pressure screw as shown below, until the cutting pin on the small pressure screw contacts the link pin. Ensure that the cutting
pin is centralised on the link pin to be removed.
cdql_1

2. Small pressure screw
5. Retain the tool body then tighten the small pressure screw until the link pin is pressed out from the chain.
6. Repeat steps 3 to 5 on the remaining chain link pin.
7. Remove the tool and separate the two ends of the chain.
8. Remove the chain cutting tail piece from the body.
Note
The replacement chain is supplied in a split condition, complete with a link kit to join the two ends.
CAUTION
The component parts of the new link kit are coated with a special grease which must not be removed. Removal of this special grease will severely reduce the service life of
the chain.
9. Use the old drive chain to pull the new chain into position as follows: Temporarily attach the end of the new chain to a free end of the old chain using the old connector link.
Carefully pull the other end of the old chain to pull the new chain around the sprockets.
Note
Do not use the new connector link as the special grease on it may be removed.

10. Using the new link supplied with the chain kit, join the two ends of the chain. Ensure that the O-rings are positioned as shown below and the link plate is fitted with its
markings facing outwards.
1 2
1 3
camw
1. O-rings
2. Link
3. Link plate
11. Insert the riveting tail piece into the tool body so its larger diameter end is facing towards the large pressure screw as shown in the following illustration.
Note
The T3880027 - Chain Link Tool Kit includes two link plate holders, one is for riveted link plates (marked PH5060R), the other is for link plates retained by a
spring clip (marked PH4060C). The holder for riveted link plates has a shallow groove to allow for chain link clearance, the holder for clipped link plates has a
deep groove to allow for chain link clearance.
12. Insert the link plate holder (marked PH5060R) into the large pressure screw.
cdqn_1
1. Tool body
3. Link plate holder (marked PH5060R)
4. Riveting tail piece
13. Position the tool to the chain. Ensure the link plate holder is correctly located in the large pressure screw.
cdqn_1
1. Tool body
3. Link plate holder (marked PH5060R)
14. Locate the split link pins such that the pins will enter the groove in the link plate holder when the link plate is pressed on to the link.
2 1

4
3
1. Link plate holder

2. Link plate
3. Chain link
4. Link plate holder groove
15. Retain the tool body and tighten the large pressure screw until the link plate is pressed fully onto the link.
16. Back off the pressure screw, slide the tool assembly to one side and check that the split link is correctly assembled.
17. Remove the link plate holder from the tool. Do not remove the riveting tail piece from the tool
18. Insert the flare pin into the large pressure screw.
cdqn_2
1. Tool body
4. Flare pin
19. Locate one of the split link pins into the riveting tail piece and screw the large pressure screw in until the flare pin contacts the split link end. Ensure the split link pin is
centrally located on the flare pin.
20. Retain the tool body and tighten the large pressure screw until the split link end is riveted-over.
cdqn_4
1. Tool body
3. Flare pin
21. Back off the large pressure screw and rivet the remaining split link pin as described above.
22. Remove the tool from the chain and check that both the split link pins are correctly riveted as shown below.
1 2 3 4
cana

1. Correct riveting
2. Insufficient riveting
3. Excessive riveting
4. Riveting off-centre
WARNING
If either split link pin is not correctly riveted, the split link must be removed and replaced with a new link. Never operate the motorcycle with an incorrectly riveted split link as
the link could fail resulting in an unsafe riding condition leading to loss of motorcycle control and an accident.
Drive Chain - Replacement (Endless type)
WARNING

Drive Chain Removal

Swinging Arm - Removal
1. Release the drive chain from the front sprocket.
Drive Chain Installation
1. Engage the chain onto the teeth of the front sprocket.

Swinging Arm - Installation
Front Sprocket - Removal
WARNING


Position the motorcycle on the side stand.
1. Bend back the front sprocket lock washer.
2. Have an assistant sit on the motorcycle, select sixth gear and apply the front and rear brakes hard.
3. Loosen the front sprocket nut.
1. Nut
2. Lock washer
3. Front sprocket
4. Remove the front sprocket nut and discard the lock washer.
5. Set the drive chain adjustment to allow maximum free play in the drive chain.
Note
Note the orientation of the front sprocket for installation.
6. Disengage the front sprocket from the drive chain and slide it off the output shaft.
Front Sprocket - Installation
WARNING


WARNING
1. Fit the front sprocket, as noted during removal, and engage it with the drive chain.
2. Fit a new lock washer engaging it with the output shaft splines, and fit the sprocket nut hand tight.
1. Nut
2. Lock washer
3. Front sprocket
3. Have an assistant sit on the motorcycle, select sixth gear and apply the front and rear brakes hard.
4. Tighten the front sprocket nut to 85 Nm.
5. Secure the front sprocket nut in position by bending the lock washer down to contact one of the nut flats.
Final Drive Chain Free-Movement - Adjustment
Rear Sprocket Carrier and Cush Drive - Removal
WARNING

CAUTION

1. Place the wheel on wooden blocks with the drive chain sprocket uppermost.
Note
Note the position and orientation of the spacer for installation.
2. Gently lever the drive chain sprocket and carrier from the wheel hub. Collect the spacer.
2 1
B00972
1. Rear wheel
2. Sprocket carrier
3. Remove the cush drive rubber.
2 1

B00969
1. Cush drive rubber

2. Sprocket carrier
Final Drive Inspection
1. Check the cush drive rubbers for deterioration, cracks etc.

2. Inspect the sprocket teeth for wear, damage and chips.
3. Check the wheel and drive flange for wear, cracks and damage.
Rear Sprocket Carrier Bearings - Disassembly

Rear Sprocket Carrier and Cush Drive - Removal
1. Remove and discard the seal.
1 2
B00968
1. Sprocket carrier
2. Seal
2. Remove and discard the bearing circlip.
1 2
B00970
1. Sprocket carrier
2. Circlip
WARNING
CAUTION
To prevent sprocket carrier damage and to aid bearing removal, always apply force evenly on both sides of the bearing to prevent it from 'tipping' and becoming stuck.
Application of uneven force will lead to difficulty in removing the bearing and to a damaged drive flange.
3. Turn the sprocket carrier over, and use a pin punch to drift out the ball bearing.
1 2

B00971
1. Sprocket carrier
2. Ball bearing
Rear Sprocket Carrier Bearings - Assembly
WARNING
When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up
1. Position the bearing to the drive flange.

2. Using a suitable press, fully insert the bearing into the sprocket carrier. Make sure that both the inner and outer races are pressed.
3. Fit a new circlip.
1 2
B00970
1. Sprocket carrier
2. Circlip
4. Install a new seal, marked side facing outwards, to the sprocket carrier.
1 2
B00968
1. Sprocket carrier
2. Seal
5. Lubricate the seal’s knife-edge with grease to NLGI 2 specification.

6. Install the cush drive rubbers to the sprocket carrier.
2 1

B00969
1. Cush drive rubber

2. Sprocket carrier
7. Fit the spacer to the wheel hub as noted for removal.

8. Refit the sprocket carrier to the wheel.
Rear Sprocket Carrier and Cush Drive - Installation
WARNING

CAUTION
1. Install the cush drive rubbers to the wheel hub.

2. Fit the spacer to the wheel hub as noted for removal.
3. Refit the sprocket carrier to the wheel.
Rear Sprocket - Removal
CAUTION

1. Place the wheel on wooden blocks with the drive chain sprocket uppermost.
2. Evenly and progressively, loosen, remove and discard the rear sprocket bolts and lock nuts.
Note
Note the orientation of the rear sprocket for installation.
3. Remove the rear sprocket from the sprocket carrier.
1 2
4 3
B00967
1. Sprocket
2. Bolt
3. Lock nut
4. Sprocket carrier
4. Discard the lock nuts.
Rear Sprocket - Installation
CAUTION
1. Fit the rear sprocket to the sprocket carrier as noted during removal.
1 2

4 3
B00967
1. Sprocket
2. Bolt
3. Lock nut
4. Sprocket carrier
2. Fit the bolts and new lock nuts. Hold the nuts and tighten the bolts evenly and progressively to 33 Nm.
Frame and Bodywork

Exploded View - Frame
Exploded View - Cockpit and Mountings

Exploded View - Fuel Tank Bodywork

Exploded View - Radiator Cowl Panels
Exploded View - Sump Guard

Exploded View - Rear Panels

Exploded View - Footrests and Mountings
Exploded View - Rear Mudguard and Battery Tray

Exploded View - Front Mudguard

Exploded View - Seats
Exploded View - Side Stand

Exploded View - Centre Stand
Exploded View - Engine Protection Bars

Exploded View - Ignition Switch and Lock Set

Exploded View - Hand Guards
Exploded View - Mirrors

Exploded View - Saree Guard - India Only

Exploded View - Reflectors
Removal
1. To remove the rider's seat, remove the passenger seat (see Passenger Seat - Removal/Installation).
WARNING
The seat has two height settings. Note the setting of the installed seat for installation.
2. Grasp the rider's seat on either side, and slide it rearwards and upwards.
3. If fitted, disconnect the electrical connector for the heated seat for complete removal from the motorcycle.

B00539
1. Rider's seat
CAUTION
To prevent damage to the seats or seat covers, care must be taken not to drop the seats. Do not lean the seats against the motorcycle or any surface which may damage
the seats or seat covers. Instead, place the seats, with the seat cover facing upwards, on a clean, flat surface which is covered with a soft cloth.
Do not place any item on the seats which may cause damage or staining to the seat covers.
Installation
WARNING
Make sure that the seat is installed at the correct height as noted during removal.
1. If fitted, reconnect the heated seat electrical connector.

2. Align the seat to the fuel tank seat panels, engage the front rail of the seat into the correct position on the bracket at the rear of the fuel tank, and lower the rear rail in to the
rear brackets.
3. Push down firmly on the rear of the seat.
4. Refit the passenger’s seat (see Passenger Seat - Removal/Installation).
WARNING
To prevent detachment of the seat during riding, after fitting always grasp the seat and pull firmly upwards. If the seat is not correctly secured it will detach from the lock. A
loose or detached seat could cause loss of motorcycle control and an accident.
1. The seat lock is located on the left rear side panel. To remove the seat, insert the ignition key into the seat lock and turn it anticlockwise while pressing down on the rear of
the seat. This will release the seat from its lock and allow it to be slid rearwards.
WARNING
The seat has two height settings. Note the setting of the installed seat for installation.
2. If fitted with heated seats, disconnect the heated seat’s electrical connector for complete removal from the motorcycle.
1
B00540
1. Seat lock
2. Subframe loops
3. Rear seat brackets
CAUTION
To prevent damage to the seats or seat covers, care must be taken not to drop the seats. Do not lean the seats against the motorcycle or any surface which may damage
the seats or seat covers. Instead, place the seats, with the seat cover facing upwards, on a clean, flat surface which is covered with a soft cloth.
Do not place any item on the seats which may cause damage or staining to the seat covers.
Installation
1. If fitted, reconnect the heated seat electrical connector.
WARNING
Make sure that the seat is installed at the correct height as noted during removal.
2. Engage the seat's two brackets under the loops on the subframe. Press down at the rear to engage in the seat lock.
WARNING

WARNING
To prevent detachment of the seat during riding, after fitting always grasp the seat and pull firmly upwards. If the seat is not correctly secured it will detach from the lock. A
loose or detached seat could cause loss of motorcycle control and an accident.
Fuel Tank Infill Panel - Removal

Fuel Tank End Panel - Removal
Cockpit Side Panel - Removal
1. Remove the six fixings that attach the fuel tank infill panel to the fuel tank.
3 2
3 2
B00628
1. Fuel tank infill panel

2. Fixings
3. Locating brackets
2. Lift the fuel tank infill panel upwards and forwards, releasing the rear hooks from the fuel tank brackets.
Fuel Tank Infill Panel - Installation
1. Engage the two moulded hooks on the fuel tank infill panel into the fuel tank brackets and position the infill panel.
3 2
3 2
B00628
1. Fuel tank infill panel

2. Fixings
3. Locating brackets
2. Install the six fixings and tighten to 3 Nm.

Cockpit Side Panel - Installation
Note
Follow the same procedure for both left and right hand sides.
1. Remove the two fixings that attach the fuel tank end panel.
2. Pull the end panel forward to release the location tab from its socket on the centre infill panel.
4
1
3

B00626
Forks removed for clarity, left side shown.

1. Fixings
2. Fuel tank end panel
3. Location tab
4. Location socket
3. Move the end panel infill panel down and inwards to release it.
B00627

1. End panel infill
2. Locating tab
3. Lower rear radiator cowl
Note
1. Insert the location tab of the infill for the fuel tank end panel, and align the bottom attachment hole with the tab on the lower rear radiator cowl.
2. Install the fuel tank end panel. Make sure that the location tab is correctly engaged in the location socket in the lower rear radiator cowl.
4
1
3
B00626

1. Fixings
2. Fuel tank end panel
3. Location tab
4. Location socket
Radiator Cowl Finisher - Removal
Note
1. Remove the fixing from the radiator cowl finisher.

B00631
1. Radiator cowl finisher

2. Fixing
2. Pivot the radiator cowl finisher up from the bottom and release it from the two locating tabs at the top edge and the attachment boss on the lower rear panel of the radiator
cowl .
B00632

2. Locating tabs
3. Attachment boss
Radiator Cowl Finisher - Installation
Note
1. Engage the two locating tabs at the top edge of the radiator cowl finisher.
2. Make sure that the attachment boss on the lower rear panel of the radiator cowl is correctly engaged.
3. Put the radiator cowl finisher into position.
4. Refit the fixing and tighten to 3 Nm.
B00631

2. Fixing
Radiator Cowl Panel - Removal
Note
Radiator Cowl Finisher - Removal
1. If the fuel tank is installed, remove the two fixings from the fuel tank.
2. Remove the shouldered fixing that attaches the radiator cowl panel to the radiator. Recover the washer.
2 2
3
4

B00629
1. Radiator cowl panel

2. Fuel tank fixings
3. Shouldered fixing
4. Washer
3. Remove the radiator cowl panel.
Radiator Cowl Panel - Disassembly
Note
CAUTION
1. Remove the three fixings that secure the front panel, infill panel and rear panel together.
2
1
3
2
4
B00630
1. Rear panel
2. Fixings
3. Infill panel
4. Front panel
2. Separate the three parts.
Radiator Cowl Panel - Assembly
Note
CAUTION
1. Assemble the front panel, infill panel and rear panel.
2
1
3
2
4
B00630
1. Rear panel
2. Fixings
3. Infill panel
4. Front panel
2. Install the three fixings and tighten to 3 Nm.
Radiator Cowl Panel - Installation
Note

Note
1. Put the radiator cowl panel in position.
2. If the fuel tank is fitted, install the two fuel tank fixings and tighten to 3 Nm.
2 2
3
4
B00629
1. Radiator cowl panel

2. Fuel tank fixings
3. Shouldered fixing
4. Washer
3. Install the washer and the shouldered fixing to attach the radiator cowl panel to the radiator. Tighten the fixing to 6 Nm.
Radiator Cowl Finisher - Installation
Radiator Cowl Duct - Removal
Note
Radiator Cowl Panel - Removal
1. Release the two plastic rivets that attach the radiator cowl duct to the housing for the radiator fan.
B00978 2 1

2. Plastic rivets
3. Radiator fan housing
2. Remove the radiator cowl duct .
Radiator Cowl Duct - Installation
Note
1. Position the radiator cowl duct.
2. Install the two plastic rivets that attach the radiator cowl duct to the housing for the radiator fan.

B00978 2 1

2. Plastic rivets
3. Radiator fan housing

Radiator Cowl Panel - Installation
Windscreen and Screen Support - Removal
WARNING

Windscreen Removal
1. Models with a front licence plate only: Counter hold the threaded spacers and remove the fixings. Remove the bracket.
ckqb 2
1. Windscreen lower fixings

2. Licence plate bracket
2. Remove the threaded spacers.

3. Models without a front licence plate: Remove the two lower fixings.
ckqb
1. Windscreen upper fixings

2. Windscreen lower fixings Windscreen lower
fixings
4. Remove the two upper fixings and remove the screen.
Screen Support Disassembly
1. Release the instrument cowl moulding from the rubber grommets.

2. Remove the well nuts from the central runner.
2 1

ckqa_1
3 4
1. Instrument cowl moulding

2. Well nuts
3. Central runner
4. Windscreen support moulding
5. Windscreen adjustment handle
3. Remove the central runner from the windscreen support moulding.

4. Remove the windscreen adjustment handle from the windscreen mounting bosses.
5. Remove the rubber washers from the windscreen mounting bosses.
3
1
3
ckpz

3. Rubber washers
6. Remove the fixings that attach the windscreen support moulding to the front subframe. Remove the windscreen support moulding.
2
1
ckpy
1. Windscreen fixings
7. Counter hold the windscreen mounting boss assembly and remove the adjuster fixing.
2
3
4
5
1
L0446

2. Windscreen mounting boss
3. Flanged sleeve
4. Adjuster spring
5. Adjuster fixing
8. Collect the windscreen mounting bosses from the windscreen support moulding.

2
1
3
5 4
ckqe
1. Fixings (left hand side)

2. Side screen (left hand)
3. Fixings (right hand side)
4. Side screen (right hand)
9. Remove the two fixings from each of the side screens and remove the side screens.
Windscreen and Screen Support - Installation
WARNING

Assemble the Screen Support
1. Fit both side screens to the windscreen support moulding. Install the fixings and tighten to 3 Nm.
WARNING
Do not fit the rubber washers and windscreen fixings at this stage.
1
3
5 4
ckqe
1. Fixings (left hand side)

2. Side screen (left hand)
3. Fixings (right hand side)
4. Side screen (right hand)
2. Fit the windscreen mounting boss to the windscreen support moulding.

3. Fit the flanged sleeve and adjuster spring.
3 4 5
7 6 2
ckqd


3. Flanged sleeve
4. Adjuster spring
5. Adjuster fixing
6. Rubber washer
7. Windscreen fixing
4. Counter hold the windscreen mounting boss assembly and tighten the adjuster fixing to 3 Nm.
5. Repeat for the remaining windscreen mounting boss assembly and tighten the adjuster fixing to 3 Nm.
2
3
4
5
1
L0446

3. Flanged sleeve
4. Adjuster spring
5. Adjuster fixing
6. Fit the windscreen support moulding to the front subframe and tighten the fixings to 5 Nm.
2
1
ckpy
1. Windscreen support fixings

7. Fit the rubber grommets into the windscreen support moulding.
2 1
ckpy
1. Grommets
8. Position the central runner to the windscreen support moulding and slide into position.
9. Fit the well nuts into the central runner.

ckqa_2
3 4

2. Well nuts
3. Central runner
10. Position the instrument cowl moulding and push firmly to locate the tabs into the grommets.
WARNING
Rubber washers are positioned between the windscreen mounting boss and the windscreen adjustment handle.
11. Fit the rubber washers to the windscreen mounting bosses.
3
1
3
ckpz

3. Rubber washers
12. Fit the windscreen adjustment handle to the windscreen mounting bosses.
4 3 3
4
ckqd
1. Windscreen adjustment handle

4. Rubber washers
Windscreen Installation
1. Models without a front licence plate: Position the windscreen to the windscreen support moulding.
WARNING
The windscreen is secured using shouldered fixings.
2. Fit and tighten the shouldered fixings to 3 Nm.

2
ckqb

3. Models with a front licence plate only: Position the windscreen to the windscreen support moulding.
WARNING
Threaded spacers and two shouldered fixings are used to secure the windscreen.
4. Fit the two shouldered fixings to the windscreen mounting boss.

5. Fit the two threaded spacers into the central runner.
6. Tighten the fixings to 3 Nm.
ckqb

2. Windscreen threaded spacers
WARNING
Threaded spacers and two fixings are used to secure the windscreen and licence plate.
7. Fit the licence plate bracket, counter hold the threaded spacers and tighten the fixings to 3 Nm.
ckqb 2

Beak - Removal and Disassembly
Beak Removal
1. Remove the four fixings that attach the beak to front subframe and remove the beak.
1
2

2
B00619
Forks shown removed for clarity.

1. Beak
2. Fixings
Beak Disassembly (If necessary)
1. Remove the three fixings that attach the beak infill panel to the beak painted panel.
B00598
1. Beak infill panel

2. Beak painted panel
3. Fixings
2. Separate the beak from the beak infill panel.
Beak - Assembly and Installation
Beak Assembly (if necessary)
1. Position the beak infill panel into the beak painted panel.
2. Install the three fixings and tighten to 1.5 Nm.
B00598
1. Beak infill panel

2. Beak painted panel
3. Fixings
Beak Installation
1. Put the beak in position on the front subframe.
1
2
2
B00619
Forks shown removed for clarity.

1. Beak
2. Fixings
2. Install the four fixings and tighten to 3 Nm.
Note
1. Remove the two fixings that attach the infill panel to the cockpit side panel.
B00620
Handlebars shown removed for clarity.

1. Cockpit side panel infill (Left side shown)
2. Fixings
2. Remove the fixing that attaches the cockpit side panel to the headlight.
B00621

1. Headlamp fixing
2. Cockpit side panel
3. Move the infill panel rearwards in the direction of the arrow shown below to release the panel from the front concealed fixing.
B00622

1. Cockpit side panel infill
4. Disconnect the electrical connectors for the indicator.

3
B00623

2. Fixings
3. Indicator connectors
5. Remove the fixings that attach the cockpit side panel bracket to the fuel tank and remove the cockpit side panel and bracket assembly.
Note
1. Position the cockpit side panel and bracket assembly onto the fuel tank.
B00623

1. Cockpit side panel (left side shown)
2. Fixings
3. Indicator connectors
3. Connect the electrical connectors for the indicator.

4. Engage the front of the infill panel onto the shouldered bolt on the cockpit side panel.
5. Push the infill panel into position.
B00624

6. Install the two fixings that attach the infill panel to the cockpit side panel and tighten to 3 Nm.

B00620

2. Fixings
7. Install the fixing that attaches the cockpit side panel to the headlamp. Tighten the fixing to 3 Nm.
B00621

1. Headlamp fixing
Seat Panel - Removal
Note
1. Remove the two fixings.
B00633
1. Seat panel
2. Fixings
2. Move the seat panel upwards in the direction of the arrows shown below to release the panel from the three attachment points.
B00635
1. Seat panel
Seat Panel - Installation
Note

1. Install the panel in the direction of the arrows shown below and engage the three attachment points.
B00634
1. Seat panel
2. Attachment points
B00633
1. Seat panel
2. Fixings

1. Note the routing of the brake hoses, the cable for the front wheel speed sensor and the hose clip positions for the installation procedure.
2. Detach the front brake hose from the clip on the front mudguard.
6
3
B00986
1. Brake hose clip

2. Brake hose
3. Wheel speed sensor cable
4. Rear fixing
5. Front fixings
6. Mudguard
3. Detach the cable for the front wheel speed sensor from the clip on the front mudguard.
4. Remove and discard the two rear fixings.
5. Support the front mudguard and remove the four front fixings. Carefully remove the mudguard towards the front of the motorcycle.
Front Mudguard - Installation
1. Position the front mudguard to the front forks.

2. Fit the four front fixings and tighten to 6 Nm
3. Fit the two rear fixings and tighten to 6 Nm.
4. Refit the front brake hose to the mudguard clip.

5. Refit the front wheel speed sensor cable into the mudguard clip.
Rear Mudguard - Removal
WARNING


Battery - Removal
Engine Electronic Control Module (ECM) Removal
Fuel Tank - Removal
Airbox - Removal
Chassis ECM - Removal
Rear Seat Lock - Removal
1. Note the routing of all electrical harnesses on the rear mudguard.
2. Where fitted, disconnect the electrical connector for the auxiliary power socket.
3. Where fitted, disconnect the electrical connector and release the heated seat switch from the left rear side panel.
2 1
B00980
1. Rear heated seat switch

4. Where fitted, release the bluetooth module and its rubber mounting from the rear mudguard.
1
2
B01026
1. Bluetooth module
2. Rubber mounting
5. If installed, disconnect the electrical connector and remove the Bluetooth module and its rubber mounting.
6. Remove and discard the fixing and move the rear brake fluid reservoir aside.
7. Remove the starter solenoid (see Starter Solenoid - Removal).
8. Disconnect the electrical connector from the ambient air pressure sensor.
9. Release the fusebox, fuse holder(s) and relay holder from the rear mudguard.
3
2

B01027
1. Main fusebox
2. Relay holder
3. Fuse holder
10. Remove the fixings that attach the main harness conduit to the frame.
B01023
1. Front fixing
2. Rear fixing
3. Main harness conduit
11. Remove the grab handle and licence plate hanger assembly (see Grab Handle - Removal).
12. Move the main harness conduit to access the front left fixing for the rear mudguard.
13. Remove the six fixings that attach the rear mudguard to the frame.
4 1 3 2
3 2
B01024 4
1. Rear mudguard
2. Front fixings
3. Middle fixings
4. Rear fixings
14. Move the rear mudguard to give access, and release the electrical connector for the rear wheel speed sensor from the rear mudguard at the front right side.
B00940
1. Rear side panel

2. Connector
15. Manoeuver the rear mudguard assembly out from the rear of the motorcycle.
Rear Mudguard - Installation
WARNING

WARNING

1. Position the rear mudguard assembly into the frame.

2. Attach the connector for the rear wheel speed sensor to the tab at the front right of the rear right side panel.
B00940
1. Rear side panel

2. Connector
3. Position the rear mudguard assembly and install the six fixings.
4 1 3 2
3 2
B01024 4
1. Rear mudguard
2. Front fixings
3. Middle fixings
4. Rear fixings
4. Tighten the fixings to 6 Nm.

5. Position the main harness conduit and install the fixings. Tighten to 3 Nm.
6. Install the grab rail and licence plate hanger assembly (see Grab Handle - Installation).
7. Position the fusebox, fuse holder(s) and relay holder onto the rear mudguard. Press down to engage the clips.
3
2
B01027
1. Main fusebox
2. Relay holder
3. Fuse holder
8. Connect the electrical connector to the ambient air pressure sensor.

9. Install the starter solenoid (seeStarter Solenoid - Installation).
10. Position the rear brake fluid reservoir. Install a new fixing and tighten to 7 Nm
11. Where installed, connect the electrical connector to the Bluetooth module.

1
2
B01026
1. Bluetooth module
2. Rubber mounting
12. Install the Bluetooth module and its rubber mounting onto the rear mudguard.
13. Where fitted, install the heated seat switch into the left rear side panel.
14. Connect the electrical connector for the heated seat switch.
2 1
B00980
1. Rear heated seat switch

15. Where fitted, connect the electrical connector for the auxiliary power socket.
Rear Seat Lock - Installation
Chassis ECM - Installation
Engine Electronic Control Module (ECM) Installation
General Frame Inspection
Inspect the frame, bodywork and footrests for accident and other damage, cracks, splits and general dilapidation. Check all fixings for security. If any faults are found, rectify as
necessary. If any faults with the frame are found, the frame must be replaced; repairs to the frame are not permitted.
WARNING
The frame must not be modified in any way. Any modification to the frame, such as welding or drilling, may weaken the structure causing an unsafe riding condition leading
to loss of motorcycle control and an accident.
WARNING
If the motorcycle is involved in an accident or collision it must be taken to an authorised Triumph dealer for inspection and repair before it is ridden again.
Models With a Side Stand Fitted
Check the operation of the side stand to make sure it is securely held in the retracted position by the spring. Rectify any faults.
WARNING
If the return spring is faulty, the side stand could extend whilst the motorcycle is being ridden. This will cause an unsafe riding condition, which could lead to loss of
Models With a Centre Stand Fitted
Check the operation of the centre stand to make sure it is securely held in the retracted position by the spring. Rectify any faults.

WARNING
If the return spring is faulty, the centre stand will not be held in the retracted position whilst the motorcycle is being ridden. This will cause an unsafe riding condition, which
could lead to loss of motorcycle control and an accident.
WARNING
If the motorcycle has recently been running, some 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 motorcycle.
1. Remove the two left side fixings. Collect the flanged sleeves.
2. Remove the two bottom fixings, collect the flanged sleeves and remove the sump guard.
1 3
1. Sump guard
2. Side fixings
3. Bottom fixings
1. Align the sump guard to the motorcycle and install the two bottom flanged sleeves and fixings. Do not fully tighten at this stage.
2. Install the two left side flanged sleeves and fixings. Tighten to6 Nm.
3. Tighten the bottom fixings 6 Nm.
1 3
1. Sump guard
2. Side fixings
3. Bottom fixings
WARNING

WARNING
Always return the handlebars to their original position. Operating the motorcycle with a handlebar position that is unfamiliar may lead to loss of motorcycle control and an
accident.
Note the original position of the handlebars in order that they can be returned to the same position when the repair operation is complete.

Mirror - Removal
1. Remove the fixing and remove the right handguard. Collect the spacer and discard the handlebar end fixing.

4
2
2 3
3
1
4
1. Handlebar end fixing

2. Spacer
3. Handguard (right hand shown)
4. Throttle
2. Repeat step one for the left handguard.
WARNING

1. If the handguard bracket has been removed from the handguard, put the bracket in position and install the fixing. Tighten to 5 Nm.
3
4
1
Right side shown
1. Fixing
2. Captive nut
3. Handguard bracket
4. Handguard
WARNING
When positioned correctly the mirror mounting boss aligns with the mirror mount stem.
2. Fit the handguard assembly to the handlebar.

3. Position the handlebar finisher and the handguard assembly to the handlebar and tighten the new handlebar end fixing to 6 Nm.
4
2
2 3
3
1
4
1. Handlebar end fixing

2. Spacer
3. Handguard (right hand shown)

4. Throttle
4. Refit the mirrors (see Mirror - Installation).

5. Check for correct operation of the front brake and clutch. Check that the throttle opens and closes without sticking. Rectify as necessary.
6. Carry out a cruise control switch check (see Cruise Control Switch Check).
WARNING
Check the brakes operate efficiently during operation.

It is dangerous to operate the motorcycle with defective brakes.
Failure to take remedial action will reduce braking efficiency leading to loss of motorcycle control and an accident.
WARNING
Move the handlebars to left and right full lock while checking that the handguards do not restrict full lock operation.
Check cables or harnesses do not bind or restrict full lock operation.
Any component, cables or harnesses that will restrict the steering may cause loss of control of the motorcycle and an accident.
WARNING

WARNING

accident.
Side Stand - Removal
WARNING

1. Raise and support the motorcycle.
WARNING
Wear hand, eye and face protection when unhooking the stand spring. Take great care to minimise the risk of personal injury and loss of components.
Note
The side stand is held in the up position by spring tension.
2. With the side stand in the up position, unhook the spring from the side stand and remove it from the motorcycle.
4 3
1 2
B00991
1. Side stand
2. Spring
3. Circlip
4. Pivot pin
3. Remove and discard the circlip securing the pivot pin.

4. Remove the pivot pin and remove the side stand.
Side Stand - Installation

WARNING


Side Stand - Clean/Lubricate
1. Fit the side stand to the motorcycle.
2. Insert the pivot pin and install a new circlip.
4 3
1 2
B00991
1. Side stand
2. Spring
3. Circlip
4. Pivot pin
WARNING
Wear hand, eye and face protection when fitting the stand spring. Take great care to minimise the risk of personal injury and loss of components.
3. With the side stand in the up position, hook the spring onto its frame lug then carefully hook it onto the side stand lug.
4. Check the operation of the side stand before riding the motorcycle. Ensure the spring holds the stand securely in the retracted position.
Centre Stand - Removal
WARNING

1. Position the motorcycle on a paddock stand.
CAUTION
When removing the rider footrest fixings ensure the rider footrest assembly is supported correctly.
If the rider footrest assembly is not supported correctly it could lead to damage to the motorcycle frame or footrest assembly.
2. Remove the two fixings securing the left hand rider footrest assembly. Retain the fixings for reuse. The footrest does not need to be completely removed from the
motorcycle.
1. Left hand rider footrest assembly

2. Fixings
3. Remove the side stand assembly from the motorcycle. Retain the side stand and fixings for reuse.

1
1. Side stand assembly

2. Fixings
WARNING
Springs under load can cause injury if released suddenly.

Always wear suitable protective eye wear and release the spring slowly.
Failure to wear protective eye wear may cause injury to the eyes.
4. Detach the spring and the spring bracket from the centre stand.
5. Remove the two circlips securing the centre stand to the frame. Collect the washers.
1 2
6 6
5
5 3 4
B00990
1. Centre stand
2. Spring
3. Spring bracket
4. Spring pin
5. Circlips
6. Washers
Note
It may be required to loosen the lower header mount fixing to allow the right hand pivot pin to be disassembled.
6. With the lower header mount fixing loosened, carefully increase the clearance between the header and right hand mounting bracket until the right hand pivot pin can be
removed from the right hand mounting bracket, as shown.
3 5
4
1. Lower header mount fixing

2. Header
3. Centre stand
4. Right hand pivot pin
5. Right hand mounting bracket
7. Remove the centre stand towards the left hand side.
Centre Stand - Installation
1. Lubricate the pivot spigots with multi-purpose grease to NLGI 2 specification.

Note

Note
It may be required to loosen the lower header mount fixing to allow the right hand pivot pin to be disassembled.
2. With the lower header mount fixing loosened, carefully increase the clearance between the header and right hand mounting bracket until the right hand pivot pin can be
inserted into the right hand mounting bracket, as shown.
3 5
4
1. Lower header mount fixing

2. Header
3. Centre stand
4. Right hand pivot pin
5. Right hand mounting bracket
3. Align the centre stand to the mounting brackets on both sides of the frame and install the centre stand from the left side.
4. Install the washer and a new circlip onto each pivot spigot.
1 2
6 6
5
5 3 4
B00990
1. Centre stand
2. Spring
3. Spring bracket
4. Spring anchor pin
5. Circlips
6. Washers
5. If the lower header mount fixing was loosened to allow fitment of the right hand pivot pin, tighten the fixing to 19 Nm
6. Refit the side stand to the motorcycle with the original fixings. Note the position of the M8 x 35 mm ad M8 x 30 mm fixings as shown below.
2
3
1. Side stand assembly

2. Fixing (M8 x 30 mm)
3. Fixings (M8 x 35 mm)
7. Tighten the M10 x 35 mm fixings to 55 Nm.

8. Tighten the M10 x 30 mm fixing to 25 Nm.
9. Refit the left hand rider footrest with the original fixings. Tighten the fixings to 30 Nm.

1
1. Left hand rider footrest assembly

2. Fixings
10. Fit the spring bracket on to the spring pin in the orientation shown.
1. Spring pin
2. Spring bracket
WARNING
Springs under load can cause injury if released suddenly.

Always wear suitable protective eye wear and release the spring slowly.
Failure to wear protective eye wear may cause injury to the eyes.
11. Hook one end of the spring into the hole in the spring bracket. Attach the other end of the spring to the lug on the centre stand in the orientation shown below.
1. Spring
2. Spring bracket
3. centre stand lug
12. Remove the motorcycle from the paddock stand and check the operation of the centre stand.
13. Check and ensure that the spring holds the centre stand securely in the retracted position, and that the centre stand correctly contacts the rubber stop on the up stop
bracket.
Bank Angle Indicators - Removal and Installation
Inspection
WARNING
Always replace the bank angle indicators before they are worn to their maximum limit.
Use of a motorcycle with bank angle indicators worn beyond the maximum limit will allow the motorcycle to be banked to an unsafe angle.

1. Inspect the bank angle indicators on the rider's footrests for wear. Bank angle indicators must be replaced when they have worn down to the maximum wear limit. The
maximum wear limit is shown by a groove on the bank angle indicator.
1
2
1. Bank angle indicator

2. Maximum wear limit groove
WARNING
The bank angle pegs must not be used as a guide to how far the motorcycle may be safely banked. This depends on many various conditions including, but not limited to,
road surface, tyre condition and weather. Banking to an unsafe angle will lead to loss of motorcycle control and an accident.
Replacement
WARNING

1. Remove and discard the bank angle indicator from the front footrest
2. Fit the new bank angle indicator and tighten to 9 Nm.
3. Repeat for the opposite side.
Mirror - Removal
Note
Note
The right mirror arm and lock nut has a left hand thread.
The left mirror arm and lock nut has a right hand thread.
1. Slide the rubber cover from the lock nut.
2. Make a note of the lock nut position on the thread of the mirror arm.
3. Loosen the lock nut and separate the mirror arm from the mirror boss.
1 2
Left Side Shown
1. Mirror arm
2. Rubber cover
3. Lock nut
4. Mirror boss
Mirror - Installation
WARNING
If the mirror fixing is too loose, the mirror may blow back at speed. This will result in a loss of vision to the rear of the motorcycle. It is dangerous to ride a motorcycle without
sufficient rearward vision.

Note
The right mirror arm and lock nut has a left hand thread.
The left mirror arm and lock nut has a right hand thread.
1. Position the locknut as noted during removal onto the thread of the mirror arm.
2. Fit the mirror boss to the handlebar clamp and tighten to 25 Nm.
1 2
Left Side Shown
1. Mirror arm
2. Rubber cover
3. Lock nut
4. Mirror boss
3. Fit the mirror arm into the mirror boss. Tighten by hand until the lock nut makes contact with the mirror boss , do not tighten fully at this stage.
4. Loosen the mirror arm one full turn.
5. Position the mirror arm to give rear visibility in the riding position and tighten the lock nut by hand.
CAUTION
Use an open ended spanner to counter-hold the mirror boss as the mirror lock nut is tightened. Failure to counter-hold the boss will cause damage to the thread and the
mirror to become loose.
6. Counter-hold the mirror boss and tighten the mirror lock nut to 25 Nm.
7. Slide the rubber cover over the lock nut.
Grab Handle - Removal

1. Remove the first aid kit or tool kit (if fitted) and the strap.
2. Remove the tool kit tray.
3. Release the seat heater electrical connectors by releasing the tabs that attach them to the fir tree clips in the phone tray.
3 5 1 5
5
B00987
1. Phone tray
2. Seat heater electrical connectors
3. Grab handle finisher
4. Finisher fixing
5. Phone tray fixings
4. Remove the fixing for the grab handle finisher and remove the finisher.
5. Remove the fixings for the phone tray.
6. Lift the phone tray to get access to the electrical connector for the USB charger.
7. Disconnect the electrical connector for the USB charger.
8. Remove the phone tray.
9. Disconnect the electrical connector for the rear light.

2
B00974
1. Rear light electrical connector

2. Rear Indicator electrical connectors
10. Disconnect the rear indicator electrical connectors.

11. Release the indicator cables from the cable clips on the rear mudguard.
12. Remove the two front fixings that attach the grab handle to the rear subframe.
1
3
4
B01015
4
1. Grab handle
2. Front fixings
3. Rear Fixings
4. Side licence plate hanger to subframe fixings
13. Remove the four rear fixings that attach the grab handle to the rear subframe.
14. Remove the fixings that attach the left and right side licence plate hangers to the rear subframe.
15. Remove the grab handle and licence plate hanger assembly.
Disassembly
1. Remove the licence plate.

2. Where fitted, remove the two fixings and the licence plate bracket.
2
1
B01066
1. Licence plate bracket (applicable markets only)

2. Fixings
3. Remove the fixings that attach the right licence plate hanger to the grab handle. Remove the right licence plate hanger.
3 1 2

B01013
Right side shown, left side is similar.

1. Right licence plate hanger
2. Front frame fixing
3. Bottom fixing
4. Top fixing
4. Remove the fixings that attach the left licence plate hanger to the grab handle. Remove the left licence plate hanger.
5. Remove the fixing that attaches the centre licence plate hanger to the grab handle. Remove the centre licence plate hanger.
B01022
1. Grab handle
2. Fixing
Grab Handle - Installation
Assembly
1. Position the licence plate hanger assembly to the grab handle.
B01022
1. Grab handle
2. Fixing
2. Install the fixing and tighten to 6 Nm.

3. Position the right licence plate hanger and install the top fixing. Tighten to 6 Nm.
3 1 2
B01013
Right side shown, left side is similar.

1. Right licence plate hanger
2. Front frame fixing
3. Bottom fixing
4. Top fixing

4. Install the bottom fixing for the right licence plate hanger. Tighten to 6 Nm.
5. Repeat stages 3 and 4 for the left licence plate hanger.
6. Where fitted, install the licence plate bracket. Tighten the fixings to 3 Nm.
2
1
B01066
1. Licence plate bracket (applicable markets only)

2. Fixings
7. Install the licence plate.
Grab Handle Installation
1. Position the grab handle and licence plate hanger assembly.

2. Install the fixings that attach the left and right licence plate hangers to the rear subframe. Tighten the fixings to 25 Nm.
1
3
4
B01015
4
1. Rear grab handle

2. Front fixings
3. Rear fixings
4. Licence plate hanger to subframe fixings
3. Install the four rear fixings that attach the grab handle to the rear subframe. Tighten the fixings to 25 Nm.
4. Remove the two front fixings that attach the grab handle to the rear subframe. Tighten the fixings to 25 Nm.
5. Locate the indicator cables into the cable clips on the rear mudguard.
6. Connect the rear indicator electrical connectors.
7. Engage the connectors into the mudguard clips.
B00974

8. Connect the electrical connector for the rear light.

9. Connect the electrical connector for the USB charger.
10. Position the phone tray.
3 5 1 5

4
5
B00987
1. Phone tray
4. Finisher fixing
11. Install the phone tray fixings and tighten to 3 Nm.

12. Install the grab handle finisher and tighten the fixing to 3 Nm.
13. Attach the seat heater electrical connectors to the fir tree clips on the phone tray.
14. Install the tool kit tray.
15. Install the first aid kit or tool kit (if fitted) and the strap.
Rear Seat Lock - Removal

3 5 1 5
5
B00987

3. Finisher fixing
9. If installed, disconnect the electrical connector for the rear seat heater switch.
2 1
B00980

1. Rear seat heater switch
2. Switch connector
10. Note the routing of the cable for the seat lock for the installation procedure.
11. Remove the fixings for the seat lock latch.
2
1
B00983
1. Seat lock latch fixings

2. Seat lock latch
12. Remove the chassis ECM (see Chassis ECM - Removal).

13. Remove the fixing that attaches the seat lock bracket to the frame.
1 3
2
B01025
1. Fixing to frame
2. Fixings to rear side panel
3. Seat lock
14. Remove the seat lock.

15. Remove the two fixings and lock nuts that attach the seat lock to the mounting bracket. Discard the lock nuts.
3
1
2 1 4
B00988_1
1. Fixings
2. Lock nut
3. Seat lock
4. Mounting bracket
Rear Seat Lock - Installation
1. Install the two fixings and new lock nuts that attach the seat lock to the mounting bracket. Tighten to 6 Nm.
3
1

2 1 4
B00988_1
1. Fixings
2. Lock nut
3. Seat lock
4. Mounting bracket
2. Position the seat lock assembly onto the rear side panel.
1 3
2
B01025
1. Fixing to frame
2. Fixings to rear side panel
3. Seat lock
3. Install the fixings for the seat lock bracket to the side panel and tighten to 1 Nm.
4. Route the seat lock cable as noted during removal.
5. Install the fixing for the seat lock bracket to the frame and tighten to 6 Nm.
6. Position the seat lock latch onto the frame crossmember.
2
1
B00983
1. Seat lock latch fixings

2. Seat lock latch
7. Install the two fixings for the seat lock latch and tighten to 6 Nm.
8. Install the chassis ECM (see Chassis ECM - Installation).
9. If installed, connect the electrical connector to the rear seat heater switch.
2 1
B00980
1. Rear seat heater switch

2. Switch connector

10. Connect the electrical connector for the USB charger and position the phone tray.
3 5 1 5
5
B00987

3. Finisher fixing
11. Install the fixings for the phone tray and tighten to 3 Nm.
Frame Guards - Removal
Note
1. Remove the two fixings and the frame guard.
2
1
B00984
Left Side Shown

1. Fixings
2. Frame guard
Frame Guards - Installation
1. Examine the condition of the foam pads on the inside of the frame guard. If necessary, replace the foam pads.
2. Position the frame guard onto the frame.
2
1
B00984

Left Side Shown
1. Fixings
2. Frame guard
3. Install the fixings and tighten to 3 Nm.

Engine Bars - Removal
WARNING

WARNING
skin damage, always allow the hot parts to cool before touching the exhaust system.
1. Move the rubber cover along the engine bar from the centre joint .
2. Remove the fixing securing the centre bar to the right hand engine bar.
4 2
3
6
B01003
1. Engine bar (left hand)

2. Engine bar (right hand)
3. Rubber cover
4. Centre bar fixings
5. Upper fixings
6. Right engine bar bottom fixing
3. Remove the lower mounting fixings securing the right hand engine bar to the engine.
4. Remove the upper fixing securing the right hand engine bar to the engine. Slide the right hand engine bar off the centre bar and remove from the motorcycle.
5. Remove the upper mounting fixing securing the left hand engine bar to the engine.
6. Get the help of an assistant to move the coolant hose aside.
3 1
B01002 2

2. Fixing
3. Coolant hose
7. Remove the bottom fixing securing the left hand engine bar to the engine and remove from the motorcycle.
Engine Bars - Installation
1. Get the help of an assistant to move the coolant hose aside.

3 1
B01002 2

2. Fixing
3. Coolant hose
2. Position the left hand engine bar to the crankcase mounting bosses and install the lower fixing. Do not tighten the fixing at this stage.
3. Refit the upper fixing securing the left hand engine bar to the engine. Do not tighten at this stage.
4 2
3
6
B01003

2. Engine bar (right hand)
3. Rubber cover
4. Centre bar fixings
5. Upper fixings
6. Right engine bar bottom fixing
4. Slide the right hand engine bar over the centre bar and position to the crankcase mounting bosses. Secure using the lower fixing. Do not tighten the fixings at this stage.
5. Refit the upper fixing securing the right hand engine bar to the engine. Do not tighten at this stage
6. Secure the right hand engine bar to the centre bar. Do not tighten the fixing at this stage.
7. Tighten the right hand engine bar fixings to 15 Nm.
8. Tighten the left hand engine bar fixings to 15 Nm.
9. Tighten the centre bar fixing to 6 Nm.
10. Slide the rubber cover over the centre bar and align it to the centre of the motorcycle.
Saree Guard - Removal - Applicable Markets
Note
3 5 1 5
5
B00987


3. Finisher fixing
9. Remove the front fixing from the saree guard.
B00989
1. Saree guards
2. Top fixings
3. Front fixing
10. Remove the two top fixings that also attach the grab handle.
B00974_1
1. Top fixings
11. Remove the saree guard.

1. Remove the fixing for grab handle finisher and remove the finisher.
1
3
2 4
B00973

2. Finisher fixing
3. Inner mudguard cover
4. Fixings
2. Remove the fixings and the inner mudguard cover.

3. Remove the front fixing from the saree guard.

1
B00989
1. Saree guards
2. Top fixings
3. Front fixing
4. Remove the two top fixings that also attach the grab handle.
B00974_1
1. Top fixings
5. Remove the saree guard.
Saree Guard - Installation - Applicable Markets
1. Position the saree guard and install the two top fixings.
B00989
1. Saree guard
2. Top fixings
3. Front fixing
2. Hold the nuts and tighten the bolts to 25 Nm.

3. Install the front fixing and tighten to 12 Nm.
4. Install the grab handle finisher and its fixing. Tighten the fixing to 3 Nm.
1
3
2 4
B00973

2. Finisher fixing
3. Inner mudguard cover
4. Fixings
5. Position the inner mudguard cover. Install the fixings and tighten to 6 Nm.
1. Position the saree guard and install the two top fixings.
B00989
1. Saree guards
2. Top fixings
3. Front fixing
2. Hold the nuts and tighten the bolts to 25 Nm.

4. Position the phone tray and connect the electrical connector for the USB charger.
Sliding Carriage - Removal
WARNING

Note
The two front fixings are 50 mm long, and the two rear fixings are 40 mm long.
Remove the four fixings and remove the sliding carriage from the rear rack.
4 2
3
1. Rear rack
2. Sliding carriage
3. Front fixings (M8 x 50 mm)
4. Rear fixings (M8 x 40 mm)
Sliding Carriage - Disassembly

Sliding Carriage - Removal
1. Place the sliding carriage assembly on a protective surface to prevent damage.
2. Counterhold the screws and remove the two centre lock nuts and retain for reuse.
3. Remove and discard the two steel washers and rubber dampers.

1
4
3
B01658_4
2
1. Centre screw (front shown)

2. Lock nut
3. Washer
4. Rubber damper
4. Counterhold the screws and remove the four outer lock nuts and retain for reuse.
5. Remove and discard the four steel washers, rubber washers and 1.5 mm PTFE washers.
5
4
3
2
B01658_5
1. Outer screw (left front shown)

2. Lock nut
3. Washer
4. Rubber washer
5. 1.5 mm PTFE washer
6. Remove the sliding carriage base and position aside.

7. Remove the nylon bearing, 2.1 mm PTFE washer, and rubber washer from the four outer screws and discard.
4
3
2
B01658_1
5
1. Sliding carriage top plate

2. Nylon bearing
4. Rubber washer
5. Metal sleeves
6. Screws
8. If required, remove the six metal sleeves from the screws and retain for reuse
9. Remove the six screws.
Sliding Carriage - Assembly
1. If removed, install the six screws to the sliding carriage top plate.
2. Place the sliding carriage assembly on a protective surface to prevent damage.
3. Install the six metal sleeves to the screws.
4. Install a new rubber washer, 2.1 mm PTFE washer and nylon bearing to the four outer metal sleeves.

6
4
3
2
B01658_1
5
1. Sliding carriage top plate

2. Nylon bearing
4. Rubber washer
5. Metal sleeve
6. Screws
5. Install the sliding carriage base over the six screws, making sure the four nylon bearings are correctly aligned to the recesses in the base.
6. Install new rubber dampers and washers to the two centre screws. Install the two centre lock nuts, do not fully tighten at this stage.
4
3
B01658_4
2
1. Centre screw (front shown)

2. Lock nut
3. Washer
4. Rubber damper
7. Install new 1.5 mm PTFE washers, rubber washers and steel washers to the four outer screws.
8. Install the four outer lock nuts.
5
4
3
2
B01658_5
1. Outer screw (left front shown)

2. Lock nut
3. Washer
4. Rubber washer
9. Counterhold the screws and tighten all six lock nuts to 8 Nm.
Sliding Carriage - Installation
Sliding Carriage - Installation
WARNING

WARNING

Align the sliding carriage to the rear rack. Fit the two M8 x 50 mm fixings through the sliding carriage front mounts. Do not fully tighten the fixings at this stage.
3 2
1. Rear rack
2. Sliding carriage
3. Front fixings (M8 x 50 mm)
Fit the two M8 x 40 mm fixings through the sliding carriage rear mounts. Tighten the fixings to 27 Nm.
2
1
1. Sliding carriage
2. Rear fixings (M8 x 40 mm)
Tighten the sliding carriage front fixings to 27 Nm.
WARNING
The sliding carriage must be allowed to move from side to side on the slide plate.
If the sliding carriage is not free to move from side to side when the top box is fitted, the stability and handling characteristics of the motorcycle may be affected, leading to
loss of control and an accident.
WARNING
If a load is carried on the sliding carriage without utilising the top box, it must be securely attached to the sliding carriage only and not any other part of the rear rack.
The sliding carriage must be allowed to move from side to side on the slide plate.
If the sliding carriage is not free to move from side to side on the slide plate, the stability and handling characteristics of the motorcycle may be affected, leading to the loss
of control and an accident.
Electrical
Exploded Views
Exploded View - Headlight

Exploded View - Fog Lights

Exploded View - Direction Indicators
Exploded View - Rear Light

Exploded View - Instruments

Exploded View - Alternator and Starter
Exploded View - Harness

Battery, Fuses and Relays
Battery
WARNING
Under some circumstances, the battery can give off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the
battery in an enclosed space.
The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
If electrolyte gets on your skin, flush with water immediately.
If electrolyte gets in your eyes, flush with water for at least 15 minutes and SEEK MEDICAL ATTENTION IMMEDIATELY.
If electrolyte is swallowed, drink large quantities of water and SEEK MEDICAL ATTENTION IMMEDIATELY.
KEEP ELECTROLYTE OUT OF THE REACH OF CHILDREN.
WARNING
The battery contains harmful materials. Always keep children away from the battery whether or not it is fitted in the motorcycle.
Do not attach jump leads to the battery, touch the battery cables together or reverse the polarity of the cables as any of these actions may cause a spark which would ignite
battery gases causing a risk of personal injury.
Battery Disposal
Should the battery ever require replacement, the original battery must be handed to a recycling agent who will ensure that the dangerous substances from which the battery is
manufactured do not pollute the environment.
Battery Maintenance
The battery is a sealed type and does not require any maintenance other than checking the voltage and routine recharging such as during storage.
It is not possible to adjust the electrolyte level in the battery.
Note
The charge level in the battery must be maintained to maximise the battery life.
With normal use of the motorcycle, the charging system will keep the battery charged. If the motorcycle is unused, the battery will gradually discharge due to battery self
discharge and the continuous current drain for the clock and the engine control module memory.
The rate of battery discharge can be greatly increased by the addition of electrical security systems or other accessories.
Allowing a battery to discharge, or leaving it discharged over a period of time, causes sulphation of the lead plates within the battery.
Sulphation is a normal chemical reaction inside the battery and over a period of time sulphate will crystallise on to the lead plates making charging difficult or impossible. The
result is a permanently damaged battery, which would not be covered by the motorcycle warranty.
Keeping a battery at full charge reduces the chance of it freezing in cold conditions. Allowing a battery to freeze can cause serious internal damage to the battery.
When leaving the motorcycle standing for more than a few days, regularly check the battery voltage using a digital multimeter. Should the battery voltage fall below 12.8 V,
charge the battery using the BatteryMate Battery Charger - see latest Parts Catalogue for part number information. Refer to the instructions supplied with the BatteryMate
Battery charger.
For extended periods of storage (beyond two weeks) the battery should be removed and the battery voltage checked regularly and charged when below 12.8 V.
Battery Already in Service
Note
Before carrying out the following procedure the battery must be disconnected and removed from the motorcycle.
Use the guidelines in the table below for charging. Always verify the battery condition before charging, and 30 minutes after charging.
Note
A fully charged battery should read 12.8 volts or higher after the battery has been off the charger for 30 minutes or more.
Table of Battery Charging Times
State of charge Voltage Action Charge time (using BatteryMate 150-9)

State of charge Voltage Action Charge time (using BatteryMate 150-9)
100% 12.8 V - 13.0 V None. Check at 4 months from date of delivery None required
75% - 100% 12.5 V - 12.8 V Charge and check in 4 months from date of last 3 - 6 hours
check
50% - 75% 12.0 V - 12.5 V Needs charge 5 - 11 hours
25% - 50% 11.5 V - 12.0 V Needs charge At least 13 hours
0% - 25% 11.5 V or less Needs recovery using BatteryMate 150-9. Retest 20 hours
after recovery
Factory Activated Battery
This model is fitted with a factory activated battery and no commissioning is required. However, routine maintenance of the battery is required.
Refer to:
Battery Maintenance
Battery Already in Service
Fuse Box Location
If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of the correct current rating.
A blown fuse is indicated when all of the systems protected by that fuse become inoperative. When checking for a blown fuse, see Fuse Identification to establish which fuse
has blown.
The riding modes allow the rider to adjust the throttle response (MAP), Anti-lock Brake System (ABS) and Traction Control (TC) settings to suit differing road conditions and
rider preference.
Before disconnecting the battery or removing a fuse, note and record the rider’s settings. Once the fuse has been refitted or the battery reconnected the rider’s settings should
be reset as noted.
WARNING
If the battery has been disconnected or the fuses removed for any reason advise the rider to confirm the original mode settings have been correctly set. Failure to reset the
motorcycle to the rider’s preferred rider mode settings and subsequently being ridden may cause loss of motorcycle control and an accident.
WARNING
Always replace blown fuses with new ones of the correct current rating (as specified on the fuse box cover) and never use a fuse of higher rating.
Use of an incorrect fuse could lead to an electrical problem, resulting in motorcycle damage, loss of motorcycle control and an accident.
Fuse Box Locations
The fuse boxes are located beneath the rider's seat. To allow access to the fuse boxes, the passenger seat and then the rider's seat must be removed (see Passenger Seat -
Removal/Installation and Rider's Seat - Removal/Installation).
3 2
1. Fuse box 1 - all models

2. Fuse box 2 - all models
3. Fuse box 3 - Tiger 900 Rally Pro only
Note
The starter solenoid has an additional 30 Amp fuse, attached directly to the solenoid under the battery, beneath the rider's seat.
Main Fuse Location
Note
The Main 30 Amp fuse is attached directly to the starter solenoid. It is located directly beneath the battery and engine electronic control module.
To allow access to the main fuse the battery and Engine ECM must be removed, (see Engine Electronic Control Module (ECM) Removal).

1
3 2
B00961
1. Starter solenoid
2. Main fuse (30 Amp)
3. Terminal cover
Fuse Identification
WARNING
Always replace blown fuses with new ones of the correct rating (as specified on the fuse box cover) and never use a fuse of higher rating.
Use of an incorrect fuse could lead to an electrical problem, resulting in motorcycle damage, loss of motorcycle control and an accident.
A blown fuse is indicated when all of the systems protected by that fuse become inoperative. When checking for a blown fuse, refer to the fuse identification table to establish
which fuse has blown.
The fuse box is located underneath the seat.
To allow access to the fuse box, the seat must be removed (see Rider's Seat - Removal/Installation).
Note
Numbers shown in the following illustration correspond to the position numbers in the fuse identification table.
The fuse identification numbers listed in the tables correspond with those printed on the fuse box covers, as shown below.
Fuse Box 1
1 2 3 4 5 6
1 10A PS1
2 10A PS2
3 10A PS3
4 10A PS4
5 20A PS5
6 15A
7 25A ABS 8 5A 9 5A OBDII

7 8 9
Position Circuit Protected Rating (Amps)
1 Chassis ECM, Cooling Fan (Right Hand Side), Horn, Fog Lights, License Plate Light, Rear Position Light 10
2 Chassis ECM, Brake Light, Dip Beam Headlight, Front Position/DRL Control, Instrument Wake, Front 10
Indicators, Heated Grips
3 Chassis ECM, Heated Seats, High Beam Headlight, Rear Indicators, USB Charger, Front Position/DRL 10
Power
4 Chassis ECM, Passenger Accessory Socket 10
5 Chassis ECM, Cooling Fan (Left Hand Side), Starter Motor Solenoid, Fuel Pump 20
6 Engine Management System 15
7 ABS 25
8 Ignition Switch 5
9 Diagnostics Connector (OBDII), Alarm 5
Fuse Box 2
Position Circuit Protected Rating (Amps)
1 Rider Accessory Socket 10
Chassis Electronic Control Module (Chassis ECM)
Many of the motorcycle’s electrical systems (such as lighting, horn, cooling fans, fuel pump, and accessories such as heated grips or seats) are controlled by the chassis
Electronic Control Module (chassis ECM).
The chassis ECM provides a primary level of protection to the electrical systems it controls. If a fault is detected, the chassis ECM will automatically cut power to the affected
system.

The chassis ECM can be reset by turning the Ignition off then on again. Power will be restored to the inoperative system, providing that the condition that caused the fault has
been rectified.
The systems controlled by the chassis ECM are also provided with a secondary level of protection, by fuses 1 to 9 in the main fuse box (see Fuse Identification). A blown fuse
is likely when all of the systems protected by that fuse become inoperative.
Refer to the following table for full details of the chassis ECM controlled systems, and their corresponding fuses.
WARNING
Always replace blown fuses with new ones of the correct rating (as specified on the fuse box cover) and never use a fuse of higher rating. Use of an incorrect fuse could
lead to an electrical problem, resulting in motorcycle damage, loss of motorcycle control and an accident.
If after resetting the automatic software protection system or replacing a blown fuse, a fault still persists, investigate the cause and take remedial action as necessary.
Relay
WARNING
This model is equipped with an Engine Management System (EMS) relay only.
The starter, fuel pump, cooling fans, lighting and accessory systems are all controlled by the chassis ECM.
To gain access to the relay, remove the rider’s seat (see Rider's Seat - Removal/Installation).
Relay Identification
1. Engine management system (EMS) main relay
Diagnostics - Starter and Charging Circuits
Starting Circuit
All Triumph models are equipped with an electric start system. This system consists of a starter relay, starter motor, starter switch, side stand switch, engine stop switch, clutch
switch and the sprag clutch. The starter motor is connected to the starter relay and the battery by heavy duty cables in order to supply the large currents required by the motor
to start the engine. When the starter button is pressed, the relay is energised, which then allows current to the starter motor. The starter motor will not operate unless the clutch
lever is pulled in. Also, the starter will not operate if the side stand is down, unless the transmission is in neutral. If the starter motor does not operate, the following basic checks
must be carried out before further diagnosis is performed:
Check the engine stop switch is in the 'RUN' position.
Check the battery terminals are clean and tight.
Check the frame and engine ground connections are clean, tight and free from corrosion.
Ensure the battery is fully charged and in good condition.
Check that any fuse in the circuit is not blown and is of the correct rating.
Using the Triumph Diagnostic Tool, check the operation of the neutral switch or gear position sensor (if fitted), side stand and clutch switches.
Note
The engine will not crank if the instruments, ABS ECM, or immobiliser/keyless ECM (if fitted)/chassis ECM (if fitted) are disconnected.
Rectify any defects as necessary.
General Fault Finding – Starter Motor and Relay
Starter relay does not click, starter motor does not turn Battery discharged or defective
Blown main or starter relay fuse
Defective starter relay wiring or starter switch
Check that the side stand, transmission and clutch lever are positioned for engine
starting i.e. transmission in neutral, clutch lever pulled in and the side stand down
Defective alarm system - ensure any alarm fitted is working correctly
Starter motor turns slowly Battery discharged or defective
Loose, corroded or dirty battery connections

Loose, corroded or dirty starter motor or starter relay connections
Defective starter motor
Loose, corroded or dirty battery ground connections
Starter relay clicks but engine does not turn over Battery discharged or defective
Crankshaft does not turn due to engine defect
Defective starter motor
Starter cable open circuit
Defective starter relay
Starter motor turns but engine does not turn over Starter motor or starter ring gear
Diagnosis – Starter Circuit
Note
Prior to carrying out the diagnosis, ensure the battery voltage is 12 - 13.5 V, the immobiliser system (if fitted) is functioning correctly, the transmission is in
neutral and the clutch lever is pulled fully to the handlebar.
WITH THE IGNITION SWITCH ON AND USING A SUITABLE HEAVY DUTY

THE ENGINE STOP SWITCH AT ‘RUN’, JUMPER CABLE, CONNECT THE
CLICKS
CHECK FOR A CLICK AT THE STARTER STARTER POSITIVE TERMINAL TO
RELAY WHEN THE STARTER SWITCH THE BATTERY POSITIVE TERMINAL
IS PRESSED
STARTER STARTER
MOTOR MOTOR
TURNS DOES NOT
TURN
LOOSE OR FAULTY STARTER

NO DISCONNECTED WIRE MOTOR
CLICK OR CABLE. FAULTY
STARTER RELAY/
SOLENOID
FAULTY NEUTRAL SWITCH

NO CONTINUITY FAULTY CLUTCH SWITCH
DISCONNECT THE STARTER RELAY
FAULTY SIDESTAND SWITCH
SWITCH CONNECTOR. CHECK THE
BAD CONTACT AT CONNECTOR
RELAY COIL GROUND WIRE
OPEN CIRCUIT IN WIRING LOOM
FAULTY ALARM OR ENGINE ECM (IF FITTED)
CONTINUITY
FAULTY IGNITION SWITCH/ ENGINE

CONNECT THE STARTER RELAY
STOP SWITCH
SWITCH CONNECTOR. MEASURE NO VOLTAGE BROKEN STARTER SWITCH CABLE
THE STARTER RELAY VOLTAGE
BAD CONTACT AT CONNECTOR
AT THE STARTER RELAY
OPEN CIRCUIT IN WIRING LOOM
SWITCH CONNECTOR
FAULTY ALARM
VOLTAGE
MEASURED
CHECK THE STARTER NORMAL

LOOSE OR POOR CONTACT
RELAY OPERATION AT STARTER RELAY
ABNORMAL FAULTY STARTER RELAY
Alternator/Charging System
The charging system consists of an alternator, a rectifier/regulator assembly and the battery. The alternator is made up of two parts, the stator, which is mounted to the
crankcase or the engine cover, and the rotor, mounted to the end of the crankshaft. The stator is an assembly of 18 coils, arranged into 3 phases. The rotor is a series of
magnets mounted in the engine flywheel, which are arranged so as to be positioned around the outside of the stator coils. As the engine rotates the alternator produces an AC
(alternating current) voltage in each of the three phases of the alternator, typically of around 35 to 40 volts AC at 4,000 - 5,000 rpm, although this figure varies between models.
As the battery requires DC (direct current) voltage for correct charging, this AC voltage must be first rectified to DC current, and then regulated to the correct voltage for the
battery of 14.5 +/- 0.5 volts. This is done by the rectifier/regulator, which uses diodes to convert the alternator output to DC Volts and limits the resulting output to the correct
figure required for optimal battery charging.
If the charging circuit does not operate correctly, the following basic checks must be carried out before further diagnosis is performed:
Check the battery terminals are clean and tight.
Check the frame and engine earth connections are clean, tight and free from corrosion.
Ensure the battery is fully charged and in good condition.
Check that any fuse in the circuit is not blown and is of the correct rating.
Rectify any defects as necessary.
Diagnosis – Charging Circuit
ENSURE THE BATTERY IS IN GOOD

NOT OK RECHARGE OR REPLACE FAULTY
CONDITION AND FULLY CHARGED.
BATTERY AND/ OR REPAIR
CHECK ALL BATTERY AND GROUND
DIRTY/ LOOSE CONNECTIONS.
TERMINALS ARE CLEAN AND TIGHT.
OK
OK
WITH THE ENGINE RUNNING AT AROUND ABOVE

2,000 RPM, MEASURE THE BATTERY 15 VOLTS
FAULTY RECTIFIER/ REGULATOR
VOLTAGE AT THE BATTERY. THE BATTERY
VOLTAGE SHOULD BE 13.5 - 15 VOLTS
BELOW
13.5 VOLTS
STOP THE ENGINE AND DISCONNECT THE

ALTERNATOR CONNECTOR. RE-START THE
BELOW
ENGINE AND ALLOW TO IDLE. 15 VOLTS AC
MEASURE THE ALTERNATING CURRENT (AC)
VOLTAGE FROM THE 3 ALTERNATOR OUTPUT
WIRES IN TURN. THE OUTPUT VOLTAGE MUST
EXCEED 15 VOLTS AC FROM EACH WIRE.
ABOVE
15 VOLTS AC
RAISE THE ENGINE SPEED ABOVE 4,000 RPM.

BELOW
MEASURE THE ALTERNATING CURRENT (AC) 30 VOLTS AC
VOLTAGE FROM THE 3 ALTERNATOR OUTPUT FAULTY ALTERNATOR
WIRES IN TURN THE OUTPUT VOLTAGE MUST

WIRES IN TURN. THE OUTPUT VOLTAGE MUST
NOW EXCEED 30 VOLTS AC FROM EACH WIRE.
ABOVE
30 VOLTS AC
FAULTY RECTIFIER/ REGULATOR
Alternator Stator
The stator is an assembly of 18 coils, arranged into three phases. It is possible to check for continuity and short circuits through the coils and to ground.
Note
Only repair the stator harness between the rectifier and where the harness goes into the crankcase.
Do not attempt to repair the stator coils.
If the battery is not fully charged, the charging Voltage may be lower than specified when checking at 2,000 rpm.
Ensure all additional accessories (auxiliary lights, heated grips etc.) are switched off.
Fault Possible cause Action
Battery not charging Battery Check the condition of the battery. Test the battery
using the BatteryMate 150-9. Refer to the instructions
supplied with the BatteryMate 150-9.
Ensure the battery is serviceable.
Alternator Proceed to pinpoint test 1:
Regulator/Rectifier Test the regulator/rectifier (see Regulator/Rectifier

Circuit).
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect the battery leads, negative (black) lead first. Disconnect
- Battery positive (+) regulator/rectifier black connector and proceed to test 2
- Battery negative (-)
- Regulator/rectifier black connector pin 1
- Regulator/rectifier black connector pin 3
- Regulator/rectifier grey connector pin 1 Faulty Rectify fault, proceed to test 4
- Regulator/rectifier grey connector pin 2
- Regulator/rectifier grey connector pin 3
2 Check cable continuity OK Reconnect the battery leads, positive (red) lead first. Reconnect the
- Regulator/rectifier black connector pin 1 to battery lead negative regulator/rectifier black connector. Disconnect the regulator/rectifier
connector grey connector and proceed to test 3
- Regulator/rectifier black connector pin 3 to battery lead positive
connector Open circuit Locate and rectify wiring fault, proceed to test 4
3 Check resistance through the coils: 0.14Ω to 0.18Ω Proceed to test 4

- Alternator pin 1 to pin 2
- Alternator pin 2 to pin 3 Open circuit or short If the fault is between the rectifier and the crankcase, repair the
- Alternator pin 3 to pin 1 circuit harness. Proceed to test 4
If the fault is after the crankcase, replace the unit. Proceed to test 5
4 Reconnect the harness and run the engine. Check the charging 13.5 V - 15 V Action complete - quit test
Voltage at 2,000 rpm at the battery
Fault still present Disconnect the regulator/rectifier grey connector and proceed to test
5
5 Check the alternator AC output Voltage at idle rpm by probing the Above 15 V Test regulator/rectifier (see Regulator/Rectifier Circuit)
3-pin stator connector as follows:
- Positive (+) probe to pin 1 negative (-) probe to pin 2
- Positive (+) probe to pin 2 negative (-) probe to pin 3 Less than 15 V AC Replace unit. Proceed to test 6
- Positive (+) probe to pin 3 negative (-) probe to pin 1
6 Reconnect the harness and run the engine. Check the charging 13.5 V - 15 V Action complete - quit test
Voltage at 2,000 rpm at the battery
B 4
4
WR 3
N 2
N 1
2
~
B
1 Y 1 Y
2 Y 2 Y
3 Y 3 Y
N 3 R
B 1 B
1

1. Battery
2. Alternator
3. Regulator/Rectifier
4. Starter solenoid/main fuse
Regulator/Rectifier Circuit
Internally the regulator/rectifier consists of three diodes, one between each input and the positive terminal, and three Field Effect Transistors (FETs), one between each input
and the ground terminal.
As the Voltage of the AC signal from the generator rises, the Voltage controller switches the FETs to avoid over Voltage on the output.
The diodes and FETs can be checked using a multimeter on DIODE setting. Disconnect the two electrical connectors from the regulator/rectifier and check the readings as
indicated below.
Note
This test does not check for Voltage regulation.
Fault Possible cause Action
Battery not charging Main Fuse (30 Amp) a single fuse, located on the Check the condition of the Main fuse:
starter solenoid beneath the battery
Battery Check the condition of the battery. Test the battery

using the Battery-Mate 150-9. Refer to the instructions
supplied with the BatteryMate 150-9.Ensure the battery
is serviceable.
Regulator/Rectifier Disconnect the black and the grey connectors from the
regulator/rectifier and proceed to pinpoint test 1:
Alternator Test the alternator stator (see Alternator Stator).
Pinpoint Tests
Test Result Action
1 Check diodes forward bias: 0.4 V to 0.7 V Proceed to test 2

- Positive (+) probe to rectifier black socket pin 1 to:
Negative (-) probe to rectifier grey socket pin 1
Open circuit or short Replace the unit. Proceed to test 4
Negative (-) probe to rectifier grey socket pin 2 circuit
2 Check FET function forward bias: 0.1 V to 0.3 V Proceed to test 3

- Negative (-) probe to rectifier black socket pin 3 to:
Positive (+) probe to rectifier grey socket pin 1
Open circuit or short Replace the unit. Proceed to test 4
Positive (+) probe to rectifier grey socket pin 2 circuit
3 Check diodes reverse bias: More than 1.4 V or OL Proceed to test 4

- Negative (-) probe to rectifier black socket pin 1 to: on meter
- Positive (+) probe to rectifier black socket pin 3 to: Less than 1.4 V or short Replace the unit. Proceed to test 4
Negative (-) probe to rectifier grey socket pin 1 circuit
4 Reconnect the harness and run the engine. Check the charging Voltage at 13 V - 15 V Action complete - quit test
2,000 rpm
Fault still present Test alternator stator (see Alternator Stator
If alternator stator is serviceable, contact Triumph service
+
3
2
1
3
3
2
1
4
2

1
3 2 1 3 2 1
2 3
1. Regulator Rectifier
2. Alternator connector (grey)
3. Battery connector (black)
4. Voltage controller
Regulator/Rectifier
The regulator/rectifier does not contain any serviceable parts and must be replaced if faulty.
System Diagnostics - Chassis ECM
System Diagnosis
The chassis ECM has an on-board diagnostics feature which allows service technicians to retrieve stored data using the 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.
For the procedure to connect the Triumph Diagnostic Tool, see Diagnostic Tool Connection.
On-board Fault Detection System
The on-board diagnostic system has two stages to fault detection. When a fault is detected, the DSM (Diagnostic Status Manager) raises a flag to indicate that a fault is present
and increments a counter. The counter checks the number of instances that the fault is noted.
When the count begins, the fault is detected but not confirmed. If the fault continues to be detected and the count reaches a predetermined threshold, the fault becomes
confirmed and a DTC (Diagnostic Trouble Code) will be logged in the ECM's memory. A confirmed fault may be indicated by the effected system(s) simply becoming
inoperative, or by the illumination of a system warning light and/or instrument warning message. Once a fault is confirmed, the number of ignition switch cycles made is
counted. If the fault clears, the ignition switch cycle counter will restore operation to the affected system(s) and extinguish any warning lights or instrument messages at a
predetermined count. DTCs are then erased from the ECM memory at another (higher) count.
Instrument Diagnostics
Described below is the range of information which can be retrieved from the Instruments and the adjustments which can be performed using the Triumph diagnostic software.
Set Interval
The Set Interval screen will show the following information.
Current Odometer Configuration
Current Odometer Reading
Distance To Next Service
Next Service Due At
It is also possible to manually adjust the service interval and reset the service interval.
Configure
The Configure screen can be used to set the instrument display measurement units by region. It can also be used to enable/disable certain instrument displays.
The menus available are:
Market Variation (UK, US, Metric or Japanese)
Units of Pressure (PSI or BAR)
Display ABS Menu (Yes/No)
Display Tyre Pressure (Yes/No)*
*If TPMS is fitted
Sensor Data
The data available under Sensor Data is:
High Beam/Passing Button On/Off
Daylight Running Light Switch On/Off
Mode Switch On/Off
Direction Indicators Left Switch On/Off
Direction Indicators Right Switch On/Off
Direction Indicators Cancel Switch On/Off

Horn Switch On/Off
Joystick Up On/Off
Joystick Down On/Off
Joystick Left On/Off
Joystick Right On/Off
Joystick Centre On/Off
Home Button On/Off
Adjust
In the Adjust screen it is possible to set the clock on the instrument display.
Set
In the Set screen it is possible to set or reset the odometer reading, provided that the current odometer reading is lower than 120 miles (200 km).
Note, these functions can only be performed once.
Chassis ECM Diagnostics
Described below is the range of information which can be retrieved from the Chassis ECM’s memory and the adjustments which can be performed using the Triumph diagnostic
software.
Note
Build Data
VIN
Chassis ECM Part Number
Chassis ECM Serial Number
Boot Software ID
Application Software ID
Calibration ID1
Calibration ID2
Calibration ID3
Calibration ID4
Date of Last Application Download
Total Application Downloads Since Manufacture
Sensor Data
When using this function it is possible to check the status of various sensors and actuators.
The data sets are divided into six groups - Sensor Voltages, Lighting, Direction Indicators, Inputs/Outputs and Heating. Each of these screens is described on the following
pages.
Sensor Voltages
The data available under Sensor Voltages is:
Battery Voltage Volts
Front Accessory Power Socket Volts
Passenger Accessory Power Socket Volts
Ambient Temperature Sensor Volts
Lighting
The data available under Lighting is:
Main Beam Left On/Off
Main Beam Right On/Off
Dipped Beam Left On/Off
Dipped Beam Right On/Off
Fog Lights On/Off
Brake Light On/Off

Front Position Light On/Off
Rear Position Light On/Off
Direction Indicators
The data available under Direction Indicators is:
Direction Indicator Left Front On/Off
Direction Indicator Left Rear On/Off
Direction Indicator Right Front On/Off
Direction Indicator Right Rear On/Off
Inputs/Outputs
The data available under Inputs/Outputs is:
Alarm Input On/Off
Cooling Fan 1 On/Off
Cooling Fan 2 On/Off
Fuel Pump Positive On/Off
Fuel Pump Negative On/Off
Horn On/Off
Ignition Status On/Off
Low Oil Pressure Warning Light On/Off
Hazard Light Switch On/Off
Engine Stop Switch On/Off
Starter Solenoid On/Off
Starter Switch On/Off
Heating
The data available under Heating is:
Heated Grip Left On/Off
Heated Grip Right On/Off
Passenger Heated Seat - Hot On/Off
Passenger Heated Seat - Warm On/Off
Function Tests
The system allows the diagnostic software to perform a series of function tests on various systems controlled by the Chassis ECM. In some cases it is necessary to make a
visual observation of a component and in others, if faults are present, DTCs will be logged.
The Function Tests available are:
*If a fault is detected
Cooling Fan 1 Observe the cooling fan/Stored fault code*
Cooling Fan 2 Observe the cooling fan/Stored fault code*
Horn Listen for operation/Stored fault code*

Note
A major cause of hidden electrical faults can be traced to faulty electrical connectors. For example:
Damp terminals
For example, the chassis electronic control module (chassis ECM) relies on the supply of accurate information to enable it to correctly monitor the motorcycle's systems. One
dirty terminal will cause an excessive voltage drop resulting in an incorrect signal to the chassis ECM.
Check for a security device that must be released before the connector can be separated, for example: tab, barb, hook and eye.
Check that the individual pins have not been bent

Check for dampness/dirt/corrosion
Check cables for security
Ensure there is no dirt around the connector/seal

Push together squarely to ensure terminals are not bent or incorrectly located
Disconnection of the Chassis ECM Connectors
CAUTION
CAUTION
Never disconnect an ECM when the ignition switch is in the ON position as this may cause multiple fault codes to be logged in the ECM memory.
1. Turn the ignition to the OFF position and wait at least 1 minute for the chassis ECM to complete its power down sequence.
2. Remove the chassis ECM (see Chassis ECM - Removal).
Note
Two different sized connectors are used in the chassis ECM, which ensures correct connection is always made. Two 16 pin connectors are coloured grey (left,
connector CN3 and right, connector CN1), and a 20 pin connector (centre, connector CN2) is coloured black.
The two 16 pin grey connectors are different so they cannot be connected incorrectly.
1. Press down on the locking device and gently pull back on the connector to release it from the chassis ECM.
2
3
1
cklm
1. Chassis ECM
2. Locking device
3. Chassis ECM connector
Reconnection of the Chassis ECM Connectors
CAUTION
1. Fit the connector into its socket and continue pushing until the locking device clicks.
2
3

1
cklm
1. Chassis ECM
2. Locking device
3. Chassis ECM connector
1. Install the chassis ECM (see Chassis ECM - Installation).
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:

After Completion of Pinpoint Tests:

4. If a DTC is stored, there is a further fault. Read the stored DTC and refer to the relevant pinpoint test.
Chassis ECM Diagnostic Trouble Codes
Diagnostic Trouble Codes (DTCs) are logged in the chassis ECM memory when there is a confirmed fault in the system.
The codes are reported to the Triumph diagnostic tool as a four digit code.
When the system detects a fault, it begins to count the number of times the fault occurs before confirming the fault and storing a fault code. A confirmed fault may be indicated
by the effected system(s) simply becoming inoperative, or by the illumination of a system warning light and/or instrument warning message.
Similarly, if a fault clears, the chassis ECM also records this fact and will extinguish any warning lights or instrument messages and restore normal operation to the affected
system, when sufficient no-fault ignition switch cycles have taken place. Any fault codes will remain in the chassis ECM memory until the required number of no-fault ignition
switch cycles have taken place. The number of ignition switch cycles required to restore normal operation will always be less than the number required to remove a DTC from
the chassis ECM memory. DTCs can be removed at any time using the Triumph diagnostic tool.
The system will log the diagnostic trouble codes listed below:
Diagnostic Fault Description Ignition switch Ignition switch Warning Pinpoint test
Trouble Code cycles before cycles before Light/Instrument
(DTC) clearing fault DTC is erased message/Visual
Indication
C1001 Main power supply 1 20 - Power Supply Rail Overvoltage/Undervoltage

overvoltage
C1002 Main power supply 1 20 - Power Supply Rail Overvoltage/Undervoltage

undervoltage
C1003 Chassis ECM internal 1 20 - Control module internal power malfunction

power supply malfunction
C1004 Alarm/tracker input signal 1 40 - Alarm/Tracker Input Signal Malfunction

malfunction
C1005 Rear brake switch 1 40 - Brake Switch

correlation error
C1006 Front brake switch 1 40 - Brake Switch

correlation error
C1008 Starter motor switch 1 20 - Starter Motor Switch Malfunction

malfunction
C1009 Ambient temperature 1 20 Blank or incorrect air Ambient Air Temperature Sensor
sensor signal under temperature display
temperature
C1010 Ambient temperature 1 20 Blank or incorrect air Ambient Air Temperature Sensor
sensor signal over temperature display
temperature
C1017 Instrument wake-up signal 1 40 - Instrument Wake-up Signal Overcurrent

overcurrent
C1031 Left headlight (high beam) 1 40 Warning bulb shows in Headlight Undercurrent/Overcurrent
undercurrent instrument display

Indication
C1032 Left headlight (high beam) 1 40 Warning bulb shows in Headlight Undercurrent/Overcurrent
overcurrent instrument display
C1035 Left headlight (low beam) 1 40 Warning bulb shows in Headlight Undercurrent/Overcurrent
undercurrent instrument display
C1036 Left headlight (low beam) 1 40 Warning bulb shows in Headlight Undercurrent/Overcurrent
C1042 Fog lights undercurrent 1 40 Warning bulb shows in Fog Lights Undercurrent/Overcurrent
instrument display
C1043 Fog lights overcurrent 1 40 Warning bulb shows in Fog Lights Undercurrent/Overcurrent
instrument display
C1045 Front position light 1 40 Warning bulb shows in Headlight Undercurrent/Overcurrent

C1047 Rear light overcurrent 1 40 Warning bulb shows in Rear Light Undercurrent/Overcurrent
instrument display
C1051 Brake light overcurrent 1 40 Warning bulb shows in Brake Light Undercurrent/Overcurrent
instrument display
C1052 Left front direction indicator 1 40 Remaining direction Direction Indicators Undercurrent/Overcurrent
undercurrent indicators flash at a
faster rate
C1053 Left front direction indicator 1 40 Remaining direction Direction Indicators Undercurrent/Overcurrent
overcurrent indicators flash at a
faster rate
C1054 Left rear direction indicator 1 40 Remaining direction Direction Indicators Undercurrent/Overcurrent
undercurrent indicators flash at a
faster rate
C1055 Left rear direction indicator 1 40 Remaining direction Direction Indicators Undercurrent/Overcurrent
overcurrent indicators flash at a
faster rate
C1056 Right front direction 1 40 Remaining direction Direction Indicators Undercurrent/Overcurrent

indicator undercurrent indicators flash at a
faster rate. Warning bulb
shows in instrument
display
C1057 Right front direction 1 40 Remaining direction Direction Indicators Undercurrent/Overcurrent

indicator overcurrent indicators flash at a
shows in instrument
display
C1058 Right rear direction 1 40 Remaining direction Direction Indicators Undercurrent/Overcurrent

indicator undercurrent indicators flash at a
shows in instrument
display
C1059 Right rear direction 1 40 Remaining direction Direction Indicators Undercurrent/Overcurrent

indicator overcurrent indicators flash at a
shows in instrument
display
C1060 Horn undercurrent 1 40 - Horn Undercurrent/Overcurrent
C1061 Horn overcurrent 1 40 - Horn Undercurrent/Overcurrent
C1062 Rider heated seat 1 40 Heated seat symbol Rider Heated Seat Undercurrent/Overcurrent
undercurrent displayed on instruments
but heat level indicators
empty
C1063 Rider heated seat 1 40 Heated seat symbol Rider Heated Seat Undercurrent/Overcurrent
overcurrent displayed on instruments
empty

Indication
C1064 Passenger heated seat 1 40 Heated seat symbol Passenger Heated Seat Undercurrent/Overcurrent
empty
C1065 Passenger heated seat 1 40 Heated seat symbol Passenger Heated Seat Undercurrent/Overcurrent
empty
C1066 Right heated grip 1 40 Heated grip symbol Heated Grips Undercurrent/Overcurrent
empty
C1067 Right heated grip 1 40 Heated grip symbol Heated Grips Undercurrent/Overcurrent
empty
C1068 Left heated grip 1 40 Heated grip symbol Heated Grips Undercurrent/Overcurrent
empty
C1069 Left heated grip overcurrent 1 40 Heated grip symbol Heated Grips Undercurrent/Overcurrent
displayed on instruments
empty
C1070 Cooling fan undercurrent 1 40 MIL* (and coolant Cooling Fan Undercurrent/Overcurrent
temperature warning light
if fault long term)
C1071 Cooling fan overcurrent 1 40 MIL* (and coolant Cooling Fan Undercurrent/Overcurrent
if fault long term)
C1072 Fuel pump undercurrent 1 40 MIL* Fuel Pump Undercurrent/Overcurrent
C1073 Fuel pump overcurrent 1 40 MIL* Fuel Pump Undercurrent/Overcurrent
C1074 Universal Serial Bus (USB) 1 40 - Universal Serial Bus (USB) Power Socket Overcurrent
power socket overcurrent
C1075 Passenger accessory 1 40 - Passenger Accessory Power Socket Overcurrent

power socket overcurrent
C1077 Starter motor solenoid 1 40 MIL* Starter Motor Solenoid Undercurrent/Overcurrent

undercurrent
C1078 Starter motor solenoid 1 40 MIL* Starter Motor Solenoid Undercurrent/Overcurrent

overcurrent
C1087 CAN fault - lost 1 40 - Instrument Communication (CAN)

communication with
instruments
C1088 CAN fault - lost 1 40 - ABS Communication (CAN)

communication with ABS
module
C1091 CAN fault - lost 1 40 - Engine ECM Communication (CAN)

communication with Engine
ECM
C1095 Chassis ECM internal error - 40 Bike continues to run Chassis ECM Internal Error
when fault logged but will
not start after first ignition
cycle.
C1114 Passenger heated seat 1 40 Heated seat symbol Passenger Heated Seat Switch
switch malfunction displayed on instruments
empty

Indication
switch position one displayed on instruments
malfunction but heat level indicators
empty
switch position two displayed on instruments
malfunction but heat level indicators
empty
C1123 CAN Error - No response to 1 40 - CAN Error - No response to control module CAN
control module CAN communication
communication
C1124 Chassis ECM restarted due 1 40 - Control module restarted due to process time out
to process time out during during normal operation
normal operation
normal operation
normal operation
C1127 Chassis ECM restarted due 1 40 - Control module restarted due to calibration download
to calibration download or
software timeout
C1128 Unexpected chassis ECM 1 40 - Unexpected control module restart

restart
C1129 Chassis ECM power supply 1 40 - Control module power supply interrupted
interrupted
C1130 Chassis ECM parameters 1 40 - Control module parameters reset to default

reset to default
C1154 Engine stop switch lock - - - Engine Stop Switch Lock

enabled
C1155 Engine stop switch lock - - - Engine Stop Switch Lock

active
C1161 Cooling fan 2 undercurrent 1 40 MIL* (and coolant Cooling Fan Undercurrent/Overcurrent
if fault long term)
C1162 Cooling fan 2 overcurrent 1 40 MIL* (and coolant Cooling Fan Undercurrent/Overcurrent
if fault long term)
* MIL illuminated by engine ECM in response to chassis ECM DTC being stored.
Pinpoint Tests - Chassis ECM
Power Supply Rail Overvoltage/Undervoltage
C1001 Main power supply over Voltage Disconnect the battery terminals, and proceed to
C1002 Main power supply under Voltage pinpoint test 1:
Blown fuse
Short circuit to ground or open circuit
Charging system fault
Pinpoint Tests
Test Result Action

- Chassis ECM connector 1 pin 8

Test Result Action
- Fuse box, 1 pins 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B, 5A, and 5B
- Regulator Rectifier pins A1, 3, B1, B2, and B3
- Starter solenoid connector pins 1 and 2 Faulty Rectify fault, proceed to test 4
- Starter Solenoid ring terminals
- Battery positive terminal
- Battery negative terminal

- Chassis ECM connector 1 pin 8 to battery negative connector
- Chassis ECM connector 2 pin 10 to battery negative
connector
- Chassis ECM connector 1 pin 8 to regulator rectifier pin A1
- Chassis ECM connector 1 pin 1 to battery positive connector

connector

- Fuse box 1, fuse 4 Open circuit Replace blown fuse(s), proceed to test 5
- Main 30 Amp fuse
5 Reconnect harness, clear fault code and run engine. Measure Greater than 14.6 V or Less Contact Triumph service
the battery voltage while the engine is running than 13.9 V
13.9 V - 14.6 V Action complete - quit test
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
2 A8 8 B8
A7 7 B7 A9 9 B9
5
A5 B5 U
4
A4 B4 GB
3
A3 B3 W
2
A2 B2 N
1
A1 B1 O
3
1 2
8 1 4
1 16 9
A08 O
A07 GU GU 1
B 2
A01 B
B01 N
B10 W
C01 GB
C08 U

C14 B
B B 6
10 1 8 1
20 11
5
16 9
8 7 B 11 B

2. Fuse box 1
7. Chassis ECM - Connector C
Control module internal power malfunction
C1003 Control module internal power malfunction If DTC C1001 or C1002 are also present, rectify DTC
C1002 (see Power Supply Rail
Overvoltage/Undervoltage) then erase DTCs. Monitor
for further instances.
If DTC C1001 or C1002 are not present, check and
record all other DTCs and contact Triumph service.
Alarm/Tracker Input Signal Malfunction
C1004 Alarm/tracker input signal malfunction Disconnect the battery terminals, chassis ECM
connector 1 and proceed to pinpoint test 1:
Pinpoint Tests
Test Result Action

- Alarm pin 7 Faulty Rectify fault, proceed to step 4

- Chassis ECM connector 1 pin 11 and battery positive
connector
- Chassis ECM connector 1 pin 11 to battery negative Short Circuit Rectify fault, proceed to test 4
connector

- Chassis ECM connector 1 pin 11 to Alarm connector pin 7
- Alarm pin 4 to battery positive connector
- Alarm pin 1 to battery negative connector Open circuit Rectify wiring fault, proceed to test 4
- Alarm pin 2 to battery negative connector
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
2 A7 7 B7 A9 9 B9
1
A1 B1 O
1 4
8 1
5 8
1 16 9
4
A08 O
A11 B B 7
B 2
B 1
5
A12 G G 4
1 8
C14 B
9 16
B B
6
8 1
16 9

B 11 B
8
7

2. Fuse box 1
4. Alarm
Brake Switch
C1005 Rear brake switch correlation error View and note freeze frame data if available.
Make sure the brake switches connectors are secure.
Make sure the battery voltage is greater than 10V.
C1006 Front brake switch correlation error Disconnect chassis ECMs, front and rear brake switched and proceed
to pinpoint test 1:
Pinpoint Tests
Test Result Action

- Front brake switch connector pin 1
- Front brake switch connector pin 2
- Front brake switch connector pin 3 Faulty Rectify fault, proceed to test 6
- Rear brake switch connector pin 1

- Front brake switch pin 3 to battery negative connector
Shot Circuit Locate and rectify wiring fault, proceed to test 6
- Rear brake switch pin 2 to battery negative connector

- Rear brake switch pin 1 to pin 2 Shot Circuit Locate and rectify wiring fault, proceed to test 6
- Rear brake switch pin 1 to pin 3

- Chassis ECM connector 2 pin 19 to front brake switch pin 1
- Chassis ECM connector 2 pin 19 to rear brake switch pin 1
- Chassis ECM connector 2 pin 18 to front brake switch pin 2 Open Circuit Locate and rectify wiring fault, proceed to test 6
- Front brake switch pin 3 to Ignition switch pin 2
5 Check switch continuity, component side of connector: OK Proceed to test 6

- Front brake switch pin 3 to pin 2 with brake inactivated
- Front brake switch pin 3 to pin 1 with brake activated
- Rear brake switch pin 3 to pin 2 with brake inactivated Open Circuit Replace faulty switch, proceed to test 6
- Rear brake switch pin 2 to pin 1 with brake activated

Fuse box 1, fuse 8
Circuit Diagram


3
1 2
3 4
2
2
G
10 1
20 11
1
1 3
B6 GP GP 1 1 PG
B19 GP
B18 GU
8 2
9 1
18 10 2 1
9 17 11 3
2 2 3
B R U
G 2 2 6
7 GP GP 1 1
GN 3 3
8
11 1
22 12
33 23
7
3 2 1
1 2 3
B R U
C14 GP
G 3 3
C26 GU GP 1 1
GU 2 2

3. Ignition switch
4. Rear light
9. ABS modulator
Starter Motor Switch Malfunction
C1008 Starter motor switch malfunction Disconnect chassis ECM connector, right hand switch
housing connectors and proceed to pinpoint test 1:
Pinpoint Tests
Test Result Action
1 Check switch integrity: OK Proceed to test 2

- Check the switch for sticking
Faulty Rectify fault, proceed to step 5

- Right hand switch housing connector A (black) pin 3 Faulty Rectify fault, proceed to step 5

Connect the right hand switch connectors. Do NOT press the
starter motor switch for the next test. Short Circuit Locate and rectify wiring fault, proceed to test 5
- Chassis ECM connector 1 pin 16 to ignition switch pin 2

The right hand switch housing must be connected and the
starter motor switch pressed for the next test.
- Chassis ECM connector 1 pin 16 to ignition switch pin 2
Circuit Diagram

4 6
1 2
3

3 4
1 3
G
3
2
G 3
Y 4
1
4
A14 Y
A16 R R 3
A15 GR GR 4
5
4 6
8 1
16 9 1 3

2. Ignition switch
3. Right hand switch housing connector B (grey)
4. Left hand switch housing connector A (black)
Ambient Air Temperature Sensor
C1009 Ambient temperature sensor signal under temperature Check sensor is clean and clear of dirt
Make sure the sensor connector is secure
C1010 Ambient temperature sensor signal over temperature Proceed to pinpoint test 1:
C1027 Sensor Supply General
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect the chassis ECM connector and the temperature
- Chassis ECM connector 1 pin 7 sensor connector. Proceed to test 2
- Temperature sensor pin 1
- Temperature sensor pin 2 Faulty Rectify fault, proceed to test 5
2 Check cable for short circuit: OK Disconnect temperature sensor connector. Proceed to test 3

- Chassis ECM connector 1 pin 7 to temperature sensor pin 1
- Temperature sensor pin 2 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 5
4 Check sensor resistance: OK Proceed to test 5

- Sensor pin 1 to sensor pin 2
(temperature dependent - see circuit diagram resistance data) Open circuit Replace temperature sensor, proceed to test 5

Fuse box 1, fuse 1
6 Reconnect harness, clear fault code and run engine to verify OK Action complete - quit test
fault cleared
Circuit Diagram

If engine is warm, remove sensor and allow time to cool to ambient prior to test.
Resistance data:
Ambient temperature resistance value
80°C - 200 to 400 Ohms
20°C - 2.35 to 2.65 K Ohms
-10°C - 8.50 to 10.25 K Ohms
A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
2 A7 7 B7
A8 8 B8
A9 9 B9
1
A1 B1 O
1 2
8 1
16 9 4
1
A08 O
A07 GU GU 1
B 2
A01 B

6
B B
5
B 11 B

2. Fuse box 1
3. Chassis ECM - connector A
Instrument Wake-up Signal Overcurrent
C1017 Instrument wake-up signal overcurrent Disconnect chassis ECM and instruments. Proceed to
pinpoint test 1:
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect instruments connector and proceed to test 2
- Instruments pin 5 Faulty Rectify fault, proceed to test 4

connector Short circuit Locate and rectify wiring fault, proceed to test 4

- Chassis ECM connector 2 pin 13 to Instruments pin 5
fault cleared
Circuit Diagram

10 1
6 1
20 11
12 7
3
1
5 GW GW B13
1. Instruments
Headlight Undercurrent/Overcurrent
C1031 High beam undercurrent Ensure all connectors are secure

C1035 Low beam undercurrent
C1032 High beam overcurrent Disconnect chassis ECM and proceed to pinpoint test
4:
C1036 Low beam overcurrent
C1045 Front position light overcurrent
Pinpoint Tests

Test Result Action
1 Check fuse integrity: OK Disconnect headlight and chassis ECM connectors, proceed to
- Fuse box 1, fuse 2 test 2

- Headlight connector all pins

- Headlight connector pin 1 to battery negative connector
- Chassis ECM connector 2 pin 14 to headlight connector pin 2
Open circuit Rectify fault, proceed to test 5
- Fuse box 1, fuse 2 to chassis ECM connector 2 pin 1
- Fuse box 1, fuse 3 to chassis ECM connector 2 pin 10

- Headlight connector pin 1 to battery negative connector
connector
connector
- Fuse box 1, fuse 2 to battery negative connector
- Fuse box 1, fuse 3 to battery negative connector
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
2 A7 7 B7 A9 9 B9
3
A3 B3 W
2
A2 B2 N
8 1
16 9
4
B01 N
B10 W
B14 UY UY 2
B02 UR UR 6
B 1
C13 UW UW 5
C09 G G 4
1 2 5
A02 P P 11 P
B 22 B
1 2 6
10 1 8 1
20 11 16 9
P 11 P
B 22 B
10 9
8
7
B 11 B

2. Fuse box 1
4. Headlight
5. Left hand fog light connector
6. Right hand fog light connector

Fog Lights Undercurrent/Overcurrent
C1042 Fog lights undercurrent Disconnect chassis ECM and fog light connectors
C1043 Fog lights overcurrent Disconnect chassis ECM and fog light connectors
Pinpoint Tests
Test Result Action


- Left fog light connector all pins
- Right fog light connector all pins
- Fuse box 1 pins 1B and 1A

- Chassis ECM connector 1 pin 8 to battery negative connector Short circuit Locate and rectify wiring fault, proceed to test 5

- Chassis ECM connector 1 pin 2 to left fog light connector pin
1
- Chassis ECM connector 1 pin 2 to right hand fog light
connector pin 1
- Left fog light connector pin 2 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 5
- Right fog light connector pin 2 to battery negative connector
- Fuse box 1, fuse 1 to Chassis ECM connector 1 pin 8
fault cleared
Fault still present Replace fog lights
If fault still present, contact Triumph service
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
2 A8 8 B8
A7 7 B7 A9 9 B9
1
A1 B1 O
3
1 2
5 6
8 1
1 16 9
4
A08 O
B14 UY UY 2
B02 UR UR 6
B 1
B13 UW UW 5
B09 G G 4
5
1 2
A02 P 1 1 P
2 2 B
1 2 6
10 1
20 11 1 1 P
2 2 B
9
B 7
B 11 B

2. Fuse box 1
4. Headlight

5. Left hand fog light connector
6. Right hand fog light connector
Rear Light Undercurrent/Overcurrent
C1047 Rear light overcurrent Disconnect chassis ECM and rear light connectors
Pinpoint Tests
Test Result Action

- Rear light connector pin 3

- Chassis ECM connector 1 pin 3 to ground

- Chassis ECM connector 1 pin 3 to rear light connector pin 3
- Rear light connector pin 2 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 4
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
2 A8 8 B8
A7 7 B7 A9 9 B9
1
A1 B1 O
3
1 2
5 6
8 1
16 9
1
A08 O
B18 GU 4
B19 GP
B06 GP 1 1 PG
A03 Y 3 3 Y
B 2 2 B
6 5
B B 11 B
10 1
20 11

2. Fuse box 1
4. Rear light connector
Brake Light Undercurrent/Overcurrent
C1051 Brake light overcurrent Disconnect chassis ECM and rear light connectors
Pinpoint Tests

Test Result Action



- Chassis ECM connector 2 pin 6 to rear light connector pin 1
- Rear light connector pin 2 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 4
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
2 A8 8 B8
A7 7 B7 A9 9 B9
2
A2 B2 N
3
1 2
5 6
10 1
20 11
1
B01 N
B18 GU 4
B19 GP
B06 GP 1 1 PG
A03 Y 3 3 Y
B 2 2 B
6 5
B B 11 B
8 1
16 9

2. Fuse box 1
4. Rear light connector
Direction Indicators Undercurrent/Overcurrent
C1052 Left front direction indicator undercurrent Make sure the direction indicator connectors are
secure
C1056 Right front direction indicator undercurrent Proceed to pinpoint test 1:
C1054 Left rear direction indicator undercurrent
C1058 Right rear direction indicator undercurrent
C1053 Left front direction indicator overcurrent Disconnect chassis ECM and relevant direction
indicator connectors
C1057 Right front direction indicator overcurrent Proceed to pinpoint test 3:
C1055 Left rear direction indicator overcurrent
C1059 Right rear direction indicator overcurrent
Pinpoint Tests
Test Result Action

Test Result Action
1 Check relevant direction indicator bulb integrity (non LED OK Proceed to test 2
direction indicators only)
Faulty Replace bulb, proceed to test 6
2 Check fuse integrity: OK Disconnect chassis ECM and relevant direction indicator
- Fuse box 1, fuse 2 connectors
- Fuse box 1, fuse 3 Proceed to test 3

- Fuse box 1, pins 2B and 2A
- All relevant direction indicator terminals

- Chassis ECM connector 2 pin 7 to right front indicator pin A1
positive connector
- Chassis ECM connector 3 pin 4 to right rear indicator pin A1
positive connector
- Chassis ECM pin connector 2 pin 8 to left front indicator pin
A1 positive connector
- Chassis ECM connector 3 pin 5 to left rear indicator pin A1
positive connector
- Right front indicator pin B1 to battery negative connector
- Right rear indicator pin B1 to battery negative connector
- Left front indicator pin B1 to battery negative connector
- Left rear indicator pin B1 to battery negative connector

- Chassis ECM pin connector 2 pin 8 to battery negative
connector
- Chassis ECM connector 3 pin 5 to ground
- Right front indicator pin B1 to battery positive connector
- Right rear indicator pin B1 to battery positive connector Short circuit Locate and rectify wiring fault, proceed to test 6
- Left front indicator pin B1 to battery positive connector
- Left rear indicator pin B1 to battery positive connector
connector
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
2 1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
A7 7 B7 A9 9 B9
3
A3 B3 W
2
A2 B2 N
10 1
20 11
1
B01 N
4
B10 W
B08 GR GR 1 1 W
B 1 1 B
5
B07 GW GW 1 1 W
B 1 1 B
C05 GR GR 1 1 W
B 1 1 B
C04 GW GW 1 1 W
B 1 1 B

8 1 B B
16 9
9 8
10 B 11 B

2. Fuse box 1
4. Front left hand direction indicator connectors
5. Front right hand direction indicator connectors
6. Rear left hand direction indicator connectors
7. Rear right hand direction indicator connectors
Horn Undercurrent/Overcurrent
C1060 Horn undercurrent Make sure all connectors are secure

C1061 Horn overcurrent
Pinpoint Tests
Test Result Action
1 Check fuse integrity: OK Disconnect chassis ECM and horn connectors, proceed to test 2

- Horn terminals
- Chassis ECM connector 1 pin 8 Faulty Rectify fault, proceed to test 5

- Horn negative terminal to battery positive connector

- Chassis ECM connector 1 pin 5 to horn positive connector
- Horn negative connector to battery negative connector
Open Circuit Locate and rectify wiring fault, proceed to test 5
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
2 A7 7 B7 A9 9 B9
1
A1 B1 O
1
3
A08 O
A05 PW PW
8 1 B
16 9
5 4
6
B 11 B

2. Fuse box 1
3. Horn
Rider Heated Seat Undercurrent/Overcurrent
Pinpoint Tests
C1062 Rider heated seat undercurrent Proceed to pinpoint test 1:
C1063 Rider heated seat overcurrent
Test Result Action
1 Check fuse integrity: OK Disconnect chassis ECM and rider heated seat connectors,
- Fuse box 1, fuse 3 proceed to test 2

- Rider heated seat pin 1
- Rider heated seat pin 2

connector
connector Short circuit Rectify fault, proceed to test 5
- Rider heated seat pin 1 to battery positive connector

- Chassis ECM connector 3 pin 11 to passenger heated seat
pin 2
- Rider heated seat pin 1 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 5
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
A7 7 B7 A9 9 B9
2
3
A3 B3 W
2
A2 B2 N
3
8 1
1 16 9
1 2
B01 N 4
B10 W
C10 PO PO 22 B
B 11 B
1 2
5
C11 PO PO 22 B
B 11 B
6
1 2 3
B17 OW OW 11 B
B16 OG OG 33 B
B 22 B
1 2
7 3 4
B15 KW KW 11 KW
B12 BG BG 33 G
B
5
B11 KB KB 22 KB
B 44 B
B BB
9 8
10 1 B 11 B
20 11
10

2. Fuse box 1
4. Passenger heated seat connector
5. Rider heated seat connector
7. Heated grips subharness
Passenger Heated Seat Undercurrent/Overcurrent
Pinpoint Tests
C1064 Passenger heated seat undercurrent Proceed to pinpoint test 1:
C1065 Passenger heated seat overcurrent
Test Result Action
1 Check fuse integrity: OK Disconnect chassis ECM and passenger heated seat connectors,
- Fuse box 1, fuse 3 proceed to test 2

- Passenger heated seat pin 1
- Passenger heated seat pin 2
Fuse box 1, pins 3B and 3A

connector
connector Short circuit Rectify fault, proceed to test 5
- Passenger heated seat pin 1 to battery positive connector

pin 2
- Passenger heated seat pin 1 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 5
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
A7 7 B7 A9 9 B9
2
3
A3 B3 W
2
A2 B2 N
3
8 1
1 16 9
1 2
B01 N 4
B10 W
C10 PO PO 22 B
B 11 B
1 2
5
C11 PO PO 22 B
B 11 B
6
1 2 3
B17 OW OW 11 B
B16 OG OG 33 B
B 22 B
1 2
7 3 4
B15 KW KW 11 KW
B12 BG BG 33 G
B
5
B11 KB KB 22 KB
B 44 B

B BB
9 8
10 1 B 11 B
20 11
10

2. Fuse box 1
Engine ECM Communication (CAN)
C1091 CAN fault - lost communication with Engine ECM Disconnect the Chassis ECM and Engine ECM,
proceed to pinpoint test 1:
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect instruments and proceed to test 2
- Engine ECM pin C24 Faulty Rectify fault, proceed to test 5

- Chassis ECM connector 1 pin 9 to battery positive and
negative connectors
- Chassis ECM connector 1 pin 10 to battery positive and Short circuit Locate and rectify wiring fault, proceed to test 5
negative connectors

- Engine ECM pin A8 to battery positive connector
- Engine ECM pin A21 to battery positive connector
- Chassis ECM connector 1 pin 9 to Engine ECM pin C25 Open circuit Locate and rectify wiring fault, proceed to test 5
- Chassis ECM connector 1 pin 10 to Engine ECM pin 24
4 Check CAN bus resistance: (Chassis ECM, Engine ECM must OK (50-65 Ohms) Proceed to test 5
be connected and battery disconnected)
- Diagnostic connector pin 6 to diagnostic connector pin 14 Faulty (less than 50 or more Locate and rectify wiring fault, proceed to test 6
than 65 ohms)

Faulty Replace blown fuse, proceed to test 6
Circuit Diagram
1
1 8
14 U
6 R
9 16 2
4 U
1 4 3 R
3
A9 R
8 1
16 9 A10 U
12
4
11 1 C25 R
22 12
33 23 C24 U
11
5
9 8 2 1
11 U
2 R
18 17 11 10 6
6 R
5 1
10 6 1 U
7
3 R
2 U
4 6
1 2 3
8 1 3
10 R
4 U
6 1
1 R 4
12 7
9
4 6 6 R 6
1 3
10

2. Connectivity module
5. ABS modulator
6. Immobilser/TPMS electronic control module
7. Inertial measurement unit
8. Instruments
9. Right hand switch housing - connector grey
10. Left hand switch housing - six pin connector
Passenger Heated Seat Switch
C1114 Passenger heated seat switch malfunction Disconnect chassis ECM connectors, passenger
heated seat switch and proceed to pinpoint test 1:
C1115 Passenger heated seat switch position one malfunction
C1116 Passenger heated seat switch position two malfunction
Pinpoint Tests
Test Result Action
1 Check switch integrity: OK Proceed to test 2

- Check the switch for sticking
Faulty Rectify fault/replace switch unit as necessary, proceed to test 6
2 Check cable and terminal integrity: OK Disconnect passenger heated seat switch connector and proceed
- Chassis ECM connector 2 pin 17 to test 3
- Passenger heated seat switch pin 1
- Passenger heated seat switch pin 2 Faulty Rectify fault, proceed to test 5
- Passenger heated seat switch pin 3

- Chassis ECM connector 2 pin 17 to chassis ECM connector 2
pin 16
connector
- Chassis ECM connector 2 pin 16 to battery negative Short Circuit Locate and rectify wiring fault, proceed to test 5
connector
- Passenger heated seat switch pin 2 to battery positive
connector

switch pin 1
switch pin 3 Open circuit Locate and rectify wiring fault, proceed to test 5
- Passenger heated seat switch pin 2 to battery negative
connector
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
A7 7 B7 A9 9 B9
2
3
A3 B3 W
2
A2 B2 N
3
8 1
1 16 9
1 2
B01 N 4
B10 W
C10 PO PO 22 B
B 11 B
1 2
5

C11 PO PO 22 B
B 11 B
6
1 2 3
B17 OW OW 11 B
B16 OG OG 33 B
B 22 B
1 2
7 3 4
B15 KW KW 11 KW
B12 BG BG 33 G
B
5
B11 KB KB 22 KB
B 44 B
B BB
9 8
10 1 B 11 B
20 11
10

2. Fuse box 1
Heated Grips Undercurrent/Overcurrent
C1066 Right heated grip undercurrent Make sure all connectors are secure
C1068 Left heated grip undercurrent
Right heated grip overcurrent Disconnect chassis ECM and heated grip connectors
C1067 Proceed to pinpoint test 2:
C1069 Left heated grip overcurrent
Pinpoint Tests
Test Result Action
1 Check fuse integrity: OK Disconnect chassis ECM and heated grip connectors, proceed to
Faulty Locate and rectify wiring fault, proceed to test 5

- Heated grip subharness pin 1 (both mating halves)
- Heated grip subharness pin 2 (both mating halves) Faulty Replace fuse, proceed to test 5
- Left heated grip pin 1
- Left heated grip pin 2
- Heated twist grip pin 1
- Heated twist grip pin 2

connector
connector
- Heated grip subharness pin 1 (subharness side) to battery
negative connector Short circuit Rectify fault, proceed to test 5
- Heated grip subharness pin 2 (subharness side) to battery
negative connector
- Heated grip subharness pin 4 (subharness and main harness
side) to battery positive connector
4 Check cable continuity (when subharness connected): OK Proceed to test 5

- Chassis ECM connector 2 pin 11 to right heated grip pin 1
- Chassis ECM connector 2 pin 12 to left heated grip pin 2
- Left heated grip pin 1 to battery negative connector
Open circuit Rectify fault, proceed to test 5
- Right hand grip pin 2 to battery negative connector

Test Result Action
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
A7 7 B7 A9 9 B9
2
3
A3 B3 W
2
A2 B2 N
3
8 1
1 16 9
1 2
B01 N 4
B10 W
C10 PO PO 22 B
B 11 B
1 2
5
C11 PO PO 22 B
B 11 B
6
1 2 3
B17 OW OW 11 B
B16 OG OG 33 B
B 22 B
1 2
7 3 4
B15 KW KW 11 KW
B12 BG BG 33 G
B
5
B11 KB KB 22 KB
B 44 B
B BB
9 8
10 1 B 11 B
20 11
10

2. Fuse box 1
Cooling Fan Undercurrent/Overcurrent
C1070 Cooling fan 1 undercurrent Proceed to pinpoint test 1:
C1071 Cooling fan 1 overcurrent Disconnect chassis ECM and cooling fan connectors
C1161 Cooling fan 2 undercurrent Proceed to pinpoint test 1:
C1162 Cooling fan 2 overcurrent Disconnect chassis ECM and cooling fan connectors
Pinpoint Tests
Test Result Action
1 Check fuse integrity: OK Disconnect chassis ECM and cooling fan connectors, proceed to


Test Result Action
- Cooling fan 1 connector pin 1
- Cooling fan 2 connector pin 2 Faulty Rectify fault, proceed to test 5
- Fuse Box 1, pins 1B and 1A
- Fuse Box 1, pins 5B and 5A

- Chassis ECM connector 3 pin 8 to battery negative connector Short circuit Locate and rectify wiring fault, proceed to test 5
- Cooling fan 1 connector pin 1 to battery positive connector
- Cooling fan 2 connector pin 1 to battery positive connector

- Chassis ECM connector 1 pin 6 to cooling fan 2 pin 2
- Chassis ECM connector 3 pin 7 to cooling fan 1 pin 2
- Cooling fan 1 pin 1 to battery negative connector
- Cooling fan 2 pin 1 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 5
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
A7 7 B7 A9 9 B9
2
5
B5 B5 U
1
A1 B1 O
3
8 1 2 1
1 16 9
A08 O 4
C08 U
C07 NK NK 22 B
B 11 B
A06 NK NK 22 B
B 11 B
8 1 2 1
16 9
7 6
8
B 11 B

2. Fuse box 1
4. Cooling fan 1 connector
5. Cooling fan 2 connector
Fuel Pump Undercurrent/Overcurrent
C1072 Fuel pump undercurrent Proceed to pinpoint test 1
C1073 Fuel pump overcurrent Disconnect chassis ECM and fuel pump connectors
Proceed to pinpoint test 2
Pinpoint Tests

Test Result Action
1 Check fuse integrity: OK Disconnect chassis ECM and fuel pump connectors, proceed to

- Fuel pump connector pin 1
- Fuel pump connector pin 2

- Chassis ECM connector 3 pin 16 to battery negative and
positive connector
- Chassis ECM connector 3 pin 15 to battery negative and
positive connector Short circuit Locate and rectify wiring fault, proceed to test 5
- Chassis ECM connector 3 pin 8 to battery negative ring
terminal

- Chassis ECM pin connector 3 pin 16 fuel pump pin 1
- Chassis ECM connector 3 pin 15 to fuel pump pin 2
fault cleared
Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
A7 7 B7 A9 9 B9
2
5
A5 B5 U
1 2
C08 U
3
C16 PW PG 1
C15 U Y 2
8 1
16 9

2. Fuse box 1
3. Fuel pump
Universal Serial Bus (USB) Power Socket Overcurrent
C1074 Universal Serial Bus (USB) power socket overcurrent Remove any device connected
Disconnect chassis ECM and proceed to pinpoint test
1:
Pinpoint Tests
Test Result Action


Test Result Action
2 Check cable continuity: OK Replace USB socket, proceed to test 3

- Chassis ECM connector 2 pin 9 to USB socket pin 1
- USB socket pin 2 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 3
fault cleared
Circuit Diagram

A1 B1
2 2
4
1
A1 B1 P P 2
3 B 1
1 1
8 1
16 9
5
2
C03 P P 2
B 1
2 1
6
B09 G G 11 W
B 22 B
B BB 8
10 1 7
20 11
B 11 B

2. Fuse box 2
3. Chassis ECM -Connector C
4. Front accessory socket (live)
5. Rear accessory socket (switched)
6. USB socket
Passenger Accessory Power Socket Overcurrent
C1075 Passenger accessory power socket overcurrent Remove and connected device
Disconnect chassis ECM and proceed to pinpoint test
1:
Pinpoint Tests
Test Result Action

2 Check cable continuity: OK Replace power socket, proceed to test 3

- Chassis ECM connector 3 pin 3 to power socket pin 2
- Power socket pin 1 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 3
fault cleared
Circuit Diagram


1
A1 B1
2 2
4
1
A1 B1 P P 2
3 B 1
1 1
8 1
16 9
5
2
C03 P P 2
B 1
2 1
6
B09 G G 11 W
B 22 B
B BB 8
10 1 7
20 11
B 11 B

2. Fuse box 2
3. Chassis ECM -Connector C
4. Front accessory socket (live)
5. Rear accessory socket (switched)
6. USB socket
Starter Motor Solenoid Undercurrent/Overcurrent
C1077 Starter motor solenoid undercurrent Proceed to pinpoint test 1
C1078 Starter motor solenoid overcurrent Disconnect chassis ECM and proceed to pinpoint test 2
Pinpoint Tests
Test Result Action
1 Check fuse integrity: OK Disconnect chassis ECM and proceed to test 2

2 Check cable and terminal integrity: OK Disconnect starter solenoid connectors and proceed to test 3
- Starter solenoid pin 3
- Starter solenoid pin 4

- Starter solenoid pin 4 to battery positive connector
4 Check cable continuity: OK Replace starter solenoid, proceed to test 5

- Chassis ECM connector 3 pin 6 to starter solenoid pin 3
- Starter solenoid pin 4 to battery negative connector
fault cleared
Circuit Diagram


A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
3 A8 8 B8
A7 7 B7 A9 9 B9
5
5
1 2
A5 B5 U 4 3 4
6
2
1
B B 1
N 1 30A
C08 U
N 2
C06 WR WR 3
B 4
12 B 1 8
7
B 1
8 1 9
16 9
B 1
11 10
B 11 B

2. Battery positive connector
3. Fuse box 1
4. Starter motor solenoid positive connector
5. Starter motor solenoid connector
6. Starter motor solenoid
7. Starter motor feed connector
8. Starter motor
9. Engine ground
Instrument Communication (CAN)
C1087 CAN fault - lost communication with instruments Proceed to pinpoint test 1:
Pinpoint Tests
Test Result Action
1 Verify instrument panel is operating. Turn the ignition to the ON OK Disconnect chassis ECM and instrument connectors and proceed
position to test 3
Faulty Proceed to test 2
2 Check fuse integrity: OK Disconnect chassis ECM and instrument connectors and proceed
- Fuse box 1, fuse 8 to test 3
Faulty Replace blown fuse, proceed to test 8

- Instruments pin 10 Faulty Rectify fault, proceed to test 8
- Instruments pin 4

- Chassis ECM connector 1 pin 9 to battery positive and
negative connector
- Chassis ECM connector 1 pin 10 to battery positive and Short circuit Locate and rectify wiring fault, proceed to test 8
negative connector

- Instruments pin 12 to battery positive connector
- Instruments pin 11 to battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 8

- Chassis ECM connector 1 pin 9 to instrument pin 10
- Chassis ECM connector 1 pin 10 to instrument pin 4 Open circuit Locate and rectify wiring fault, proceed to test 8
7 Check CAN bus resistance: (Chassis ECM, instruments must OK (50-65 Ohms) Proceed to test 8
be connected and battery disconnected)
- Diagnostic connector pin 6 to diagnostic connector pin 14 Fault (Less that 50 or more than Locate and rectify wiring fault, proceed to test 8
65 Ohms)

Test Result Action
fault cleared
Circuit Diagram

8 1
16 9
A09 R
A10 U
4
10 R
4 U 3 2
12 P
11 B B B 11 B
6 1 4
12 7
8
A8 B8 WU
A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
A7 7 B7 A9 9 B9

4. Fuse box 1
5. Instruments
ABS Communication (CAN)
C1088 CAN fault - lost communication with ABS module Disconnect Chassis ECM connectors and proceed to
pinpoint test 1:
Pinpoint Tests
Test Result Action

Fuse box 1, fuse 7
Faulty Replace faulty fuse, proceed to test 7

- ABS ECM pin 18 to battery positive connector
- ABS ECM pin 10 battery negative connector Open circuit Locate and rectify wiring fault, proceed to test 7
3 Check cable and terminal integrity: OK Disconnect ABS ECM connector, proceed to test 4
- ABS ECM pin 2 Faulty Locate and rectify wiring fault, proceed to test 7
- ABS ECM pin 11

- Chassis ECM connector 1 pin 9 to positive and negative
battery connector
- Chassis ECM connector 1 pin 10 to positive and negative Short circuit Locate and rectify wiring fault, proceed to test 7
battery connector

- Chassis ECM connector 1 pin 9 to ABS pin 2
- Chassis ECM connector 1 pin 10 to ABS pin 11 Open circuit Locate and rectify wiring fault, proceed to test 7
6 Check CAN bus resistance: (Chassis ECM, ABS must be OK (50-65 Ohms) Proceed to test 7
connected and battery disconnected)
- Diagnostic connector pin 6 to diagnostic connector pin 14 Fault (Less that 50 or more than Locate and rectify wiring fault, proceed to test 7
65 Ohms)

Test Result Action
fault cleared
Circuit Diagram

8 1
16 9
A09 R
A10 U
4
2 R
11 U 3 2
18 R
10 B B B 11 B
9 8 2 1
18 17 11 10 7
A7 B7 R
A1 A2 A3 A4 A5 A6
1 2 3 4 5 6
B1 B2 B3 B4 B5 B6
A8 8 B8
A7 7 B7 A9 9 B9

4. Fuse box 1
5. ABS ECM
Chassis ECM Internal Error
C1095 Chassis ECM internal error Note and investigate any other stored DTCs
Erase DTC and monitor for further issues
If the fault fails to clear, contact Triumph service
CAN Error - No response to control module CAN communication
C1123 CAN Error - No response to control module CAN Proceed to pinpoint test 1:
communication
Pinpoint Tests
Control module restarted due to process time out during normal operation
C1124 Chassis ECM restarted due to process time out during Note and investigate any other stored DTCs
normal operation Contact Triumph service
C1125
C1126
Control module restarted due to calibration download
C1127 Control module restarted due to calibration download Erase DTC

No further action required
Unexpected control module restart
C1128 Unexpected control module restart Note and investigate any other stored DTCs

If the fault fails to clear or reoccurs, contact Triumph
service
Control module power supply interrupted
C1129 Control module power supply interrupted Make sure voltage across battery is acceptable. Note
Voltage
Pinpoint Tests
Test Result Action
1 Has the battery been disconnected? Yes Proceed to test 5
No Disconnect Chassis ECM and proceed to test 2

- Fuse box 1 pins A1, B1, A2, B2, A3, B3, A4, B4, A5 and B5
- Regulator/rectifier pins A1 and A3
- Regulator/rectifier pins B2and B3
- Starter motor solenoid connector pins 1 and 2
- Battery positive terminal
- Battery negative terminal

- Chassis ECM connector 2 pins 1 and 10 to battery negative
connector
- Chassis ECM connector 3 pins 1 and 8 to battery negative
connector
- Chassis ECM connector 2 pins 1 and 10 to regulator/rectifier
pin A1 Short circuit Proceed to test 5
pin A1
- Chassis ECM connector 1 pin1 to battery positive connector
-Chassis ECM connector 1 pin1 to regulator/rectifier pin A3
- Chassis ECM connector 3 pin 14 to regulator/rectifier pin A3
4 Check cable continuity: Same as 'across battery' Proceed to test 5

- Chassis ECM connector 1 pin 8 to battery positive connector Voltage
- Chassis ECM connector 2 pins 1 and 10 to battery positive
connector
- Chassis ECM connector 3 pins 1 and 8 to battery positive
connector
pin A3
Less than 'across battery' Locate and rectify wiring fault, proceed to test 5
Voltage
pin A3
-Chassis ECM connector 1 pin1 to battery negative connector
connector
- Chassis ECM connector 1 pin1 to regulator/rectifier pin A1
- Chassis ECM connector 3 pin 14 to regulator/rectifier pin A1

- Fuse box 1, Fuse 1
Faulty Replace fuse(s), proceed to test 6
6 Reconnect all harness, clear the fault code and run engine. OK Contact Triumph service
Measure the battery voltage while the engine is running.
Fault still present Action complete - quit test

Circuit Diagram

A1 A2 A3 A4 A5 A6
1 2 3 4 5 6 4
B1 B2 B3 B4 B5 B6 1 2 3
A8 8 B8
A7 7 B7 A9 9 B9
A1 B1 5
A2 B2
3
A3 B3
5
A5 B5 O
4
A4 B4 GB
3
A3 B3 W
2
A2 B2 N
1
A1 B1 O
1 2
8 1
16 9
1
6
A08 O
A07 GU GU 1
A01 B 6 B 2
B01 N
B10 W
C01 GB
C08 U
C14 B
10 1 8 1
20 11 16 9
B B 8
7
10 9
B 11 B

3. Fuse box 1
5. Regulator/rectifier - Connector A
Unexpected control module restart
C1128 Unexpected control module restart Note and investigate any other stored DTCs
If the fault fails to clear or reoccurs, contact Triumph
service
Control module parameters reset to default
C1130 Control module parameters reset to default Download the latest chassis ECM calibration to make
sure correct model specific configuration
Erase stored DTCs from all ECMs
C1130 Control module parameters reset to default Download the latest chassis ECM calibration to make
sure correct model specific configuration
Erase stored DTCs from all ECMs
Engine Stop Switch Lock
C1154 Engine stop switch lock enabled Commission the motorcycle as follows:
Motorcycle not commissioned Download the latest instrument calibration
In this condition the engine can only be started once Download the latest chassis ECM calibration
After the engine is turned Off, DTC C1155 will be Download the latest Engine ECM Calibration
stored and the engine will no longer start Unlock the engine ECM as described in the Triumph
Diagnostic Tool User Guide
The unlock code can be found on www.triumphonline
C1155 Engine stop switch lock active
Start the engine and make sure neither fault codes are
Motorcycle not commissioned present
In this condition the engine will not start If either fault code reoccurs, contact Triumph Service

Lighting Adjustment and Bulb Replacement
Headlight
WARNING
Adjust road speed to suit the visibility and weather conditions in which the motorcycle is being operated.
Make sure that the head light beam is adjusted to illuminate the road surface sufficiently far ahead without dazzling oncoming traffic. An incorrectly adjusted headlight may
impair visibility causing an accident.
WARNING
Never attempt to adjust a headlight beam when the motorcycle is in motion.

Any attempt to adjust a headlight beam when the motorcycle is in motion may result in loss of control and an accident.
CAUTION
Do not cover the headlight or lens with any item likely to obstruct air flow to, or prevent heat escaping from, the headlight lens.
Covering the headlight lens during operation with items of clothing, luggage, adhesive tape, devices intended to alter or adjust the headlight beam or non genuine headlight
lens covers will cause the headlight lens to overheat and distort, causing irreparable damage to the headlight assembly.
Damage caused by overheating is not considered a manufacturing defect and will not be covered under warranty.
If the headlight must be covered during use - such as taping of the headlight lens required during closed-course conditions - the headlight must be disconnected.
Headlight Bulb - Replacement
This model is fitted with light emitting diodes (LED) headlights. The headlights, DRL or LED position light are situated within the headlight assembly and are sealed,
maintenance free LED units. The headlight unit must be replaced in the event of failure of the headlights, DRL or LED position lights.
Rear Light/Licence Plate Light
The rear light unit is a sealed, maintenance-free LED unit. The licence plate light is integral to the rear light unit.
LED Direction Indicators
The LED direction indicators are sealed for life units and must be replaced in the event of a failure.
LED Fog Lights
The LED fog light units are sealed, maintenance free LED units. The fog light units must be replaced in the event of the failure of the fog lights.
Removal and Installation - Electrical Components
WARNING
Ensure that the battery terminals do not touch the motorcycle frame as this may cause a short circuit or spark, which would ignite battery gases causing a risk of personal
injury.
rider preference.
be reset as noted.
WARNING

Rider's Seat - Removal/InstallationRemove the rider's seat.
1. If installed, open the tool kit tray.
2. Remove the protective caps from the terminals.
3. Disconnect the battery terminals, negative (black) lead first.
WARNING
injury.
1. Apply a light coat of grease to the terminals to prevent corrosion.

3. Cover the terminals with their protective caps.
4. If installed, close the tool kit tray.
Note
Once the battery has been reconnected the rider’s configuration settings should be reset as noted prior to the battery being disconnected.

WARNING

Rider's Seat - Removal/InstallationInstall the rider's seat.
Battery - Removal
WARNING
injury.
rider preference.
be reset as noted.
WARNING

Rider's Seat - Removal/InstallationRemove the rider's seat.
1. If installed, open the tool tray.
2. Remove the battery strap.
3. Noting it’s orientation remove the battery cover.
2
1
5
3
4
B00517
1. Tool tray
2. Positive (+) battery terminal
3. Negative (-) battery terminal
4. Battery strap
5. Battery cover
4. Disconnect the battery, negative (black) lead first.

5. Remove the battery from the tray.
WARNING
injury.
1. Place the battery in the battery tray.

2
1
5
3
4
B00517

1. Tool tray
2. Positive (+) battery terminal
3. Negative (-) battery terminal
4. Battery strap
5. Battery cover
3. Apply a light coat of grease to the terminals to prevent corrosion.

4. Cover the positive terminal with the protective cap.
5. Refit the battery cover.
6. Refit the battery strap.
7. Close the tool tray.
Note
WARNING

Rider's Seat - Removal/InstallationInstall the rider's seat.
Instruments - Removal
WARNING

rider preference.
be reset as noted.
WARNING

1. Release the locking tab and remove the electrical connector.
2 1
2
B01004
1. Instruments
2. Fixings
2. Release the four fixings and remove the instrument assembly.
Instruments - Installation
WARNING

1. Position the TFT instrument assembly to its bracket.

2. Refit the electrical connector making sure the lock tab is fully locked in position.
3. Fit the four fixings and tighten to 3 Nm.
2 1
2
B01004
1. Instruments
2. Fixings

Note
WARNING
Ambient Air Temperature Sensor - Removal

1. Remove the beak (see Beak - Removal and Disassembly).
3. Release the fixing that attaches the ambient air temperature sensor to the Cable tidy and remove the sensor.
2 3
B00613

3. Fixing
4. Cable tidy
Ambient Air Temperature Sensor - Installation
1. Fit the sensor to the cable tidy, tightening the fixing to 3 Nm.
2 3

B00613

3. Fixing
4. Cable tidy
2. Connect the electrical connector.

Headlight Bulb - Replacement
This model is fitted with light emitting diodes (LED) headlights. The headlights, DRL or LED position light are situated within the headlight assembly and are sealed,
maintenance free LED units. The headlight unit must be replaced in the event of failure of the headlights, DRL or LED position lights.
Headlight Assembly - Removal

1. Release the two fixings that attach the headlamp to the cockpit side panels.
2. Release the four fixings securing the headlight to the front subframe. Collect the washers.
3. Disconnect the electrical connector and remove the headlight.
1 3
B01016
1. Headlight
2. Subframe fixings
3. Cockpit side panel fixing
Headlight Assembly - Installation
1. Inspect the rubber grommets for integrity and replace if required.

2. Position the headlight and install the four washers and fixings that attach the headlight to the front subframe. Tighten the fixings to 4 Nm.
1 3
B01016
1. Headlight
2. Subframe fixings
3. Cockpit side panel fixing
3. Install the two fixings that attach it to the cockpit side panels. Tighten the fixings to 3 Nm.
4. Adjust the vertical and horizontal adjustment of the headlight (see Headlight - Adjustment).

Headlight - Adjustment
The headlight can be adjusted by the vertical adjustment screw located on the rear of the headlight.
1. Vertical (UP - DOWN) adjustment screw
Switch the headlight dipped beam on.

Turn the vertical (UP - DOWN) adjustment screw on the headlight clockwise to raise the beam or anti-clockwise to lower the beam.
Switch the headlights off when the beam settings are satisfactory.
Rear Light - Removal
Note
The rear light is a sealed for life unit and must be replaced in the event of a failure.
3 5 1 5
5
B00987
1. Phone tray
4. Finisher fixing
B00974

9. Disconnect the Rear light electrical connector.

10. Remove the two rearmost rear mudguard fixings.
1. Rear mudguard fixings
11. Move the rear of the rear mudguard down sufficiently to allow the electrical connector and harness for the rear light to pass through.
12. Release the electrical harness from cable clips in the license plate hanger assembly.
4
1
2 3
B01020
1. Rear light unit

2. Rear light fixings
3. Electrical harness
4. Licence plate hanger assembly
13. Release the fixings securing the light unit to the rear light bracket.
14. Remove the rear light.
Rear Light - Installation
1. Position the rear light onto the licence plate hanger assembly.
4
1
2 3
B01020
1. Rear light unit

2. Rear light fixings
3. Electrical harness
4. Licence plate hanger assembly

3. Locate the rear light harness into the cable clips in the license plate hanger assembly.
4. Move the rear of the rear mudguard down sufficiently to allow the electrical connector and harness for the rear light to pass through.
5. Install the two rearmost rear mudguard fixings and tighten to 6 Nm.

1
1. Rear mudguard fixings
6. Connect the electrical connector for the rear light.
B00974

7. Connect the USB charger electrical connector.

8. Position the phone tray.
3 5 1 5
5
B00987
1. Phone tray
4. Finisher fixing
9. Install the phone tray fixings and tighten to 3 Nm.

10. Install the grab handle finisher and tighten the fixing to 3 Nm.
Front Direction Indicator - Removal
Note
1. Note the routing of the electrical cable through the cable clips for the installation procedure.

1 4 5
2
3
B01011
1. Direction indicator
3. Nut
4. Direction indicator fixing
5. Cable clips
2. Release the electrical cable from the cable clips.

3. Release the fixing securing the direction indicator to the cockpit side panel and remove the direction indicator.
Front Direction Indicator - Installation
Note
1. Position the indicator to the cockpit side panel.
2. Install the fixing with a new nut and tighten to 3 Nm.
1 4 5
2
3
B01011
3. Nut
4. Direction indicator fixing
5. Cable clips
3. Route the electrical cable as noted during the removal procedure and secure it in the cable clips.
Rear Direction Indicator - Removal

Grab Handle - Removal
3 5 1 5

5
B00987
1. Phone tray
4. Finisher fixing
B00974

9. Disconnect the applicable rear indicator electrical connectors.

10. Release the indicator cables from the cable clips on the rear mudguard.
11. Remove the licence plate.
12. Where installed, remove the fixings and the licence plate bracket.
2
1
B01066

2. Fixings
13. Remove the side fixing for the side licence plate hanger.
3 1 2
B01013
1. Side licence plate bracket

2. Front fixing
3. Bottom fixing
4. Top fixing
14. Remove the bottom and top fixings and remove the side licence plate bracket.

15. Disconnect the direction indicator electrical connectors.
B00962
2. Side licence plate hanger
3. Nut
4. Fixing
Rear Direction Indicator - Installation
1. Position the indicator to the side licence plate hanger.

2. Install the fixing with a new nut and tighten the direction indicator fixing to 3 Nm.
B00962
2. Side licence plate hanger
3. Nut
4. Fixing
3. Position the side licence plate bracket and install the top and bottom fixings.
3 1 2
B01013
1. Side licence plate bracket

2. Front fixing
3. Bottom fixing
4. Top fixing
4. Tighten the top fixing to 6 Nm.

5. Tighten the bottom fixing to 6 Nm
7. Refit the rear rack and tighten the fixings to 25 Nm.
8. Where installed, position the licence plate bracket and install the two nuts and fixings. Tighten the fixings to 3 Nm.
2
1

B01066

2. Fixings
9. Install the licence plate.

10. Connect the applicable rear indicator electrical connectors.
11. Engage the connectors into the mudguard clips.
12. Install the indicator cables into the cable clips on the rear mudguard.
B00974

13. Connect the electrical connector for the USB charger.

14. Position the phone tray and install the fixings. Tighten the fixings to 3 Nm.
3 5 1 5
5
B00987
1. Phone tray
4. Finisher fixing
15. Position grab rack finisher and install the fixing. Tighten the fixing to 3 Nm.
Grab Handle - Installation
Fog Lights - Removal
WARNING


Fog Light Assembly - Removal
1. Disconnect the electrical connectors from the horn.

2. Disconnect the electrical connectors for the fog lights.
2 3
B01007
Horn shown removed for clarity

1. Fog lights assembly
2. Fog light electrical connectors
3. Fixings
3. Release the electrical cables for the horn and the fog lights from the cable tidy.
WARNING
When the fog light assembly is released from the front subframe, the horn assembly and the cable tidy will also be released.
4. Remove the centre fixing that attaches the fog light assembly and the horn to the cable tidy.
5. Remove and discard the two remaining fixings that attach the fog light assembly and cable tidy to the front subframe.
Fog Light Removal
Note
1. Release the plastic end cover from the fog light mount bar.
1
B01008
1. Fog light
2. End cap
3. Grommet
2. Release the grommets from the mount bar and the shroud.
3. Remove the fixing to release the shroud, clamp and fog light.
4 5 2 4
B01009

1. Fixing
2. Fog light
3. Shroud
4. Electrical cable
5. Clamp
4. Release the fog light from the clamp.

5. Route the electrical cable for the fog light through the mount bar.
Fog Lights - Installation
WARNING

Fog Light Installation
1. Position the clamp onto the fog light. Make sure that the type approval text on the fog light lens is positioned the correct way up.
2. Route the electrical cable for the fog light through the mount bar.
4 5 2 4
B01009
1. Fixing
2. Fog light
3. Shroud
4. Electrical cable
5. Clamp
3. Assemble the fixing through the shroud and the clamp onto the mount bar. Do not fully tighten.
4. Adjust the fog light so that the oval part of the lens is aligned horizontally with the mount bar.
3 2
B01006
1
1. Lens oval part

2. Mount bar
3. Type approval markings
5. Tighten the fixing to 6 Nm.

6. Install the grommets into the mount bar and the shroud.
7. Install the plastic end cap.
Fog Light Assembly - Installation
1. Position the cable tidy, horn and the fog light assembly onto the front subframe.
2. Install the centre fixing to attach the fog light assembly and the horn to the cable tidy. Do not fully tighten at this stage.
3. Install two new fixings that attach the fog light assembly and cable tidy to the front subframe. Tighten the fixings to 20 Nm.
4. Tighten the fixing that attaches the fog light assembly and horn to the cable tidy to 12 Nm.
5. Connect the harness electrical connectors to the horn.
6. Connect the electrical connectors for the fog lights to the main harness.
7. Install the electrical cables for the horn and the fog lights into the cable tidy.

Left Hand Switch Housing - Removal
WARNING


1. Release the fixing and detach the clutch switch from the clutch lever assembly.
2
1
L0387
1. Clutch switch
2. Fixing
2. Release the fixings and remove the clamp from the clutch lever assembly. Without disconnecting the clutch cable, lay the lever aside.
3. Remove the cable tie securing the switch housing wiring harness to the left hand switch housing.
1 2
1. Wiring harness
2. Cable tie
4. Gently pull on the wiring harness to disconnect the switch housing connectors.
1. Switch housing connectors
Note

Note
The T3880369 - Switch Housing Removal Tool is required to release the handlebar switch housings from their retaining clips.
When inserting T3880369 - Switch Housing Removal Tool into the switch housing, a click can be felt/heard as the retaining clip is released.
The retaining clip will remain in position on the handle bar as the switch housing is removed. Note the position and orientation of the clip for installation.
5. Insert T3880369 - Switch Housing Removal Tool into the opening on the left hand switch housing until a click is felt/heard.
1 3
L0386_1

2. Opening
3. T3880369 - Switch Housing Removal Tool
6. Slide the switch housing towards the end of the handlebar to free it from the retaining clip.
7. Withdraw T3880369 - Switch Housing Removal Tool from the switch housing.
2
1
L0386_2

3. Retaining clip
8. Slide the switch housing off the handlebar and collect the retaining clip.
1
L0385
1. Switch housing
2. Retaining clip
Left Hand Switch Housing - Installation
WARNING

Note
During installation make sure the damper rubber remains seated in the groove of the switch housing.

1. Position a new retaining clip into the handlebar in the orientation noted during removal and slide the switch housing onto the handlebar.
2. Slide over the retaining clip until it locks into position.
1
L0385
1. Switch housing
2. Retaining clip
Note
The switch housing electrical connections are recessed into the switch housing body.
When inserting the connectors, carefully locate the connectors into their sockets, then use a suitable tool, push the connectors fully home. An audible click
can be heard when the connectors are fully inserted.
Do not use sharp tools, such as a flat bladed screw driver, to insert the connectors.
3. Fit the switch housing connectors.
4. Using a new cable tie, secure the switch housing wiring harness to the left hand switch housing.
1 2
1. Wiring harness
2. Cable tie
5. Position the clutch switch to the clutch lever assembly and tighten the fixing to 2 Nm.
2
1

L0387
1. Clutch switch
2. Fixing
WARNING
Move the handlebars to left and right full lock while checking that the brake hose, clutch cable and electrical harnesses do not bind or that the steering feels tight or difficult
to turn. A hose, cable or harness that binds, or steering that is tight/difficult to turn will restrict the steering and may cause loss of control and an accident.

Check for correct operation of the handlebar switches. Rectify if necessary.
WARNING
Check for correct operation of the front brake, clutch and twist grip. Check that the brake hose, clutch cable and electrical harnesses do not bind or restrict the steering when
the handlebars are turned from lock-to-lock. Rectify as necessary.
Right Hand Switch Housing - Removal
WARNING


Note
The harness with the grey connector and the rubber harness shroud is secured with a cable tie.
The harness with the black connector and no rubber shroud is not be secured to the switch housing with the cable tie.
1. Remove the cable tie securing the wiring harness to the switch housing.
3 2
L0523
1. Rubber shroud
2. Switch housing
3. Cable tie
2. Gently pull on the wiring harness to disconnect the switch housing connectors.
L0522

Note
The T3880369 - Switch Housing Removal Tool is required to release the Switch housings from their retaining clips.
When inserting T3880369 - Switch Housing Removal Tool into the switch housing, a click can be felt/heard as the retaining clip is released.
The retaining clip will remain in position on the handle bar as the switch housing is removed. Note the position and orientation of the clip for installation.
3. Insert T3880369 - Switch Housing Removal Tool into the opening on the switch housing until a click is felt/heard.
2
1 3
L0519
1. Switch housing
2. Opening
4. Slide the switch housing towards the end of the handlebar to free it from the retaining clip.
5. Withdraw T3880369 - Switch Housing Removal Tool from the switch housing.
3
2
1
L0520
1. Switch housing
3. Retaining clip
6. Slide the switch housing off the handlebar and collect the retaining clip.
2
1
L0521
1. Switch housing
2. Retaining clip
Right Hand Switch Housing - Installation
WARNING


Note
During installation make sure the damper rubber remains seated in the groove of the switch housing.
1. Position a new retaining clip into the handlebar in the orientation noted during removal and slide the switch housing onto the handlebar.
2. Slide over the retaining clip until it locks into position.
1. Right hand switch housing

2. Retaining clip
Note
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. An audible click
can be heard when the connectors are fully inserted.
Do not use sharp tools, such as a flat bladed screw driver to insert the connectors.
3. Fit the switch housing connectors.
L0522
4. Using a new cable tie, secure the wiring harness with the rubber shroud only to the switch housing.
3 2
L0523
1. Rubber shroud
2. Switch housing
3. Cable tie

WARNING

WARNING
Check for correct operation of the front brake, clutch and twist grip. Check that the brake hose, clutch cable and electrical harnesses do not bind or restrict the steering when
the handlebars are turned from lock-to-lock. Rectify as necessary.
Heated Grip (Left Hand) - Removal
WARNING


Note
Note the orientation of the heated grip wires prior to removal of the heated grips.
1. Release the two fixings and remove the heated grips switch housing cover from the left hand grip. Collect the two fixings.
1
3
L0517

2. Fixings
3. Heated grip wire
Note
The heated grip switch is an integral part of the heated grip and is not available as a separate assembly.
2. Release the two fixings, collect the washers and remove the heated grip.
2
3
1
L0518
1. Heated grip
3. Fixings
Heated Grip (Left Hand) - Installation
WARNING

1. Connect the heated grip harness connector to the main harness.

2. Fit the heated grip to the handlebar.

3. Fit the two fixings and washers. Tighten the fixings to 3 Nm.
2
3
1
L0518
1. Heated grip
3. Fixings
4. Refit the heated grips switch housing covers. Tighten the fixings to 0.5 Nm.
1
3
L0517

2. Fixings
3. Heated grip wire
5. Position the heated grip wires as noted during removal.

Starter Motor - Removal

Fuel Tank - Removal
Airbox - Removal
1. Disconnect the low oil pressure warning light switch.
2. Disconnect the electrical connector from the coolant temperature sensor.
3. Release the electrical connector for the crankshaft angle sensor from the connector bracket on the starter motor mounting, and move the harness aside.
4. Release the fixings that attach the starter motor to the crankcase and lift the starter motor for access to the starter cable terminal.
2
1
3
5 4
B01032
Some wiring and hoses shown removed for clarity

1. Starter motor
2. Starter cable fixing

3. Fixings
5. Starter cable
5. Remove the nut that attaches the starter cable to the starter motor.
6. Detach the cable.
7. Remove the starter motor from the upper crankcase.
Starter Motor - Installation
1. Lubricate the starter motor O-ring with a small amount of petroleum jelly.
2. Fit the starter motor to the upper crankcase. Make sure that the O-ring does not become damaged during installation.
2
1
3
5 4
B01032
Some wiring and hoses shown removed for clarity

1. Starter motor
2. Starter cable fixing
3. Fixings
5. Starter cable
3. Install and the starter motor attachment bolts and connector bracket. Make sure that the connector bracket is under the rear bolt. Tighten to 10 Nm.
4. Refit the starter cable and secure with the nut. Tighten to 3 Nm.
5. Engage the connector for the crankshaft angle sensor to the connector bracket on the starter motor mounting.
6. Connect the electrical connector to the coolant temperature sensor.
7. Connect the electrical connector to the low oil pressure warning light switch.
Starter Solenoid - Removal
WARNING

Note
The ambient air pressure sensor is located on the battery tray, under the battery.
Battery - Removal
WARNING
The starter solenoid is attached by a rubber mounting that is pushed onto tabs in the bottom of the battery compartment.
1. Release the starter solenoid and its rubber mounting from the mounting tabs on the rear mudguard.
2. Disconnect the electrical connector from the starter solenoid.
5
1
4 2

B00961
1. Starter solenoid
3. Mounting tabs
4. Terminal cover
5. Cables
3. Release the plastic terminal cover from the battery cable terminals.
4. Remove the nuts that attach the cables to the terminals and release the cables.
5. Remove the starter solenoid.
Starter Solenoid - Installation
WARNING

1. Remove the 30A fuse.

2. Check the fuse and the fuse holder for damage and the fuse holder for grease.
cksw
1. Fuse holder
3. Clean out the fuse holder and fill the fuse holder with grease (Castrol LCX 222 or equivalent).
cksw
1. Grease (Solenoid shown removed for clarity)
4. Check the 30A fuse for damage, replace if necessary.

5. Fit the 30A fuse.
6. Connect the electrical cables to the starter solenoid. Tighten the nuts to 5 Nm.
5
1
4 2
B00961

1. Starter solenoid
3. Mounting tabs
4. Terminal cover
5. Cables
7. Install the plastic terminal cover.
cksx
1. Cover
8. Connect the electrical connector to the starter solenoid.

9. Locate the solenoid onto the mounting tabs on the rear mudguard.
Alternator Stator - Removal
Note
The crankshaft position sensor and the alternator stator are an assembly and cannot be replaced separately. If either component becomes faulty, both must be
replaced.
1. Remove the alternator stator and crankshaft position sensor assembly (see Crankshaft Position Sensor Removal).
Alternator Stator - Installation
1. Install the alternator stator and crankshaft position sensor assembly (see Crankshaft Position Sensor Installation).
Alternator Rotor - Removal

1. Clean the alternator rotor to remove all traces of oil.
2. Fit T3880375 - Alternator Rotor Holder to the rotor as shown below.
3. Retain the tool to prevent the crankshaft from rotating and remove the centre bolt from the crankshaft.
3
1
cdwv_6
1. Rotor
2. T3880375 - Alternator Rotor Holder
3. Centre bolt
4. With the bolt removed, locate the spigot from the larger of the two thrust pads supplied with tool T3880365 - Alternator Housing Puller to the crankshaft.

1
cdwv_5
1. Thrust pad
5. Assemble T3880365 - Alternator Housing Puller to the threaded centre section of the rotor.
Note
Ensure that the thrust pad does not fall out during assembly of the tool.
6. Hold the centre of the tool to prevent rotation then tighten the draw-bolt in the centre of the tool to release the taper seating of the rotor from the crankshaft.
2
cdwv_4
1. Rotor
2. T3880365 - Alternator Housing Puller
7. Withdraw the rotor and tool as an assembly and then separate the tool from the rotor. Collect the Woodruff key and the tool thrust pad from the crankshaft.
Alternator Rotor - Installation
1. Refit the Woodruff key to the crankshaft.

2. Assemble the rotor to the keyway on the crankshaft, ensuring the Woodruff key remains in position.
CAUTION
Do not use tools to tighten T3880375 - Alternator Rotor Holder. Tighten the tool by hand only. Over-tightening of the tool will lead to damage to the alternator rotor.
1. Refit T3880375 - Alternator Rotor Holder to prevent the crankshaft from rotating, ensuring the rotor is free from oil and the tool is not over-tightened.
2. Tighten the rotor retaining bolt to 130 Nm
3
1
cdwv_6
1. Rotor
2. T3880375 - Alternator Rotor Holder
3. Centre bolt
3. Remove T3880375 - Alternator Rotor Holder.

Regulator/Rectifier - Removal

The regulator/rectifier is located under the headstock, behind the radiator. To access the rectifier, remove the radiator.
WARNING


1. Release the connector cover from the regulator/rectifier.
1
B00963
2. Connector cover
2. Disconnect the two electrical connectors from the regulator/rectifier.

3. Remove and discard the two lock nuts that attach the regulator/rectifier to the frame.
1 3
B00964
2. Lock nuts
4. Remove the regulator/rectifier.
Regulator/Rectifier - Installation
Note
The electrical connectors are colour coded and will only fit to the respective colour on the regulator/rectifier.
1. Support the regulator/rectifier. Refit the electrical connectors and make sure that the tangs are fully locked into position.
2. Position the regulator/rectifier to the frame. Fit new lock nuts and tighten to 9 Nm.
1 3
B00964
2. Lock nuts

3. Refit the connector cover to the regulator/rectifier.
1
B00963
2. Connector cover

Inertial Measurement Unit (IMU) - Removal

1. Release the four fixings and remove the front seat bridge.
2
1
B00625
1. Fixings
2. Front seat bridge
2. Remove the two fixings that attach the air intake duct to the rear mudguard moulding. Remove the air intake duct.
B01005
1. Air intake duct

2. Fixings
3. Remove and discard the four fixings that attach the IMU and bracket assembly to the frame. Collect the four flanged bushes.
1
3 3
3 2

3 2
B01017
2. IMU
3. Fixings
4. Flanged bushes
4. Lift the IMU with its bracket and disconnect the electrical connector.
5. Turn the IMU over with its bracket. Remove the two fixings and separate the IMU from its bracket.
Inertial Measurement Unit (IMU) - Installation
1. Position the IMU into its bracket.

2. Install the two fixings and tighten to 3 Nm
3. Connect the electrical connector to the IMU.
1
3 3
3 2
B01017
2. IMU
3. Fixings
4. Flanged bushes
4. Position the IMU and bracket assembly onto the frame.

5. Install the four flanged bushes and four new fixings. Tighten the fixings to 6 Nm.
6. Fit the air duct and install the two fixings. Tighten to 1 Nm
B01005
1. Air intake duct

2. Fixings
7. Refit the front seat bridge and tighten its four fixings to 5 Nm.
2
1
B00625

1. Fixings
2. Front seat bridge

Chassis ECM - Removal

3 5 1 5
5
B00987
1. Phone tray
4. Finisher fixing
9. Remove the front fixings for the grab handle.
1 3 2
5 4
2
B00958
1. Grab handle front fixings

2. Seat hook front fixings
3. Left seat hook
4. Right seat hook
5. USB charger electrical connector
10. Release the electrical connector for the USB charger from the chassis ECM rubber mounting.
11. Remove the front fixing for the left seat hook and remove the seat hook.
12. Remove the front fixing for the right seat hook and remove the seat hook.
13. Release the electrical connector for the USB charger from the rubber mounting for the chassis ECM.

2 3
B00959
1. Chassis ECM rubber mounting

2. Location tabs
14. Release the chassis ECM and its rubber mounting from the location tabs on the rear mudguard moulding.
15. Disconnect the three electrical connectors and remove the chassis ECM.
Chassis ECM - Installation
1. Connect the three electrical connectors to the chassis ECM.
2 3
B00959
1. Chassis ECM rubber mounting

2. Location tabs
2. Fit the chassis ECM and its rubber mounting into position on the rear mudguard location tabs.
3. Locate the electrical connector for the USB charger into the rubber mounting.
1 3 2
5 4
2
B00958
1. Grab handle front fixings

2. Seat hook front fixings
3. Left seat hook
4. Right seat hook
5. USB charger electrical connector
4. Position the right seat hook. Install and tighten the fixing to 5 Nm.
5. Position the left seat hook. Install and tighten the fixing to 5 Nm.
6. Install the front fixings for the grab handle and tighten to 25 Nm.
7. Connect the electrical connector to the USB charger in the phone tray and position the phone tray.
WARNING
If a replacement chassis ECM is fitted, it must be setup as described in Chassis ECM Calibration Download Flow Chart.

Circuit Diagrams
Glossary of Circuit Diagram Symbols
The following is a description of the symbols and information found in the circuit diagrams for this model.
Note
Wire colours and connector pin references shown in the illustrations below are examples and may differ from those contained in circuit diagrams for this
model.
Components with a Fly lead and an In-line Connector
FRONT BRAKE SWITCH FRONT BRAKE SWITCH, INLINE
COMMON B M71M-3 M71-3

N/C Y M71M-2 M71-2
N/O N M71M-1 M71-1
The illustration shows an example of a component with a fly lead and an in-line connector.
The component is represented by a white box, with fly lead wires leading to an in-line connector (shaded grey). Information provided with the component includes:
The component name - located above the component.
A function reference for each terminal - located inside the component, adjacent to the connecting wire (provided in English only).
Wire colour references - located on each wire.
An in-line connector name - located above the in-line connector.
A component and pin number reference - located on each wire entering the in-line connector.
In the above example, the component and pin number references can be interpreted as follows:
M71 Component reference for the front brake switch
M Identifies the mating connector (component side only)
- Separator
1, 2, 3 Connector pin number reference
Components with an Integral Connector
INSTRUMENTS
CAN_H M01-25 R
CAN_L M01-24 U
The illustration shows an example of a component with an integral connector.

The component is identified by a white box, with a grey shaded area representing the integral connector. Information provided with the component includes:
The component name - located above the component.
A function reference for each terminal - located inside the component, adjacent to the connecting wire (provided in English only).
Wire colour references - located on each wire.
A component and pin number reference - located on each wire entering the integral connector.
In the above example, the component and pin number references can be interpreted as follows:
M01 Component reference for the instruments
- Separator
24, 25 Connector pin number reference
Components with Multiple Integral Connectors
ENGINE ECM
KNOCK#2 E02C-9 N/O
SHG_R-GND E02A-33 B
APS#2 EO2B-28 S

The illustration shows an example of a component with multiple integral connectors.
The multiple integral connectors can be identified by separated grey shaded areas (as shown), or by a grey shaded area that is divided into multiple sections by black line(s).
The above example shows an engine ECM with three integral connectors, connectors A, B and C. The component, connector and pin number references can be interpreted as
follows:
E02 Component reference for the engine ECM
A, B, C Connector reference
- Separator
9, 28, 33 Connector pin number reference
Fuse Boxes
FUSE BOX 2
F001
N F23-1A 7.5 F23-1B P
F002
R F23-2A 25.0 F23-2B R
F003
N/K F23-3A 15.0 F23-3B N/K
The illustration shows an example of a fuse box.

A fuse is a device which protects a circuit in the event of a fault. The fuse will 'blow' should a short circuit occur, protecting that circuit from further damage.
Information provided with the fuse box includes:
The fuse box name - located above the fuse box.
A fuse number/location reference for each fuse - located above the fuse.
A fuse rating (in Amps) for each fuse - located inside the fuse.
A fuse box, terminal number and terminal block reference - located on each wire entering the fuse box.
In the above example, the fuse box, terminal number and terminal block references can be interpreted as follows:
F Reference code for a fuse box
2 Denotes the type of fuse box:

1 = Fuse box 1 (Main fuse)
2 = Fuse box 2 (Individual circuit protection)
3 Indicates the number of fuses contained in the fuse box
- Separator
1, 2, 3 Connector terminal number reference
A or B Terminal block reference A (power in) or B (power out)
Relays
A relay is effectively an electromagnetic switch. To close the relay contacts and complete the circuit, an electromagnet in the relay is energised which causes the relay contacts
to close, making the circuit complete.
Relays are used when the electrical current is too great for a mechanical switch, usually when the switching must be done quickly to prevent arcing across the switch contacts.
If a mechanical switch were used, the mechanical switch contacts would quickly burn away.
Relays Connected with a Single Socket Connector
RELAY, COOLING FAN
R04-5 N/K
N/K R04-3
B R04-1 R04-2 G
The illustration above shows an example of a relay connected to the wiring harness with a single socket relay connector.
A pin diagram of a typical single socket relay connector is shown below.
5 1

2 3
Information provided on the circuit diagram for relays with a single socket harness connector includes:
The relay name - located above the relay.
A relay and terminal number reference - located on each wire entering the relay connector terminals.
In the above example, the relay and terminal number reference can be interpreted as follows:
R Indicates the component is a relay
04 Reference number for the relay (cooling fan relay in the example shown)
- Separator
1, 2, 3, 5 Connector terminal number reference
Relays connected with a Dual Socket Connector
A COOLING FAN RELAY

B FUEL PUMP RELAY
N/K R0403-A3 R0403-A5 N/K
B R0403-A1 R0403-A2 G
The illustration above shows an example of a relay connected to the wiring harness with a dual socket relay connector.
A dual socket relay connector provides sockets for two individual relays, socket A and socket B. A pin diagram of a typical dual socket relay connector is shown below.
B3 A2 A4 A1
B5 A5
B1 B4 B2 A3
Information provided on the circuit diagram for relays with a dual socket harness connector includes:
The names of the relays connected to sockets A and B - located above the relay.
A dual relay and terminal number reference - located on each wire entering the relay connector terminals.
In the above example, the relay and terminal number reference can be interpreted as follows:
R Indicates the component is a relay
04 Reference number for the relay connected to socket A (cooling fan relay in the example shown)
03 Reference number for the relay connected to socket B (fuel pump relay in the example shown)
- Separator
A or B Socket reference (socket A or socket B)

In the example above, all references show socket A. This indicates that the component shown is the cooling fan relay.
1, 2, 3, 5 Connector terminal number reference for the socket/relay identified
Ring Terminals
B M96-1

The illustration shows the symbol used to identify a ring terminal (commonly used as ground points).
A ring terminal reference is provided on the wire entering the terminal.
Shielded Wires
ENGINE ECM
TPS #1 E02 A-26 K E47 -6 TPS #1
TPS #2 E02 A-38 U E47 -4 TPS #2
TPS _SHIELD SHIELD_TPS B1
The illustration shows the symbol used to identify wires that are shielded against electromagnetic interference.
Examples of components that have shielded wires include:
ABS wheel speed sensors
Immobiliser antenna
Throttle position sensor
USB socket
The wire shielding is typically connected to ground.
Splices
B B
B B
B2
B B
The illustration shows an example of a splice.

A splice is a hard cable joint where two or more cables are joined in the wiring harness. A splice is a potential source of both open and short circuits.
A splice reference code is provided at the nearest convenient location to the splice symbol.
Twisted Wires
INSTRUMENTS
CAN_H M6-25 R
CH1
CAN_L M6-24 U
CL1
The illustration shows the symbol used to indicate a pair of wires that are twisted together, such as CAN circuit wires.
Starter Motor Grounding
Starter motors fitted to Triumph motorcycles are connected to ground through the mating faces of the starter motor body and the crankcase.
Key To Wiring Colour Codes
Code Wiring Colour
B Black
U Blue
N Brown
G Green
S Slate/Grey
O Orange

Code Wiring Colour
K Pink
R Red
P Purple
W White
Y Yellow
LG Light Green
LU Light Blue
Main Wiring Harness Electrical Connectors
The table below shows the connector pin diagrams for each electrical connector on the main wiring harness for this model.
8 1 10 1
16 9 20 11
CN1 - Chassis ECM connector 1 CN2 - Chassis ECM connector 2
8 1 3 1
16 9
6 4
CN3 - Chassis ECM connector 3 E01 - Main harness connector
11 1
22 12
33 23
13 1
26 14
39 27
E02A - Engine ECM connector A E02B - Engine ECM connector B
11 1 1 8
22 12
33 23
9 16

E02C - Engine ECM connector C E04 - Diagnostic connector
1 2
1 2
E05 - Crankshaft position sensor E06 - Fuel pump
1 6
1 2
E07 - Fuel level sensor E08 - Throttle position sensor
1 2
1 2
E09 - Purge valve E10 - Coolant temperature sensor
2 1
1 2
4 3
E11 - Fuel injector 1 E15 - Gear position sensor

E12 - Fuel injector 2
E13 - Fuel injector 3
2 1 2 1
4 3
E16 - Oxygen sensor, bank 1 sensor 1 E17 - Side stand switch

2 1
1 2
E19A - Cooling fan 1 E20 - Intake air temperature sensor

E19B - Cooling fan 2
1 2
E21 - Ignition coil 1 E25 - Oil pressure sensor

E22 - Ignition coil 2
E23 - Ignition coil 3
1 2 1 2 3
E37 - Secondary air injection E38 - Manifold absolute pressure sensor

E39 - Ambient air pressure sensor
1 3 1 2
E48 - Triumph shift assist E52 - Throttle actuator motor
1 2 1 3
3 4
4 6
H04 - Heated grips H05 - Engine subharness

B
H10 - Sub harness ground H10M - Sub harness ground
4 6
6 1
12 7
1 3
M01 - Instruments M02A - Left handlebar switch housing connector (6 pin)
2 1
M02B - Left handlebar switch housing connector (2 pin) M04A - Front left direction indicator connector A
M04B - Front left direction indicator connector B
1 2
1 2 3 5 6
M06 - Inertial measurement unit M07 - Headlight
1 2
3 4
M11A - Horn connector A M13 - Ignition switch

M11B - Horn connector B

4 6 4 6
1 3 1 3
M14A - Right handlebar switch housing connector A (Black) M14B - Right handlebar switch housing connector B (Grey)
M19A - Front right direction indicator connector A M21 - Accessory socket, live
M19B - Front right direction indicator connector B
2 1
3
2
M22 - Rear accessory socket, switched M26 - Rear brake switch
1 2
3 4
M28 - Starter solenoid M28A - Starter solenoid connector A

M28B - Starter solenoid connector B
1 4
5 8
M35A - Rear left direction indicator M36 - Alarm

M35B - Rear left direction indicator

1 3
M37 - Rear light M38A - Rear right direction indicator

M38B - Rear right direction indicator
1 2
1 2 3
M48A - Regulator rectifier connector A M52 - Ambient air temperature sensor

M48B - Regulator rectifier connector B
9 8 2 1
1 2
18 17 11 10
M57 - Front ABS wheel speed sensor M59 - ABS modulator

M58 - Rear ABS wheel speed sensor
5 1
10 6 2 1
M68 - Immobiliser/TPMS ECM M70 - USB socket
1 4
1 2 3
M71 - Front brake switch M72 - Bluetooth module

1 2
1 2
5 6
M73 - Twist grip position sensor M77 - Rider heated seat (black)
1 2
1 2 3
M78 - Passenger heated seat (grey) M79 - Passenger heated seat switch
1 2
M81 - Right hand foglight M86 - Battery positive terminal

M82 - Left hand foglight
5 1
2 3
M96 - Battery negative terminal R07 - Engine management system relay

M97 - Engine ground
M100 - Starter motor
Power Distribution
STARTER SOLENOID
BATTERY POSITIVE TERMINAL

Battery +
M86-1 B M28A-1
MAIN
30.0
ALTERNATOR REGULATOR RECTIFIER
AC 1 B M48B-1 AC 1
N1 N M28-1
AC 2 B M48B-2 AC 2 Supply M48A-3 B/R N M28-2
AC 3 B M48B-3 AC 3
CHASSIS ECM FUSE BOX 1

FUSE_CCU PS1
Battery +VE PS1 CN1-8 O F19-1B 10.0
FUSE_CCU PS2
Battery +VE PS2 CN2-1 N F19-2B 10.0 F19-2A N
FUSE_CCU PS3
Battery +VE PS3 CN2-10 W F19-3B 10.0
FUSE_CCU PS4
Battery +VE PS4 CN3-1 G/B F19-4B 10.0
FUSE_CCU PS5
Battery +VE PS5 CN3-8 U F19-5B 20.0 F19-5A N
ENGINE MANAGEMENT SYSTEM RELAY
FUSE_ECM
R07-3 N/K F19-6B 15.0
ABS MODULATOR
FUSE_ABS
KL30 M59-18 R F19-7B 25.0 F19-7A N
FUSE_IGN
IG1 W/U F19-8B 5.0 F19-8A N
FUSE_ACC
AC1 U/R F19-9B 5.0 F19-9A N
FRONT ACCESSORY SOCKET, LIVE FUSE BOX 2

FUSE AUX
Power M21-2 P F21-1B 10.0 F21-1A N
Starter Motor Circuit

STARTER SOLENOID
BATTERY POSITIVE TERMINAL

Battery +
M86-1 B M28A-1
N1 N M28-1 MAIN
CHASSIS ECM 30A

N M28-2
Starter Solenoid Control +
Starter Motor Solenoid CN3-6 W/R M28-3
Starter Solenoid Control -

PG16 B M28-4
M28B-1 Starter Motor Supply
STARTER MOTOR
B B M100-1 Supply
ENGINE GROUND
M97-1
BATTERY SUBHARNESS BATTERY NEGATIVE TERMINAL

B
PG1 B H10-1 H10M-1 B M96-1
Ignition Circuit
FUSE BOX 1
FUSE_IGN
5.0 F19-8B W/U
IGNITION SWITCH
IMMOBILISER/TPMS ECM
IG1 W/U M13-1
LF
LF2 M68-5 U M13-3
LF
ANTENNA
LF1 M68-10 W M13-4
G1
BATTERY / IGNITION M68-2 G G M13-2
PIS M68-8 G
ABS MODULATOR LEFT HANDLEBAR SWITCH HOUSING
IGN M59-4 G G M02A-2 POWER + ILLUMINATION
INSTRUMENTS RIGHT HANDLEBAR SWITCH HOUSING
IGNITION M01-7 G G M14A-6 RUN SW INPUT
G M14B-3 START SW INPUT
REAR BRAKE SWITCH REAR BRAKE SWITCH

INERTIAL MEASUREMENT UNIT
G G M26-2 M26M-2 B COM
Power / Ignition M06-4 G
CHASSIS ECM DIAGNOSTIC CONNECTOR
Ignition On Status CN1-12 G G E04-12 Wake
CONNECTIVITY MODULE ALARM
Supply M72-1 G B M36-4 IGNITION

G11
ABS Circuit
FUSE BOX 1
FUSE_ABS
25.0 F19-7B R
ABS MODULATOR
KL30 M59-18
IGN M59-4 G
G1
ENGINE ECM
BLS M59-7 G/P G/P E02C-14 BRAKESW#2
GP1
DIAGNOSTIC CONNECTOR
RRC M59-13 O/G E04-1 Rolling Road
ISO_K M59-5 B/G E04-7 K-LINE
FRONT ABS WHEEL SPEED SENSOR FRONT ABS WHEEL SPEED SENSOR
F_SIG M59-8 U/W M57-2 M57M-2 W V+
F_GND M59-17 B/G M57-1 M57M-1 B V-
REAR ABS WHEEL SPEED SENSOR REAR ABS WHEEL SPEED SENSOR
R_SIG M59-6 U/R M58-2 M58M-2 W V+
R_GND M59-15 B/G M58-1 M58M-1 B V-
BATTERY SUBHARNESS
BATTERY NEGATIVE TERMINAL
Ground M59-10 B B H10-1 H10M-1 B M96-1
PG1
Brake Circuit
IGNITION SWITCH
G M13-2
CHASSIS ECM REAR LIGHT REAR LIGHT
Brake Light (Power) CN2-6 G/P M37-1 M37M-1 P/G Brake Light
Brake Switch (Normally Open) CN2-19 G/P

Brake Switch (Normally Closed) CN2-18 G/U
REAR BRAKE SWITCH REAR BRAKE SWITCH
G1

G1 COM
G M26-2 M26M-2 B
NO
G/P M26-1 M26M-1 R
ABS MODULATOR
NC
BLS M59-7 G/P M26-3 M26M-3 U
FRONT BRAKE SWITCH FRONT BRAKE SWITCH

ENGINE ECM COM
G/N M71-3 M71M-3 B
NO
BRAKESW#2 E02C-14 G/P G/P M71-1 M71M-1 R
GP1
NC
BRAKESW#1 E02C-26 G/U G/U M71-2 M71M-2 U
GU1
Chassis Control Circuit
FUSE BOX 1
FUSE_CCU PS5
20.0 F19-5B U
FUSE_CCU PS4
10.0 F19-4B G/B
FUSE_CCU PS3
10.0 F19-3B W
FUSE_CCU PS2
10.0 F19-2B N
FUSE_CCU PS1
10.0 F19-1B O
CHASSIS ECM
AMBIENT AIR TEMPERATURE SENSOR
Battery +VE PS1 CN1-8
Ambient Temperature Sensor CN1-7 G/U M52-1 SIGNAL
GND CN1-1 B B M52-2 Ground

PG161

B
GND CN3-14 B PG16

PG15
B B
BATTERY SUBHARNESS
B H10-1 H10M-1 B M96-1

PG1
Engine Management – ECM Power and Ground
R07-3 R07-5 N/K

ENGINE ECM
MAR E02A-27 Y/S R07-1 R07-2 B
BATT#1 E02A-8 N/K NK1

BATT#2 E02A-21 N/K
RIGHT HANDLEBAR SWITCH HOUSING
G M14A-4 RUN SW OUTPUT
CHASSIS ECM
IGP E02A-11 G/R G/R CN1-15 Kill Switch Status
GN1
PG#1 E02A-24 B
PG#2 E02A-10 B
PG#3 E02A-9 B
BATTERY SUBHARNESS
PG#4 E02A-23 B BATTERY NEGATIVE TERMINAL
PG#5 E02A-22 B B B H10-1 H10M-1 B M96-1
PG16 PG1
LG-C E02A-7 B/Y
LG-E E02B-12 B/Y B/Y

LG1
Engine Management - Pressure Sensors
ENGINE ECM AMBIENT PRESSURE SENSOR
PA E02A-5 K/P E39-2 SIGNAL
K1
SVCC#4 E02B-18 K K E39-3 5V
KB1
SG#4 E02B-23 K/B K/B E39-1 SENSOR GROUND
MANIFOLD ABSOLUTE PRESSURE SENSOR
K/B E38-1 GND
K E38-3 5V
PM#1 E02C-29 K/O E38-2 SIGNAL
CHASSIS ECM ENGINE SUBHARNESS OIL PRESSURE SENSOR
Oil Pressure Switch CN1-13 B/U H05-5 H05M-5 B E25S-1
Engine Management Circuit - Temperature Sensors
ENGINE ECM INTAKE AIR TEMPERATURE SENSOR
TA E02A-17 K/O E20-1 SIGNAL
B/Y E20-2 Ground
ENGINE SUBHARNESS COOLANT TEMPERATURE SENSOR
TW E02B-20 K/G H05-1 H05M-1 K/G E10-1 Signal
LG1 B/Y H05-2 H05M-2 K/B E10-2 Ground Eng Temp
BATTERY SUBHARNESS
B/Y B B H10-1 H10M-1 B M96-1
PG16 PG1
Engine Management Circuit - Switches

ENGINE ECM SIDE STAND SWITCH
SSTAND E02A-18 B/R E17-3 E17M-3 U Signal
K1
SVCC#4 E02B-18 K K E17-1 E17M-1 B Power
SG#4 E02B-23 K/B K/B E17-2 E17M-2 P Ground
KB1
Engine Management Circuit - Position sensors
ENGINE ECM TRIUMPH SHIFT ASSIST TRIUMPH SHIFT ASSIST
EGS#1 E02B-21 R/B E48-1 E48M-1 G SIGNAL
K E48-3 E48M-3 R 5V
K/B E48-2 E48M-2 U GND
K1
SVCC#4 E02B-18 K
SG#4 E02B-23 K/B KB1
GEAR POSITION SENSOR GEAR POSITION SENSOR
K/B E15-4 E15M-4 B GND
K E15-3 E15M-3 R 5V
GP E02B-30 G/K E15-1 E15M-1 U SIGNAL
ENGINE SUBHARNESS CRANK POSITION SENSOR CRANK POSITION SENSOR
CRK_G E02B-17 U/B H05-4 H05M-4 U/B E05-1 E05M-1 U/B -
CRK_P E02B-16 U/P H05-3 H05M-3 U/P E05-2 E05M-2 U/P +
Engine Management Circuit - Level sensor
ENGINE ECM FUEL LEVEL SENSOR
FLS#1 E02C-5 B/O E07-1 SIGNAL
LG1 B/Y E07-2 Ground
B/Y
BATTERY SUBHARNESS
B B H10-1 H10M-1 B M96-1
PG16 PG1
Engine Management Circuit - Fuel Injection Components
ENGINE ECM INJECTOR 3
INJ#3 E02C-7 Y/B E13-1 INJ_P
N/K E13-2 IGP
INJECTOR 2
INJ#2 E02C-6 Y/P E12-1 INJ_P
N/K E12-2 IGP
INJECTOR 1
INJ#1 E02C-23 Y/K E11-1 INJ_P
N/K E11-2 IGP
OXYGEN SENSOR, BANK 1 SENSOR 1 OXYGEN SENSOR, BANK 1 SENSOR 1
PHG#1 E02C-32 B/O E16-1 E16M-1 B Sig +
PHG#1-GND E02C-21 B E16-2 E16M-2 S Sig -
PHG#1-HT E02C-22 B/W E16-3 E16M-3 W Heater
N/K E16-4 E16M-4 W Heater
BATT#1 E02A-8 N/K

BATT#2 E02A-21 N/K NK1
IGNITION COIL 1
IG#1 E02B-33 G/K E21-1 Primary -
N/K N/K E21-2 Primary +
IGNITION COIL 2
IG#2 E02B-22 G/P E22-1 Primary -
N/K E22-2 Primary +
IGNITION COIL 3
NK11 N/K E23-2 Primary +
IG#3 E02B-11 G/B E23-1 Primary -
PURGE VALVE
N/K E09-2 POSITIVE
PCV E02B-1 Y/R E09-1 SIGNAL
SECONDARY AIR
INJECTION SOLENOID
N/K E37-2 POSITIVE
EXAI E02B-2 Y/O E37-1 SIGNAL
Engine Management Circuit - Throttle Control
ENGINE ECM TWIST GRIP POSITION SENSOR
SVCC#2 E02B-26 R M73-5 M73M-5 R APS 1 VCC
SG#2 E02B-24 B M73-1 M73M-1 B APS 1 GND
APS#1 E02B-27 S M73-3 M73M-3 W APS 1 SIG
SVCC#3 E02B-25 R M73-2 M73M-2 R APS 2 VCC
SG#3 E02B-13 B M73-6 M73M-6 B APS 2 GND
APS#2 E02B-28 S M73-4 M73M-4 W APS 2 SIG
THROTTLE ACTUATOR MOTOR
DBW-M E02B-4 U/G E52-1 DBW Minus
DBW-P E02B-3 U/O E52-2 DBW Plus
THROTTLE POSITION SENSOR
SVCC#1 E02A-32 R E08-2 TPS SUPPLY
TPS#1 E02A-26 K E08-3 SIGNAL 1
TPS#2 E02A-38 U E08-4 SIGNAL 2
SG#1 E02A-20 B B E08-5 TPS GROUND

OPEN_END_2
SH_TPS_END SH_TPS
Engine Management Circuit - Cooling Fan

CHASSIS ECM COOLING FAN 1 COOLING FAN 1
Cooling Fan 1 CN3-7 N/K E19A-2 E19AM-2 W Supply
B E19A-1 E19AM-1 B Ground
COOLING FAN 2 COOLING FAN 2
Cooling Fan 2 CN1-6 N/K E19B-2 E19BM-2 W Supply
PG13 B E19B-1 E19BM-1 B Ground
B
BATTERY SUBHARNESS
B H10-1 H10M-1 B M96-1

PG1
Engine Management Circuit - Fuel Pump
CHASSIS ECM FUEL PUMP
Fuel Pump +VE CN3-16 P/W E06-1 MOTOR POSITIVE
Fuel Pump -VE CN3-15 B E06-2 MOTOR NEGATIVE
Instruments Circuit
IGNITION SWITCH
M13-2 G
FUSE BOX 1
FUSE_IGN
5.0 F19-8B W/U
INSTRUMENTS
KL30 M01-12 P
IG1
IGNITION M01-7 G
G1
CHASSIS ECM
WAKE_1 CCU M01-5 G/W CN2-13 Instrument Wake-Up
ALARM
ALARM - M01-2 B M36-6 ALARM LED -
ALARM + M01-8 B M36-5 ALARM LED +
BATTERY SUBHARNESS
Ground M01-11 B B B H10-1 H10M-1 B M96-1
PG17 PG1
Lighting Circuit - Front
CHASSIS ECM HEADLIGHT

Front Position
and DRL (Logic) CN2-14 U/Y M07-2 Position / DRL Logic
Dip Light Left CN2-2 U/R M07-6 Low Beam
B M07-1 Ground
Main Light Left CN3-13 U/W M07-5 Main Beam

Front Position
and DRL (Power) CN3-9 G M07-4 Position / DRL Power
LEFT HAND FOG LIGHT LEFT HAND FOG LIGHT

FG1
Fog Lights L/R CN1-2 P P M82-1 M82M-1 P Power
B M82-2 M82M-2 B Ground
RIGHT HAND FOG LIGHT

RIGHT HAND FOG LIGHT
P M81-1 M81M-1 P Power
PG14 B M81-2 M81M-2 B Ground
BATTERY SUBHARNESS
B H10-1 H10M-1 B M96-1
PG1
Lighting Circuit - Rear
CHASSIS ECM
Brake Switch (Normally Closed) CN2-18 G/U

GU1
Brake Switch (Normally Open) CN2-19 G/P
REAR LIGHT REAR LIGHT
GP1
Brake Light (Power) CN2-6 G/P M37-1 M37M-1 P/G Brake Light
Lights (License Plate, Rear Position) CN1-3 Y M37-3 M37M-3 Y Rear Position Light
BATTERY SUBHARNESS
B B H10-1 H10M-1 B M96-1
PG12 PG1
Lighting Circuit - Indicators
CHASSIS ECM FRONT LEFT DIRECTION INDICATOR FRONT LEFT DIRECTION INDICATOR
Direction Indicator
- Left Front CN2-8 G/R M04A-1 M04AM-1 W Supply
FRONT LEFT DIRECTION INDICATOR
B M04B-1 M04BM-1 B Ground

FRONT RIGHT DIRECTION INDICATOR FRONT RIGHT DIRECTION INDICATOR
Direction Indicator
- Right Front CN2-7 G/W M19A-1 M19AM-1 W Supply
FRONT RIGHT DIRECTION INDICATOR
PG13 B M19B-1 M19BM-1 B Ground
REAR LEFT DIRECTION INDICATOR REAR LEFT DIRECTION INDICATOR

Direction Indicator
- Left Rear CN3-5 G/R M35A-1 M35AM-1 W Supply
REAR LEFT DIRECTION INDICATOR
REAR RIGHT DIRECTION INDICATOR REAR RIGHT DIRECTION INDICATOR

Direction Indicator
- Right Rear CN3-4 G/W M38A-1 M38AM-1 W Supply
REAR RIGHT DIRECTION INDICATOR

PG11
B B
BATTERY SUBHARNESS
B H10-1 H10M-1 B M96-1
PG1
Communication Network Circuit
CAN LOW E04-14 U

CAN HIGH E04-6 R
CONNECTIVITY MODULE
BT CAN - M72-4 U
BT CAN + M72-3 R
CHASSIS ECM
CAN - CN1-10 U CL1

CAN + CN1-9 R
CH1
ENGINE ECM
CAN#1_H E02C-25 R
CAN#1_L E02C-24 U
R U
CAN - M06-2 U
CAN + M06-3 R
CH2
CAN+ M68-6 R
CAN- M68-1 U CL2
ABS MODULATOR
CAN HIGH M59-2 R

CAN LOW M59-11 U
INSTRUMENTS
CAN + M01-10 R
CAN - M01-4 U
LIN M01-1
LEFT HANDLEBAR SWITCH HOUSING

LIN M02A-4 R
HOME INPUT LIN M02A-6 R M14B-6 HOME OUTPUT LIN
Horn Circuit
CHASSIS ECM HORN
Horn CN1-5 P/W M11A-1 Power
PG14 B M11B-1 Ground
B
BATTERY SUBHARNESS
B H10-1 H10M-1 B M96-1
PG1
Immobiliser Circuit
G1
BATTERY / IGNITION M68-2 G
IGNITION SWITCH
PIS M68-8 G
LF1 M68-10 W M13-4 LF
LF2 M68-5 U M13-3 LF
BATTERY SUBHARNESS
Ground M68-7 B B B H10-1 H10M-1 B M96-1
PG17 PG1
Diagnostic Connector Circuit
U/R E04-16 Battery Power
AC1
G E04-12 Wake
G11
ABS MODULATOR
ISO_K M59-5 B/G E04-7 K-LINE
RRC M59-13 O/G E04-1 Rolling Road
B E04-4 Ground
BATTERY SUBHARNESS
B B H10-1 H10M-1 B M96-1

PG12 PG1
Accessories Circuit

FUSE BOX 2 FRONT ACCESSORY SOCKET, LIVE
FUSE AUX
10.0 F21-1B P M21-2 Power
PG14 B M21-1 Ground
CHASSIS ECM REAR ACCESSORY SOCKET, SWITCHED
Accessory Power 2 CN3-3 P M22-2 Supply
B M22-1 Ground
PG12
USB SOCKET USB SOCKET
Accessory Power 1 CN2-9 G M70-1 M70M-1 W Supply

PG11
B B B
BATTERY SUBHARNESS
B H10-1 H10M-1 B M96-1

PG1
Heated Accessories Circuit
LEFT HEATED GRIP
M84-3 Switch
M84-2 Power
CHASSIS ECM HEATED GRIPS SUBHARNESS
B M84-1 Ground
Heated Grips Microswitch CN2-15 B/G H04-3 H04M-3 G

RIGHT HEATED GRIP
Heated Grips Left CN2-12 K/W H04-1 H04M-1 K/W
Heated Grips Right CN2-11 K/B H04-2 H04M-2 K/B M83-1 Power
PG13 B H04-4 H04M-4 B B M83-2 Ground
BATTERY SUBHARNESS
B H10-1 H10M-1 B M96-1
PG1
Alarm Circuit
ALARM
B M36-3 SUPPLY
AC1
B M36-4 IGNITION
G11
INSTRUMENTS
ALARM + M01-8 B M36-5 ALARM LED +
ALARM - M01-2 B M36-6 ALARM LED -
CHASSIS ECM
Alarm Indicator, Tracker Driver CN1-11 B M36-7 LEFT INDICATOR
B M36-2 Ground
PG11 B M36-1 Ground
BATTERY SUBHARNESS
B H10-1 H10M-1 B M96-1
PG1
Rider Information Circuit
M14B-4 HAZZARDS
IGNITION SWITCH
G1 U M14B-5 ILLUMINATION
START SW INPUT
M13-2 G G M14B-3
M14B-1 POWER SWITCH OUTPUT
M14B-2 LOCK SW OUTPUT
S
R T
Y M14A-2 LOCK SW INPUT U A
N M14A-1 POWER SW INPUT N R
CHASSIS ECM T
RUN SW INPUT
Hazard Warning Light Microswitch CN1-14 Y G M14A-6
START SW OUTPUT
Engine Start Switch CN1-16 R M14A-3
RUN SW OUTPUT
Kill Switch Status CN1-15 G/R G M14A-4
GN1 B B M14A-5 Ground
PG13
ENGINE ECM LEFT HANDLEBAR SWITCH HOUSING
IGP E02A-11 G/R G M02A-2 POWER + ILLUMINATION
M02A-5 ILLUMINATION
CLUTCH#1 E02A-6 Y M02A-3 CLUTCH SW
B/Y B/Y M02A-1 Ground
PG16 LG1
C.C SET/DECEL E02C-30 W/U M02B-1 CC SET
C.C RES/ACCEL E02C-28 W/G M02B-2 CC RES
BATTERY SUBHARNESS
B H10-1 H10M-1 B M96-1
PG1
Ground Circuit - Front
ENGINE GROUND
M97-1 B
LEFT HEATED GRIP
Ground M84-1 B HEATED GRIPS SUBHARNESS
B H04M-4 H04-4 B
RIGHT HEATED GRIP
Ground M83-2 B
FRONT LEFT DIRECTION INDICATOR FRONT LEFT DIRECTION INDICATOR
Ground B M04BM-1 M04B-1 B
FRONT RIGHT DIRECTION INDICATOR FRONT RIGHT DIRECTION INDICATOR

PG13
Ground B E19AM-1 E19A-1 B
Ground B E19BM-1 E19B-1 B
Ground M14A-5 B
FRONT ACCESSORY SOCKET, LIVE
Ground M21-1 B
HORN
Ground M11B-1 B
HEADLIGHT
Ground M07-1 B B B
PG14
LEFT HAND FOG LIGHT LEFT HAND FOG LIGHT
Ground B M82M-2 M82-2 B
RIGHT HAND FOG LIGHT RIGHT HAND FOG LIGHT

INSTRUMENTS
Ground M01-11 B
Ground M68-7 B B
PG17
Ground M06-1 B
REGULATOR RECTIFIER
Ground M48A-1 B
ABS MODULATOR BATTERY SUBHARNESS BATTERY NEGATIVE TERMINAL
Ground M59-10 B B H10-1 H10M-1 B M96-1

PG1
Ground Circuit - Middle

LEFT HANDLEBAR SWITCH HOUSING
Ground M02A-1 B/Y
FUEL LEVEL SENSOR
Ground E07-2 B/Y
COOLANT TEMPERATURE SENSOR ENGINE SUBHARNESS
Ground Eng Temp E10-2 K/B H05M-2 H05-2 B/Y
INTAKE AIR TEMPERATURE SENSOR
Ground E20-2 B/Y LG1
ENGINE ECM
LG-E E02B-12 B/Y
LG-C E02A-7 B/Y B/Y

PG#1 E02A-24 B
PG#2 E02A-10 B
PG#3 E02A-9 B
PG16
PG#4 E02A-23 B
PG#5 E02A-22 B
R07-2 B
STARTER SOLENOID
Starter Solenoid Control - M28-4 B B
AMBIENT AIR TEMPERATURE SENSOR
Ground M52-2 B
PASSENGER HEATED SEAT SWITCH PASSENGER HEATED SEAT SWITCH BATTERY SUBHARNESS
Ground B M79M-2 M79-2 B B B H10-1 H10M-1 B M96-1
PG161 PG1
Ground Circuits - Rear
REAR LEFT DIRECTION

INDICATOR REAR LEFT DIRECTION INDICATOR
REAR RIGHT DIRECTION INDICATOR REAR RIGHT DIRECTION INDICATOR
USB SOCKET USB SOCKET
Ground B M70M-2 M70-2 B B

PG11
ALARM
Ground M36-1 B
Ground M36-2 B
REAR ACCESSORY SOCKET, SWITCHED
Ground M22-1 B
REAR LIGHT REAR LIGHT
PASSENGER HEATED SEAT PASSENGER HEATED SEAT

B
RIDER HEATED SEAT RIDER HEATED SEAT PG12
CONNECTIVITY MODULE
Ground M72-2 B
Ground E04-4 B
CHASSIS ECM
GND CN3-14 B
BATTERY SUBHARNESS
GND CN1-1 B B B H10-1 H10M-1 B M96-1
PG15 PG1
Electronic Systems Configuration and Setup

General Information
Calibration Downloading General Information
CAUTION
The calibration download procedures detailed in the flow charts provided in the following chapters must be followed precisely. Failure to precisely follow the procedures may
result in permanent damage to the component receiving the calibration download.
CAUTION
When downloading a calibration, always ensure the calibration selected is correct for your model and region. Failure to select the correct calibration may result in permanent
damage to the component receiving the calibration download.
CAUTION
When downloading an engine ECM calibration, always ensure the correct calibration is selected for your fuel type. Engine damage may result if a calibration for an incorrect
fuel type is installed.
Note
Some calibration downloads can take up to 40 minutes to complete. Before starting a download, ensure the battery voltage is at least 12.8 Volts.
The headlight fuse may be removed prior to starting a download to prevent the headlight draining the battery. Refer to the label on the fuse box cover for the
fuse location.
Ensure the ignition and engine Start/Stop switches are set to the positions detailed at the beginning of each download process flowchart.
Once the calibration download has been started, do not switch the ignition or engine Start/Stop switches to a different position unless instructed to do so by
the Triumph Diagnostic Tool/download process flow chart.
Do not disconnect the diagnostic interface during the calibration download.
During a calibration download, multiple files are downloaded and the progress bar displayed will repeatedly rise from 0% to 100% as each file is downloaded.
Always wait for the Verifying Download screen to appear to confirm that the full calibration has downloaded successfully and click the Finish button to end the
process. Do not click the Cancel button while the download is still in progress.
Instrument Calibration Downloads
Following an instrument calibration download, the following items (if fitted) may return to their factory default settings. Before starting an instrument calibration download, record
the settings of each item where applicable so that the settings can be restored after the download has finished.
Time/date
Distance/time to next service
TPMS instrument display (enabled/disabled)
All riding mode settings
Self cancelling indicators (enabled/disabled).
Downloading Sequence - Calibration Downloads to Multiple ECMs
When planning to download a calibration, check each of the motorcycle’s ECMs for out of date calibrations and ensure all ECMs are updated as necessary. Where calibration
updates are available for more than one ECM, the ECMs should be updated in the following order.
1. Instruments
2. Chassis ECM/Keyless ECM (if fitted)
3. Engine ECM
Instruments

Odometer Reset
This model is equipped with an odometer that allows the recorded odometer value to be reset to zero during the PDI check.
In the event of replacement this functionality will also allow a new set of instruments to be programmed with the motorcycle’s existing odometer value.
Note
Motorcycles with the odometer reset functionality enabled will display the Set/Reset Odometer option in the chassis diagnostics menu.
If the odometer has recorded more than 120 miles (200 km) or previously been reset the option will not be available and the buttons will be greyed out.
Triumph Motorcycles LTD. would like to emphasise the importance of following the correct process whilst using the Triumph Diagnostic Tool to SET/RESET the odometer.
CAUTION
This operation can only be performed once and cannot be undone.

Check the new value is correct before proceeding.
When setting or resetting the odometer value ensure:

The CORRECT odometer value is displayed in the Set Odometer box before pressing the Set or Reset button.
DO NOT press the Set or Reset buttons before entering the correct odometer value. Once pressed the option to set or reset the odometer will no longer be available.
REMEMBER, pressing the set or reset buttons will lock the odometer and no further programming will be allowed.
To Set/Reset the Odometer always refer to Set/Reset Odometer in the Chassis Diagnostics chapter of the Triumph Diagnostic User Guide.
Chassis ECM
Chassis ECM Calibration Download Flow Chart
Note
If the download fails to complete, turn the ignition OFF, disconnect the diagnostic tool and allow the chassis ECM to power down (approximately 30 seconds).
Restart the download using Manual Model Selection.

Engine ECM
Replacement Engine ECM Setup
Engine ECM Calibration Download Flow Chart

Note
If the download fails to complete, turn the ignition OFF and allow the motorcycle to power down (approximately one minute). Restart the download using
Manual Model Selection.
Connectivity Module
Connectivity Module Calibration Download Flow Chart
Note
If the download fails to complete, turn the ignition OFF, disconnect the diagnostic tool and allow the suspension ECM to power down (approximately 30
seconds). Restart the download using Manual Model Selection.
Enable/Disable Instrument Connectivity Menus
To enable the instrument connectivity menus:
1. Connect the Triumph diagnostic tool and turn the ignition ON.
2. Navigate to CHASSIS DIAGNOSTICS - INSTRUMENT DIAGNOSTICS - Adjust.
3. Click Enable Connectivity Menus.
4. The connectivity menus will be enabled providing the following conditions have been met:

A Connectivity Module must be installed.
The Connectivity Module calibration must be up to date.
The instruments must be programmed with a Connectivity Module ready calibration.
The instruments must be programmed with a valid VIN (this is programmed automatically when downloading a Connectivity Module ready calibration to the instruments).
5. If any of the above conditions are not met, the diagnostic to will display a message identifying which conditions are not correct. Rectify as necessary before attempting to
enable the instrument connectivity menus again.
To disable the instrument connectivity menus:
2. Navigate to CHASSIS DIAGNOSTICS - INSTRUMENT DIAGNOSTICS - Adjust.
3. Click Disable Connectivity Menus.
Gear Position Adaption and Triumph Shift Assist (if fitted)
Gear Position Sensor
This model is fitted with a hall effect gear position sensor that provides a constant voltage output ranging from 0.5 to 4.5 Volts. The output voltage is used to determine which
gear is currently engaged.
Voltage Characteristics
The gear position is determined by the following voltage ranges:
Gear Minimum Voltage Maximum Voltage
1 0.5 V 0.7 V
N 0.9 V 1.1 V
2 1.3 V 1.5 V
3 2.0 V 2.2 V
4 2.8 V 3.0 V
5 3.5 V 3.7 V
6 4.3 V 4.5 V
The sensor voltage can be read using the Triumph diagnostic tool.
Further Diagnostics
Refer to Gear Position Sensor for details of pinpoint tests relating to diagnostic trouble codes P0914 and P0917.
Neutral Position Adaption
The motorcycle is delivered from the factory with the neutral position fully adapted.
The neutral position adaption must be reset and re-adapted under the following conditions:
If a gear position sensor malfunction occurs (DTC P0914 and P0917, see Gear Position Sensor).
The sensor has been removed or disconnected for any reason.
Refer to Neutral Position Adaption.
Neutral Position Adaption
The neutral position adaption is required to allow for manufacturing tolerances of the gearbox and gear position sensor. The motorcycle is delivered from the factory with the
neutral position fully adapted.
The neutral position adaption must be reset and re-adapted under the following conditions:
The gear position sensor has been removed or disconnected for any reason.
Adaption Reset
The Gear Position/Neutral Position Adaption Reset function provided in the Triumph diagnostic tool will erase all previous Gear Position/Neutral Position Adaptions.
To reset the Neutral Position adaptions:
2. Select ENGINE DIAGNOSTICS.
3. Check and erase any stored DTCs.
4. Select ADJUST TUNE then select Gear Position/Neutral Position Adaption Reset.
5. Click Start.
6. The software will confirm that the adaption has been successfully reset.
7. The neutral position will now be reported as Not Adapted.
Re-Adaption
WARNING
To re-adapt the neutral position:

1. Ensure the transmission is in neutral.
Note
For successful and accurate adaption, The engine must be at normal idle speed and the gear change pedal must be in its normal rested position.
During adaption, do not raise the engine speed and do not touch or move the gear change pedal.
3. The neutral position will adapt shortly after engine start provided the above conditions are met.
4. The adaption status can be confirmed by selecting GEAR POSITION ADAPTION STATUS on the Triumph diagnostic tool.
Triumph Shift Assist System (if fitted)
System Description
The Triumph Shift Assist (TSA) system enables the rider to change gears without the use of the clutch. The system uses signals from the Shift Force Sensor (if fitted) (located
on the gear change linkage) and the Gear Position Sensor to detect when a shift force is applied to the gear change pedal. Engine torque is then adjusted to facilitate a smooth,
clutch free gear change.
System Operation
The Triumph shift assist system allows clutch free shifts for the majority of gear changes. However, it is recommended that the clutch is used for gear changes at slow riding
speeds, or when riding in slow traffic.
The clutch must be used when selecting any gear from neutral, and also when selecting neutral from any other gear.
To ensure a smooth gear change, use a positive pedal force to select the next gear then release the pedal. Do not hold the pedal in its upper or lower positions.
Clutch free Up shifts are disabled by the system at engine speeds lower than 1,500 revolutions per minute (rpm) to prevent stalling.
At maximum engine speeds, clutch free up shifts are allowed by the system, but clutch free down shifts are disabled to prevent engine over speed.
The Triumph shift assist system is disabled if the motorcycle is traveling at its limited top speed. The system is automatically re-enabled when the motorcycle slows down
from its limited top speed.
Engine torque is reduced when changing gear at high engine loads.
A throttle 'blip' is applied when changing gear at low engine loads.
Engine torque is returned to normal control when the gear change is complete.
Malfunction Action
If a Triumph shift assist malfunction occurs, the system will be inhibited and the Transmission Warning symbol will be illuminated on the instrument panel.
All Triumph shift assist related malfunctions must be rectified before the system can be re-enabled.
If the malfunction is related to the gear position sensor, the neutral position and gear position adaption must be reset and re-adapted before the system can enabled.
If the malfunction is related to the shift force sensor, the shift force sensor adaption must be reset and re-adapted before the system can enabled.
The Transmission Warning symbol will continue to be displayed until each adaption is completed successfully.
Shift Force Sensor (if fitted)
The shift force sensor is used to detect when a force is applied to the gear change pedal.
Voltage Characteristics
The sensor output voltage changes as follows during normal operation:

Sensor State Voltage
At rest 2.6 V
In compression (up shift) 1.6 V
In tension (down shift) 3.6 V
The sensor voltage can be read using the Triumph diagnostic tool.
Further diagnostics
Refer to Shift Force Sensor Circuit (Triumph Shift Assist) for details of pinpoint tests relating to diagnostic trouble codes P1702 and P1703.
Adaption
If Triumph Shift Assist is fitted as standard, the motorcycle is delivered from the factory with the shift force sensor fully adapted.

If the Triumph Shift Assist has been fitted as an accessory, the shift force sensor must be adapted as part of the accessory kit installation process.
The shift force sensor adaption must be reset and the sensor re-adapted under the following conditions:
If a shift force sensor malfunction occurs (DTC P1702 and P1703, see Shift Force Sensor Circuit (Triumph Shift Assist)).
The sensor has been removed or disconnected for any reason.
Refer to Shift Force Sensor Adaption (if fitted).
Shift Force Sensor Adaption (if fitted)
The shift force sensor adaption is required to allow for manufacturing tolerances of the shift force sensor.
If Triumph Shift Assist is fitted as standard, the motorcycle is delivered from the factory with the shift force sensor fully adapted.
If the Triumph Shift Assist has been fitted as an accessory, the shift force sensor must be adapted as part of the accessory kit installation process.
The shift force sensor adaption must be reset and re-adapted under the following conditions:
If a shift force sensor malfunction occurs (DTC P1702 and P1703, see Shift Force Sensor Circuit (Triumph Shift Assist)).
If the shift force sensor has been removed or disconnected for any reason.
Adaption Reset
The Shift Force Sensor Adaption Reset function provided in the Triumph diagnostic tool will erase all previous shift force sensor adaptions.
To reset the shift force sensor adaption:
4. Select ADJUST TUNE then select Shift Force Sensor Adaption Reset.
5. Click Start.
7. The Shift Force Sensor Adaption Status will now be reported as Not Adapted.
Re-Adaption
WARNING
Note
If necessary, the neutral position can be re-adapted simultaneously with the shift force sensor re-adaption (see Neutral Position Adaption).
To re-adapt the shift force sensor:
Note
For successful and accurate adaption, The engine must be at normal idle speed and the gear change pedal must be in its normal rested position.
During adaption, do not raise the engine speed and do not touch or move the gear change pedal.
3. The shift force sensor will adapt shortly after engine start provided the above conditions are met.
4. The adaption status can be confirmed by selecting TRIUMPH SHIFT ASSIST ADAPTION STATUS on the Triumph diagnostic tool.
Gear Position Adaption
Gear position adaption is required to allow for manufacturing tolerances of the gearbox and gear position sensor.
If Triumph Shift Assist is fitted as standard, the motorcycle is delivered from the factory with each gear position fully adapted.
If the Triumph Shift Assist has been fitted as an accessory, each gear position must be fully adapted as part of the accessory kit installation process.
Gear position adaption must be reset and re-adapted under the following conditions:
The gear position sensor has been removed or disconnected for any reason.
Adaption Reset
The Gear Position/Neutral Position Adaption Reset function provided in the Triumph diagnostic tool will erase all previous Gear Position/Neutral Position Adaptions.
To reset the Gear Position/Neutral Position adaptions:
4. Select ADJUST TUNE then select Gear Position/Neutral Position Adaption Reset.
5. Click Start.
7. The neutral position and each gear position will now be reported as Not Adapted.
Re-Adaption
WARNING
WARNING

WARNING
Do not start the motorcycle and engage gears while it is parked on its centre stand. Do not attempt to adapt the gear positions with the motorcycle parked on its centre
stand.
Should the motorcycle fall off its centre stand while the rear wheel is in motion, the motorcycle would accelerate rapidly. This could result in serious injury or death as well as
causing damage to the motorcycle and other property.
To re-adapt the gear positions:

2. Start the engine and allow the neutral position to adapt (see Neutral Position Adaption).
WARNING
When riding the motorcycle the rider must always wear a safety helmet, eye protection, gloves, boots, trousers (close fitting around the knee and ankle) and a brightly
coloured jacket. Brightly coloured clothing will considerably increase a rider's visibility to other operators of road vehicles. Although full protection is not possible, wearing
correct protective clothing can reduce the risk of injury when riding.
Note
A suitable safe place should be found to carry out the road test.
The Transmission Warning symbol is illuminated on the instrument display.
3. Road test the motorcycle as follows:
Ride the motorcycle smoothly at low engine speeds, changing up through each gear in turn.
Fully close the throttle and use the clutch at each gear change.
As soon as each gear engages, allow the gear change pedal to return to its normal resting position. Do not rest your foot on the pedal as any movement of the pedal can
cause incorrect adaption.
When each gear change is complete, release the clutch and ride normally using gentle acceleration. Avoid rapid acceleration or deceleration as this will prevent adaption.
The gear position will adapt a few seconds after each gear change is completed.
When all gear positions have successfully adapted, the Transmission Warning symbol will turn off.
After completing the road test, turn the ignition OFF for at least 60 seconds to allow the adaption settings to be stored in ECM memory.
The gear position adaption status can be confirmed using the Triumph diagnostic tool.

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Service Manual - Tiger 900 Rally Pro

How to use this manual

Warnings, Cautions and Notes

Particularly important information is presented in the following form:

Tampering with Noise Control System Prohibited

Owners are warned that the law may prohibit:

Repairs and Replacements

Service Manual - Tiger 900 Rally Pro 1 of 527

26 Nm to 100 Nm +10% -0%

101 Nm to 200 Nm +10% -0%

Use of Crow Foot Spanner Adapters with Torque Wrenches

M2 is the required tightening torque to be applied 90 Nm

M1 is the calculated torque wrench setting 83 Nm

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Third Party Products

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

Health Protection Precautions

Environmental Protection Precautions

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Diagnostic Trouble Codes

Jacking and Lifting

Precautions Against Damage

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A high flashpoint solvent is recommended to reduce fire hazard.

Joints and Joint Faces

Assemble joints dry unless otherwise specified in this manual.

Liquid Gasket, Non-permanent Locking Agent

Metric threads to ISO standard are used.

Never lubricate a thread unless instructed to do so.

Fitting a Split Pin

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Oil and Grease Seals

Chassis Bearing Lubrication

Lubrication and Checks While Servicing a Bearing

1. Disassemble parts as necessary to access the bearing.

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Angular Contact and Ball Bearing

1. Grease the bearing races and the ball bearing carrier.

Needle Roller Bearings

1. Coat the needle rollers with grease.

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Fuel Handling Precautions

Fuel Tank Removal

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Before disconnecting the battery, switch off all electrical equipment.

Glossary of Circuit Diagram Symbols

Electromagnetic Winding (solenoid)

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LED (Light Emitting Diode)

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Power is calculated by multiplying Volts x Amps -

the bulb resistance can be calculated by using -

Basic Electrical Circuits

Basic Circuit Diagram

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Locate each end of the wire.

Turn the circuit to be tested 'ON'.

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CAN (Controller Area Networking)

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