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.

Dangers, Warnings, Cautions and Notices

Particularly important information is presented in the following form:

Noise Control System

Owners are warned that the law may prohibit:

1. 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,

2. the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

• Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.

• Removal of, or puncturing of any part of the intake system.

• Lack of proper maintenance.

• Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

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 600 mile/1000 km service, and thereafter should be maintained at the figures specified in this manual.

Repairs and Replacements

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

Force

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

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

Edges

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

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

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

Fixings

Locking devices, where specified, must be fitted.

If the efficiency of a locking device is impaired during removal it must be renewed.

Micro-encapsulated and patch locked fixings must always be replaced if disturbed.

Where necessary, the text in this manual will indicate where such a fixing is used.

• An encapsulated fixing can be identified by the diameter of threads is encompassed by the locking agent.

• A patch locked fixing can be identified by a coloured section of thread which is treated with a locking agent.

Fixing Encapsulation Mating surface Screw Patch locking

Tightening Procedures

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

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 and patch locked 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.

M1 = M2 x L1 / L2	Example
M2 is the required tightening torque to be applied	90 Nm
L1 is the normal length of the torque wrench, measured from the centre of the drive square to the centre of the handle	300 mm
L2 is the extended length of the torque wrench, measured from the centre of the crow foot spanner head to the centre of the handle	325 mm
M1 is the calculated torque wrench setting	83 Nm

Using a Micrometer

Calibration

• The thimble is fixed to the spindle so that both components turn together.

• The sleeve is fixed to one end of the frame. It has graduations and an index line to aid the reading of the graduations on the thimble.

Micrometer frame Anvil Spindle Sleeve Thimble

Measuring

Component Serviceability

Premature wear of a surface finish should be visually checked for:

• Abrasive wear;

• Corrosion and oxidation;

• Erosive wear;

• Fretting;

• Surface fatigue.

Examples

• Taper - to become gradually smaller toward one end.

• Wear - the continuing loss of material from the surface of a solid body.

• Ovality - the difference between the maximum and minimum dimensions of the overall diameter.

The following illustration measures a crankshaft as an example.

Wear check/ Taper Wear check/ Taper Wear check Ovality check Ovality check Ovality check

General Information

Ignition System Safety Precautions

Dangerous Substances

Third Party Products

Fluoroelastomers

Oils

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.

Environmental Protection Precautions

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

Safety Instructions

Diagnostic Trouble Codes

Jacking and Lifting

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

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.

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).

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.

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.

Motorcycle Inspection after an Accident, Collision or Fall

If the motorcycle is involved in an accident, collision or fall, it must be carefully inspected and repaired before being used again.

Damage may not be obvious. Even apparently minor damage may conceal more serious concerns, inspect all signs of damage carefully.

Items such as fairings, bodywork, engine covers and other components may require removal prior to inspection.

Damaged components may require removal from the motorcycle for further inspection or measurement to fully assess the extent of any damage.

Below is a non-exhaustive list of areas that should be inspected when assessing accident damage.

• Check wheel alignment for signs of a damaged or twisted main frame or damaged suspension.

• Check the main frame for any damage including twisting or cracking of materials or welds.

• Check front forks for any bending.

• Check wheels for any tyre, rim or spoke damage. Tyre removal may be required.

• Check for damage to extremities (levers, mirrors, handlebars and end weights, footrests (including bank angle indicators), silencers, etc).

• Check the functionality of all controls, throttle, clutch, brakes, gear selection, electronic functionality.

• Check lighting, braking and indicator functionality (if fitted).

• Check for any fluid leaks (engine oil, final drive oil, fuel, coolant, brake fluids).

• Check for bodywork damage.

• Check for correct torque or damage (including bolt bending) of fasteners including frame to engine bolts, brake calliper bolts, wheel axle bolts, fork pinch bolts.

• Check for any stored Diangostic Trouble Codes (DTCs). Clear the DTCs and check if the DTC reappears. Investigate the component giving rise to the DTC.

Chassis Bearing Lubrication

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.

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:

Lubrication and Checks While Servicing a Bearing

Several common bearing types and the lubrication procedures for each are identified below:

Sealed Bearings

Taper Bearings

Angular Contact and Ball Bearing

Needle Roller Bearings

Metal Bushes

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.

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

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.

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.

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

Disciplines

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

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

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

Electrical Wires

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

Glossary of Circuit Diagram Symbols

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

Connector

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

Diode

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

Electromagnetic Winding (solenoid)

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

Fuse

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

Ground Point

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

Lamp or Bulb

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

LED (Light Emitting Diode)

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

Motor

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

Relay

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

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

Resistor

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

Splice

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

Switches

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

Electrical Testing

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

Ohm’s Law

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

• 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:

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

• 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.

• 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) and other components. Each component 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 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.

CAN works by components sending and/or receiving 'packets' of information (such as engine speed or fuel consumption information) onto 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 components 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. If one ECM fails or the transmit is corrupted, or otherwise incorrect messages are transmitted, none of the other ECMs on the network will be affected. Then, 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 Diagnostic Trouble Code (DTC).

Triumph currently uses CAN for communication between the following:

• 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).

• Bluetooth module (if fitted)

• Suspension ECM (if fitted)

• Blind spot radar (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.

Instruments 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 and Garage Equipment

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

Special Service Tools

Specifications

Specification

Dimensions, Weights, and Performance

Engine

Cylinder Head

Camshafts

Clutch and Primary Drive

Balancer

Pistons

Connecting Rods

Crankshaft

Transmission

Final Drive

Lubrication

Ignition System

Fuel System

Fuel Injection System

Emissions Controls

Coolant System

Suspension

Frame

Brakes

Wheels and Tyres

Electrical Equipment

Torque Wrench Settings

Cylinder Head

Clutch

Balancer, Crankshaft and Crankcase

Engine Covers

Transmission

Lubrication System

Final Drive

Cooling System

Fuel System, Exhaust System and Airbox

Front Suspension

Rear Suspension

Wheels

Front Brakes

Rear Brakes

ABS System

Frame, Footrests, Control Plates and Engine Mountings

Electrical

Routings

Routings - Main Harness

Routings - ABS

Routings - Evaporative Hose Routing

Routings - Clutch Cable

Scheduled Maintenance

Scheduled Maintenance

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 in three ways; annual maintenance, mileage based maintenance or a combination of both, depending on the mileage the motorcycle travels each year.

1. Motorcycles travelling less than 10,000 miles (16,000 km) per year must be maintained annually. In addition to this, mileage based items require maintenance at their specified intervals, as the motorcycle reaches this mileage.

2. Motorcycles travelling approximately 10,000 miles (16,000 km) per year must have the annual maintenance and the specified mileage based items carried out together.

3. Motorcycles travelling more than 10,000 miles (16,000 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. For advice on which maintenance schedule is most suitable for your motorcycle, contact a competent person with the specialist knowledge and technical understanding of motorcycles, such as an authorised Triumph dealer.

Triumph Motorcycles cannot accept any responsibility for damage or injury resulting from incorrect maintenance or improper adjustment.

Scheduled Maintenance Table

Service Specifications

Service Torque Wrench Settings

Engine Check For Fluid Leaks

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.

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.

Oil and Oil Filter Change

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.

Rectification if required:

Fuel/evaporative leaks must be rectified.

Damaged fuel/evaporative system components must be replaced.

An incorrectly fitting fuel cap must be replaced.

MAP Sensor Drain Hose - Draining

The MAP sensor drain hose is to be drained every 10,000 miles.

• Seat - Removal

• Battery - Removal

• Fuel Tank - Removal

• Battery - Installation

• Seat - Installation

Air Filter Element - Renew

Removal

Installation

Spark Plugs - Renew

Coolant System - Check For Fluid Leaks

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 Level Inspection

Coolant Level Adjustment

Coolant Renew

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

• Drain the coolant (see Coolant Replacement - Drainage).

• Refill the coolant with Triumph D2053 OAT (see Coolant Replacement - Filling).

Clutch Cable - Check/adjust

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.

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.

Rectification if required:

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 Adjustment

Camshaft Timing Adjust

• Camshaft Cover - Removal

• Crankcase Right Hand Cover - Removal

• Valve Clearance Measurement

• Camshaft Cover - Installation

• Crankcase Right Hand Cover - Installation

• Crankshaft Position Adaption (European Markets Only)

Wheels - Check For Damage

Wheel Bearings - Inspection

Tyres - Check For Wear/Damage

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.

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

Steering Check

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 the Front suspension section of this service manual or consult an authorised Triumph dealer.

Rear Suspension Unit - Inspection

• Rear Suspension Unit - Removal

• Rear Suspension Unit - Installation

Headstock Bearing - Inspection

Headstock Bearings - Lubricate

Steering Head Bearing - Check

Steering Head Bearing - Adjustment

Maintenance - Fork Oil Renew

• Drain the fork oil (see Fork Oil Change - Oil Draining).

• Refill the fork with Showa SS47G oil (see Fork Oil Change - Oil Refilling).

Brake Master Cylinders - Inspection

Inspect both the front and rear master cylinders for fluid leaks. Rectify as necessary.

Front Brake Wear inspection

Brake pads must be inspected in accordance with scheduled requirements and replaced if worn to, or beyond the minimum service thickness.

Carrier plate Brake pad

If the lining thickness of any pad is less than that specified in the table, replace all the pads on the wheel.

Brake pads for this model supplied by Triumph will have the carrier plate at the correct thickness. Always have replacement brake pads supplied and fitted by your Triumph dealer.

Carrier plate Brake pad lining

Rear Brake Wear inspection

If the lining thickness of any pad is less than that specified in the table, replace all the pads on the wheel.

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.

Carrier plate Brake pad lining

Front Brake Fluid Level Inspection

Rear Brake Fluid Level Inspection

Rear reservoir cap Rear reservoir upper level Rear reservoir lower level

Brake Fluid - Renew

Front Brake Fluid

• Note the original setting of the brake lever adjuster in order that it can be returned to the same position when the bleeding operation is complete. Set the brake lever adjuster to position No. 1.

Adjuster wheel Arrow mark

Rear Brake Fluid

Drive Chain Free Movement - Inspection

Drive Chain Free Movement - Adjustment

If the drive chain free movement measurement is incorrect, adjustments must be made as follows: