Triumph Scrambler 1200 XC Service Manual Download

Page: 104 / 640

cJ a a _1

Rocker shaft

Rocker arm

Shims (cylinder 1 inlet shown)

Camshaft

Note

The underside of the shim displays the shim size.
Always place the shim with the shim size facing towards the valve.

Remove the shim from the valve(s) that requires adjustment.

cizw_1

2.40

Shim

Valve

Measure the original shim, using a micrometer.

Calculate the shim thickness required to give the correct clearance, for
specifications refer toService Specifications.

Clearance too small - Fit a thinner shim.
Clearance too large - Fit a thicker shim.

Service Manual - Scrambler 1200 XC

104 of 640

Summary of Contents for Scrambler 1200 XC

Page 1: ...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 ...

Page 2: ...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 in...

Page 3: ...n 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...

Page 4: ... 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...

Page 5: ...tion 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 Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circui...

Page 6: ...l 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 ...

Page 7: ...en 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 ...

Page 8: ...hedule 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 le...

Page 9: ...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 ...

Page 10: ... 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 ...

Page 11: ...ents 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 qu...

Page 12: ... 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 th...

Page 13: ... 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 proc...

Page 14: ...mage 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 p...

Page 15: ... between the roller elements and the roller cage 2 Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts 3 Any excess grease should be smeared on the outside of the rollers 4 Lubrication and Checks While Servicing a Bearing Disassemble parts as necessary to access the bearing 1 Inspect the old grease covering the bearing looking for signs o...

Page 16: ...eals If the seals are damaged dirt and water will ingress and the life of the bearing will be greatly reduced ceon Taper Bearings Grease must be forced between the inner race and the roller carrier 1 Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts 2 Any excess grease should be smeared on the outside of the rollers 3 Service Manual Scr...

Page 17: ...grease 1 Ensure the needle rollers turn so that the grease is distributed over the entire circumference of the internal parts 2 Assemble the parts adjust and check as necessary 3 Metal Bushes Disassemble the parts as necessary to access the bush 1 Remove the old grease 2 Apply fresh grease to the metal bush 3 Fuel Handling Precautions General The following information provides basic precautions wh...

Page 18: ...sent 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...

Page 19: ...rked 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 drillin...

Page 20: ...e 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...

Page 21: ...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...

Page 22: ... 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 ...

Page 23: ...rcuit 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...

Page 24: ... to illustrate the various system components and will be accompanied by a key indicating circuit diagram components and wiring colour codes 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 disassembli...

Page 25: ...stic 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 ...

Page 26: ...xample below the circuit voltage is being measured at the bulb positive terminal V 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 ...

Page 27: ...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 continuit...

Page 28: ...ata 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 ...

Page 29: ... 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 CAN...

Page 30: ...d 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 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...

Page 31: ...Gauge T3880016 Balancer Gear C Spanner T3880039 T3880023 50 mm Socket T3880039 Idler Gear Timing Pin T3880041 cczb T3880041 Idler Gear Timing Wrench T3880053 Wheel Bearing Extraction Kit Service Manual Scrambler 1200 XC 31 of 640 ...

Page 32: ...stic Interface T3880067 Fork Spring Compressor cczb ccgs T3880075 Bearing Installer T3880085 Fork Piston Holder cdoa T3880104 Swinging Arm Adjuster Wrench T3880105 Torque Angle Gauge Service Manual Scrambler 1200 XC 32 of 640 ...

Page 33: ...sion Ratio 11 00 1 Cylinder numbering Left to right Firing Order 1 2 Cylinder Head and Valves Cylinder head Flatness tolerance 0 030 mm Valve Head Diameter Inlet 35 60 mm Exhaust 29 70 mm Valve Lift Inlet 10 3 mm Exhaust 9 2 mm Valve Stem Diameter Inlet 4 975 4 990 mm standard 4 965 mm service limit Exhaust 4 970 4 980 mm standard Service Manual Scrambler 1200 XC 33 of 640 ...

Page 34: ...Exhaust 0 020 0 045 mm standard 0 083 mm service limit Valve Seat Width in head Inlet 1 000 1 100 mm standard 1 500 mm service limit Exhaust 1 200 1 300 mm standard 1 700 mm service limit Valve Seat Width valve 1 50 1 85 mm Valve Seat Angle 90 inclusive Valve Spring Length 49 9 mm Inlet Exhaust Valve Spring Load at Length 214 N 10 at 39 5 mm Valve Clearance Inlet 0 05 0 13 mm Exhaust 0 12 0 22 mm ...

Page 35: ...urnal Clearance 0 040 0 091 mm standard 0 130 mm service limit Camshaft Journal Bore Diameter 23 000 23 021 mm Camshaft End Float 0 05 0 20 mm standard Camshaft Run out 0 015 mm standard Clutch and Primary Drive Primary Drive Type Gear Reduction Ratio 1 26 1 93 74 Clutch Type Wet multi plate No of Friction Plates 8 Steel Plate Flatness Limit 0 15 mm Service Manual Scrambler 1200 XC 35 of 640 ...

Page 36: ...e top of the barrel 97 585 97 601 mm standard Cylinder Barrel Diameter 97 mm from the top of the barrel 97 600 97 615 mm standard Piston Diameter 97 570 97 580 mm standard 97 530 mm service limit Piston Ring to Groove Clearance Top 0 02 0 07 mm standard 0 085 mm service limit Second 0 02 0 06 mm standard 0 075 mm service limit Piston Ring Groove Width Top 1 21 1 24 mm standard Second 1 01 1 03 mm ...

Page 37: ...040 mm service limit Gudgeon Pin Diameter 20 995 21 000 mm standard 20 985 mm service limit Connecting Rod Small End Diameter 21 016 21 029 mm standard 21 039 mm service limit Connecting Rod Big End Diameter 41 000 41 009 mm standard Connecting Rod Big End Side Clearance 0 15 0 30 mm standard 0 50 mm service limit Crankshaft Crankshaft Big End Journal Diameter 38 000 37 984 mm standard 37 9469 mm ...

Page 38: ...arance 0 018 0 042 mm standard 0 100 mm service limit Crankshaft End Float 0 05 0 20 mm standard 0 50 mm service limit Crankshaft Run out 0 02 mm standard 0 035 mm service limit Transmission Type 6 Speed Constant Mesh Gear Ratios Primary 1 26 1 93 74 1st 3 50 1 49 14 2nd 2 50 1 45 18 3rd 1 85 1 37 20 4th 1 48 1 37 25 5th 1 30 1 35 27 6th 1 17 1 34 29 Service Manual Scrambler 1200 XC 38 of 640 ...

Page 39: ...Chain EK525ZVX3 110 links Final Drive Ratio 2 75 1 44 16 Drive Chain Slack See Final Drive Chain Adjustment Drive Chain Lubrication Chain spray suitable for X ring chains Lubrication Oil Capacity including filter dry fill 3 80 litres Oil and Filter Change 3 40 litres Oil Change only 3 20 litres Recommended Oil Approval Rating API SH or higher and JASO MA Viscosity 10W 40 or 10W 50 Type Semi or ful...

Page 40: ...andard 0 12 mm service limit Ignition System Type Digital electronic Electronic Rev Limiter 7 500 rpm Pick up Coil Air Gap Fixed not adjustable Primary Coil Resistance 0 185 Kohms Ignition Coil Type Inductive plug top Spark Plug Type NGK LMAR8A 9 Spark Plug Gap 0 9 mm 0 0 0 1 mm Fuel System Fuel Type Unleaded 91 RON CLC or AKI octane rating R M 2 of 87 or higher Fuel Tank Capacity 16 litres Servic...

Page 41: ...e Speed Control Electronic 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 Catalysts One in the catalytic converter box Oxygen Sensor One per cylinder heated in header pipe Evaporative Control Activated carbon canister certain markets only Cooling Sys...

Page 42: ...ravel 200 mm Recommended Fork Oil Grade Showa SS47 Oil Level spring spring seat and spacer removed and fork fully compressed 114 mm Oil Volume dry fill 602cc Front Fork Pull Through 45 7 mm 0 5 mm from lower edge of top yoke to the top of the inner tube not the top cap Fork Spring Rate 4 5 N mm Rear Wheel Travel 200 mm Brakes Front Type Four piston monobloc calipers acting on twin discs Service Ma...

Page 43: ...iameter 18 mm Recommended Fluid DOT 4 Rear Type Twin piston sliding caliper acting on single disc Rear Caliper Piston Diameter 28mm Rear Disc Diameter 255mm Rear Disc Thickness 5 5mm 5mm Rear Disc Run out Max 0 25mm Rear Master Cylinder Diameter 14mm Recommended Fluid DOT 4 Frame Frame Type Tubular steel Service Manual Scrambler 1200 XC 43 of 640 ...

Page 44: ...out 1 mm Front Wheel Rim Radial Run out 1 mm Rear Wheel Size MT 17 x 4 5 Rear Tyre Size 150 70R17 69V Rear Tyre Pressure 2 9 bar 42 psi lb in Rear Wheel Rim Axial run out 1 mm Rear Wheel Rim Radial Run out 1 mm Approved Tyres A list of approved tyres specific to these models is available from your authorised Triumph dealer or on the Internet at www triumph co uk Electrical Equipment Service Manual...

Page 45: ...ion Torque Nm Notes Camshaft cover to cylinder head See Camshaft Cover Installation Camshaft drive chain tensioner blade to cylinder head 10 Nm Fit new fixing s if loosened or removed Camshaft drive chain tensioner to cylinder barrel 16 Nm Camshaft frame to cylinder head See Camshaft Installation Camshaft idler shaft bolt 10 Nm Fit new fixing s if loosened or removed Camshaft sprocket to camshaft ...

Page 46: ... s if loosened or removed Flanged plug to cylinder head 22 Nm Fit new fixing s if loosened or removed Spark plugs 12 Nm Service tool T3880609 Timing Torque Limiter 0 6 Nm Clutch Application Torque Nm Notes Clutch cable lower lock nut 3 Nm Clutch centre nut 98 Nm Fit new fixing s if loosened or removed Fit new Belleville washer Clutch lever clamp bolts 12 Nm Clutch lever nut 3 4 Nm Clutch pressure ...

Page 47: ...m Fit new fixing s if loosened or removed Crankcase to crankcase bolts See Crankcase Assembly Dead shaft clamp pinch bolt 10 Nm Dead shaft clamp retaining bolt 10 Nm Fit new fixing s if loosened or removed Dead shaft preload See Balancer Shafts Dynamic Adjustment Dry seal plug 23 Nm Fit new fixing s if loosened or removed Flanged plug 10 Nm Fit new fixing s if loosened or removed Oil filler cap 3 ...

Page 48: ...orque Nm Notes Alternator cover embellisher to cover 4 Nm Fit new fixing s if loosened or removed Alternator cover to crankcase 10 Nm Baffle to sump 6 Nm Cable cover to alternator cover 6 Nm Fit new fixing s if loosened or removed Camshaft cover Camshaft Cover Installation Clutch cover embellisher to clutch cover 4 Nm Fit new fixing s if loosened or removed Clutch cover plug 10 Nm Clutch cover to ...

Page 49: ...12 Nm Fit new fixing s if loosened or removed Detent arm spring fixing 12 Nm Fit new fixing s if loosened or removed Detent wheel to selector drum 12 Nm Fit new fixing s if loosened or removed Front sprocket to output shaft nut 180 Nm Fit new fixing s if loosened or removed Gear change pedal pinch bolt 8 Nm Input selector fork plug 22 Nm Fit new fixing s if loosened or removed Input shaft bearing ...

Page 50: ...9 Nm Fit new fixing s if loosened or removed Oil filter 10 Nm Apply clean engine oil to the seal s Oil filter adapter 10 Nm Fit new fixing s if loosened or removed Oil pressure relief valve plug 10 Nm Oil pressure switch 15 Nm Fit new sealing washer s Oil pump drive chain guide fixings 7 Nm Fit new fixing s if loosened or removed Oil pump drive sprocket to oil pump 12 Nm Oil pump rotor cover to oi...

Page 51: ...finisher mounting 3 Nm Fit new fixing s if loosened or removed Air temperature sensor 1 5 Nm Airbox to frame 6 Nm Ambient air pressure sensor 2 Nm Crankshaft position sensor 6 Nm Fit new fixing s if loosened or removed Engine ECM bracket 4 Nm Exhaust centre cover assembly 6 Nm Exhaust headers to cylinder head Left Hand Header Pipe Installation Exhaust Catalytic Converter Installation Exhaust rear ...

Page 52: ...lamp 3 Nm Fuel pump clamp 4 Nm Fuel pump mounting bracket to fuel pump plate 7 Nm Fit new fixing s if loosened or removed Fuel pump mounting plate to fuel tank Fit new sealing washer s See Fuel Pump Installation Fuel rail to cylinder head 6 Nm Fuel tank strap 5 Nm Fuel tank strap boss 1 5 Nm Fit new fixing s if loosened or removed Fuel tank to frame 8 Nm Gear position sensor 5 Nm Fit new fixing s ...

Page 53: ...hrottle body to inlet manifold 9 Nm Twist grip position sensor 2 5 Nm Fit new fixing s if loosened or removed Cooling System Application Torque Nm Notes Coolant expansion tank 3 Nm Fit new fixing s if loosened or removed Coolant expansion tank mounting 19 Nm Coolant filler neck 3 Nm Coolant manifold to crankcase 9 Nm Fit new fixing s if loosened or removed Coolant temperature sensor 18 Nm Apply Th...

Page 54: ...olt 25 Nm Instrument bracket to upper yoke 5 Nm Damping cylinder bolt 20 Nm Fit new sealing washer s Damping rod to top cap lock nut 20 Nm Handlebar to riser clamp bolt 24 Nm Handlebar end weights 5 Nm Fit new fixing s if loosened or removed Headstock bearing adjuster and lock nut See Steering Head Bearing Adjustment Left hand heated grip 2 Nm Left hand heated grip switch housing fixings 0 5 Nm Se...

Page 55: ...d rear fixing 9 Nm Drive chain guard lower 4 Nm Drive chain slack adjuster lock nut 20 Nm Drive chain rubbing strip 9 Nm Rear suspension unit lower mounting bolt 48 Nm Rear suspension unit upper mounting bolt 30 Nm Fit new fixing s if loosened or removed Rear suspension unit shroud 4 Nm Swinging arm pivot bolt adjuster See Swinging Arm Installation Swinging arm pivot nut See Swinging Arm Installat...

Page 56: ...t Installation Tyre valve 4 Nm Apply ThreeBond 1305 to the threads Final Drive Application Torque Nm Notes Rear sprocket to cush drive See Rear Sprocket Installation Rear sprocket studs See Rear Sprocket Installation Front Brakes Application Torque Nm Notes Brake caliper to front fork 55 Nm Brake disc to wheel 22 Nm Fit new fixing s if loosened or removed Brake hose to front caliper 25 Nm Fit new ...

Page 57: ...first Rear Brakes Application Torque Nm Notes Brake disc to wheel 22 Nm Fit new fixing s if loosened or removed Brake hose P clip to engine 5 Nm Brake hose to master cylinder 25 Nm Fit new sealing washer s Brake hose to rear caliper 25 Nm Fit new sealing washer s Brake master cylinder reservoir to frame 3 Nm Fit new sealing washer s Brake master cylinder to right hand control plate 18 Nm Brake ped...

Page 58: ...tor 5 Nm Fit new fixing s if loosened or removed Brake line union block to headstock 8 Nm Fit new fixing s if loosened or removed Brake line union to modulator 25 Nm Fit new sealing washer s Brake pressure switch 15 Nm Hose guide to swinging arm 5 Nm Rear brake line to modulator P clip 5 Nm Frame Footrests Control Plates and Engine Mountings Application Torque Nm Notes Bank angle indicator 9 Nm Fi...

Page 59: ...ylinder head front left hand bolt to frame See Engine Installation Cylinder head rear mounting to frame See Engine Installation Cylinder head to rear mounting See Engine Installation Drive chain roller 3 Nm Drive chain rubbing block 6 Nm Engine rear lower mounting lock nuts See Engine Installation Engine upper rear mounting lock nuts See Engine Installation Frame adjuster See Engine Installation F...

Page 60: ...ckets 8 Nm Front right hand cylinder head bolt to frame stage one See Engine Installation Front right hand cylinder head bolt to frame stage two See Engine Installation Front sprocket inner cover 3 Nm Front sprocket middle cover and rear brake reservoir 3 Nm Front sprocket outer cover 9 Nm Fuel tank infill panel 3 Nm Grab rail front fixings 28 Nm Grab rail mounting to frame 10 Nm Fit new fixing s ...

Page 61: ... moulding to mudguard support bracket 3 Nm Licence plate hanger nuts 5 Nm Licence plate hanger upper moulding to mudguard support bracket 3 Nm Lower rear crankcase mounting Mirror 20 Nm Mirror brackets 5 Nm Rear footrest clevis 24 Nm Rear footrest hanger 24 Nm Rear footrest rubber inserts 6 Nm Fit new fixing s if loosened or removed Rear mudguard tray to ABS bracket 9 Nm Rear mudguard tray to airb...

Page 62: ...1 Nm Side stand magnet 3 Nm Fit new fixing s if loosened or removed Side stand spring peg 7 Nm Fit new fixing s if loosened or removed Side stand switch 3 Nm Fit new fixing s if loosened or removed Steering lock fixing 12 Nm Fit new fixing s if loosened or removed Sump guard bracket 6 Nm Sump guard to bracket 4 Nm Sump guard to frame 6 Nm Fit new fixing s if loosened or removed Sump guard side pan...

Page 63: ...ng s if loosened or removed Alternator stator wire guide to alternator cover 6 Nm Battery cage 6 Nm Battery ground cable to frame 6 Nm Battery terminal 4 5 Nm Connector bracket to headstock 3 Nm Crankshaft position sensor to alternator cover 6 Nm Fit new fixing s if loosened or removed Fall detection switch 3 Nm Fit new fixing s if loosened or removed Fall detection switch bracket 4 Nm Front direc...

Page 64: ...m Headlight rim bracket fixings 6 Nm Headlight vertical adjuster 10 Nm Headstock connector bracket 3 Nm Headstock tidy 5 Nm Fit new fixing s if loosened or removed Headstock tidy outer cover bottom fixing 3 Nm Headstock tidy outer cover top fixing 5 Nm Heated grip left hand 2 Nm Heated grip switch housing 0 5 Nm Horn 24 Nm Ignition coil bracket 3 Nm Instrument adjustment bearing 5 5 Nm Service Man...

Page 65: ...enna 1 5 Nm Licence plate light 1 Nm Licence plate upper hanger to lower hanger 5 Nm Main harness front conduit 3 Nm Main harness to frame 3 Nm Rear direction indicators 5 Nm Fit new fixing s if loosened or removed Rear light 9 Nm Rear light assembly to mudguard and support bracket nuts 9 Nm Rear light assembly to rear mudguard 8 Nm Fit new fixing s if loosened or removed Rear reflector bracket 1 ...

Page 66: ...nut 10 Nm Smartkey fob 0 3 Nm Starter motor cable guide 4 Nm Fit new fixing s if loosened or removed Starter motor power lead connection 5 Nm Starter motor solenoid lead connection 5 Nm Starter motor to crankcase 7 Nm Routings Main Wiring Harness Routing Service Manual Scrambler 1200 XC 66 of 640 ...

Page 67: ...ckju Evaporative Hose Routing Service Manual Scrambler 1200 XC 67 of 640 ...

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

Page 69: ...torcycles cannot accept any responsibility for damage or injury resulting from incorrect maintenance or improper adjustment carried out by the owner Incorrect or neglected maintenance can lead to a dangerous riding condition Service Manual Scrambler 1200 XC 69 of 640 ...

Page 70: ...ecks 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 motor...

Page 71: ...arning 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 5...

Page 72: ...stem check for leaks Fuel system check fuel hoses for chafing cracks or damage Replace if necessary Air filter renew Fuel filter renew Throttle body plate butterfly check clean Fuel hoses renew Every 4 years regardless of mileage Evaporative loss hoses renew Every 4 years regardless of mileage Ignition System Spark plugs check Spark plugs renew Cooling System Cooling system check for leaks Day Ser...

Page 73: ...system check hoses for chafing cracks or damage Replace if necessary Coolant level check adjust Day Coolant renew Every 3 years regardless of mileage Engine Clutch cable check function and adjust as necessary Day Valve clearances check adjust Camshaft timing check Wheels and Tyres Wheels inspect for damage Day Wheel bearings check for wear smooth operation Wheels check for broken or damaged Day Se...

Page 74: ...40 000 64 000 spokes and check spoke tightness not alloy wheels Tyre wear tyre damage check Day Tyre pressures check adjust Day Steering and Suspension Steering check for free operation Day Headstock bearings check adjust Headstock bearings lubricate Front and rear suspension check for damage leaks smooth operation Day Fork oil renew Brakes Brake pads check wear levels Day Service Manual Scrambler...

Page 75: ...Brake calipers check for fluid leaks and seized pistons Brake fluid levels check Day Brake fluid renew Every 2 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 for wear cracks or damage Replace if necessary Electrical Lights instruments and electrical...

Page 76: ...and Keyless ECM check for latest calibration download using the Triumph diagnostic tool Bank angle indicators check for wear Day Fasteners inspect visually for security Day Centre stand and or side stand check for wear smooth operation Day Centre stand pivots clean grease Side stand pivot pin clean Rear brake pedal adjuster pivot pin clean lubricate Carry out all outstanding Service Bulletin and w...

Page 77: ...d to models for certain markets only Service Specifications Engine Oil Type 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 Engine Oil Capacity Wet Fill Including Filter 3 40 litres Spark Plug Type NGK LMAR8A 9 Spark Plug Gap 0 9 mm 0 0 0 1 mm...

Page 78: ...ork Oil Volume 602cc Front Fork Pull Through 45 7 mm 0 5 mm from lower edge of top yoke to the top of the inner tube not the top cap Front Brake Pad Minimum Thickness 1 0 mm Front Brake Disc Minimum Thickness 4 0mm Front Brake Disc Maximum Run Out 0 25mm Rear Brake Pad Minimum Thickness 1 5 mm Rear Brake Disc Minimum Thickness 5mm Service Manual Scrambler 1200 XC 78 of 640 ...

Page 79: ...2 56 in Drive Chain Lubrication Chain spray suitable for X ring chains Bank Angle Indicator Service Limit 15mm 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 to Airbox 1 5 Nm Spark Plugs 12 Nm Camshaft Cover 14 Nm See Camshaft Cover Installation for tightening sequence Service Manual Scrambler 1200 XC 79 of 6...

Page 80: ...ke Master Cylinder Bleed Screw 14 Nm Front Brake Hose to Caliper 25 Nm Front Brake Hose to Master Cylinder 25 Nm Front Brake Caliper 55 Nm Front Brake Caliper Bleed Screw 8 Nm Rear Brake Master Cylinder Reservoir 3 Nm Rear Brake Hose to Master Cylinder 25 Nm Rear Brake Master Cylinder to Control Plate 18 Nm Rear Brake Caliper Bleed 6 Nm Service Manual Scrambler 1200 XC 80 of 640 ...

Page 81: ...uid leaks Visually inspect the oil hoses 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 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 I...

Page 82: ... 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 Start the engine and run at idle for approximately five minutes 1 Stop the engine then wait for at least three minutes to allow the o...

Page 83: ...d adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle 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 can cause cancer Wear suitable clothing and avoid skin contact The engine oil and filter must...

Page 84: ...mentally friendly way 7 Apply a smear of clean engine oil to the sealing ring of the new oil filter 8 Using T3880313 Oil Filter Wrench fit the new oil filter and tighten to 10 Nm 9 Fit a new sealing washer to the drain plug 10 Fit and tighten the drain plug to 25 Nm 11 Using a suitable funnel fill the engine with new semi or fully synthetic 10W 40 or 10W 50 motorcycle engine oil which meets specif...

Page 85: ...ly and investigate the cause Running the engine with low oil pressure will cause engine damage Ensure that the oil pressure warning light extinguishes shortly after starting 16 Stop the engine and check the oil level Adjust if necessary 17 Air Filter Element Renew WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and ca...

Page 86: ...and detach the relay bracket from the left hand side of the airbox 2 L0916a 2 1 1 Fixings 1 Relay bracket 2 Release the four fixings securing the air filter cassette to the airbox and remove the air filter cassette 3 1 1 2 Service Manual Scrambler 1200 XC 86 of 640 ...

Page 87: ...from the air filter 5 L0750 2 1 Cassette 1 Air filter element 2 Installation Clean the air filter cassette and the interior of the airbox 1 Locate the new air filter element into the air filter cassette as noted for removal 2 Fit the air filter and cassette assembly to the airbox and tighten its fixings to 1 Nm 3 Attach the relay bracket to the airbox and tighten its fixings to 1 5 Nm 4 1 Service ...

Page 88: ... and the keyless electronic control module ECM multiplug to the relay braket 5 L0916 2 1 Main fuse 1 Keyless ECM multiplug 2 Perform the following operations Refit the left hand Side Panels Fuel Filter Renew Removal Service Manual Scrambler 1200 XC 88 of 640 ...

Page 89: ...andling of fuel and fuel containers A fire causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly Perform the following operations Fuel Pump Assembly Removal Release the two fuel hose clips from either side of the fuel filter 1 Remove the hose bracket from the fuel pump bracket 2 civv 2 1 Hose clips 1 Hose bracket 2 Carefully detach th...

Page 90: ...lip 2 Remove the fuel pump securing bolt and strap 4 civx 1 2 Strap 1 Bolt 2 Disconnect the fuel pump hose from the fuel filter inlet 5 Remove and discard the two fuel filter cable ties 6 1 Service Manual Scrambler 1200 XC 90 of 640 ...

Page 91: ...fraying and other damage Replace as necessary 1 Check all hose clamps for cracks and signs of distortion Replace as necessary 2 Check the mesh filter for damage and replace the fuel pump if necessary 3 Installation Install the fuel filter to the outlet hose ensuring the arrow on the filter points away from the pump Secure the hose with the hose clip 1 Check and ensure that the feet of the rubber i...

Page 92: ...is will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Throttle Body and Inlet Manifold Assembly Removal 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 1 Check for any signs of damage and ensure the butte...

Page 93: ...e 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 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 ...

Page 94: ...ap seal for wear and or damage Replace as necessary 3 Check for signs of abnormal discolouration or deposits see Spark Plugs Inspection 4 Check and if necessary adjust the spark plug gap to 0 9 mm 0 0 0 1 mm 5 Refit the spark plugs or if required fit new spark plugs and tighten to 12 Nm 6 ckhy 2 3 1 Spark plug cap 1 Spark plug 2 Service Manual Scrambler 1200 XC 94 of 640 ...

Page 95: ...g 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 ...

Page 96: ...nd 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 Service Manual Scrambler 1200 XC 96 of 640 ...

Page 97: ...the insulator tip melt and give the 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 Service Manual Scrambler 1200 XC 97 of 640 ...

Page 98: ...g 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 Service Manual Scrambler 1200 XC 98 of 640 ...

Page 99: ...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 Service Manual Scrambler 1200 XC 99 of 640 ...

Page 100: ... of the leak and rectify as necessary Loss of coolant may cause the engine to overheat and suffer severe damage Note Only inspect the coolant level when the engine is cold The coolant level within the expansion tank can be inspected without removing any covers The expansion tank can be viewed from the left hand side of the motorcycle at the front of the engine Position the motorcycle on level grou...

Page 101: ...sing injury to the operator or damage to the motorcycle 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 Allow the engine to cool for a minimum of 30 minutes 1 Remove the sump guard see Sump Guard R...

Page 102: ...orcycle 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 Allow the engine to cool for a minimum of 30 minutes 1 Drain the coolant see Coolant Replacement Drainage Refill the coolant with Triumph HD4...

Page 103: ...mshaft lobe is positioned pointing directly away from the roller on the rocker shaft 2 Using feeler gauges measure and record the clearances for this pair of valves only 3 1 Feeler gauges 1 Measure and record all valve clearances as described previously 4 Release the two rocker shaft retaining bolts and remove the rocker shaft and rocker arm of a valve that requires adjustment 5 3 3 1 2 Service Ma...

Page 104: ... the valve Remove the shim from the valve s that requires adjustment 6 cizw_1 2 40 2 1 1 Shim 1 Valve 2 Measure the original shim using a micrometer 7 Calculate the shim thickness required to give the correct clearance for specifications refer toService Specifications 8 Clearance too small Fit a thinner shim Clearance too large Fit a thicker shim Service Manual Scrambler 1200 XC 104 of 640 ...

Page 105: ...rrectly set 11 Rotate the engine several times to fully seat the shims 12 Repeat the clearance checks on all valves adjust as necessary 13 Perform the following operations Camshaft Cover Installation Fuel Tank Installation Battery Installation Seat Installation Clutch Cable Check adjust WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent...

Page 106: ...er 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 Tyres Check For Wear Damage WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from ...

Page 107: ...ators 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 1 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 w...

Page 108: ...efore 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 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 Remove the caps from the tyre valves 1 Position the ty...

Page 109: ...g and causing injury to the operator or damage to the motorcycle Perform the following operations Position the motorcycle on level ground and place on a paddock stand Hold the wheel at the top and bottom and rock the wheel checking for movement when a force is applied 1 Check the wheel bearings spin smoothly with no signs of play 2 If the bearings do not spin smoothly or there is excessive play in...

Page 110: ...ure 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 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 1 Fork Inspection WARNING Before...

Page 111: ...ith defective or damaged suspension can cause loss of motorcycle control and an accident Never ride with damaged or defective suspension Headstock Bearings Check Adjust WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Adjust...

Page 112: ...hen tighten the lock nut to 40 Nm cjbu 1 2 3 4 5 T3880023 50 mm Socket 1 Lock nut 2 Tab washer 3 Adjuster nut 4 Dust seal 5 Perform the following operations Refit the upper yoke see Upper Yoke Installation Headstock Bearings Lubricate WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator S...

Page 113: ... Rotate the ball bearing to ensure that the grease is distributed over the entire circumference of the internal parts 3 Any excess grease should be smeared on the outside of the rollers 4 ckid 3 1 2 Roller bearing 1 Inner carrier face 2 Outer carrier face 3 Headstock Bearing Inspection WARNING Only remove raised witness marks from within the frame Removal of material below any raised areas will re...

Page 114: ...jury to the operator or damage to the motorcycle 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 2 Brake pads 1 Minimum thickness line 2 WARNING Do not replace indivi...

Page 115: ...t from falling and causing injury to the operator or damage to the motorcycle In accordance with the Scheduled Maintenance chart inspect the brake fluid level in the front and rear master cylinder reservoirs Front Brake Fluid Reservoir The brake fluid level must be kept between the upper and lower level lines with the motorcycle on its side stand and the steering on full left lock 1 3 4 jajc_2 1 2...

Page 116: ...e cap and the reservoir body 4 Refit the two fixings and tighten to 0 7 Nm 5 Rear Brake Fluid Reservoir The reservoir fluid level lines are visible on the right hand side of the motorcycle on the front sprocket cover 1 The brake fluid level must be kept between the upper and lower level lines reservoir held horizontal 2 ckhe_1 1 2 Upper level line 1 Lower level line 2 Rear Brake Fluid Level Adjust...

Page 117: ...over also secures the brake fluid reservoir to the sprocket cover Release the fixing and remove the front sprocket middle cover Discard the fixing 2 ckhd 1 2 Fixings 1 Sprocket middle cover 2 Detach the brake fluid reservoir from the sprocket cover 3 1 Service Manual Scrambler 1200 XC 117 of 640 ...

Page 118: ...the sprocket middle cover and tighten the new fixing to 3 Nm 8 Refit the sprocket outer cover and tighten the fixings to 9 Nm 9 Brake Calipers Inspection WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle WARNING Always renew caliper seals and pistons after r...

Page 119: ...y to the operator or damage to the motorcycle Inspect both the front and rear master cylinders for fluid leaks Rectify as necessary Final Drive Chain Adjustment 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 Drive Chain Free Movement Inspection 1 Maximum ...

Page 120: ...nd right hand chain adjuster bolts 2 citw_5 3 1 2 Adjuster bolt 1 Adjuster bolt lock nut 2 Rear wheel spindle nut 3 Moving both adjusters by an equal amount turn the adjuster bolts clockwise to increase chain free movement and anticlockwise to reduce chain free movement 3 When the correct amount of chain free movement has been set push the wheel into firm contact with the adjusters 4 CAUTION Check...

Page 121: ...d This will help prevent it from falling and causing injury to the operator or damage to the motorcycle 10 20 KG 2 1 Measurement across 20 links 1 10 20 kg Weight 2 Stretch the chain taut by hanging a 10 20 kg 20 40 lb weight on the drive chain 1 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 vari...

Page 122: ...ears 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 app...

Page 123: ...e Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Raise and support the motorcycle 1 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 With the s...

Page 124: ...r corrosion or damage and replace if required Installation Prior to fitting the side stand ensure the pivot pin and the bushes in the side stand are clean and free from grease 1 Fit the side stand to the motorcycle and insert the pivot pin 2 Fit a new E clip to secure the pivot pin 3 1 3 2 Service Manual Scrambler 1200 XC 124 of 640 ...

Page 125: ...y in the retracted position 5 Rear Brake Pedal Grip Lubricate WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle 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...

Page 126: ...l surplus lubricant off the rear brake pedal and grip assembly 5 Bank Angle Indicators Inspect the bank angle indicators on the rider s footrests for wear 1 The bank angle indicators have a wear indicator groove Replace a bank angle indicator if it has worn down to the groove 2 2 1 Service Manual Scrambler 1200 XC 126 of 640 ...

Page 127: ...any 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 Latest Calibrations Check 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 Check f...

Page 128: ...njuries 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 th...

Page 129: ... 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 m...

Page 130: ...erate 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 c...

Page 131: ...Tool See the Triumph Diagnostic Tool User Guide for more information Stamp and date the relevant section of the Service Record 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 compo...

Page 132: ...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 ...

Page 133: ... 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 Engine Covers Exploded Vie...

Page 134: ...Exploded View Clutch Cover Service Manual Scrambler 1200 XC 134 of 640 ...

Page 135: ...Exploded View Alternator Cover Service Manual Scrambler 1200 XC 135 of 640 ...

Page 136: ...Exploded View Sprocket Cover Exploded View Camshaft Cover Service Manual Scrambler 1200 XC 136 of 640 ...

Page 137: ...ury to the operator or damage to the motorcycle 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 Perform the following operations Service Manual Scrambler 1200 XC 137 of 640 ...

Page 138: ...sed engine oil contains potentially harmful contaminants which can cause cancer Wear suitable clothing and avoid skin contact Drain the engine oil and remove the oil filter see Engine Oil and Filter Renew 1 Remove the sump to lower crankcase fixings 2 L0152 1 2 2 2 2 2 2 Sump 1 Fixings 2 Release the sump from the lower crankcase 3 Note The water pump drain tube may remain attached to the water pum...

Page 139: ...move and clean if found to be blocked or restricted 1 Sump Installation Lubricate the four new O rings with a commercially available soft petroleum jelly and fit two each end of the drain tube 1 Position the water pump drain tube to the oil pump 2 cjaq_1 2 1 Water pump drain tube 1 O rings 2 Incorporating a new sump gasket baffle position the sump to the lower crankcase 3 Tighten the sump fixings ...

Page 140: ...in smear of clean engine oil to the sealing ring of the new oil filter Fit the oil filter using T3880313 Oil Filter Wrench and tighten to 10 Nm 7 L0151 1 2 Oil filter 1 Oil drain plug 2 Perform the following operations Cradle Assemblies Installation Fuel Tank Installation Battery Installation Service Manual Scrambler 1200 XC 140 of 640 ...

Page 141: ...e with low oil pressure will cause engine damage 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 Clutch Cover Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling an...

Page 142: ...crankcases Note the position of the encapsulated fixings and discard 3 ciup 2 2 2 2 1 1 1 1 2 2 2 2 3 3 2 Fixings M6 x 50 mm 1 Fixings M6 x 40 mm 2 Encapsulated fixings M6 x 35 mm 3 Place an oil catch tray beneath the clutch cover to collect any oil that may spill out on removal 4 Carefully withdraw the cover 5 Remove the gasket and clean the surfaces of the crankcase and the clutch cover 6 Servic...

Page 143: ...te The sound suppression assembly has been removed from the clutch cover from VIN 803544 The clutch cover without the sound suppression assembly is retrofittable to models from the start of production If you install a new clutch cover to an engine before VIN 803544 do not try to install the sound suppression assembly CAUTION Do not drill or tap the latest condition clutch cover to fit the sound su...

Page 144: ... piece claw engages correctly with the pull rod during assembly It may be necessary to rotate the lifter piece rack to allow assembly to take place Fixings 4 and 10 are encapsulated and must be replaced during fitment Refit the two brackets for the clutch cable and fixings as noted during removal tighten the fixings as described below 5 Tighten fixings 1 to 13 in the sequence shown below to 10 Nm ...

Page 145: ...the actuator arm to the spline Fit the fixing and tighten to 8 Nm 2 4 3 1 L0710 Gear change actuator arm 1 Fixing 2 Actuator arm alignment mark 3 Gear change actuator arm split line 4 Refit and adjust the clutch cable see Clutch Cable Installation Perform the following operations Battery Installation Seat Installation Service Manual Scrambler 1200 XC 145 of 640 ...

Page 146: ...nkshaft position sensor share the same harness Note that the white tape on the harnesses within the harness guide aligns with the upper gap for installation Note the routing of the alternator harness for installation Perform the following operations Seat Removal Battery Removal Front Sprocket Cover Removal Rear Mudguard Removal Route the alternator harness from the alternator regulator rectifier t...

Page 147: ...arness guide 3 civh 2 1 Harness guide 1 Harness 2 Place an oil catch tray beneath the alternator cover to collect any oil that may spill out on removal 4 Release the fixings securing the alternator cover to the crankcases 5 ciuo 2 7 10 3 1 5 8 4 9 6 Service Manual Scrambler 1200 XC 147 of 640 ...

Page 148: ...The rotor magnets are very strong When handling the alternator cover the magnets may grab the stator causing injury to the hands or fingers When handling the alternator cover wear suitable gloves and only grip the alternator cover by the outside surfaces always keep hands and fingers clear when handling the alternator cover Thoroughly clean the crankcase harness grommet and alternator cover mating...

Page 149: ... each other within five minutes of application Apply a 2 mm 0 5 mm bead of silicone sealant to the outer surface of the gasket in the area shown in the diagram below during manufacture ThreeBond 1216E is used 4 ckjh 1 2 Sealant area 1 Gasket 2 Apply a 2 mm 0 5 mm bead of silicone sealant to the area of the alternator 5 Service Manual Scrambler 1200 XC 149 of 640 ...

Page 150: ...cture ThreeBond 1216E is used ckjc 2 3 1 Sealant area 1 Alternator cover 2 Rubber grommet harness removed for clarity 3 Fit the alternator cover and tighten the fixings to 10 Nm in the sequence shown below 6 ciuo 2 7 10 3 1 5 8 4 9 6 Tightening Sequence Service Manual Scrambler 1200 XC 150 of 640 ...

Page 151: ...e and tighten the new fixings to 4 Nm 10 L0706 2 1 3 4 Fixings 1 Harness guide 2 Upper gap 3 White tape 4 Perform the following operations Rear Mudguard Installation Front Sprocket Cover Installation Battery Installation Seat Installation Camshaft Cover Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causi...

Page 152: ...Discard the camshaft cover gasket and rubber seals 5 Remove any residual oil from the mating face of the cylinder head using a lint free cloth 6 Camshaft Cover Installation Fit a new camshaft cover seal to the camshaft cover Ensure the groove in the gasket is correctly seated to the camshaft cover 1 Position the camshaft cover to the cylinder head Ensure that the gasket remains in position 2 Lubri...

Page 153: ...e operator or damage to the motorcycle WARNING Rotating the rear wheel will cause the drive chain to rotate on the sprockets To prevent injury never place loose clothing fingers or hands near the drive chain or sprockets Loose clothing fingers or the hands could become trapped as the drive chain rotates on the sprockets causing a crushing injury to the fingers hands or other parts of the anatomy P...

Page 154: ...elease the fixing and remove the front sprocket middle cover Discard the fixing 2 ckhd 1 2 Fixings 1 Sprocket middle cover 2 CAUTION To prevent paint damage do not spill brake fluid onto any area of the bodywork Spilled brake fluid will damage paintwork Detach the brake fluid reservoir from the sprocket cover 3 1 Service Manual Scrambler 1200 XC 154 of 640 ...

Page 155: ...er 2 Secure the rear brake fluid reservoir in an upright position 4 Release the fixings and remove the sprocket cover 5 ckhn_1 1 1 1 2 Fixings 1 Sprocket cover 2 Front Sprocket Cover Inspection WARNING Service Manual Scrambler 1200 XC 155 of 640 ...

Page 156: ...uately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle WARNING Rotating the rear wheel will cause the drive chain to rotate on the sprockets To prevent injury never place loose clothing fingers or hands near the drive chain or sprockets Loose clothing fingers or the hands could become trapped as the drive chain rotates on the sprocket...

Page 157: ...r 2 Attach the brake fluid reservoir to the sprocket cover 4 ckhn 2 1 Brake fluid reservoir 1 Sprocket cover 2 Refit the sprocket middle cover and tighten the new fixing to 3 Nm 5 ckhd 1 2 Service Manual Scrambler 1200 XC 157 of 640 ...

Page 158: ...ter cover and tighten the fixings to 9 Nm 6 ckhe 1 2 Fixings 1 Sprocket outer cover 2 Perform the following operations Battery Installation Seat Installation Cylinder Head Exploded View Camshaft and Camshaft Drive Service Manual Scrambler 1200 XC 158 of 640 ...

Page 159: ...Exploded View Cylinder Head Service Manual Scrambler 1200 XC 159 of 640 ...

Page 160: ...s set to open between 12 16 bar The chain is guided by two nylon tensioner blades The rubbing blade is located in the cylinder barrel by lugs on the blade The cylinder head must be removed to remove this blade The tensioner blade is secured to the cylinder head by two bolts at its upper end and its lower end rests on the tensioner plunger Camshaft valve valve shim and valve seat wear affect the va...

Page 161: ... Ignition Coils Removal Camshaft Cover Removal Alternator Cover Removal Rotate the engine until the T3880601 Camshaft Timing Pin can be inserted through the hole in the alternator rotor crankcase and into the idler gear 1 civb 1 2 T3880601 Camshaft Timing Pin 1 Timing hole in alternator rotor 2 In addition to the alignment mark at TDC the offset slot on the camshaft will align with the upper surfa...

Page 162: ...drive chain in position during removal of the tensioner 3 cjag 1 2 Camshaft drive chain tensioner blade 1 Tension hand held 2 WARNING The hydraulic tensioner is under spring tension Always wear hand eye and face protection when withdrawing the tensioner Take great care to minimise the risk of injury and loss of components Service Manual Scrambler 1200 XC 162 of 640 ...

Page 163: ...r for wear and damage Renew as necessary 2 Camshaft Drive Chain Tensioner Installation WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Ensure that the camshaft drive chain tensioner blade is in contact with the camshaft drive chain 1 Check that the camshaf...

Page 164: ...tchet WARNING The plunger of the camshaft drive chain tensioner is under spring tension Always wear hand eye and facial protection when removing the tensioner as unprotected areas of the body can be injured if the spring tension is released in an unexpected or uncontrolled way Hold the resister ring ends together and pull out the plunger 4 1 2 cfei_2 Resister ring ends 1 Plunger 2 Remove the sprin...

Page 165: ...rectly located as shown below 7 1 cfho Resister ring 1 Refit the spring 8 Support the tensioner in a soft jawed vice 9 Hold the resister ends together close the vice allowing the plunger to be pushed through the resister ring until the snap ring aligns with the snap ring groove 10 1 2 3 Service Manual Scrambler 1200 XC 165 of 640 ...

Page 166: ...it the tensioner to the cylinder head as noted for removal Using T3880649 Timing Chain Tensioner Socket tighten the tensioner to 16 Nm 13 Release pressure to the camshaft drive chain tensioner blade taking care not to move the tensioner blade 14 Remove T3880601 Camshaft Timing Pin 15 To release the plunger from the snap ring holding the hydraulic tensioner rotate the crankshaft anticlockwise until...

Page 167: ...t the tensioner plunger This could take up to 5 seconds Check that the tensioner plunger is correctly located in the middle of the camshaft drive chain tensioner blade when viewed from above 19 Rotate the engine through 4 full revolutions and reset number 1 cylinder to TDC Ensure that the T3880601 Camshaft Timing Pin aligns with the hole in the crankcase and the crankshaft 20 civb 1 2 T3880601 Cam...

Page 168: ...ation Camshaft Drive Chain Rubbing Blade Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Note The camshaft drive chain rubbing blade can only be removed after the cylinder head has been removed The camshaft drive chain tensioner blade can be remove...

Page 169: ...ft drive chain rubbing blade upper mounting for installation Lift the camshaft drive chain tensioner rubbing blade out of the crankcase 3 2 1 cftg Camshaft drive chain tensioner rubbing blade 1 Mounting lugs 2 Camshaft Drive Chain Rubbing Blade Installation Refit the camshaft drive chain rubbing blade Ensure the lower mounting tip is correctly located in the upper crankcase and the lugs are locate...

Page 170: ...NG Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Engine Removal WARNING The rotor magnets are very strong When handling the alternator cover the magnets may grab the stator causing i...

Page 171: ... chain camshaft or camshaft driven gears Severe engine damage will result if impact is applied to machined parts Note To ensure the camshaft drive chain can be refitted in the same orientation use a suitable marker pen to permanently mark one of the outer plates of the camshaft drive chain prior to removing the camshafts Note the side of which the marked outer plate is facing for installation Secu...

Page 172: ...Gear Timing Pin 3 Remove and discard the fixing from the idler gear shaft 6 cjac 1 Fixing 1 Withdraw the idler gear shaft and collect the idler gear and camshaft drive chain from the upper crankcase 7 cizl 1 3 2 Idler gear shaft 1 Service Manual Scrambler 1200 XC 172 of 640 ...

Page 173: ...g excessive heat build up 1 Examine all of the pins for signs of rotation 2 Check for cracking or deep scratching of the drive chain plates 3 Check for severe wear of the inner plates as indicated in the diagram below 4 ccrv For a more thorough check proceed as follows Remove the drive chain from the engine 1 Suspend the drive chain from a pin or hook with a 13 kg weight attached at the lower end ...

Page 174: ...longer than 147 50 mm Measurements beyond 147 50 mm indicate that the drive chain must be replaced 3 cajt 1 2 3 4 22 23 Check for severe wear of the inner surface of the outer plates at the side contact points with the sprocket teeth 4 ccru Check for signs of stiffness or kinking 5 Service Manual Scrambler 1200 XC 174 of 640 ...

Page 175: ...7 Camshaft Drive Chain and Idler Gear Installation Preload the backlash gear using T3880041 Idler Gear Timing Wrench and locking plate T3880016 Balancer Gear C Spanner 2 as shown below 1 cizm 2 1 3 Idler gear 1 Locking plate part of T3880016 Balancer Gear C Spanner 2 T3880041 Idler Gear Timing Wrench 3 Service Manual Scrambler 1200 XC 175 of 640 ...

Page 176: ...plate on the camshaft drive chain is facing the same direction as noted for removal 3 cizl 1 3 2 Idler gear shaft 1 Idler gear 2 Camshaft drive chain 3 Install T3880039 Idler Gear Timing Pin through the hole in the crankcase alternator side and through the smaller hole in the idler gear as shown below 4 cjac 2 3 3 1 Service Manual Scrambler 1200 XC 176 of 640 ...

Page 177: ... Refit the camshafts see Camshaft Installation 8 Recheck the tensioner plunger location against the camshaft drive chain tensioner blade 9 Remove T3880601 Camshaft Timing Pin from the crankcase 10 Remove T3880039 Idler Gear Timing Pin from the idler gear 11 Perform the following operations Camshaft Cover Installation Alternator Cover Installation Engine Installation Fuel Tank Installation Battery ...

Page 178: ...perator or damage to the motorcycle Note The camshaft can be removed from the cylinder head without complete removal of the camshaft drive chain However the camshaft drive chain must first be detached from the camshaft Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Ignition Coils Removal Camshaft Cover Removal Alternator Cover Removal Rotate the engine until T38806...

Page 179: ...ate into the camshaft slot Ensure that the tool is centrally located on the cylinder head and secure as shown below 3 cizt 1 2 3 3 T3880650 Camshaft Timing Plate 1 Camshaft slot 2 Fixings 6 x 12 mm 3 Remove the camshaft drive chain tensioner see Camshaft Drive Chain Tensioner Removal 4 CAUTION To avoid damage to the camshaft frames always ensure as many camshaft lobes as possible are facing downwa...

Page 180: ... item It can only be obtained as part of a new cylinder head Once all of the upward force on the camshaft frames has been released collect the bolts 6 CAUTION The camshaft frames are located to the cylinder head with dowels When removing the camshaft frames collect the dowels at the same time Failure to collect the dowels could cause them to fall into the crankcase and may cause serious damage to ...

Page 181: ...guide 1 Bearing journal 2 Camshaft 3 Detach the camshaft drive chain from the camshaft 10 Slide the camshaft to the right and remove it from the cylinder head 11 cjak 1 2 3 Camshaft 1 Camshaft drive chain 2 Service Manual Scrambler 1200 XC 181 of 640 ...

Page 182: ...ing 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 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 fixing holes This allows for very accu...

Page 183: ...cated within the slotted holes of the sprocket DO NOT tighten the fixings at this stage the sprocket must be free to rotate If removed refit the camshaft sprocket noting its orientation and secure using the original fixings 3 Locate the camshaft to the cylinder head from the right hand side hooking the camshaft drive chain over the sprocket 4 Align the slot in the camshaft end to the upper surface...

Page 184: ...cizs 1 2 3 Camshaft slot 1 Cylinder head 2 Camshaft ladder cylinder two 3 Adjust the camshaft sprocket so that the camshaft chain is taut on the inlet side rear of the engine 8 Ensure there is no slack in the chain between the crankshaft and the sprocket and the sprocket fixings are centrally located within the slotted holes 9 1 2 Service Manual Scrambler 1200 XC 184 of 640 ...

Page 185: ...iming Plate into the camshaft slot Ensure that the tool is centrally located on the cylinder head and secure as shown below 10 cizt 1 2 3 3 T3880650 Camshaft Timing Plate 1 Camshaft 2 Fixings 6 x 12 mm 3 Check that the camshaft drive chain is engaged around the idler gear and the camshaft sprocket is positioned against the tensioner blade 11 Fit the T3880651 Timing Chain Tensioner and tighten to 1...

Page 186: ...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 Note The T3880609 Timing Torque Limiter is pre set to 0 6 Nm Using the T3880609 Timing Torque Limiter tighten the internal screw thread to 0 6 Nm 13 cizu 3 2 1 T3880651 Timing Chain Tensioner 1 Adaptor...

Page 187: ...ing and tighten to 22 Nm 18 Remove T3880601 Camshaft Timing Pin 19 Note With the aid of an assistant hold the camshaft drive chain taut during removal of the T3880651 Timing Chain Tensioner Release the tension on the T3880651 Timing Chain Tensioner 20 Refit the timing chain tensioner incorporating two new O rings see Camshaft Drive Chain Tensioner Installation 21 To activate the tensioner rotate t...

Page 188: ...lot to check that the camshaft timing has not moved during the removal of the T3880651 Timing Chain Tensioner 24 Lubricate the camshaft bearing areas of the camshaft frame with a 50 50 solution of engine oil and molybdenum disulphide grease 25 Fit the shims to the valves as noted during removal 26 Position cylinder one camshaft frame to the cylinder head 27 cizw 2 4 3 1 6 5 Camshaft ladder cylinde...

Page 189: ...t fully tighten at this stage 32 Finger tighten the fixings until the under head areas are in contact with the camshaft frame 33 cjab 3 1 2 Fixings inlet rocker shaft 1 Fixings exhaust rocker shaft 2 Dot mark 3 Remove the fixing and rocker shaft from cylinder number two camshaft frame 34 Lubricate the threads of the camshaft frame fixings with clean engine oil 35 Note The rocker shaft must be fitt...

Page 190: ...as many camshaft lobes as possible are facing away from the rocker shaft This will reduce stress on the camshaft frame during assembly Damage to the camshaft frame will result in replacement of the cylinder head In the sequence shown below 38 Tighten cylinder one camshaft frame fixings to 5 Nm Tighten cylinder one camshaft frame fixings to 12 Nm 1 3 Service Manual Scrambler 1200 XC 190 of 640 ...

Page 191: ...be checked and adjusted Running with incorrectly adjusted valve clearances may cause excess engine noise rough running and engine damage Check all of the valve clearances and adjust as necessary until the correct clearances are achieved see Valve Clearance Adjustment 39 Perform the following operations Alternator Cover Installation Camshaft Cover Installation Ignition Coils Installation Fuel Tank ...

Page 192: ...ting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Note Valve clearance checking and adjustment must be carried out with the engine cold Remove the camshaft cover see Camshaft Cover Removal 1 Note R...

Page 193: ...nd remove the rocker shaft and rocker arm of a valve that requires adjustment 6 cJaa_1 3 3 1 2 4 Rocker shaft 1 Rocker arm 2 Shims cylinder 1 inlet shown 3 Camshaft 4 Note The underside of the shim displays the shim size Always place the shim with the shim size facing towards the valve Service Manual Scrambler 1200 XC 193 of 640 ...

Page 194: ...clearance for specifications refer toCylinder Head and Valves 9 Clearance too small Fit a thinner shim Clearance too large Fit a thicker shim Note Shims are available ranging from 2 00 mm to 3 20 mm in increments of 0 025 mm Fit the selected shim to the valve 10 Refit the rocker arm and shaft tighten the bolts in the sequence shown below to 10 Nm 11 2 1 Service Manual Scrambler 1200 XC 194 of 640 ...

Page 195: ...t Installation Cylinder Head Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Engine Removal Camshaft Cover Removal Camshaft Removal Noting their position and the thickn...

Page 196: ...aced mallet to break the gasket seal Remove the cylinder head from the crankcase 4 Remove and discard the cylinder head gasket 5 Note Note the position of the camshaft drive chain rubbing blade upper mounting for installation Lift the camshaft drive chain tensioner rubbing blade out of the crankcase 6 2 1 cftg Camshaft drive chain tensioner rubbing blade 1 Service Manual Scrambler 1200 XC 196 of 6...

Page 197: ...arrel Clamps 2 Cylinder Head Inspection Thoroughly clean the surface of the cylinder head and check for damage and or pitting of the combustion chambers 1 Using a straight edge and feeler gauges check the cylinder head face for warp which could lead to gasket failure Replace the cylinder head if warped beyond the flatness limit 2 2 1 Service Manual Scrambler 1200 XC 197 of 640 ...

Page 198: ...aged 7 CAUTION Ensure all traces of fluid coolant oil etc are removed from the threaded holes in the crankcase Should any fluid remain in any of the threaded holes severe crankcase damage could result from hydraulic locking of head bolts on assembly of the engine Cylinder Head Installation Thoroughly clean the upper faces of the cylinder barrel 1 Refit the camshaft drive chain rubbing blade Ensure...

Page 199: ... cylinder head over the camshaft drive chain rubbing blade and locate it onto the dowels 5 Position the washers onto the new cylinder head bolts and lubricate the bolt threads with clean engine oil 6 CAUTION Use the correct procedure to tighten the cylinder head bolts carefully following the four stage procedure below This will ensure the long term reliability of the cylinder head gasket Failure t...

Page 200: ...grease and engine oil then refit them to their original locations in the cylinder head 8 Perform the following operations Camshaft Installation Valve Clearance Adjustment Camshaft Cover Installation Engine Installation Fuel Tank Installation Battery Installation Seat Installation Start the engine and allow it to idle while checking for air oil coolant and exhaust leaks Rectify as necessary Valves ...

Page 201: ...ow removal of the valve collets Valve removal Once the collets are released remove the following items 2 Valve spring retainer Valve spring Valve spring base Valve stem oil seal Valve deburr before removal 1 carr Service Manual Scrambler 1200 XC 201 of 640 ...

Page 202: ...nto the valve guide and refit the spring base to the valve spring recess in the head 2 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 3 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 th...

Page 203: ...e spring ensuring that the spring is compressed squarely to prevent damage to the valve stem and cylinder head 3 Fit the valve collets ensuring correct collet location in the spring retainer and valve as the spring compressor is released 4 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 engin...

Page 204: ...e is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Service Manual Scrambler 1200 XC 204 of 640 ...

Page 205: ...e gasket joint 2 CAUTION Do not strike or lever against the barrel cooling fins to break the seal as the fins are easily damaged Note Secure the camshaft drive chain to ensure that it does not fall into the crankcase during removal of the barrels CAUTION Support the pistons as the barrels are removed to prevent piston damage Lift off the barrels and recover the locating dowels 3 ciyg 1 Locating do...

Page 206: ...t preventing contact with the crankcase rotate the crankshaft to position the pistons level with each other 3 ciyu 1 2 3 150mm 10mm 25mm 150mm 10mm 25mm Pistons 1 Spacer 2 Crankcase 3 CAUTION Do not allow the pistons to fall against the crankcase when turning the engine Piston and or crankcase damage could occur if the pistons are not supported while turning the engine Ensure the piston ring end g...

Page 207: ...cated into their grooves before continuing The use of force may result in piston ring breakage With the aid of an assistant ease the barrels carefully over the pistons whilst guiding the piston rings into the base of the cylinder bores 6 ciyv 2 1 1 3 Piston 1 Barrel 2 Spacer 3 Slide the barrels fully down remove the spacers and locate on the dowels 7 Refit the cylinder head see Cylinder Head Insta...

Page 208: ...ing and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Barrels Removal Note If both pistons are being removed mark each piston to ensure it is refitted in its original location Remove and discard the gudgeon pin circlip from one side of the piston 1 CAUTION If a circlip is dropped into the crankcase it must...

Page 209: ...from the piston and discard it 3 Remove the piston rings 4 Note The rings may be removed using a proprietary piston ring expander tool or if a tool is not available carefully spread the ring opening using thumb pressure then push up on the opposite side of the ring to remove it from the piston Piston Wear Check Remove any carbon build up from the piston crown Inspect the piston crown for signs of ...

Page 210: ... limit 4 Piston Installation Fit a new circlip to the inside of the piston Ensure the circlip is correctly located in the piston groove 1 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 1 Service Manual Scrambler 1200 XC 210 of 640 ...

Page 211: ...wards the front of the engine 3 Note If the original pistons are being refitted ensure they are fitted in their original locations Insert the gudgeon pin into the piston and push it fully into position 4 T908_7 1 Gudgeon Pin Secure the gudgeon pin in position with the remaining new circlip Ensure the circlip is correctly located in the piston groove 5 CAUTION Service Manual Scrambler 1200 XC 211 o...

Page 212: ... when turning the engine Piston and or crankcase damage could occur if the pistons are not supported while turning the engine Install the remaining piston 6 Perform the following operations Barrels Installation Fuel Tank Installation Battery Installation Seat Installation Piston Ring to Groove Clearance Note Prior to removing the rings check the ring to groove clearance of each compression ring Se...

Page 213: ...ains too large with new piston rings the piston must also be replaced If the gap is too small check the piston ring grooves closely for distortion replacing the piston as necessary Do not file the ring grooves Piston Rings Removal CAUTION Do not expand the piston rings any more than is necessary to allow them to be removed from the piston The rings are brittle and will break if expanded too much E...

Page 214: ...Check each piston ring end gap as follows 1 Note The piston ring end gap must be measured in the cylinder bore to which the piston ring will be fitted to on installation Ensure all piston rings are fitted in their original locations if original rings are being reused or to the piston bore which the end gaps were checked if new rings are being installed 2 Position the piston ring into the top of th...

Page 215: ...the end gaps were checked if new rings are being fitted CAUTION Do not expand the piston rings any more than is necessary to allow them to be installed on the piston The rings are brittle and will break if expanded too much Fit the oil control ring expander to the piston then install the upper and lower control rings the oil control rings are both the same and can be fitted either way up 2 Fit the...

Page 216: ...ition the piston ring end gaps as follows piston viewed from above triangular mark facing forwards 6 1 1 2 2 4 4 3 3 caqj_4 3 5 5 Piston Ring End Gap Locations Top ring 1 Second ring 2 First steel oil control ring 3 Oil control ring expander 4 Service Manual Scrambler 1200 XC 216 of 640 ...

Page 217: ...ng gap should be in the 6 o clock position The first oil control ring gap should be in the 12 o clock position The second oil control ring gap should be in the 6 o clock position The oil control ring expander gap should be in the 7 o clock position Clutch Exploded View Clutch Controls Service Manual Scrambler 1200 XC 217 of 640 ...

Page 218: ...val WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Service Manual Scrambler 1200 XC 218 of 640 ...

Page 219: ...ck nut and release the adjuster at the clutch cover end to give maximum play in the cable 1 L0705 2 1 3 Clutch cable 1 Adjuster nut 2 Lock nut 3 From the left hand side of the headstock remove the cable retaining bracket and discard its fixings 2 1 2 L0713 Service Manual Scrambler 1200 XC 219 of 640 ...

Page 220: ...cable 1 Boss 2 Detach the cable retaining guides from the frame down tube 4 Align the cable adjuster and lever bracket slots 5 Pull in the clutch lever and turn the inner cable adjuster anticlockwise through the lock nut until the cable can be detached from the lever 6 2 1 Service Manual Scrambler 1200 XC 220 of 640 ...

Page 221: ...ble for frayed strands 2 Examine the two inner cable nipples for signs of looseness and damage Replace the cable if necessary 3 Clutch Cable Installation WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Ensure the steering is set to the straight ahead posit...

Page 222: ...n equal adjustment is possible in both directions 7 Set the adjuster bracket at the clutch cover end to give a preliminary setting of 2 3 mm of free play as measured at the lever 8 Operate the clutch lever several times and recheck the amount of free play present 9 Tighten the clutch adjuster bracket lock nut at the clutch cover end to 3 Nm 10 Set the final adjustment of the cable to give 1 2 mm o...

Page 223: ...pported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Clutch Cover Removal 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 ...

Page 224: ...ng a suitable tool carefully remove the oil seal in the clutch cover without damaging the clutch cover 3 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 4 2 1 Service Manual Scrambler 1200 XC 224 of 640 ...

Page 225: ...s will help prevent it from falling and causing injury to the operator or damage to the motorcycle Press a new clutch lifter rod oil seal to the clutch cover ensure the sealing lip is facing inwards 1 Lubricate the seal lip with molybdenum disulphide grease and fit the clutch lifter arm into the clutch cover as noted for removal 2 ckfg 1 Service Manual Scrambler 1200 XC 225 of 640 ...

Page 226: ...m plate is positioned as shown in the following illustration 3 ckfi 1 Clutch lifter arm plate 1 Note The horizontal tang on the spring fits into the slot of the clutch lifter arm Fit the spring as noted for removal 4 ckfh 1 Service Manual Scrambler 1200 XC 226 of 640 ...

Page 227: ...uately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Clutch Cover Removal Note The spring seats will remain seated in the pressure plate during removal Release the three fixings remove the stopper plate springs and pressure plate 1 OU T 3 2 4 5 1 Fixings 1 Stopper plate 2 Springs 3 Spring seats 4 Ser...

Page 228: ...he each component as they are removed 3 Note The two outermost and the inner friction plate are different to the remainder and must not be fitted in any other position Refer to Friction Plate Inspection for details of clutch friction plate inspection Engage second gear and lock the inner and outer clutch drums together using T3880307 Clutch Anti rotation Jig as shown below 4 1 Service Manual Scram...

Page 229: ...ft Removing the bearing sleeve will allow the oil pump drive chain to become dislodged If the oil pump drive chain becomes dislodged the oil pump will not operate causing severe engine damage Slide the bearing sleeve forward and backwards a maximum of 10 mm to allow the needle roller bearing to become dislodged 8 Remove the needle roller bearing from the clutch outer drum 9 cixd 3 2 1 Bearing slee...

Page 230: ... plate 1 For the clutch friction plate thickness refer to Clutch and Primary Drive 2 Steel Plate Inspection Bend warp Check all plates for bend and warp as follows 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 ...

Page 231: ...ed prior to installation of new clutch plates When building a new clutch pack its height must be correct To achieve this build the new clutch pack using the following 2 x new outer friction plates 5 x new friction plates 1 x new inner friction plate 6 x steel plates 2 0 mm thick 1 x outer steel plate 2 0 mm thick Arrange the new friction and new steel plates in a stack as shown below 1 Service Man...

Page 232: ...943_1 1 Clutch pack height 1 The clutch pack height for this clutch assembly is shown in the specification table see Clutch and Primary Drive 3 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 4 Note 1 6 mm and 2 3 mm steel plates are available refer to the Parts Catalogue for part numbers Service Manual Sc...

Page 233: ...m steel plate indicated below with a new 1 6 mm steel plate 5 2 0 mm steel plate to be replaced 1 Note No more than one 2 3 mm thick steel plate is to be used in the clutch pack If the clutch pack height is too low replace the 2 0 mm steel plate indicated below with a new 2 3 mm steel plate 6 Service Manual Scrambler 1200 XC 233 of 640 ...

Page 234: ...ngaged with the oil pump drive gears Running the engine without drive to the oil pump will stop oil supply to the engine Running the engine without oil pressure will cause severe engine damage Visually check the oil pump drive chain is engaged with the drive gears 1 cixe 1 3 2 Oil pump drive sprocket 1 Oil pump drive chain 2 Pump sprocket 3 Position the clutch outer drum assembly to the input shaf...

Page 235: ... 2 Clutch outer drum sprocket drive holes 3 While holding the clutch outer drum in position and ensuring correct engagement with the oil pump drive refit the bearing 3 ciwy 3 2 1 Outer drum 1 Bearing sleeve 2 Needle roller bearing 3 Service Manual Scrambler 1200 XC 235 of 640 ...

Page 236: ...facing outwards and a new centre nut 6 cixc 6 5 4 3 2 1 Shaft 1 Thrust washer 2 Clutch inner drum 3 Flat washer 4 Belleville Washer OUT Mark 5 Centre nut 6 Using T3880307 Clutch Anti rotation Jig lock the inner and outer drums together Depress the rear brake pedal to prevent the engine rotating and tighten the centre nut to 98 Nm 7 Remove T3880307 Clutch Anti rotation Jig 8 1 Service Manual Scramb...

Page 237: ...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 11 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 fitte...

Page 238: ...noted for removal 13 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 Fit the springs and stopper plate ensure that the OUT mark on the stopper plate is facing outwards Secure with the fixings and tighten to 10 Nm 14 OU T 3 2 4 5 1 Fixings...

Page 239: ...wing operations Clutch Cover Installation Clutch Cable Installation Battery Installation Seat Installation Crankcase Crankshaft and Connecting Rods Exploded View Crankshaft and Connecting Rod Service Manual Scrambler 1200 XC 239 of 640 ...

Page 240: ...arting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Service Manual Scrambler 1200 XC 240 of 640 ...

Page 241: ...otating up to seven times Align the timing holes in the crankcase and camshaft idler gear Lock in position using T3880039 Idler Gear Timing Pin 1 ciyy 1 2 Crankcase 1 T3880039 Idler Gear Timing Pin 2 Remove the oil and water pump see Oil and Water Pump Removal 2 Release the fixing and remove the coolant drain tube discard the fixing and the O ring 3 2 1 Service Manual Scrambler 1200 XC 241 of 640 ...

Page 242: ...n tube 1 Fixing 2 Release the lower crankcase fixings noting their positions in the sequence shown below 4 ciyl 15 17 19 7 8 3 4 10 14 11 23 21 22 13 9 2 6 5 1 12 24 16 18 20 Service Manual Scrambler 1200 XC 242 of 640 ...

Page 243: ...ting to separate the crankcases Separate the lower crankcase from the upper crankcase noting the position of the three location dowels 5 ciyi 1 1 1 2 Dowels 1 Upper crankcase 2 Perform the following operations Front Balancer Shaft Removal Rear Balancer Shaft Removal Crankshaft Removal Selector Forks and Drum Removal Coolant Manifold Removal Breather Plate Removal Crankcase Assembly Service Manual ...

Page 244: ...s with clean engine oil see page Crankshaft Main Bearing Journal Checking Measuring and Bearing Selection before proceeding 4 Install and lubricate the front balancer shaft with clean engine oil see Front Balancer Shaft Installation 5 Install and lubricate the rear balancer shaft with clean engine oil see Rear Balancer Shaft Installation 6 Lubricate the crankshaft journals with clean engine oil 7 ...

Page 245: ...upport the crankcase during alignment 9 Note The rear balancer shaft will rotate one tooth when the upper and lower crankcase are joined To check that the balancer shaft is correctly timed to the crankshaft proceed as follows 10 Check that the dot mark on the rear balancer shaft gear is aligned with the tab on the crankcase as shown below 11 cjcm 1 2 Lower crankcase identification mark 1 Rear bala...

Page 246: ...follows 13 Note The crankcase fixings are tightened in stages CAUTION Failure to follow the correct tightening sequence may result in permanent crankcase damage Stage 1 All Fixings In the sequence shown below 14 Tighten all of the crankcase fixings to 10 Nm 15 17 19 7 8 3 4 10 14 11 9 2 6 5 1 12 24 16 18 20 Service Manual Scrambler 1200 XC 246 of 640 ...

Page 247: ...ge 2 In the sequence shown below 15 Loosen fixings 1 to 8 through 140 using T3880105 Torque Angle Gauge or similar to measure the torque angle ciyl 15 17 19 7 8 3 4 10 14 11 23 21 22 13 9 2 6 5 1 12 24 16 18 20 Service Manual Scrambler 1200 XC 247 of 640 ...

Page 248: ...n fixings 1 to 8 to 11 Nm ciyl 15 17 19 7 8 3 4 10 14 11 23 21 22 13 9 2 6 5 1 12 24 16 18 20 Fixings 1 to 8 Tightening Sequence In the sequence shown below 17 Tighten fixings 1 to 8 through a further 75 using T3880105 Torque Angle Gauge Service Manual Scrambler 1200 XC 248 of 640 ...

Page 249: ...e ciyl 15 17 19 7 8 3 4 10 14 11 23 21 22 13 9 2 6 5 1 12 24 16 18 20 Fixings 1 to 8 Tightening Sequence Stage 4 In the sequence shown below 18 Tighten fixings 9 to 13 to 32 Nm 15 17 19 16 18 20 Service Manual Scrambler 1200 XC 249 of 640 ...

Page 250: ...10 14 11 23 21 22 13 9 2 6 5 1 12 24 Fixings 9 to 13 Tightening Sequence Stage 5 In the sequence shown below 19 Tighten fixings 14 to 24 to 12 Nm 15 17 19 7 3 5 1 16 18 20 Service Manual Scrambler 1200 XC 250 of 640 ...

Page 251: ...to 24 Tightening Sequence Note Prior to fitting an O ring coat the surfaces with a commercially available petroleum jelly Refit the breather drain tube fit a new O ring tighten the new fixing to 9 Nm 20 ciyk 2 1 Service Manual Scrambler 1200 XC 251 of 640 ...

Page 252: ...the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Engine Removal Crankcase Disassembly Connecting Rods Removal Note Support the connecting rods during crankshaft removal to prevent damage to the rods liners and upp...

Page 253: ... idler gear timing will result in incorrect camshaft timing Rotating or attempting to start an engine with incorrectly adjusted camshaft timing will result in severe engine damage Install the crankshaft to the upper crankcase ensuring the crankshaft drive gear is correctly timed to the balancer shafts and idler gear see Front Balancer Shaft Installation 4 Align the connecting rod big ends to the c...

Page 254: ...uld also be identified using a paint marker or similar Engine Removal Clutch Removal Barrels Removal Crankcase Disassembly Remove and discard the connecting rod bolts ciyh 3 2 1 Connecting rod bolts 1 Connecting rod cap 2 Connecting rod 3 Collect the connecting rod caps 1 Collect the piston and connecting rod 2 Label the assembly to identify the cylinder from which it was removed 3 Connecting Rod ...

Page 255: ...y cause bolt breakage resulting in engine damage loss of motorcycle control and an accident WARNING 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 bolts will be stretched beyond their yield point This may cause bolt breakage resulting in engine damage loss of motorcycle control and an accid...

Page 256: ...e Plastigauge The crankshaft journal clearances are measured using Plastigauge Triumph part number 3880150 T0301 Remove the bearing cap from the journal to be checked 2 Wipe the exposed areas of the crankshaft journal and the bearing face inside the cap 3 Apply a thin smear of grease to the journal and a small quantity of silicone release agent to the bearing 4 Trim a length of the Plastigauge to ...

Page 257: ... If any journal has worn beyond the service limit the crankshaft must be replaced Due to the advanced techniques used during manufacture the crankshaft cannot be reground and no oversize bearings are available Connecting Rod Bearing Selection Note Minor differences in dimensions are compensated for by using selective bearings For further information on bearing part number to colour cross reference...

Page 258: ... 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 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 Crankshaft Main Bearing Journa...

Page 259: ... to hold the Plastigauge in position 4 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 Lubricate the threads and the face of the fixings with molybdenum disulphide grease Refit the crankcase and tighten the original fixings see Crankcase Assembly 5 Release the fixings and remov...

Page 260: ...g journal 2 Measure and record each bearing bore diameter in the crankcase bearings removed journal caps fitted and all fixings fully torqued 3 Select and install the correct bearings by matching the information found in the main bearing selection chart 4 Install the new bearings 5 Main Bearing Selection Chart Shell Colour Crankcase Bore Crankshaft Journal Diameter Running Clearance Red 46 113 to ...

Page 261: ...r running clearance Coolant Manifold Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Engine Removal WARNING The oil may be hot to the touch Contact with hot oil may cau...

Page 262: ...e the fixings and remove the coolant manifold discard the fixings and the sealing ring 2 ciyo 1 2 2 2 Coolant manifold 1 Fixings 2 Coolant Manifold Installation Fit a new sealing ring to the coolant manifold 1 cizf 1 2 3 3 Service Manual Scrambler 1200 XC 262 of 640 ...

Page 263: ...ing sequence Refit the input and output shafts 4 Perform the following operations Crankcase Assembly Engine Installation Fuel Tank Installation Battery Installation Start the engine and ensure that the low oil pressure warning light goes out shortly after starting Stop the engine and check the engine oil level Adjust if necessary see Engine Oil Level Inspection Seat Installation Breather Plate Rem...

Page 264: ... Tank Removal Engine Removal WARNING The oil may be hot to the touch Contact with hot oil may cause the skin to be scalded or burned Crankcase Disassembly Remove the breather drain tube from the crankcase discard the fixing and the O ring 1 Remove the input and output shafts 2 Remove the engine oil breather plate and baffle discard the fixings 3 ciyz 4 5 3 1 2 Oil breather plate 1 Fixings 2 Breath...

Page 265: ... Torque fixings 1 and 2 again to 9 Nm 2 Note Before you install the two O rings coat the surfaces with petroleum jelly Put a new O ring onto each end of the breather tube and install the breather drain tube into the crankcase Make sure that the tube is correctly installed in the breather plate housing 3 Install a new fixing and tighten to 9 Nm 4 4 2 1 3 Service Manual Scrambler 1200 XC 265 of 640 ...

Page 266: ...tallation Fuel Tank Installation Battery Installation Start the engine and ensure that the low oil pressure warning light goes out shortly after starting Stop the engine and check the engine oil level Adjust if necessary see Engine Oil Level Inspection Seat Installation Balancer Exploded View Balancers Service Manual Scrambler 1200 XC 266 of 640 ...

Page 267: ...cause 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 Rear Balancer Shaft Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations...

Page 268: ...ng screw 2 Remove the dead shaft clamp securing screw and washer Discard the screw retain the washer for reuse 3 ciyx 5 3 4 1 2 Dead shaft clamp 1 Locking screw 2 Securing screw 3 Washer 4 Dead shaft 5 Release the dead shaft screw and washer Discard the dead shaft screw and retain the washer 4 1 3 Service Manual Scrambler 1200 XC 268 of 640 ...

Page 269: ...card the O rings from the deadshaft 7 1 2 2 Deadshaft 1 O rings 2 Front Balancer Shaft Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Service Manual Scrambler 1200 XC 269 of 640 ...

Page 270: ...d be identified using a paint mark or similar Remove and discard the connecting rod bolts 1 ciyh 3 2 1 Connecting rod bolts 1 Connecting rod cap 2 Connecting rod 3 Remove the crankshaft 2 Remove the front balancer shaft blanking screw and discard the washer 3 cizb 2 1 Service Manual Scrambler 1200 XC 270 of 640 ...

Page 271: ...dead shaft clamp locking screw 4 Remove the dead shaft clamp securing screw and washer Discard the screw retain the washer for reuse 5 ciza 3 1 2 5 4 Dead shaft clamp 1 Locking screw 2 Securing screw 3 Washer 4 Dead shaft 5 Support the balancer shaft and noting its orientation slide the dead shaft from the crankcase 6 1 Service Manual Scrambler 1200 XC 271 of 640 ...

Page 272: ...shaft clamp 3 Remove the balancer shaft 7 Remove and discard the O rings from the deadshaft 8 1 2 2 Deadshaft 1 O rings 2 Balancer shafts Inspection Inspect all gears for chipped or missing teeth 1 Service Manual Scrambler 1200 XC 272 of 640 ...

Page 273: ...e a correct relationship the balancer shaft must be installed in a specific orientation relative to the crankshaft Check T3880039 Idler Gear Timing Pin is fully inserted into the idler gear and that the camshaft to idler gear timing is correct 1 Fit a new O ring to the grooves at each end of the deadshaft 2 1 2 2 Deadshaft 1 O rings 2 CAUTION The balancer shaft gear is designed to mesh with the cr...

Page 274: ...g its orientation slide the dead shaft through the balancer shaft and into the upper crankcase 5 cizd 2 2 1 3 Balancer 1 Dead shaft 2 Dead shaft clamp 3 Position the alignment mark on the dead shaft with the alignment mark on the crankcase 6 Note The static alignment of the balancer shaft will allow for initial starting of the engine Final adjustment must be carried out with the engine running and...

Page 275: ... shaft gear 8 Allow the balancer shaft to rotate anticlockwise until the flat surface rests against the machined surface of the crankcase as shown 9 cize 2 3 4 5 1 Balancer shaft 1 Balancer shaft F front mark 2 Balancer shaft alignment mark 3 T3880811 Front Balancer Timing Tool 4 Crankcase 5 Clean the crankshaft crankshaft bearings and big end bearings with a high 10 Service Manual Scrambler 1200 ...

Page 276: ...haft with the machined surface of the crankcase 13 cizc 4 1 2 3 Crankshaft timing mark 1 Balancer gear timing marks 2 T3880811 Front Balancer Timing Tool 3 T3880601 Camshaft Timing Pin 4 To check that the balancer shaft is correctly timed to the crankshaft proceed as follows 14 The alignment hole in the crankshaft is visible through the hole in the crankcase The alignment mark on the balancer shaf...

Page 277: ...hafts timing is incorrect the procedure must be restarted from the beginning Refit the dead shaft clamp and tighten the new securing screw to 10 Nm and then tighten the dead shaft clamp locking screw to 11 Nm 15 ciza 3 1 2 5 4 Dead shaft clamp 1 Locking screw 2 Securing screw 3 Service Manual Scrambler 1200 XC 277 of 640 ...

Page 278: ...ngine Installation Fuel Tank Installation Battery Installation Seat Installation Rear Balancer Shaft Installation Fit a new O ring to the grooves at each end of the deadshaft 1 1 2 2 Deadshaft 1 O rings 2 Lubricate the balancer shaft needle roller bearings and O rings with clean engine oil 2 Position the balancer shaft as noted during removal 3 Fit the deadshaft into the crankcase as noted during ...

Page 279: ... with the engine running and at operating temperature see Balancer Shafts Dynamic Adjustment Align the dot mark on the dead shaft with the dot mark on the crankcase 5 ciyw 1 3 2 Crankcase dot mark 1 Dead shaft dot mark 2 Dead shaft 3 Fit a new screw to the washer install the screw and washer to the dead shaft ensuring the dot marks are aligned Tighten to 12 Nm 6 Position the balancer shaft so that...

Page 280: ...ring screw 3 Washer 4 Balancer shaft 5 Lock the balancer shaft into position using T3880809 Rear Balancer Timing Tool 9 Lubricate the crankshaft and bearings with clean engine oil 10 ciyn 4 1 3 2 5 Crankcase identification mark 1 Service Manual Scrambler 1200 XC 280 of 640 ...

Page 281: ...it from falling and causing injury to the operator or damage to the motorcycle 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 touch hot oil WARNING If the engine has recently been running the exhaust components may be hot to the touch Contact with the hot components may c...

Page 282: ...rature must be at least 103 C Front Balancer Shaft Dynamic Adjustment Start the motorcycle s engine and allow to run to operating temperature 1 CAUTION The dead shaft is an eccentric shaft which runs inside the balancer shaft When rotated the dead shaft therefore closes or opens the gap between the teeth of the balancer gear and the teeth of the crankshaft gear If the gap between the balancer gear...

Page 283: ...e engine 2 Remove the embellisher from the alternator cover and discard the fixings 3 Remove the dead shaft clamp blanking plug and discard the washer 4 cizg 2 4 3 1 Service Manual Scrambler 1200 XC 283 of 640 ...

Page 284: ...ead shaft clamp locking screw 1 Blanking plug orifice 2 CAUTION When adjusting the balancer shafts do not allow the gears to whine or rattle for a prolonged period Allowing the gears to mesh incorrectly for extended periods may cause damage to the gears and or bearings Start the engine and allow to idle 6 Gently rotate the dead shaft clockwise until a whining noise can just be heard 7 1 F Service ...

Page 285: ... the dead shaft anticlockwise until the whining noise can no longer be heard 8 ciyc 1 1 F Dead shaft 1 Tighten the dead shaft clamp locking screw to 11 Nm 9 Stop the engine 10 2 1 1 2 Service Manual Scrambler 1200 XC 285 of 640 ...

Page 286: ...ten the dead shaft clamp blanking plug to 23 Nm 12 Refit the embellisher cover to the alternator cover tighten the new fixings to 4 Nm 13 cizg 2 4 3 1 Embellisher 1 Fixings 2 Dead shaft clamp blanking plug 3 Oil filler cap 4 Rear Balancer shaft Dynamic Adjustment Remove the clutch cover plug 1 1 Service Manual Scrambler 1200 XC 286 of 640 ...

Page 287: ... and discard the O ring 2 cizg 1 Oil filler cap 1 Using T3880652 Dead Shaft Key Tool loosen the dead shaft clamp locking screw a maximum of two complete turns to allow smooth rotation of the balancer dead shaft in the clamp 3 3 Service Manual Scrambler 1200 XC 287 of 640 ...

Page 288: ...or a prolonged period Allowing the gears to mesh incorrectly for extended periods may cause damage to the gears and or bearings Start the engine and allow to idle 4 Rotate the rear dead shaft clockwise until a whining noise can be heard 5 1 Dead shaft 1 Rotate the dead shaft anticlockwise until the whining noise can no longer be heard 6 Service Manual Scrambler 1200 XC 288 of 640 ...

Page 289: ...ocking screw to 11 Nm 7 Stop the engine 8 Wipe away any spilled oil from the upper crankcase 9 Using a new O ring refit the oil filler cap and tighten to 3 Nm 10 cizg 1 Oil filler cap 1 Refit the clutch cover plug and tighten to 10 Nm 11 Service Manual Scrambler 1200 XC 289 of 640 ...

Page 290: ...iwp_1 1 2 Clutch cover plug 1 Clutch cover 2 Inspect the engine oil level see Engine Oil Level Inspection 12 Transmission Exploded View Input and Output Shafts Service Manual Scrambler 1200 XC 290 of 640 ...

Page 291: ...Exploded View Gear Selector Service Manual Scrambler 1200 XC 291 of 640 ...

Page 292: ...ore starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Service Manual Scrambler 1200 XC 292 of 640 ...

Page 293: ...fixings and remove the oil pump drive chain guide from the crankcase 1 cjcb 1 2 Oil pump drive chain guide 1 Fixings 2 Withdraw the abutment dowel from the crankcase 2 cjca 1 2 Abutment dowel 1 Abutment spring 2 Service Manual Scrambler 1200 XC 293 of 640 ...

Page 294: ...e abnormal gaps between coils If any of the components are damaged or worn replace the complete assembly 1 Gear Change Shaft Installation WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Position the selector mechanism into the crankcase and locate the pivo...

Page 295: ...e abutment dowel with the spring tangs positioned to either side 2 cjca 1 2 Abutment dowel 1 Abutment spring 2 Refit the pump drive chain guide to the crankcase Tighten the new fixings to 7 Nm 3 1 2 Service Manual Scrambler 1200 XC 295 of 640 ...

Page 296: ... and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Gear Change Shaft Removal Remove the gear change shaft see Gear Change Shaft Removal Release the detent arm spring 1 Release the detent arm fixing and remove the detent arm Discard the fixing 2 2 3 1 Service Ma...

Page 297: ...eel Installation Lubricate the selector drum bearings with clean engine oil 1 Refit the detent wheel to the selector drum ensuring the pin on the drum locates in the slot in the detent wheel Prevent the drum from turning and tighten the fixing to 12 Nm 2 3 4 1 2 cfwy Selector drum 1 Detent wheel 2 Pin 3 Slot 4 Refit the spacer detent arm washer and a new fixing as noted during removal 3 Service Ma...

Page 298: ...n Seat Installation Selector Forks and Drum Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Engine Removal Crankcase Disassembly Service Manual Scrambler 1200 XC 298 of...

Page 299: ... Removal Remove and discard the fixing securing the output selector shaft retainer 1 cjci 3 2 1 Fixing 1 Output selector shaft retainer 2 Output selector shaft 3 Remove and discard the fixing securing the input selector shaft 2 cjck 1 Service Manual Scrambler 1200 XC 299 of 640 ...

Page 300: ...rk 3 Withdraw the output selector shafts and noting their orientation collect the two selector forks 4 3 2 5 1 4 cjcj Output selector shaft 1 Input selector shaft 2 Selector fork input shaft 3 Selector fork output shaft 4 Selector fork output shaft 5 Remove the selector drum bearing keeper plate and discard the fixing 5 Remove the selector drum 6 3 2 Service Manual Scrambler 1200 XC 300 of 640 ...

Page 301: ...the selector forks and selector grooves for wear beyond the service limits Renew the components as necessary Refer to the specifications table see Transmission Selector Forks and Drum Installation If removed refit the detent wheel to the selector drum ensuring the pin on the drum locates in the slot in the detent wheel Prevent the drum from turning and tighten the new fixing to 12 Nm 1 3 4 1 2 cfw...

Page 302: ...n the fixing to 12 Nm 3 cjch 3 2 1 Selector drum 1 Bearing keeper plate 2 Fixing 3 Lubricate the forks and shafts with clean engine oil 4 Position the output selector fork shaft and selector forks to the crankcase as noted during removal 5 Position the input selector fork shaft and selector fork to the crankcase as noted during removal 6 3 2 5 Service Manual Scrambler 1200 XC 302 of 640 ...

Page 303: ...t shaft 4 Selector fork output shaft 5 Using a new fixing secure the output selector shaft retainer tighten the fixing to 12 Nm 7 cjci 3 2 1 Fixing 1 Retainer 2 Selector shaft 3 Using a new fixing secure the input selector shaft tighten the fixing to 22 Nm 8 1 Service Manual Scrambler 1200 XC 303 of 640 ...

Page 304: ...nge Shaft Installation Refit the transmission shafts Crankcase Assembly Engine Installation Fuel Tank Installation Battery Installation Seat Installation Exploded View Output Shaft 1 2 3 5 6 7 8 9 10 11 12 15 17 21 25 26 4 13 14 18 19 20 22 23 24 Service Manual Scrambler 1200 XC 304 of 640 ...

Page 305: ...h gear 10 Plain bush 11 Output shaft 12 Plain bush 13 Third gear 14 Splined thrust washer 15 Circlip 16 Sixth gear 17 Thrust washer 18 Plain bush 19 Second gear 20 Second gear spacer 21 Outer bearing 22 Snap ring 23 Distance sleeve 24 Output shaft seal 25 Sprocket 26 Tab washer 27 Sprocket nut 28 Output Shaft Disassembly WARNING Service Manual Scrambler 1200 XC 305 of 640 ...

Page 306: ...hing injury to the hand arms or other parts of the anatomy Note Make a note or mark the orientation of all transmission parts prior to removal Mark one side of the needle roller bearing outer carrier to denote its correct orientation and slide it away from the needle roller bearing 1 cjbz 2 1 Bearing outer carrier 1 Needle roller bearing 2 Remove and discard the circlip 2 Noting its orientation re...

Page 307: ... output shaft seal 5 cjgk 2 1 3 Output shaft seal 1 Roller bearing 2 Distance sleeve 3 Mark one side of first gear to denote its correct orientation and remove it from the shaft 6 Remove the needle roller bearing from the shaft 7 2 3 1 Service Manual Scrambler 1200 XC 307 of 640 ...

Page 308: ...utput shaft 4 Mark one side of fifth gear to denote its correct orientation and remove it from the shaft 8 cjgg_1 2 1 Fifth gear 1 Output shaft 2 Remove the circlip and splined thrust washer 9 Discard the circlip 10 1 3 2 Service Manual Scrambler 1200 XC 308 of 640 ...

Page 309: ...emove it from the shaft 11 Noting its orientation remove the plain bush which runs inside the gear 12 cjgf 5 1 2 3 4 Circlip 1 Splined thrust washer 2 Fourth gear 3 Plain bush 4 Output shaft 5 Working on the opposite end of the shaft attach a proprietary bearing separator 13 Service Manual Scrambler 1200 XC 309 of 640 ...

Page 310: ...sleeve 2 Output shaft 3 Bearing separator 4 Discard the bearing 14 Remove the second gear spacer 15 Mark one side of second gear to denote its correct orientation and remove it from the shaft 16 Noting its orientation remove the plain bush from the shaft 17 Remove the thrust washer from the shaft 18 5 1 2 3 4 Service Manual Scrambler 1200 XC 310 of 640 ...

Page 311: ...Bush 3 Thrust washer 4 Output shaft 5 Noting its orientation remove the sixth gear 19 cjgd_1 2 1 Sixth gear 1 Output shaft 2 Remove the circlip and the splined thrust washer discard the circlip 20 2 4 Service Manual Scrambler 1200 XC 311 of 640 ...

Page 312: ...3 4 5 1 Circlip 1 Splined thrust washer 2 Third gear 3 Third gear bush 4 Output shaft 5 Output Shaft Inspection Examine all gears bearings 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 1 Output Shaft Assembly Ser...

Page 313: ...le control and an accident CAUTION Bushes 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 r...

Page 314: ...rclip 1 Splined washer 2 Third gear 3 Output shaft 4 Fit the sixth gear as noted during disassembly 3 cjgd_1 2 1 Sixth gear 1 Output shaft 2 Fit the thrust washer 4 CAUTION Service Manual Scrambler 1200 XC 314 of 640 ...

Page 315: ... components Locate second gear and the plain bush to the shaft as noted during disassembly 5 Fit the second gear spacer 6 cjge_1 5 1 2 3 4 Second gear spacer 1 Second gear 2 Bush 3 Thrust washer 4 Output shaft 5 Place the output shaft on a press bar align the inner race of the ball bearing to the output shaft 7 Press the output shaft through the bearing until the bearing face contacts the thrust w...

Page 316: ...ate the distance sleeve to the bearing 9 Press the output shaft through the distance sleeve until it comes into contact with the bearing face 10 cjgb_1 4 1 2 3 Distance sleeve 1 Ball bearing 2 Spacer 3 Output shaft 4 Lubricate and fit a new output shaft seal 11 2 1 Service Manual Scrambler 1200 XC 316 of 640 ...

Page 317: ...n 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 Working from the opposite end of the shaft fit the plain bush as noted during disassembly 13 Fit fourth gear as noted during disassembly 14 Fit the splined thrust washer and retain using a new circlip as shown below 15 5 1 2 ...

Page 318: ...r as noted during disassembly Ensure that the smaller dogs face towards fourth gear 16 cjgg_1 2 1 Fifth gear 1 Output shaft 2 Fit the plain bush as noted during disassembly 17 Fit first gear as noted during disassembly 18 Fit the thrust washer 19 2 3 1 Service Manual Scrambler 1200 XC 318 of 640 ...

Page 319: ...ng disassembly 20 Retain the roller bearing using a new circlip 21 T908 07 27 1 2 3 Circlip 1 Needle roller bearing 2 Thrust washer 3 Lubricate the bearing with oil and then slide the bearing outer roller carrier over the needle roller bearing in the orientation noted during disassembly 22 Service Manual Scrambler 1200 XC 319 of 640 ...

Page 320: ... Bearing outer carrier 1 Needle roller bearing 2 Exploded View Input Shaft Bearing retainer bolts 1 Bearing retainer plate 2 Ball bearing 3 Input shaft 4 Plain bush 5 Service Manual Scrambler 1200 XC 320 of 640 ...

Page 321: ...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 Note The gears on the input shaft can not be fully disassembled or assembled in service If for any reason a gear requires replacing the comple...

Page 322: ...cted 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 Attach T3880109 Bearing Separator to the bearing ensuring the flat side of the tool s jaws are in contact with the bearing 1 Service Tool Installation Support the T3880109 Bearing Separator on press bars then press the shaft through the b...

Page 323: ... 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 CAUTION Removing the input shaft bearing from the shaft will damage the bearing Never reuse removed bearings as use of damaged or weakened componen...

Page 324: ...rt the inner race of the bearing 2 Press the bearing fully on to the shaft 3 cjcg 3 1 2 Input shaft 1 Bearing 2 Press plates 3 Fit the roller bearing and restrictor washer to the input shaft 4 cjbx 3 2 1 Restrictor washer 1 Roller bearing 2 Service Manual Scrambler 1200 XC 324 of 640 ...

Page 325: ...Input shaft 3 Starter Drive and Sprag Clutch Exploded View Starter and Sprag Starter Drive Sprag Clutch Removal WARNING Service Manual Scrambler 1200 XC 325 of 640 ...

Page 326: ...r Removal Whilst holding the first idler gear in position withdraw the second starter idler shaft and gear noting the fitted position of the components 1 ciwu 3 1 2 Starter idler gear first 1 Starter idler gear second 2 Starter sprag gear 3 Using T3880375 Alternator Rotor Holder to retain the flywheel remove and discard the fixings securing the starter gear thrust washer to the sprag clutch housin...

Page 327: ...der 2 Sprag clutch housing 3 Thrust washer 4 Remove and discard the fixings securing the sprag clutch housing to the flywheel 3 ciwt 1 1 Fixings 1 Withdraw the starter sprag gear and sprag clutch assembly 4 Service Manual Scrambler 1200 XC 327 of 640 ...

Page 328: ...e starter sprag gear from the sprag clutch housing assembly 5 cixh 2 1 3 Starter sprag gear 1 Sprag clutch housing 2 Sprag clutch 3 Remove the sprag clutch from the sprag clutch housing 6 2 1 Service Manual Scrambler 1200 XC 328 of 640 ...

Page 329: ...utch 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 3 Starter Drive Sprag Clutch Installation Locate the sprag clutch to the sprag clutch housing as shown below Push firmly until the lip seats in the recess provided in the housing 1 2 1 Sprag clutch housing 1 Sprag clutch 2 Fit the starter sprag...

Page 330: ...e rotor 5 cixh 2 1 3 Starter sprag gear 1 Sprag clutch housing 2 Sprag clutch 3 Note Ensure the sprag is seated and flush fitting to the housing before tightening the fixings fully Align the drilled holes in the sprag clutch housing with the holes in the flywheel 6 ciws Service Manual Scrambler 1200 XC 330 of 640 ...

Page 331: ...ce until all are correctly torqued and do not move when checked this will ensure the sprag clutch housing is correctly seated on the rotor 7 1 3 5 6 4 2 Tightening Sequence Using tool T3880375 Alternator Rotor Holder Tool to retain the flywheel and using new fixings secure the starter gear thrust washer to the flywheel Tighten the fixings to 12 Nm 8 ciwv 3 1 2 4 Service Manual Scrambler 1200 XC 33...

Page 332: ...r and shaft as noted during removal 9 ciwr 1 3 2 Starter idler gear second 1 Starter idler gear first 2 Starter sprag gear 3 Perform the following operations Clutch Cover Installation Battery Installation Seat Installation Lubrication Exploded View Oil Filter and Pump Service Manual Scrambler 1200 XC 332 of 640 ...

Page 333: ...Oil Circuit Diagram Service Manual Scrambler 1200 XC 333 of 640 ...

Page 334: ... bearings Here it is delivered to the crankshaft main bearings and via drillings in the crankshaft to the big end bearings Oil is also fed to the alternator to aid cooling of the alternator The oil is taken from the crankshaft oil feed and directed to the alternator stator and rotor Spray jets located in the upper crankcase above the front balance shaft lubricate the pistons and connecting rod sma...

Page 335: ...rds 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 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 R...

Page 336: ...e 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 Oil and Water Pump Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle WARNING Prolonged or repeated contac...

Page 337: ...perations Seat Removal Battery Removal Drain the coolant Coolant Replacement Drainage Drain the engine oil Engine Oil and Filter Renew Sump Removal Clutch Removal Release the oil pick up from the oil seal 1 Remove and discard the oil seal 2 cjaq 2 1 Oil pick up 1 Oil seal 2 Slide the oil pump drive sprocket gently backwards and forwards to release the needle roller bearing 3 1 Service Manual Scram...

Page 338: ...cket and carefully remove the bush spacer and needle roller bearing while noting it s orientation 4 ciue 4 2 3 1 Oil pump drive sprocket 1 Needle roller bearing 2 Spacer 3 Bush 4 Release and discard the fixings securing the oil and water pump 5 1 Service Manual Scrambler 1200 XC 338 of 640 ...

Page 339: ...drive sprocket 1 Drive chain 2 Carefully withdraw the oil and water pump from the crankcase 7 Note The water pump inlet sleeve O rings can become dislodged during removal of the oil pump Remove the coolant outlet sleeve and the oil pump outlet sleeve from the crankcase 8 Service Manual Scrambler 1200 XC 339 of 640 ...

Page 340: ...l 3 Remove and discard the four O rings from the coolant outlet sleeve and then remove and discard the two O rings from the oil outlet sleeve 9 ciuh 3 4 2 1 Coolant outlet sleeve 1 O ring coolant 2 Oil outlet sleeve 3 O ring oil 4 Service Manual Scrambler 1200 XC 340 of 640 ...

Page 341: ... the shaft and shaft bearings for side and end float Replace the pump if wear is found 2 Carry out a visual inspection for corrosion and scale build up around the coolant pump impeller and in the coolant pump body Replace the pump assembly if necessary 3 Oil Pump Disassembly Using T3880603 Oil Pump Restraint release the fixing and remove the drive sprocket and spacer washer 1 Service Manual Scramb...

Page 342: ...mage may result from the continued use of a faulty oil pump Oil Pump Inspection Inspect the sprocket and chain for wear and or damage Replace the pump and chain if wear is found 1 Check the shaft and shaft bearings for side and end float Replace the pump if wear is found 2 Carry out a visual inspection for corrosion and scale build up around the coolant pump impeller and in the coolant pump body R...

Page 343: ...earance using feeler gauges 1 For specifications refer toLubrication 2 chho_1 Rotor Tip Clearance Oil Pump Body Clearance Measure the pump body clearance using feeler gauges 1 For specifications refer toLubrication 2 chhp Service Manual Scrambler 1200 XC 343 of 640 ...

Page 344: ...otor and a small quantity of silicone release agent to the face of the end plate 3 Cut a length of the Plastigauge to fit across the rotor Fit the strip to the rotor using the grease to hold the Plastigauge in place 4 cdqi_1 1 2 Outer rotor 1 Plastigauge 2 Without any twisting action refit the oil pump cover and tighten its fixings to 10 Nm 5 Release the bolts and carefully remove the end plate 6 ...

Page 345: ...e outer rotor and oil pump cover 9 If any clearance measured is outside the service limits renew the complete pump 10 Oil Pump Assembly If all clearances are within service limits liberally apply clean engine oil to all internal components and refit the rotor to the oil pump body 1 Refit the end plate Apply ThreeBond 1374 to the fixings refit and tighten to 10 Nm 2 ciuk 1 2 2 Service Manual Scramb...

Page 346: ...re fitting the 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 Install four new O rings to the water pump outlet sleeve 1 Install two new O rings to the oil pump outlet ...

Page 347: ...he oil outlet sleeve and the coolant inlet O ring to the crankcase 3 ciuj 3 1 2 Coolant outlet sleeve 1 Oil outlet sleeve 2 O ring coolant inlet 3 Fill the oil pump with new engine oil turning the pump rotor as the oil is poured in to ensure all surfaces are coated with oil 4 Service Manual Scrambler 1200 XC 347 of 640 ...

Page 348: ...the use of excessive force Feed the drive chain over the transmission input shaft and fit to the sprocket 6 Fit the drive chain on to the oil pump sprocket 7 Refit the oil and water pump Install new fixings and tighten to 10 Nm in the sequence shown below 8 ciud_1 1 2 3 4 Tightening Sequence Support the oil and water pump drive sprocket and carefully refit the bush spacer and needle roller bearing...

Page 349: ...oil pick up 10 cjaq 2 1 Oil pick up 1 Oil seal 2 Perform the following operations Clutch Installation Sump Installation Engine Oil and Filter Renew Coolant Replacement Filling Battery Installation Seat Installation Oil Pressure Relief Valve Removal WARNING Service Manual Scrambler 1200 XC 349 of 640 ...

Page 350: ...mination which can cause cancer Wear suitable clothing and avoid skin contact The engine oil and filter must be replaced in accordance with scheduled maintenance requirements The oil pressure relief valve is located in the oil pump housing It is positioned behind a threaded blanking plug in the oil pump body Perform the following operations Seat Removal Battery Removal Sump Removal WARNING The oil...

Page 351: ...t to the oil pressure relief valve 1 city 1 2 Oil pressure relief valve 1 O ring 2 Refit the oil pressure relief valve as noted during removal 2 Refit the blanking plug and tighten to 10 Nm 3 Refit the sump ensuring the water pump drain tube is correctly installed see Sump Installation 4 Perform the following operations Battery Installation Seat Installation Low Oil Pressure Warning Light Switch R...

Page 352: ...quirements 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 The low oil pressure warning light switch is located in the lower crankcase behind the sprocket cover Front Sprocket Cover Removal WARNING Do not allow a brake component to hang unsupported ...

Page 353: ...uitable receptacle to collect any displaced oil from the oil gallery 3 Remove the switch and discard the sealing washer 4 ciua 1 Low oil pressure warning light switch 1 Low Oil Pressure Warning Light Switch Installation Incorporating a new sealing washer fit the low oil pressure light switch 1 Tighten the switch to 15 Nm 2 1 Service Manual Scrambler 1200 XC 353 of 640 ...

Page 354: ...s shortly after starting 7 Allow the engine to idle for a minimum of 30 seconds 8 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 Stop the engine and check the oil level as describe...

Page 355: ...Silencer Removal Left Hand Header Pipe Removal and Exhaust Catalytic Converter Removal Side Panels Front Sprocket Cover Removal If required drain the engine oil Engine Oil and Filter Renew Disconnect the coolant hose from the thermostat housing 1 From the top of the frame disconnect the following electrical connectors 2 Spark plug leads Fuel injectors Coolant temperature sensor Disconnect the clut...

Page 356: ...egulator rectifier see Rear Mudguard Removal 5 Detach the crankshaft position sensor electrical connector from the rear of the airbox Disconnect the crankshaft position sensor from the main harness 6 Disconnect the starter motor lead from the starter motor solenoid 7 ckjp 2 1 Crankshaft position sensor electrical connector 1 Starter motor lead 2 Route the three cables down to the engine 8 Release ...

Page 357: ...move the fixing and remove the air intake finishers 10 2 1 L0825 Fixing 1 Air intake finisher right hand side shown 2 Remove the two fixings and remove the mountings for the air intake finisher 11 2 1 Service Manual Scrambler 1200 XC 357 of 640 ...

Page 358: ...for installation Disconnect the MAP hose and the evaporative emissions hose from the inlet manifold 12 cjdq 1 2 Evaporative hose 1 MAP sensor hose 2 Loosen the throttle body hose clamp 13 Remove the four fixings securing the inlet manifold to the cylinder head and detach it from the cylinder head Remove and discard the two seals on the inlet manifold 14 3 Service Manual Scrambler 1200 XC 358 of 64...

Page 359: ... Fixings 1 Heel guard 2 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 Service Manual Scrambler 1200 XC 359 of 640 ...

Page 360: ...ywork Spilled brake fluid will damage paintwork Release the fixings and detach the right hand control plate from the frame 16 ckjo 2 1 Fixings 1 Right hand control plate 2 Disconnect the oil pressure switch electrical connector 17 ciua_1 1 Service Manual Scrambler 1200 XC 360 of 640 ...

Page 361: ...nd control plate 2 Carefully remove the swinging arm pivot cover on the left hand side of the frame 21 Remove the swinging arm pivot nut and collect the washer on the left hand side of the frame 22 Partially remove the swinging arm spindle to access the frame adjuster sleeve 23 Engage T3880104 Swinging Arm Adjuster Wrench in the slots of the frame adjuster sleeve and rotate anticlockwise to loosen...

Page 362: ...djuster Left hand cylinder head mounting adjuster Remove the right hand cylinder head mounting bolt 30 Remove the remaining mounting bolts collecting the spacer from the lower crankcase mounting bolt 31 CAUTION Three brake lines the rear brake switch harness rear wheel ABS sensor and the bluetooth connector are attached to the brake line tidy on the rear of the crankcase Failure to detach the brak...

Page 363: ... 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 While carefully locating the engine to the frame attach the brake lines and harnesses to the brake line tidy as noted for removal 1 ckjl 6 1 5 4 3 2 Brake line front brake master cylinder 1 Service Manual Sc...

Page 364: ...om the right hand side Do not fit the washer and new lock nut at this stage Insert the cylinder head rear mounting bolt and washer from the left hand side Stage 2 5 Partially withdraw the crankcase rear lower mounting bolt and tighten the frame adjuster to 5 Nm using T3880377 Engine Mounting Adjuster Refit the bolt and washer 6 Partially withdraw the crankcase rear upper mounting bolt and tighten ...

Page 365: ... washer and a new lock nut to the crankcase upper rear mounting bolt Counter hold the bolt and tighten the nut to 80 Nm 12 1 2 3 3 4 4 Crankcase lower rear mounting bolt 1 Crankcase upper rear mounting bolt 2 Washer 3 Lock nut 4 Counter hold the nut and tighten the cylinder head front right hand mounting bolt to 105 Nm 13 Fit the washer and a new lock nut to the cylinder head front left hand mount...

Page 366: ...g T3880104 Swinging Arm Adjuster Wrench tighten the swinging arm pivot bolt adjuster sleeve to 6 Nm 17 Fit the washer and a new lock nut to the swinging arm spindle Counter hold the spindle and tighten the nut to 110 Nm 18 Refit the swinging arm pivot cover to the left hand side of the frame 19 On the left hand side connect the engine ground cable 20 Refit the rider s left hand control plate fit t...

Page 367: ...ctor 1 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 CAUTION To prevent paint damage do not spill brake fluid onto any area of the bodywork Service Manual Scrambler 12...

Page 368: ... s right hand control plate fit the upper fixing only and do not fully tighten at this stage 24 ckjo 2 1 Upper fixing 1 Right hand control plate 2 Refit the engine breather hose and secure with the hose clips 25 L0758_1 2 1 Service Manual Scrambler 1200 XC 368 of 640 ...

Page 369: ...ankshaft position sensor to the main harness and attach the connector to the rear of the airbox 28 ckjp 2 1 Crankshaft position sensor electrical connector 1 Starter motor lead 2 Connect the alternator harness to the regulator rectifier and refit the rear mudguard see Rear Mudguard Installation 29 On the right side of the airbox connect the gear position sensor electrical connector to the main har...

Page 370: ...d 34 Tighten the inlet manifold to cylinder head fixings to 9 Nm in the sequence shown below 35 Retighten the fixings one and two to 9 Nm 36 ckgn 1 4 3 2 Tightening Sequence Ensure the throttle body hose is correctly fitted and tighten the clip to 1 5 Nm 37 Connect the MAP hose and the evaporative emissions hose to the inlet manifold as noted for removal 38 Fit the mountings for the air intake fin...

Page 371: ...ature sensor Fuel injectors Spark plug leads Refit the coolant hose to the thermostat housing and secure using T3880207 Hose Clip Pliers 42 Refit the side panels see Side Panels 43 Refit the exhaust catalytic system see Exhaust Catalytic Converter Installation Left Hand Header Pipe Installation and Exhaust Silencer Installation 44 Refit the cradle assemblies see Cradle Assemblies Installation 45 S...

Page 372: ... 46 ckjo 2 1 Upper fixing 1 Right hand control plate 2 Refit the right hand heel guard and tighten its fixings to 7 Nm 47 L0904 1 2 Fixings 1 Heel guard 2 Tighten the rider s left hand control plate upper fixing to 25 Nm 48 Service Manual Scrambler 1200 XC 372 of 640 ...

Page 373: ...llation Radiator Installation Sump Guard Installation Fuel Tank Installation Battery Installation Seat Installation If required refill the engine with engine oil Engine Oil and Filter Renew Reset the neutral position adaption see Neutral Position Adaption Fuel and Exhaust System and Engine Management Exploded Views Exploded View Fuel Tank Service Manual Scrambler 1200 XC 373 of 640 ...

Page 374: ...Exploded View Fuel Pump Service Manual Scrambler 1200 XC 374 of 640 ...

Page 375: ...Exploded View Fuel Rail Throttles and Injectors Service Manual Scrambler 1200 XC 375 of 640 ...

Page 376: ...Exploded View Engine Management Exploded View Airbox Service Manual Scrambler 1200 XC 376 of 640 ...

Page 377: ...Exploded View Exhaust System Service Manual Scrambler 1200 XC 377 of 640 ...

Page 378: ...Exploded View Evaporative System if fitted Service Manual Scrambler 1200 XC 378 of 640 ...

Page 379: ...ating 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 cause damage to emissions control components Oxyg...

Page 380: ... be used in Triumph motorcycles as damage to components in the fuel system can be caused by contact with methanol MTBE Methyl T ertiary Butyl Ether The use of gasolines containing up to 15 MTBE Methyl Tertiary Butyl Ether is permitted in Triumph motorcycles 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 m...

Page 381: ...nd a reduction reaction Closed throttle position Throttle position at idle measured as a voltage and expressed as 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 Cruise control cancel switch if fitted A switch located in the twist grip housin...

Page 382: ... 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...

Page 383: ... 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 ...

Page 384: ...urrent 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 throt...

Page 385: ...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 T arget 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...

Page 386: ...agnostic function For additional information see System Diagnostics System Sensors Intake air temperature sensor situated on left hand side of the airbox As the density of the air changes with temperature therefore the amount of oxygen available to ignite the fuel an intake air temperature sensor is fitted Changes in air temperature are compensated for by adjusting the amount of fuel injected to a...

Page 387: ...M on the content of the exhaust gases Based on this information adjustments to 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 Fall detection switch situated under the storage box The fall detection switch will detect if the motorcycle is on its side and will ...

Page 388: ...he throttle actuator motor opens and closes the throttle plate in the throttle body in response to commands from the engine ECM The throttle actuator motor is an integral part of the throttle bodies Canister purge valve certain markets only situated In front of camshaft cover attached to the frame The purge valve controls the return of vapour which has been stored in the carbon canister during the...

Page 389: ...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 fuel at 3 5 bar 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 fan situated behind t...

Page 390: ...liser will allow the engine to start These components can only be paired using the Triumph diagnostic tool In addition the system has an on board diagnostic function This ensures that should a malfunction occur in the immobiliser system a malfunction code is stored in the keyless ECM memory This stored data can then be recovered using the Triumph diagnostic tool see System Diagnostics System Compo...

Page 391: ...e conditions described in the accessory alarm instructions are met Keys When the motorcycle is delivered from the factory it is supplied with two standard keys and one smart key Note An additional smart key can be purchased from your Triumph dealer However only three keys can be programmed to the motorcycle This can be any combination of smart keys and standard keys A previously paired key must be...

Page 392: ... is able to learn about new or changing operating conditions and continuously adapt itself without needing to constantly make major adjustments from a fixed baseline setting Adaptive changes can become necessary because of changing rider behaviour 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...

Page 393: ... Oxygen sensor adaption range off idle Oxygen sensor adaption status idle Oxygen sensor adaption range idle T erminology Where the term status is used this indicates how far the present operating parameter is from the stored baseline value The nearer these figures are to zero the better as it indicates the motorcycle has adapted to its current operating conditions The term range indicates how much...

Page 394: ...e 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 adapti...

Page 395: ...reached maximum indicating a mechanical fault exists on the motorcycle This can be due to a number of faults but the most likely causes will be low high fuel pressure faulty injectors or air leaks at the throttle bodies or airbox In these circumstances locate and rectify the fault and reset the adaptions as described above Diagnostics and Testing Electrical Connectors Before beginning any diagnosi...

Page 396: ...onnector 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 Turn the ignition to the OFF position and wait at least 1 minute for the engi...

Page 397: ...n of the engine ECM Connectors CAUTION Damage to the connector pins may result if an attempt to fit the connectors incorrectly is made Fit the connector into its socket When the locking lever starts to move stop pushing the connector and use the locking lever to fully insert the connector home and lock it 1 2 1 Service Manual Scrambler 1200 XC 397 of 640 ...

Page 398: ...c 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 t...

Page 399: ... 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 s...

Page 400: ...e numbered from right to left with number one in the top right corner System Diagnostic Tool Connection Diagnostic T ool Connection To connect the Triumph diagnostic interface to the motorcycle remove the left hand side panel see Side Panels and release the diagnostic connector from its locating tang 1 1 Diagnostic connector 1 Plug the Triumph diagnostic interface directly into the diagnostic conn...

Page 401: ...h 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 and how to interpret the data can be found in the Triumph Diagnostic Tool User Guide Build Data The Build Data screen will display the following information Motorcycle model Vehicle Identification Number VIN ECM type ECM ID ECM seria...

Page 402: ...erm fuel trim bank 1 Short term fuel trim bank 2 Intake manifold absolute pressure mmHg Engine speed rpm Vehicle speed km h Ignition timing advance cylinder 1 degrees Intake air temperature C Absolute throttle position Bank 1 oxygen sensor 1 Volts Bank 1 oxygen sensor 1 short term fuel trim Bank 2 oxygen sensor 2 Volts Bank 2 oxygen sensor 2 short term fuel trim Sensor Data Service Manual Scramble...

Page 403: ...witch to ECM Volts Air temperature sensor voltage Volts Coolant temperature sensor voltage Volts Atmospheric pressure sensor voltage Volts Manifold absolute pressure sensor 1 voltage Volts Manifold absolute pressure sensor 2 voltage Volts Throttle position sensor voltage Volts Fuel level sensor voltage Volts Oxygen sensor output 1 voltage Volts Oxygen sensor output 2 voltage Volts Exhaust butterfl...

Page 404: ...or voltage Applies to models fitted with an exhaust butterfly valve only All other models will show Not Applicable in this field Injector Data The data available under Injector Data is Item Checked Result Unit Injector 1 pulse time milliseconds Injector 2 pulse time milliseconds Ignition Data The data available under Ignition Data is Item Checked Result Unit Ignition timing cyl 1 degrees BTDC Igni...

Page 405: ...numeric Idle speed control target steps numeric Throttle position open Secondary air injection status SAI on off Applies to models fitted with secondary air injection only All other models will show Not Applicable in this field Inputs The data available under Inputs is Item Checked Result Unit Starter switch status switch on off Side stand status up down Fall detection switch status normal over Cl...

Page 406: ... status MIL on off Cooling fan status fan on off Purge valve duty cycle Accessory control relay status relay on off Headlight relay status headlight on off 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 altitude component wear air leaks etc This screen displays information on the adaption...

Page 407: ...atus off idle Oxygen sensor 2 adaption status idle Function T ests 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 Function Examined Report Method Instr...

Page 408: ... if the component is fitted Adjust Calibration Using the Triumph diagnostic software it is possible to reset the adaptions balance the throttle bodies Freeze Frame Data Freeze frame data is stored at the time a DTC is recorded confirmed by the ECM 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 associate...

Page 409: ...Volts Oxygen sensor 1 short term fuel trim Oxygen sensor 2 output voltage Volts Oxygen sensor 2 short term fuel trim 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 ...

Page 410: ...et 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 del...

Page 411: ...mission is in neutral 1 Start the engine 2 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 The neutral position will adapt shortly after engine start provided the above conditions are met 3 The adaption status...

Page 412: ... switch check is not carried out the green cruise control warning light will illuminate when the ignition is turned to the ON position but the cruise function will be disabled Cruise Control Switch Check Function If the engine is running you will be prompted to turn it off before the test will start If the cruise control is turned on you will be prompted to turn it off before the test will start F...

Page 413: ...umber of warm up cycles required to extinguish the MIL will always be less than the number required to remove a DTC from the ECM memory DTCs can be removed at any time using the Triumph diagnostic software The system will log the diagnostic trouble codes listed below over Diagnostic Trouble Code DTC Fault Description Number of no fault cycles before turning off MIL Number of no fault cycles before...

Page 414: ... pressure sensor 1 short circuit to ground 3 40 Yes Manifold Absolute Pressure MAP Sensor P0110 Intake air temperature sensor open circuit or short circuit to 5 Volt sensor supply 3 40 Yes Intake Air Temperature Sensor P0112 Intake air temperature sensor short circuit to ground 3 40 Yes Intake Air Temperature Sensor P0115 Engine coolant temperature sensor open circuit or short circuit to 5 Volt se...

Page 415: ...d 3 40 Yes Throttle Position Sensor P0130 Oxygen sensor 1 open circuit or short circuit to battery Voltage 3 40 Yes Oxygen Sensor P0131 Oxygen sensor 1 short circuit to ground 3 40 Yes Oxygen Sensor P0150 Oxygen sensor 2 circuit open circuit or short circuit to battery Voltage 3 40 Yes Oxygen Sensor P0151 Oxygen sensor 2 short circuit to ground 3 40 Yes Oxygen Sensor P0201 Injector 1 circuit malfu...

Page 416: ...t sensor circuit malfunction 3 40 Yes Crankshaft Sensor P0351 Ignition coil 1 malfunction 3 40 Yes Ignition Coils P0352 Ignition coil 2 malfunction 3 40 Yes Ignition Coils P0443 Purge valve short circuit to ground or open circuit 3 40 Yes Purge Valve P0459 Purge valve short circuit to battery Voltage 3 40 Yes Purge Valve P0460 Fuel level sensor circuit malfunction 3 40 No Fuel Level Sensor Circuit...

Page 417: ...3 EEPROM Error 0 40 No EEPROM Error P0606 ECM internal error 0 0 Yes Linked procedure not present at the moment P0616 Starter relay short circuit to ground or open circuit 3 40 Yes Starter Motor Relay P0617 Starter relay short circuit to battery Voltage 3 40 Yes Starter Motor Relay P0914 Gear position sensor short circuit to ground or open circuit 3 40 Yes Gear Position Sensor P0917 Gear position ...

Page 418: ...unction 3 40 Yes Traction Control Disabled Due to ABS Malfunction P1231 Fuel pump relay short circuit to ground or open circuit 3 40 Yes Fuel Pump Relay P1232 Fuel pump relay short circuit to battery Voltage 3 40 Yes Fuel Pump Relay P1508 Unmatched Immobiliser chassis ECM 3 40 Flashing Immobiliser and TPMS Control Module ID Incompatible P1520 Unmatched ABS module 3 40 Flashing Linked procedure not...

Page 419: ...vented Due to Other Malfunction 3 40 Yes Cruise Control Prevented Due to Other Malfunction P1575 Cruise Control disabled until button press sequence completed 3 40 Yes Cruise Control Disabled Until Button Press Sequence Completed P1576 Brake 1 switch correlation error with brake switch 2 3 40 Yes Brake Switches P1577 Brake 2 switch correlation error with brake switch 1 3 40 Yes Brake Switches P160...

Page 420: ...ed procedure not present at the moment P1614 Instrument ID incompatible Only if Instrument ID Matching Flashing Instrument ID Incompatible P1631 Fall detection circuit short circuit to ground 3 40 Yes Fall Detection Switch P1632 Fall detection circuit short circuit to battery Voltage 3 40 Yes Fall Detection Switch P1650 CAN fault lost communication with Immobiliser ECM 3 40 Yes Keyless ECM Communi...

Page 421: ...ion 3 40 Yes 5 Volt Sensor Supply Circuit P2100 Throttle actuator control motor open circuit 3 40 Yes Throttle Actuator Motor P2102 Throttle actuator control internal motor relay does not operate 3 40 Yes Linked procedure not present at the moment P2103 Throttle actuator control internal motor relay operates continually 3 40 Yes Linked procedure not present at the moment P2111 Throttle valve drive...

Page 422: ...sor 2 short circuit to ground or open circuit 3 40 Yes Twist Grip Position 2 P2128 Twist grip position sensor 2 short circuit to battery Voltage 3 40 Yes Twist Grip Position 2 P2135 Throttle position sensor 1 correlation error with throttle position sensor 2 3 40 Yes Throttle Position Sensor P2138 Twist grip position sensor 1 correlation error with twist grip position sensor 2 3 40 Yes Twist Grip ...

Page 423: ... code has been stored Pinpoint Tests Fuel Oxygen Sensor Heater Fault Code Possible cause Action P0030 Oxygen sensor 1 heater open circuit or short to ground View and note freeze frame data if available View and note sensor data Ensure sensor connector is secure Disconnect the engine ECM and proceed to pinpoint test 1 P0050 Oxygen sensor 2 heater open circuit or short to ground P0032 Oxygen sensor ...

Page 424: ...able continuity ECM pin A21 to left hand oxygen sensor pin 1 ECM pin A22 to right hand oxygen sensor pin 1 OK Proceed to test 5 Open circuit Locate and rectify wiring fault proceed to test 5 4 Check cable for short circuit ECM pin A01 to ECM pin A21 left hand oxygen sensor ECM pin A01 to ECM pin A22 right hand oxygen sensor OK Renew relevant oxygen sensor and proceed to test 5 Short circuit Locate...

Page 425: ...nnector B 6 Manifold Absolute Pressure MAP Sensor Fault Code Possible cause Action P0107 Manifold absolute pressure sensor 1 short circuit to ground View and note freeze frame data if available View and note sensor data Ensure sensor connector is secure Disconnect the engine ECM and proceed to pinpoint test 1 P0105 Manifold absolute pressure sensor 1 open circuit or short circuit to 5 Volt sensor ...

Page 426: ... to ECM pin B34 OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 4 3 Check cable for continuity Engine ECM pin B34 to MAP sensor pin 3 Engine ECM pin B18 to MAP sensor pin 1 Engine ECM pin B36 to MAP sensor pin 2 OK Renew relevant MAP pressure sensor proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 4 4 Reconnect harness clear fault co...

Page 427: ...ntrol Module Connector B 3 Intake Air Temperature Sensor Coolant Temperature Sensor Throttle Position Sensor Oxygen Sensor Fuel Injectors Crankshaft Sensor Ignition Coils Purge Valve Fuel Level Sensor Circuit Vehicle Speed Sensor System Voltage Twist Grip Cruise Cancel Switch Circuit Malfunction Service Manual Scrambler 1200 XC 427 of 640 ...

Page 428: ... note diagnostic software freeze frame data if available View and note diagnostic software sensor data Ensure sensor connector is secure Disconnect the engine ECM and proceed to pinpoint test 1 P0112 Intake air temperature sensor short circuit to ground Disconnect the engine ECM and inlet air temperature sensor and proceed to pinpoint test 6 Pinpoint T ests Test Result Action 1 Check cable and ter...

Page 429: ...ircuit Locate and rectify wiring fault proceed to test 7 5 Check sensor resistance Sensor pin 1 to sensor pin 2 Temperature dependent see Resistance data OK Proceed to test 7 Faulty Renew air temperature sensor proceed to test 7 6 Check cable for short circuit Engine ECM pin B42 to ground OK Proceed to test 7 Short circuit Locate and rectify wiring fault proceed to test 7 7 Reconnect harness clear...

Page 430: ... 12 24 36 25 13 1 1 2 1 2 3 4 Intake Air Temperature Sensor 1 Engine Electronic Control Module 2 Engine Electronic Control Module Connector A 3 Engine Electronic Control Module Connector B 4 Fault Code Possible cause Action P0115 Engine coolant temperature sensor View and note diagnostic software freeze frame data if Service Manual Scrambler 1200 XC 430 of 640 ...

Page 431: ...lty Rectify fault proceed to test 7 2 Check resistance value Engine ECM pin B40 to ground Temperature dependent see Resistance data under typical conditions table OK Proceed to test 6 Open circuit Disconnect temperature sensor and proceed to test 3 Short circuit Disconnect temperature sensor and proceed to test 4 3 Check cable continuity Engine ECM pin B40 to sensor pin 1 Ground to sensor pin 2 OK...

Page 432: ...d to test 7 Short circuit Locate and rectify wiring fault proceed to test 7 7 Reconnect harness clear fault code and run engine to verify fault cleared OK Action complete quit test Fault still present Contact Triumph service Resistance data under typical conditions Cold engine Resistance Value 20ºC ambient 2 22 to 2 71 K Ohms 10ºC ambient 8 50 to 10 25 K Ohms Warm engine Resistance Value 100 to 40...

Page 433: ...circuit View and note diagnostic software freeze frame data if available View and note diagnostic software sensor data Ensure throttle body connector is secure Disconnect the engine ECM and proceed to pinpoint test 1 P0122 Throttle position sensor 1 short circuit to ground P0220 Throttle position sensor 2 short circuit to battery Voltage or open circuit P0222 Throttle position sensor 2 short circu...

Page 434: ...e continuity Engine ECM pin B20 to throttle body connector pin 6 Engine ECM pin B26 to throttle body connector pin 4 Engine ECM pin B19 to throttle body connector pin 3 Engine ECM pin B33 to throttle body connector pin 5 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 5 4 Check cable for short circuit Engine ECM pin B33 to ECM pin B20 Engine ECM pin B33 to ECM pin...

Page 435: ...rcuit to ground Pinpoint T ests Test Result Action 1 Check cable and terminal integrity ECM pin B02 ECM pin B03 Left hand oxygen sensor pin 3 Left hand oxygen sensor pin 4 Right hand oxygen sensor pin 3 Right hand oxygen sensor pin 4 EMS relay pin 5 OK Disconnect oxygen sensors and proceed to test 2 Faulty Rectify fault proceed to test 5 2 Check cable for short circuit ECM pin B02 to ground ECM pi...

Page 436: ...right hand oxygen sensor OK Renew relevant oxygen sensor proceed to test 5 Short circuit Locate and rectify wiring fault proceed to test 5 5 Reconnect harness clear fault code and run engine Check adaption status OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram 4 2 3 1 A01 WB BU NK 5 2 3 1 A21 B02 A22 B03 4 2 3 1 BY NK WB B B NK B NK NK 1 2 3 4 12 24 36 25 1...

Page 437: ...ta if available Ensure relevant injector connector is secure Disconnect the engine ECM and proceed to pinpoint test 1 P0202 Injector 2 circuit malfunction Pinpoint T ests Test Result Action 1 Check Fuse box fuse 8 for integrity OK Proceed to test 2 Faulty Rectify fault proceed to test 9 2 Check cable and terminal integrity ECM pin A10 ECM pin A11 Injector 1 pin 1 Injector 1 pin 2 Injector 2 pin 1 ...

Page 438: ...t injector pin 2 ECM pin A10 to injector 1 pin 1 ECM pin A11 to injector 2 pin 1 OK Proceed to test 7 Open circuit Locate and rectify wiring fault proceed to test 9 6 Check cable for short circuit to supply box ECM pin A01 to ECM pin A10 injector 1 ECM pin A01 to ECM pin A11 injector 2 OK Proceed to test 7 Short circuit Locate and rectify wiring fault proceed to test 9 7 Check relevant injector re...

Page 439: ... fault cleared OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram 1 2 12 24 36 25 13 1 6 11 10 NK 5 2 3 1 1 2 1 1 2 2 A01 A10 A11 YR YP NK NK NK 3 2 1 5 1 2 3 4 EMS Relay 1 Fuel Injectors 2 Engine Electronic control Unit 3 Service Manual Scrambler 1200 XC 439 of 640 ...

Page 440: ...or and proceed to test 2 Faulty Rectify fault proceed to test 6 2 Check cable for short circuit Engine ECM pin A35 to ground Engine ECM pin A36 to ground OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 6 3 Check cable continuity Engine ECM pin A35 to sensor pin 1 Engine ECM pin A36 to sensor pin 2 OK Proceed to test 4 Open circuit Locate and rectify wiring fault ...

Page 441: ...mph service Circuit Diagram 12 24 25 13 1 35 1 2 36 2 1 A35 A36 UP UB 2 1 Crankshaft Sensor 1 Engine Electronic Control Module Connector A 2 Fault Code Possible cause Action P0351 Ignition coil 1 malfunction View and note diagnostic software freeze frame data if available Ensure relevant ignition coil connector is secure Disconnect the engine ECM and proceed to pinpoint test 1 P0352 Ignition coil ...

Page 442: ...Engine ECM pin B15 to ground OK Proceed to test 6 Short circuit Locate and rectify wiring fault proceed to test 6 4 Check cable continuity EMS relay pin 5 to relevant ignition coil pin Engine ECM pin B14 to ignition coil 2 pin 1 Engine ECM pin B15 to ignition coil 1 pin 1 OK Proceed to test 5 Open circuit Locate and rectify wiring fault proceed to test 6 5 Check relevant ignition coil resistance I...

Page 443: ...Engine Management system Relay 3 Fuse Box 4 Engine Electronic Control Module Connector A 5 Engine Electronic Control Module Connector B 6 Fault Code Possible cause Action P0443 Purge valve short circuit to ground or open circuit View and note diagnostic software sensor data Ensure purge valve connector is secure Disconnect the engine ECM and Service Manual Scrambler 1200 XC 443 of 640 ...

Page 444: ... 7 2 Check resistance value ECM pin A01 to ECM pin B06 22 to 30 Ohms Proceed to test 3 Open circuit Disconnect purge valve and proceed to test 4 Short circuit Disconnect purge valve and proceed to test 5 3 Check cable for short circuit ECM pin B06 to ground OK Proceed to test 7 Short circuit Locate and rectify wiring fault proceed to test 7 4 Check cable continuity EMS relay pin 5 to valve pin 2 E...

Page 445: ...st 8 7 Check purge valve resistance Valve pin 1 to valve pin 2 22 to 30 Ohms Proceed to test 7 Faulty Renew purge valve proceed to test 7 8 Reconnect harness clear fault code and run diagnostic software function test to visually verify operation of purge valve OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram NK 5 2 3 1 A01 B06 B NK NK NK 12 24 36 25 13 1 16 ...

Page 446: ... frame data if available View and note sensor data Ensure sensor connector is secure Disconnect the engine ECM and proceed to pinpoint test 1 Pinpoint T ests Test Result Action 1 Check cable and terminal integrity Engine ECM pin B27 Engine ECM pin B18 Engine ECM pin B34 Sensor pin 1 Sensor pin 2 Sensor pin 4 OK Disconnect sensor and proceed to test 2 Faulty Rectify fault proceed to test 4 2 Check ...

Page 447: ... pin 4 Engine ECM pin B34 to sensor pin 2 Engine ECM pin B18 to sensor pin 1 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 4 5 Reconnect harness clear fault code OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram 1 2 B18 B34 BY KB K B27 4 16 32 48 17 1 33 18 34 27 2 1 4 3 1 2 3 Service Manual Scrambler 1200 XC 447 of 640 ...

Page 448: ...tact Rear Wheel Sensor Open Circuit Short Circuit Rear Wheel Sensor Abnormal Input Losing Contact Fault Code Possible cause Action P0560 System voltage battery circuit malfunction View and note diagnostic software sensor data Ensure voltage across battery is greater than 12 0 Volts note voltage Disconnect the engine ECM and proceed to pinpoint test 1 Pinpoint T ests Test Result Action 1 Check cabl...

Page 449: ...3 With Ignition on check voltage at Engine ECM pin A01 Engine ECM pin A13 Same as across battery voltage Proceed to test 4 Less than across battery voltage Locate and rectify wiring fault proceed to test 4 4 Reconnect harness clear fault code and run engine to verify fault cleared OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram 5 2 3 1 A01 NK NK A20 A25 A23...

Page 450: ...Diagnostic Tool and turn the ignition ON Check and investigate any other stored DTCs Select Sensor Data Sensor Voltages on the diagnostic tool and proceed to pinpoint test 1 Pinpoint T ests Test Result Action 1 Roll the twist grip forward to its fully closed cruise cancel position and note the following voltages Twist Grip Position Sensor 1 Twist Grip Position Sensor 2 OK Position sensor 1 voltage...

Page 451: ...ult Code Possible cause Action P0571 Brake 1 switch malfunction View and note freeze frame data if available Ensure brake switches connectors are secure Disconnect engine ECM and proceed to pinpoint test 1 P1576 Brake 1 switch correlation error with brake switch 2 P1571 Brake 2 switch malfunction P1577 Brake 2 switch correlation error with brake switch 1 Pinpoint T ests Test Result Action 1 Turn i...

Page 452: ...tch pin 2 to pin 3 The following should be open circuit Front brake switch pin 1 to pin 3 Rear brake light switch pin 1 to pin 3 OK Proceed to test 4 Faulty Replace relevant brake switch proceed to test 7 4 With both brakes applied check brake switch operation The following should be open circuit Front brake switch pin 2 to pin 3 Rear brake switch pin 2 to pin 3 The following should be short circu...

Page 453: ...e the following Voltages back to battery negative ECM pin A06 to ground Rear brake switch pin 2 Rear brake switch pin 3 Front brake switch pin 2 Front brake switch pin 3 Ignition switch relay pin 5 Greater than 10V Proceed to test 7 Less than 10V Locate and rectify wiring fault proceed to test 7 7 Reconnect harness clear fault code and run engine OK Action complete quit test Fault still present Co...

Page 454: ... View and note freeze frame data if available No tests available contact Triumph service Fault Code Possible cause Action P0616 Starter relay short circuit to ground or open circuit Ensure starter motor relay connector is secure Disconnect the engine ECM and proceed to pinpoint test 1 P0617 Starter relay short circuit to battery Voltage Disconnect the engine ECM and starter motor relay proceed to ...

Page 455: ...housing detach the front brake master cylinder from the handlebar see Check cable continuity Engine ECM pin B25 to starter relay pin 2 Engine ECM pin A19 to starter relay pin 1 Fuse box fuse 3 to alarm pin 5 Alarm pin 3 to engine ECM pin A19 Alarm pin 5 to right hand switch housing black connector pin 3 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 5 4 Check cab...

Page 456: ... 6 1 3 4 6 4 1 2 3 5 6 7 8 9 Starter Motor Relay 1 Engine Electronic Control Module 2 Alarm 3 Right Hand Switch Housing 4 Fuse Box 5 Right Hand Switch Housing Grey Connector 6 Right Hand Switch Housing Black Connector 7 Engine Electronic Control Module Connector A 8 Engine Electronic Control Module Connector B 9 Service Manual Scrambler 1200 XC 456 of 640 ...

Page 457: ...eed to test 5 2 Check cable for short circuit Engine ECM pin B23 to ground Engine ECM pin B34 to ground OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity Engine ECM pin B23 to sensor pin 1 Engine ECM pin B18 to sensor pin 4 Engine ECM pin B34 to sensor pin 3 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test...

Page 458: ... been completed reset the neutral position sensor adaption see Neutral Position Adaption Circuit Diagram B18 B34 1 4 KB K BK 3 B23 16 32 48 17 1 33 18 34 23 1 2 3 4 1 2 3 Gear Position Sensor 1 Engine Electronic Control Module 2 Engine Electronic Control Module Connector B 3 Service Manual Scrambler 1200 XC 458 of 640 ...

Page 459: ... P1232 Fuel pump relay short circuit to battery Voltage Disconnect the engine ECM and fuel pump relay and proceed to pinpoint test 4 Pinpoint T ests Test Result Action 1 Check cable and terminal integrity Engine ECM pin A26 Alarm pin 1 Alarm pin 2 Fuel pump relay 1 Fuel pump relay 2 Fuel pump relay 3 Fuel pump relay 5 OK Disconnect fuel pump relay and proceed to test 2 Faulty Rectify fault proceed...

Page 460: ...d to test 5 Short circuit Locate and rectify wiring fault proceed to test 5 5 Reconnect harness clear fault code and run diagnostic software function test to verify fault cleared OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram 5 2 3 1 A26 B01 BP GR GR 1 B 8 PW PW B BP 12 24 36 25 13 1 26 1 6 5 12 2 16 32 48 17 1 33 3 2 1 5 4 3 1 2 5 6 Fuel Pump Relay 1 Serv...

Page 461: ...oint T ests Test Result Action 1 Follow the Pair ECM and Immobiliser procedure as described in the Triumph Diagnostic Tool user guide OK Action complete quit test Fault still present Contact Triumph service Fault Code Possible cause Action P1521 CAN fault lost communication with ABS module or ABS system status error View and note freeze frame data if available Ensure ABS modulator connector is sec...

Page 462: ...ng fault proceed to test 6 4 Check cable for short circuit ABS pin 2 to ground ABS pin 11 to ground OK Proceed to test 5 Faulty Locate and rectify wiring fault replace relevant fuse proceed to test 6 5 Check cable continuity ECM pin A33 to ABS pin 2 ECM pin A34 to ABS pin 11 ABS pin 10 to ground Fuse box Fuse 5 to ABS pin 18 Fuse box Fuse 7 to ABS pin 4 OK Proceed to test 6 Fault still present Loc...

Page 463: ...Code Possible cause Action P1552 Cooling fan relay short circuit to ground or open circuit View and note diagnostic software sensor data Ensure fan relay connector is secure Disconnect the engine ECM and proceed to pinpoint test 1 P1553 Cooling fan relay short circuit to battery Voltage or over temp Disconnect the engine ECM and fan relay and proceed to pinpoint test 4 Pinpoint T ests Service Manu...

Page 464: ...circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity Engine ECM pin A27 to fan relay pin 2 EMS relay pin 5 to fan relay pin 1 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 5 4 Check cable for short circuit Engine ECM pin A27 to ECM pin A01 OK Proceed to test 5 Short circuit Locate and rectify wiring fault proceed to test 5 5 Reconne...

Page 465: ...m Relay 2 Cooling Fan 3 Engine Electronic Control Module 4 Engine Electronic Control Module Connector A 5 Fuse Box 6 Cruise Control Disabled Until Button Press Sequence Completed Calibration Lock Instrument ID Incompatible Fault Code Possible Cause Action P1574 Cruise control prevented Check that there is no Service Manual Scrambler 1200 XC 465 of 640 ...

Page 466: ...trol disabled until button press sequence completed 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 Carry out the button press sequence see Cruise Control Switch Check Fault Code Possible cause Action P1605 Engine ECM locked by the calibration lock function This is also identified by a...

Page 467: ...part and proceed to test 3 2 Check that the calibration is correct for the motorcycle using the diagnostic software OK Proceed to test 3 Incorrect Update calibration using diagnostic software proceed to test 3 3 Clear fault code check for normal operation OK Action complete quit test Fault still present Contact Triumph service Fault Code Possible cause Action P1650 Lost communication with Keyless ...

Page 468: ... 6 3 Check fuse box 2 Fuse 6 integrity OK Proceed to test 5 Faulty Proceed to test 4 4 Check cable for short circuit Keyless ECM pin 13 to ground Keyless ECM pin 5 to ground OK Proceed to test 5 Faulty Locate and rectify wiring fault replace relevant fuse proceed to test 6 5 Check cable continuity ECM pin A33 to keyless ECM pin 13 ECM pin A34 to keyless ECM pin 1 Keyless ECM pin 4 to ground Fuse b...

Page 469: ... 1 8 9 16 6 1 2 3 4 5 6 7 8 9 12 24 36 25 13 1 34 33 1 2 3 4 Fuse Box 1 Engine Electronic Control Module 2 Engine Electronic Control Module connector A 3 Keyless Electronic Control Module 4 Fault Code Possible cause Action P1631 Fall detection circuit View and note freeze frame data Service Manual Scrambler 1200 XC 469 of 640 ...

Page 470: ...connect sensor and proceed to test 2 Faulty Rectify fault proceed to test 4 2 Check cable for short circuit ECM pin B38 to ECM pin B18 ECM pin B38 to ECM pin B34 OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 4 3 Check cable continuity ECM pin B34 to sensor pin 4 ECM pin B18 to sensor pin 6 OK Proceed to test 4 Open circuit Locate and rectify wiring fault procee...

Page 471: ...t Code Possible cause Action P1659 Ignition power supply malfunction Disconnect the engine ECM and proceed to pinpoint test 1 Pinpoint T ests Test Result Action 1 Check fuse box 1 Fuse 6 integrity OK Proceed to test 3 Faulty Proceed to test 2 2 Check cable for short circuit ECM pin B01 to ground OK Replace Fuse 10 and proceed to test 3 Service Manual Scrambler 1200 XC 471 of 640 ...

Page 472: ...ult proceed to test 5 4 Check cable continuity Engine ECM pin B01 to KL15 relay pin 5 KL15 relay pin 3 to fuse box fuse 6 Note that the engine stop switch must be in the RUN position and any alarm fitted must be disarmed OK Proceed to test 5 Open circuit Locate and rectify wiring immobiliser or engine stop switch fault proceed to test 5 5 Reconnect harness clear fault code and run engine to verify...

Page 473: ...3 Alarm 4 Fuel Pump Relay 5 Engine Electronic Control Module 6 Engine Electronic Control Module Connector B 7 Fuse Box 8 Fault Code Possible cause Action P1685 Main relay circuit malfunction Note that the starter motor cannot be powered if a main relay fault exists Ensure the EMS main relay connector is secure Proceed to pinpoint test 1 Pinpoint T ests Test Result Action Service Manual Scrambler 1...

Page 474: ...Check cable and terminal integrity Engine ECM pin B31 EMS main relay pin 1 EMS main relay pin 2 EMS main relay pin 3 EMS main relay pin 5 OK Disconnect main relay and proceed to test 4 Faulty Rectify fault proceed to test 5 4 Check fuse box fuse 5 integrity OK Proceed to test 5 Short circuit Replace fuse and proceed to test 5 5 Check cable continuity Engine ECM pin A01 to EMS main relay pin 5 Engi...

Page 475: ...sent Contact Triumph service Circuit Diagram 5 2 3 1 A01 B31 NK YS NK 5 B 12 24 36 25 13 1 1 16 32 48 17 1 33 31 1 2 3 4 5 6 7 8 9 3 2 1 5 1 2 3 4 5 EMS Relay 1 Fuse Box 2 Engine Electronic Control Module 3 Engine Electronic Control Module Connector A 4 Engine Electronic Control Module Connector B 5 Fault Code Possible cause Action Service Manual Scrambler 1200 XC 475 of 640 ...

Page 476: ...le pin 2 ABS module pin 11 Keyless ECM pin 5 Keyless ECM pin 13 Bluetooth module pin 3 Bluetooth module pin 4 OK Disconnect instruments and proceed to test 2 Faulty Rectify fault proceed to test 5 2 Check cable for short circuit Engine ECM pin A34 to ground Engine ECM pin A33 to ground OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity Eng...

Page 477: ...ctify wiring fault proceed to test 5 4 Check cable for short circuit Engine ECM pin A34 to ECM pin A33 OK Proceed to test 5 Short circuit Locate and rectify wiring fault proceed to test 5 5 Reconnect harness clear fault code and run engine OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram A33 13 2 25 6 11 14 5 24 R R R R R U U U U U A34 1 2 6 3 4 1 8 9 16 18 ...

Page 478: ...ommunication CAN 5 Volt Sensor Supply Circuit Throttle Actuator Motor Twist Grip Position 1 Twist Grip Position 2 Twist Grip Position Sensor 1 Correlation Error with Twist Grip Position 2 Ambient Air Pressure Sensor Removal and Installation Fuel and Air Components Fuel Cap Cover Removal Fuel Cap Cover Installation Fuel Tank Removal Fault Code Possible cause Action P1695 Lost communication with Vie...

Page 479: ...4 to ground OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity ECM pin A33 to Instrument pin 25 ECM pin A34 to Instrument pin 24 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 5 4 Check cable for short circuit ECM pin A33 to ECM pin A34 OK Proceed to test 5 Short circuit Locate and rectify wiring fault pr...

Page 480: ...nnector A 3 Fault Code Possible cause Action P1698 5 Volt sensor supply malfunction View and note sensor data Note ECM sensors requiring a power supply will not be active Disconnect the engine ECM and proceed to pinpoint test 1 Pinpoint T ests Test Result Action 1 Check cable and terminal OK Proceed to test 2 Service Manual Scrambler 1200 XC 480 of 640 ...

Page 481: ...K Replace sensor last removed and proceed to test 5 Faulty Proceed to test 4 4 Check cable for short circuit Engine ECM pin B18 to ground Engine ECM pin B34 to ground Engine ECM pin B18 to A01 Engine ECM pin B34 to A01 Engine ECM pin B18 to battery positive Engine ECM pin B34 to battery positive OK Proceed to test 5 Short circuit Locate and rectify wiring fault proceed to test 5 5 Reconnect harnes...

Page 482: ...Detection Switch 4 Fuel Level Sender 5 Side Stand Switch 6 Gear Position Sensor 7 Engine Electronic Control Module Connector A 8 Engine Electronic Control Module Connector B 9 Fault Code Possible cause Action P2100 Throttle actuator short circuit to ground or short circuit to battery Voltage Throttle actuator with View and note diagnostic tool freeze frame data if available View and note diagnosti...

Page 483: ...d OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 5 3 Check fuse box Fuse 5 integrity Check cable continuity Engine ECM pin A02 to throttle body connector pin 1 Engine ECM pin A03 to throttle body connector pin 2 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 5 4 Check cable for short circuit Engine ECM pin A02 to ECM pin A01 En...

Page 484: ...r B 4 Fuel Tank Installation Fault Code Possible cause Action P2120 Twist grip position sensor 1 short circuit to ground or open circuit View and note sensor data Note ECM sensors requiring a power supply will not be active Ensure twist grip position sensor is secure Disconnect the engine ECM and proceed to pinpoint test 1 P2123 Twist grip position sensor 1 short circuit to battery Voltage Pinpoin...

Page 485: ... cable continuity Engine ECM pin B17 to sensor pin 5 Engine ECM pin B21 to sensor pin 3 Engine ECM pin B35 to sensor pin 1 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 5 4 Check cable for short circuit Engine ECM pin B21 to Engine ECM pin B17 Engine ECM pin B21 to Engine ECM pin B35 OK Renew twist grip position sensor proceed to test 5 Short circuit Locate and ...

Page 486: ...ible cause Action P2125 Twist grip position sensor 2 short circuit to ground or open circuit View and note sensor data Note ECM sensors requiring a power supply will not be active Ensure twist grip position sensor is secure Disconnect the engine ECM and proceed to pinpoint test 1 P2128 Twist grip position sensor 2 short circuit to battery Voltage Pinpoint T ests Test Result Action Service Manual S...

Page 487: ...ngine ECM pin B28 to sensor pin 4 Engine ECM pin B33 to sensor pin 2 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 5 4 Check cable for short circuit Engine ECM pin B28 to Engine ECM pin B19 Engine ECM pin B28 to Engine ECM pin B33 OK Renew twist grip position sensor proceed to test 5 Short circuit Locate and rectify wiring fault proceed to test 5 5 Reconnect har...

Page 488: ...ation error with twist grip position sensor 2 View and note diagnostic tool freeze frame data if available View and note diagnostic tool sensor data Disconnect twist grip position sensor and proceed to pinpoint test 1 Pinpoint T ests Test Result Action 1 Turn the ignition on and measure the Voltage between Engine ECM pin B33 and Engine ECM pin B19 5V DC Proceed to test 2 Faulty Rectify fault proce...

Page 489: ...and proceed to test 3 Open circuit Rectify fault proceed to test 3 3 Reconnect harness clear fault code and run engine to verify fault cleared OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram 2 B R S B R S B35 B21 B17 B28 B19 B33 B R S B R S 3 1 6 5 4 16 32 48 33 17 1 21 35 28 19 3 2 1 6 5 4 1 3 2 Service Manual Scrambler 1200 XC 489 of 640 ...

Page 490: ... 1 Check cable and terminal integrity ECM pin B18 ECM pin B34 ECM pin B41 Sensor pin 1 2 3 OK Disconnect ambient pressure sensor and proceed to test 2 Faulty Rectify fault proceed to test 4 2 Check cable for short circuit ECM pin B41 to ECM pin B18 ECM pin B41 to ECM pin B34 OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 4 3 Check cable for continuity ECM pin B3...

Page 491: ... service Circuit Diagram B18 B41 B34 2 1 3 KP KB K 16 32 48 17 1 33 18 34 41 2 1 3 1 2 3 Ambient Air Pressure Sensor 1 Engine Electronic Control Module 2 Engine Electronic Control Module Connector B 3 Fuel Pressure Checking WARNING Service Manual Scrambler 1200 XC 491 of 640 ...

Page 492: ...d causing injury to the operator or damage to the motorcycle Open the fuel cap cover and remove the fuel cap 1 Note Note that the chamfered edge of the plastic locking ring is uppermost for installation Note the four locating lugs on the plastic locking ring that fit into the cut outs in the fuel tank filler neck Using a suitable proprietary lever remove the plastic locking ring 2 cjwf 1 2 Plastic...

Page 493: ... in open position 4 Carefully lift off the fuel cap cover 4 WARNING Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers A fire causing personal injury and damage to property could result from spilled Service Manual Scrambler 1200 XC 493 of 640 ...

Page 494: ...r or damage to the motorcycle Note Note that the chamfered edge of the plastic locking ring is uppermost as noted during removal Note the four locating lugs on the plastic locking ring that fit into the cut outs in the fuel tank filler neck Position the fuel cap cover and then turn anticlockwise to lock its four locating lugs into the fuel tank filler neck 1 4 cjwg 1 3 2 Service Manual Scrambler 1...

Page 495: ...c locking ring 2 cjwf 1 2 Plastic locking ring 1 Locating lug 2 shown 2 Refit the fuel cap and check the operation of the lock 3 WARNING Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers A fire causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly Service Manual Scramb...

Page 496: ...the motorcycle Perform the following operations Seat Removal Battery Removal Remove the fixing securing the rear of the fuel tank to the frame Discard the lock nut 1 L0768 1 Fixings 1 Pivot the fuel tank upwards at the rear 2 Detach the breather hose from its retaining clips on the fuel tank then disconnect it from the fuel tank 3 2 Service Manual Scrambler 1200 XC 496 of 640 ...

Page 497: ...Fuel pump electrical connector 2 WARNING If the fuel rail is dismantled without first reducing pressure fuel may escape causing clothing and components to be coated with fuel This would represent a serious fire hazard which could lead to burn injuries and damage to property Temporarily reconnect the battery positive red lead first and tighten the terminals to 4 5 Nm 5 Note Service Manual Scrambler...

Page 498: ...r the components to absorb the small amount of fuel that may come from the fuel tank and its fuel lines Briefly crank the engine to reduce the fuel pressure in the fuel rail 6 Disconnect the battery negative black lead first 7 To release the double check clip ease the latch away from the connector until the release buttons are exposed 8 cekp 1 2 Locked Position 1 Unlocked Position 2 Disconnect the...

Page 499: ...bly Removal Fuel Pump Assembly Inspection Fuel Pump Assembly Installation Fuel Pressure Regulator Removal Fuel Pressure Regulator Inspection Fuel Pressure Regulator Installation Fuel Pump Removal Fuel Pump Inspection Fuel Pump Installation Fuel Level Sensor Removal WARNING Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers A fire ca...

Page 500: ... are correctly fitted 1 Manoeuvre the tank into position engaging it with the front mounting rubbers 2 Reconnect the fuel feed hose by gently pushing inwards until the hose engages with a click 3 ciwd 1 Fuel hose 1 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 an...

Page 501: ...ew lock nut to 8 Nm 9 If removed use a proprietary professional automotive workshop equipment approved for fuel handling to refill the fuel tank with any fuel removed earlier 10 Perform the following operations Perform the following operations Battery Installation Seat Installation Fuel Level Sensor Installation Airbox Removal Airbox Installation Throttle Body and Inlet Manifold Assembly Removal T...

Page 502: ...ss to the fuel tank 2 Select the fuel pressure gauge adaptor marked A from T3880001 Fuel Pressure Gauge 3 WARNING Always use the correct fuel pressure gauge adaptor 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 Connect the adaptor hose to the fuel pump plate outlet and fuel hose as shown in the illustration ...

Page 503: ...This will allow the gauge to spring upwards from the adaptor Ensure the gauge is visible to the side of the motorcycle 6 If fuel has been removed from the fuel tank during removal use a proprietary professional automotive workshop equipment approved for fuel handling to add fuel to the tank with any fuel removed earlier 7 Reconnect the battery positive red lead first 8 Start the engine and observe...

Page 504: ...onic Control Module ECM Installation Throttle Actuator Motor Twist Grip Removal Twist Grip Installation Twist Grip Position Sensor Removal Twist Grip Position Sensor Installation Intake Air Temperature Sensor Removal WARNING Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers A fire causing personal injury and damage to property coul...

Page 505: ... all fuel from the fuel tank 1 Remove the fuel tank see Fuel Tank Removal 2 Invert the fuel tank and place on a protective surface to prevent paint damage 3 Remove the ring of fixings securing the fuel pump mounting plate to the tank 4 ciwg 1 2 Fuel pump mounting plate 1 Fixing 2 Detach the pump assembly from the fuel tank 5 Disconnect the fuel level sensor from the fuel pump assembly harness 6 1 ...

Page 506: ...rning advice given in the General Information section on the safe handling of fuel and fuel containers A fire causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly Position a new fuel pump plate seal to the fuel pump plate as noted for removal 1 Route the fuel level sensor harness under the baffle hose and fuel pump assembly harness a...

Page 507: ...htening Sequence Refit the fuel tank see Fuel Tank Installation 4 Refill the fuel tank with the fuel drained during removal and check carefully for fuel leaks 5 Perform the following operations Battery Installation Seat Installation Perform the following operations Fuel Pump Assembly Removal Remove and discard the circlip securing the fuel pressure regulator in its housing 1 1 Service Manual Scram...

Page 508: ...ousing 2 cixv 2 1 3 Large O ring 1 Fuel pressure regulator 2 Small O ring 3 Inspect all hoses for cracks splits fraying and other damage Replace as necessary 1 Check all hose clamps for cracks and signs of distortion Replace as necessary 2 Check the mesh filter for damage and replace the fuel pump if necessary 3 Install new O rings to the fuel pressure regulator 1 Service Manual Scrambler 1200 XC ...

Page 509: ...sure regulator with a new circlip 4 Refit the hose and secure with the hose clip Check for any fuel leaks and rectify if necessary 5 Perform the following operations Fuel Pump Assembly Installation Perform the following operations Fuel Pump Assembly Removal Release the fuel hose clip from the fuel pump side of the fuel filter 1 Remove the hose bracket from the fuel pump bracket 2 civv 2 1 Service ...

Page 510: ...ffle housing for installation It is not necessary to disconnect the baffle housing hose from the fuel pressure regulator unless it is to be removed at the same time as the fuel pump civw 2 1 Baffle housing 1 Hose clip 2 Remove the baffle housing hose clip over the inlet filter 5 Disconnect the fuel pump electrical connector 6 Remove the fuel pump securing bolt and strap 7 1 2 Service Manual Scramb...

Page 511: ...ge Replace as necessary 1 Check all hose clamps for cracks and signs of distortion Replace as necessary 2 Check the mesh filter for damage and replace the fuel pump if necessary 3 If removed refit the connector hose to the fuel pump Secure with the hose clip 1 Position the fuel pump to the bracket ensuring the feet of the rubber isolator engage correctly in the fork 2 1 2 cevu Fork 1 Isolator feet...

Page 512: ... baffle housing over the fuel pump as noted for removal Refit the hose clip and tighten to 3 Nm 8 Perform the following operations Fuel Pump Assembly Installation WARNING Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers A fire causing personal injury and damage to property could result from spilled fuel or fuel not handled or stor...

Page 513: ... 1 3 2 Locking device 1 Locating lugs 2 Bracket 3 Remove the fuel level sensor 2 WARNING Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers A fire causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly Align the two locating lugs into the holes in the bracket 1 Slide the...

Page 514: ...e operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Fuel Tank Removal Exhaust Silencer Removal Side Panels Rear Mudguard Removal Engine Electronic Control Module ECM Removal Note Before the disconnection of any wiring note the routing of all wiring and wiring connectors on both sides of the airbox Release the fixing and detach the air temperature se...

Page 515: ...ket 3 Remove the fixings and detach the connector bracket from the right hand side of the airbox 4 L0756 2 1 1 Fixings 1 Connector bracket 2 Detach the main fuse from the relay bracket 5 Disconnect the electrical connector from the keyless electronic control module 6 Service Manual Scrambler 1200 XC 515 of 640 ...

Page 516: ...l connector 2 Remove the fixings and detach the relay bracket from the left hand side of the airbox 7 L0916a 2 1 1 Fixings 1 Relay bracket 2 Release the two hose clips and remove the engine breather hose 8 Service Manual Scrambler 1200 XC 516 of 640 ...

Page 517: ...ps 1 Engine breather pipe 2 Clamp 3 Remove the rear grommet for the left hand side panel for access to battery box lower fixing 10 Remove the two fixings securing the battery box to the frame 11 L0752 2 3 1 Grommet 1 Fixings 2 Service Manual Scrambler 1200 XC 517 of 640 ...

Page 518: ... is attached to the underside of the battery box Release the fixing and carefully manoeuvre the battery box rearward for removal 13 L0753 1 3 2 Starter motor solenoid 1 Fixing 2 Battery box 3 Remove the fixing and shouldered washer from both sides of the airbox 14 3 1 2 2 Service Manual Scrambler 1200 XC 518 of 640 ...

Page 519: ... causing injury to the operator or damage to the motorcycle Note When installing the airbox ensure that the brake lines on the right hand side of the frame do not get damaged Position the airbox to the frame ensuring the throttle body air duct is correctly aligned to the throttle body 1 Check that the harnesses and hoses are routed as noted on removal 2 Tighten the intake hose clamp to 1 5 Nm 3 Fi...

Page 520: ...battery box to the rear of the airbox and connect the electrical connector to the keyless electronic control module ECM 6 L0916 2 1 Main fuse 1 Keyless ECM electrical connector 2 Attach the relay bracket to the left hand side of the airbox ensuring the harness is not trapped and tighten the three fixings to 1 5 Nm 7 1 1 Service Manual Scrambler 1200 XC 520 of 640 ...

Page 521: ...the rear of the airbox and secure to the frame Tighten the fixings to 6 Nm 8 Tighten the airbox fixings to 6 Nm 9 L0751 3 1 2 2 Fixing 1 Airbox 2 Attach the starter motor solenoid to the right hand side of the battery box 10 1 3 2 Service Manual Scrambler 1200 XC 521 of 640 ...

Page 522: ...e left hand side panel 11 Refit the engine breather hose and secure with the hose clips 12 L0758 2 1 3 Clips 1 Engine breather pipe 2 Attach the connector bracket to the right hand side of the airbox and tighten the fixings to 1 5 Nm 13 1 Service Manual Scrambler 1200 XC 522 of 640 ...

Page 523: ... 1 Air pressure sensor 2 Perform the following operations Engine Electronic Control Module ECM Installation Rear Mudguard Installation Side Panels Fuel Tank Installation Battery Installation Seat Installation WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator Service Manual Scrambler 12...

Page 524: ...hers 1 2 1 L0825 Fixing 1 Air intake finisher right hand side shown 2 Note For the USA and Canadian Markets only there is an ignition master switch and bracket assembly secured to the left hand side of the throttle body by the finisher mounting and its fixings Remove the two fixings and remove the mountings for the air intake finisher 2 2 1 Service Manual Scrambler 1200 XC 524 of 640 ...

Page 525: ...Throttle actuator motor 2 Note Note which spigot on the inlet manifold the MAP sensor hose is fitted to and if fitted which spigot the evaporative emissions hose is fitted to for installation Disconnect the MAP hose and the evaporative emissions hose from the inlet manifold 4 1 2 Service Manual Scrambler 1200 XC 525 of 640 ...

Page 526: ...o the inlet manifold 6 Remove the four fixings securing the inlet manifold to the cylinder head and remove the inlet manifold 7 Remove the throttle body 8 cjdr 5 4 2 3 1 Clamp 1 Throttle body fixings left hand side 2 Inlet manifold fixings left hand side 3 Throttle body 4 Inlet manifold 5 Service Manual Scrambler 1200 XC 526 of 640 ...

Page 527: ...fore 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 CAUTION From VIN 783907 the purge valve restrictor has been removed from the purge valve hose The restriction is now controlled by the purge valve spigot on the inlet manifold Fitting a new manifold with the purge valv...

Page 528: ...olled by the spigot pressed into the new inlet manifold When ordering replacement parts always refer to the EPC Ensure the mating surfaces on the inlet manifold and the cylinder head are clean 1 Fit three new seals to the mating surfaces of the inlet manifold 2 1 2 2 Inlet manifold 1 Seals 2 Fit the inlet manifold to the cylinder head Do not fully tighten the fixings at this stage 3 Ensure the mat...

Page 529: ...ixings one and two to 9 Nm 8 ckgn 1 4 3 2 Tightening Sequence Tighten the throttle body to inlet manifold fixings to 9 Nm 9 Ensure the throttle body hose is correctly fitted and tighten the clip to 1 5 Nm 10 cjdr 5 4 2 3 1 Clamp 1 Throttle body fixings left hand side 2 Service Manual Scrambler 1200 XC 529 of 640 ...

Page 530: ...ote For the USA and Canadian Markets only there is an ignition master switch and bracket assembly secured to the left hand side of the throttle body by the finisher mounting and its fixings Fit the mountings for the air intake finisher and tighten its new fixings to 3 Nm 13 L0859 2 1 1 Fixings 1 Mounting right hand side shown 2 Fit the air intake finishers and tighten the new fixing to 1 5 Nm 14 2...

Page 531: ... Air Pressure Sensor Removal Ambient Air Pressure Sensor Installation Fall Detection Switch Removal Fall Detection Switch Installation Gear Position Sensor Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Remova...

Page 532: ...n 2 Note For the USA and Canadian Markets only there is an ignition master switch and bracket assembly secured to the left hand side of the throttle body by the finisher mounting and its fixings Remove the two fixings and remove the mountings for the air intake finisher 2 L0859 2 1 1 Service Manual Scrambler 1200 XC 532 of 640 ...

Page 533: ... 2 Electrical connector right hand side shown 1 Fuel rail cover right hand side shown 2 Fixing right hand side shown 3 Spacer 4 Fuel rail 5 Gently ease the fuel rail and injectors upwards to release them from the cylinder head 5 Note The fuel injectors are not to be removed from the fuel rail unless they are to be replaced If the injectors require replacing continue from step 6 Note the position o...

Page 534: ... fuel rail continue from step 1 and omit steps 3 and 4 If the fuel injectors have not been removed continue from step 3 Lightly lubricate the O rings with clean engine oil and fit the new fuel injectors to the fuel rail 1 Fit the retaining clip for each fuel injector as noted for removal 2 1 2 3 Service Manual Scrambler 1200 XC 534 of 640 ...

Page 535: ...ers between the fuel rail and cylinder head fit the fuel rail covers fit and tighten the fixings to 6 Nm 6 cjdk 3 5 1 4 2 Electrical connector right hand side shown 1 Fuel rail cover right hand side shown 2 Fixing right hand side shown 3 Spacer 4 Fuel rail 5 Connect the electrical connectors to the fuel injectors 7 Note For the USA and Canadian Markets only there is an ignition master switch and b...

Page 536: ... Nm 8 L0859 2 1 1 Fixings 1 Mounting right hand side shown 2 Fit the air intake finishers and tighten the new fixing to 1 5 Nm 9 2 1 L0825 Fixing 1 Air intake finisher right hand side shown 2 Perform the following operations Side Panels Service Manual Scrambler 1200 XC 536 of 640 ...

Page 537: ...r damage to the motorcycle Note The engine ECM is located at the rear of the battery box Perform the following operations Seat Removal Battery Removal Rear Mudguard Removal Remove the engine electronic control module ECM strap and detach it from the battery box 1 Disconnect the two electrical connectors and remove the engine ECM see Electrical Connectors 2 1 3 L0747 2 Electrical connectors 1 Engin...

Page 538: ... must not be loosened or removed If the fixings have been loosened or removed the throttle body assembly must be replaced as there are no means to reset the throttle actuator motor to its correct position The throttle actuator motor is an integral part of the throttle body and cannot be adjusted or replaced separately WARNING Before starting work ensure the motorcycle is stabilised and adequately ...

Page 539: ...ed any warranty claims for the twist grip housing will not be honoured Release the fixings and remove the clamp for the twist grip housing from the handlebar 2 L0422 2 1 Anti tamper fixings 1 Fixings 2 Note Note the position and orientation of the twist grip to its housing for installation Slide the twist grip off the handlebar 3 Service Manual Scrambler 1200 XC 539 of 640 ...

Page 540: ...e twist grip to the twist grip position sensor as noted for removal 1 Fit the twist grip clamp Ensure the locating lug fits into its hole on the handlebar 2 L0421 2 3 1 Locating lug 1 Hole 2 Twist grip clamp 3 Fit the fixings and tighten upper one first to 2 5 Nm 3 Refit the right hand handlebar end weight and spacer Tighten the new fixing to 5 Nm 4 2 1 4 Service Manual Scrambler 1200 XC 540 of 64...

Page 541: ...he operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Twist Grip Removal Note Note the orientation of the twist grip position sensor for installation Note the routing of the twist grip harness and its rubber bands for installation Note the routing of the brake lines clutch cable and harnesses through the headstock tidy for installation Release the fi...

Page 542: ...ne 4 Clutch cable 5 Release the fixings and remove the headstock centre cover 2 L0813 1 3 2 Fixing M5 1 Fixing M4 2 Centre cover 3 Disconnect the twist grip position sensor electrical connector from the main harness and route the harness to the twist grip 3 1 Service Manual Scrambler 1200 XC 542 of 640 ...

Page 543: ...lide the twist grip position sensor onto the handlebar in the orientation noted for removal 1 Route the twist grip harness to the main harness as noted for removal 2 Connect the twist grip position sensor electrical connector to the main harness 3 L0913 1 Twist grip position sensor electrical connector 1 Position the harnesses to the headstock tidy as noted for removal Fit the headstock centre cov...

Page 544: ...rake lines and the clutch cable to the headstock tidy as noted for removal 5 Fit the headstock tidy outer cover and tighten the fixings to 3 Nm 6 5 1 L0713_1 2 3 4 Fixings 1 Outer cover 2 Front brake master cylinder brake line 3 Service Manual Scrambler 1200 XC 544 of 640 ...

Page 545: ... and an accident Check for correct operation of the front brake clutch and twist grip Check that the brake hose clutch hose and electrical harnesses do not bind or restrict the steering when the handlebars are turned from lock to lock Rectify as necessary Gear Position Sensor Installation Ignition Coils Removal Ignition Coils Installation Keyless ECM Removal Keyless ECM Installation Crankshaft Pos...

Page 546: ...tery Removal Right hand Side Panels Disconnect the electrical connector from the sensor 1 Remove the fixing and remove the sensor from the airbox 2 3 2 1 L0817 Fixing 1 Electrical connector 2 Airbox 3 Exhaust Catalytic Converter Removal Exhaust Catalytic Converter Installation Evaporative System Components Evaporative Loss Control System Certain Markets Only Evaporative Control System Engine Off S...

Page 547: ...ator and Hoses Exploded View Coolant Expansion Tank Radiator Hoses Radiator and Cooling Fan Inspection Coolant Coolant Replacement Drainage Coolant Replacement Filling Water Pump Water Pump Inspection Coolant System Pressure Test Coolant Pressure Cap Test Thermostat Removal Thermostat Inspection Thermostat Installation Radiator Removal Radiator Installation Coolant Expansion Tank Removal Service M...

Page 548: ... Bearing Adjustment Upper Yoke Removal Upper Yoke Installation Lower Yoke and Headstock Bearings Removal Lower Yoke and Headstock Bearings Installation Handlebars Removal Handlebars Installation Fit the sensor to the airbox and tighten the fixing to 1 5 Nm 1 Reconnect the electrical connector to the sensor 2 Perform the following operations Refit the right hand Side Panels Battery Installation Sea...

Page 549: ...on coils bracket 2 Press the wire locking device fully in and detach the coolant temperature sensor from the main harness 2 Note Note the routing of the coolant temperature harness for installation Remove the rubber cover and using a suitable 19 mm slotted socket remove the coolant temperature sensor from the cylinder head and discard the washer 3 1 Service Manual Scrambler 1200 XC 549 of 640 ...

Page 550: ...al connector to the ignition coils bracket 5 Perform the following operations Radiator Installation Coolant Replacement Filling Fuel Tank Installation Battery Installation Seat Installation WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the follow...

Page 551: ...efore starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Throttle Body and Inlet Manifold Assembly Removal Disconnect the electrical connector from the sensor 1 Release the fixing and remove the sensor 2 2 1 3 Se...

Page 552: ...Ambient air pressure sensor 3 Perform the following operations Throttle Body and Inlet Manifold Assembly Installation Battery Installation Seat Installation WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Servi...

Page 553: ...ical connector and remove the fall detection switch 2 L0809 1 2 3 Fixings 1 Fall detection switch 2 Electrical connector 3 Connect the electrical connector to the fall detection switch 1 Fit the fall detection switch to the frame below storeage box and tighten the new fixings to 3 Nm 2 L0809 1 2 3 Service Manual Scrambler 1200 XC 553 of 640 ...

Page 554: ... will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Seat Removal Battery Removal Right hand Side Panels Front Sprocket Cover Removal On the right side of the airbox disconnect the gear position sensor electrical connector from the main harness 1 1 L0810 Gear position sensor electrical connector 1 Note Service Manual Scr...

Page 555: ...Note that the white tape on the harnesses within the harness guide aligns with the upper gap for installation Remove and discard the fixings and detach the harness guide from the crankcase 3 L0706 2 1 3 4 Fixings 1 Harness guide 2 Upper gap 3 White tape 4 Carefully remove the gear position sensor harness from the harness guide 4 2 1 Service Manual Scrambler 1200 XC 555 of 640 ...

Page 556: ...cle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Fit new O rings to the sensor Lubricate the O rings with a smear of petroleum jelly 1 Position the sensor to the engine ensuring that the lug on the sensor engages with the slot in the selector drum shaft 2 1 Service Manual Scrambler 1200 XC 556 of 640 ...

Page 557: ...t the gear position sensor harness into the harness guide as noted for removal with the white tape shown in the upper gap 4 Secure the harness guide to the crankcase and tighten the new fixings to 4 Nm 5 L0706 2 1 3 4 Fixings 1 Harness guide 2 Upper gap 3 White tape 4 Service Manual Scrambler 1200 XC 557 of 640 ...

Page 558: ...y Installation Seat Installation WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Disconnect the high tension cables from the spark plugs 1 Note The ignition coil wires identified with the red tape are fitted to the right hand side of the ignition coils Not...

Page 559: ...gnition coils 2 Detach the coolant temperature connector from the ignition coils bracket 3 ciwk 1 Coolant temperature sensor connector 1 Remove the three fixings and detach the ignition coil bracket from the motorcycle frame 4 Service Manual Scrambler 1200 XC 559 of 640 ...

Page 560: ...arness on the ignition coil bracket for installation Detach the fuel pump harness from the ignition coils bracket 5 Disconnect the MAP sensor hose and the electrical connector from the MAP sensor 6 ciya 2 3 1 Fuel pump harness 1 MAP sensor electrical connector 2 Service Manual Scrambler 1200 XC 560 of 640 ...

Page 561: ...cycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Position the ignition coils onto their bracket secure with new fixings and tighten to 3 Nm 1 Connect the MAP sensor hose and the electrical connector to the MAP sensor 2 Attach the fuel pump harness to the ignition coil bracket as noted for removal 3 1 ...

Page 562: ...ttach the coolant temperature sensor connector onto the ignition coil bracket 5 Note The wires for the right hand side of the ignition coils are identified with the red tape Connect the four wires from the ignition coils as noted for removal two either side of the ignition coils 6 ciwj 2 1 2 Ignition coil connections right hand side shown 1 Ignition coils 2 Service Manual Scrambler 1200 XC 562 of ...

Page 563: ...e motorcycle Perform the following operations Exhaust Silencer Removal Side Panels Rear Mudguard Removal Engine Electronic Control Module ECM Removal Note Before the disconnection of any wiring note the routing of all wiring and wiring connectors on both sides of the airbox Disconnect the electrical connector from the keyless electronic control module ECM 1 L0916_1 1 Keyless ECM electrical connect...

Page 564: ...from the right hand side of the battery box 3 Note The keyless ECM is attached to the underside of the battery box Remove the two fixings securing the battery box to the frame and carefully manoeuvre the battery box rearward for removal 4 L0753 1 3 2 Service Manual Scrambler 1200 XC 564 of 640 ...

Page 565: ...CM 2 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 Fit the keyless ECM to the battery box as noted for and tighten the fixings to 3 Nm 1 Service Manual Scrambler 1200 XC 565 of 640 ...

Page 566: ...nnector to the keyless ECM 2 L0916_1 1 Keyless ECM electrical connector 1 Carefully position the battery box to the rear of the airbox and secure to the frame Tighten the fixings to 6 Nm 3 Attach the starter motor solenoid to the right hand side of the battery box 4 1 3 2 Service Manual Scrambler 1200 XC 566 of 640 ...

Page 567: ...bilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Note If the crankshaft position sensor needs to be replaced the alternator stator will also be replaced as they are one assembly Perform the following operations Seat Removal Battery Removal Alternator Cover Removal Remove and discard the fixings securing the crank...

Page 568: ...cover and remove the stator 3 cjcs 3 4 2 1 Fixing 1 Harness cover 2 Fixings 3 Stator 4 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 Position the stator to the alternator cover and route the harness as noted for removal Secure the stator with new fixings...

Page 569: ...Fit the harness cover and tighten the new fixing to 6 Nm 2 Note The air gap for the crankshaft position sensor is not adjustable Fit the crankshaft position sensor with two new fixings and tighten to 6 Nm 3 civn 1 2 Service Manual Scrambler 1200 XC 569 of 640 ...

Page 570: ...g injury to the operator or damage to the motorcycle 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 Perform the following operations Seat Removal Release the two fixings and remove the silencer ...

Page 571: ...heat shield bracket rearwards for removal Collect the two rubber grommets 2 L0722 1 3 2 Fixing 1 Rubber grommets 2 Heat shield bracket 3 Release the fixings and remove the centre heat shield 3 L0703 1 2 Service Manual Scrambler 1200 XC 571 of 640 ...

Page 572: ... on assembly Release the clamps securing the silencers to the catalytic converter 4 L0721 1 2 3 Upper silencer clamp 1 Lower silencer clamp 2 Catalytic converter 3 Note Note the position of the shouldered washers and rubber bushes in the silencer mountings for installation Support the silencer assembly and remove the upper fixing 5 Service Manual Scrambler 1200 XC 572 of 640 ...

Page 573: ...llation Release the lower mounting fixing and remove the exhaust silencer assembly Collect the rubber bushes and the shouldered washer 6 L0718 3 1 2 Fixing 1 Shouldered washer 2 Rubber bushes 3 Remove and discard the exhaust gaskets 7 Rear Suspension Exploded View Rear Suspension Units Exploded View Swinging Arm Service Manual Scrambler 1200 XC 573 of 640 ...

Page 574: ...rear mounting as noted for removal 2 Fit new exhaust silencer gaskets to the catalytic converter ensure they are positioned up to the collar 3 1 2 2 3 Exhaust gaskets 1 Collar 2 Catalytic converter 3 Fit the two rubber bushes and the shouldered washer to the lower mounting as noted for removal 4 Position the exhaust clamps onto the silencer 5 Position the silencer assembly onto the catalytic conve...

Page 575: ...ncer upper mounting to the frame and fit the fixing but do not fully tighten at this stage 8 L0724 1 Fixing 1 Position the exhaust gaskets into the silencer clamp area until flush with the end of the silencer clamp area 9 1 3 Service Manual Scrambler 1200 XC 575 of 640 ...

Page 576: ... silencer clamp 1 Lower silencer clamp 2 Catalytic converter 3 Tighten the silencer assembly upper fixing to 19 Nm 11 Tighten the silencer assembly lower fixing to 19 Nm 12 Position the inner and outer covers of the centre heat shield to the silencers fit the fixings and tighten to 6 Nm 13 Service Manual Scrambler 1200 XC 576 of 640 ...

Page 577: ...racket 14 Fit the heat shield bracket to its locating lugs on the exhaust silencer Fit and tighten the bracket rear fixing to 6 Nm 15 L0722 1 3 2 Fixing 1 Rubber grommets 2 Heat shield bracket 3 Fit the rear heat shield and tighten its fixings to 6 Nm 16 1 Service Manual Scrambler 1200 XC 577 of 640 ...

Page 578: ... 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 Note The right hand header pipe is part of the catalytic converter Note Always note the position and orientation of exhaust clamps prior to releasing them and re...

Page 579: ...he catalytic converter 1 cjzs 3 1 2 Exhaust clamp 1 Left hand header pipe 2 Catalytic converter 3 Release the fixing and detach the connector bracket from the right hand side of the headstock 2 1 2 L0823 Fixing 1 Connector bracket 2 Service Manual Scrambler 1200 XC 579 of 640 ...

Page 580: ...of red tape for identification The oxygen sensors are NOT marked Always ensure the right hand oxygen sensor harness is connected to the correct main harness connector identified by the red tape Disconnect the left hand oxygen sensor from the main harness 3 2 1 L0824 Left hand oxygen sensor connector 1 Right hand oxygen sensor connector 2 Remove the fixings and the finned clamps securing the exhaus...

Page 581: ...ycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle 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 1 Fit a new gasket to the header pipe and position the clamp over the joint 2 Note To retain the gaskets during assemb...

Page 582: ... At the same time attach the header pipe to the catalytic converter 5 Fit the fixings to the cylinder head studs and tighten in the sequence shown below 6 Stage 1 Header pipe lower nut to 10 Nm Header pipe upper nut to 10 Nm Retighten the header pipe lower nut to 10 Nm 2 1 Header pipe lower nut 1 Header pipe upper nut 2 Stage 2 Header pipe lower nut to 19 Nm Header pipe upper nut to 19 Nm Service ...

Page 583: ...he right hand side of the headstock and tighten its fixing to 3 Nm 3 1 2 L0823 Fixing 1 Connector bracket 2 Perform the following operations Fuel Tank Installation Battery Installation Seat Installation Start the engine and check for exhaust gas leaks Rectify if necessary WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from fallin...

Page 584: ...val Exhaust Silencer Removal Left Hand Header Pipe Removal Fuel Tank Removal Note Note the routing of the oxygen sensor harness for installation The oxygen sensor electrical connections must not be swapped between cylinders If the connections are swapped over engine malfunctions will occur The right hand Cylinder 2 oxygen sensor connector on the main harness has a red connector main harness side T...

Page 585: ...RNING 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 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 1 Note To retain the gaskets during assembly apply a smear of grease or pe...

Page 586: ...aust header pipe to the cylinder head ensure the gasket does not become displaced during assembly 4 Fit the fixings to the cylinder head studs and tighten in the sequence shown below 5 Stage 1 Header pipe lower nut to 10 Nm Header pipe upper nut to 10 Nm Retighten the header pipe lower nut to 10 Nm 1 2 Service Manual Scrambler 1200 XC 586 of 640 ...

Page 587: ...nsor harness as noted for removal and connect to the main harness as noted for removal 1 Fit the connector bracket to the right hand side of the headstock and tighten its fixing to 3 Nm 2 1 2 L0823 Fixing 1 Connector bracket 2 Perform the following operations Left Hand Header Pipe Installation Exhaust Silencer Installation Fuel Tank Installation Service Manual Scrambler 1200 XC 587 of 640 ...

Page 588: ...rbs vapour while the engine is not running When the engine is started the vapour is returned to the engine and burned There are two distinct phases to the system s operation engine off and engine running These two conditions are explained overleaf Component Locations Evaporative Canister under the airbox Purge Control Valve electronically controlled by the engine ECM left hand side of the airbox b...

Page 589: ...k due to a rise in ambient temperature will cause the fuel vapour to pass down the breather pipe A to a carbon filled evaporative canister that stores the vapour Once in the canister vapour cannot return to the fuel tank because the purge valve is closed ckjg_1 2 3 1 Service Manual Scrambler 1200 XC 589 of 640 ...

Page 590: ...uum applied to the purge valve now begins to draw stored vapour from the carbon filled evaporative canister and returns it to the inlet manifold for burning in the engine In order to control the speed at which vapour is purged from the canister the engine management system regularly shuttles the purge control valve between open and closed positions ckjg 2 2 3 1 Service Manual Scrambler 1200 XC 590...

Page 591: ...rd Removal Note Note the routing and locations of the hoses connected to the evaporative canister for installation Not the orientation of the evaporative canister for installation Detach the hoses from the evaporative canister 1 Cut and remove the two cable ties securing the evaporative emissions canister to the frame and remove the evaporative canister 2 L0821 4 1 2 3 Hose to purge valve 1 Hose t...

Page 592: ...vaporative canister to its mounting bracket with two cable ties as noted for removal 2 L0821 4 1 2 3 Hose to purge valve 1 Hose to fuel tank vent 2 Hose evaporative cannister vent 3 Cable ties 4 Perform the following operations Sump Guard Installation WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury ...

Page 593: ...uting of the purge valve hoses for installation Remove the fixing securing the purge control valve to its mounting bracket and manoeuvre it to left hand side of the frame 1 1 2 L0917 Fixing 1 Purge valve 2 Disconnect the electrical connector from the purge control valve 2 Detach the two hoses and remove the purge control valve 3 1 2 3 Service Manual Scrambler 1200 XC 593 of 640 ...

Page 594: ...d causing injury to the operator or damage to the motorcycle Connect the hoses to the purge control valve as noted during removal 1 L0918 1 2 3 Purge valve 1 Hose from evaporative cannister 2 Hose to inlet manifold 3 Connect the electrical connector to the purge control valve 2 Position the purge control valve to its mounting bracket and tighten the fixing to 3 Nm 3 Service Manual Scrambler 1200 X...

Page 595: ...1 2 L0917 Fixing 1 Purge valve 2 Perform the following operations Fuel Tank Installation Service Manual Scrambler 1200 XC 595 of 640 ...

Page 596: ...Check the radiator hoses for cracks or deterioration and hose clamps for tightness in accordance with scheduled maintenance requirements Radiator CAUTION Service Manual Scrambler 1200 XC 596 of 640 ...

Page 597: ... To prevent injury never place loose clothing fingers or hands near the cooling fan until the engine is stopped Loose clothing fingers or the hands could become trapped during cooling fan operation and cause crushing injury to the fingers hands or other parts of the anatomy The motorcycle is fitted with a thermostatically controlled electric fan situated behind the radiator When the fan operates w...

Page 598: ...iumph is premixed and does not need to be diluted prior to filling or topping up the cooling system CAUTION If hard water is used in the cooling system it will cause scale accumulation in the engine and radiator and considerably reduce the efficiency of the cooling system Reduced cooling system efficiency may cause the engine to overheat and suffer severe damage WARNING Before starting work ensure...

Page 599: ...ollowing operations Seat Removal Battery Removal Fuel Tank Removal Remove the coolant pressure cap 1 cixw 1 Coolant pressure cap 1 Position a container below the engine and radiator to collect the displaced coolant 2 Using T3880207 Hose Clip Pliers release the hose clamps then release the bottom hose from the radiator and allow the coolant to drain 3 2 4 3 Service Manual Scrambler 1200 XC 599 of 6...

Page 600: ...using injury to the operator or damage to the motorcycle 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 coolant will cause scalds and skin damage Refit the bottom hose Ensure the hose is positioned to the alignment mark and the clamp is positioned as noted for removal 1 cjf...

Page 601: ... escapes from the filler opening 3 Note If the system has filled correctly and fully there should be coolant visible through the filler opening Note During filling squeezing the bottom hose with both hands will help to pump coolant around the system and remove trapped air Refit the coolant pressure cap 4 Lower the motorcycle s rear wheel to the ground 5 Refit the fuel tank see Fuel Tank Installati...

Page 602: ... the operator or damage to the motorcycle 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 Water Pump Removal for removal and Oil and Water Pump Installation for installation Check the water pump face and shaft seals for signs of leakage Renew the pump if leakage is evident 1 WARNING Before starting work e...

Page 603: ...use with T3880147 bayonet type adapter and securely fasten to the coolant filler neck 3 Carefully connect the hand pump part of T3880147 Radiator and Cap Tester Kit to the T3880176 Radiator Pressure Test use with T3880147 ensuring an air tight seal is maintained 4 cjhr 2 3 1 Coolant filler neck 1 Service Manual Scrambler 1200 XC 603 of 640 ...

Page 604: ... 6 Note If the engine oil is contaminated further exploratory investigation will be required Engine oil with a hazy or milky appearance may indicate water emulsion If the engine oil is contaminated rectify the cause of the problem and then renew the oil and filter Remove the engine oil filler cap and check for contamination of the engine oil caused by coolant escaping into the engine sump 7 De pre...

Page 605: ...e 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 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 coolant will cause scalds and skin damage Allow ...

Page 606: ... recommended to carry out coolant pressure cap and cooling system pressure tests consecutively 1 5 4 3 2 Hand held pump 1 Bayonet type connector 2 Pressure cap test adapter 44 mm 3 Pressure cap test adapter 46 mm 4 Coolant cap type connector 5 Select the correct test adapter and securely fasten to the pressure cap 5 Carefully connect the hand pump to the adapter ensuring an air tight seal is maint...

Page 607: ...ks replace the cap 7 Perform the following operations Refit the coolant pressure cap Fuel Tank Installation Battery Installation Seat Installation Rear Suspension Unit Disassembly Rear Suspension Unit Assembly Rear Suspension Units Installation Swinging Arm Removal Swinging Arm Disassembly Swinging Arm Inspection Swinging Arm Assembly Swinging Arm Installation Brakes Service Manual Scrambler 1200 ...

Page 608: ...ing Brake Fluid Brake Pads Wear Brake Pad Wear Inspection Breaking in New Brake Pads and Discs Bleeding the Front Brakes Renewing Brake Fluid Bleeding the Rear Brakes Renewing Brake Fluid Air Gap Measurement Anti lock Brake System ABS Management Anti lock Brake System ABS ABS ECM Connector Pin Numbering Diagnostics and Testing System Diagnostics Triumph Diagnostic Software ABS Diagnostic Trouble C...

Page 609: ...Front or Rear Input Output Solenoid Open Short Circuit Front or Rear Wheel Actuator Hydraulic Control Wheel Lock Motor Lock Motor Does Not Run Motor Runs Continually Power Source Voltage Drop Voltage Rise Incorrect Tyre Size Detected ABS ECM Internal Error CAN Fault ABS Modulator Malfunction ABS Variant Coding Error Removal and Installation Front Brakes Components Front Brake Pads Removal Front Br...

Page 610: ... Front Brake Master Cylinder Hose Inlet Removal Front Brake Master Cylinder Hose Inlet Installation Removal and Installation Rear Brakes Components Rear Brake Pads Removal Rear Brake Pads Inspection Rear Brake Pads Installation Rear Brake Caliper Removal Rear Brake Caliper Disassembly Rear Brake Caliper Inspection Rear Brake Caliper Assembly Rear Brake Caliper Installation Rear Brake Disc Wear Rea...

Page 611: ...Speed Sensor Removal Rear ABS Wheel Speed Sensor Installation Front ABS Pulser Ring Removal Front ABS Pulser Ring Inspection Front ABS Pulser Ring Installation Rear ABS Pulser Ring Removal Rear ABS Pulser Ring Inspection Rear ABS Pulser Ring Installation ABS Hydraulic Modulator ECM Removal ABS Hydraulic Modulator ECM Installation Wheels and Tyres Exploded View Front Wheel Exploded View Rear Wheel ...

Page 612: ...View Final Drive Final Drive Chain Drive Chain Replacement Front Sprocket Removal Front Sprocket Installation Rear Sprocket Removal Rear Sprocket Installation Rear Sprocket Carrier and Cush Drive Removal Rear Sprocket Carrier and Cush Drive Inspection Rear Sprocket Carrier and Cush Drive Installation Rear Sprocket Carrier Bearings Disassembly Drive Pulley Flange Bearings Inspection Rear Sprocket C...

Page 613: ... Switch Steering Lock Lockset and Keyless ECM US only Exploded View Sump Guard Exploded View Side Panels Exploded View Grab Rail Exploded View Side Stand General Frame Inspection Bank Angle Indicators Seat Removal Seat Installation Side Panels Mirrors Removal Mirrors Installation Steering Lock Removal Steering Lock Installation Front Mudguard Removal Front Mudguard Installation Service Manual Scra...

Page 614: ...radle Assemblies Installation Electrical Exploded Views Exploded View Instruments Exploded View Alternator and Starter Motor Exploded View Headlight Exploded View Rear Lights Exploded View Direction Indicators Exploded View Keyless Exploded View Battery Horn and Wiring Exploded View Battery Horn and Wiring US only Battery Fuses and Relays Battery Battery Disposal Service Manual Scrambler 1200 XC 6...

Page 615: ...ystem Alternator Stator Regulator Rectifier System Diagnostics Keyless ECM System Diagnosis Keyless ECM System Diagnostic Tool Connection Keyless ECM Diagnostic Trouble Codes Pinpoint Tests Keyless ECM Power Supply Rail Overvoltage Undervoltage Keyless ECM Internal Power Supply Malfunction Starter Motor Switch Malfunction Instrument Wake up Signal Overcurrent Instrument Communication CAN Service M...

Page 616: ... Interrupted Keyless ECM Parameters Reset to Default Keyless ECM Ignition Fault Output 1 Key Missing During Riding Right Hand Switch Housing Malfunction Ignition ON Requested With No Key in Range Lighting Adjustment and Bulb Replacement Headlight Vertical Adjustment Headlight Position Light LED Unit Replacement Rear Light Bulb Replacement LED LED Direction Indicators LED Licence Plate Light Remova...

Page 617: ...ed error has occurred error message Front Direction Indicators Removal An unexpected error has occurred error message An unexpected error has occurred error message An unexpected error has occurred error message An unexpected error has occurred error message An unexpected error has occurred error message An unexpected error has occurred error message Service Manual Scrambler 1200 XC 617 of 640 ...

Page 618: ...or message An unexpected error has occurred error message An unexpected error has occurred error message An unexpected error has occurred error message Front Direction Indicators Installation Rear Direction Indicators Removal Rear Direction Indicators Installation Rear Licence Plate Light Removal Rear Licence Plate Light Installation Service Manual Scrambler 1200 XC 618 of 640 ...

Page 619: ...Service Manual Scrambler 1200 XC 619 of 640 ...

Page 620: ...ctors for the front indicators from the main harness 1 Release the fixings and remove the headlight brackets 2 Remove the fixings and release the brake hose assembly from the lower yoke 3 L0730 2 1 3 4 Headlight brackets 1 Headlight bracket fixings 2 Brake hose fixings 3 Brake hose assembly 4 UseT3880023 50 mm Socket to remove the lock nut 4 Service Manual Scrambler 1200 XC 620 of 640 ...

Page 621: ... 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 Using a suitable drift evenly and progressively drive the bearing races from the frame headstock 8 Remove the inner race and dust seal from the lower yoke using a press or puller 9 WARNING Before starting work ensure the mo...

Page 622: ...r bolt and remove the suspension unit Discard the bolt 3 2 1 L0735 3 Rear suspension unit 1 Upper mounting bolt 2 Lower mounting nut and bolt 3 Repeat steps 2 and 3 for the other rear suspension unit if required 4 Fit a new dust seal to the steering stem on the lower yoke as noted for removal 1 CAUTION Protect the threads of the lower yoke when using a press or a puller as damaged threads may mean...

Page 623: ... 1 Headstock 1 Lubricate the headstock bearings using Castrol LCX 222 or an equivalent heavy duty lithium based grease 4 Fit the bearing to the bearing inner race on the steering stem 5 Insert the lower yoke to the frame headstock fit the upper bearing inner race dust seal and retain with the adjuster nut 6 Service Manual Scrambler 1200 XC 623 of 640 ...

Page 624: ... It is essential that the adjuster nut is not overtightened If the adjuster is overtightened it will cause a preload on the headstock bearings This will introduce tight steering which could cause loss of motorcycle control and an accident Note Ensure the adjuster nut does not move as the lock nut is tightened cjbu 1 2 3 4 5 T3880023 50 mm Socket 1 Lock nut 2 Tab washer 3 Adjuster nut 4 Dust seal 5...

Page 625: ...ertical Adjustment Check that the free play has been eliminated and that the steering can be turned freely from lock to lock without any sign of tightness Readjust if necessary WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operation...

Page 626: ...L0745 1 2 3 Fixing 1 Switch cover 2 Clutch switch 3 Release the fixings and remove the clamp from the clutch lever assembly Without disconnecting the clutch cable lay the lever aside 4 Remove the cable tie securing the switch housing wiring harness to the left hand switch housing 5 Service Manual Scrambler 1200 XC 626 of 640 ...

Page 627: ... 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 Insert T3880369 Switch Housing Removal Tool into the opening on the left hand switch housing until a...

Page 628: ...e switch housing towards the end of the handlebar to free it from the retaining clip 8 Withdraw T3880369 Switch Housing Removal Tool from the switch housing 9 3 1 L0386_2 2 Left hand switch housing 1 T3880369 Switch Housing Removal Tool 2 Retaining clip 3 Service Manual Scrambler 1200 XC 628 of 640 ...

Page 629: ...connect and remove the right hand switch housing as described in steps 4 9 11 Release the fixings and remove the clamp from the front brake master cylinder Taking care to not invert the brake fluid reservoir lay the assembly aside 12 L0879 3 1 4 2 Fixings 1 Clamp 2 Alignment mark 3 Service Manual Scrambler 1200 XC 629 of 640 ...

Page 630: ...wiring lay the sensor aside 14 Disconnect and remove the right hand switch housing as described in steps 3 to 8 15 If removed put the two handlebar risers and spacers if installed in position 1 Install the fixings that attach the two handlebar risers and torque the fixings to 38 Nm 2 Refit the upper yoke Make sure that the two pins on the underside of the upper yoke are engaged into the grommets f...

Page 631: ...xings but do not fully tighten at this stage 6 Rotate the handlebar so that the alignment mark on the handlebar aligns with the bottom face of the handlebar clamp 7 L0869 3 1 2 Alignment mark 1 Handlebar clamp 2 Right riser 3 Tighten the handlebar clamp fixings front ones first to 24 Nm 8 Put the instrument and bracket assembly in position 9 Install three new fixings and torque to 5 Nm 10 Service ...

Page 632: ... 3 Connect the electrical connector to the instruments 11 Install the cover for the connector 12 Install and torque the fixing for the cover to 3 Nm 13 L0733 1 2 Fixing 1 Cover 2 Perform the following operations Service Manual Scrambler 1200 XC 632 of 640 ...

Page 633: ...ight hand switch housing retaining clip to the handlebar as noted during removal 1 Slide the right hand switch housing onto the handlebar and over the retaining clip until it locks into position 2 1 2 Switch housing 1 Retaining clip 2 Slide the twist grip position sensor onto the right hand side of the handlebar 3 Locate the handlebar onto the risers fit the clamp and the fixings Do not fully tigh...

Page 634: ...k 2 Handlebar riser 3 Tighten the handlebar clamp fixings front ones first to 24 Nm 6 Connect the right hand switch housing electrical connectors 7 Use a new cable tie to secure the wiring harness to the switch housing 8 Do steps 1 and 2 again for the left switch housing 9 Note The left hand switch housing electrical connections are recessed into the switch housing body Service Manual Scrambler 12...

Page 635: ...at bladed screw driver to insert the connectors 1 Switch housing electrical connectors 1 Connect the left hand switch housing electrical connectors 10 Use a new cable tie to secure the wiring harness to the switch housing 11 Locate the master cylinder to the handlebars and position the clamp with the UP arrow pointing upwards Do not tighten the clamp bolts at this stage 12 Align the split line of ...

Page 636: ...clamp fixings upper one first to 12 Nm 15 Put the clutch switch and switch cover in position 16 Install the fixing to attach the clutch switch and switch cover to the clutch lever assembly Torque the fixing to 1 Nm 17 L0745 1 2 3 Fixing 1 Switch cover 2 Clutch switch 3 If a non heated left handgrip is installed install the grip and tighten the top and bottom fixings to 2 Nm 18 1 Service Manual Scr...

Page 637: ... the two mirror brackets and tighten the fixings to 5 Nm Perform the following operations Install the heated twist grip see Twist Grip Installation Install the two mirrors see Mirrors Installation Battery Installation Seat Installation Instruments Removal Instruments Disassemble Service Manual Scrambler 1200 XC 637 of 640 ...

Page 638: ...ernator Rotor Installation Alternator Regulator Rectifier Removal Alternator Regulator Rectifier Installation Side Stand Switch Removal Side Stand Switch Installation Starter Motor Removal Starter Motor Installation Ignition Master Switch US Markets Only Removal Ignition Master Switch US Markets Only Installation Circuit Diagrams Glossary of Circuit Diagram Symbols Main Wiring Harness Electrical C...

Page 639: ...t Relay Management Brake Circuit Lighting Circuit Front Lighting Circuit Rear Standard Lighting Circuit Rear Multifunction Rider Information and Controls Circuit Heated Grip Circuit Horn Circuit CAN and LIN Circuit Auxiliary Connection Circuit Alarm Circuit Diagnostic Connector Circuit Earth Circuit 01 Earth Circuit 02 Earth Circuit 03 Electronic Systems Configuration and Setup General Information...

Page 640: ... Flow Chart Engine ECM Replacement Engine ECM Setup Engine ECM Calibration Download Flow Chart Immobiliser System Keyless Ignition Keys Smart Key Battery Replacement Keyless Ignition System Key Pairing General Information Pairing New or Replacement Keys Guidelines Replacing a Lost Smart Key Guidelines Adding a Second Smart Key All Keys Lost Pairing the Engine ECM Trouble Shooting Spares Kits Matri...

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