Triumph Tiger Explorer XR 2016 Service Manual Download Page 196 | Manualshive

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Splined thrust washer

3.

Remove the circlip from in front of sixth gear.

8.

Remove sixth gear.

9.

1

2

chfj

Circlip

1.

Sixth gear

2.

Remove the circlip from in front of second gear.

10.

Remove the thrust washer and slide off second gear.

11.

1
2

3

chfg

Circlip

1.

Thrust washer

2.

Second gear

3.

At this stage, the input shaft bearing can be removed from the transmission housing as follows:

12.

Remove the fixing and collect the bearing keeper plate. Discard the fixing
Using a proprietary bearing puller, remove the bearing from the housing
Collect the oil restrictor plate.

Output Shaft - Assembly

Bevel Box Damper Shaft Oil Seal - Removal

Tiger Explorer XR Series

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Summary of Contents for Tiger Explorer XR 2016

Page 1: ...2016 2017 Triumph Tiger Explorer XR XRX XRT Motorcycle Service Maniual...

Page 2: ......

Page 3: ...cheduled Maintenance Cylinder Head Clutch Crankshaft Balancer Transmission Lubrication Engine Removal and Refit Fuel System Engine Management Cooling Front Suspension Rear Suspension Brakes Final Driv...

Page 4: ......

Page 5: ...mise the life of your motorcycle Accurately follow the maintenance requirements of the periodic maintenance chart in the Service Manual Do not allow problems to develop Investigate unusual noises and...

Page 6: ...y from the specification figures given in this manual These will be reset by the dealer at the 500 mile 800 km service and thereafter should be maintained at the figures specified in this manual Repai...

Page 7: ...devices should not be in close proximity to ignition circuits and or diagnostic equipment The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing i...

Page 8: ...olonged and repeated contact with oils particularly used engine oils Wear protective clothing including impervious gloves where practicable Do not put oily rags in pockets Overalls must be cleaned reg...

Page 9: ...RE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING EFFICIENCY LEADING TO AN ACCIDENT WARNING If there has been an appreciable drop in the level of the fluid in either brake fluid reservoir con...

Page 10: ...e Avoid spilling brake fluid or battery acid on any part of the bodywork Wash spillages off with water immediately Disconnect the battery earth lead before starting work see ELECTRICAL PRECAUTIONS Alw...

Page 11: ...hey are not intended This manual makes reference to molybdenum disulphide grease in the assembly of certain engine and chassis parts Always check manufacturer recommendations before using such special...

Page 12: ...lling circlips and retaining rings take care to compress or expand them only enough to install them Always use the correct replacement circlip as recommended in the Triumph parts catalogue Self Lockin...

Page 13: ...bearing to be serviceable for its anticipated life span it must be checked adjusted and lubricated at regular intervals as specified in the service schedules given in the Owner s Handbook and this Se...

Page 14: ...a sealed bearing will damage the integrated seals If the seals are damaged dirt and water will ingress and the life of the bearing will be greatly reduced ceon Taper Bearings Grease must be forced bet...

Page 15: ...ing Precautions General The following information provides basic precautions which must be observed if petrol gasoline is to be handled safely It also outlines other areas of risk which must not be ig...

Page 16: ...incorrect installation and repair of items associated with petrol gasoline Repairs carried out by untrained personnel could bring about a safety hazard leading to a risk of personal injury WARNING Dr...

Page 17: ...ulated 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 moto...

Page 18: ...e power source the battery via the components and back to the battery No circuit means no electrical flow Once the power has left the positive side of the battery and run through the component it must...

Page 19: ...ome circuits on the circuit diagram may at first seem more complicated it will generally be found that they can be broken down into sections which do not differ greatly from the basic circuit above Ci...

Page 20: ...on Triumph circuit diagrams The numbers in the box relate to the terminal numbers of the connector pins On ECMs with two connectors the number would be prefixed with the letters A or B to identify ea...

Page 21: ...s and rear light brake lights on various models Motor M An electric motor This could be the starter motor or a motor within an actuator for example within the ABS modulator Relay 1 4 6 8 A relay is ef...

Page 22: ...or by a loose connection Open circuits can often be intermittent making diagnosis difficult Short Circuit A short cut in an electrical circuit current bypasses the intended circuit either to ground o...

Page 23: ...Ensure the circuit being tested is switched off before measuring continuity Damage to the Digital Multi Meter DMM may result from testing a live circuit with the meter set to resistance In the example...

Page 24: ...a splice it is necessary to peel back the insulation and examine the splice for its integrity The most common fault is where one of the wires at the joint has come adrift usually causing the circuit i...

Page 25: ...s 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 E...

Page 26: ...ols Service Tools and Garage Equipment Special service tools have been developed to facilitate removal dismantling and assembly of certain mechanical components in a practical manner without causing d...

Page 27: ...il Filler Evacuator T3880660 Clutch Restraint T3880602 Alternator Wrench T3880313 Oil Filter Wrench cczh 3880070 T0301 Bearing Installer T3880365 Alternator Housing Puller cjkh Tiger Explorer XR Serie...

Page 28: ...ame from Cylinder Liner Extractor T3880315 cdoa2 T3880377 Engine Mounting Adjuster T3880606 Flywheel Restraint cdgh T3880023 50 mm Socket T3880001 Fuel Pressure Gauge T3880607 Camshaft Timing Tensione...

Page 29: ...eel Bearing Extraction Kit T3880123 Extension Cable BatteryMate Battery Charger See Latest Parts Catalogue for Part Number Information T3880620 Adjuster Socket 48 mm T3880624 Housing Support Tiger Exp...

Page 30: ...Cap Tester Kit T3880625 Bearing Installer 39 mm T3880626 Bearing Installer 46 mm T3880627 Bearing Puller 32 42 mm T3880628 Bearing Installer 26 mm T3880601 Crankshaft Timing Pin Tiger Explorer XR Seri...

Page 31: ...g Cap T1343 T3880640 Camshaft Timing Plate T3880643 Fork Top Cap Socket T3880661 Fork Seal Installer T3880662 Fork Seal Guide cjix T3880629 Bearing Installer Handle T3880171 Fork holding Tool Tiger Ex...

Page 32: ...ine Configuration 3 cylinder 12 valve DOHC Arrangement Transverse in line Displacement 1215 cc Bore x Stroke 85 x 71 4 mm Compression Ratio 11 1 Cylinder Numbering Left to right no 3 adjacent to camsh...

Page 33: ...rd 5 040 mm service limit Exhaust 5 000 5 012 mm standard 5 080 mm service limit Valve Stem to Guide Clearance Inlet 0 010 0 037 mm standard 0 068 mm service limit Exhaust 0 020 0 042 mm standard 0 12...

Page 34: ...BDC 1 0 mm lift Duration 221 7 Exhaust Open 45 3 BBDC 1 0 mm lift Close 4 7 BTDC 1 0 mm lift Duration 220 6 Camshaft Journal Diameter 23 93 23 96 mm Camshaft Journal Clearance 0 040 0 091 mm standard...

Page 35: ...er 15 mm from top of bore Grade A 84 995 85 003 mm standard Grade B 84 985 94 994 mm standard Service Limit all grades 85 100 mm Piston Diameter at 90 to gudgeon pin 12 5 from bottom of piston Grade A...

Page 36: ...Connecting Rod Big End Side Clearance 0 150 0 300 mm standard 0 500 mm service limit Crankshaft Crankshaft Big End Journal Diameter 38 020 38 036 mm standard 37 996 mm service limit Crankshaft Big En...

Page 37: ...8 5 9 mm standard 5 7 mm service limit Output shaft 6 3 6 4 mm standard 6 2 mm service limit Gear Selector Groove Width Input shaft 6 0 6 1 mm standard 6 2 mm service limit Output shaft 6 5 6 6 mm st...

Page 38: ...wet fill excluding filter 3 75 litres Oil Pressure in main gallery 2 76 bar 40 lb in min 80 C oil temperature 5 000 rpm Oil Pump Rotor Tip Clearance 0 050 0 150 mm standard 0 200 mm service limit Oil...

Page 39: ...Multi hole solenoid operated plate valve Throttle Butterfly electronically controlled Control Sensors Ambient air pressure throttle position accelerator position coolant temperature crankshaft positio...

Page 40: ...ring preload spacers and spring removed 105 mm Oil Volume dry fill 700 cc Front Fork Pull Through Top of Fork Outer Tube Set Flush with the Upper Surface of the Upper Yoke Rear Wheel Travel 193 mm Bra...

Page 41: ...19 Front Tyre Size 120 70 R19 Front Tyre Pressure 2 21 bar 32 lb in Front Tyre TPMS Warning Light On Pressure 1 93 bar 28 lb in Front Wheel Rim Axial Run out 0 6 mm Front Wheel Rim Radial Run out 0 6...

Page 42: ...olt 18 Amp Hour Alternator Rating 70 Amp Headlight 2 x 12 Volt 55 60 Watt H4 Halogen Front Position Light 12 Volt 5 Watt Fog Lights if fitted Tail Brake Light LED Direction Indicators Standard if fitt...

Page 43: ...ead 10 Nm Apply clean engine oil to the thread s Camshaft sproket to camshaft See Camshaft Drive Chain Tensioner Installation Camshaft drive chain top pad to cylinder head 10 Nm Apply clean engine oil...

Page 44: ...lave cylinder cover 4 Nm Fit new fixing s if loosened or removed Clutch switch to clutch master cylinder 2 Nm Crankshaft and Crankcases Application Torque Nm Notes Crankcase lower M8 bolts See Crankca...

Page 45: ...iner 12 Nm Fit new fixing s if loosened or removed Detent wheel to selector drum 11 Nm Fit new fixing s if loosened or removed Selector drum bearing retaining screw 9 Nm Fit new fixing s if loosened o...

Page 46: ...crankcase 9 Nm Fit new fixing s if loosened or removed Oil pump drive sprocket to pump shaft 12 Nm Fit new fixing s if loosened or removed Oil pump drive chain guide 6 Nm Fit new fixing s if loosened...

Page 47: ...lencer to frame 30 Nm Exhaust silencer front and rear end cap fixings 5 Nm Fit new fixing s if loosened or removed Exhaust downpipe heatshield fixings 5 Nm Fit new fixing s if loosened or removed Exha...

Page 48: ...gine 18 Nm Radiator drain plug 1 5 Nm Fit new sealing washer s Thermostat housing to cylinder head 9 Nm Fit new sealing washer s Crankcase coolant drain plug 8 Nm Water temperature sensor 18 Nm Apply...

Page 49: ...Fit new fixing s if loosened or removed Headstock adjuster nut stage 1 40 Nm See Headstock Bearing Check Adjustment Headstock adjuster nut stage 2 10 Nm See Headstock Bearing Check Adjustment Headsto...

Page 50: ...lationFit new fixing s if loosened or removed Drop links to swinging arm 85 Nm See Drag and Drop Links InstallationFit new fixing s if loosened or removed Torque arms to rear bevel box 48 Nm Torque ar...

Page 51: ...er cylinder union 25 Nm Fit new sealing washer s Front brake hose clamp on front fork 3 Nm Front brake master cylinder reservoir cover 1 5 Nm Front brake disc to wheel 22 Nm Fit new fixing s if loosen...

Page 52: ...to main bracket 9 Nm Fit new fixing s if loosened or removed ABS modulator to main bracket 9 Nm Fit new fixing s if loosened or removed ABS modulator bracket to frame lower fixing 9 Nm ABS rear pulse...

Page 53: ...front left hand mounting to frame final torque 115 Nm See Engine Installation Cylinder head front right hand mounting to frame 100 Nm See Engine Installation Upper and lower crankcase to frame adjuste...

Page 54: ...tor duct to radiator covers 1 2 Nm Fuel tank infill lower brackets to radiator covers 1 2 Nm Fuel tank upper infill brackets to radiator covers 3 Nm Side fairings to fuel tank fixings 3 Nm Side fuel t...

Page 55: ...onic control module cover bolt and lock nut to under seat tray 2 Nm Centre stand mounting bolts 50 Nm Fit new fixing s if loosened or removed Centre stand spring upper mounting pin 7 Nm Centre stand s...

Page 56: ...r 54 Nm Fit new fixing s if loosened or removed Alternator decoupler to drive gear 3 Nm Alternator power lead connector 10 Nm See Warning Battery terminals Starter motor to crankcase 9 Nm Starter moto...

Page 57: ...Nm See Inertial Measurement Unit IMU Installation Chassis electronic control module cover wing nut 1 25 Nm Ambient air temperature sensor 1 5 Nm Swinging arm position sensor 4 Nm Position sensor drop...

Page 58: ...cipf Main Wiring Harness Routing Tiger Explorer XR Series 54 of 746 ROUTINE MAINTENANCE...

Page 59: ...cjrs ABS and Brake Hose Routing cjma Tiger Explorer XR Series 55 of 746 ROUTINE MAINTENANCE...

Page 60: ...the schedule of daily checks and also in line with the Scheduled Maintenance chart Weather terrain and geographical location affects maintenance The maintenance schedule should be adjusted to match t...

Page 61: ...y 10 000 miles 16 000 km per year must have the annual maintenance and the specified mileage based items carried out together Motorcycles travelling more than 10 000 miles 16 000 km per year must have...

Page 62: ...hafing cracks or damage Replace if necessary Air cleaner renew Throttle body plate butterfly check clean Throttle bodies balance Fuel hoses renew Every four years regardless of mileage Evaporative los...

Page 63: ...mage Day Wheel bearings check for wear smooth operation Wheels check wheels for broken or damaged spokes and check spoke tightness models with spoked wheels only Tyre wear tyre damage check Day Tyre p...

Page 64: ...eck for oil leaks Day Final drive oil level check Final drive oil renew only first service Electrical All lights instruments and electrical systems check Day General Instruments chassis ECM and engine...

Page 65: ...00 16 000 and 48 000 20 000 32 000 40 000 64 000 Centre stand flanged sleeves check clean grease Gear change pedal clean bushes Carry out all outstanding Service Bulletin and warranty work Carry out r...

Page 66: ...Exploded View Clutch Cover Tiger Explorer XR Series 62 of 746 ENGINE COVERS...

Page 67: ...Exploded View Engine Covers Exploded View Sump Tiger Explorer XR Series 63 of 746 ENGINE COVERS...

Page 68: ...lead first Remove the fuel tank see Fuel Tank Removal Remove the airbox see Airbox Removal Remove the throttle bodies see Throttle Bodies Injectors Removal Drain the coolant see Coolant Replacement N...

Page 69: ...lves on top of the camshaft cover 3 3 2 1 Spring close clip 1 Secondary air injection hose 2 Reed valve assemblies 3 Detach the connectors from the connector bracket and position aside then release th...

Page 70: ...racket 1 Fixings 2 Reed valve covers 3 Ease the reed valve covers from the valves 6 Noting its position move the air deflector towards the front of the motorcycle to allow access to the camshaft cover...

Page 71: ...ry recover the dowels from the secondary air injection holes in the head these may come away in the cover or gasket 10 Discard the camshaft cover seal bolt seals and the spark plug tower seals 11 Remo...

Page 72: ...ew camshaft cover seal to the groove in the camshaft cover 3 1 chdk Camshaft cover seal groove 1 Apply silicone sealer to the areas shown in the diagram below at the factory ThreeBond 1215E is used 4...

Page 73: ...uence Reposition the air deflector onto the camshaft cover as noted during removal 9 Refit the reed valve covers and fuel transfer pipe bracket to the camshaft cover as noted during removal Tighten th...

Page 74: ...stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the clutch slave cylinder see Clutch Slave Cylinder Rem...

Page 75: ...Tighten fixings one and two again to 11 Nm Tighten fixing 11 to 11 Nm chhw_2 4 9 7 2 5 11 8 3 6 10 1 Clutch Cover Tightening Sequence Remove the cable tie or rubber band from the clutch slave cylinder...

Page 76: ...necessary to remove or drain the expansion tank 2 Remove the fixings and remove the flywheel cover Collect the expansion tank bracket Discard the gasket 3 chek 1 3 2 Flywheel cover 1 Expansion tank fi...

Page 77: ...following sequence 4 Tighten the fixings in the sequence shown below to 11 Nm Tighten fixings one and two again to 11 Nm 1 3 2 6 7 9 5 4 8 10 chek_2 Flywheel Cover Tightening Sequence Refit the expan...

Page 78: ...causing injury to the operator or damage to the motorcycle Remove the seven fixings noting the position of the encapsulated fixing 1 Remove the crank cover Discard the encapsulated fixing and gasket 2...

Page 79: ...to 11 Nm Tighten fixings one and two again to 11 Nm chel_3 1 3 4 6 2 7 5 8 Crankshaft Cover Tightening Sequence Balancer Shaft Cover Removal Balancer Shaft Cover Installation WARNING Before starting w...

Page 80: ...tor or damage to the motorcycle Thoroughly clean the balancer shaft cover 1 Position a new gasket to the crankcase dowels 2 Refit the balancer shaft cover 3 2 1 chel_2 Balancer cover 1 Fixings 2 Tight...

Page 81: ...ting the position of the three M6 x 16 mm and four M6 x 35 mm fixings 1 cige_1 2 1 2 1 2 M6 x 16 mm fixings 1 M6 x 35 mm fixings 2 Remove the breather cover Discard the fixings and gasket 2 Breather C...

Page 82: ...s 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 b...

Page 83: ...nt mounting point of the harness guide is secured with a fir tree clip instead of a bolt Remove the scrivet bolt s and fir tree clip if fitted and remove the harness guide from the right hand side of...

Page 84: ...ain attached to the water pump or become detached with the sump 1 2 Water pump drain tube 1 O rings 2 Sump Inspection Inspect the oil pick up for correct fitment in the lower crankcase 1 Sump Installa...

Page 85: ...14 10 6 2 12 8 4 13 9 5 1 Sump Tightening Sequence Note Use new exhaust gaskets at the downpipe connections with the cylinder head Refit the exhaust system see Exhaust System Removal 5 Note For model...

Page 86: ...ngine with the correct grade of engine oil see Oil and Oil Filter Change 9 Reconnect the battery positive red lead first 10 Start the engine and ensure that the low oil pressure warning light goes out...

Page 87: ...Exploded View Camshaft Camshaft Drive and Valves Tiger Explorer XR Series 83 of 746 CYLINDER HEAD...

Page 88: ...ankcase Once supplied to the head the oil is distributed along internal drillings within the cylinder head casting and camshaft Single valve springs are used to close both the inlet valves and exhaust...

Page 89: ...d of the crankshaft Stop rotation just before the marks on the camshaft bosses point inwards at a point level with the joint face 2 gaaa_2 1 Alignment marks 1 Insert T3880601 Crankshaft Timing Pin int...

Page 90: ...protection when withdrawing the tensioner mounting bolts and take great care to minimise the risk of injury and loss of components Note Note the orientation of the tensioner before removal Evenly rel...

Page 91: ...release the plunger before fitting If installing the original camshaft drive chain tensioner the engine oil must be drained out of the tensioner to enable the plunger to be set onto the first tooth of...

Page 92: ...o push the plunger through the resister ring until the groove for the snap ring aligns with the snap ring 8 1 2 cfei_2 3 4 Resister ring 1 Plunger 2 Groove for snap ring 3 Snap ring 4 When the groove...

Page 93: ...he timing marks on the camshaft bosses are correctly aligned 15 Note After fitting to the engine the hydraulic tensioner will be empty of engine oil After starting the engine the camshaft drive chain...

Page 94: ...compression resistance when turning the engine 1 Rotate the engine using the 24 mm hexagon on the end of the crankshaft so any two camshaft sprocket fixings are accessible 2 Note The camshaft sprocke...

Page 95: ...been released 6 Remove the tensioner and discard the O ring and gasket 7 Note the orientation of the camshaft ladder in relation to the head 8 Progressively release the bolts securing the camshaft lad...

Page 96: ...t Timing Pin 1 Timing hole in crankcase 2 At this stage the camshafts and sprockets can be separated if required 15 Camshaft and Sprocket Identification Note The inlet and exhaust camshafts are differ...

Page 97: ...er toCamshafts 3 1 cheg Camshaft journal 1 Examine all camshaft and camshaft bearing caps for excessive wear and damage 4 Check the journal to head clearances using Plastigauge Triumph part number 388...

Page 98: ...ng and therefore improved performance and fuel economy Never fit the camshaft sprockets without correctly setting the camshaft timing using the service tools and timing procedure described below Sever...

Page 99: ...f the camshaft journals are pointing towards one another 10 gaaa1 Camshaft Boss to Cylinder Head Alignment Marks CAUTION The T3880640 Camshaft Timing Plate must be located centrally between the camsha...

Page 100: ...ns centrally located between the camshafts 13 chec 11 3 7 9 10 1 13 14 5 12 4 8 2 6 Camshaft Ladder Fixing Tightening Sequence Refit the top pad and tighten the fixings to 10 Nm 14 chei 1 Camshaft dri...

Page 101: ...dition may result in serious damage to the engine reduced engine performance or reduced fuel economy Using T3880609 Torque Limiter and the 6 mm Ball Ended Allen Key supplied tighten the Camshaft Timin...

Page 102: ...80607 Camshaft Timing Tensioner and remove it 24 Refit the camshaft drive chain tensioner incorporating a new gasket and O ring see Camshaft Drive Chain Tensioner Installation 25 Fit a new fir tree cl...

Page 103: ...rocess until the valve clearances for all valves have been checked 4 Note If the measurement does not fall within the specified range adjustment must be made For the inlet and exhaust valve clearances...

Page 104: ...new shim as required 4 Clearance too small Fit a thinner shim Clearance too large Fit a thicker shim Note Shims are available ranging from 1 70 mm to 3 00 mm in increments of 0 025 mm Fit the new shim...

Page 105: ...remove it through the right hand crankshaft cover opening in the crankcase 3 Remove the rubbing strip through the right hand crankshaft cover opening in the crankcase 4 Camshaft Chain Inspection Visu...

Page 106: ...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...

Page 107: ...e Chain Tensioner Blade Disassembly Note For the purpose of this instruction the top of the tensioner blade is where the pad is located Release the clips and remove the pad 1 1 2 cfee Pad 1 Clip one s...

Page 108: ...njury to the operator or damage to the motorcycle Loosely refit the rubbing blade Do not fit the pin at this stage 1 Lower the chain through the cylinder head opening and hook over the crankshaft spro...

Page 109: ...tensioner blade and rubbing strip see Camshaft Drive Chain Tensioner Blade and Rubbing Strip Removal Note the position of all tappet buckets and shims so that they can be refitted in the same position...

Page 110: ...ad if warped 2 2 1 chef 3 Straight edge 1 Cylinder head gasket face 2 Feeler gauge 3 For specifications refer to Cylinder Head and Valves 3 WARNING Before starting work ensure the motorcycle is stabil...

Page 111: ...g the three stage procedure given below Failure to observe these important items may damage the head gasket and lead to severe engine damage Fit the bolts and washers if fitted to the head and tighten...

Page 112: ...crankcase and tighten to 10 Nm 9 1 1 Cylinder head to upper crankcase screws 1 Clean and lubricate the tappet buckets with clean engine oil and refit the buckets and shims in the same locations from w...

Page 113: ...Valve stem seal Spring platform Valve de burr before removal 1 carr Valve stem seal 1 Note Ensure inlet and exhaust valve components do not become mixed ccrx 1 2 3 4 5 6 Collets 1 Valve spring retaine...

Page 114: ...valve guide wear Excessive force will bend the valve stem and give a false reading The valve should be gently rocked to one side of the valve guide in line with the camshaft 2 Note A flat ended conta...

Page 115: ...ings see Valves and Valve Stem Seals Installation Install the cylinder head see Cylinder Head Installation Valve Face Inspection Remove any carbon build up from the valve head area Examine the valve s...

Page 116: ...n fitting the seal as this may break the seal ring Install the valve spring over the valve stem 4 Compress the valve spring ensuring that the spring is compressed squarely to prevent damage to the val...

Page 117: ...Exploded View Clutch Controls Tiger Explorer XR Series 113 of 746 CLUTCH...

Page 118: ...THE ABOVE WARNINGS MAY IMPAIR CLUTCH OPERATION LEADING TO LOSS OF MOTORCYCLE CONTROL AND AN ACCIDENT WARNING If there has been an appreciable drop in the level of the fluid in the clutch fluid reservo...

Page 119: ...level in the master cylinder reservoir Ensure that the clutch fluid level in the clutch fluid reservoir is between the upper and lower level lines reservoir held horizontal 1 5 1 1 2 3 4 chgv Fixings...

Page 120: ...ap 1 Bleed nipple 2 Bleed tube 3 Container 4 Place the other end of the tube into a suitable receptacle containing new clutch fluid 6 Loosen and remove the two fixings securing the clutch reservoir co...

Page 121: ...OT 4 fluids listed in the General Information section may reduce the efficiency of the clutch system leading to an accident CAUTION To prevent body damage do not spill clutch fluid onto any area of th...

Page 122: ...voir to the upper level 14 WARNING Use only DOT 4 specification brake and clutch fluid as listed in the General Information section of this manual The use of clutch fluids other than those DOT 4 fluid...

Page 123: ...f the clutch lever pivot bolt 3 1 Lubrication area 1 Position the clutch lever to the clutch master cylinder Ensure that the pivot boss is correctly aligned and fitted to the push rod and that the clu...

Page 124: ...ter cylinder clamp 2 Switch housing 3 Remove the nut and pivot bolt securing the clutch lever to the master cylinder 1 Remove the clutch lever from the master cylinder 2 Release the union bolt securin...

Page 125: ...t clutch operation that each component is installed in the correct order and orientation during reassembly Remove dust cover boot 1 from the rear of the master cylinder body 1 Remove the cylinder push...

Page 126: ...d Apply brake and clutch fluid to the bore of the cylinder 1 Fit a new seal and piston set ensuring that the seal is fitted in the same position as noted during removal 2 Note It is essential for corr...

Page 127: ...Tighten the fixing to 2 Nm 3 Using Castrol Metal Parts Cleaner or an equivalent clean the clutch lever pivot and the shank of the clutch lever pivot bolt 4 Apply a smear of silicone grease to the shan...

Page 128: ...system for correct clutch operation and for any fluid leakage Clutch Slave Cylinder Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help pr...

Page 129: ...clutch slave cylinder Place the hose fitting into the container to collect the fluid 3 Release the three bolts securing the clutch slave cylinder to the clutch cover 4 Detach the cylinder taking care...

Page 130: ...d fit the union bolt to the clutch hose incorporating new sealing washers Connect the hose to the slave cylinder 2 Fit the slave cylinder to the clutch cover ensuring that the lifter piece locates cor...

Page 131: ...ramps When correctly located the tool s mounting plate will sit flush against the clutch centre For clutch removal the tool should be rotated clockwise until the rounded sides of the locating pins eng...

Page 132: ...then loosen and remove the centre nut and Belleville washer from the input shaft Discard the nut and washer 6 cjih Hold the Service Tool and Loosen the Centre Nut Remove T3880660 Clutch Restraint 7 W...

Page 133: ...ve while supporting the clutch drum 10 4 1 2 chib_2 3 Outer drum 1 Bearing sleeve 2 Shim if fitted 3 Thrust washer 4 Remove the clutch outer drum leaving the oil pump drive sprocket bearing and sleeve...

Page 134: ...plates and steel plates together with the anti judder spring and anti judder seat washer 4 Note Record the orientation of all components as they are removed The plates must be assembled in the same or...

Page 135: ...ve been replaced The clutch pack height is critical for a smooth operation of the transmission and must be measured prior to installation of new clutch plates If used clutch plates are being refitted...

Page 136: ...tion table see Clutch Primary Drive 3 If the clutch pack height measurement is incorrect proceed as described below 4 Clutch Pack Height Too High Note No more than one 1 6 mm thick steel plate may be...

Page 137: ...t friction plates can also be identified by pink paint markings on the outer tabs The innermost steel plate differs from the other seven steel plates and can be identified by a larger internal diamete...

Page 138: ...washer Anti judder spring Outer friction plate 7 x steel plates 6 x friction plates 1 2 3 4 5 6 Clutch centre 1 Anti judder seat washer 2 Anti judder spring 3 Outer friction plate 4 7 x steel plates...

Page 139: ...h the clutch centre 6 cjhy 1 Pressure plate ramps 1 Note Do not allow the clutch centre and pressure plate to separate at this point as this may cause the innermost steel plate to disengage from the p...

Page 140: ...utch centre and pressure plate assembly and secure with the three fixings Evenly and progressively tighten the release plate fixings until a small amount of spring preload is applied Do not fully tigh...

Page 141: ...Shallow slot 2 Remove the clutch centre and pressure plate assembly from the outer drum assembly Take care not to disturb the friction plate tabs 2 Position the clutch outer drum assembly to the input...

Page 142: ...bly aligning the friction plate tabs with the clutch drum slots noting that the outermost friction plate engages in its own shallow slot Align the clutch centre splines with those of the input shaft a...

Page 143: ...e at an angle resulting in severe clutch judder 3 4 1 2 Release plate 1 Chamfered edge 2 Fixing tower 3 Machined face 4 Evenly and progressively tighten the release plate bolts to 10 Nm ensuring that...

Page 144: ...iclockwise until the machined face of the locating pins engages with the flat face of the clutch centre ramps cjht_2 1 3 2 Clutch centre ramp opening 1 Ramp 2 Flat face 3 Position T3880660 Clutch Rest...

Page 145: ...tre nut to the shaft 14 Fit the lifter piece and bearing carrier ensuring they are correctly installed in the release plate 15 Refit the clutch cover see Clutch Cover Installation Crankshaft Connectin...

Page 146: ...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 Tiger Expl...

Page 147: ...l Remove the oil pump see Oil Pump Removal Remove the starter drive and flywheel see Flywheel Starter Drive Gears and Sprag Clutch Removal Note If the crankshaft or connecting rods are to be removed t...

Page 148: ...etc can be removed Crankcases Assembly Connecting Rods Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and caus...

Page 149: ...crankshaft bearing shells with clean engine oil see bearing selection before proceeding 5 Lubricate the crankshaft journals with clean engine oil 6 Position the lower crankcase to the upper crankcase...

Page 150: ...Nm 12 Stage 2 M6 screws only In the correct sequence tighten the M6 size lower crankcase screws numbers 15 to 22 to 12 Nm 13 1 5 6 11 2 12 19 17 16 18 10 4 9 8 7 3 21 20 22 14 13 15 Lower Crankcase Bo...

Page 151: ...Bolt Tightening Sequence Invert the engine 19 In the correct sequence tighten the upper crankcase bolts number 23 and 24 to 12 Nm 20 23 24 Upper Crankcase Bolt Tightening Sequence Rotate the cranksha...

Page 152: ...d pair and to identify the correct orientation of the bearing cap to the connecting rod 1 Release and discard the connecting rod nuts and remove the big end cap Ensure that the bearing shell remains i...

Page 153: ...nd However ensure all three are fitted facing the same way in relation to the piston To aid correct assembly the connecting rods have assembly markers cast in to them as shown overleaf Fit the pistons...

Page 154: ...nut with molybdenum disulphide grease Tighten the nuts progressively in two stages as follows 6 Tighten to 14 Nm Tighten through 180 of nut rotation as measured using T3880105 Angular Torque Gauge T3...

Page 155: ...with the Plastigauge kit measure the width of the compressed Plastigauge 7 chdv Checking the Measured Clearance For specifications refer toCrankshaft 8 Note If the measured clearance exceeds the servi...

Page 156: ...008 Crankshaft Journal Diameter 38 020 Required Bearing Red Note Repeat the measurements for all connecting rods and their respective crankshaft journals It is normal for the bearings selected to dif...

Page 157: ...AUTION During crankcase assembly ensure all three piston cooling jets are re installed If the jets are omitted oil pressure will be reduced Running the engine with low oil pressure will cause severe e...

Page 158: ...Rods Installation Assemble the crankcases see Crankcases Assembly Assemble the camshaft drive chain see Camshaft Drive Chain Tensioner Blade and Rubbing Strip Installation Refit the engine to the fra...

Page 159: ...fer toCrankshaft 9 If the clearance exceeds the service limit measure the diameter of the crankshaft main journal Note If any journal has worn beyond the service limit the crankshaft must be replaced...

Page 160: ...toCrankshaft Note Crankshaft end float is controlled by the tolerances in crankshaft and crankcase machining No thrust washers are used If crankshaft end float is outside the specified limit the cran...

Page 161: ...t from the piston Remove the piston rings 3 Piston Ring to Groove Clearance Note There are three grades of piston used during manufacture these are grades A AB and B For spare parts use only a grade A...

Page 162: ...s refer to the specifications table see Pistons Note If the ring to groove clearance is too large replace the piston rings with a new set If the gap remains too large with new piston rings the piston...

Page 163: ...rings 5 Piston Assembly Clean the piston ring grooves and fit the piston rings to the piston 1 Note The top ring upper surface is marked N and can be identified by a chamfer on the inside edge The se...

Page 164: ...accident The piston ring gaps must be arranged as shown in the diagram below 6 Top ring 1 Second ring 2 Steel oil control rings 3 Oil control ring expander 4 Note The top ring gap should be positione...

Page 165: ...llow withdrawal of the liner then turn the extraction nut clockwise to extract the liner Take care to ensure that the piston connecting rod is not allowed to fall against the inside of the crankcase 5...

Page 166: ...2 If any reading is outside the specified limits replace the liner and piston as an assembly 3 Cylinder Liners Installation Thoroughly clean the liner removing all traces of old silicone sealer 1 Rem...

Page 167: ...engine do not allow the pistons to contact the inside of the crankcase and also do not allow fitted liners to lift off the crankcase base Continue fitting each liner in turn until all are fitted and...

Page 168: ...o remove the left hand bearing slide the bearing circlip and bearing sleeve from the balancer shaft 2 To remove the right hand bearing remove the circlip and slide the bearing race and thrust washer f...

Page 169: ...ccur leading to damage to components chhs 1 2 3 4 Circlip left hand shown 1 Crankcase circlip groove 2 Pin 3 Pin groove 4 Check that the balancer and crankshaft are correctly aligned before continuing...

Page 170: ...Exploded View Flywheel Sprag Clutch and Starter Gears Tiger Explorer XR Series 166 of 746 TRANSMISSION...

Page 171: ...Exploded View Gear Selectors and Drum Tiger Explorer XR Series 167 of 746 TRANSMISSION...

Page 172: ...ransmission is of a cassette type design which allows removal of the complete transmission as an assembly with the front bevel box without separating the crankcase halves Removal of the input shaft ca...

Page 173: ...ilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the three fixings and remove the expansion tank cover Disca...

Page 174: ...n the harness for the side stand switch Note the routing of the harness for the side stand switch for installation Release the fixings detach the side stand and position aside 4 2 1 chme Fixings 1 Sid...

Page 175: ...oint 6 If necessary remove the lock nuts from the gear change linkage 8 Gear Change Pedal Cleaning and Inspection Remove the pinch bolt and remove the gear pedal from the gear change shaft 1 Note The...

Page 176: ...r 2 Housing 3 Remove the gear change shaft from the housing and remove the wavy washer 4 ckbp 2 1 Shaft 1 Wavy washer 2 Using Castrol Metal Parts Cleaner or an equivalent thoroughly clean the gear cha...

Page 177: ...nspect all parts for wear and replace as necessary 6 Refit the wavy washer 7 ckbp 2 1 Shaft 1 Wavy washer 2 Fit the shaft into the housing and refit the flat washer as noted during removal 8 3 2 1 Tig...

Page 178: ...washer 2 Circlip 3 Refit the gear change pedal ensuring the punch mark on the pedal is aligned with the punch mark on the gear change shaft Fit the pinch bolt and tighten to 9 Nm 10 2 1 3 Punch marks...

Page 179: ...d by three complete turns 3 While holding the ball joint and transmission linkage assembly stationary turn the gear change linkage to adjust the distance between the two ball joints to 101 5 mm 4 101...

Page 180: ...mission linkage 2 Gear change mechanism 3 Punch mark 4 Tighten the upper lock nut left hand thread on the gear change linkage to 6 Nm 12 Check that the lower ball joint is facing the pivot for the gea...

Page 181: ...rcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the rider s seat see Rider s Seat Removal Dis...

Page 182: ...selector cover fixings and detach the starter solenoid and bracket Position the starter solenoid aside 3 chjc 1 2 Starter solenoid 1 Fixings 2 Remove the three remaining fixings and remove the selecto...

Page 183: ...to remove the transmission and or sump to recover the washer Remove the spring abutment sleeve 7 Remove the selector shaft along with the inner washer 8 1 2 chmx Selector shaft 1 Inner washer 2 Selec...

Page 184: ...at the long straight part of the detent spring is pointing up Position the selector shaft to the transmission housing aligning the shaft to the inner bearing Ensure the inner washer remains in positio...

Page 185: ...8 CAUTION Take care to avoid damaging the lip of the seal when installing the selector shaft cover over the selector shaft A damaged seal will lead to oil loss and could result in engine damage Fit a...

Page 186: ...ed for removal 14 Fit the pinch bolt and tighten it to 9 Nm 15 chmh 1 2 3 4 Pinch bolt 1 Transmission linkage 2 Gear change mechanism 3 Punch mark 4 Refit the coolant expansion tank see Expansion Tank...

Page 187: ...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 two dowels are in positio...

Page 188: ...emove the fixing and remove the detent wheel from the selector drum Discard the fixing The detent wheel is a tight fit in the selector drum and can be removed using a rocking motion 1 1 2 chga Detent...

Page 189: ...ips 1 CAUTION The selector forks and shafts can be fitted incorrectly Ensure the position and orientation of the selector forks are marked prior to removal Incorrect fitting of the selector forks or s...

Page 190: ...the selector fork and the transmission housing 2 1 chmt E clips 1 CAUTION The selector forks can be fitted incorrectly Ensure the position and orientation of the selector forks are marked prior to rem...

Page 191: ...ission Installation Input 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 opera...

Page 192: ...ring 2 Thrust washer 3 Remove the output shaft first gear needle bearing and thrust washer 4 1 2 3 chfo First gear 1 Needle bearing 2 Thrust washer 3 Withdraw the input shaft assembly from its bearing...

Page 193: ...t fully in to the bearing 1 Refit the output shaft thrust washer needle bearing and first gear 2 Refit the output shaft thrust washer and needle bearing 3 Secure the output shaft needle bearing with a...

Page 194: ...Third gear 15 Thrust washer 16 Circlip 17 Sixth gear 18 Circlip 19 Thrust washer 20 Second gear 21 Note The output shaft is an integral part of the front bevel box assembly and cannot be removed Remov...

Page 195: ...on and remove the splined lock washers Note the UP mark on the lower splined lock washer 6 1 2 3 Fourth gear 1 Splined bush 2 Splined lock washer 3 Slide third gear off the shaft and also remove the s...

Page 196: ...3 chfg Circlip 1 Thrust washer 2 Second gear 3 At this stage the input shaft bearing can be removed from the transmission housing as follows 12 Remove the fixing and collect the bearing keeper plate...

Page 197: ...rom the bevel box Fit the splined thrust washer see note above for thrust washer identification and retain with a new circlip 1 1 2 3 chfg Second gear 1 Thrust washer 2 Circlip 3 Fit sixth gear with t...

Page 198: ...ock washer with the UP mark visible Fit the lock washer ensuring the three tabs in the smaller washer locate in the three slots in the larger washer Note the lock washer will only fit the splined lock...

Page 199: ...re 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 Remove the transmission from the engine s...

Page 200: ...1 2 chii Oil feed O ring 1 Front cover O ring 2 Withdraw the damper shaft from the bevel box 3 1 chig Damper shaft 1 Drift out the oil seal 4 1 chij Tiger Explorer XR Series 196 of 746 TRANSMISSION...

Page 201: ...press 1 Using the collar from T3880053 Wheel Bearing Extraction Kit smaller diameter positioned on the outer edge of the seal carefully press in a new oil seal 2 1 2 chil Bevel box 1 Collar part of T3...

Page 202: ...as you do so 8 Secure the cover with four new fixings and tighten to 25 Nm 9 Refit the transmission to the engine see Transmission Installation Flywheel Starter Drive Gears and Sprag Clutch Inspectio...

Page 203: ...Set flywheel pin set to T3880606 Flywheel Restraint flywheel restraint ensuring the shorter pin is fitted to the short arm of T3880606 Flywheel Restraint Fit the nuts and tighten to 10 Nm 3 1 3 2 T38...

Page 204: ...wheel Rotor Puller to the crankshaft 5 1 chfq Thrust pad 1 Assemble T3880365 Alternator Flywheel Rotor Puller to the threaded centre section of the flywheel 6 Note Ensure that the thrust pad does not...

Page 205: ...broken or seized rollers overheating and for any other damage 3 Examine the end of the crankshaft for damage 4 Flywheel Starter Drive Gears and Sprag Clutch Installation WARNING Before starting work e...

Page 206: ...e limiter engaging the gear teeth to the starter motor shaft 6 Lubricate the idler gear shaft 7 Fit the small idler gear and shaft to the crankcase 8 Refit the flywheel cover see Flywheel Cover Instal...

Page 207: ...ankshaft main bearings and via drillings in the crankshaft to the big end bearings Spray jets located in the upper crankcase behind the main bearing shells lubricate the pistons and connecting rod sma...

Page 208: ...he engine coolant at lower engine temperatures this allows the engine oil to reach its optimum operating temperature more quickly thereby helping to improve engine oil life reduce exhaust emissions an...

Page 209: ...correctly maintain the engine oil at the correct level and change the oil and oil filter in accordance with scheduled maintenance requirements WARNING Motorcycle operation with insufficient deteriora...

Page 210: ...ghten the filler plug 8 Oil and Oil Filter Change WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to...

Page 211: ...display screen 12 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 in...

Page 212: ...that the low oil pressure warning light goes out shortly after starting Oil Pump Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help preven...

Page 213: ...1 Oil pick up 1 Seal 2 Release and discard the two fixings and remove the oil feed pipe Remove and discard the two O ring seals 2 1 2 2 chhf Oil feed pipe 1 Fixings 2 Slide the oil pump drive sprocke...

Page 214: ...lease the three oil pump fixings 6 2 chhe 1 2 2 Oil pump 1 Fixings 2 Using a suitable tool slide the dowel upwards to release the oil pump from the crankcase It is not necessary to remove the dowel co...

Page 215: ...ng using T3880603 Oil Pump Restraint and remove the centre fixing Discard the fixing 1 1 chhn T3880603 Oil Pump Restraint 1 Remove the drive sprocket and spacer washer 2 1 2 4 3 chhm Oil pump 1 Spacer...

Page 216: ...plete pump must be replaced Severe engine damage may result from the continued use of a faulty oil pump Measure the rotor tip clearance using feeler gauges 4 For specifications refer toLubrication 5 c...

Page 217: ...re 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 Before fitti...

Page 218: ...ion input shaft and fit to the sprocket 7 Fit the drive chain to the oil pump sprocket 8 Support the oil pump drive sprocket and carefully refit the needle roller bearing 9 2 1 chhi Oil pump drive spr...

Page 219: ...first Remove the sump see Sump Removal Remove the oil pump see Oil Pump Removal Release the heat exchanger fixings 1 2 1 2 chhj Heat exchanger 1 Fixings 2 Detach the heat exchanger 2 Collect the four...

Page 220: ...the rider s seat see Rider s Seat Removal Remove the battery see Battery Removal Remove the engine bars see Engine Bars Removal Remove the fuel tank see Fuel Tank Removal Remove the airbox see Airbox...

Page 221: ...e Note the spacer s position for installation Remove the engine mounting bolts and a spacer from the rear of the cylinder head Discard the mounting bolts 6 Remove the engine mounting bolts washers and...

Page 222: ...lower the rear of the engine to gain access to the rear cable tidy on the crankcase 10 Release the fixing and detach the cable tidy from the crankcase Discard the fixing 11 2 1 Fixing 1 Cable tidy 2...

Page 223: ...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 Position the engine b...

Page 224: ...unting is aligned correctly to its threaded hole for the brake line clip Attach the cable tidy to the crankcase and tighten its new fixing to 6 Nm 7 2 1 Fixing 1 Cable tidy 2 Carefully remove the cove...

Page 225: ...while raising the rear of the engine Raise the rear of the engine and align the engine to the frame 11 CAUTION Unless the following engine mounting bolt tightening sequence is precisely followed seve...

Page 226: ...the engine to frame alignment bars to be inserted and removed freely 2 1 T3880637 Kit Engine to Frame Alignment Bars Crankcase alignment bars 1 Cylinder head alignment bar 2 Insert the crankcase align...

Page 227: ...oint Allow enough clearance on the right hand side of the frame to enable the threaded adjuster to be adjusted 14 3 2 1 Right hand front cylinder head mounting point 1 Cylinder head alignment bar end...

Page 228: ...ter to 5 Nm Tighten the cylinder head front right hand adjuster to 3 Nm chma 1 2 4 3 Lower crankcase adjuster 1 Upper crankcase adjuster 2 Cylinder head right hand front adjuster 3 Adjuster 4 Remove t...

Page 229: ...ront cylinder head mounting and fit the bolt and washer Fit a new locknut and tighten to 100 Nm Tighten the right hand engine protection bar centre mounting bolt to 18 Nm 28 Tighten the right hand eng...

Page 230: ...Bevel Box Installation Refit the clutch hose to the clutch master cylinder see Clutch Master Cylinder Installation Fill and bleed the clutch system see Bleeding the Clutch Refit the coolant expansion...

Page 231: ...Tiger Explorer XR Series 227 of 746 FUEL SYSTEM ENGINE MANAGEMENT...

Page 232: ...Exploded View Airbox Tiger Explorer XR Series 228 of 746 FUEL SYSTEM ENGINE MANAGEMENT...

Page 233: ...Exploded View Exhaust System Exploded View Evaporative System Tiger Explorer XR Series 229 of 746 FUEL SYSTEM ENGINE MANAGEMENT...

Page 234: ...Exploded View Secondary Air Injection Tiger Explorer XR Series 230 of 746 FUEL SYSTEM ENGINE MANAGEMENT...

Page 235: ...er 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 wil...

Page 236: ...y of Terms Engine Management System Description Engine Management System Sensors Engine Management System Sensor Locations The following terms and abbreviations will be found in this section A brief e...

Page 237: ...he twist grip DTC Diagnostic Trouble Code Engine ECM Engine Electronic Control Module Engine speed The crankshaft revolutions per minute Freeze frame A data set captured at the time a Diagnostic Troub...

Page 238: ...e Oxygen sensor The oxygen sensor measures the oxygen levels in the exhaust gases and feeds this information to the ECM Based on this information adjustments to air fuel ratio are made Purge valve dut...

Page 239: ...e ECM is electronically paired to the chassis ECM to help prevent theft of the motorcycle see Immobiliser System The engine ECM also draws information from sensors positioned around the engine cooling...

Page 240: ...The oxygen sensor constantly feeds information to the engine ECM on the content of the exhaust gases Based on this information adjustments to air fuel ratio are made Side stand switch situated at the...

Page 241: ...coils are switched off at the point of ignition the timing of which is optimised for good engine performance Main power relay situated under the seat When the ignition is switched on the main power r...

Page 242: ...the antenna coil when the ignition switch is turned to the ON position Antenna coil situated around the ignition switch When the ignition switch is turned to the ON position and the transponder chip...

Page 243: ...les if used correctly help to pinpoint a fault in the system once a diagnostic trouble code has been stored see Chassis ECM Diagnostic Trouble Codes Tyre Pressure Monitoring System TPMS System Descrip...

Page 244: ...ill be visible in the display area until the tyre pressure signal is received The wheel sensor is a sealed unit and must not be opened The battery inside the sensor is not replaceable and a new sensor...

Page 245: ...Control Module 2 Manifold Absolute Pressure Sensor 3 Ambient Air Pressure Sensor 4 Gear Position Sensor 5 Throttle Position Sensor 6 Accelerator Position Sensor 7 Diagnostic Connector 8 Fuel Level Se...

Page 246: ...mp 16 Chassis ECM 17 Oxygen Sensor 18 Secondary Air Injection Solenoid 19 Engine Sub Harness 20 Coolant Temperature Sensor 21 Injector 1 22 Injector 3 23 Injector 2 24 Purge Valve 25 Coil 3 26 Coil 2...

Page 247: ...9 B28 B21 B17 B35 B30 B29 B22 B42 B45 B43 A02 A03 A35 A36 M M KS KP BW BK K U B W W R B BN BY BY KO BO BR UR UW RB RU R R KB K KB K K KB B B B PW PB NK NK WG GK GP GU BW YB NK NK YP YK KG GU GY GU NK...

Page 248: ...te which tests are performed by the on board system and what information can be retrieved by the Triumph diagnostic software Note Full details of how to operate the software can be found in the Triump...

Page 249: ...ector Data Ignition Data Idle Speed Throttle Data and Inputs and Adaption Status Each of these screens is described on the following pages Sensor Voltages The data available under Sensor Voltages is I...

Page 250: ...olute pressure one reading per cylinder mmHg Low fuel light on off Oxygen sensor 1 short term fuel trim Oxygen sensor heater status on off Injector Data The data available under Injector Data is Item...

Page 251: ...rrent steps numeric Idle speed control target steps numeric Throttle position 1 open Throttle position 2 open Secondary air injection status SAI on off Twist grip position Inputs The data available un...

Page 252: ...t status MIL on off Cooling fan status fan on off Purge valve duty cycle Throttle actuator motor internal relay on off Adaption Status Because the fuel system is adaptive the engine management system...

Page 253: ...ise control switch check Operate the cruise control switches as instructed Observe the relevant switch response and rectify as necessary If a fault is detected Adjust Tune Using the Triumph diagnostic...

Page 254: ...ear brake switch Clutch switch Twist grip cruise cancel switch operated by holding the twistgrip in the fully closed position Cruise control accelerate switch Cruise control decelerate switch A malfun...

Page 255: ...fault continues to be detected and the count reaches a predetermined threshold the fault becomes confirmed If the fault is an emissions related fault or a serious malfunction affecting engine perform...

Page 256: ...t code As mentioned earlier when the system detects a fault it begins to count the number of times the fault occurs before illuminating the MIL and storing a fault code Similarly if a fault clears the...

Page 257: ...es Manifold Absolute Pressure MAP Sensor P0110 Intake air temperature sensor open circuit or short circuit to 5 Volt sensor supply 3 40 Yes Inlet Air Temperature Sensor P0112 Intake air temperature se...

Page 258: ...ircuit to vBatt or open circuit 3 40 Yes Throttle Position Sensors 1 and 2 P0222 Throttle position sensor 2 short circuit to ground 3 40 Yes Throttle Position Sensors 1 and 2 P0335 Crankshaft sensor c...

Page 259: ...3 40 Yes Brake Switches P0603 EEPROM Error 0 0 Yes EEPROM Error P0606 ECM internal error 3 40 Yes Engine ECM Internal Error P0914 Gear position sensor short circuit to ground or open circuit 3 40 Yes...

Page 260: ...nce completed 0 0 No Cruise Control Disabled Until Button Press Sequence Completed P1604 ECM tamper detected return to Triumph 0 0 No Engine ECM Tamper Detected P1605 ECM locked by the tune lock funct...

Page 261: ...MU present but ID incompatible 0 0 No Inertial Measurement Unit IMU Incompatible P16A1 Engine ECM detects Inertial Measurement Unit IMU circuit malfunction 0 40 No Inertial Measurement Unit IMU Circui...

Page 262: ...o vBatt 3 40 Yes Twist Grip Position Sensor 1 P2125 Twist grip position sensor 2 short circuit to ground or open circuit 3 40 Yes Twist Grip Position Sensor 2 P2128 Twist grip position sensor 2 short...

Page 263: ...lug for the following When Disconnecting a Connector Check for a security device that must be released before the connector can be separated e g barb hook and eye etc When Inspecting a Connector Check...

Page 264: ...orrespond with identical connectors on the main harness Press down on the locking device and gently pull back on the connector to release it from the engine ECM 3 1 2 Locking device 1 Locking lever 2...

Page 265: ...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 rec...

Page 266: ...Result Action 1 Check cable and terminal integrity Engine ECM pin A12 Engine ECM pin A11 Engine ECM pin A10 EMS relay pin 5 OK Proceed to test 2 Faulty Rectify fault proceed to test 7 2 Check resista...

Page 267: ...to Engine ECM pin A11 injector 2 Engine ECM pin A01 to Engine ECM pin A12 injector 3 OK Proceed to test 6 Short circuit Locate and rectify wiring fault proceed to test 7 6 Check relevant injector resi...

Page 268: ...test 5 2 Check cable for short circuit Engine ECM pin B20 to ground Engine ECM pin B26 to ground OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable con...

Page 269: ...osition sensor and proceed to test 2 Faulty Rectify fault proceed to test 5 2 Check cable for short circuit Engine ECM pin B21 to ground OK Proceed to test 3 Short circuit Locate and rectify wiring fa...

Page 270: ...ests Test Result Action 1 Check cable and terminal integrity Engine ECM pin B19 Engine ECM pin B28 Engine ECM pin B33 OK Disconnect twist grip position sensor and proceed to test 2 Faulty Rectify faul...

Page 271: ...rip position sensor 1 correlation 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 p...

Page 272: ...throttle actuator connector is secure Disconnect Engine ECM and proceed to pinpoint test 1 Pinpoint Tests Test Result Action 1 Check cable and terminal integrity Engine ECM pin A02 Engine ECM pin A03...

Page 273: ...ault still present Contact Triumph service Circuit Diagram Throttle Valve Drive Error Fault Code Possible cause Action P2111 Throttle valve drive error stuck open View and note freeze frame data if av...

Page 274: ...rt 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 ECM pin B06 to valve pin 1...

Page 275: ...n B23 Engine ECM pin B44 OK Disconnect gear position sensor and proceed to test 2 Faulty Rectify fault proceed to test 5 2 Check cable for short circuit Engine ECM pin B23 to ground Engine ECM pin B34...

Page 276: ...ssible Cause Action P0351 Ignition coil 1 malfunction View and note diagnostic tool freeze frame data if available Ensure relevant ignition coil connector is secure Disconnect Engine ECM and proceed t...

Page 277: ...M pin B15 to ignition coil 2 pin 2 Engine ECM pin B16 to ignition coil 3 pin 2 OK Proceed to test 5 Open circuit Locate and rectify wiring fault proceed to test 7 5 Check cable for short circuit Engin...

Page 278: ...ctify fault proceed to test 7 2 Check resistance value Engine ECM pin B40 to ground temperature dependant see circuit diagram resistance data OK Proceed to test 6 Open circuit Disconnect coolant tempe...

Page 279: ...gine ECM and proceed to pinpoint test 1 P0112 Intake air temperature sensor short circuit to ground Disconnect sensor and proceed to pinpoint test 4 Pinpoint Tests Test Result Action 1 Check cable and...

Page 280: ...e sensor and proceed to test 6 6 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 If e...

Page 281: ...lt cleared OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram Cornering Traction Control and Roll over Detection Disabled Vehicle Speed Sensor Fault Code Possible...

Page 282: ...uit Locate and rectify wiring fault proceed to test 5 4 Check cable for short circuit Engine ECM pin A01 to Engine ECM pin A21 Engine ECM pin A01 to Engine ECM pin B02 OK Renew oxygen sensor and proce...

Page 283: ...MU pin 4 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 A33 to IMU pin 3 Engine ECM pin A34 to IMU pin 2 IMU pin...

Page 284: ...Fault Code Possible Cause Action P1690 CAN Fault View and note freeze frame data if available Disconnect Engine ECM and proceed to pinpoint test 1 Pinpoint Tests Test Result Action 1 Check cable and t...

Page 285: ...33 to diagnostic connector pin 6 Engine ECM pin A34 to diagnostic pin 14 Engine ECM pin A33 to ABS ECM pin 11 Engine ECM pin A34 to ABS ECM pin 10 OK Proceed to test 4 Open circuit Locate and rectify...

Page 286: ...ult proceed to test 6 3 Check cable for short circuit Engine ECM pin A33 to ground Engine ECM pin A34 to ground OK Proceed to test 4 Faulty Locate and rectify wiring fault proceed to test 6 4 Check ca...

Page 287: ...onnect fuel level sensor and proceed to test 2 Faulty Rectify fault proceed to test 4 2 Check cable for short circuit Engine ECM pin B22 to ground OK Proceed to test 3 Short circuit Locate and rectify...

Page 288: ...connect ambient air pressure sensor and proceed to test 2 Faulty Rectify fault proceed to test 4 2 Check cable for short circuit Engine ECM pin B41 to Engine ECM pin B18 Engine ECM pin B41 to Engine E...

Page 289: ...nal integrity ECM pin B18 ECM pin B34 ECM pin B36 Sensor pin 1 2 3 OK Disconnect MAP sensors and proceed to test 2 Faulty Rectify fault proceed to test 4 2 Check cable for short circuit ECM pin B36 to...

Page 290: ...OK Disconnect the secondary air injection solenoid and proceed to test 2 Faulty Rectify fault proceed to test 5 2 Check cable for short circuit Engine ECM pin B07 to ground Engine ECM pin A01 to grou...

Page 291: ...is secure Proceed to pinpoint test 1 Pinpoint Tests Test Result Action 1 Ensure ignition has been switched off for longer than 90 seconds Identify EMS Main Relay on the harness Check that relay opera...

Page 292: ...EMS main relay and proceed to test 6 Open circuit Locate and rectify wiring fault proceed to test 6 6 Reconnect harness clear fault code Switch ignition off for longer than 90 seconds Switch ignition...

Page 293: ...in 1 Alarm connector pin 2 Right hand switch housing 10 way connector pin 1 Right hand switch housing 10 way connector pin 2 OK Proceed to test 4 Faulty Rectify fault proceed to test 5 4 Check cable c...

Page 294: ...ure sensor Gear position sensor And retest for short circuit Engine ECM pin B18 to Engine ECM pin B34 OK Replace sensor last removed and proceed to test 5 Faulty Proceed to test 4 4 Check cable for sh...

Page 295: ...point Tests Test Result Action 1 Check cable and terminal integrity Engine ECM pin A33 Engine ECM pin A34 OK Disconnect IMU and proceed to test 2 Faulty Rectify fault proceed to test 5 2 Check cable f...

Page 296: ...e Action P16A3 Chassis ECM communication error View and note freeze frame data if available Ensure Chassis ECM connectors are secure Check Chassis ECM diagnostic trouble codes Disconnect Engine ECM an...

Page 297: ...M pin A34 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 Cont...

Page 298: ...resent Contact Triumph service Immobiliser and TPMS Control Module ID Incompatable Fault Code Possible cause Action P1508 Unmatched Immobiliser chassis ECM causing the engine ECM to be disabled to pre...

Page 299: ...note freeze frame data if available Ensure ABS modulator connector is secure Proceed to pinpoint test 1 Pinpoint Tests Test Result Action 1 Check cable and terminal integrity Engine ECM pin A33 Engin...

Page 300: ...use box to ABS modulator pin 6 OK Proceed to test 6 Fault still present Locate and rectify wiring fault proceed to test 6 6 Reconnect harness clear fault code and run engine OK Action complete quit te...

Page 301: ...to ABS modulator pin 10 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 A34 to Engine ECM pin A33 OK Proceed to test...

Page 302: ...ngine ECM pin A31 to right hand switch housing 8 way connector pin 8 Alarm pin 1 to right hand switch housing 8 way connector pin 4 OK Proceed to test 4 Open circuit Locate and rectify wiring fault pr...

Page 303: ...nce see Cruise Control Switch Check Traction Control Prevented Due to Malfunction Fault Code Possible cause Action P1135 Traction Control prevented due to malfunction Check that there is no other DTC...

Page 304: ...ys Engine ECM and Chassis ECM are all correctly paired Fuel Tank Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from fallin...

Page 305: ...80630 Fuel Hose Clamp clamp the fuel drain hose Ensure there is enough space to move the clip securing the plug to the hose 2 cimg 1 2 3 T3880630 Fuel Hose Clamp 1 Clip 2 Plug 3 Remove the plug from t...

Page 306: ...and breather hose has a larger diameter than the left hand hose Ensure they are returned to the same locations when refitting the tank Disconnect the two breather hoses 8 1 2 chjx Right hand breather...

Page 307: ...1 Note When disconnected the fuel tank is self sealing but a small amount of fuel may dribble from the hose To protect the components under the fuel tank place suitable material over the components to...

Page 308: ...radiator while fitting removing the clamp or removing fitting the fuel transfer pipes Damaged radiator fins may impair the radiator s cooling efficiency Using the clamps from T3880630 Fuel Hose Clamp...

Page 309: ...nk to their rubber mountings on the frame and push forward until fully engaged 3 chka_1 1 Front mountings 1 Remove the blanking cap from one of the front spigots At the same time refit the front fuel...

Page 310: ...l tank infill panels see Fuel Tank Infill Panels Installation Refit the rider s seat see Rider s Seat Installation Fuel Pump and Filter Assembly Removal Note The fuel pump and filter assembly is a sea...

Page 311: ...t from the fuel tank aperture 3 Disconnect the fuel level sensor electrical connector and remove the fuel pump and filter assembly 4 1 cegz Fuel level sensor electrical connector 1 Noting its orientat...

Page 312: ...re to ensure the sealing ring is not damaged or dislodged manoeuvre the fuel pump assembly into the tank aperture 2 Reconnect the fuel level sensor electrical connector and locate the fuel pump and fi...

Page 313: ...er s Seat Removal Disconnect the battery negative black lead first Remove the fuel pump and filter assembly see Fuel Pump and Filter Assembly Removal Release the locking device and slide the bottom of...

Page 314: ...possible to fit the float unit upside down An incorrect fuel level reading will be indicated during motorcycle operation if the float unit is fitted upside down chpo_1 1 2 3 5 4 Support tube 1 Float u...

Page 315: ...nstallation Reconnect the battery positive red lead first Start the engine and check carefully for fuel leaks Rectify as necessary Refit the rider s seat see Rider s Seat Installation WARNING Observe...

Page 316: ...he correct fuel pressure gauge adapter adapter B for Explorer models Use of an incorrect adapter will result in a fuel leak A fuel leak can result in a fire causing damage to property and injury to pe...

Page 317: ...Start the engine and observe the fuel pressure reading on the gauge 9 Note The fuel pressure should be 3 5 bar nominally When fuel pressure checking is complete turn the ignition to the OFF position d...

Page 318: ...moval Disconnect the battery negative black lead first Remove the fuel tank see Fuel Tank Removal Disconnect the multiplugs from the following 1 Air temperature sensor Secondary air injection control...

Page 319: ...etach the air intake duct from the frame and slide the airbox rearwards to release it from its front mounting for complete removal 7 1 2 chji Air intake duct 1 Front mounting 2 Inspect the intake rubb...

Page 320: ...injection control valve 6 Connect the multiplugs to the following 7 Air temperature sensor Secondary air injection control valve Refit the MAP sensor see Manifold Absolute Pressure MAP Sensor Install...

Page 321: ...on Lift the air filter out of the airbox lower section 3 1 2 Airbox lower section 1 Air filter element 2 Air Filter Element Installation WARNING Before starting work ensure the motorcycle is stabilise...

Page 322: ...see Seat Bridge Removal Remove the engine ECM from its housing and disconnect the two electrical connectors see Electrical Connectors Engine Electronic Control Module ECM Installation WARNING Before...

Page 323: ...fuel tank see Fuel Tank Installation Reconnect the battery positive red lead first and tighten the terminals to 4 5 Nm Refit the rider s seat see Rider s Seat Installation Manifold Absolute Pressure M...

Page 324: ...allation Reconnect the battery positive red lead first and tighten the terminals to 4 5 Nm Refit the rider s seat see Rider s Seat Installation Ambient Air Pressure Sensor Removal WARNING Before start...

Page 325: ...rst and tighten the terminals to 4 5 Nm Refit the rider s seat see Rider s Seat Installation Roll Over Valve Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately sup...

Page 326: ...s connected to the roll over valve are marked with a white spot When correctly fitted and in the crankcase tidy these spots will face the rear of the motorcycle From the right hand side of the motorcy...

Page 327: ...oll over valve 1 Hose from fuel tank 2 Hose to atmosphere 3 Arrow and UP 4 White spots 5 Carefully attach the roll over valve to the crankcase tidy Ensure that the hoses are also secured by the crankc...

Page 328: ...age to the motorcycle Refit the crankshaft position sensor Fit and tighten new fixings to 6 Nm 1 Reconnect the sensor multiplug 2 Refit the harness grommet to the crankcase opening 3 Refit the harness...

Page 329: ...aft 2 Fit two new fixings and tighten to 5 Nm 3 Reconnect the electrical connector 4 Refit the coolant expansion tank see Expansion Tank Installation Reconnect the battery positive red lead first and...

Page 330: ...sor and evaporative emissions control system hoses from the throttle bodies 4 Release the clips securing the throttle bodies to the transition pieces 5 chip 1 3 2 Throttle body 1 Transition piece one...

Page 331: ...the fixings and remove the transition pieces 5 Throttle Bodies Injectors Inspection Check all joints and seals for splits cuts and damage 1 Check the throttles for sticking loose or damaged throttle...

Page 332: ...on sensor multiplug 5 Reconnect the MAP sensor and evaporative emissions control hoses as noted during removal 6 Refit the airbox see Airbox Installation Refit the fuel tank see Fuel Tank Installation...

Page 333: ...stic Software Engine ECM 5 Select BALANCE THROTTLES 6 Adjust Tune Procedure Adjust the throttle balance as described in the Service Manual until balanced Press cancel to cancel the adjustment process...

Page 334: ...g located between cylinders one and two 7 chiq 1 Throttle balance blanking screw 1 Using a suitable Torx T20 screwdriver adjust the throttle adjusters until the words THROTTLES BALANCED appear on the...

Page 335: ...removed replaced or adjusted in service If necessary the throttle bodies and throttle position sensor must be replaced as an assembly Engine Management Adaption The throttle actuator motor is an inte...

Page 336: ...wing adaption details can be examined Function Examined Report Method Closed throttle position reference status Adapted not adapted Idle speed control adaption status Oxygen sensor adaption status off...

Page 337: ...ensuring the motorcycle is positioned in a well ventilated area Ensure the engine is cold 1 WITHOUT TOUCHING THE THROTTLE start the engine and allow it to warm up until the cooling fan comes on 2 Leav...

Page 338: ...lways allow the hot parts to cool before working on the exhaust system Remove the rider s seat see Rider s Seat Removal Disconnect the battery negative black lead first Remove the sump guard see Sump...

Page 339: ...ss guide from the right hand side of the engine Discard the bolt s and fir tree clip 4 1 4 3 2 chhb_1 Harness guide 1 Scrivet 2 Bolt 3 Bolt fir tree clip 4 Detach the oxygen sensor harness from the ca...

Page 340: ...er head ports 10 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 mo...

Page 341: ...not fully tighten at this stage 4 chjq_1 2 1 3 Bolt 1 Header pipe 2 Mounting lug 3 Note The header pipe nuts are tightened in stages in order to progressively and evenly compress the seals Tighten th...

Page 342: ...ition the silencer clamp to the header pipe 8 Engage the silencer to the header outlet align its mounting to the frame and fit the mounting bolt Do not fully tighten the bolt or the clamp at this stag...

Page 343: ...ous and can cause loss of consciousness and death within a short period of time Always operate your motorcycle in the open air or in an area with adequate ventilation Start the engine and check for ex...

Page 344: ...d lead to rough running Secondary Air Injection Solenoid Valve Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling...

Page 345: ...motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the rider s seat see Rider s Seat Removal...

Page 346: ...he valves 3 Note the orientation of the valves and remove them from the camshaft cover 4 1 chkg Valves 1 Secondary Air Injection Reed Valves Inspection Check for cracks bending or other damage to the...

Page 347: ...battery positive red lead first and tighten the terminals to 4 5 Nm Refit the rider s seat see Rider s Seat Installation Evaporative Canister Removal WARNING Before starting work ensure the motorcycle...

Page 348: ...er for installation Slide the canister to the right to disengage its locating lugs from the frame 3 3 1 2 chjm Lugs 1 Canister 2 Frame left hand side 3 Disconnect the vacuum and purge hoses from the c...

Page 349: ...ator or damage to the motorcycle Fit the new cable ties to the mounting bracket for the canister as noted at removal 1 Refit the vacuum and purge hoses to the canister 2 chjl 1 3 2 Canister 1 Vacuum h...

Page 350: ...r s Seat Removal Disconnect the battery negative black lead first Remove the fuel tank see Fuel Tank Removal Disconnect the swinging arm position sensor push rod from the swinging arm and position asi...

Page 351: ...noted during removal 1 Reconnect the hoses to the purge control valve as noted during removal 2 Fit the purge control valve to the frame and tighten the fixing to 3 Nm 3 Apply a smear of proprietary...

Page 352: ...onically controlled by the Engine ECM mounted beneath the fuel tank to the right hand side of the frame When the engine is stationary any pressure increase in the fuel tank due to a rise in ambient te...

Page 353: ...he Engine ECM opens the purge valve The vacuum applied to the purge valve now begins to draw stored vapour from the carbon filled evaporative canister and returns it to the throttle bodies for burning...

Page 354: ...Coolant Tiger Explorer XR Series 350 of 746 COOLING...

Page 355: ...or that helps prevent damage to the cooling system and engine Without this inhibitor the coolant would attack the metals and the resulting corrosion would cause blockages in the cooling system leading...

Page 356: ...d on or off by the chassis ECM in response to a request sent by the engine ECM The request from the engine ECM to turn the cooling fan on or off is sent to the chassis ECM in response to a signal rece...

Page 357: ...rectify as necessary Loss of coolant may cause the engine to overheat and suffer severe damage Coolant Level Adjustment WARNING Before starting work ensure the motorcycle is stabilised and adequately...

Page 358: ...t Replacement 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 motor...

Page 359: ...Note It is not possible to completely drain all of the coolant a small amount may remain in the water pump or heat exchanger Filling CAUTION Filling the cooling system with the motorcycle positioned o...

Page 360: ...e pressure cap 7 Install the right hand hose bleed screw and tighten to 1 5 Nm 8 With the aid of an assistant lean the motorcycle fully over to the right hand side and then the left hand side to relea...

Page 361: ...Adaptor hose B 1 Fuel pump plate outlet 2 T3880123 Extension Cable 3 Connect the fuel hose to the adaptor hose as shown in the illustration below 17 1 3 4 2 5 6 chpl_1 Motorcycle fuel hose 1 Adaptor...

Page 362: ...t pressure cap when the engine is hot When the engine is hot the coolant inside the cooling system is hot and also under pressure Contact with the pressurised coolant will cause scalds and skin damage...

Page 363: ...o open at 1 1 bar replace the cap 4 Note It is recommended to carry out coolant pressure cap and cooling system pressure tests consecutively Coolant Pressure Cap Test 1 2 4 3 cgwp Hand held pump 1 Bay...

Page 364: ...essurise the cooling system to the operating pressure using the hand pump taking care not to exceed the maximum cap pressure 3 Hold the pressure for a minimum of 10 minutes whilst visually inspecting...

Page 365: ...ntact with hot coolant will cause scalds and skin damage Remove the rider s seat see Rider s Seat Removal Disconnect the battery negative black lead first Drain the coolant see Coolant Replacement Rem...

Page 366: ...ostat opens The thermostat should start to open at 88 C 5 C 2 If the temperature at which thermostat opening takes place is incorrect replace the thermostat 3 Thermostat Installation Fit a new seal to...

Page 367: ...ation Radiator Removal Radiator 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 op...

Page 368: ...er bolts securing the radiator to the frame 4 1 Fixings 1 Lower the radiator and disconnect the cooling fan connection located below the headstock 5 Remove the radiator 6 Radiator Installation Check t...

Page 369: ...iator to the frame and connect the fan connector 1 Align the radiator upper mounting to the frame Fit the two fixings but do not fully tighten at this stage 2 1 Fixings 1 Fit the two lower mounting fi...

Page 370: ...Retain the lower M6 fixings for reuse 1 2 chgw_2 1 3 Expansion tank cover 1 Upper fixings M5 2 Lower fixings M6 3 Position a container to collect the displaced coolant 2 WARNING Do not disconnect the...

Page 371: ...e with the two washers and fixings Tighten to 3 Nm 2 3 1 2 2 4 chjg Expansion tank 1 Fixings 2 Upper hose 3 Lower hose 4 Refit the upper hose and secure in position with its clip 3 Check and adjust th...

Page 372: ...ing M5 2 Lower fixings M6 3 Reconnect the battery positive red lead first and tighten the terminals to 4 5 Nm Refit the rider s seat see Rider s Seat Installation Exploded View Handlebars Tiger Explor...

Page 373: ...Exploded View Hand Guards Tiger Explorer XR Series 369 of 746 FRONT SUSPENSION...

Page 374: ...or consult an authorised Triumph dealer Check for smooth operation of the forks as follows Place the motorcycle on level ground While holding the handlebars and applying the front brake pump the fork...

Page 375: ...nt ABS wheel speed sensor 2 Clip 3 Remove the front brake calipers see Front Brake Caliper Removal 3 Remove the front wheel see Front Wheel Removal 4 Remove the front mudguard see Front Mudguard Remov...

Page 376: ...7 cjja 1 Upper yoke clamp bolt 1 Remove the TSAS damping motor connector cover 8 cjja 1 TSAS damping motor connector cover 1 Disconnect the TSAS damping motor connector 9 cjjc 1 Tiger Explorer XR Ser...

Page 377: ...riser bolts 2 1 chiv_2 10 mm bolts 1 8 mm bolts 2 As an assembly raise the handlebars until clear of the top yoke Rest the assembly forward of the steering stem such that access to the fork top caps...

Page 378: ...dlebar risers in order that they can be returned to the same position when the repair operation is complete Note The bolt positions shown below are in the standard position as delivered from the facto...

Page 379: ...on of the shim before use Do not use a shim which is bent or damaged Position the wheel speed sensor to the left hand fork leg with its shim between the sensor and fork leg Temporarily fit the origina...

Page 380: ...eat and lower spring preload spacer s if fitted are left in position on the damper assembly Holding the inner and outer tubes together invert the fork and pour out any remaining fork oil into a suitab...

Page 381: ...any trapped air keep the inner damper rod pressed down into the main damper rod assembly using one finger cirb_3 2 1 Main damper rod assembly 1 Inner damper rod 2 Pump the fork and damper assembly se...

Page 382: ...Fork Disassembly 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 m...

Page 383: ...0171 Fork Holding Tool 2 Note The top cap is not under spring tension and will not spring upwards when the threads disengage Unscrew the top cap from the outer tube 3 cjiw 1 2 3 4 Soft jawed vice 1 T3...

Page 384: ...er to compress the spring and remove the nut and washer 10 Remove the spanner used to compress the spring 11 Note Between the spring and the spring guide there could be one or more spacers fitted Remo...

Page 385: ...and oil seal to 50 C 122 F Use a suitable heat sensitive marker or thermometer to accurately measure the temperature 20 WARNING The fork outer tube will be hot to the touch Avoid contact with the hot...

Page 386: ...ng cylinder is required remove the damper bolt from the bottom of the fork Discard the washer from the damper bolt Remove the damping cylinder from the fork inner tube 24 Clean the inner and outer tub...

Page 387: ...parts Total cleanliness must be observed at all times and assembly must take place in a dirt dust free environment Dirt ingress may cause damage to the fork parts leading to incorrect operation instab...

Page 388: ...covers the bush groove fully 4 ccup_4 2 1 Fork inner tube 1 T3880662 Fork Seal Guide 2 Apply a smear of fork oil to the upper and lower bushes and the new fork seal and dust cover 5 Slide the dust sea...

Page 389: ...rk Seal Installer 1 Long small diameter end 2 Short large diameter end 3 T1323_2 2 1 3 4 T3880661 Fork Seal Installer 1 Bush 2 Circlip 3 Seal and dust seal 4 Reposition the washer into the fork outer...

Page 390: ...with oil see Fork Oil Change Oil Refilling 16 WARNING While performing steps 17 to 25 If for any reason the main damper rod assembly needs to be moved up or down inside the fork assembly keep the inne...

Page 391: ...er 1 Spring guide 2 Spring 3 Refit the spring guide 19 Fit a suitable ring spanner over the spring guide and seat it onto the taper section of the spring guide 20 WARNING While compressing the fork sp...

Page 392: ...awed vice 25 cirb_1 2 1 T3880317 Damper Tube Clamp 1 Damper rod 2 Fit the top cap to the damper rod and tighten to 2 5 Nm 26 Hold the top cap while tightening the damper rod lock nut to 25 Nm 27 With...

Page 393: ...instrument TSAS mode and damping settings are returned to the settings noted prior to disassembly Turn the ignition off Check WARNING Before starting work ensure the motorcycle is stabilised and adequ...

Page 394: ...m bolts 1 8 mm bolts 2 As an assembly raise the handlebars until clear of the top yoke Rest the assembly forward of the steering stem such that access to the headstock top nut and the adjustment nuts...

Page 395: ...r nut is not over tightened If the adjuster is over tightened it will cause a preload on the headstock bearings This will introduce tight steering which could cause loss of motorcycle control and an a...

Page 396: ...abilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove both forks see Front Fork Removal 1 Note the orientation...

Page 397: ...e top yoke clamp bolts 5 CAUTION Care must be taken when removing the headstock top nut to ensure that the top nut and top yoke do not become scratched Protect the surfaces with a suitable cloth or ta...

Page 398: ...tom yoke using a press or puller 13 Headstock Bearing Inspection Headstock Bearing Installation Handlebars Removal Handlebars Installation Rear Suspension Exploded View Swinging Arm Exploded View Rear...

Page 399: ...a new upper dust seal and bearing cover and retain with the adjuster nut 8 Adjust the headstock bearings see Headstock Bearing Check Adjustment 9 Locate the upper yoke to the steering stem Install bu...

Page 400: ...rator or damage to the motorcycle Remove the rider s seat see Rider s Seat Removal Disconnect the battery negative black lead first Release the two fixings and remove the spacer handguard and the hand...

Page 401: ...rews and remove the clamp from the clutch master cylinder Taking care to not invert the clutch fluid reservoir lay the assembly aside 3 chid_1 2 1 Clamp 1 Screws 2 Release the screws and free the left...

Page 402: ...is returned to the same position for installation 8 Remove the pivot lock nut and bolt securing the brake lever to the master cylinder and remove the lever Discard the lock nut 9 Note The front of the...

Page 403: ...st grip 1 Switch housing 2 Slide the heated twist grip off the handlebar while carefully feeding the harness into the left hand side of the handlebar 12 Disconnect the electrical connector and remove...

Page 404: ...position when the repair operation is complete Note the position of the 8 mm and 10 mm bolts for installation Remove the handlebar rear 8 mm threaded clamp bolts and then the front 10 mm threaded cla...

Page 405: ...Secure with the two fixings and washers Tighten the fixings to 3 Nm 9 ciqf 2 3 1 Heated grip left hand 1 Harness 2 Electrical connector 3 Align the left hand switch housing to the handlebar and secur...

Page 406: ...y to the handlebar Fit the clamp UP arrow pointing upwards and clamp fixings 14 Align the split line of the master cylinder clamp to the alignment mark on the upper surface of the handlebar 15 Tighten...

Page 407: ...loop of the cables is just inside the end of the heated twist grip as shown below 21 1 Cable position throttle off 1 Fit the rear of the switch housing and tighten its fixings to 2 5 Nm 22 Apply a sm...

Page 408: ...sticking Rectify as necessary WARNING Operation of the motorcycle with incorrect throttle operation may result in loss of motorcycle control and an accident WARNING Move the handlebars to left and rig...

Page 409: ...Tiger Explorer XR Series 405 of 746 REAR SUSPENSION...

Page 410: ...Drag and Drop Links Removal Drag and Drop Links Inspection Drag and Drop Links Installation Tiger Explorer XR Series 406 of 746 REAR SUSPENSION...

Page 411: ...ear wheel has been removed position a suitable strap to support the swinging arm 1 Note The bolt securing the drag link to the frame is longer than the two bolts securing the drop links to the rear su...

Page 412: ...rop links 2 Lock nuts 3 Rear Suspension Unit Disassembly Clean all components and inspect the drag link and bearings for damage wear 1 Check the rear suspension unit lower bearings for wear 2 Check th...

Page 413: ...ing sleeve 5 Refit the drop link plates and fit the bolts and new lock nuts from the right hand side Do not fully tighten them at this stage 6 With the weight of the motorcycle on its wheels 7 Hold th...

Page 414: ...hot components may cause damage to exposed skin To avoid skin damage always allow the hot parts to cool before working on the exhaust system WARNING Before starting work ensure the motorcycle is stab...

Page 415: ...otection Do not leave a compressed spring unattended Ensure the jaws and the body of the compressor are correctly aligned at all times during spring compression Do not compress the spring to an extent...

Page 416: ...ical connector is a push fit and is sealed with an o ring When releasing the electrical connector the wires are hidden and could become detached if the electrical connector is not removed carefully Re...

Page 417: ...ring compressor 9 Note Manufacturing tolerances of the spring require spacers to be placed at both ends of the spring If for any reason the spring is replaced the original spacers must be discarded an...

Page 418: ...ws and the body of the compressor are correctly aligned at all times during spring compression Do not compress the spring to an extent where the coil windings touch Do not operate the spring compresso...

Page 419: ...te Do not compress the spring to an extent where the coil windings touch The split collar is positioned in such a way to allow for the correct fitment of the electrical connector Using a proprietary s...

Page 420: ...to 5 Nm 9 Secure the fly lead to the stone protector with a new cable tie as noted during removal 10 cjks_1 4 3 2 1 Cable tie 1 Fly lead 2 Fixings 3 Stone protector 4 Refit the rear suspension unit se...

Page 421: ...of the RSU Before calibration of the swinging arm position sensor Note The RSU preload motor calibration is started automatically the first time the ignition is switched on If a new chassis ECM has b...

Page 422: ...ft handlebar switch housing Upon clearing the warning message the information message TSAS SYSTEM CALIBRATING PLEASE WAIT will be displayed Calibration is complete when the instrument messages clear a...

Page 423: ...motor away from the end stop as described later in this procedure Repeatedly driving the rear preload motor against an end stop may cause the motor to overheat which can result in permanent damage Not...

Page 424: ...t motor operation in both directions 7 Note If no adjustment collar movement can be observed check for any stored DTCs rectify as necessary and repeat the rear preload motor test If the rear preload m...

Page 425: ...sition fully retracted 3 Visually Check the position of the rear preload motor 3 Note If the rear preload motor appears to be stuck at the minimum or maximum adjustment end stop drive the motor away f...

Page 426: ...the chassis ECM is first allowed to power down Turn the ignition switch on and allow the rear preload motor to calibrate see Rear Suspension Unit Preload Motor Calibration During calibration observe t...

Page 427: ...the T3880062 Lock Ring Wrench 38 mm remove the locking ring from the right hand pivot pin 5 1 T1053 2 T3880062 Lock Ring Wrench 38 mm 1 Locking ring 2 While supporting the swinging arm remove the lef...

Page 428: ...amage splits etc Replace as necessary 4 Check the swinging arm gaiters for splits and other damage Replace as necessary 5 Swinging Arm Assembly Pivot Bearings Remove the seal and inner bearing assembl...

Page 429: ...eal 3 1 2 choc Swinging arm 1 Drift 2 Swinging Arm Installation Pivot Pin Bearings WARNING When using a press always wear overalls eye face and hand protection Objects such as bearings frequently brea...

Page 430: ...the swinging arm 5 1 chnz Seal and inner race assembly 1 Drop Link Bearings WARNING The bearings must be installed with the marked side of the bearing facing towards T3880628 Bearing Installer 26 mm...

Page 431: ...Position the service tools and bearing to the swinging arm on a press 4 Press in the new bearing until the tool contacts the swinging arm 5 1 2 3 choh T3880629 Bearing Installer Handle 1 T3880628 Bear...

Page 432: ...mperature copper based grease 1 CAUTION When installing the swinging arm care must be taken not to the damage swinging arm and rear suspension unit Use a soft cloth or other suitable material to prote...

Page 433: ...ng correctly may lead to severe frame damage Lubricate the threads of the locking ring with a smear of proprietary high temperature copper based grease 6 Fit the locking ring to the swinging arm right...

Page 434: ...4 Refit the rear wheel see Rear Wheel Installation 15 Refit the exhaust silencer see Exhaust System Installation 16 With the weight of the motorcycle on its wheels 17 Hold the rear suspension unit low...

Page 435: ...winging arm position sensor see Swinging Arm Position Sensor Calibration Pump the rear brake pedal several times to position the brake pads in the caliper Rectify as necessary if correct brake operati...

Page 436: ...ts of a crown wheel and pinion arrangement that has no dealer serviceable parts Maintenance of the rear bevel box consists solely of the following Oil change at the first 500 mile 800 km service only...

Page 437: ...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 Have an assistant stand the motorcycle u...

Page 438: ...GL5 such as Castrol SAF XO fully synthetic hypoid oil until the level of oil inside the unit is level with the bottom of the filler 6 Incorporating a new washer refit the plug and tighten to 25 Nm 7 R...

Page 439: ...to the rear bevel box 2 Release the fixing detach the rear wheel speed sensor and position it aside Discard the fixing 3 chnb 2 3 1 P clip 1 Fixing 2 Wheel speed sensor 3 Remove and discard the five f...

Page 440: ...ree fixings and remove the expansion tank cover Discard the upper M5 fixing Retain the lower M6 fixings for reuse 6 2 chgw_2 1 3 Expansion tank cover 1 Upper fixings M5 2 Lower fixings M6 3 Note Note...

Page 441: ...m 3 Punch mark 4 Note Do not allow the side stand to hang on the harness for the side stand switch Note the routing of the harness for the side stand switch for installation Release the fixings detach...

Page 442: ...s for installation Release the two clamps and detach the rubber boot from the front of the swinging arm and the transmission 10 1 chmc 2 Clamps 1 Boot 2 Detach the rubber boot from the rear of the swi...

Page 443: ...the lock nut and bolt securing the drop links to the swinging arm Discard the lock nut 12 chnw_2 1 3 2 Drop links 1 Lock nut 2 Swinging arm 3 Remove the bolt and lock nut securing the rear bevel box t...

Page 444: ...and drive shaft assembly rearwards for complete removal 16 Inspect the rear bevel box bearings and the bearings outer race for damage cracks and signs of bearing rollers indenting the outer race Renew...

Page 445: ...2 Thoroughly lubricate the pivot pin bearings with grease to NLGI 2 specification and fit them to the rear bevel box 3 1 2 chmf Left hand bearing 1 Right hand bearing 2 Note It may be necessary to rai...

Page 446: ...it the locking ring to the right hand pivot pin and tighten to 110 Nm Hold the nut while tightening the torque arms bolt to 48 Nm 9 3 chmq 2 1 Bolt 1 Lock nut 2 Torque arms 3 Attach the rubber boot to...

Page 447: ...ten its fixings to 70 Nm 14 2 1 chme Fixings 1 Side stand 2 Tighten the upper fixings for the left hand control plate to 18 Nm 15 Fit the transmission linkage to the gear change mechanism as noted for...

Page 448: ...xings to 4 Nm 18 2 chgw_2 1 3 Expansion tank cover 1 Upper fixing M5 2 Lower fixings M6 3 Align the pulser ring to the hub Fit new fixings and tighten to 5 Nm 19 Align the brake disc to the hub Fit ne...

Page 449: ...ll help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the rear bevel box see Rear Bevel Box Removal 1 With the aid of an assistant holding the rear beve...

Page 450: ...supplied with the cap detached from the bearing race CAUTION T3880624 Housing Support must be used when pressing in the bearing outer race Failure to use this service tool may result in damage to the...

Page 451: ...25 Bearing Installer 39 mm press the new bearing race to the left hand side of the rear bevel box until it is pressed fully to the locating shoulder in the bevel box 3 Using T3880626 Bearing Installer...

Page 452: ...Fit the bevel box to the motorcycle see Rear Bevel Box Installation 11 Rear Bevel Box Oil Seal Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This w...

Page 453: ...ween the back plate assembly and the bevel box housing Ensure the shims are kept clean when removed from the bevel box The shims and back plate assembly will only fit the bevel box housing in one posi...

Page 454: ...e shim s and ensure they are kept clean 7 chnd 1 2 3 4 Fixings 1 Back plate assembly 2 Shim one shown 3 Housing 4 Remove and discard the O ring 8 chmy 1 O ring 1 Working from the opposite side of the...

Page 455: ...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 Using a suitable drift press in...

Page 456: ...ox 4 Align the back plate to the bevel box housing and shim s as noted for removal 5 Note When fitting the back plate to the bevel box housing ensure that the sealing lips of the seal fit evenly aroun...

Page 457: ...motorcycle see Rear Bevel Box Installation 9 Fill the rear bevel box with 75W 90 fully synthetic hypoid oil that meets specification API Service Level GL5 such as Castrol SAF XO fully synthetic hypoid...

Page 458: ...Exploded View Front Brake Caliper Exploded View Rear Brake Master Cylinder Tiger Explorer XR Series 454 of 746 BRAKES...

Page 459: ...Tiger Explorer XR Series 455 of 746 BRAKES...

Page 460: ...Exploded View Rear Brake Caliper Tiger Explorer XR Series 456 of 746 BRAKES...

Page 461: ...reduction in braking efficiency Replace brake fluid in line with the Scheduled Maintenance chart A dangerous riding condition could result if this important maintenance item is neglected Do not spill...

Page 462: ...d in the Scheduled Maintenance chart may reduce braking efficiency resulting in loss of motorcycle control and an accident WARNING Never use mineral based grease in any part of the braking system or i...

Page 463: ...rom 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 reserv...

Page 464: ...l Fill the reservoir to the upper level line using new DOT 4 fluid from a sealed container Refit the reservoir cap ensuring that the diaphragm seal is correctly positioned between the cap and reservoi...

Page 465: ...and may cause loss of motorcycle control and an accident Brake Disc Thickness Check Brake Disc Run out Check WARNING Before starting work ensure the motorcycle is stabilised and adequately supported T...

Page 466: ...rcycle we recommend a period of careful breaking in that will optimise the performance and longevity of the discs and pads The recommended distance for breaking in new pads and discs is 200 miles 300...

Page 467: ...the reservoir sealing diaphragm Replace if necessary 1 Sealing diaphragm 1 Core Activity WARNING Ensure absolute cleanliness when adding brake and clutch fluid to the brake fluid reservoir Do not allo...

Page 468: ...bled first followed by the right hand caliper Working on the left hand caliper first remove the rubber cap from the bleed nipple on the brake hose union 1 cjje_1 1 2 3 Bleed nipple 1 Rubber cap 2 Bra...

Page 469: ...stage lasts for 20 seconds The ABS modulator can be heard operating during the flush stage and will become silent when flush stage has completed With bleed nipples closed repeatedly operate the front...

Page 470: ...loss of motorcycle control and an accident Ensure both manual and ABS system bleed procedures have been completed and repeated in the sequence described at the beginning of the Core Activity section I...

Page 471: ...to one caliper see Front Brake Pads Installation before removing the pads from the other caliper Front Brake Pads Inspection Front Brake Pads Installation Check the brake pad retaining pin retaining p...

Page 472: ...section see Brakes CAUTION To prevent paint damage do not spill brake fluid onto any area of the bodywork Spilled brake fluid will damage paintwork Check the front brake fluid level and top up as req...

Page 473: ...result from direct contact with compressed air WARNING Ensure the seal grooves in the caliper bores are not damaged during the removal of the seals Damage to the seal grooves may allow brake fluid to...

Page 474: ...new components are used A dangerous riding condition leading to loss of control of the motorcycle or an accident could result if this warning is ignored Check the pistons and caliper bores for corros...

Page 475: ...e bores taking care not to displace the seals 3 WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to t...

Page 476: ...e a minimum gap of 0 3 mm between the caliper and brake disc Using feeler gauges measure the gap between the brake disc and the caliper at the four measurement points shown in the following illustrati...

Page 477: ...nt brakes see Bleeding the Front Brakes Renewing Brake Fluid Check the brakes for correct operation Rectify any faults as necessary WARNING It is dangerous to operate the motorcycle with defective bra...

Page 478: ...tion before you attempt to ride the motorcycle again Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident WARNING Before starting work en...

Page 479: ...ke lever to the master cylinder and remove the lever Collect the handguard bracket if fitted 4 Disconnect the brake hose from the master cylinder Discard the two sealing washers 5 Release the clamp bo...

Page 480: ...ports in the master cylinder bore are not blocked 3 1 ceqq Ports 1 Front Brake Master Cylinder Assembly WARNING Never use mineral based grease such as lithium or copper based grease in any area where...

Page 481: ...riding condition leading to an accident could result from incorrect assembly of the master cylinder Fit the new piston set into the master cylinder and retain with a new circlip 2 Refit the master cyl...

Page 482: ...he General Information section of this manual The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce the efficiency of the braking system leading to...

Page 483: ...tarting 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 Preliminary Steps Releas...

Page 484: ...amage to hoses A dangerous riding condition leading to an accident could result if this warning is ignored CAUTION To prevent paint damage do not spill brake fluid onto any area of the bodywork Spille...

Page 485: ...SYSTEM see the Triumph Diagnostic Tool User Guide 2 Note On pressing the Start button the diagnostic software will send a command to the ABS ECM to begin the ABS bleed sequence The bleed sequence las...

Page 486: ...ke remedial action before you attempt to ride the motorcycle again Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident CAUTION To preven...

Page 487: ...ition the caliper to allow withdrawl of the pad retaining pins 2 2 1 Pad retaining pins 1 Caliper mounting bolts 2 WARNING Before removing the brake pads note the relationship of the pads to the calip...

Page 488: ...ads to the caliper in the positions noted during removal 4 WARNING Do not apply more than a minimum coating of grease to the brake pad retaining pins Excess grease may contaminate the brake pads hydra...

Page 489: ...not spill brake fluid onto any area of the bodywork Spilled brake fluid will damage paintwork Disconnect the rear brake hose at the caliper and place the free end of the hose in a suitable container t...

Page 490: ...ntact with the braking system hydraulic seals and dust seals is possible Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders Damage caused by conta...

Page 491: ...riumph then reassemble the bracket and caliper Ensure the pin gaiters are correctly located on both the bracket and caliper 3 chlo 1 2 Mounting bracket 1 Sliding pins 2 WARNING Do not apply more than...

Page 492: ...a sealed container 5 Bleed the rear brake see Bleeding the Rear Brakes Renewing Brake Fluid 6 Check for correct brake operation Rectify as necessary 7 WARNING It is dangerous to operate the motorcycl...

Page 493: ...he disc 3 Fit the caliper retaining bolts and tighten to 40 Nm 4 Refit the rear wheel see Rear Wheel Installation 5 Check for correct brake operation Rectify as necessary 6 WARNING It is dangerous to...

Page 494: ...Heel guard 2 Drain the fluid from the master cylinder by bleeding the system at the rear caliper until all fluid has been expelled see Bleeding the Front Brakes Renewing Brake Fluid 2 Detach the brake...

Page 495: ...tem hydraulic seals and dust seals is possible Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders Damage caused by contact with mineral based grea...

Page 496: ...6 cdlu1 1 2 3 4 5 6 7 Reservoir hose 1 Piston set 2 Dust boot 3 Push rod 4 Clevis pin 5 Clip 6 Circlip 7 If the pushrod has been disassembled set the pushrod free length to 73 5 mm as shown below 7 1...

Page 497: ...it the right hand heel guard tightening the fixings to 7 Nm 7 Reconnect the battery positive red lead first and tighten the terminals to 4 5 Nm Refit the rider s seat see Rider s Seat Installation Che...

Page 498: ...lised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle WARNING Check the condition of the shim before use Do not use a shi...

Page 499: ...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 Using feeler gauges measure...

Page 500: ...dequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the front wheel see Front Wheel Removal 1 WARNING Damage to the wheel c...

Page 501: ...Sensor Air Gap Measurement 3 Check for correct brake operation Rectify as necessary 4 WARNING It is dangerous to operate the motorcycle with defective brakes you must have your authorised Triumph dea...

Page 502: ...torcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the rider s seat see Rider s Seat Removal R...

Page 503: ...e brake line and the harness for the rear wheel speed sensor from the cable guide 3 1 2 3 chle Harness 1 Brake line 2 Cable guide 3 Detach the harness from its clip on the final drive unit 4 Release t...

Page 504: ...ing with a new M5 encapsulated fixing Secure the lower mounting with the two original fixings Tighten the upper fixing to 3 Nm and the lower fixings to 4 Nm 5 2 chgw_2 1 3 Expansion tank cover 1 Upper...

Page 505: ...pulser ring as necessary 1 Rear ABS Pulser Ring Installation Locate the pulser ring to the hub 1 Install new fixings and tighten to 5 Nm 2 Refit the rear brake disc see Rear Brake Disc Installation Re...

Page 506: ...moval Disconnect the battery negative black lead first Remove the fuel tank see Fuel Tank Removal Remove the airbox see Airbox Removal Remove the fir trees and detach the headstock infill panel from t...

Page 507: ...are incorrectly assembled the performance of the ABS system will be seriously compromised leading to loss of motorcycle control and an accident WARNING Do not allow the brake hard lines to become bent...

Page 508: ...ets is required release the fixings shown below collect the flanged sleeve and remove the mounting bracket from the ABS modulator Discard the fixings 8 cjjn 4 2 3 1 M6 x 10 fixings 1 M6 x 25 fixing 2...

Page 509: ...hose guide to the ABS modulator Tighten the fixings to 3 Nm 1 cjjj 2 1 Fixings 1 Brake hose guide 2 Align the ABS modulator to its bracket and secure with two new M6 x 10 mm fixings Do not fully tigh...

Page 510: ...to the ABS module as marked for removal 7 Tighten the four unions to 25 Nm taking care to ensure the brake lines do not twist during tightening 8 Reconnect the ABS modulator multiplug see ABS Electri...

Page 511: ...action may reduce braking efficiency leading to loss of motorcycle control and an accident ABS System Description This model is fitted with an electronic partially integrated Optimised Cornering Anti...

Page 512: ...an angle measurements to continually adapt the level of ABS intervention in a manner most suitable to help the rider maintain motorcycle control If the rider reduces braking effort or traction increas...

Page 513: ...lator 2 Diagnostic Connector 3 Rear Wheel Speed Sensor 4 Front Wheel Speed Sensor 5 Engine ECM 6 ABS Fuse Box Key To Wiring Colour Codes Code Wiring Colour B Black U Blue N Brown G Green S Slate Grey...

Page 514: ...em used in the ABS circuit diagram As viewed on the mating face with the ABS ECM as per the illustration pins are numbered from left to right with number one in the bottom left hand corner ABS System...

Page 515: ...gnostic Trouble Codes Diagnostic trouble codes DTCs are logged in the ABS ECM memory when there is a confirmed fault in the system The codes are reported to the Triumph Diagnostic Tool as a four digit...

Page 516: ...t code DTCs can be removed at any time using the Triumph diagnostic tool The system will log the diagnostic trouble codes listed below Diagnostic Trouble Code DTC Fault Description Pinpoint Test Front...

Page 517: ...circuit Rear wheel output solenoid short circuit to ground or open circuit Front or Rear Input Output Solenoid Open Short Circuit Master cylinder isolation valve short circuit to ground or open circu...

Page 518: ...rce short term under voltage detected Power source short term under voltage detected Power Source Voltage Drop Voltage Rise Power source long term Under voltage detected Power source long term Under v...

Page 519: ...rtial Measurement Unit IMU Inertial Measurement Unit IMU Communication Inertial Measurement Unit IMU signal error Inertial Measurement Unit IMU signal error Inertial Measurement Unit IMU Communication...

Page 520: ...rming an ABS manouevre when fault is logged Operation is inhibited when ABS manouevre is completed ABS will automatically resume operation if fault clears DTC still stored for 40 cycles Front wheel se...

Page 521: ...d and ABS has initialised DTC stored for 40 cycles Front wheel input solenoid short circuit to ground or open circuit Front wheel input solenoid short circuit to ground or open circuit Yes Yes No Fron...

Page 522: ...Front wheel Actuator Hydraulic control wheel lock Yes Yes Yes if after ignition cycle no fault is detected and ABS has initialised DTC stored for 40 cycles Rear wheel Actuator Hydraulic control wheel...

Page 523: ...ge detected Yes Yes Yes if voltage rises above a preset threshold Power source long term Under voltage detected Power source long term Under voltage detected Yes Yes No DTC stored for 40 cycles Incorr...

Page 524: ...intergrated braking and hill hold If Fitted are inhibited Standard ABS remains operational No DTC stored for 40 cycles Modulator output wheel pressure sensor malfunction Modulator output wheel pressur...

Page 525: ...S initialisation Inertial Measurement Unit IMU signal error prior to ABS initialisation Yes Not applicable Fault code is logged before ABS is initialised After ABS has initialisedOptimised Cornering A...

Page 526: ...ether squarely to ensure terminals are not bent or incorrectly located Push the two halves together positively Disconnection of ABS ECM Connector CAUTION When disconnecting a connector never pull dire...

Page 527: ...n stored Pinpoint Tests Before Starting Pinpoint Tests Delete the stored DTCs 1 Switch the ignition OFF and ON 2 WARNING If the ABS is not functioning the brake system will continue to function as a n...

Page 528: ...peed sensor proceed to test 9 Short circuit Locate and rectify wiring harness fault proceed to test 9 4 Check cable for short circuit ABS ECM connector pin 36 and Ground OK Proceed to test 6 Short cir...

Page 529: ...urrent consumption data under typical conditions Supply Voltage Min Typical Max 10 16 V 5 9 mA 7 0 mA 16 8 mA Fault Code Possible Cause Action Rear wheel sensor short circuit to ground or open circuit...

Page 530: ...rness side OK Proceed to test 7 Open circuit Locate and rectify wiring harness fault proceed to test 9 7 Check cable continuity ABS ECM connector pin 30 and Wheel speed sensor connector pin 1 motorcyc...

Page 531: ...to 1 5 mm OK Proceed to test 2 Faulty Rectify the fault and proceed to test 5 2 Check the pulser ring for damage or contamination by road grime or ferrous metal filings OK Proceed to test 3 Faulty Cl...

Page 532: ...Proceed to test 3 Faulty Clean or replace the ABS pulser ring proceed to test 5 3 Check the wheel speed sensors for correct installation and the fixings for correct torque OK Proceed to test 4 Faulty...

Page 533: ...cleared OK Action complete quit test Fault still present Contact Triumph service Front or Rear Input Output Solenoid Open Short Circuit Fault Code Possible cause Action Rear wheel pulser ring missing...

Page 534: ...pen circuit Rear wheel input solenoid short circuit to ground or open circuit Rear wheel output solenoid short circuit to ground or open circuit Rear wheel output solenoid short circuit to ground or o...

Page 535: ...ctuator Hydraulic Control Wheel Lock Fault Code Possible Cause Action Front wheel Actuator Hydraulic control wheel lock Front wheel Actuator Hydraulic control wheel lock Ensure ABS ECM connector is se...

Page 536: ...ly Motor runs continually Pinpoint Tests Test Result Action 1 Check ABS fuse integrity OK Proceed to test 2 Faulty Replace fuse and proceed to test 5 2 Check the motor function Check that with the mot...

Page 537: ...nt Tests Test Result Action 1 Check ABS fuse integrity OK Proceed to test 2 Faulty Replace fuse and proceed to test 6 2 Check cable and terminal integrity ABS ECM connector pin 6 ABS ECM connector pin...

Page 538: ...eed to test 5 2 Check the tyre pressures OK Proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check the pulser ring for damage or contamination by road grime or ferrous metal filings OK Proce...

Page 539: ...o test 4 Faulty Rectify the fault and proceed to test 4 4 Clear fault code and test ABS to verify fault cleared OK Action complete quit test Fault still present Contact Triumph service ECM Communicati...

Page 540: ...ngine ECM pin A34 OK Proceed to test 6 Open circuit Locate and rectify wiring fault proceed to test 7 6 Check cable for short circuit ABS ECM pin 11 to ABS ECM pin 10 OK Proceed to test 7 Short Circui...

Page 541: ...est 6 3 Check cable for short circuit ABS ECM pin 11 to ground ABS ECM pin 10 to ground OK Proceed to test 4 Short Circuit Locate and rectify wiring fault proceed to test 6 4 Check cable continuity AB...

Page 542: ...test 2 Faulty Rectify fault proceed to test 5 2 Check cable for short circuit ABS ECM pin 11 to ground ABS ECM pin 10 to ground OK Proceed to test 3 Short circuit Locate and rectify wiring fault proce...

Page 543: ...n Modulator active pressure control malfunction Modulator active pressure control malfunction Contact Triumph service Modulator input master cylinder pressure sensor malfunction Modulator input master...

Page 544: ...test 3 2 Check that the engine ECM calibration is correct for the motorcycle using the diagnostic tool OK Proceed to test 3 Incorrect Download the correct calibration using diagnostic tool proceed to...

Page 545: ...6 4 Check cable continuity ABS ECM pin 11 to IMU pin 3 ABS ECM pin 10 to IMU pin 2 OK Proceed to test 5 Open circuit Locate and rectify wiring fault proceed to test 6 5 Check cable for short circuit A...

Page 546: ...IMU pin 4 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 4 4 Reconnect harness clear fault code and run engine OK Action complete quit test Fault still present Conta...

Page 547: ...s are tightened to the correct torque Check the IMU electrical connector is securely connected OK Proceed to test 3 Incorrect Rectify fault Proceed to test 3 3 Clear fault code and check for normal op...

Page 548: ...Tiger Explorer XR Series 544 of 746 WHEELS TYRES...

Page 549: ...equipped with tubeless tyres valves and wheel rims Use only tyres marked TUBELESS and tubeless valves on rims marked SUITABLE FOR TUBELESS TYRES chez Typical Wheel Marking Tiger Explorer XR Series 545...

Page 550: ...cause abnormal tread wear and instability problems which may lead to loss of control and an accident Under inflation may result in the tyre slipping on or coming off the rim Over inflation will cause...

Page 551: ...ce chart measure the depth of the tread with a depth gauge and replace any tyre that has worn to or beyond the minimum legally allowable tread depth specified see Wheels and Tyres WARNING Triumph moto...

Page 552: ...If tyre or inner tube damage is suspected such as after striking the kerb ask your authorised Triumph dealer to inspect the tyre both internally and externally and to also inspect the inner tube Reme...

Page 553: ...iles 160 km to become accustomed to the new handling characteristics After both 24 hours and 100 miles 160 km the tyre pressures should be checked and adjusted and the tyre examined for correct seatin...

Page 554: ...6 1 2 chom Wheel spindle 1 Wheel spacer right hand shown 2 Place the wheel on wooden blocks 7 WARNING Do not allow the wheel to rest on either brake disc as this may damage the disc and could lead to...

Page 555: ...on both sides of the bearing to prevent it from tipping and becoming stuck Application of uneven force will lead to difficulty in removing the bearing and to a damaged wheel Using a suitable pin punc...

Page 556: ...0301 Bearing Installer Large face to wheel Fit the wheel bearing to the left hand side of the wheel using the method described above 1 Fit the wheel bearings and centre sleeve using the method describ...

Page 557: ...cs 6 Refit the front brake calipers see Front Brake Caliper Installation 7 WARNING It is dangerous to operate the motorcycle with defective brakes you must have your authorised Triumph dealer take rem...

Page 558: ...hop Rear wheel nuts 1 The rear brake disk and caliper will remain in position on the final drive unit when the wheel is removed 3 Frame and Bodywork Exploded View Frame WARNING Before starting work en...

Page 559: ...o loss of motorcycle control and an accident Check the operation of the rear brake 4 Inform the owner to check and if necessary tighten the rear wheel nuts to 70 Nm 5 Exploded View Front Mudguard Tige...

Page 560: ...Exploded View Cockpit and Mountings Tiger Explorer XR Series 556 of 746 FRAME BODYWORK...

Page 561: ...Exploded View Mirrors Tiger Explorer XR Series 557 of 746 FRAME BODYWORK...

Page 562: ...Exploded View Side Fairings Exploded View Sump Guard Tiger Explorer XR Series 558 of 746 FRAME BODYWORK...

Page 563: ...Exploded View Engine Protection Bars Tiger Explorer XR Series 559 of 746 FRAME BODYWORK...

Page 564: ...Exploded View Front and Rear Footrests Tiger Explorer XR Series 560 of 746 FRAME BODYWORK...

Page 565: ...Exploded View Side Stand and Centre Stand Tiger Explorer XR Series 561 of 746 FRAME BODYWORK...

Page 566: ...Exploded View Seat and Tool Kit Exploded View Rear Panels and Luggage Rack Tiger Explorer XR Series 562 of 746 FRAME BODYWORK...

Page 567: ...Exploded View Rear Mudguard and Battery Tray Exploded View Pannier Mounting Frames Tiger Explorer XR Series 563 of 746 FRAME BODYWORK...

Page 568: ...Tiger Explorer XR Series 564 of 746 FRAME BODYWORK...

Page 569: ...control and an accident If fitted check the operation of the centre stand to make sure it is securely held in the retracted position by the spring Rectify any faults 3 WARNING If the return spring is...

Page 570: ...r brackets 1 Subframe loops 2 Rear seat inner brackets 3 Rider seat brackets 4 WARNING To prevent detachment of the seat during riding after fitting always grasp the seat and pull firmly upwards If th...

Page 571: ...ear of the seat Refit the passenger seat see Passenger Seat Installation 1 WARNING To prevent detachment of the seat during riding after fitting always grasp the seat and pull firmly upwards If the se...

Page 572: ...prevent it from falling and causing injury to the operator or damage to the motorcycle Position the front mudguard and fork protector assembly to the front forks Ensure that the front brake hoses are...

Page 573: ...d causing injury to the operator or damage to the motorcycle Slide the rubber cover off the mirror boss and lock nut 1 chnk_1 1 Rubber cover 1 Note The mirror arm and its lock nut has a left hand thre...

Page 574: ...ing is too loose the mirror may blow back at speed This will result in a loss of vision to the rear of the motorcycle It is dangerous to ride a motorcycle without sufficient rearward vision Note The e...

Page 575: ...bber cover over the lock nut and mirror boss 6 chnk_1 1 Rubber cover 1 Repeat the procedure for the other mirror 7 Windscreen Removal Windscreen Installation Cockpit Panels Removal WARNING Before star...

Page 576: ...the windscreen to its mounting frame and tighten its fixings to 4 Nm 1 1 2 2 Windscreen 1 Fixings 2 WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will...

Page 577: ...om falling and causing injury to the operator or damage to the motorcycle Ensure that the rubber grommets are fitted to the wind deflector panel 1 1 2 3 Wind deflector panel 1 Grommets 2 Locating slot...

Page 578: ...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 Remove the rider s seat see Rider s Seat Rem...

Page 579: ...emove the four fixings securing high level mudguard to the cockpit sub frame 1 1 1 Fixings 1 Lower the high level mudguard and disconnect the ambient air temperature sensor s electrical connection 2 1...

Page 580: ...motorcycle is stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Protect the side fairings from damage by applyin...

Page 581: ...tabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the rider s seat see Rider s Seat Removal Disconnect the...

Page 582: ...ep 3 for the other infill panel 4 Side Fairings Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from falling and causing inj...

Page 583: ...ead first and tighten the terminals to 4 5 Nm Refit the rider s seat see Rider s Seat Installation Side Fairings Installation WARNING Before starting work ensure the motorcycle is stabilised and adequ...

Page 584: ...move the badge from the side fairings 2 1 2 Fixings 1 Badge left hand shown 2 Note Note the orientation of the mounting bracket for the fuel tank infill panels for installation Release the fixing and...

Page 585: ...m the fuel tank 5 Release the side panel from the lower locating lug on the radiator and remove the side panel 6 2 1 Upper mounting 1 Lower locating lug 2 Seat Infill Panel Removal WARNING Before star...

Page 586: ...the rubber grommet in the lower fairing to its locating lug on the radiator mounting bracket 2 2 1 3 4 Rubber grommet 1 Bracket 2 Locating lug 3 Lower fairing 4 Position the upper fairing s mounting...

Page 587: ...l as noted for removal and tighten the fixing to 3 Nm 5 1 2 chpp Mounting bracket left hand shown 1 Fixing 2 Fit the badge to the side fairing and tighten the fixings to 3 Nm 6 1 2 Fixings 1 Badge lef...

Page 588: ...seat see Rider s Seat Removal Disconnect the battery negative black lead first Remove the side fairings see Side Fairings Removal Release the fixing securing the rear of the seat infill panel to the...

Page 589: ...e locating lug on the infill panel to the rear of its mounting screw on the fuel tank Move the infill panel forward to fully engage the centre lug to the mounting screw 1 Align the front locating lug...

Page 590: ...TION The Inertial Measurement Unit IMU located beneath the seat bridge is a highly sensitive device Exposure to excessive shock and vibration can cause permanent damage to IMU internal components Care...

Page 591: ...amage to IMU internal components Care must be taken when removing or installing the seat bridge not to expose the IMU to excessive shock or vibration When releasing or tightening the fixings use suita...

Page 592: ...fixings 2 cjjq 1 2 Sump guard 1 Fixings left hand shown 2 Engine Bars Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help prevent it from...

Page 593: ...irst This will allow access to the lock nut for the lower crankcase mounting bolt Left Hand Engine Bar Release the fixing securing the link bar to the left hand engine bar 1 2 1 3 Fixing 1 Link bar 2...

Page 594: ...unting bolt the left hand control plate must be removed Remove the three fixings and remove the expansion tank cover Discard the upper M5 fixing Retain the lower M6 fixings for reuse 3 2 chgw_2 1 3 Ex...

Page 595: ...ch mark 4 Note Do not allow the side stand to hang on the harness for the side stand switch Note the routing of the harness for the side stand switch for installation Release the remaining fixing deta...

Page 596: ...e rear brake pedal remove the lower crankcase mounting bolt 8 Note Note that there is a 13 mm spacer between the right hand engine bar s centre mounting and the engine for installation Remove the cent...

Page 597: ...WARNING During installation of the right hand engine bar it is necessary to loosen various engine to frame and rear suspension mounting fixings The engine to frame alignment must then be reset using T...

Page 598: ...e two upper fixings securing the radiator to the frame Do not fully remove 4 1 Fixings 1 Position the lower end of the radiator forwards to allow access to the front cylinder head frame mountings 5 CA...

Page 599: ...t fully remove 7 Remove the upper crankcase mounting bolt washer and lock nut Discard the lock nut 8 Remove the bolt and washer from the right hand front cylinder head mounting 9 Note There are three...

Page 600: ...Note The right hand swinging arm pivot pin must be loosened before the frame bolts can be tightened Release the fixings and remove the right hand heel guard 11 chgp_1 2 1 Fixings 1 Heel guard 2 Carefu...

Page 601: ...ine mounting bolt tightening sequence is precisely followed severe frame damage can occur Note The engine MUST be cold prior to starting the frame bolt tightening sequence The T3880637 Kit Engine to F...

Page 602: ...w enough clearance on the right hand side of the frame to enable the threaded adjusters to be adjusted 15 Crankcase alignment bar 1 Frame to crankcase mounting lower mounting shown left hand side of f...

Page 603: ...lower crankcase adjuster to 5 Nm Tighten the upper crankcase adjuster to 5 Nm Tighten the right hand front cylinder head adjuster to 3 Nm chma 1 2 4 3 Lower crankcase adjuster 1 Upper crankcase adjust...

Page 604: ...emaining frame bolts in the following sequence 26 Tighten the right hand rear cylinder head bolt to 85 Nm Tighten the left hand front cylinder head bolt to 115 Nm Using T3880377 Engine Mounting Adjust...

Page 605: ...ly mark the pivot pin alignment in relation to the frame 32 1 2 3 4 Swinging arm pivot pin 1 Locking ring 2 Pivot pin alignment mark 3 Frame alignment mark 4 Note If the pivot pin and frame markings d...

Page 606: ...to 18 Nm 39 Fit the transmission linkage to the gear change mechanism as noted for removal 40 Fit the pinch bolt and tighten it to 9 Nm 41 chmh 1 2 3 4 Pinch bolt 1 Transmission linkage 2 Gear change...

Page 607: ...ngine Bar Align the left hand engine bar to the link bar and engine 48 Ensure that the radiator mounting bracket is between the upper mounting for the engine bar and the engine Fit the M8 x 25 mm bolt...

Page 608: ...ne bar centre mounting bolt to 18 Nm 56 Position the link bar equally between the left hand and right hand engine bars Tighten the fixings to 5 Nm 57 Lower the motorcycle and park on the side stand 58...

Page 609: ...ar footrest hanger right hand shown 2 Washers 3 Spacer 4 Repeat step 3 for the left hand side 4 Remove the four fixings and remove the right hand pannier mounting frame 5 Repeat step 5 for the left ha...

Page 610: ...Position the right hand pannier mounting frame to the motorcycle and secure with the four fixings Do not tighten the fixings at this stage 2 2 1 1 3 3 Fixings 1 Pannier mounting frame right hand shown...

Page 611: ...nuts to prevent rotation tighten the two right hand pannier link bar fixings to 20 Nm 9 While holding the lock nut to prevent rotation tighten the left hand pannier link fixing to 20 Nm 10 If fitted f...

Page 612: ...to 27 Nm 2 1 1 chpq 2 Fixings 1 Pannier rail 2 If fitted fit the pannier mounting frames see Pannier Mounting Frames Installation WARNING Before starting work ensure the motorcycle is stabilised and...

Page 613: ...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...

Page 614: ...elp prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the rider s seat see Rider s Seat Removal Disconnect the battery negative black lead first Remove the...

Page 615: ...to the motorcycle Note If fitted reconnect the electrical connectors for the rear heated seat switch and rear electrical accessory socket Fit the rear panel to the motorcycle Ensure that the lip at th...

Page 616: ...oval Disconnect the battery negative black lead first Remove the pannier rails see Pannier Rails Removal Remove the rear panel see Rear Panel Removal Release the fixing and detach the seat latch from...

Page 617: ...he frame Collect the side reflectors bracket if fitted Do not allow the rear mudguard to hang from the rear light and direction indicator harnesses 5 Fixings 1 Note The right hand indicator wiring is...

Page 618: ...ycle Attach the rear light connector block to the rear light bracket 1 1 2 chpr Connector block 1 Bracket 2 Connect the electrical connectors for the rear light and indicators as noted for removal 2 A...

Page 619: ...ngs at the top of the rear mudguard to 7 Nm 6 Attach the seat latch outer cable to the subframe 7 Attach the seat latch inner cable to the seat s latch 8 Fit the seat latch to the frame and tighten it...

Page 620: ...gine Electronic Control Module ECM Removal Remove the rear mudguard see Rear Mudguard Removal Remove the rear wheel see Rear Wheel Removal Note Note the routing of the rear section of the harness and...

Page 621: ...l on the main harness and position aside 4 cjid 2 1 Battery leads 1 Channel 2 Remove the scrivet securing the harness channel to the battery tray 5 1 Scrivet 1 Release the harness clip 6 2 1 Tiger Exp...

Page 622: ...1 1 Fixings 1 Lower the battery tray and remove towards the rear of the motorcycle 9 Side Stand Removal WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This...

Page 623: ...with the clip 2 cjid_1 2 1 Clip 1 Harness 2 Ensure that the harness channel is located correctly to the battery tray and secure with a new scrivet 3 1 Scrivet 1 Route the battery leads into their cha...

Page 624: ...Rear wheel speed sensor electrical connection Front heated seat switch electrical connector if fitted Heated seats sub harness to main harness electrical connectors if fitted Alarm electrical connecto...

Page 625: ...d the E clip securing the pivot pin 3 Remove the pivot pin and remove the side stand 4 1 2 4 3 Side stand 1 Spring 2 Pivot pin 3 E clip 4 Side Stand Installation Smear the upper and lower contact surf...

Page 626: ...d adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Perform the following operations Side Stand Lubrication Fit the side stand...

Page 627: ...mponents With the side stand in the up position hook the spring onto its frame lug then carefully hook it onto the side stand lug 3 Check the operation of the side stand before riding the motorcycle E...

Page 628: ...Exploded View Headlight Tiger Explorer XR Series 624 of 746 ELECTRICAL...

Page 629: ...Exploded View Rear Light and Reflectors Tiger Explorer XR Series 625 of 746 ELECTRICAL...

Page 630: ...Exploded View Direction Indicators Exploded View Alternator and Starter Motor Tiger Explorer XR Series 626 of 746 ELECTRICAL...

Page 631: ...ntact with skin or eyes may cause severe burns Wear protective clothing and a face shield If electrolyte gets on your skin flush with water immediately If electrolyte gets in your eyes flush with wate...

Page 632: ...operator or damage to the motorcycle WARNING Ensure that the battery terminals do not touch the motorcycle frame as this may cause a short circuit or spark which would ignite battery gases causing a r...

Page 633: ...a recycling agent who will ensure that the dangerous substances from which the battery is manufactured do not pollute the environment Battery Commissioning and Charging Battery Maintenance New Battery...

Page 634: ...container in place 7 Check that all of the electrolyte has drained from the container Do not remove the container at this point If the container has not completely drained tap the sides of the contain...

Page 635: ...the battery voltage fall below 12 8 V charge the battery using the BatteryMate Battery Charger see latest Parts Catalogue for part number information Refer to the instructions supplied with the Batter...

Page 636: ...the cause and then replace it with a new fuse of the correct current rating A blown fuse is indicated when all of the systems protected by that fuse become inoperative When checking for a blown fuse r...

Page 637: ...ocated beneath the rider s seat To allow access to the main fuse box the rider s seat and chassis ECM cover must be removed ciuu_1 1 Main fuse box 1 A blown fuse is indicated when all of the systems p...

Page 638: ...Rating Amps PS1 1 20 PS2 2 25 PS3 3 30 PS4 4 25 PS5 5 25 Ignition 6 5 Front accessory socket 7 10 Engine management 8 20 Instruments 9 5 Chassis Electronic Control Module Chassis ECM System Diagnosis...

Page 639: ...ems and their corresponding fuses Electrical System Fuse Left headlight main beam PS1 Left headlight dipped beam Left front direction indicator Left rear direction indicator Rear position light RSU po...

Page 640: ...stem sensors and actuators test various component functions read build data and make minor adjustments to the set up of the system The data and tests available are described on the following pages On...

Page 641: ...y and the adjustments which can be performed using the Triumph diagnostic software The tables indicate which tests are performed by the on board system and what information can be retrieved by the Tri...

Page 642: ...n PWM Data Each of these screens is described on the following pages Sensor Voltages The data available under Sensor Voltages is Item Checked Result Unit Battery Voltage Volts Front Accessory Power So...

Page 643: ...dicator Left Front On Off Direction Indicator Left Rear On Off Direction Indicators Right Switch On Off Direction Indicator Right Front On Off Direction Indicator Right Rear On Off Inputs Outputs The...

Page 644: ...Up Switch On Off Instruments Scroll Down Switch On Off Mode Switch On Off Heating The data available under Heating is Function Examined Result Unit Heated Grips Switch On Off Heated Grip Left On Off...

Page 645: ...tor Calibration If a fault is detected Electrical Connectors Diagnostic Trouble Codes DTCs are logged in the chassis ECM memory when there is a confirmed fault in the system The codes are reported to...

Page 646: ...signal low 1 40 TSAS light warning message Swinging Arm Position Sensor Signal C1012 Swinging arm position sensor signal high 1 40 TSAS light warning message Swinging Arm Position Sensor Signal C1013...

Page 647: ...rcurrent Overcurrent C1033 Right headlight high beam undercurrent 1 40 Headlight Undercurrent Overcurrent C1034 Right headlight high beam overcurrent 1 40 Headlight Undercurrent Overcurrent C1035 Left...

Page 648: ...ash at a faster rate Direction Indicators Undercurrent Overcurrent C1054 Left rear direction indicator undercurrent 1 40 Remaining direction indicators flash at a faster rate Direction Indicators Unde...

Page 649: ...t level indicators empty Passenger Heated Seat Undercurrent Overcurrent C1065 Passenger heated seat overcurrent 1 40 Heated seat symbol displayed on instruments but heat level indicators empty Passeng...

Page 650: ...ger accessory power socket overcurrent 1 40 Passenger Accessory Power Socket Overcurrent C1076 Top box accessory power socket overcurrent 1 40 Top Box Accessory Power Socket Overcurrent C1077 Starter...

Page 651: ...Unit RSU Preload Motor C1087 CAN fault lost communication with instruments 1 40 Instrument Communication CAN C1088 CAN fault lost communication with ABS module 1 40 ABS Communication CAN C1089 Inerti...

Page 652: ...Wheel Sensors C1101 Front wheel sensor unit loss of communication error 1 20 TPMS light warning message Tyre Pressure Monitoring System TPMS Wheel Sensors C1102 Rear wheel sensor unit loss of communic...

Page 653: ...heated seat switch position two malfunction 1 40 Heated seat symbol displayed on instruments but heat level indicators empty Rider Heated Seat Switch C1114 Passenger heated seat switch malfunction 1...

Page 654: ...1124 Chassis ECM restarted due to process time out during normal operation 1 40 Chassis ECM Restarted Due to Process Time Out During Normal Operation C1125 Chassis ECM restarted due to process time ou...

Page 655: ...owing connector related information should be noted Note A major cause of hidden electrical faults can be traced to faulty electrical connectors For example Dirty corroded terminals Damp terminals For...

Page 656: ...disconnecting a connector never pull directly on the wires as this may result in cable and connector damage CAUTION Never disconnect an ECM when the ignition switch is in the ON position as this may c...

Page 657: ...tors are used for the chassis ECM Ensure that the chassis ECM is in its fitted position on the motorcycle before reconnecting the connectors This will ensure that the correct connector aligns with its...

Page 658: ...n C1001 C1002 Main power supply overvoltage Main power supply undervoltage Blown fuse Short circuit to ground or open circuit Charging system fault Disconnect chassis ECM connectors and proceed to pin...

Page 659: ...omplete quit test Circuit Diagram Ambient Air Temperature Sensor Fault Code Possible Cause Action C1009 Ambient temperature sensor signal under temperature Check sensor is clean and clear of dirt Ensu...

Page 660: ...1 Temperature sensor pin 2 to ground OK Proceed to test 5 Open circuit Locate and rectify wiring fault proceed to test 6 5 Check sensor resistance Sensor pin 1 to sensor pin 2 temperature dependent s...

Page 661: ...Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity Chassis ECM pin A26 to sensor pin 4 Chassis ECM pin A16 to sensor pin 5 Chassis ECM pin A15 t...

Page 662: ...fault proceed to test 4 2 Check cable for short circuit Chassis ECM pin A44 to ground OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 4 3 Check cable continuity Cha...

Page 663: ...B08 Chassis ECM pin B01 OK Disconnect rear rebound damping solenoid and proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check cable continuity Chassis ECM pin B07 to solenoid pin 2 Chassis...

Page 664: ...A41 Chassis ECM pin B01 OK Proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check cable for short circuit Chassis ECM pin A53 to ground Chassis ECM pin A41 to ground OK Proceed to test 4 Sho...

Page 665: ...o test 8 3 Check cable for short circuit Chassis ECM pin A16 to ground Chassis ECM pin A15 to ground Ok Proceed to test 4 Short circuit Locate and rectify wiring fault proceed to test 8 4 Check cable...

Page 666: ...harness clear fault code and run engine to verify fault cleared OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram Fault Code Possible Cause Action C1028 Preload...

Page 667: ...Tests Test Result Action 1 Check fuse integrity Main fuse box fuse 3 PS3 OK Proceed to test 2 Faulty Replace fuse proceed to test 6 2 Check cable and terminal integrity Chassis ECM pin B05 Chassis ECM...

Page 668: ...plete quit test Fault still present Contact Triumph service Circuit Diagram Fog Lights Undercurrent Overcurrent Fault Code Possible Cause Action C1031 Left headlight high beam undercurrent Ensure all...

Page 669: ...sis ECM pin A06 to headlight connector pin 1 Chassis ECM pin A18 to headlight connector pin 2 Chassis ECM pin A10 to headlight connector pin 4 Chassis ECM pin A42 to headlight connector pin 5 Chassis...

Page 670: ...ontact Triumph service Circuit Diagram Rear Light Undercurrent Overcurrent Brake Light Undercurrent Overcurrent Fault Code Possible Cause Action C1042 Fog lights undercurrent Disconnect chassis ECM an...

Page 671: ...light connector pin 2 Left fog light connector pin 1 to ground Right fog light connector pin 1 to ground Main fusebox fuse 3 PS3 to Chassis ECM pin B01 OK Proceed to test 5 Open circuit Locate and re...

Page 672: ...fy fault proceed to test 5 3 Check cable for short circuit Chassis ECM pin A43 to ground OK Proceed to test 4 Short circuit Rectify fault proceed to test 5 4 Check cable continuity Chassis ECM pin A43...

Page 673: ...connector pin 1 Rear light connector pin 2 OK Proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check cable for short circuit Chassis ECM pin A09 to ground OK Proceed to test 4 Short circuit...

Page 674: ...dicator overcurrent C1059 Right rear direction indicator overcurrent Pinpoint Tests Test Result Action 1 Check relevant direction indicator bulb integrity non LED direction indicators only OK Proceed...

Page 675: ...19 Chassis ECM pin A20 Chassis ECM pin A31 Chassis ECM pin A32 Chassis ECM pin A01 Chassis ECM pin A02 All relevant direction indicator terminals OK Proceed to test 5 Faulty Rectify fault proceed to t...

Page 676: ...terminals OK Proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check cable for short circuit Chassis ECM pin A29 to ground OK Proceed to test 4 Short circuit Rectify fault proceed to test 5 4...

Page 677: ...1 Rider heated seat connector pin 2 OK Proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check cable for short circuit Chassis ECM pin B14 to ground OK Proceed to test 4 Short circuit Rectif...

Page 678: ...switch connector and proceed to test 3 Faulty Rectify fault proceed to test 6 3 Check cable for short circuit Chassis ECM pin B19 to ground Chassis ECM pin B20 to ground OK Proceed to test 4 Short cir...

Page 679: ...hassis ECM pin B16 Chassis ECM pin B02 Passenger heated seat sub harness connector pin 1 Passenger heated seat connector pin 2 OK Proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check cable...

Page 680: ...ch position one malfunction C1116 Passenger heated seat switch position two malfunction Pinpoint Tests Test Result Action 1 Check switch integrity Check the switch for sticking OK Proceed to test 2 Fa...

Page 681: ...cuit Locate and rectify wiring fault proceed to test 6 6 Reconnect harness clear fault code and run engine to verify fault cleared OK Action complete quit test Fault still present Contact Triumph serv...

Page 682: ...pin B13 to ground Chassis ECM pin B15 to ground OK Proceed to test 4 Short circuit Rectify fault proceed to test 5 4 Check cable continuity Chassis ECM pin B13 to heated grip pin 3 Chassis ECM pin B15...

Page 683: ...fan connector pin 1 Cooling fan connector pin 2 OK Proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check cable for short circuit Chassis ECM pin A17 to ground OK Proceed to test 4 Short cir...

Page 684: ...B03 Fuel pump connector pin 1 Fuel pump connector pin 2 OK Proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check cable for short circuit Chassis ECM pin B18 to ground Chassis ECM pin B30 t...

Page 685: ...ircuit Locate and rectify wiring fault proceed to test 3 2 Check cable continuity Chassis ECM pin B11 to USB socket pin 1 USB socket pin 2 to ground OK Replace USB socket proceed to test 3 Open circui...

Page 686: ...n 1 to ground OK Replace power socket proceed to test 3 Open circuit Locate and rectify wiring fault proceed to test 3 3 Reconnect harness clear fault code and run engine to verify fault cleared OK Ac...

Page 687: ...e quit test Fault still present Contact Triumph service Circuit Diagram TSAS Error Fault Code Possible Cause Action C1077 Starter motor solenoid undercurrent Proceed to pinpoint test 1 C1078 Starter m...

Page 688: ...lace starter solenoid proceed to test 5 Open circuit Locate and rectify wiring fault proceed to test 5 5 Reconnect harness clear fault code and run engine to verify fault cleared OK Action complete qu...

Page 689: ...ty Chassis ECM pin A07 Chassis ECM pin A08 Instruments pin 3 Instruments pin 2 OK Proceed to test 5 Faulty Rectify fault proceed to test 8 5 Check cable for short circuit Chassis ECM pin A07 to ground...

Page 690: ...uity ABS ECM pin 1 to battery positive terminal ABS ECM pin 13 to ground OK Proceed to test 3 Open circuit Locate and rectify wiring fault proceed to test 7 3 Check cable and terminal integrity Chassi...

Page 691: ...till present Contact Triumph service Circuit Diagram Inertial Measurement Unit IMU Signal CAN Fault Code Possible Cause Action C1089 Inertial Measurement Unit IMU ID incompatible Proceed to pinpoint t...

Page 692: ...ct IMU connector and proceed to test 2 Faulty Rectify fault proceed to test 5 2 Check cable for short circuit Chassis ECM pin A07 to ground Chassis ECM pin A08 to ground IMU pin 4 to ground OK Proceed...

Page 693: ...obiliser communication C1109 TSAS Engine ECM implausible signal Pinpoint Tests Test Result Action 1 Check cable and terminal integrity Engine ECM pin A33 Engine ECM pin A34 Chassis ECM pin A07 Chassis...

Page 694: ...TPMS Wheel Sensors Immobiliser Antenna Fault Code Possible cause Action C1097 Front wheel sensor unit battery alert Replace the relevant wheel pressure sensor following the procedure described in the...

Page 695: ...oint Tests Test Result Action 1 If available try to start the motorcycle with the second registered key OK Transponder chip in the key not functioning correctly Register a new key using the Triumph Di...

Page 696: ...red OK Action complete quit test Fault still present Contact Triumph service Circuit Diagram Left Fork Stepper Motor Compression Damping Fault Code Possible Cause Action C1117 Left fork stepper motor...

Page 697: ...cable continuity Chassis ECM pin A11 to left fork stepper motor pin B Chassis ECM pin A12 to left fork stepper motor pin C Chassis ECM pin A47 to left fork stepper motor pin D Chassis ECM pin A48 to l...

Page 698: ...able for short circuit Chassis ECM pin B09 to ground Chassis ECM pin B10 to ground Chassis ECM pin B23 to ground Chassis ECM pin B24 to ground OK Proceed to test 4 Short circuit Locate and rectify wir...

Page 699: ...ther stored DTCs Contact Triumph service C1125 C1126 Fault Code Possible Cause Action C1127 Chassis ECM restarted due to calibration download Erase DTC No further action required Unexpected Chassis EC...

Page 700: ...With Ignition ON check Voltage at Chassis ECM pin A01 Chassis ECM pin B01 Same as across battery Voltage Proceed to test 5 Less than across battery Voltage Locate and rectify wiring fault proceed to t...

Page 701: ...load motor not inhibited C1134 Rear preload motor Maximum end stop detection error Preload motor inhibited Chassis Electronic Control Module ECM Removal WARNING Before starting work ensure the motorcy...

Page 702: ...the engine ECM 2 Download the latest chassis ECM calibration 3 Register the tyre pressure sensor ID numbers activate TPMS and enable the TPMS instrument display if TPMS is fitted 4 For models fitted...

Page 703: ...the IMU An IMU that has been dropped will be irreparably damaged and must be replaced Using a suitable hand tool release the fixings and remove the IMU and bracket assembly from the seat bridge 1 cjj...

Page 704: ...ools When removed from the motorcycle place the IMU on a flat surface in a location that is isolated from shock and vibrations caused by other workshop processes Do not drop the IMU An IMU that has be...

Page 705: ...o the touch Contact with the hot components may cause damage to exposed skin To avoid skin damage always allow the hot parts to cool before working on the exhaust system WARNING Before starting work e...

Page 706: ...onents of the swinging arm position sensor Release the link rod from the ball stud 2 cjlu 2 1 Link rod 1 Ball stud 2 Note To gain access to the electrical connector the position sensor must first be r...

Page 707: ...t it from falling and causing injury to the operator or damage to the motorcycle Note Prior to installing the position sensor the electrical connector must first be connected Connect the position sens...

Page 708: ...damage to the actuator arm or the internal components of the swinging arm position sensor Note Apply a smear of proprietary general purpose grease to NLGI 2 standard to the ball stud If the ball stud...

Page 709: ...the rider s seat see Rider s Seat Removal 1 WARNING The rear suspension unit preload motor MUST be calibrated before attempting to calibrate the swinging arm position sensor Failure to calibrate the r...

Page 710: ...suspension at full extension This calibration occurs instantaneously Click start The calibration will be completed instantaneously as described above 6 Disconnect the Triumph Diagnostic Tool and turn...

Page 711: ...nect the battery positive red lead first and tighten the terminals to 4 5 Nm Refit the rider s seat see Rider s Seat Installation Windscreen Motor Installation WARNING Before starting work ensure the...

Page 712: ...e the fixings and remove the windscreen motor cover 2 cjlj 2 1 Fixings 1 Windscreen motor cover 2 Release the fixings and remove the clear wind deflector panels 3 1 2 Wind deflector panel right hand s...

Page 713: ...e windscreen motor away from the front subframe Disconnect the electrical connector and remove the motor 6 Instruments Removal WARNING Before starting work ensure the motorcycle is stabilised and adeq...

Page 714: ...nserted into the grommets on the front subframe 3 cjlf 2 3 1 1 Fixings 1 Windscreen motor 2 Instrument cover 3 Refit the wind deflector panels and tighten the fixings to 3 Nm 4 1 2 Wind deflector pane...

Page 715: ...fixing Tighten the fixing to 5 Nm 7 Tighten the windscreen support upper mountings to 4 Nm 8 cjlk_1 1 2 3 Lower mounting fixing 1 Upper mounting fixings 2 Windscreen support bracket 3 Refit the cockp...

Page 716: ...e three fixings and release the instruments from the bracket bayonet fixings Collect the washers 3 cjlh 2 1 1 3 Fixings 1 Electrical connector 2 Instruments 3 Headlight Adjustment WARNING Before start...

Page 717: ...am when the motorcycle is in motion may result in loss of control and an accident CAUTION Do not cover the headlight or lens with any item likely to obstruct air flow to or prevent heat escaping from...

Page 718: ...damage to the motorcycle Each headlight bulb can be replaced as follows WARNING The bulb becomes hot during use Always allow sufficient time for the bulb to cool before handling Avoid touching the gl...

Page 719: ...uately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the rider s seat see Rider s Seat Removal Disconnect the battery negative...

Page 720: ...rd Removal Release the four fixings and washers securing the headlight to the front subframe 1 cjle 2 1 Fixings left hand shown 1 Washers 2 Ease the headlight away from the cockpit subframe and discon...

Page 721: ...s stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Note The rear light is a sealed for life unit and must be re...

Page 722: ...s stabilised and adequately supported This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Refit the bracket to the rear light and tighten the fixings...

Page 723: ...s Seat Installation Front Direction Indicator Removal Front Direction Indicator Installation WARNING Before starting work ensure the motorcycle is stabilised and adequately supported This will help p...

Page 724: ...Seat Removal Disconnect the battery negative black lead first Remove the headlight see Headlight Assembly Removal Note Note the routing of the indicator harness prior to removal Disconnect the indica...

Page 725: ...eadlight Assembly Installation Reconnect the battery positive red lead first and tighten the terminals to 4 5 Nm Refit the rider s seat see Rider s Seat Installation Check the operation of the directi...

Page 726: ...nsure that the drain hole in the indicator lens is at the bottom Refit the direction indicators to the rear mudguard 1 Secure with the fixings and tighten to 5 Nm 2 chlz_5 1 2 2 1 Fixings 1 Direction...

Page 727: ...turns freely and without binding 1 Check the starter O ring for damage and deterioration Replace as necessary 2 Alternator Disassembly WARNING Before starting work ensure the motorcycle is stabilised...

Page 728: ...on Check that any fuse in the circuit is not blown and is of the correct rating Using the Triumph Diagnostic Tool check the operation of the neutral switch or gear position sensor if fitted side stand...

Page 729: ...ITCH CONNECTOR CHECK THE STARTER RELAY OPERATION FAULTY NEUTRAL SWITCH FAULTY CLUTCH SWITCH FAULTY SIDESTAND SWITCH BAD CONTACT AT CONNECTOR OPEN CIRCUIT IN WIRING LOOM FAULTY ALARM OR ENGINE ECM IF F...

Page 730: ...ay Removal Remove the two upper selector cover fixings and detach the starter solenoid and bracket Position the starter solenoid aside 1 chjc 1 2 Starter solenoid 1 Fixings 2 Disconnect the alternator...

Page 731: ...he alternator decoupler and drive gear assembly 1 Fit T3880602 Alternator Wrench to the splines of the alternator decoupler and drive gear assembly 2 T3880602 Alternator Wrench Prevent the alternator...

Page 732: ...ollowing Note Tighten the drive gear to decoupler fixings to 3 Nm Always fit a new nut when refitting the decoupler and drive gear assembly Tighten the decoupler and drive gear assembly nut to 54 Nm W...

Page 733: ...n to 10 Nm 3 Refit the alternator cable boot 4 Reconnect the alternator multiplug 5 chjd 1 2 Alternator multiplug 1 Cable nut 2 Reposition the starter solenoid to the selector cover and secure with th...

Page 734: ...s not contain any serviceable parts and must be replaced if faulty The alternator and regulator rectifier are integrated in the same unit It is not possible to check for continuity and short circuit t...

Page 735: ...trol connector Proceed to test 4 Faulty Rectify fault Reconnect the alternator control connector Proceed to test 4 4 Ensure the alternator control connector is plugged and secured Run the engine Check...

Page 736: ...ted Seat Switch Rider 10 Heated Seat Rider 11 Heated Seat Switch Passenger 12 Heated Seat Passenger 13 Windscreen Motor 14 Engine ECM 15 Rear Light 16 Left Fog Light 17 Right Fog Light 18 Left Rear In...

Page 737: ...Orange K Pink R Red P Purple W White Y Yellow LG Light Green LU Light Blue 1 2 4 5 6 3 1 2 1 2 1 1 1 1 1 1 1 1 2 1 2 1 1 2 2 1 A06 A18 A10 A42 A30 A19 A31 B53 B17 B11 B15 B13 UR UW Y UW UR UR UW Y UW...

Page 738: ...WR WG WY WU Y YN A53 A41 A27 B38 A16 A15 13 TSAS Circuit Diagram Key to Circuit Diagram Key Item Description 1 Battery 2 Starter Solenoid 3 Starter Motor 4 Chassis ECM 5 Engine Control Module Connecto...

Page 739: ...ht Blue Key to Engine Management Circuit Diagram M A01 A02 B01 B02 B03 6 1 2 3 4 5 B06 A51 A52 6 6 7 A40 A39 10 1 2 4 B01 2 A37 B39 40 0 Amp WR N N N N O N W G U GB Y G U WY K G G G G GN B BO BO WR BO...

Page 740: ...ch 6 Scroll Up Switch 7 Scroll Down Switch 8 Select Switch 9 Main Dipped Beam Switch 10 Pass Switch 11 Mode Switch 12 Horn Switch 13 Right Hand Switch Housing 14 Hazard Lights Switch 15 Cruise Control...

Page 741: ...th Module Connector 28 Diagnostic Connector 29 Main Fuse Box Key To Wiring Colour Codes Code Wiring Colour B Black U Blue N Brown G Green S Slate Grey O Orange K Pink R Red P Purple W White Y Yellow L...

Page 742: ...9 10 11 12 P p 13 14 15 16 5 10 1 7 6 Y G W R R WG WU 17 Y B 8 4 WN 18 2 3 1 B R U 19 20 21 WG WU WN 22 23 24 25 26 27 28 29 Complete System Circuit Diagram Key Item Description 1 Chassis ECM 2 Left H...

Page 743: ...B A C D 2 3 1 5 4 B A C D 2 1 2 1 4 3 A34 A33 A48 A11 A12 A47 B24 B10 B09 B23 B08 B07 B05 A36 B04 A07 A08 A53 A41 A27 B38 A16 A15 A26 Y WG WR WU WY YN YS Y YN Y WG WR WU WY YN YS B U R YO YK YG YB YO...

Page 744: ...ctor 8 Fuel Level Sender 9 Intake Air Temperature Sensor 10 Clutch Switch 11 Side Stand Switch 12 Throttle Actuator Motor 13 Crankshaft Position Sensor 14 Cooling Fan 15 Fuel Pump 16 Chassis ECM 17 Ox...

Page 745: ...wn G Green S Slate Grey O Orange K Pink R Red P Purple W White Y Yellow LG Light Green LU Light Blue 1 2 1 2 1 2 1 3 5 2 4 4 2 2 1 3 3 2 1 3 8 1 B14 B15 B16 B31 B36 B41 B18 B34 B44 B23 KS KP BW BK KB...

Page 746: ...B YR 2 1 2 1 B S 2 4 3 1 GY GU 2 4 3 1 W S W B NK B R O 1 9 B BG 1 2 1 2 1 2 1 2 1 2 1 2 Key Item Description 1 Chassis ECM 2 Rear Suspension Unit Damping Valve 3 Right Hand Front Fork Rebound Damping...

Page 747: ...trol 26 Alternator Power 27 Starter Motor 28 Starter Solenoid 29 Battery 30 40 Amp Main Fuse 31 Fuse Box 2 32 Fog Light Switch 33 Heated Grips Switch 34 Fog Light Heated Grips Connector 35 Horn Switch...

Page 748: ...51 Engine Stop Switch 52 Right Handlebar Switch Housing 53 Cruise Control Cancel Switch 54 Accelerator Position Sensor 55 Throttle Position Sensor 56 Inertial Measurement Unit 57 Alarm Connector 58 Di...

Page 749: ...t Indicator 74 Horn 75 Heated Oxygen Sensor 76 Coolant Temperature Sensor 77 Oil Pressure Sensor 78 Injector 1 79 Injector 2 80 Injector 3 81 Purge Valve 82 Engine Subharness Connector 83 Coil 3 84 Co...

Page 750: ...de Stand Switch 91 Fuel Level Sender 92 Intake Air Temperature Sensor 93 Secondary Air Injection Solenoid 94 Throttle Control 95 Engine ECM 96 Engine Management System Relay Tiger Explorer XR Series 7...

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