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Triumph Tiger Explorer XR 2016, Руководство по обслуживанию


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Clutch Pack Height Too Low

Note

No more than one 2.3 mm thick steel plate may be used in the clutch pack.
The 2.3 mm steel plate cannot be used to replace the inner most steel plate.

Replace one 2.0 mm steel plate with a 2.3 mm steel plate. The thicker plate can be installed in any position
except the innermost position.

1. 

Recheck the clutch pack height as described earlier.

2. 

Clutch - Assembly

The outermost and two innermost friction plates differ from the six centre friction plates. Identification is as
follows:

The outermost and two innermost friction plates have a larger internal diameter to accommodate the anti-
judder spring and pressure plate splines respectively.
The outermost and two innermost friction plates also have more friction pads (60 pads) than the other plates
(50 pads).
The outermost and two innermost 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
diameter.

CAUTION

Do not use brake cleaner or any other similar cleaning fluids to clean the clutch plates. The use of brake
cleaner or other similar cleaning fluids may adversely affect the operation of the clutch.

Remove any contamination or debris from the clutch plates using a soft dry cloth.

1.

Coat all friction and steel plates in clean engine oil.

2.

CAUTION

Ensure the clutch plates are all installed in the correct locations. Failure to do so will adversely affect the
operation of the clutch.

Note

During installation, ensure that the anti-judder spring is installed with its smaller (internal) diameter
facing outwards towards the clutch centre.
Also ensure that the steel plates are installed so that the face with the curved edges is facing
outwards towards the clutch centre.

Tiger Explorer XR Series

133 of 746

CLUTCH

Содержание Tiger Explorer XR 2016

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

Страница 2: ......

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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