Speed Triple Vin 461332 Onwards Speed Triple R

SPEED TRIPLE
VIN 461332 ONWARDS
SPEED TRIPLE R
Triumph Speed Triple
From VIN 461332 onwards
and Speed Triple R
Motorcycle Service Manual
/
{
Part Number 3856544 issue 1, 11.2011

Table of Contents
Introduction
General Information
Scheduled Maintenance
Cylinder Head
Clutch
Crankshaft
Balancer
Transmission
Lubrication
Engine Removal and Refit
Fuel System/Engine Management
Cooling
Front Suspension
Rear Suspension
Brakes
Wheels/Tyres
Frame and Bodywork
Electrical System
Seivice Manual - Speed Triple and Speed Triple R iii

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iv Seivice Manual - Speed Triple and Speed Triple R

Introduction
Table of Contents
How to Use This Manual ........ . ... ... ......... ..... ...... . .. ...... ... .... .. ..... . ..... .... .. vi
Warnings, Cautions and Notes . ..... . . .. .......................... . ... ... ..... ... . ........... vi
Tampering with Noise Control System Prohibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Repairs and Replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Force ... ....... .. ...... .... ....... . ................. .... ................. .. .... ... ...... v11
Edges.. ............ . ...... .. .... ... ......... ... ...... . ......... . .. .. . .. . . ... ... ...... .... vii
Tightening procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Service Manual - Speed Triple and Speed Triple R v

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

Introduction
Tampering with Noise Control Repairs and Replacements

System Prohibited Before removal and disassembly, thoroughly clean the
motorcycle. Any dirt entering the engine or other parts
Owners are warned that the law may prohibit:
will work as an abrasive and shorten the life of the
The removal or rendering inoperative by any motorcycle. Particular attention should be paid when
person other than for purposes of maintenance, installing a new part, that any dust or metal filings are
repair or replacement, of any device or element cleared from the immediate area.
of design incorporated into any new vehicle for
the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is Force
in use; and Common sense should dictate how much force is
the use of the vehicle after such device or necessary in assembly and disassembly. If a part seems
element of design has been removed or especially difficult to remove or install, stop and examine
rendered inoperative by any person. what may be causing the problem. Never lever a
component as this will cause damage both to the
component itself and to the surface being levered against.
References Whenever tapping to aid removal of an item is necessary,
tap lightly using a hide or plastic faced mallet
References to the left hand or right hand side given in this
manual are made when viewing the motorcycle from the
rear. Edges
Operations covered in this manual do not always include Watch for sharp edges, especially during engine
reference to testing the motorcycle after repair. It is disassembly and assembly. Protect the hands with
essential that work is inspected and tested after industrial quality gloves.
completion and if necessary a road test of the motorcycle
When replacement parts are required, it is essential that
is carried out particularly where safety related items are
only genuine Triumph parts are used.
concerned.
Safety features and corrosion prevention treatments
embodied in the motorcycle may be impaired if other
Dimensions than genuine Triumph parts are fitted. In certain territories,
The dimensions quoted are to design engineering legislation prohibits the fitting of parts not to the
specification with service limits where applicable. manufacturer's specification.
During the period of running-in from new, certain
adjustments may vary from the specification figures given Tightening Procedure
in this manual. These will be reset by the dealer at the
Generally, when installing a part with several bolts, nuts or
500 mile/800 km service, and thereafter should be
screws, they should all be started in their holes and
maintained at the figures specified in this manual.
tightened to a snug fit, evenly and in a cross pattern. This
is to avoid distortion of the part and/or causing gas or oil
leakage. Conversely, bolts, nuts, or screws should all be
loosened Cin sequence if specified) by about a quarter of a
turn and then removed.
Where there is a tightening sequence specified in this
service manual, the bolts, nuts, or screws must be
tightened in the order and by the method indicated.
Torque wrench setting figures given in this manual must
be observed. The torque tools used must be of accurate
calibration.
Locking devices, where specified, must be fitted. If the
efficiency of a locking device is impaired during removal it
must be renewed. This applies particularly to micro-
encapsulated fixings which must always be replaced if
disturbed. Where necessary, the text in this manual will
indicate where such a fixing is used.
Service M anual - Speed Triple and Speed Triple R VII

Introduction
viii Service Manual - Speed Triple and Speed Triple R

1 General Information
Table of Contents
Ignition System Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Dangerous Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Third Party Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Fluoroelastomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Oils....................................... . ........... ....... .... ............... ........ 1.5
Health Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Environmental Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Brakes ... . ................. . ...... ..... ......... .. ....... . . . ......................... ..... 1.6
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Jacking and Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Precautions Against Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Coolant.. .... ... ................ . ......................... ....... ... ........ ... ........ 1.7
Cleaning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Joints and Joint Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Gaskets, 0-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Liquid Gasket, Non-permanent Locking Agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Screw Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Locking Devices.. .... ... ....................... .... ..... ........ ..... ........ ..... . . .... 1.9
Fitting a Split Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Circlips, Retaining Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Self-Locking Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Encapsulated Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Oil and Grease Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Ball Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Chassis Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Petrol - Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Chassis Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Service Manual - Speed Triple and Speed Triple R 1.1

General Information
Electrical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

Battery Disconnecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Disciplines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Electrical Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Ohm's Law ........... ... .............................................................. 1.14
Basic Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
Glossary of Circuit Diagram Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
Tracing Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
To Check Continuity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
Splices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18
CAN (Controller Area Networking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19
Alternator/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20
Diagnosis - Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20
Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21
General Fault Finding - Starter Motor and Relay............................... . .. ... ...... .. 1.21
Diagnosis - Starter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
Specification .................................... .. ............. ... ...... . .............. 1.23
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23
Service Tools and Garage Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
Torque Wrench Settings.... .................................. . ............................ 1.38
Cylinder Head Area.. .............. ... .. . ............................................... 1.38
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
Balancer, Crankshaft and Crankcase...... .......... ... ...................... . ............. 1.39
Engine Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.39
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.39
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
Fuel System, Exhaust System and Airbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
Front Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45
ABS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45
Frame, Footrests, Control Plates and Engine Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.47
Bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48
1.2 Seivice Manual - Speed Triple and Speed Triple R

General Information
Clutch Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.49

Throttle Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
Main Wiring Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51
Brake Hose Routing - Models without ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
Brake Hose Routing - Models with ABS...... ....... .... ............ . .. ... ... .. .............. 1.53
Fuel Tank Breather Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54
Seivice Manual - Speed Triple and Speed Triple R 1.3

General Information
Ignition System Safety Precautions Third Party Products
The ignition system produces extremely high voltages. Many proprietary products, such as chemicals, solvents
Do not touch any part of the ignition system or any and cleaning agents, will cause damage to components
cables while the engine is running. if used incorrectly or inappropriately. Always follow the
manufacturer's instructions printed on the product
An electric shock caused by contact with the ignition
container's labels and obey the instructions given. These
system may lead to illness, injury or death. instructions are included for your safety and well-being.
Damage to the motorcycle components caused by the
incorrect or inappropriate use of chemicals, solvents and
cleaning agents may reduce the components efficiency,
resulting in loss of motorcycle control and an accident.
Wearers of surgically implanted heart pacemaker
devices should not be in close proximity to ignition
circuits and or diagnostic equipment. Fluoroelastomers
The ignition system and any diagnostic equipment may
interrupt the normal operation of such devices causing
illness or death.
Fluoroelastomer material is used in the manufacture of
Dangerous Substances various seals in Triumph motorcycles.
In fire conditions involving temperatures greater than
315°C this material will decompose and can then be
potentially hazardous. Highly toxic and corrosive
decomposition products, including hydrogen fluoride,
Many liquids and other substances used in motor carbonyl fluoride, fluorinated olefins and carbon
vehicles are poisonous and should under no monoxide can be generated and will be present in
circumstances be consumed and should, as far as fumes from fires.
possible, be kept from contact with the skin. These In the presence of any water or humidity hydrogen
substances among others include acid, anti-freeze, fluoride may dissolve to form extremely corrosive liquid
asbestos, brake fluid, fuel, lubricants, and various hydrofluoric acid.
adhesives. Always pay close attention to any warnings
If such conditions exist, do not touch the material and
and instructions printed on the container labels and
avoid all skin contact. Skin contact with liquid or
obey the instructions contained within. These
decomposition residues can cause painful and
instructions are included for your safety and well-being.
penetrating burns leading to permanent, irreversible
NEVER DISREGARD THESE INSTRUCTIONS! skin and tissue damage.

General Information
Oils Environmental Protection Precautions
A Caution
The engine oil may be hot to the touch. Contact with Do not pour oil on the ground, down sewers or drains,
hot oil may cause the skin to be scalded or burned. or into water courses. To prevent pollution of water-
courses etc., dispose of used oil sensibly. If in doubt
contact your local authority.
Burning of used engine oil in small space heaters or

boilers can be recommended only for units of approved
Prolonged or repeated contact with engine oil can lead design. If in doubt, check with the appropriate local
to skin dryness, irritation and dermatitis. In addition used authority and/or manufacturer of the approved appliance.
engine oil contains potentially harmful contaminants
Dispose of used oil and used filters through authorised
which can cause cancer. Wear suitable clothing and
waste disposal contractors, to licenced waste disposal sites,
avoid skin contact.
or to the waste oil reclamation trade. If in doubt, contact
your local authority for advice on disposal facilities.
Health Protection Precautions
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.
Do not put oily rags in pockets.
Overalls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
First aid treatment should be obtained
immediately for open cuts and wounds. Always
be aware of who your nearest first-aider is and
where the first aid equipment is kept.
Use barrier creams, applying before each work
period to protect the skin from the effects of oil
and grease and to aid removal of the same after
completing work.
Wash with soap and water to ensure all oil is
removed <skin cleansers and nail brushes will
help). Preparations containing lanolin replace
the natural skin oils which have been removed.
Do not use petrol, kerosene, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
If skin disorders develop, obtain medical advice
without delay.
Where practicable, de-grease components prior
to handling.
Any risk of eye injury must be avoided. Always wear eye

protection when using a hammer, air line, cleaning
agent or where there is ANY risk of flying debris or
chemical splashing.
Setvice Manual - Speed Triple and Speed Triple R 1.5

General Information
Brakes
Use only DOT 4 specification brake fluid as listed in the

general information section of this manual. The use of
Brake fluid is hygroscopic which means it will absorb brake fluids other than those DOT 4 fluids listed in the
moisture from the air. Any absorbed moisture will general information section may reduce the efficiency of
greatly reduce the boiling point of the brake fluid the braking system leading to an accident.
causing a reduction in braking efficiency. Failure to change the brake fluid at the interval specified
Replace brake fluid in line with the routine maintenance in the routine maintenance schedule may reduce
schedule. A dangerous riding condition could result if braking efficiency resulting in an accident.
this important maintenance item is neglected!
Do not spill brake fluid onto any area of the bodywork
as this will damage any painted or plastic surface.
Always use new brake fluid from a sealed container and
never use fluid from an unsealed container or from one Never use mineral based grease in any part of the
that has been previously opened. braking system or in any area where contact with the
braking system is possible. Mineral based grease will
Do not mix different brands of fluid. Check for fluid
damage the hydraulic seals in the calipers and master
leakage around brake fittings, seals and joints.
cylinders.
Check regularly for brake hose damage.
Damage caused by contact with mineral based grease
FAILURE TO OBSERVE ANY OF THE ABOVE may reduce braking efficiency resulting in an accident.
WARNINGS MAY REDUCE BRAKING EFFICIENCY
LEADING TO AN ACCIDENT.
Before installation, all internal brake components should

be cleaned and lubricated with clean new DOT 4 brake
If there has been an appreciable drop in the level of the fluid.
fluid in either brake fluid reservoir, consult your
Never use solvents, petrol (gasoline), engine oil, or any
authorised Triumph dealer for advice before riding.
other petroleum distillate on internal brake components
If the brake lever or pedal feels soft when it is applied, or as this will cause deterioration of the hydraulic seals in
if the lever/pedal travel becomes excessive, there may the calipers and master cylinders.
be air in the brake lines or the brake may be defective.
A dangerous riding condition leading to loss of
It is dangerous to operate the motorcycle under such motorcycle control and an accident could result if this
conditions and remedial action must be taken by your warning is ignored.
authorised Triumph dealer before riding the motorcycle.
Failure to take remedial action may reduce braking
efficiency leading to an accident.
1.6 Service Manual - Speed Triple and Speed Triple R

General Information
Safety Instructions
Jacking and Lifting

A Caution
The coolant anti-freeze contains a corrosion inhibitor
which helps prevent damage to the metal surfaces inside
the cooling system. Without this inhibitor, the coolant
would 'attack' the metals and the resultin g corrosion
would cause blockages in the cooling system leading to
Always ensure that any lifting apparatus has adequate
engine overheating and damage. Always use the correct
load and safety capacity for the weight to be lifted.
anti-freeze as specified in the Owner's Handbook.
Ensure the motorcycle is well supported to prevent any
Never use a methanol based anti-freeze as this does not
possibility of the machine falling during lifting or jacking
contain the required corrosion inhibition properties.
or while repairs and servicing are carried out.
Never rely on a single means of support when working
with the motorcycle. Use additional safety supports and
straps to prevent toppling. A Caution
Do not leave tools, lifting equipment, spilt oil, etc. in a Distilled water must be used with the anti-freeze (see
place where they could become a hazard to health. specification for anti-freeze) in the cooling system.
Always work in a clean, tidy area and put all tools away
If hard water is used in the system, it causes scale
when the work is finished.
accumulation in the water passages, and considerably
reduces the efficiency of the cooling system. Reduced
Precautions Against Damage cooling system efficiency may lead to the engine
Avoid spilling brake fiuid or battery acid on any part of the overheating and engine damage.
bodywork. Wash spillages off with water immediately.
Disconnect the battery earth lead before starting work, see
ELECTRICAL PRECAUTIONS.
Always use the recommended service tool where
specified.
Protect exposed bearing and sealing surfaces, and screw
threads from damage.
Coolant
Coolant mixture, which is blended with anti-freeze and

--· corrosion inhibitors, contains toxic chemicals which are
harmful to the human body. Never swallow anti-freeze,
corrosion inhibitors or any of the motorcycle coolant.
Do not remove the radiator cap when the engine is hot.

When the engine is hot, the coolant inside the radiator is
hot and also under pressure. Contact with the
pressurised coolant will cause scalds and skin damage.

General Information
Cleaning Components Liquid Gasket, Non-permanent Locking Agent

A high flash-point solvent is recommended to reduce fire Follow manufacturer's directions for cleaning and
hazard. preparing surfaces where these compounds will be used.
Always follow container directions regarding the use of Apply sparingly as excessive amounts of sealer may block
any solvent. engine oil passages and cause serious damage.
Always use the recommended cleaning agent or Prior to reassembly, blow through any pipes, channels or
equivalent. crevices with compressed air.
Do not use degreasing equipment for components
containing items which could be damaged by the use of
this process. Whenever possible, clean components and
the area surrounding them before removal. Always To prevent 1n1ury, always use eye, face and ear
observe scrupulous cleanliness when cleaning dismantled protection when using compressed air. Always wear
components. protective gloves if the compressed air is to be directed
in proximity to the skin.
Lubrication
Screw Threads
The majority of engine wear occurs while the engine is
warming up and before all the rubbing surfaces have an Metric threads to ISO standard are used.
adequate lubrication film. During assembly, oil or grease Damaged nuts, bolts and screws must always be
(whichever is more suitable) should be applied to any discarded.
rubbing surface, which has lost its lubrication film. Old
Castellated nuts must not be slackened back to accept a
grease and dirty oil should be cleaned off. This is because
split pin, except in those recommended cases when this
used lubricants will have lost some lubrication qualities
forms part of an adjustment
and may contain abrasive foreign particles.
Do not allow oil or grease to enter blind threaded holes.
Use recommended lubricants. Some oils and greases in
The hydraulic action on screwing in the bolt or stud could
particular should be used only in certain applications and
split the housing.
may be harmful if used in an application for which they
are not intended. This manual makes reference to Always tighten a nut or bolt to the recommended torque
molybdenum disulphide grease in the assembly of certain figure. Damaged or corroded threads can affect the
engine and chassis parts. Always check manufacturer torque reading.
recommendations before using such special lubricants. Unless specified, threaded fixings must always be fitted
dry (no lubrication).
Joints and Joint Faces

Assemble joints dry unless otherwise specified in this
manual.
Never lubricate a thread unless instructed to do so.
If gaskets and/or jointing compound is recommended for
use; remove all traces of old jointing material prior to When a thread of a fixing is lubricated, the thread
reassembly. Do not use a tool which will damage the joint friction is reduced. When the fixing is tightened,
faces and smooth out any scratches or burrs on the joint reduced friction will cause overtightening and possible
faces using an oil stone. Do not allow dirt or jointing fixing failure.
material to enter any tapped holes. A fixing which fails during vehicle operation could cause
component detachment leading to loss of control and an
accident.
Gaskets, 0 -rings
Do not re-use a gasket or 0-ring once it has been in
service. The mating surfaces around the gasket should be
free of foreign matter and perfectly smooth to avoid oil or
compression leaks.
1.8 Service M anual - Speed Triple and Speed Triple R

General Information
Locking Devices Oil and Grease Seals

Always release locking tabs and fit new locking washers, Replace any oil or grease seals that are removed.
do not re-use locking tabs. Removal will cause damage to an oil seal which, if re-used,
would cause an oil leak.
Fitting a Split Pin Ensure the surface on which the new seal is to run is free
of burrs or scratches. Renew the component if the original
Always fit new split pins of the correct size for the hole in sealing surface cannot be completely restored.
the bolt or stud. Do not slacken back castellated nuts
Protect the seal from any surface which could cause
when fitting split pin, except in those recommended cases
damage over which it has to pass when being fitted. Use a
when this forms part of an adjustment.
protective sleeve or tape to cover the relevant surface and
Always fit new roll pins of an interference fit in the hole. avoid touching the sealing lip.
Lubricate the sealing lips with a recommended lubricant.
Circlips, Retaining Rings This will help to prevent damage in initial use. On dual
lipped seals, smear the area between the lips with
Replace any circlips and retaining rings that are removed. appropriate grease.
Removal weakens and deforms circlips causing looseness
When pressing in a seal which has manufacturer's marks,
in the circlip groove. When installing circlips and retaining
press in with the marks facing out.
rings, take care to compress or expand them only enough
to install them. Seals must be pressed into place using a suitable driver.
Use of improper tools will damage the seal.
Always use the correct replacement circlip as
recommended in the Triumph parts catalogue.
Press
Self-Locking Nuts A part installed using a press or driver, such as a wheel
bearing, should first be coated with oil or grease on its
Self-locking nuts can be re-used, if resistance can be felt
outer or inner circumference so that it will locate smoothly.
when the locking portion passes over the thread of the
bolt or stud.
DO NOT re-use self-locking nuts in critical locations, Ball Bearings
e.g. suspension components. Always use the correct
When installing a ball bearing, the bearing race which is
replacement self-locking nut.
an interference fit should be pushed by a suitable driver.
This prevents severe stress or damage to the load
Encapsulated Bolts carrying components. Press a ball bearing until it touches
the shoulder in the bore or on the shaft.
An encapsulated bolt can be identified by a coloured
When installing an oil seal, always install the seal with the
section of thread which is treated with a locking agent.
sealing lip facing the lubricant to be retained. Press or drift
Unless a specified repair procedure states otherwise, the seal to the depth of its housing if the housing is
encapsulated bolts cannot be re-used and MUST be shouldered, or flush with the face of the housing where
replaced if disturbed or removed. no shoulder is provided.
Chassis Bearing Lubrication
Failure to replace an encapsulated bolt could lead to a Note:

dangerous riding condition. Always replace This information relates only to bearing
encapsulated bolts. lubrication. For the procedures necessary to
replace a bearing, always refer to the relevant
section of this service manual.
• Bearings installed in engine and transmission
applications are not covered by this
information. Refer to the lubrication chapter or
the relevant engine chapter for additional
information.

General Information
General Below/overleaf several common bearing types and the

For a bearing to be serviceable for its anticipated life span lubrication procedures for each are identified:
it must be checked, adjusted and lubricated at regular
intervals, as specified in the service schedules given in the
owner's handbook and this service manual.
A correctly lubricated bearing will have a film of
lubrication that separates the moving parts, disperses heat
and protects the bearing surfaces from corrosion.
Note:
In all cases, use the lubricant recommended in
the seivice manual.
Grease the bearing, not the cavity where it is
located.
A bearing that is not regularly checked and
lubricated will have a reduced life span.
Sealed Bearings (wheel bearings & swinging
New Bearings arm, depending on the model>
New bearings are typically protected with an oil Note:
preservative to prevent corrosion etc. during storage. This
is NOT the lubrication for the bearing but DOES NOT Sealed bearings can be identified by their
need to be washed off prior to assembly and in-service integrated seals.
lubrication. Sealed bearings are lubricated for life by the
When lubricating a new bearing with grease the following manufacturer.
steps should be taken: Any attempt to change the grease in a sealed
bearing will damage the integrated seals. If the
1. Do not clean off the oil preservative. seals are damaged dirt and water will ingress
2. Grease must be forced between the roller elements and the life of the bearing will be greatly
and the roller cage. reduced.
3. Rotate the bearing to ensure that the grease is

distributed over the entire circumference of the
internal parts.
4. Any excess grease should be smeared on the outside
of the rollers.
Lubrication and Checks While Seivicing a Bearing
1. Disassemble parts as necessary to access the

bearing. Refer to the relevant service manual.
2. Inspect the old grease covering the bearing, looking
for signs of bearing damage, i.e. flakes or specks of
metal.
3. Remove the old grease.
Taper Bearings (swinging arm & headstock,
4. Check the bearing for smooth operation and visually depending on the model>
check for corrosion, dents and flaking in the bearing
race, rollers or cage. Replace if necessary. Refer to 1. Grease must be forced between the inner race and
the relevant service manual. the roller carrier.
internal parts.

General Information
3. Any excess grease should be smeared on the outside Fuel Handling Precautions
of the rollers.
General
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk which
must not be ignored. This information is issued for basic
guidance only and, if in doubt, appropriate enquiries
should be made of your local Fire Officer.
Petrol - Gasoline
When petrol (gasoline) evaporates it produces 150 times
its own volume in vapour which when diluted with air
becomes a readily ignitable mixture. The vapour is heavier
Angular Contact and Ball Bearings than air and will always fall to the lowest level. It can
(headstock> readily be distributed throughout any indoor environment
by air currents, consequently, even a small spillage of
1. Grease the bearing races and the ball bearing carrier. petrol (gasoline) is potentially very dangerous.

internal parts.
Petrol (gasoline) is highly flammable and can be
explosive under certain conditions. When opening the
fuel tank cap always observe all the following items:
Turn the motorcycle ignition switch OFF.
Do not smoke.
Always have a fire extinguisher containing FOAM, C0 2,
HALON or POWDER close at hand when handling or
draining fuel or fuel systems. Fire extinguishers must
also be present in areas where fuel is stored.
Always disconnect the vehicle battery, negative (black)
lead first, before carrying out dismantling or draining
work on a fuel system.
Whenever petrol (gasoline) is being handled, drained,
ceop
stored or when fuel systems are being dismantled, make
Needle Roller Bearings (swinging arm, rear
sure the area is well ventilated. All potential forms of
hub, rear suspension linkages, depending on
ignition must be extinguished or removed (this includes
the model>
any appliance with a pilot lightl. Any lead-lamps must
be flame-proof and kept clear of any fuel spillage.
1. Coat the needle rollers with grease.
Warning notices must be posted at a safe distance from
2. Ensure the needle rollers turn so that the grease is
the site of the work to warn others that petrol is being
openly handled. The notice must instruct the reader of
internal parts.
the precautions which must be taken.
3. Assemble the parts, adjust and check as necessary.
Failure to observe any of the above warnings may lead
to a fire hazard which could result in personal injury.
Metal Bushes
1. Disassemble the parts as necessary to access the

bush. Refer to the relevant service manual.
2. Remove the old grease.
3. Apply fresh grease to the metal bush.

General Information
Electrical Precautions
The following guidelines are intended to ensure the safety
of the operator whilst preventing damage to the electrical
No one should be permitted to repair components
and electronic components fitted to the motorcycle.
associated with petrol/gasoline without first having
Where necessary, specific precautions are detailed in the
specialist training on the fire hazards which may be
relevant sections of this manual which should be referred
created by incorrect installation and repair of items
to prior to commencing repair operations.
associated with petrol/gasoline.
Equipment - Prior to commencing any test procedure on
Repairs carried out by untrained personnel could bring
the motorcycle ensure that the relevant test equipment is
about a safety hazard leading to a risk of personal injury.
working correctly and any harness or connectors are in
good condition, in particular mains leads and plugs.
Draining or extraction of petrol/gasoline from a vehicle

fuel tank must be carried out in a well ventilated area. The ignition system produces extremely high voltages.
Do not touch any part of the ignition system or any
The receptacle used to contain the petrol/gasoline must
be more than adequate for the full amount of fuel to be cables while the engine is running.
extracted or drained. The receptacle should be clearly An electric shock caused by contact with the ignition
marked with its contents, and placed in a safe storage system may lead to illness, injury or death.
area which meets the requirements of local authority
regulations.
When petrol/gasoline has been extracted or drained
from a fuel tank, the precautions governing naked lights
and ignition sources should be maintained. · Wearers of surgically implanted heart pacemaker
Failure to observe any of the above warnings could devices should not be in close proximity to ignition
bring about a safety hazard leading to a risk of personal circuits and/or diagnostic equipment.
injury. The ignition system and any diagnostic equipment may
interrupt the normal operation of such devices causing
illness or death.
Fuel Tank Removal
Fuel tanks should have a 'PETROL <GASOLINE)
VAPOUR' warning label attached to them as soon as they
are removed from the vehicle. In all cases, they must be
stored in a secured, marked area. The battery contains harmful materials. Always keep
children away from the battery whether or not it is fitted
in the motorcycle.
Chassis Repairs
Do not jump start the battery, touch the battery cables
together or reverse the polarity of the cables as any of
these actions may cause a spark which would ignite
battery gases causing a risk of personal injury.
If the motorcycle is involved in an accident or collision it
High Voltage Circuits - Whenever disconnecting live High
must be taken to an authorised Triumph dealer for
Tension <Hn circuits always use insulated pliers. Exercise
repair or inspection. Any accident can cause damage to
caution when measuring the voltage on the coil terminals
the motorcycle, which if not correctly repaired, may
while the engine is running, high Voltage spikes can occur
cause a second accident which may result in injury or
on these terminals.
death.
The frame must not be modified as any modification to
the frame such as welding or drilling may weaken the
frame resulting in an accident
1. 12 Seivice Manual - Speed Triple and Speed Triple R

General Information
Connectors and Harness - The engine of a motorcycle is a Disciplines

particularly hostile environment for electrical components
Switch off the ignition prior to making any connection or
and connectors. Always ensure these items are dry and oil
disconnection in the system. An electrical surge, which
free before disconnecting and connecting test equipment.
Never force connectors apart either by using tools or by can damage electronic components, can be caused by
disconnecting 'live' connections.
pulling on the wiring itself. Always ensure locking
mechanisms are disengaged before removal and note the Ensure hands and work surfaces are clean and free of
orientation to enable correct reconnection. Ensure that grease, swarf, etc. as grease collects dirt which can cause
any protective covers and substances are replaced if tracking or high-resistance contacts.
disturbed. Prior to commencing any test, and periodically during any
Having confirmed a component to be faulty, switch off the test, touch a good earth to discharge body static. This is
ignition and disconnect the battery negative (black) lead because some electronic componen~ are vulnerable to
first. Remove the component and support the static electricity.
disconnected harness. When replacing the component
keep oily hands away from electrical connection areas and
Electrical Wires
push connectors home until any locking mechanism
becomes fully engaged. All the electrical wires are either single-colour or
two-colour and, with only a few exceptions, must be
connected to wires of the same colour. On any of the two-
Battery Disconnecting colour wires there is a greater amount of one colour and a
Before disconnecting the battery, switch off all electrical lesser amount of a second colour. A two-colour wire is
equipment identified by first the primary colour and then the
secondary colour. For example, a yellow wire with thin red
stripes is referred to as a 'yellow/red' wire; it would be a
'red/yellow' wire if the colours were reversed to make red
the main colour.
To prevent the risk of a battery exploding and to prevent
damage to electrical components ALWAYS disconnect
the battery negative (black> lead first When 1
reconnecting the battery, always connect the positive

(redl lead first, then the negative (black) lead. Always
disconnect the battery when working on any part of the
electrical system.
Failure to observe the above warnings may lead to
electrical damage and a fire hazard which could cause
personal injury.
Always ensure that battery leads are routed correctly and

are not close to any potential chafing points.

General Information
Electrical Testing For example, if a battery of 12 V is connected to a bulb

of 60 W:
For any electrical system to work, electricity must be able
the current flowing in the circuit can be
to ftow in a complete circuit from the power source (the
calculated by using -
battery) via the components and back to the battery. No
circuit means no electrical ftow. Once the power has left
the positive side of the battery and run through the W =I 60 = S
component it must then return to the battery on its v 12
negative side (this is called earth or ground). To save on
wiring, connections and space, the negative side of the the bulb resistance can be calculated by using -
battery is connected directly to the frame or engine.
Around the frame and engine will be various other ~=R _g
s = 2 .4
ground points to which the wiring coming from I
components will be connected. For example, the starter
motor bolts directly to the engine, which is then bolted to To use either of the following triangles, put your finger
the frame. Therefore the frame and engine also form part over the value you want to find. Multiply the remaining
of the earth return path. values if side-by-side, or divide if one is over the other.
Ohm's Law
The relationship between voltage, current and resistance
is defined by Ohm's Law.
The potential of a battery is measured in
Volts M. Basic Electrical Circuits
The ftow of current in a circuit (I) is measured in

Amperes.
The power rating of a consumer is measured in +
Watts CW>.
The resistance (R) of a circuit is measured in Basic Circuit Diagram
Ohms cm. In the above circuit an electrical reservoir (the battery) is
connected via a cable to a terminal on the controlling
Ohms law, for practical work can be described as -
device (the switch) whose contacts are either open or
closed. The other terminal on the switch is connected via a
Voltage . cable to the consumer (the bulb), and the other side of the
= Resistance
C urrent bulb filament is connected to ground (earth) by another
cable. The ground point is usually a part of the frame or
Power is calculated by multiplying Volts x Amps -
engine, to which the battery negative terminal is also
connected.
Watts = Volts x Amps When the switch contacts are open (as shown in the
diagram), the circuit is broken and no current flows. When
By transposing either of these formulae, the value of any the switch contacts are closed the circuit is made and
unit can be calculated if the other two values are known. current flows from the battery positive terminal through
the switch contacts and bulb filament to ground. The
frame completes the circuit to the battery negative
terminal and the bulb illuminates.
Although some circuits on the circuit diagram may at first
seem more complicated, it will generally be found that
they can be broken down into sections which do not differ
greatly from the basic circuit above.

General Information
Circuit Diagrams Glossary of Circuit Diagram Symbols

Circuit diagrams are created to provide a 'picture' of the The following is a description of the symbols found in the
electrical system and to identify the route taken by each circuit diagrams used in all Triumph service manuals.
individual wire through the system, in order to identify
which components it feeds and which connectors the wire Connector
runs through. Circuit diagrams are an essential tool for
fault finding, as it is possible to locate start and finish
points for a circuit without having to manually trace the
wire through the motorcycle itself. Circuit diagrams may
look confusing at first but when they are studied closely
[]
they soon become logical. This illustration is used to show all multi-plug type
Due to the complex circuits and the number of individual electrical connectors on Triumph circuit diagrams. The
wires, Triumph uses two types of circuit diagram in its numbers in the box relate to the terminal numbers of the
service manuals. connector pins. On ECMs with two connectors, the
number would be prefixed with the letters 'A' or 'B' to
Within the manual conventional circuit
identify each connector. An additional number outside the
diagrams are used to show the layout of the
box will identify the component.
main circuits of the motorcycle. These are:
Engine Management/Ignition, Lighting, Starting
Diode
and Charging, and Auxiliary and Accessory. In
these diagrams no attempt is made to show the
components of the system in any particular
order or position in relation to the motorcycle.
At the back of the service manual a full colour An electrical one-way valve. Diodes allow current to flow
layout circuit diagram is used to show the main in one direction but will not allow it to return. The arrow,
electrical components in a position similar to which forms part of the diode symbol, indicates the
the actual position on the motorcycle. direction of current flow.
Both of these circuit diagrams use similar symbols to Electromagnetic Winding (solenoid)
illustrate the various system components and will be
accompanied by a key to circuit diagram components and
wiring colour codes.
Circuit diagrams also depict the inner workings of a switch
cube (i.e. which wire connects to which when a switch is An electromagnetic winding (or solenoid) is used to
turned from one position to another) so that a test of that convert an electrical current into a lateral movement. This
switch can be made using the wire terminals in the can then be used to operate switches (as used in relays) or
connector instead of disassembling the switch itself. other components such as fuel injectors or secondary air
injection solenoids.
Fuse
~2 ~
3
or
A fuse is a device which protects a circuit in the event of a

fault. The fuse will 'blow' if a short circuit occurs,
protecting that circuit from further damage. The number
next to the fuse on the circuit diagram indicates the
position of the fuse in the fusebox.

General Information
Ground or Earth Point Resistor
1 or 1
This symbol is used to show ground points. This is the A device placed in a cable to reduce a Voltage or restrict
negative connection to either the frame or engine, and is the maximum current a device can draw.
a common cause of intermittent faults due to loose or
corroded connections. Splice
Lamp or Bulb
+
A hard cable joint where two or more cables are joined in
the wiring harness. A potential source of both open and
short circuits.
This symbol is used to show all types of light bulbs. The
numbers in the box relate to the terminal numbers of the Switches
connector pins. An additional number outside the box will
identify the component Normally Normally Change
Open Closed Over
LED <Light Emitting Diode)
Q ___ Q
~o 0---0 0 0
Triumph use LEDs for the alarm warning light, instrument
illumination and warning lights, gear change lights and or or or
rear light/brake lights on various models.
Motor 0 0 0 0
A mechanical device for completing or breaking a circuit.
There are three common types of switch: Normally Open,
Normally Closed and Change Over.
An electric motor. This could be the starter motor or a
motor within an actuator, for example within the ABS
modulator.
Relay
A relay is effectively an electromagnetic switch. To close

the relay contacts and complete the circuit, an
electromagnet in the relay is energised which causes the
relay contacts to close, making the circuit complete.
Relays are used when the electrical current is too great for
a mechanical switch, usually when the switching must be
done quickly to prevent arcing across the switch contacts.
If a mechanical switch were used, the mechanical switch
contacts would quickly burn away.

General Information
Tracing Circuits To Check Continuity:
The following is a description of two types of common

electrical failures, and some of the methods which may be
used to find them.
A Caution
Ensure the circuit being tested is switched off before
Open Circuit measuring contin uity. Damage to the Digita l Multi
Meter CDMMl may result from testing a 'live' circu it with
Break the meter set to resistance cm.
+
1 In the example below, the ground circuit continuity is
being tested from the battery to the frame.
A break in an electrical circuit - current cannot flow.
Usually caused by a break in a wire or cable or by a loose
connection. Open circuits can often be intermittent,
making diagnosis difficult.
Short Circuit
A 'short cut' in an electrical circuit - current by-passes the

intended circuit, either to earth or to another, different
circuit. Often caused by failure of the cable insulation due
to chafing or trapping of the wire. There are two different Continuity <resistance> Check
types of short circuit - short to ground and short to Vbatt. Locate each end of the wire.
A short to ground means that the current is going to earth
Set the Digital Multi Meter CDMMl to
before it reaches the component it is supposed to feed.
These are often caused by chafing of the harness to the
resistance check cm.
frame or wires trapped between a bolted component, and Probe each end of the wire.
will often blow the fuse on that circuit.
If there is continuity, the meter will usually
A short to Vbatt is a short to battery voltage (12 Volts) bleep or register the resistance of the cable.
and is caused by a live power supply wire contacting an
adjacent cable. Note that it is also possible for a 5 Volt A high resistance figure could indicate a dirty or
sensor reference voltage to short to an adjacent circuit, corroded connection.
which can also cause electrical failures and DTCs If there is a break in the wire, the meter will not
(Diagnostic Trouble Code) to be stored. bleep or register a resistance.
When tracing a wire that is suspect, carefully check the
By probing the wire in various places, the
circuit diagram before starting. Remember:
position of a high resistance or break in the wire
a wire may diverge at a splice and go off to Copen circuit> can be narrowed down until it is
feed other circuits. If these circuits are working, found.
check for wiring faults from the splice onwards.
the circuit diagram is not an accurate guide to
the actual location of the parts when fitted on
the bike. It is a schematic diagram of the
circuits.
particularly where engine management items
are concerned, the circuit is only completed by
the ECM. If the ECM is not connected, the
circuit may register as open.
Service Manual - Speed Triple and Speed Triple R 1. 17

General Information
To Measure Voltage: Splices

In the example below, the circuit Voltage is being Splices are probably the most common cause of wiring
measured at the bulb positive (+) terminal. faults after connectors. Splices are made where two or
more wires come together and diverge in different
directions, usually to feed a different circuit.
To locate a splice, it is necessary to peel back the insulation
and examine the splice for its integrity. The most common
fault is where one of the wires at the joint has come adrift
usually causing the circuit it feeds or earths to become
'dead'.
Switches
To check a switch, set the multimeter to
resistance/continuity and probe the two pins that form a
closed circuit when the switch is pushed. If the switch is
+ working correctly, the resistance should register or the
meter will bleep.
Voltage Check Relays
Turn the circuit to be tested 'ON'. All relay cases have a circuit path engraved on them
showing the circuit path across the electromagnet and the
Set the Digital Multi Meter COMM> to Voltage switch. Before making any checks, first note the pin
check M. Ensure the multi meter is set to designations, current paths, and whether or not there is a
DC Volts for direct current circuits (most diode in either circuit path.
circuits) or AC Volts for alternating current
circuits (typically alternator output Voltage tests). Diode
Set the range of the DMM to the range best 86 --------,
suited to the Voltage of the circuit being tested • • 87
(typically 20 Volts for most DMMs). Refer to Electromagnet
the DMM manufacturers instructions.
Connect the black (ground) lead of the DMM 85 ---~ 30
to a reliable ground connection (usually the
Make continuity checks across the electromagnet first,
battery or frame ground).
usually from pin 86 (positive) to pin 85 (negative). If a
Locate the positive terminal of the wire or diode appears in the circuit use the diode check on the
component to be tested. multimeter Nolts scale) in the direction of current flow. If
there is no diode, use the resistance check facility. An
Connect the red (positive) lead of the DMM to
open circuit or unusually high resistance value indicates a
the positive terminal.
faulty relay.
Read the voltage from the meter. To check the switch side, apply a 12 Volt supply between
pins 86 and 85. With the supply connected the relay
should be heard to click and there should be continuity
between pins 30 and 87. An open circuit indicates a faulty
relay.
1. 18 Service Manual - Speed Triple and Speed Triple R

General Information
CAN <Controller Area Networking> The receiving ECM confirms the data has been received
correctly and that the data is valid, and this information is
CAN <sometimes called CANbusl is a protocol for data then used by the ECM as necessary. Specific data not
communication between Electronic Control Modules required by an ECM will still be received and
<ECMsl. Each ECM on the network is connected by a acknowledged as correct but then disregarded (for
single pair of twisted wires (or busl which are used for the example if an ECM does not require 'clutch switch
transmission of vehicle sensor data. By using CAN, the position' information, this data packet would be ignored).
overall number of system sensors, and the amount of This allows for a very high speed system of
cabling required to allow ECMs to communicate with communication, which is also very reliable. Should one
each other is greatly reduced. ECM fail or transmit corrupted or otherwise incorrect
This saves cost, weight and space, and makes the system messages, none of the other ECMs on the network will be
more reliable, as the physical number of wires and affected, and after a certain time that ECM will be
connections is reduced. prevented from transmitting further messages until the
fault is rectified. This stops the ECM from clogging the
network with incorrect data and preventing other
Pair of Twisted messages from getting through. The fault would then be
R Wires reported by a OTC <Diagnostic Trouble Codel.
828 4
u Instrument Triumph currently use CAN for commun ication between
827 5
Pack the engine ECM and the instruments.
~
16
ECM
1
KY
A34 3
2
~ Vehicle Speed
Sensor
Extract from the Circuit Diagram showing
CAN Connection between ECMs
CAN works by each ECM sending out 'packets' of
information (such as engine speed or fuel consumption
information) on to the network bus (note that the network
must be free of data before any ECM is allowed to
transmitl. This data is given a priority according to its
importance (for example 'engine speed' may have a
higher priority than 'low fuel level'), so that even if two
ECMs send data at the same time, high priority
information is always sent first. Lower priority data is then
resent after the high priority data has been received by all
ECMs on the network.

General Information
Alternator/Charging System which uses diodes to convert the alternator output to

DC Volts and limit the resulting output to the correct
The charging system consists of an alternator and a figure required for optimal battery charging.
rectifier/regulator assembly and the battery. The alternator If the charging circuit does not operate correctly, the
is made up of two parts, the stator, which is mounted to following basic checks must be carried out before further
the crankcase or the engine cover, and the rotor, diagnosis is performed:
mounted to the end of the crankshaft. The stator is an
assembly of 18 coils, arranged into 3 phases. The rotor is a Check the battery terminals are clean and tight
series of magnets mounted in the engine flywheel, which Check the frame and engine earth connections
are arranged so as to be positioned around the outside of are clean, tight and free from corrosion.
the stator coils. As the engine rotates, the alternator
produces an AC (alternating current) voltage in each of Ensure the battery is fully charged and in good
the three phases of the alternator, typically of around condition.
35 to 40 Volts AC at 4,000 - 5,000 rpm, although this Check that any fuse in the circuit is not blown
figure varies between models. As the battery requires DC n.
and is of the correct rating (see page 17-1
(direct current> voltage for correct charging, this
AC voltage must be first rectified to DC current, and then Rectify any defects as necessary.
regulated to the correct voltage for the battery of
14.5 ± 0.5 Volts. This is done by the rectifier/regulator,
Diagnosis - Charging Circuit
ENSURE THE BATIERY IS IN GOOD

Not OK RECHARGE OR REPLACE FAULTY
CONDITION AND FULLY CHARGED.
BATIERY AND/OR REPAIR DIRTY/
CHECK ALL BATIERY AND GROUND
LOOSE CONNECTIONS
TERMINALS ARE CLEAN AND TIGHT
OK
I
OK
' l
WITH THE ENGINE RUNNING AT Above
AROUND 2000 RPM. MEASURE THE 15 Volts ~
BATIERY VOLTAGE AT THE BATIERY. FAULTY RECTIFIER/ REGULATOR
THE BATIERYVOLTAGE SHOULD BE
14.5 ±0.5 VOLTS
Below
14 Volts
.,,
STOP THE ENGINE AND DISCONNECT THE
ALTERNATOR CONNECTOR. RE-START
THE ENGINE AND ALLOW TO IDLE.
MEASURE THE ALTERNATING CURRENT
(AC) VOLTAGE FROM THE 3 ALTERNATOR
OUTPUT WIRES IN TURN.
THE OUTPUT VOLTAGE MUST EXCEED 10
VOLTS AC FROM EACH WIRE
Above 10
Volts AC
•
RAISE THE ENGINE SPEED ABOVE
4000 RPM. MEASURE THE
Below 30
ALTERNATING CURRENT (AC)
Volts AC
VOLTAGE FROM THE 3ALTERNATOR
OUTPUT WIRES IN TURN .
. FAULTY ALTERNATOR
THE OUTPUT VOLTAGE MUST NOW
EXCEED 30 VOLTS AC FROM EACH
WIRE
Above 30
Volts AC
•
FAULTY RECTIFIER/ REGULATOR
1-20 Service Manual - Speed Triple and Speed Triple R

General Information
Starting Circuit Check the frame and engine earth connections

are clean, tight and free from corrosion.
All Triumph models are equipped with an electric start
Ensure the battery is fully charged and in good
system. This system consists of a starter relay, starter
condition.
motor, starter switch, sidestand switch, engine stop switch,
clutch switch and the sprag clutch. The starter motor is Check that any fuse in the circuit is not blown
connected to the starter relay and the battery by heavy and is of the correct rating.
duty cables in order to supply the large currents required
Using the Triumph diagnostic tool, check the
by the motor to start the engine. When the starter button
operation of the neutral switch or gear position
is pressed the relay is energised, which then allows battery
sensor (if fitted), sidestand and clutch switches.
current to flow to the starter motor. The starter motor will
not operate unless the clutch lever is pulled in. Also, the
Note:
starter will not operate if the sidestand is down, unless the
transmission is in neutral. If the starter motor does not On all new models from Daytona 675 onwards,
operate, the following basic checks must be carried out which use a CAN connection between the
before further diagnosis is performed: instruments and the ECM, the engine will not
crank if the instruments are disconnected.
Check the engine stop switch is in the 'RUN'
position. Rectify any defects as necessary.
Check the battery terminals are clean and tight.
General Fault Finding - Starter Motor and Relay
Symptom Possible causeCs>

Starter relay does not click, starter motor does not turn Battery discharged or defective
Blown main or starter relay fuse

Defective starter relay wiring or starter switch
Check that the sidestand, transmission and clutch lever are

positioned for engine starting i.e. transmission in neutral,
clutch lever pulled in and the sidestand down
Defective alarm system - ensure any alarm fitted is working

correctly
Starter motor turns slowly Battery discharged or defective
Loose, corroded or dirty battery connections
Loose, corroded or dirty starter motor or starter relay

connections
Defective starter motor

Loose, corroded or dirty battery ground connections
Starter relay clicks but engine does turn over Battery discharged or defective
Crankshaft does not tum due to engine defect
Defective starter motor
Starter cable open circuit

Defective starter relay
Starter motor turns but engine does not tum over Defective sprag clutch
Defective idler gear, reduction gear or starter motor

General Information
Diagnosis - Starter Circuit
WITH THE IGNITION SWITCH ON AND USING A SUITABLE HEAVY DU1Y

THE ENGINE STOP SWITCH AT 'RUN', Clicks ~ JUMPER CABLE, CONNECT THE
CHECK FOR A CLICK AT THE STARTER !-----------~ STARTER POSITIVE TERMINAL TO THE
RELAY WHEN THE STARTER SWITCH BATTERY POSITIVE TERMINAL
IS PRESSED
Starter Starter motor

motor turns does not turn
,,
LOOSE OR FAUL1Y
DISCONNECTED STARTER
WIRE OR CABLE. MOTOR
FAUL1Y
No Click STARTER
RELAY/
SOLENOID
FAUL1Y NEUTRAL SWITCH

FAUL1Y CLUTCH SWITCH
DISCONNECT THE STARTER RELAY No FAUL1Y SIDESTAND SWITCH
SWITCH CONNECTOR. CHECK THE 1 - - - - -Co ..:....__ _~~~
-_n_ti_nu_ity BADCONTACTATCONNECTOR
RELAY COIL EARTH (GROUND) WIRE OPEN CIRCUIT IN WIRING LOOM
FAUL1Y ALARM OR ENGINE ECM (IF
FITTED)
Continuity
'
FAUL1Y IGNITION SWITCH/ENGINE
No STOP SWITCH
Voltage BROKEN STARTER SWITCH CABLE
BAD CONTACT AT CONNECTOR
OPEN CIRCUIT IN WIRING LOOM
FAUL1Y ALARM
Voltage
Measured
CHECK THE STARTER RELAY Normal LOOSE OR POOR CONTACT AT

OPERATION STARTER RELAY
Abnormal
. FAUL1Y STARTER RELAY

General Information
Specification Service Data

Triumph are constantly seeking to improve the The service data listed in this manual gives dimensions
specification, design and production of their motorcycles and specifications for brand new, original parts. Where it is
and alterations take place accordingly. permissible to allow a part to exceed these figures, then
While every effort has been made to ensure the accuracy the service limit is given.
of this manual, it should not be regarded as an infallible The terms of the motorcycle warranty will be invalidated
guide to current specifications of any particular by the fitting of other than genuine Triumph parts.
motorcycle. All genuine Triumph parts have the full backing of the
Authorised Triumph dealers are not agents of Triumph motorcycle warranty. Triumph dealers are obliged to
and have no authority to bind the manufacturer by any supply only genuine Triumph recommended parts.
expressed or implied undertaking or representation.
Inspection
Replacement Parts
Disassembled parts should be visually inspected and
replaced with new ones if there are any signs of the
following:
Abrasions, cracks, hardening, warping, bending, dents,
Only Triumph genuine parts should be used to service, scratches, colour changes, deterioration, seizure or
repair or convert Triumph motorcycles. To ensure that damage of any nature.
Triumph genuine parts are used, always order parts,
accessories and conversions from an authorised
Triumph dealer. The fitting of non-approved parts,
accessories or conversions may adversely affect the
handling, stability or other aspects of the motorcycle
operation which may result in an accident causing
serious injury or death.
Always have Triumph genuine parts, accessories and

conversions fitted by an authorised Triumph dealer. The
fitment of parts, accessories and conversions by a dealer
who is not an authorised Triumph dealer may affect the
handling, stability or other aspects of the motorcycle
operation which may result in an accident causing
serious injury or death.
Always have Triumph approved parts, accessories and

conversions fitted by a trained technician. To ensure
that a trained technician is used, have an authorised
Triumph dealer fit the parts. The fitment of parts,
accessories and conversions by personnel other than a
trained technician at an authorised Triumph dealer may
affect the handling, stability or other aspects of the
motorcycle operation which may result in an accident
causing serious injury or death.

Service Tools and Garage Equipment
Special service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical
components in a practical manner without causing damage. Some operations in this service manual cannot be carried out
without the aid of the relevant service tools. Where this is the case, the tools required will be described during the
procedure.
Special Service Tools
3880105 - Angular Torque Gauge T3880371 - Holder, Oil Pump Drive Gear
cbxt
T3880057 - Triumph Diagnostic Tool T38800027 - Chain Link Tool Kit
T3880388 Pulser Ring Alignment Tool T3880046 - Socket, 46mm 112'' Drive

General Information
3880085-T0301 - Fork Piston Holder T3880017 - Holder, Sprag Clutch 1
cczf
ccgs
3880160-T0301 - Fork Filler I Evacuator T3880305 - Clutch Anti-rotation Tool
ccrnl
ccha
T3880375 - Alternator Rotor Holder T3880313 - Oil Filter Wrench
gahc
1. Older versions of tool T3880017 require modification to function correctly with later models. Refer to
Technical News issue 86 <April 2006) for information.

General Information
T3880315 - Extractor, Cylinder Liners T3880203 - Puller, Alternator Rotor
gakh
cche
T3880016 - Holder, Balancer Gear T3880159 - Collet, nylon, fork support
T3880377 - Engine mounting adjuster T3880104 - Swinging Arm Adjuster
1.26 Seavice Manual - Speed Triple and Speed Triple R

General Information
T3880023 - Socket 50 mm T3880003 - Fork Seal and Bush Fitment
cdbp
ccxb
T3880153 - Support Plate T3880067 - Fork Spring Compressor
ccxa_1
T3880001 - Fuel Pressure Gauge 3880065-T0301 - Bearing Installer
~
[f:ln1~------~--------i1A°"'bt~
,a"
D I! l~U cczb
cdgh

General Information
3880075-T0301 - Bearing Installer 3880053 - Bearing Installer
T3880123 - Extension Cable BatteryMate Battery Charger - See Latest Parts Catalogue
for Part Number Information
T3880340 - Greasing Tool - Eccentric Bearing T3881003 - Ohlins Piston Shaft Clamp
cesj1

General Information
T3880147 - Radiator and Cap Tester 3880080-T0301 - Fork Seal/Bearing Drift
ccgv
T3880162 - Li-Spanner, 17 mm T3881005 -Ohlins Cap/cartridge Tool
T3880163 - Rod, Pull Up T3880161 - Socket, Pin Sleeve, Top Nut

General Information
Specifications
Full Specification Speed Triple and Speed Triple R
Engine
Engine Configuration 3 Cylinder 12 valve DOHC
Arrangement Transverse in-line
Displacement 1050 cc
Bore x Stroke 79 x 71.4 mm
Compression Ratio 12.0:1
Cylinder numbering Left to right (no.3 adjacent to camshaft drive
chain)
Cylinder Sequence Number 1 at left
Firing Order 1-2-3
Maximum Power 135 PS <133 bhp) at 9,400 rpm)
Maximum Torque 111 Nm C82 ft.lbf) at 7,750 rpm
Cylinder Head Valves

Valve Head Diameter Inlet 33.5 mm
Exhaust 2ZOmm
Valve Lift Inlet 8.75 mm
Exhaust Z45 mm
Valve Stem Diameter Inlet 4.975 - 4.990 mm (standard>
4.965 mm (service limit)
Exhaust 4.955 - 4.990 mm (standard)
Valve Guide Bore Diameter Inlet 5.020 - 5.015 mm (standard>
5.043 mm <service limit>
5.063 mm <service limit)
Valve Stem to Guide Clearance Inlet 0.010 - 0.040 mm
Exhaust 0.030 - 0.060 mm
Valve Seat Width <in head) Inlet 0.9 - 1.1 mm (std)
1.7 mm (service limit>
Valve Seat Width (valve) 1.5 - 1.9 mm
Valve Seat Angle 45°
Inlet/Exhaust Valve Spring 'Load at Length' 470 N +/- 30 at 26.30 mm <inner)
Valve Clearance Inlet 0.10 - 0.20 mm
Exhaust 0.20 - 0.30 mm
Valve Bucket Diameter Inlet and Exhaust 28.476 - 28.490 mm (standard)

General Information
Cylinder Head (continued)

Valve Bucket Bore Diameter Inlet and Exhaust 28.515 - 28.535 mm (standard)
Camshafts
Camshaft Timing Inlet Open 9.25° BTDC (@ 1.0 mm lift)
Close 39.25° ABDC (@1.0 mm lift)
Duration 228.50°
Exhaust Open 31° BBDC <@ 1.0 mm lift)
Close 1° ATDC (@1.0 mm lift)
Duration 212°
Camshaft Journal Diameter 22.930 - 22.960 mm
22.953 - 22.956 mm (outrigger)
Camshaft Journal Clearance 0.040 - 0.091 mm (standard)
0.13 mm <service limit>
Outrigger 0.044 - 0.068 mm (standard)
Camshaft Journal Bore Diameter 23.000 - 23.021 mm
Camshaft End Float 0.03 - 0.12 (standard)
0.20 (service limit)
Camshaft Run-out 0.05 mm max.
Clutch I Primary Drive

Primary Drive Type Gear
Redudion Ratio 1.750 (60/105)
Clutch Type Wet multi-plate
No. of Fridion Plates 10
Plate Flatness Within 0.2 mm
Fridion Plate Thickness (inner and outer) 3.80 mm (standard)
3.60 mm (service limit
Fridion Plate Thickness Call others> 3.30 mm (standard)
Clutch Aduation Method Cable
Cable Free Play (at lever) 2.0 - 3.0 mm
Balancer
End Float 0.06 - 0.41 mm

General Information
Pistons
Cylinder Bore Diameter 79.040 - 79.060 mm (standard)
Piston Diameter (at 90x to gudgeon pin 78.970 - 78.980 mm (standard)
Piston Diameter 103.771 - 103.787 mm (standard)
103. 721 mm <service limit)
Piston Ring to Groove Clearance Top 0.02 - 0.06 mm <standard)
Second 0.02 - 0.06 mm (standard)
Piston Ring End Gap Top 0.28 - 0.49 mm (standard)
Second 0.43 - 0.64 mm (standard)
Oil 0.33 - 0.89 mm (standard)
Gudgeon Pin Bore Diameter in Piston 16.993 - 1Z001 mm <standard>
Gudgeon Pin Diameter 16.984 - 16.989 mm (standard)
Connecting Rods
Connecting Rod Small End Diameter 17.005 - 17.018 mm (standard>
Connecting Rod Big End Side Clearance 0.15 - 0.30 mm (standard)
Crankshaft
Crankshaft Big End Journal Diameter 34.984 - 35.000 mm (standard)

Crankshaft Big End Bearing Clearance 0.036 mm - 0.066 mm (standard)
Crankshaft Main Bearing Journal Diameter 37.960 - 37.967 mm
37.936 mm
Crankshaft End Float 0.05 - 0.20 mm
0.40 mm
Crankshaft Run-out 0.02 mm or less
0.05 mm

General Information
Transmission
Type 6 Speed, Constant Mesh
Gear Ratios 1st 2.733 (15/41)
2nd 1.947 (19/37)
3rd 1.545 (22/34)
4th 1.292 (24/31)
5th 1.154 (26/30)
6th 1.074 (27/29)
Gear Selector Fork Thickness 5.8 - 5.9 mm (standard)
Gear Selector Groove Width 6.0 - 6.1 mm (standard)
Gear Selector Fork to Groove Clearance 0.55 mm max.
Final Drive
Final Drive Chain
Final Drive Ratio 2.389 (18/43)
Chain Type RK X-ring
Number of Links 108
20 Link Length 321 mm (srvice limit)
Drive Chain Play 21 - 3 0 mm <Refer to section 13)
Chain Lubrication Chain spray suitable for 0-ring chains
Lubrication
Type Pressure Lubrication, Wet Sump
Oil Capacity <dry fill) 3.50 litres
Oil Capacity (wet fill including filter) 3.20 litres
Oil Capacity (wet fill excluding filter) 3.00 litres
Oil pressure {in main gallery> 40.0 lb/in2 min. @ 80°C oil temperature @
5,000 rpm
Oil Pump Rotor Tip Clearance 0.15 mm (standard)
Oil Pump Body Clearance 0.15 - 0.22 mm (standard)
Oil Pump Rotor End Float 0.02 - 0.07 mm (standard)
0.10 mm {service limit)

General Information
Ignition System
Type Digital Inductive
Electronic Rev Limiter 9,500 rpm
Pick-up Coil Resistance 0.56 KW ±100/o@ 20°c
Ignition Coil Type Plug-top
Spark Plug Type NGK CR8EK
Spark Plug Gap 0.7 mm +0.05/-0.1 mm
Fuel System
Fuel Type Unleaded, 95 RON CU.S. 89 CLC/AKI>
Fuel Tank Capacity lZS litres
Low Level Warning Lamp 4 litres remaining
Fuel Pump Type Submerged
Fuel Pressure (nominal> 3.0 bar
Purge Control System Electronic, via fuel system ECM
Fuel Injection System

Type Electronic, sequential
Idle Speed 1,200 rpm
Injector Type Twin jet, solenoid operated plate valve
Throttle Cable/twist grip/electronic throttle
potentiometer
Control Sensors Barometric pressure, throttle position, coolant
temperature, crankshaft position sensor,
lambda sensor, induction air temperature.
Emissions Controls*
Catalysts 1 in down pipe
Oxygen sensor Heated, in down pipe
Secondary Air injection Solenoid controlled, reed valve type
Evaporative Contra Activated carbon canister (certain markets
only)
*Catalysts and oxygen sensor fitted in all markets except Australia, New Zealand and South Africa.

General Information
Coolant System
Coolant Mixture Pre-mixed
Anti-Freeze Type Triumph HD4X Hybrid OAT coolant
Cooling System Capacity 2.4 litres
Radiator Cap Opening Pressure 1.1 Bar
Thermostat Opening Temperature 88°C (nominal>
Cooling Fan Switch On Temperature 103°C
Temperature Gauge Sensor Resistance 2.9 - 3.3 KW@ 1s c
0
Suspension
Front Fork Travel 120 mm
Recommended Fork Oil Grade Showa SS8 oil <SAE 1QW) <Speed Triple}
Ohlins fork oil <Speed Triple R)
Oil Level (fork fully compressed) 85 mm <Speed Triple>
130 mm <Speed Triple R)
Oil Volume (dry fill) 552 cc <Speed Triple)
478 cc <Speed Triple R>
Front Fork Pull Through Groove on the outer tube is 5 mm below the
lower surface of the top yoke
Rear Wheel Travel 130 mm
Brakes
Front Type Two four piston calipers acting on twin discs
Front Caliper Piston Diameter 34 mm
Front Disc Diameter 320 mm
Front Disc Thickness 4.5 mm (standard>
4.0 mm (seivice limit>
Front Disc Run-out Max. 0.3 mm
Recommended Fluid DOT4
Rear Type Twin piston sliding caliper acting on single
disc
Rear Caliper Piston Diameter 27mm
Rear Disc Dia. 255 mm
Rear Disc Thickness 6.0 mm <standard>
5.0 mm (seivice limit>
Rear Disc Run-out Max. 0.25 mm
Rear Master Cylinder Diameter 14 mm
Recommended Fluid DOT4

General Information
Wheels and Tyres

Front Wheel Size MT 3.5 x 17
Front Tyre Size 120/70 ZR17
Front Tyre Pressure 2.35 bar (34 lb/in2)
Recommended Front Tyre Option 1 Metzeler Racetc K3 Interact
Option 2 Bridgestone Battlax BT003 RS
Option 3 Bridgestone Battlax BT016
Option 4 Pirelli Diablo Rosso
Option 5 Michelin Power Pure
Option 6 Michelin Pilot Road 2
Front Wheel Rim Axial Run-out 0.5 mm
Front Wheel Rim Radial Run-out 0.5 mm
Rear Wheel Size MT 6.0 x 17
Rear Tyre Size 190/55ZR17
Rear Tyre Pressure 2.90 bar (42 lb/in2)
Recommended Rear Tyres Option 1 Metzeler Racetc K3 Interact
Option 2 Bridgestone Battlax BT003 RS
Option 3 Bridgestone Battlax BT016
Option 4 Pirelli Diablo Rosso
Option 5 Michelin Power Pure
Option 6 Michelin Pilot Road 2
Rear Wheel Rim Axial Run-out 0.5 mm
Rear Wheel Rim Radial Run-out 0.5 mm
Frame
Frame Type Twin-spar aluminium
Overall Length 2,100 mm (82.6 in)
Overall Width 795 mm (31.3 in)
Overall Height 1,110 mm (43. 7 in)
Wheelbase 1,435 mm (56.5 in)
Seat Height 825.5 mm <32.5 in)
Rake 23.0°
Trail 91 mm
Wet Weight 214 kg
Max. Payload Crider, passenger, luggage 8. accessories) 195 kg

General Information
Electrical Equipment
Battery Type
Battery Rating 12 V - 12 Amp. Hour
Alternator Rating 35 A
Tail/Brake Light LED
Front Fuse Box #1 ABS (for non ABS models empty)
=#=2 ABS (for non ABS models empty)
#3 License plate light
#4 Direction indicator lights, Tail light, Position
lights
=#=5 Alarm, Instrument lights
=#=6 Empty
Rear Fuse Box #1 Dip and main beam lights
#2 Engine management system
=#=3 Cooling fan
=#=4 Fuel pump
=#=5 Ignition switch
=#=6 Empty

General Information
Torque Wrench Settings
Cylinder Head Area
Application Torque <Nm> Notes
Camshaft cover to cylinder head 14
Secondary air injection valve covers to camshaft cover 9

Camshaft drive chain tensioner to crankcase 9
Camshaft drive chain tensioner to centre bolt 23
Camshaft bearing caps and camshaft bearing ladder to head 10 Refer to section 5
Camshaft sprocket to camshaft 15 Replace fixing(s) if removed
Camshaft drive chain tensioner blade to crankcase 18 Replace fixing(s) if removed
Camshaft drive chain rubbing blade to crankcase 18 Replace fixingCs> if removed
Camshaft drive chain top pad to cylinder head 10 Replace fixing(s) if removed
Cylinder head to crankcase CM6 screws) 10 Replace fixing(s) if removed
Cylinder head to crankcase bolts * Refer to section 3
Camshaft cap and ladder to head * Refer to section 3
Cylinder head dry seal plug 22
Sound suppression bolt in head 10

Oil feed pipe 25
Spark plugs 12
Cylinder head exhaust stud 10 Replace fixing(s) if removed
Wire guide 20
Clutch
Clutch cover to crankcase 8

Clutch centre nut 150 Replace fixing(s) if removed
Clutch pressure plate to centre drum 10

Clutch lever clamp bolts 12
Clutch lever nut 3.4

Switch cube screws Cleft) 4
Clutch cable to crankcase locknut 3

General Information
Balancer, Crankshaft and Crankcase
Application Torque CNm> Notes

Crankcase upper to lower CM8 fixings) * Refer to section 5
Crankcase upper to lower CM6 fixings) * Refer to section 5
Connecting rod big end nut * Refer to section 5
Balancer retaining bolt 60 Apply ThreeBond 1305 to the

threads
Big end bearings * Refer to section 5
Crankcase coolant drain plug 8 Replace washer if removed
Breather plate to crankcase 12 Replace fixing(s) if removed
Sprag clutch to crankshaft 54
Stud on upper crankcase 3 Replace fixing(s) if removed
Engine Covers
Application Torque <Nm) Notes

Clutch cover to crankcase 8
Sprocket cover to crankcase 8
Alternator cover to crankcase 8
Wire retainer on alternator cover 6
Crank cover to crankcase 8
Starter cover to crank cover 8
Crank cover inspection plate 18
Transmission
Application Torque CNm) Notes

Output sprocket to output shaft 132 Use new tab washers
Input shaft bearing retainer 12 Replace fixing(s) if removed
Detent wheel to selector drum 12 Replace fixing(s) if removed
Detent arm bolt 12 Replace fixing(s) if removed
Detent spring retainer 12

Selector drum bearing retaining screw 12 Replace fixing(s) if removed
Selector shaft retainer 12 Replace fixingCs) if removed

Detent spring abutment bolt 23 Replace fixing{s) if removed
Neutral switch 10
Gear pedal crank pinch bolt 9
Gear change rod locknuts 6
Gear pedal pivot bolt 22 Replace fixing(s) if removed

General Information
Lubrication System
Sump to crankcase 12
Sump drain plug to sump 25 Use a new washer
Oil pressure relief valve 15 Apply ThreeBond 1305 to the

threads
Low oil pressure warning light switch to crankcase 13 Use new washers
Oil filter adapter 10

Oil filter to adapter 10
Oil cooler pipe unions 9 Replace fixing(s) if removed
Oil cooler to mountings to radiator 9

Oil cooler mounting bracket to frame 9
Oil cooler to bracket 9
Oil pump to crankcase 12
Oil pump drive sprocket to pump shaft 15 Replace fixing(s) if removed
Oil feed pipe union to head 25
Transmission oil feed pipe to crankcase 8
Final Drive

Rear sprocket to cush drive 33
Chain guard bolts 5
Chain rubbing strip to swinging arm 5
Cush drive housing to shaft 146 Replace fixing(s) if removed

General Information
Cooling System

Water pump to crankcase 10
Radiator to frame 9
Water elbow to head 8
Thermostat housing to head 8
Crankcase coolant drain plug 8
Water temperature sensor 18
Radiator cowl fixings 4 Apply ThreeBond 13 60 to the
threads
Radiator cowl rear bracket 10
Radiator cowl front bracket 7
Expansion tank bracket to frame 10
Radiator bracket to frame 9
Hose guide 12
Hose clip 2
Frame front shield 4
Camshaft cover shield 3
Radiator cowl assembly 4
Radiator bleed screw 1.5

General Information
Fuel System, Exhaust System and Airbox

Fuel tank to frame (front fixing) 4
Fuel tank to frame <rear fixing) 9
Fuel cap to fuel tank 4
Fuel pump mounting plate to fuel tank 9
Throttle body transition piece to cylinder head 12
Fuel rail bracket to cylinder head 6

Fuel rail to bracket 6
Throttle position sensor 2
Idle speed control stepper motor 3.5
Exhaust downpipe to cylinder head 23 Refer to section 10
Exhaust downpipe to frame 25

Exhaust intermediate pipe to frame 15
Exhaust downpipe clamp to intermediate pipe 15 Torque every service
Silencer to frame 15
Silencer rear heat shield 3
Silencer front heat shield 5
Silencer clamp to intermediate pipe 10
Oxygen sensor 25
Catalytic converter heat shield 5
Secondary air injection solenoid 2
Air filter housing 3
Airbox rear mounting 5
Air box front mounting 10 Replace fixing(s) if removed
Air temperature sensor 2
Air pressure sensor 1.5
MAP sensor 2
Barometric pressure sensor 4
Fall detection switch 3 Replace fixing(s) if removed
Crankshaft sensor 10 Replace fixing(s) if removed
Throttle body adaptor clip 1.5
Throttle cable locknuts 2.5
Road speed sensor 10 Replace fixing(s) if removed
Immobiliser and TPMS module 2
Throttle cable guide 3

General Information
Rear Suspension

Swinging arm spindle nut 110
Chain rubbing strip to swinging arm 5 Refer to section 13
Rear caliper carrier 27

Rear hub/eccentric adjuster clamp bolt 55
Rear suspension unit upper mounting bolt 48
Rear suspension unit lower mounting bolt to drop link 48
Drag link pivot at frame 48
Drop links to swinging arm 48
Swinging arm pivot adjuster 6 Refer to section 12
Lower chain guard 4.5

Hugger 3
Front Suspension

Upper yoke pinch bolt 20
Lower yoke pinch bolt 25
Fork top cap <Speed Triple) 35
Fork top cap <Speed Triple R) 20
Upper yoke centre nut 90
Damping cylinder bolt <Speed Triple) 35 Fit a new washer if removed
Front fork damping cylinder (Speed Triple R) 40

Damping rod locknut 20
Handlebar clamp base to top yoke 35
Handlebar upper clamp to lower clamp 26
Handlebar end weights 3 Replace fixing(s) if removed
Throttle grip guide 3

Switch cube screws 2.5
Cable guide 7

General Information
Wheels

Front wheel spindle/axle bolt 65
Front wheel spindle pinch bolts (Speed Triple) 22
Front wheel spindle pinch bolts <Speed Triple R) 19
Rear wheel to stub axle 146
Drive pin to stub axle 9 Replace fixing(s) if removed
Tyre valve - models without tyre pressure monitoring system 6

Tyre valve - models with tyre pressure monitoring system 5
Front Brakes
Application Torque CNm> Notes

Front brake caliper to fork 55
Front brake pad retaining pin 18
Front brake caliper bleed screw 6
Front brake hose to caliper 25
Front brake master cylinder to handlebar 8
Front brake master cylinder reservoir to mounting 6
Front brake hose to master cylinder 25
Front brake disc to wheel 22 Replace fixing(s) if removed
Brake lever pivot bolt 1
Brake lever pivot bolt locknut 6
Master cylinder hose support to lower yoke 5
Front caliper hose support to lower yoke 7
Rear brake light switch 15
Master cylinder brake hose to caliper brake hose 17
Front brake master cylinder clamp 8
1.44 Se1Vice Manual - Speed Triple and Speed Triple R

General Information
Rear Brakes

Rear brake caliper to carrier 40 Replace fixing(s} if removed
Rear brake pad retaining pin 18

Rear brake caliper bleed screw 6
Rear brake hose to caliper 25
Rear brake master cylinder to control plate (includes heel 18
guard)
Rear brake master cylinder reservoir to mounting 5

Rear brake hose to master cylinder 25
Brake pedal pivot bolt 22 Replace fixing(s) if removed
Brake hose P-clip bolt 6 Replace fixing(s} if removed
Brake line cover 6 Replace fixing(s) if removed
Rear brake disc to axle shaft 22 Replace fixing(s) if removed
ABS System
ABS module to bracket 9

ABS sensor ring to brake disc 5 Replace fixing(s) if removed
ABS sensor to bracket 9 Replace fixing(s) if removed
ABS lines to modulator 25

ABS hard line to front brake hose 17

General Information
Frame, Footrests, Control Plates and Engine Mountings

Upper crankcase to frame 80 Refer to section 9
Lower crankcase to frame 80 Refer to section 9
Cylinder head to frame 80 Refer to section 9
Engine mounting bracket to frame 80 Refer to section 9
Engine mounting bracket to cylinder head 30

Control plate to frame 27
Engine to frame adjuster - except cylinder head front adjuster 5 Refer to section 9 .
Engine to frame adjuster - cylinder head front adjuster 3 Refer to section 9
Swinging arm to frame adjuster 6 Refer to section 12
Rear footrest hanger to frame 27
Side stand mounting bracket 40

Side stand pivot 20
Side stand switch 7 Replace fixing<s> if removed
Rear subframe to frame fixings 58

Side infill panel 4
Bank angle peg to footrest 9
Seat lock barrel to frame 4 Apply ThreeBond 13 60 to the
threads
Seat lock to frame 9
Instrument pack and headlight bracket 13

General Information
Electrical

Alternator rotor to crankshaft 105
Alternator stator to cover 12 Replace fixing(s) if removed
Alternator regulator bracket to frame 5

Alternator regulator to bracket 3
Starter motor to crankcase 10
Starter motor power lead connection 7
Starter motor solenoid bracket 7
Starter motor solenoid lead connection 5
Spark plug to cylinder head 12
Horn 15
Immobiliser ECU 1.5
Engine control unit 12 Replace fixing{s) if removed
Ignition switch 12 Replace fixing(s) if removed
Instrument pack 3
Headlight vertical adjuster 15
Headlight horizontal adjuster 30
headlight to headlight bowl 3
Rear light 4
Licence plate light 2

Front and rear indicator 3

General Information
Bodywork
Mirror 25
Rear panels to frame 5
Rear light moulding 5
Front mudguard to forks 6
Under seat tray 4
Licence plate bracket 23
Licence plate bracket cover 4 Replace fixing(s) if removed
Hugger 4.5
Fuel tank front panel fixings 2
Side cover to fuel tank 4
Front infill panel 6
Side infill panels 4
Splash guard 4 Replace fixing(s) if removed
Bellypan upper moulding to side panels 3

Bellypan lower moulding to side panels 3
Bellypan front mounting brackets M6 bolt 7
Bellypan front mounting brackets MS bolt 15
Bellypan rear mounting brackets 7
Bellypan to mounting brackets 4
Flyscreen infill panel 7
Flyscreen to infill panel 3
Seat cowl 3

General Information
Clutch Cable Routing

General Information
Throttle Cable Routing

General Information
Main Wiring Harness Routing

General Information
Brake Hose Routing - Models without ABS

General Information
Brake Hose Routing - Models with ABS

General Information
Fuel Tank Breather Hose Routing
1.54 Setvice Manual - Speed Triple and Speed Triple R

2 Scheduled Maintenance
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Scheduled Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

Introduction
To maintain the motorcycle in a safe and reliable
condition, the maintenance and adjustments outlined in
All maintenance is vitally important and must not be ·
this section must be carried out as specified in the
neglected. Incorrect maintenance or adjustment may
schedule of daily checks, and also in line with the
cause one or more parts of the motorcycle to
scheduled maintenance chart.
malfunction. A malfunctioning motorcycle is dangerous
Weather, terrain and geographical location affect and may lead to an accident.
maintenance. The maintenance schedule should be
adjusted to match the particular environment in which the
vehicle is used and the demands of the individual owner.
For advice on adjusting the service schedule, consult your
authorised Triumph dealer.
Triumph Motorcycles cannot accept any responsibility
for damage or injury resulting from incorrect
maintenance or improper adjustment carried out by the
owner.
In order to correctly carry out the maintenance items Since incorrect or neglected maintenance can lead to a
listed in the scheduled maintenance chart, special tools dangerous riding condition, always have an authorised
and specialist knowledge will be required. As only an Triumph dealer carry out the scheduled maintenance of
authorised Triumph dealer will have this knowledge and this motorcycle.
equipment, Triumph strongly recommends that your
authorised Triumph dealer carries out all scheduled
maintenance.
A dangerous riding condition could result from incorrect
maintenance leading to loss of motorcycle mntrol and
an accident

Scheduled Maintenance Chart
Odometer Reading in Miles CKms) or time period,

whichever comes first
First A Service B Service C Service D Service
Service
Operation Description Every 500 6,000 12,000 18,000 24,000
(800) (10000> (20000> (30000) (40000)
1 month 1 year 2 years 3 years 4 years
Engine & oil cooler - check for leaks Day . . . . .
. . .
Engine oil - renew
Engine oil filter - renew
-
- . •
• . .• .
Valve clearances - check - • •
Air cleaner - renew - . •
Autoscan - carry out a full Autoscan using
the Triumph Diagnostic tool (print a - . . . . .
customer copy>
- . . . .
.•
ABS ECM - check for stored DTCs
Spark plugs - check - •
- .
.•
Spark plugs - renew
Throttle bodies - balance - . . .
• . .
.• .•
Throttle cables - check/adiust Day
Cooling system - check for leaks Day • . •
Coolant level - check/adjust Day • . .
Coolant - renew - . .
Fuel system - check for leaks Day . . • . .
Lights, instruments & electrical systems -
check
Day • . • . .
Steering - check for free operation Day • . • . •
Headstock bearings - check/adjust - • . • • .
Headstock bearings - lubricate - . .
Forks - check for leaks/smooth operation Day . . . . .
Fork oil - renew - .
Brake fluid levels - check Day . . . . •
Brake fluid - renew Every 2 years
Brake pad wear - check Day • • . • .
Brake calipers - check for leaks and
seized pistons
- • . • . •
Brake master cylinders - check for leaks - • . . . .
Drive chain - lubricate Every 200 miles (300 kms)
Drive chain - wear check Every 500 miles (800 kms)
Drive chain slack - check/adjust Day . . . . .
Drive chain rubbing strip - check - . . . .
Rear wheel needle roller bearing -
lubricate
- . .

Odometer Reading in Miles <Kms> or time period,

whichever comes first
First A Service B Service C Service D Service
Service
Operation Description Every 500 6,000 12,000 18,000 24,000
(800) (10000> (20000> (30000) (40000>
1 month 1 year 2 years 3 years 4 years
Wheel bearings - check for wear/smooth
operation
- • . • • •
Brake master cylinders - check for leaks - . . . . .
. . .
.• •
Exhaust clamp bolt - check/adjust torque -
Fasteners - inspect visually for security Day . . . •

Wheels - inspect for damage Day . . . . •
Tyre wear/tyre damage - check Day . . . . .
• . .
.• •
Tyre pressures - check/adjust Day
Clutch cable - check/adjust Day • . . •
Stand - check operation Day . . . . .
Secondary air injection system - check - . .
Fuel and evaporative loss hoses - renew* - .
*Evaporative system fitted to models for certain markets only.

3 Cylinder Head
Table of Contents
Exploded View - Cylinder Head and Valves. ................................................... 3.2
Exploded View - Camshaft Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Exploded View - Camshaft and Camshaft Drive ...... . ............ . . .. ........ .. .. . ......... . .. 3.4
Cylinder Head Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Camshaft Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Camshaft Drive Chain Tensioner . ·.. . ........... . . . .................................... .. ..... 3.9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Camshafts. . . .......... . ..................... . ........................... . ............... 3.1 1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Camshaft and Bearing Cap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Valve Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Valve Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Camshaft Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
Cylinder Head ......... . ............. . ............................................. . ..... 3.19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Valves and Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Removal from the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
Valve to Valve Guide Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
Valve Face Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
Se1Vice Manual - Speed Triple and Speed Triple R 3.1

Cylinder Head
Exploded View - Cylinder Head and Valves
See text
10Nm
i
10Nm

Cylinder Head
Exploded View - Camshaft Cover
14Nm
Lubricate
both sides

Cylinder Head
Exploded View - Camshaft and Camshaft Drive
9Nm
8
g

Cylinder Head
Cylinder Head Description Camshaft Cover

The engine is fitted with an aluminium alloy cylinder head,
which carries the camshafts, valves and spark plugs. The Removal
cylinder head is cast as a single entity and various
components are permanently added after machining. 1. Remove the seat <see page 16-10).
The camshafts run directly in the head without separate 2. Remove the battery (see page 17-8>.
bearings. Valve clearances are adjusted by changing 3. Remove the fuel tank {see page 10-93>.
variable thickness shims which sit between the valve
4. Remove the radiator cowls <see page 11-5).
tappet bucket and the valves.
5. Remove the airbox (see page 10-100>.
The camshafts are driven by a silent-type drive chain. The
camshaft drive chain is tensioned by a spring loaded 6. Disconnect the electrical connections to the ignition
device fitted in the cylinder head, and is guided by two coils and remove the coils.
rubber blades.
Oil is supplied to the head by an external feed pipe which
is situated at the right hand rear side of the head. Once
supplied to the head, the oil is distributed along internal
drillings within the head casting and camshaft.
Single valve springs are used to close the inlet valves and
single springs to close the exhaust valves. These valve
springs have close wound coils at one end to assist in the
prevention of valve bounce at high engine speed and to
give a smooth valve actuation. When assembling the
cylinder head it is important that the close wound, colour
coded ends of the springs are fitted downwards (towards
the piston). Both the tip and seating face of the valves are
hardened to give a long service life.
Due to the methods used to assemble the valve seat and
valve guides to the head, these parts cannot be replaced. 1. Electrical connectors
2. Ignition coils
A Caution Z Detach the secondary air in1ection hose from the

reed valves on top of the camshaft cover.
In any of the following operations which necessitate the
removal or disconnection of the camshaft drive chain,
NEVER turn the engine without the camshaft drive
chain and tensioner correctly fitted and adjusted. In the
disassembled condition, the pistons will contact the
valves if the crankshaft is turned, causing severe engine
damage.
1. Spring-close clip
2. Secondary air iniection hose
3. Reed valve assembly

Cylinder Head
8. Release the fixings and remove the engine infill 11. Release the clips securing the throttle bodies to the
panels. transition pieces.
1. Throttle body
2. Transition piece <one per cylinder>
3. Clip <one per cylinder)
3 12. Ease the throttle bodies from the transition pieces
~
and lay the assembly to one side.
13. Progressively release the camshaft cover bolts in the
sequence shown below.
Note:
1. Fixings Two shorter bolts are fitted at the end adiacent
2. Left hand infill panel to the camshaft drive chain.
3. Right hand infill panel
9. Disconnect the coolant expansion tank hose from
the radiator.
3
ca pa
5 2
Camshaft Cover Bolt Release Sequence
1. Clamp
2. Expansion tank hose
10. Disconnect the electrical connectors for the throttle
position sensor and the idle speed control stepper
motor.

Cylinder Head
14. Manoeuvre the camshaft cover to the right of the Installation

motorcycle. Then turn the left hand edge of the
cover towards the rear of the motorcycle and 1. Fit a new camshaft cover seal to the groove in the
manoeuvre the cover rearwards to remove it from camshaft cover.
the motorcycle.
capb
capa_1
1. Camshaft cover seal groove
1. Move to the right
2. Fit new plug tower seals to the camshaft cap ladder.
2. Tum to the rear
1
A Caution ·
Never use a lever to remove the camshaft cover from
the head.
Using a lever will cause damage to the head and
camshaft cover which could lead to an oil leak.
15. Remove the camshaft cover gasket and plug tower

seals. If necessary, recover the dowels from the
secondary air injection holes in the head (these may
come away in the cover or gasket>.
16. Discard the camshaft cover seal, bolt seals and the
spark plug tower seals.
lZ Remove any residual oil from the front of the head 1. Plug tower seals
using a syringe or lint free cloth.
3. Apply silicone sealer to the areas arrowed in the
diagram below.
cas!
Silicone Sealer Areas

Cylinder Head
4. Fit the camshaft cover, ensuring that the gasket and 12. Refit the secondary air injection hose to the reed
seals remain in the correct positions. valves.
5. Refit the dowels to the camshaft cover before
locating it onto the head.
1. Spring-close hose clip

2. Secondary air injection hose
1. Dowels 3. Reed valve assembly
6. Apply a thin film of engine oil to both sides of the 13. Check the condition of the ignition coil seal for wear
new washers for the camshaft cover bolts. and/or damage. Replace as necessary <see
page 10-103).
Z Fit the camshaft cover screws and screw seals, then
tighten until finger tight 14. Fit the ignition coils and reconnect.
8. Finally, tighten the camshaft cover bolts to 14 Nm in

the sequence shown below.
1. Coils
15. Refit the airbox Csee page 10-101>.

Camshaft Cover Bolts Tightening Sequence 16. Refit the fuel tank (see page 10-94>.
9. Refit the throttle bodies to the transition pieces and lZ Refit the radiator cowls (see page 11-TJ.
secure with their clips. 18. Reconnect the battery positive (red) lead first.
10. Reconnect the coolant expansion hose to the 19. Refit the seat (see page 16-1 n.
radiator.
11. Refit the engine infill panels and tighten their fixings
to 4 Nm.

Cylinder Head
Camshaft Drive Chain Tensioner Note:

In addition to the 'T1' mark alignment, at TDC,
the alignment marks on the camshaft sprockets
Removal
will point inwards at a point level with the ioint
face.
1. Remove the camshaft cover (see page 3-SJ.
2. Remove the inspection plate from the right hand
crankshaft cover.
)11&8_1
Camshaft to Cylinder Head Alignment Marks

4. Place a suitable wedge between the tensioner blade
1. Inspection plate and crankcase, to hold the camshaft drive chain taut
during removal of the tensioner.
3. Rotate the crankshaft clockwise (the normal direction
of rotation>, using the bolt fitted to the end of the
crankshaft. Stop rotation when number 1 cylinder is
at top dead centre ITDC>, that is when the 'T1 1 mark
on the sprag clutch aligns with the line at the bottom The tensioner centre nut is under spring tension. Always
of the cover. wear hand, eye and face protection when withdrawing
the centre nut and take great care in order to minimise
the risk of injury and loss of components.
(; 5. Carefully remove the centre nut from the tensioner

and withdraw the tensioner spring.
1. 'T1' Mark
2. Marker line
1. Centre nut
2.Spring
6. Remove the bolts securing the tensioner to the

cylinder head. Remove the tensioner and gasket.

Cylinder Head
Installation 6. Fit a new sealing washer to the centre nut. Using

finger pressure only, push the ratchet section of the
1. Check that number 1 cylinder is still at top dead tensioner into firm contact with the tensioner blade.
centre <TDC>. Refit the spring and centre nut to the tensioner.
2. Ensure that the wedge fitted earlier is still holding the Tighten the centre nut to 23 Nm.
tensioner blade in contact with the camshaft drive Z Check that the tensioner plunger is correctly located
chain. Check that the camshaft timing marks point in the middle of the tensioner blade when viewed
inwards and are level with the joint face of the head. from above.
3. Set the tensioner plunger onto the first tooth of the 8. Rotate the engine through 4 full revolutions, and
ratchet (i.e. minimum extension) by manually lifting reset number 1 cylinder to TDC. Ensure that the
the tensioner pawl. 'Tl ' mark on the sprag clutch aligns with the line at
the bottom of the cover.
gabh
Tensioner Plunger Set-up

1. 'T1' Mark
4. Fit the tensioner, complete with a new gasket, to the 2. Marker line
cylinder head and tighten the retaining bolts to
9Nm. 9. Check that the camshaft timing marks align as
illustrated below.
Note:
If fitting a new tensioner, observe the
following:
Remove the new tensioner assembly from the
packaging. On examination, it can be seen that
the tensioner nut will not be tightened fully
into the tensioner body and that the tensioner
'nose' <i.e. the part which actually contacts the
drive chain rubbing strip) is fully retracted into
the housing.
Prior to assembly into the engine it is
necessary to disassemble the tensioner nut,
washer and spring. To do this without
damaging the internal components, turn the ......._,
tensioner nut at least a half turn clockwise <i.e.
tighten it further into the housing) until the
plunger springs outwards. The tensioner nut Camshaft to Cylinder Head Alignment Marks
can then be withdrawn safely without causing 10. Re-check tensioner plunger location against the
internal damage to tensioner components. tensioner blade.
5. Remove the tensioner blade wedge, taking care not 11. Refit the camshaft cover (see page 3-'7>.
to move or damage the tensioner blade. 12. Check the 0-ring in the crankshaft cover inspection
plate. Renew as necessary.
13. Refit the crankshaft cover inspection plate, tightening
it to 18 Nm.

Cylinder Head
Camshafts 3. For removal of the camshaft drive chain only:

To ensure that the camshaft drive chain is fitted in
the same orientation as prior to removal, use a
Removal suitable marker pen to make a permanent mark on
one of the outer plates of the chain.
1. Remove the camshaft drive chain tensioner
(see page 3-9).
1
Note:
It is not necessary to remove the camshaft
drive chain completely.
Each camshaft and sprocket is removed as an
assembly.
Before commencing work, ensure the
crankshaft 'T1 ' mark is in alignment with the
line in the crankshaft cover inspection plate.
2. Remove the camshaft drive chain top pad from the
camshaft caps and cylinder head.
gaaa_1
1. Camshaft drive chain

2. Permanent marker, outer plates only
4. To ensure that all components are refitted in the
same positions as prior to removal, mark the position
of each camshaft cap and the orientation of the
camshaft bearing ladder in relation to the head.
Note:
A laundry marker or similar may be used to
mark the cap positions.
5. Progressively release each of the remaining fasteners
securing the individual camshaft caps to the cylinder
head.
1. Camshaft drive chain top pad
6. Remove the caps.
2. Camshaft caps
Z Progressively release the bolts securing the camshaft
cap ladder to the head in the sequence shown
below.
Never use a 'dot punch' or 'centre punch' to mark the

camshaft drive chain, camshaft or camshaft driven gears.
Severe engine damage will result if impact is applied to
machined parts.
caqm
Camshaft Ladder Bolt Release Sequence

8. Remove the camshaft cap ladder and collect the
dowels (if loose) and spark plug tower 0-rings.

Cylinder Head
9. Lift the camshaft drive chain from the exhaust Camshaft and Bearing Cap Inspection
camshaft sprocket and remove the exhaust camshaft.
10. Repeat the procedure for the inlet camshaft. 1. Inspect the camshaft sprockets for damaged and
worn teeth. Replace as necessary.
A Caution
The same sprocket is used for both inlet and exhaust
camshafts. To attach the sprocket to the different
camshafts, different bolt holes are used.
Never fit a camshaft sprocket to a camshaft using
incorrectly identified bolt holes. Severe engine damage
will result from incorrect attachment.

2. Inlet camshaft
Note:
• The inlet and exhaust camshafts are different.
They can be identified by a plain section in the
centre of the exhaust camshaft and ·a groove in
the same place on the inlet camshaft. 2
gaab
2 1 1. Inlet camshaft bolt holes

2. Exhaust camshaft bolt holes
2. Measure the camshaft journals with a micrometer. If
any journal is outside the specified tolerance, replace
the camshaft.
1. Exhaust camshaft
2. Plain section
3. Inlet camshaft
4. Grooved section

Cylinder Head
Outrigger Journal Diameter Note:
j Standard: I 22.953 - 22.956 mm • The camshaft caps and ladder are unique to
each cylinder head and are, therefore, not
Standard Journal Diameters available individually. If a camshaft cap or the
ladder is worn or damaged, the complete
Standard: 22.93 - 22.96 mm cylinder head must be replaced.
Measuring the Compressed Plastigauge

1. Outrigger journal
2. Standard journal Z Calculate the journal clearance using the Plastigauge
3. Examine all camshaft and camshaft bearing caps for chart supplied with the Plastigauge kit.
excessive wear and damage, paying particular
attention to the outrigger caps. Camshaft Journal Clearance, Standard
4. Check the journal-to-head clearances, using Standard: 0.040 - 0.091 mm

'Plastigauge' <Triumph part number 3880150-T0301J
as follows: Service Limit: 0.13 mm
5. Ensuring that the camshaft sprocket alignment Camshaft Journal Clearance, Outrigger
marking is located as for removal, assemble one
camshaft to the head and progressively tighten the Standard: 0.044 - 0.068 mm
bearing caps and camshaft cap ladder to 10 Nm.
Service Limit: 0.13 mm
6. Remove the camshaft cap and camshaft cap ladder
using the bolt release sequence given earlier. Wipe 8. If the clearance measured is within the specified
the exposed areas of both the camshaft journal and tolerance, remove the cap/ladder and clean off all
a single cap or cap area of the ladder. traces of Plastigauge. Assemble the camshafts (see
page 3-14).
Apply a thin smear of grease to the journal and
a small quantity of silicone release agent to the Note:
cap. If the measured clearance is outside the
Size a length of the Plastigauge to fit across the tolerance, and the camshaft iournals are within
camshaft journal. Fit the Plastigauge to the tolerance, the cylinder head must be replaced.
camshaft journal using the grease to hold the
strip in place.
Refit the cap and camshaft cap ladder then
A. Caution
evenly and progressively tighten all the Although Plastigauge is oil soluble, all traces of the
camshaft cap and ladder bolts to 10 Nm in the material must be removed to prevent blockage of the oil
correct sequence (see camshaft installation). dril lings and resultant engine damage.
Release the cap bolts and remove the
cap/ladder. Using the gauge provided with the
Plastigauge kit, measure the width of the now
compressed Plastigauge.

Cylinder Head
Installation 5. Assemble the camshaft caps, dowels, camshaft

ladder and top pad in the same location and
1. Thoroughly dean the camshafts and journals. Inspect orientation as prior to removal.
the ends of the camshafts for correct fitment of the
sealing plugs. Lubricate the camshafts with clean
engine oil before fitting to the head.
2. Locate each camshaft to the head ensuring the
camshafts are correctly identified (inlet and exhaust)
and are also correctly located over their respective
valve banks.
3. Working on one camshaft at a time, locate the
camshaft drive chain over the camshaft sprocket.
Position the camshaft in the same position as for
removal before attempting to fit the caps and ladder
(that is, with the timing marks on the camshaft
sprockets level and pointing inwards, and with the
Tl' mark on the sprag clutch in alignment with the
line at the bottom of the cover).
1. Camshaft drive chain top pad
6. Fit and evenly tighten the camshaft cap screws to
10 Nm, in the sequence shown below.

2. Inlet camshaft
4. Repeat the procedure for the other camshaft. cape
Camshaft-cap and Ladder Bolt Tightening
A Caution
Z
Sequence
Before fitting the camshaft drive chain tensioner,
If the camshafts and caps/ladder are fitted without first ensure that each camshaft rotates freely. Do not
aligning the timing marks on both the crankshaft and rotate either camshaft by more than 5°.
camshaft sprockets, the inlet and exhaust valves will
contact each other causing damage to both the head
and the valves.
A Caution
If any components have been renewed, the valve
clearances must be checked and adjusted. Running with
incorrectly adjusted valve clearances may cause excess
engine noise, rough running and engine damage.
8. Assemble the camshaft drive chain tensioner using

the instructions given earlier in this section.

Cylinder Head
9. Rotate the engine through 4 full revolutions, and Valve Clearance Measurement
reset number 1 cylinder to TDC. Ensure that the 'Tl'
Note:
mark on the sprag clutch aligns with the line at the
bottom of the cover. Valve clearance measurement must be carried
out with the engine cold.
1. Remove the camshaft cover (see page 3-5).

2. Remove the spark plugs to reduce compression
resistance when turning the engine.
3. Select a high gear and, using the rear wheel, turn the
engine until a pair of camshaft lobes are positioned
pointing away from the valves.
4. Using feeler gauges, measure and record the
clearances for this pair of valves only.
5. Repeat the process until the valve clearances for all
valves have been checked.
Note:
If the measurement does not fall within the
1. 'T1' mark specified range, adiustment must be made.
2. Marker line
Note:
10. Check that the camshaft timing marks align as
The correct valve clearances are in the range
illustrated below. Rectify any misalignment before
given.
proceeding.
Inlet: 0.10 - 0.20 mm

Exhaust: 0.20 - 0.30 mm
A Caution
If the valve clearances are not checked and corrected,
wear could cause the valves to remain partly open,
which lowers performance, burns the valves and valve
seats and may cause serious engine damage.
6. Record the measured valve clearances on a chart

similar to the example shown.
iaaa_1
Camshaft to Cylinder Head Alignment Marks

11. Check the valve clearances. Adjust as necessary (see
page 3-16>.
12. Refit the camshaft drive chain tensioner (see
page 3-10>.
Valve Clearances
Camshaft, valve, valve shim and valve seat wear affects the
valve clearances. The effect of this wear is to change the
gap between the camshaft and tappet bucket, causing
engine noise and improper running. If the valve
clearances become too small, permanent damage to the
valve and valve seat will take place. If the valve clearance
becomes too great, the engine will become noisy and will
not run correctly.

Cylinder Head
Typical Valve Clearance Chart 3. Remove the shim from the valve head.
Inlet Valve No. Gap Measured

1 as measured <mm)
2 as measured <mm)
3 as measured (mm)
4 as measured (mm)
5 as measured (mm)
6 as measured (mm)
Exhaust Valve No. Gap Measured
1 as measured (mm)
2 as measured <mm)
3 as measured <mm)
4 as measured (mm)
1. Shim
5 as measured (mm)
4. Measure the original shim, using a micrometer and
6 as measured (mm) select the appropriate new shim as required.
Clearance too small:
Valve Clearance Adjustment
Fit a thinner shim.
Note:
Clearance too large:
To adiust the valve clearances th~ camshafts
Fit a thicker shim.
must be removed. Follow the camshaft
removal procedure (see page 3-11>. Note:
Shims are available ranging from 1. 70 mm to
1. Remove the camshafts (see page 3-11).
3.00 mm in increments of 0.025 mm.
2. Remove the tappet bucket from the cylinder head.
5. Fit the new shim to the valve head.
6. Lubricate the tappet bucket(s) with a 50/50 solution
of engine oil and molybdenum disulphide grease.
Z Refit the tappet bucket.
8. Refit the camshafts (see page 3-14>.
9. Re-check all valve clearances.
10. Repeat the procedure if the valves require further
adjustment.
1. Tappet bucket
Note:
The shim may withdraw with the tappet
bucket.

Cylinder Head
Camshaft Chain 4. Check for severe wear of the inner plates as

indicated in the diagram below.
Removal
1. Remove the camshafts <see page 3-7 n.

2. Remove the starter gear cover (see page 7-24).
3. Remove the right hand crankshaft cover (see
page 7-24>.
4. Remove the sprag clutch and drive gear <see
page 7-24).
5. Remove the bolt from the centre of the camshaft
drive chain housing in the cylinder head.
ccrv
For a more thorough check, proceed as follows:
1. Remove the drive chain from the engine.

2. Suspend the drive chain from a pin or hook with a
13 kg weight attached at the lower end.
1. Centre bolt
6. The camshaft drive chain is removed from inside the
head-space or through the crankcase, after first
detaching the drive chain from the crankshaft gear.
Inspection
Visual in-situ checks can also be made as follows:
cajs
1. Check for significant blue discolouration of the drive

chain plates indicating excessive heat build-up.
2. Examine all pins for signs of rotation.
3. Check for cracking or deep scratching of the drive
chain plates.

Cylinder Head
3. Measure across 23 links as shown in the diagram 6. Check for severe wear of the plates in the area
below. If the drive chain is within limits, the shown below.
measurement should be no longer than 150.14 mm.
Measurements beyond 150.14 mm indicate that the
drive chain must be replaced.
ca ju
If any of these symptoms are evident, the camshaft drive

chain must be replaced.
4. Check for severe wear of the inner surface of the

Installation
outer plates at the side-contact points with the
sprocket teeth.
1. Fit the camshaft drive chain and locate the lower end
around the crankshaft gear.
2. Refit the bolt to the centre of the camshaft drive
chain housing in the cylinder head, tightening to
10Nm.
3. Refit the camshafts <see page 3-14}.
ecru
5. Check for signs of stiffness or kinking.

Cylinder Head
Cylinder Head 4. Release the screws securing the outside of the

cylinder head to the upper crankcase.
Removal
Note:
The rubbing blades for the camshaft drive
chain protrude from the crankcase such that
removal of the head while in the frame is made
extremely difficult and may lead to damage to
the head, rubbing blades and frame.
1. Remove the engine from the frame (see page 9-2).

2. Remove the camshafts (see page 3-11>.
3. Note the position of all tappet buckets and shims so
that they can be refitted in the same positions.
Remove all the tappet buckets and shims.
1. Cylinder head to upper crankcase screws
5. Progressively release the cylinder head bolts in the

order shown below.
1. Shim
Note:
cary
To prevent the tappet buckets and shims from
becoming mixed, place the shim and tappet Cylinder Head Bolt Release Sequence
together in a marked container. The
6. Lightly tap the cylinder head with a rubber mallet to
components must be refitted in their original
break the seal of the gasket.
positions.
Z Lift the head directly upwards until clear of the
camshaft drive chain rubbing blades.

Cylinder Head
Inspection 5. Carefully lower the cylinder head over the camshaft

drive chain and rubbing strips and locate the head
1. Thoroughly clean the surface of the head and check onto the dowels.
for damage and pitting of the combustion chambers.
2. Using a straight edge, check the cylinder head
gasket face for warp which could lead to gasket A Caution
failure. Replace the head if warped. Using the correct procedure to fit and tighten the
cylinder head bolts will ensure the long term reliability of
the cylinder head gasket.
Clean each bolt, paying particular attention to the
threads and under-bolt-head areas. If any of the threads
or bolt-head areas are damaged, replace the bolt<s>.
Lubricate the threads with engine oil, and then wipe
clean with a lint-free cloth leaving minimal oil on the
threads (that is, almost dry to touch).
Tighten the bolts using the three-stage procedure given
below.
Failure to observe these important items may damage
the head gasket and lead to severe engine damage.
1. Straight edge
2. Cylinder head gasket face
3. Check the camshaft drive chain rubbing blade.
Renew if worn or damaged.
Installation
1. Thoroughly clean the upper faces of the crankcase

taking care not to damage the mating surfaces.
2. Fit a new cylinder head gasket Ctop' marking
uppermost) ensuring that the head to crankcase
location dowels are correctly in place.
1. Rubbing strips
6. Fit the bolts and washers (if fitted) to the head and
tighten until finger .tight The head bolts are finally
tightened in three stages. This is to ensure that the
cylinder head gasket seals correctly to the head and
crankcase. The three stages are as follows:
Note:
For stages A and B of the head bolt tightening
operation, a torque wrench of known, accurate
calibration must be used.
a) Tighten the head bolts, in the same numerical
cart
sequence used to release the bolts, to 20 Nm.
b) Tighten the head bolts in the same numerical
1. Cylinder head gasket sequence used to release the bolts, to 40 Nm.
3. Ensure that the cylinder head face is completely

clean.
4. If removed, install the camshaft drive chain rubbing
strips.

Cylinder Head
For the final torque operation, which again is Valves and Valve Stem Seals
carried out in the same numerical sequence
used to release the bolts, a 'torque turn'
method is used. The bolts must be turned by Removal from the Cylinder Head
90° to reach the final setting. To accurately
gauge the 90° turn, use service tool 3880105- 1. Remove each valve from the head using a valve
T0301 as follows: spring compressor. The compressor must ad on the
Fit the tool between the torx socket and the top cup to allow removal of the valve collets.
drive handle and locate the torx drive to the
head bolt. Pick an increment point on the
torque turn gauge which aligns with a suitable
reference point on the head. Tighten the bolts
until nine of the 10° gauge increments have
rotated past the chosen point on the head.
gadh
Valve Removal
2. Once the collets are released, remove the following
items:
cary
collets
valve spring cap
Cylinder Head Bolt Tightening Sequence
valve spring
Z Fit the screws securing the side of the cylinder head
to the crankcase and tighten to 10 Nm. valve stem seal
spring platform
valve {de-burr before removal>
1. Cylinder head to upper crankcase screws
8. Clean and lubricate the tappet buckets with clean

engine oil and refit the buckets and shims in the
same locations from which they were removed. 1. Valve stem seal
9. Refit the camshafts {see page 3-74).
10. Install the engine to the frame {see page 9-3).

Cylinder Head
Note:
Ensure inlet and exhaust valve components do
not become mixed.
A Caution
Incorrect fitment of the valve stem oil seals could lead to
high oil consumption and blue smoke emissions from
the exhaust system. Do not use excessive force in fitting
the seal as this may break the seal ring.
4. Install the valve spring over the valve stem.

5. Compress the valve spring ensuring that the spring
is compressed squarely to prevent damage to the
valve stem and cylinder head.
6. Fit the valve collets ensuring correct collet location in
the spring cap and valve as the spring compressor is
released.
A Caution
1. Collets Always check for correct location of the valve collets
2. Valve spring retainer during and after assembly. If not fitted correctly, the
3. Valve spring collets may become dislodged when the engine is
4. Valve spring platform running allowing the valves to contact the pistons. Any
5. Stem oil seal such valve to piston contact will cause severe engine
6. Valve damage.
Installation Valve to Valve Guide Clearance

If the valve guides are worn beyond the service limit given
1. Apply a thin coat of molybdenum disulphide grease below, the cylinder head must be replaced.
to the valve stem.
2. Install the valve into the valve guide and refit the Valve Stem to Guide Clearance
spring platform to the valve spring recess in the
head. Inlet: 0.010 - 0.040 mm
3. Fit the valve stem seal over the valve stem and, using Exhaust: 0.030 - 0.060 mm
a suitable tool, press down fully until the seal is
correctly seated over the valve guide. Valve Guides
Note: If a valve guide is found to be worn beyond the service
limit, the complete cylinder head must be renewed.
During fitment of the valve stem seal, two
distinctly different degrees of resistance will be
noted when the seal is correctly fitted. Valve Face Inspection
Firstly, press the seal down the valve stem until
the lower side of the seal comes into contact 1. Remove any carbon build-up from the valve head
with the valve guide. Greater resistance is felt area. Examine the valve seat face, checking in
at this contact point and further gentle particular for signs of cracking or pitting.
pressure is then required to locate the seal
over the top end of the valve guide.
On application of this pressure, the seal can be
felt to positively locate over the top face of the
valve guide. Once correctly positioned, the seal
cannot be pushed down any further.

4 Clutch
Table of Contents
Exploded View - Clutch Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Exploded View - Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Exploded View - Clutch Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Clutch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.S
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.S
Inspection ..... ............................................... ... ...................... 4.6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Clutch ....................... ~........... .......................... ...................... 4.7
Disassembly..... ................ . ............ ...... .... .. ............... .... ........ .. 4.7
Clutch Plate Inspection.................. ................................ .. .............. ... 4.8
Friction plate Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Steel Plate Bend/Warp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Clutch Pack Height....... .......... ....... .... .. ......... .. .. ... ...... ... ... ........... 4.9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

Clutch
Exploded View - Clutch Cover
8Nm

Clutch
Exploded View - Clutch Assembly
10Nm
150Nm

Clutch
Exploded View - Clutch Controls
12 Nm
~~ 0
v~
,.-
p~
· 3.4Nm
3Nm

Clutch
Clutch Cable 5. Slacken the cable locknut and release the adjuster at
the clutch cover end to give maximum play in the
cable.
Removal
1. Release the three fixings and remove the front panel

from the fuel tank.
1. Clutch cable
2. Adjuster
6. Release the clutch cable from the actuating arm by
pushing the inner cable nipple through the arm and
1. Front panel
sliding the cable out of the slot. Detach the cable
2. Fixings
from the bracket.
2. Disconnect the battery, negative <black> lead first
3. Remove the right hand radiator cowl <see
page 11-5).
4. Detach the clutch cable retaining clip from the
radiator.
kaij
1. Actuating arm
2. Inner cable
Z Align the slot in the adjuster with the slot in lever.
1. Cip
2. Clutch cable

Clutch
8. Pull in the clutch lever and turn the inner cable, anti- 6. Set the adjuster at the clutch end to give a
clockwise through the slot in the adjuster and lever, preliminary setting of 2 - 3 mm of free play as
until the cable can be detached by pushing measured at the lever. Tighten the locknut to 3 Nm.
downwards. 7. Operate the clutch lever several times and recheck
the amount of free-play present.
8. Set the final adjustment of the cable to give
2 - 3 mm of free-play at the lever by turning the
adjuster nut and locknut at the lever end.
1. Adjuster slot
2. Lever slot
3. Cable release point
9. Remove the cable from the motorcycle noting the
cable routing, particularly where it passes through 1. Clutch lever
the air deflector shield. 2. Correct setting, 2 - 3 mm
9. Reconnect the battery positive <red> lead first

Inspection 10. Refit the front panel to the fuel tank and tighten the
fixings to 2 Nm.
1. Check the inner cable for free movement through
the outer cable.
2. Examine the inner cable for frayed strands.
3. Examine the two inner cable nipples for signs of
looseness and damage. Replace the cable if
necessary.
Installation
1. Position the cable to the motorcycle using the same

routing as noted during removal.
2. Attach the inner cable to the clutch lever and
actuating arm using a reversal of the removal
process.
3. Refit the outer cable to the adjuster bracket at the
clutch end.
4. Attach the cable retaining clip to the radiator.
Note:
Ensure that the two adiuster nuts are
positioned, one either side of the bracket.
5. Set the lever adjuster to a point where an equal
adjustment is possible in both directions.

Clutch
Clutch Note:
Record the orientation of all components as
they are removed. The plates must be
Disassembly
assembled in the same order.
t. Release the clutch cable from the actuating arm.
2. Remove the starter cover, right hand crankshaft
cover and associated starter gears to gain access to
the clutch cover bolt at the centre-right hand side
(see page 7-24 up to Engine Number 487366, see
page 7-27 from Engine Number 487367 to 491323,
see page 7-Jo>.
1. Friction plate
2. Steel plate
3. Anti-iudder spring
4. Anti-judder seat washer
Note:
~ kajl The outermost and innermost friction plates
differ from all others and must not be fitted in
1. Right hand crankshaft cover (starter cover removed> any other positions. They are thicker and are
3. Remove the clutch cover. also darker in colour.
Refer to the following page of this section for
4. Undo the bolts and springs and remove the clutch
details of clutch friction plate checking.
pressure plate.
It is not normally necessary to disassemble the
5. Remove the clutch pull rod.
clutch further, but if the clutch inner and outer
drums are to be removed, proceed as follows:
Z Engage second gear and lock the inner and outer
clutch drums together using service tool T3880305.
1. Clutch pull rod
6. Remove all the clutch friction plates and steel plates gaaz
together with the anti-judder spring and anti-judder

seat washer. 1. Service Tool T3880305
8. Depress the rear brake pedal to prevent the engine

from turning, then release the clutch centre nut

Clutch
9. Remove the centre nut, Belleville washer, clutch Clutch Plate Inspection
inner drum and thrust washer. Discard centre nut
and the Belleville washer.
Friction Plate Thickness
1. If any friction plate thickness is outside the service

limit, replace the friction plates as a set.
1. Centre nut
2. Belleville washer
3. Inner drum gaal
4. Thrust washer
1. Clutch friction plate
10. Slide the clutch outer drum assembly gently
backwards and forwards to dislodge the inner
Friction Plate Thickness - Inner and Outermost Plates
bearing sleeve. Carefully remove the bearing sleeve
while supporting the clutch drum.
Standard 3.80 mm
Service Limit 3.60 mm
Friction Plate Thickness - All Other Plates
Standard 3.30 mm
1. Outer drum
2. Bearing sleeve
11. Remove the clutch outer drum leaving the oil pump
drive sprocket, bearing and sleeve in place on the
input sha~

Clutch
Steel Plate Bend/Warp 1. Arrange the new friction and new steel plates in a
stack as shown below.
Check all plates for bend and warp as follows:
1. Place the plate being checked on a clean surface

plate and attempt to pass a feeler gauge of the
maximum specified thickness between the friction
plate and surface plate at several points around the
plate. If the feeler gauge can be passed beneath the
steel plate at any point, renew the plates as a set
Clutch outer +
T0944_16
1. Outer friction plate

2. Friction plates
3. Steel plate, 1.6 mm thickness
4. Steel plates, 2.0 mm thickness
5. Inner friction plate
2
gaas 2. Place the assembled clutch pack on a flat surface and
1. Steel plate measure its height as shown below.
2. Feeler gauge
3. Surface plate
Steel Plate Bend/Warp

0
Standard up to 0.15 mm
Service Limit 0.20mm
Clutch Pack Height

The clutch pack height should only be measured if the
friction plates and the steel plates have been replaced.
The clutch pack height is critical for a smooth operation of
the transmission and must be measured prior to
installation of new clutch plates.
T0943_1
If used clutch plates are being re-fitted, the clutch pack 1. Clutch pack height
height measurement is not necessary, as the plates may
not be worn to the service limit <and are therefore still 3. The correct clutch pack height for this clutch
serviceable), but could fall outside of the clutch pack assembly is shown in the table below.
height tolerance when measured.
Standard height in mm Tolerance in mm
If building a new clutch pack its height must be correct. To
achieve this, build the new clutch pack with the following: 50.00 +0.37/-0.63
1 x new outer friction plate; 4. If the clutch pack height measurement is incorrect,
proceed as described below:
8 x new friction plates;
Note:
1 x new inner friction plate;
Due of the maximum of four 2.0 mm thick
4 x steel plates, 2.0 mm thick; steel plates that can be fitted to this clutch
5 x steel plate, 1.6 mm thick. pac~ the height can only be adiusted if it is too
high (greater than 50.3 7 mm).

Clutch
Clutch Pack Too High 2. To fully engage the outer drum, insert a suitable tool
to preload and align the primary gear and backlash
Note:
eliminator gear through the hole shown in the
No more than six 1.6 mm thick steel plates are illustration below.
to be used in the clutch pack.
No less than three and no more than four
2.0 mm thick steel plates are to be used in the
clutch pack.
1. Replace the 2.0 mm steel plate next to the 1.6 mm

steel plate (indicated below) with a new 1.6 mm steel
plate.
1. Alignment hole
2. Outer drum
3. While holding the clutch outer drum in position and

ensuring correct engagement with the oil pump
drive, refit the bearing sleeve.
Clutch outer+
T0944_17
1. 2.0 mm steel plate to be replaced

2. 1.6 mm steel plate
2. Re-check the clutch pack height as described earlier.
Assembly
1. Position the clutch outer drum assembly to the input

shaft and align the oil pump drive pegs with the
corresponding holes in the rear of the clutch outer
drum.
1. Outer drum
2. Bearing sleeve
Note:
When the bearing sleeve is correctly fitted, it
will be a flush fit with the clutch drum face. In
addition, a groove around the input shaft will
be visible.
4. Fit the thrust washer to the shaft.
5. Fit the clutch inner drum.
1. Clutch outer drum

2. Oil pump sprocket drive pegs
3. Oil pump drive holes

Clutch
6. Fit a new Belleville washer C'out' mark facing Note:

outwards), and fit a new centre nut
The innermost and outermost friction plates
are different to the remainder. For
identification, they are darker in colour and are
thicker.
The outermost clutch friction plate is fitted
such that the outer tags of the plate are
engaged with the corresponding individual tags
in the clutch outer drum.
Belleville Washer 'Out' Mark

Z Lock the inner and outer drums together using
service tool T3880305. Depress the rear brake pedal
to prevent the engine from turning, and tighten the
clutch centre nut to 150 Nm. Remove the service
tool.
3. Individual tags
10. Refit the clutch pullrod.
11. Refit the clutch pressure plate together with the
springs and bolts. Tighten the bolts to 10 Nm.
Note:
The pull rod should be free to move in and out
and also it should be free to turn.
The sump fixings 1 and 2 are torqued twice as
15 and 16 respectively.
12. Refit the outer cable to the adjuster bracket at the
gaaz
clutch end.
1. Seivice Tool T3880305 13. Set the clutch adjustment (see page 4-6).
8. Disengage second gear and check for free rotation
of the clutch inner drum.
9. Coat all clutch friction plates in clean engine oil
before fitting the friction plates, steel plates,
anti-judder spring and anti-judder seat washer to the
clutch basket in the same order and orientation as
noted during removal.

Clutch

5 Crankshaft, Connecting Rods
and Pistons
Table of Contents
Exploded View - Crankshaft, Connecting Rod, Piston and Liner. ........................ .. ... ..... 5.2
Exploded View - Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Crankcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Assembly ....... ........ ........ . . . . . ........ ... .............. . . .. ..... .. ............. 5.4
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Connecting Rods. ......... .. ................... ... ........................... ..... ..... . .. 5.8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Connecting Rod Big End Bearing Selection/Crankshaft Journal Wear Check . . . . . . . . . . . . . . . . . . . . . . . 5.10
Checking the Measured Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Connecting Rod Bearing Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Piston Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Cylinder Liners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19

Crankshaft, Connecting Rods and Pistons
Exploded View - Crankshaft, Connecting Rod, Piston and Liner
oczm_1

Exploded View - Crankcase
fl
I
I
I
fl
I

Crankcases 3. Release the lower crankcase bolts in the sequence

shown in the diagram below.
A Caution
The upper and lower crankcases are machined as a
matched set and must never be assembled to
non-matching halves. Doing so may cause seizure of the
engine.

2. Remove the sump (see page 8-13).
3. Remove the left hand engine covers (up to Engine
Number 487366 see page 7-24, from Engine
Number 487367 to 491323 see page 7-27, from
Engine Number 491324 see page 7-30>.
4. Remove the left hand engine cover (see page 17-21).
5. Remove the clutch (see page 4-7>. Lower Crankcase Bolt Release Sequence
6. Remove the oil pump drive chain and gears 4. Separate the lower and upper crankcases ensuring
(see page 8-9). that the 3 locating dowels remain in the upper
7. Remove the water pump <see page 11-7>. crankcase.
Disassembly
A Caution
Do not use levers to separate the upper and lower
A Caution sections of the crankcase or damage to the crankcases
could result.
Failure to follow the correct screw release sequence may
result in permanent crankcase damage. Note:
1. Working on the upper crankcase bolts first, release • At this point the transmission shafts, balancer,
crankshaft, bearings etc. can be removed.
the bolts in the sequence shown below.
Note:
Note the position of each individual bearing
screw prior to removal.
Assembly
1. Use high flash-point solvent to clean the crankcase

mating faces. Wipe the surfaces clean with a lint-free
cloth.
2. Fit the gearbox shafts {if removed), ensuring the
locating ring on the input shaft is in position in the
circlip groove on the crankcase.
3. Ensure that the transmission is in neutral.
5 3 6
Upper Crankcase Bolt Release Sequence

2. Invert the engine to give access to the lower
crankcase bolts.

4. Ensure that the 3 locating dowels are in position in 8. Locate a new oil gallery 0-ring to the upper
the upper crankcase. crankcase.
1. Locating dowels 1. 0-ring
5. Apply a thin bead of silicone sealant to the lower 9. Position the lower crankcase to the upper, ensuring
crankcase mating faces. CAt the factory, that all selectors engage correctly. An assistant may
ThreeBond 1215 is used.> be required to support the crankcase during
alignment.
10. Fit the screws into the lower crankcase and hand
tighten until the bolt heads are near contact with the
crankcase.
11. Invert the engine.
12. Fit the screws into the upper crankcase and hand
tighten until the bolt heads are near contact with the
crankcase.
Note:
The crankcase screws are tightened in stages.
Two different sizes of crankcase screw are
used. All screws are tightened through the first
stage of the tightening procedure but only the
MS size screws are tightened at the second
1. Sealer areas stage.
-A Caution A Caution
Failure to follow the correct screw tightening sequence
Do not use excessive amounts of sealer. The extra sealer
may result in permanent crankcase damage.
may become dislodged and could block the oil passages
in the crankcases causing severe engine damage.
6. Install and lubricate the crankshaft bearing shells

with clean engine oil Csee bearing selection before
proceeding}.
Z Lubricate the crankshaft journals with clean engine
oil.

Stage 1 - All Screws Stage 2 - MS Screws Only
1. Invert the engine. 1. In the correct sequence, tighten only the M8 size
2. In the correct sequence, tighten all lower crankcase upper crankcase screws <numbers 22 to 29) to
screws to 12 Nm. 32Nm.
2. Invert the engine.
3. In the correct sequence, tighten only the M8 size
lower crankcase screws (number 1 to 14) to 3 2 Nm.
4. Rotate the crankshaft clockwise. Check for tight spots
and rectify as necessary.
5. Refit the water pump (see page 11-8).
6. Refit the oil pump drive chain and gears (see
page 8-1 n.
Z Refit the clutch Csee page 4-10>.
8. Refit the right hand engine covers Cup to Engine
Number 487366 see page 7-26, from Engine
Number 487367 to 491323 see page 7-29, from
Engine Number 491324 see page 7-32).
9. Refit the left hand engine cover (see page 17-23>.
Lower Crankcase Bolt Tightening Sequence 10. Refit the sump <see page 8-13).
3. Invert the engine. 11. Install the engine in the frame <see page 9-3).
4. In the correct sequence, tighten all upper crankcase

screws to 12 Nm.
28 32 30 27
Upper Crankcase Bolt Tightening Sequence

Crankshaft Z Collect the piston cooling jets from the crankcase

oilways beneath the crankshaft bearings.
Removal
1. Remove the sprag clutch (see page 7-24).
A Caution
1. Needle roller bearing During crankcase assembly, ensure all three piston
2. Gear/sprag clutch assembly cooling jets are re-installed. If the jets are omitted, oil
3. Plain washer pressure will be reduced. Running the engine with low
2. Remove the connecting rods (see page 5-8). oil pressure will cause severe engine damage.
3. Remove the alternator rotor from the crankshaft (see 8. Remove the balancer (see page 6-3).
page 17-21>.
4. Separate the two halves of the crankcase (see
Installation
page 5-4>.
5. Remove the camshaft drive chain (see page 3-m.
6. Release and remove the crankshaft from the upper
crankcase.
A Caution
Always check the bearing journal clearance (see
Note:
page 5-73), before final assembly of the crankshaft.
Identify the location of each bearing shell. Failure to correctly select crankshaft bearings will result
Remove all bearings and inspect for damage, in severe engine damage.
wear, overheating (blueing) and any other
signs of deterioration. Replace the bearings as 1. If removed, insert the three piston cooling jets into
a set if necessary. the main bearing housings in the upper crankcase.

2. Select and fit new main and big end shell bearings Connecting Rods
using the selection processes detailed later in this
section.
Removal
Connecting rods may be removed from the engine after
first removing it from the frame. The cylinder head must
be removed and the crankcase halves separated.
1. Mark each big end cap and connecting rod to

identify both items as a matched pair and to identify
the correct orientation of the bearing cap to the
connecting rod.
2. Release the connecting rod nuts and remove the big
end cap. Ensure that the bearing shell remains in
place in the cap.
1. Big end shells
3. Lubricate all bearings with engine oil.

4. Ensure that the crankshaft is clean, and that the
oilways within the crankshaft are clean and free from
blockages and debris.
5. Refit the balancer (see page 6-4).
6. Install the crankshaft ensuring that the crankshaft
journals align with the big ends and that the
crankshaft and balancer gear markings align as
shown in the next illustration.
1. Big end cap
Note:
It may be necessary to gently tap the big end
cap with a rubber mallet to release the cap
from the bolts.
3. Push the connecting rod up through the crankcase
and collect the piston and connecting rod from the
top.
4. Label the assembly to identify the cylinder from
which it was removed.
1. Balancer backlash and drive gear markings

A Caution
2. Crankshaft markings
Never re-use connecting rod bolts or nuts. If the
connecting rod cap is disturbed, always renew the bolts
Z Refit the connecting rods (see page 5-9). and nuts. Using the original bolts and nuts may lead to
8. If removed, refit the transmission shafts. severe engine damage.
9. Assemble the crankcases Csee page 5-4).
5. Remove the liner using tool T3880315
10. Assemble the alternator rotor (see page 17-23). (see page 5-m.
11. Assemble the sprag clutch (see page 7-26>. 6. Detach the piston from the connecting rod
12. Assemble the camshaft drive chain (see page 3-18). (see page 5-14).

Installation 3. Apply silicone sealer to the liner to crankcase mating

face Cat the factory, ThreeBond 1215 is used>.
Note:
Connecting rod bolts and nuts are treated with
an anti-rust solution which must not be
removed.
Clean the connecting rod with high flash-point
solvent.
Remove all bearings and inspect for damage,
wear and any signs of deterioration and replace
as necessary.
"'~~ -...-~-~.~..,..?.";i
l~.;~.· ~.·~i~- ~-~~!;~~{~~·~~:. :~·:~?~~.·~.d~~·' . .~·-·_: .·;~'.~

Connecting rod bolts and nuts MUST only be used
once. If the bolts or nuts are removed or undone for any
ccvk
reason, new bolts and nuts MUST always be used.
Re-using bolts can cause connecting rods and their caps 1. Liner
to detach from the crankshaft causing severe engine 2. Sealer area
damage, loss of motorcycle control and an accident. 4. Fit the piston and connecting rod assembly into the
liner from the bottom.
1. Fit new connecting rod bolts to the big end.
5. Fit the liner into the crankcase ensuring that the
Note: arrow/dot on the piston faces forward.
Ensure the piston is fitted correctly to the Note:
connecting rod.
Ensure that the piston/liner/connecting rod
If a previously run engine is being rebuilt,
assembly aligns correctly with the crankshaft
always ensure that the piston and con-rod are
iournal during assembly into the crankcase.
assembled in the same orientation as prior to
strip-down. 6. Select big end bearing shells (see page 5-10>.
2. Fit the piston to the connecting rod (see page 5-16). Z Fit the bearing shells to the connecting rod and big
end cap and lubricate with a 50/50 solution of
Note: engine oil and molybdenum disulphide grease.
• Avoid touching any bearing surfaces of the 8. Align the connecting rod to the crankshaft and fit the
bearing shells with the hand. big end cap.
1. Big end

9. Lubricate the threads of the bolt and the face of the Connecting Rod Big End Bearing
nut with molybdenum disulphide grease. Tighten the
nuts progressively in five stages as follows:
Selection/Crankshaft Journal Wear
Check
A. Caution Note:
New crankshafts with larger big end iournal
The torque characteristics of the connecting rod nuts
diameters were introduced from Engine
and bolts are sensitive to the rate at which they are
Number 506366 and are retrofittable.
tightened. If all the torque is applied in one action, the
bolt may be stretched and the nut may become loose When measuring the crankshaft big end
when in service resulting in an expensive engine failure. ioumals, make a note of which condition
crankshaft the measurement represents. For
a) Tighten to 22 Nm. example, a iournal measuring 3 S.018 mm is
b) Release by 140°.
the new condition crankshaft. This information
is needed for the crankshaft ioumal clearance.
d Tighten to 10 Nm.
d) Tighten to 14 Nm. 1. Measure the bearing and crankshaft journal
e) Tighten through 120° of nut rotation as clearance as follows.
measured using the Triumph torque turn Note:
gauge 3880105-T0301.
Do not turn the connecting rod and crankshaft
during the clearance measurement as this will
damage the 'Plastigauge'. The crankshaft
iournal clearances are measured using
'Plastigauge' <Triumph part number 3880150-
T0301).
2. Remove the big end cap from the journal to be
checked.
3. Wipe the exposed areas of the crankshaft journal,
and the bearing face inside the cap.
4. Apply a thin smear of grease to the journal and a
small quantity of silicone release agent to the
bearing.
5. Trim a length of the Plastigauge to fit across the
cbxt
journal. Fit the strip to the journal using the grease to
hold the Plastigauge in place.
Service Tool 3880105-T0301
6. Release the nuts and remove the cap being
measured. Using the gauge provided with the
Plastigauge kit, measure the width of the
compressed Plastigauge.

Z Lubricate the threads of the bolt and the face of the Connecting Rod Bearing Selection
nut with molybdenum disulphide grease. Refit the
Minor differences in connecting rod dimensions are
bearing and cap and tighten the big end nuts <see
compensated for by using selective bearings. For further
page 5-9).
information on bearing part number to colour cross-
references, see the latest parts information.
1. Select the correct big end bearing shell as follows:

Measure each crankshaft journal diameter.
Note the connecting rod marking.
2. Select the correct bearings by matching the

information found with the chart below.
Big End Bearing Selection Chart - Old Condition

Crankshaft
Shell White Red Red Blue

Colour
Rod
5 5 4 4
Checking the Measured Clearance Marking
Con-rod 38.008 38.018 38.018
38.008
Connecting Rod Big End Bearing/Crankshaft Big End
Journal Clearance 38.000 38.000 38.009 38.009
Bore Dia.
Crankshaft 35.000 34.991 35.000 34.991
Standard - old condition
0.03 6 - 0.066 mm Journal
crankshaft: 34.992 34.984 34.992 34.984
Dia.
Standard - new condition 0.066
0.030 - 0.056 mm Running
crankshaft:
Clearance 0.036
Note: Big End Bearing Selection Chart - New Condition
Crankshaft
If the measured clearance exceeds the service
limit, measure the crankshaft iournal diameter. Shell White Red Red Blue
Colour
Crankshaft Journal Diameter
Rod
5 5 4 4
Standard - old condition Marking
34.984 - 35.000 mm
crankshaft: Con-rod 38.008 38.018 38.018
38.008
Big End
Standard - new condition 38.000 38.000 38.009 38.009
35.002 - 35.018 mm Bore Dia.
crankshaft
Service Limit - old 34.960 mm Crankshaft 35.018 35.009 35.018 35.009
condition crankshaft: Journal
Dia.
35.010 35.002 35.010 35.002
Service Limit: - new 34.978 mm
condition crankshaft: Running 0.056
Clearance 0.030
Note:
For instance on an old condition crankshaft:
If any crankshaft iournal has worn beyond the
service limit, the crankshaft must be replaced. Con-rod Mark .. .. . . . . .. . .... .5
Due to the advanced techniques used during Con-rod Big End Diameter . .... .38.002
manufacture, the crankshaft cannot be Crankshaft Journal Diameter ... . .34.987
reground and no oversize bearings are Required Bearing .. . .. .. . .. ... .Red
available.

Note:
Repeat the measurements for all connecting
rods and their respective crankshaft iournals.
A Caution
It is normal for the bearings selected to differ Always confirm, using the Plastigauge method, that the
from one connecting rod to another. running clearance is correct before final assembly.
Severe engine damage could result from incorrect
3. Install the new bearings in the connecting rod.
clearance.
1. Big end bearings

Crankshaft Main Bearing/Journal Wear
Main Bearing Selection Chart

<all dimensions in mm>
Shell Colour White Red Red Blue Blue Green
Crankcase 41.109 41.109 41.118 41.118 41.127 41.127
Bore 41.101 41.101 41.110 41.110 41.119 41.119
Journal Dia. 37.976 37.968 37.976 37.968 37.976 37.968
37.969 37.960 37.969 37.960 37.969 37.960
Running 0.043 0.044 0.044 0.043 0.043 0.044
Clearance 0.020 0.020 0.020 0.019 0.020 0.020
Minor differences in crankshaft dimensions are Note:

compensated for by using selective bearings. For further
If any iournal has worn beyond the se1Vice
information on bearing part number to colour cross-
limit, the crankshaft must be replaced. Due to
references, see the latest parts microfiche.
the techniques used during manufacture, the
Measure the bearing to crankshaft main journal crankshaft cannot be reground and no oversize
clearance using Plastigauge <Triumph part bearings are available.
number 3880150-T0301) <see page 5-10). Select bearings as follows:
1. Measure and record the diameter of each crankshaft

main bearing journal.
2. Measure and record each main bearing bore
diameter in the crankcase (bearings removed).
Compare the data found with the chart above to select
bearings individually by journal.
For example:
Crankshaft Journal diameter ..... 37.972 mm
Crankcase Bore... . ........... .41.125 mm
Bearing Required .............. Blue
Note:
It is normal for the bearings selected to differ
from one iournal to another.
Checking Crankshaft Journal Clearance using
It is also normal for there to be two options of
Plastigauge
bearing shell colour. In such cases, pick the
shell size which gives the greater running
Crankshaft Main Bearing/Journal Clearance
clearance.
Standard: 0.019 - 0.044 mm
If the clearance exceeds the service limit, measure the
A Caution
Always confirm, using the Plastigauge method, that the
diameter of the crankshaft main journal.
running clearance is correct before final assembly.
Severe engine damage could result from incorrect
Crankshaft Main Journal Diameter
clearance.
Standard: 37.960 - 37.976 mm Crankshaft End Float
Standard 0.05 - 0.20 mm

Note: Note:
Crankshaft end float is controlled by the • If the gudgeon pin is found to be tight in the
tolerances in crankshaft and crankcase piston, check the piston for a witness mark
machining. No thrust washers are used. If caused by the circlip. Carefully remove the
crankshaft end float is outside the specified mark to allow the pin to be removed.
limit, the crankshaft and/or the crankcases 5. Piston rings must be removed from the piston using
must be replaced. hand pressure only.
Pistons Piston Wear Check
1. Measure the piston outside diameter, 5 mm up from

Disassembly the bottom of the piston and at 90° to the direction
Note: of the gudgeon pin.
It is not necessary to remove the connecting

rods from the crankshaft.
1. Remove the cylinder head (see page 3-19).

2. Remove the liner, using tool T3880315 (see
page s-m.
3. Remove the gudgeon pin cirdip from one side of the
piston.
J_
2
T
capt
1. Piston outside diameter

2. Measurement point
3. Circlip removal groove
All Cylinders 78.980 - 78.970 mm

cape
Replace the piston if the measured diameter falls outside
the specified limit.
Removing the Gudgeon Pin Circlip
4. Remove the gudgeon pin by pushing the pin
through the piston and rod toward the side from
which the circlip was removed.
A Caution
Never force the gudgeon pin through the piston. This
may cause damage to the piston which may also
damage the liner when assembled.

Piston Rings/Ring Grooves Piston Ring Gap
Check the pistons for uneven groove wear by visually Note:
inspecting the ring grooves. -
Before final assembly the piston ring gap, when
If all the rings do not fit parallel to the groove upper and
fitted in the liner, must first be checked.
lower surfaces, the piston must be replaced.
Clean the piston ring grooves. 1. Place the piston ring inside the liner.
Fit the piston rings to the pistons. Check, using feeler 2. Push the ring into the top of the cylinder, using the
gauges, for the correct clearance between the ring piston to hold the ring square with the inside of the
grooves and the rings. Replace the piston and rings if bore. Continue to push the ring into the bore until
outside the specified limit. the third groove of the piston is level with the
cylinder top, around full circumference of cylinder.
capg
ccvj
Piston Ring to Ring Groove Clearance Check

Piston ring/Groove Clearance Aligning Piston Rings using the Piston
3. Remove the piston and measure the gap between
Top ring 0.02 - 0.06 mm
the ends of the piston ring using feeler gauges.
Second 0.02 - 0.06 mm Piston Ring End Gap Tolerances
Top 0.28 - 0.49 mm
Second 0.43 - 0.64 mm
Oil Control 0.33 - 0.89 mm
Service Limit 1.03mm
Note:
• If the end gap is too large, replace the piston
rings with a new set.
If the gap remains too large with new piston
rings, both the pistons and barrels must be
replaced.
If the gap is too small, check the cylinder bore
for distortion, replacing as necessary. DO NOT
FILE PISTON RINGS!

Piston Assembly 5. The piston ring gaps must be arranged as shown in
the diagram below.
1. Clean the piston ring grooves and fit the piston rings
to the piston.
•
Note: FRONT
The top ring upper surface is marked 'N' and
can be identified by a chamfer on the inside
edge.
The second ring upper surface is marked '2N'
but is plain on the inside edge and has a bronze
appearance. 3= =3
• The oil control rings can be fitted with either
face upward.
caqj
1. Top ring
2. Second ring
3. Steel oil control rings
4. Oil control ring expander
Note:
• The top ring gap should be positioned in the
7 o'clock position, the second ring gap in the
1 o'clock position and the steel oil control ring
gaps in the 9 & 3 o'clock positions <one in each
position).
6. Fit the piston into the liner using a gentle rocking
motion to engage the rings in the bore.
Piston Ring Identification
Cylinder Wear
1. Fit the piston onto the connecting rod.
Measure the inside diameter of each cylinder using an
Note: internal micrometer or similar accurate measuring
Connecting rods may be fitted either way equipment.
around. However, ensure all three are fitted
the same way.
2. Align the small end in the connecting rod with the
gudgeon pin hole in the piston.
3. Lubricate the piston, small end and gudgeon pin
with clean engine oil and fit the gudgeon pin.
4. Fit new circlips on both sides of the gudgeon pin
ensuring the circlips are correctly fitted in the
grooves.
Failure to use new gudgeon pin circlips could allow the

pin to detach from the piston. This could seize the
engine and lead to an accident

Cylinder Bore Diameter Cylinder Liners

Standard: 79.040 - 79.060 mm
Service Limit: 79.110 mm Removal
gaep ccvi
1. Paint Mark
Test Positions For Bore Wear Check (bore shown in
section> 1. Mark each liner to identify correct orientation and
the cylinder number from which it has been
1. If any reading is outside the specified limits, replace removed.
the liner and piston as an assembly. .
2. Turn the crankshaft until the piston in the liner to be
removed is at the bottom of its stroke.
1. Tool T388031S
2. Extraction nut
3. locking nut
3. Check that the Jocking nut on tool T3880315 is
loose, then fully unscrew the extraction nut.
4. Carefully fit the tool fully into the cylinder bore,
positioning the tool legs on the crankcase. Turn the
locking nut clockwise until the rubber sleeve on the
tool tightly grips the bore of the liner.

5. Check that the tool legs are positioned to allow 4. Fit each liner over the piston using a gentle rocking
withdrawal of the liner, then turn the extraction nut motion to allow compression of the piston rings.
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.
6. Turn the locking nut anticlockwise to release the liner.
Note:
The tool must be used to release the seal
between the liner and the crankcase.
It is not intended that the tool is used to fully
extract the liner. Once the seal is released, the
tool must be removed and the liner extracted
by hand.
Installation CCVI
1. Thoroughly clean the liner removing all traces of old Arrowed: Liner-Piston Fitment
silicone sealer.
Note:
2. Remove all traces of sealer from the crankcase bores.
3. Apply silicone sealer to the liner to crankcase mating
The liners have a large chamfer at the bottom
face. of the bore enabling fitting of the piston
without need for a piston ring compressor.
A Caution
Fit each liner over whichever piston is at TDC. When
turning the 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.
5. Continue fitting each liner in turn until all are fitted

and sealed.
Note:
When the liners have been fitted, they should
ccvk
not be disturbed. If it is necessary to remove
the liner after fitting, the sealer must be re-
1. Liner applied.
2. Sealer area

Crankcase Breather 2. The hose is retained by means of a spring-clip and

protrudes into the sump as shown below.
The upper crankcase is fitted with a labyrinth type
breather system, which requires no maintenance.
However, when assembling the crankcases, ensure that
the breather hose is not damaged and is securely fitted to
the breather as follows:
1. Push the hose fully on to the breather outlet.
cddd


6 Balancer
Table of Contents
Exploded View - Balancer Shaft. .................................................... . ........ 6.2
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

Balancer
Exploded View - Balancer Shaft
60Nm ()~6)
~

Balancer
Balancer 5. To strip the backlash eliminator from the drive gear,

release the circlip and remove the wave-washer,
The balancer is fitted to control 'pulsing' within the engine. backlash gear and spring.
Without any form of balancer, the engine would 'pulse'
each time the crankshaft rotated. This 'pulsing' would be
felt as a vibration which would amplify as the engine
speed was increased.
The balancer has the effect of a pair of counterbalance
weights which create an equal amount of energy in the
opposite direction, and at the same time as that produced
by the crankshaft, pistons and connecting rods. Because
the opposing pulses occur at the same point of crankshaft
rotation, and are of an equal magnitude, a state of
equilibrium or balance is reached.
Removal
1. Separate the crankcase halves (see page 5-4}. kajq
2. With the crankcase halves separated, lift out the

balancer shaft complete with the shaft 1. Wave washer
bearings/circlips. 2. Circlip
Note:
Inspection
As the shaft is released from the crankcase, the
backlash eliminator gear will spring out of 1. Inspect all gears for chipped or missing teeth.
alignment with the crankshaft.
2. Inspect all bearings for signs of overheating
3. To remove the left hand bearing, slide the bearing, (blue discolouration), seized or damaged rollers, and
cirdip and bearing sleeve from the balancer shaft. any other damage.
4. To remove the right hand bearing, remove the bolt 3. Inspect the backlash spring for deformities, damage
and slide the circlip, bearing race and inner ring from etc.
the shaft.
4. Inspect the gear teeth for overheating <blue
discolouration).
A Caution Note:
When removing the circlip, always ensure that the area Signs of blue discolouration on the gear centre
where the breather seal runs does not become are due to the manufacturing process and must
scratched or damaged. A damaged seal track will cause be disregarded.
oil to be ejected from the engine.

Balancer
Assembly/Installation Note:
Prior to installation in the crankcase, it is
1. If the backlash gear was disassembled, fit the
essential that the markings on the backlash
backlash spring to the balancer drive gear,
eliminator and drive gears are brought into
positioning the spring ends on either side of the peg.
alignment against the tension of the spring.
2. Fit the backlash gear, ensuring its peg is located This will facilitate correct positioning of the
clockwise of the balancer gear peg and also between balancer in relation to the crankshaft when
the spring ends. both are installed in the crankcase.
3. Fit the wave washer and secure all components in
position with the circlip.
0
1. Backlash gear line
:alt>
2. Drive gear dot
1. Wave washer 8. Using tool T3880016, bring the backlash and drive
2. Circlip gear marks into alignment against the backlash
4. Lubricate and fit the right hand bearing and circlip to spring.
the shaft. Note:
5. Apply ThreeBond TB 1305 locking compound to the
threads of the balancer bearing bolt
When in alignment, the line on the backlash
gear must be located directly above the drive
6. Fit the bolt and tighten to 60 Nm. gear tooth marked with a dot.
7. Lubricate and fit the left hand bearing and circlip. Since the drive gear dot cannot be seen when
the backlash gear is in alignment, always mark
the dot-marked gear tooth with chalk in order
that it can always be identified.

Balancer
9. Secure the backlash gear in position with the fixture

supplied with the tool by placing the fixture pegs
across two gear teeth (ensure that the fixture will not A Caution
be in the way when assembling the balancer to the
If the balancer and crankshaft are not correctly aligned,
crankshaft).
severe engine vibration will occur leading to damage to
components.
kajs
1. Tool T3880016
2. Securing fixture
1. Circlips
10. With the drive and backlash eliminator gears still
2. Crankcase circlip grooves
correctly aligned, locate the balancer to the
crankcase aligning the balancer gears and crankshaft 11. Remove the securing fixture.
as shown in the illustration below, while ensuring 12. Check that the balancer and crankshaft are correctly
that the bearing circlips locate correctly in their aligned before continuing to assemble the crankcase
corresponding grooves in the crankcase. halves.
1. Balancer backlash and drive gear markings

2. Crankshaft markings

Balancer

7 Transmission
Table of Contents
Exploded View - Input and Output Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Exploded View - Sprag Clutch and Starter Gears - up to Engine Number 487366 . . . . . . . . . . . . . . . . . . . 7.3
Exploded View - Sprag Clutch and Starter Gears - from Engine number 487367 to 491323 . . . . . . . . . . . 7.4
Exploded View - Sprag Clutch and Starter Gears - from Engine number 491324 to 496387... ... . .... 7.5
Exploded View - Sprag Clutch and Starter Gears - from Engine Number 496388 . . . . . . . . . . . . . . . . . . . 7.6
Exploded View- Gear Selectors and Drum .................................... ....... ......... 7.7
Exploded View - Gear Change Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
Selector Shaft, Selector Forks and Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Input and Output Shafts Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Removal...... ........ ..... .......................................................... . 7.14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Input Shaft... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Exploded View - Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
Exploded View - Output Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
Starter Drive Gears/Sprag Clutch - up to Engine Number 487366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
Removal. .... ........ ... .... ....... . ... .............. . ....... . .... ................. .. 7.24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
Starter Drive Gears/Sprag Clutch - from Engine Number 487367 to Engine Number 491323 . . . . . . . . 7.27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
Starter Drive Gears/Sprag Clutch - from Engine Number 491324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32

Transmission
Exploded y·1ew - lnput and 0 utput Shafts
132 Nm
r\a~
( --\})
~ /////
//////
0
AJ
~~
L///////: / ~~rcoOfiJ
®·~·~
7.2 serv1ce
. Manual - Speed Triple and Speed Triple R
Transmission
Exploded View - Sprag Clutch and Starter Gears - up to Engine

Number 487366
54Nm

Transmission
Exploded View - Sprag Clutch and Starter Gears - from Engine

Number 487367 to 491323
54Nm

Transmission

Number 491324 to 496387
54Nm

Transmission

Number 496388
~6/
/ -1
i
i
~ i
!
/
_/ -
/
/
_/ ~~
/
/ '
/
~ ~~
I © ~
~/~
54Nm
abgq

Transmission
Exploded View - Gear Selectors and Drum
()~ ~
12 Nm
10Nm
12Nm

Transmission
Exploded View - Gear Change Mechanism
22 Nm
y
~
CC@6
, ____ 9Nm
/
/
/
/
-
/
~
/
/
/
~~
/ ~6>
1'
/
/
23 Nm

Transmission
Selector Shaft, Selector Forks and Note:
Drum The centre selector fork locates in the selector

drum as shown below:
Removal
1. Remove the engine from the frame (see page 9-2>.

2. Separate the two halves of the crankcase
(see page 5-4).
3. Remove the input and output shafts from the
crankcase <see page 7-14>.
4. Remove the fixing and take out the U-shaped
keeper plate from the selector shaft. Discard the
fixing.
1. Selector fork stop

2. Selector fork guide
3. Selector drum
5. Using a suitable tool, push the selector shaft out
from the crankcase in the direction of the keeper
plate. Collect each selector fork as they are released
by the selector shaft.
6. If not already removed, note the position and
orientation of the gear pedal crank in relation to the
shaft, then remove the pedal.
7. Remove the E-clip and washer from the gear pedal
1. Fixing end of the gear change shaft.
2. Keeper plate
3. Selector shaft
A Caution
The selector forks can be fitted incorrectly. Ensure the 1
position and orientation of the selector forks are marked
prior to removal. Incorrect fitting of the selector forks will
cause gearbox damage.
1. Gear change shaft

2. E-clip
3. Washer

Transmission
8. Withdraw the gear change shaft from the clutch end
of the crankcase and collect the washer from inside
the crankcase. A Caution
Take care to avoid damaging the oil pressure relief valve
when inserting a stout rod into the selector drum. A
damaged oil pressure relief valve may lead to oil
pressure loss and could resu lt in engine damage.
Note:
To prevent drum rotation, use a stout rod
through one of the through-holes in the drum.
Care must be taken not to damage the oil
pressure relief valve.
11. Remove the fixing from the centre of the detent
wheel {discard the fixing) and withdraw the wheel.
12. Release and remove the bolt securing the selector
drum bearing to the crankcase. Discard the bolt.
=gwj
Z. Washer
Note:
The detent arm is held in position under spring
pressure. Prior to removal, note the orientation
of the detent arm, fixing, spring and washer.
The same orientation must be retained on
assembly.
1. Bolt
13. Ease the selector drum backwards and forwards to

push the drum bearing out of the crankcase.
14. Withdraw the drum from within the crankcase.
1. Washer
2. Detent arm
3.Spring
4. Fixing
9. Release and remove the fixing securing the detent

arm.
10. Withdraw the detent arm complete with its spring
and washer. Un-hook the spring from the bearing
keeper plate as the detent arm is withdrawn. Discard
the fixing.
Selector Drum Removal

Transmission
Inspection Installation
Note:
1. Examine all components for damage and/or wear,
paying particular attention to the selector forks and The detent wheel is keyed to the selector
selector drum. Replace any parts that are damaged drum.
and/or worn.
1. Position the selector drum into the crankcase.
Gear Selector Fork Thickness

Gear Selector Groove Width

Selector Fork to Groove Clearance
I 0.55 mm max.
2. Examine the gear change shaft seal for damage
and/or wear. Replace the seal if damaged and/or
worn.
Locating the Selector Drum
2. Using clean engine oil, lubricate the selector drum
bearing.
3. Position the bearing into the crankcase recess and
engage with the selector drum.
4. Refit the bearing retainer. Secure with a new bolt
and tighten to 12 Nm.
1. Bearing retaining bolt
5. Fit the detent wheel engaging the wheel with the

locator pin in the selector drum. Tighten a new fixing
to 12 Nm.

Transmission
6. Assemble the detent arm as noted on removal and 11. Feed the washer onto the shaft and insert the gear
place up to the crankcase. change shaft into the crankcase. Gently push the
gear pedal end of the shaft through the bearing and
seal located, at the gear pedal end, in the crankcase.
1. Washer
2. Detent arm :gwj
3.Spring 1. Gearchange shaft

4. Fixing 2. Washer
7. Hold the detent arm assembly in position and fit a 12. Ensure that the gear change shaft locates in the
new fixing. Start the thread and push the detent arm, detent wheel and that the spring fits over the
using finger pressure, to locate on the detent wheel. abutment bolt
Ensure the detent arm remains correctiy located on
the detent wheel. Tighten the capscrew to 12 Nm.
8. Rotate the selector drum and ensure a smooth
movement. Rectify as necessary.
9. Using clean engine oil, lubricate the bearing and lip
of the seal on the gear change shaft.
10. Lubricate, with a 50/50 solution of engine oil and
molybdenum disulphide grease, both sides of the
fingers of the selector mechanism on the gear
change shaft.
A. Caution
Take care to avoid damaging the lip of the seal when
clao_1
inserting the gear change shaft into the crankcase. A
damaged seal will lead to oil loss and could result in 1. Gear change shaft
engine damage. 2. Detent ann
3. Abutment bolt
4.Spring

Transmission
13. Fit the large washer and E-clip to the gear pedal end lZ Push the selector shaft into the crankcase from the
of the gear change shaft. keeper plate end. As the shaft is inserted locate the
selector forks and also fit a new 0-ring CO-ring
located at the keeper plate end>. Ensure the forks are
fitted in the positions noted during removal.
3
2. E-clip
3. Washer
1. 0-ring
14. Fit the gear pedal crank to the shaft in the same
orientation as noted prior to removal. Tighten the Note:
fixing to 9 Nm.
The centre selector fork locates in the selector
15. Position the selector drum in the neutral position. drum as shown below:
16. Check that the detent arm locates in the raised
profile in the detent wheel (neutral position).
1. Selector fork stop

2. Selector fork guide
1. Raised profile 3. Selector drum
2. Detent arm
18. Fit the U-shaped keeper plate.
19. Fit a new capscrew, and tighten to 12 Nm.
A Caution 20. Fit the input and output shafts (see page 7-14>.
The selector forks can be fitted incorrectly. Ensure the

position and orientation of the selector forks are the
same as noted during removal. Incorrect fitting of the
selector forks will cause gearbox damage when
changing gear.

Transmission
Input and Output Shafts Assemblies 4. Ensure the dowel in the output shaft needle roller
bearing is positioned to locate in the hole provided
in the upper crankcase.
Removal

2. Separate the two halves of the crankcase <see
page 5-4).
3. Remove the fixings and the input shaft bearing
retainer. Discard the fixings.
cdqj_1
1. Roller bearing
2. Dowel
5. Place the input shaft in position in the crankcase.

6. Fit the input shaft bearing retainer with the 'OUT'
mark facing outwards. Fit new fixings but do not
tighten at this stage.
2. Bearing retainer
3. Fixings
4. Lift the input and output shaft assemblies out of the
upper crankcase.
Installation
1. Place the output shaft in position in the crankcase.

2. Ensure the bearing retaining ring locates in the
groove provided in the crankcase.
3. Ensure the output shaft seal aligns with its recess in
the crankcase.
1. Input shaft
2. Bearing retainer
3. Fixings
4. 'our mark
Z Assemble the two halves of the crankcase <see
page 5-4>.
8. Fit the input shaft bearing retainer and tighten the
new fixings to 12 Nm.
J
9. Refit the engine to the frame <see page 9-3).
1. Groove in crankcase
2. Retaining ring
3. Seal
4. Bearing

Transmission
Input Shaft
Disassembly
When using a press, always wear overalls, eye, face and
Note: hand protection. Objects such as bearings frequently
break up under load and the debris caused during
The numbers in brackets in the following text
break-up may cause damage and injury to unprotected
refer to the exploded view on page 7- 16.
parts of the body.
Working from the opposite end to where the clutch
Never wear loose clothing which could become trapped
assembly is fitted, dismantle the input shaft as follows:
in the press and cause crushing injury to the hand, arms
or other parts of the anatomy.
1. Remove the pegged bearing sleeve (1) from the end
of the shaft.
2.
3.
Slide off the
washer rn.
needle
Remove second gear (4).

bearing (2) and thrust
+
4. Remove sixth gear (5), complete with the splined
bush (6) which runs inside the gear.
5. Remove the thrust washer (7) from in front of the
circlip between sixth and third/fourth gear.
6. Remove the circlip (8) from the shaft.
7. Slide off the combined third/fourth gear (9).
8. Remove the circlip (10) from in front of fifth gear.
9. Remove the thrust washer (11) adjacent to fifth gear.
10. Remove fifth gear (12). ccsh
11. Place the shaft in a press with the input shaft bearing
supported on press bars and the clutch end of the
Pressing Off the Input Shaft Bearing
shaft facing the press ram. Protect the shaft thread
with a thread protector or similar and press the shaft
through the bearing.

Transmission
Exploded View - Input Shaft
~-1
I
I
I
1
8--2
I
I
0-3
5
13
I
I
14--~ ','
I
9
15~ I
v
I
16
I
I
0--10
I
I 0--_11
12
I
I
'- I
I
ccsa_2
1. Bearing Sleeve 9. Third/Fourth Gear

2. Needle Roller Bearing 10.Circlip
3. Thrust Washer 11. Thrust Washer
4. Second Gear 12.Fifth Gear
5. Sixth Gear 13.lnput Shaft
6. Splined Bush 14.lnput Shaft Bearing
7. Thrust Washer 15.Bearing retainer
8. Circlip 16.Screws

Transmission
Assembly 5. Fit a new circlip (10) to the input shaft ensuring that
the clip is located in the circlip groove.
Note:
Lubricate each gear and bush with clean engine
oil during assembly.
Examine all gears, bearings and sleeves for
damage, chipped teeth and wear beyond the
service limits. Replace all suspect components
and always use new circlips to assemble the
shaft.
refer to the exploded view on page 7- 16.
1. Place the input shaft bearing on press bars ensuring

the inner race of the bearing is supported by the
bars and the circlip groove is pointing upwards.
ccwb
2. Position the mainshaft to the bearing with the clutch
end pointing downwards through the bearing. Press
1. Fifth gear
the shaft through the bearing until the bearing
2. Thrust washer
comes into contact with the fixed gear on the shaft.
3. Circlip
~~!~~:;-"'· .....·.~-~~~~ 6. Fit the combined third/fourth gear (9) with the larger
1·;_ ...- ! \ .\ ~i!fi1xmtG·1, .-_ . = ·- ·-~/~·. ~ gear facing towards fifth gear. Ensure that the oil hole
in the input shaft DOES NOT align with the oil hole
When using a press, always wear overalls, eye, face and in the gear.
hand protection. Obiects such as bearings frequently
break up under load and the debris caused during
break-up may cause damage and iniury to unprotected
parts of the body.
Never wear loose clothing which could become trapped If the oil hole in the third/fourth gear is aligned with the
in the press and cause crushing injury to the hand, arms corresponding hole in the input shaft, engine oil
or other parts of the anatomy. pressure and gear lubrication will be reduced_
Reduced oil pressure and gear lubrication will cause
engine damage and could also lead to engine seizure
ccsi
Pressing On the Input Shaft Bearing

3. Fit fifth gear (12) to the input shaft with the dog teeth
pointing away from the input shaft bearing.
4. Slide on the thrust washer (11 ).

Transmission
Z Fit a new circlip (8) to the input shaft ensuring that 11. Fit second gear (4) with the stepped side facing away
the circlip is located in the circlip groove. from the clutch end. of the input shaft.
12. Fit the thrust washer (4) adiacent to second gear and
slide on the needle roller bearing m.
1. Third/fourth gear
ccvq
2. Thrust washer
3. Circlip 1. Second gear
8. Fit the thrust washer (7) to the input shaft and slide 2. Thrust washer
up the shaft until in contact with the circlip. 13. Finally, fit the bearing sleeve (1) to the needle roller
9. Fit the splined bush (6) from sixth gear ensuring that bearing.
the oil hole in the shaft DOES NOT align with the
hole in the bush. ·
10. Fit sixth gear (5) with the dog teeth facing
third/fourth gear.
ccvz
1. Sixth gear
2. Splined bush

Transmission
Output Shaft 12. Remove thrust washer (17) and slide off second gear
(18).
Working from the opposite end to the drive sprocket, 13. Position the output shaft C19) in a vice with soft jaws
dismantle the output shaft as follows. fitted. Tighten the vice to prevent the shaft from
turning and release the lock tab (21) from the output
Disassembly sprocket nut (20), then release the nut.
14. Remove the transmission sprocket nut (20), locktab
Note:
(21) and sprocket (22).
The numbers in brackets in the following text 15. Collect the oil seal C24) and retaining ring C23).
refer to the exploded view on page 7-20.
16. If it is necessary to replace the large bearing (25) at
the end of the shaft, use a press to remove both the
1. Remove the output shaft bearing sleeve (1), needle
bearing and output shaft sprocket sleeve together.
roller bearing (2) and hardened thrust washer (3).
2. Mark one side of first gear to denote its correct
orientation. Remove first gear (4) from the shaft.
3. Remove the first gear bearing and thrust washer
(5 and 6).
When removing the output shaft bearing, always wear
4. Slide fifth gear (7) from the shaft overalls, eye, face and hand protection. The bearing
5. Remove the circlip (8) from in front of the third gear. races are hardened and are liable to splinter if broken.
6. Remove the splined thrust washer (9) from the shaft. Debris from broken bearings could cause injury to eyes,
face and any unprotected parts of the body.
Z Remove the fourth gear C1D>.
8. Slide third gear (11) off the shaft and also remove the
splined bush (12) and thrust washer (13).
9. Remove the cirdip (14) from in front ·of sixth gear.
10. Remove sixth gear (15) from the shaft.
11. Remove the circlip (16) from in front of second gear.

Transmission
Exploded View - Output Shaft
----15 ~ 14
~------------- 13
or
Qr 11
ie---------12
0-10
0--9
Q--a
~7
tQ)-- 6
e-s
18-0
17 ---------0
e--4 ~- 3
16 -----0 --2
cssb_1
~-- 1
---
1. Bearing Sleeve 14.Circlip
2. Needle Roller Bearing 15.Sixth Gear
3. Thrust Washer 16.Circlip
4. First Gear 17. Thrust washer
S. Needle Roller Bearing 18.Second Gear
6. Thrust Washer 19.0utput Shaft
7. Fifth Gear 20.Nut
8. Circlip 21.Locktab
9. Thrust Washer 22.0utput Sprocket
10.Third Gear 23.Retaining Ring
11. Fourth Gear 24.0il Seal
12.Third Gear Bush 25.Bearing
13.Thrust Washer 26.Sleeve
7.20 Sesvice Manual - Speed Triple and Speed Triple R

Transmission
Assembly 5. Locate the second gear (18) to the shaft with the
large step side facing away from the output sprocket
Note:
end. Fit the thrust washer (17) and retain with a new
Lubricate each gear and bush with clean engine circlip ( 16).
oil during assembly.
Examine all gears, bearings and sleeves for
damage, chipped teeth and wear beyond the
service limits. Replace all suspect components
and always use new cirdips to assemble the
shaft.
refer to the exploded view on page 7-20.
1. Working from the output sprocket end of the shaft,

fit a new bearing (25) and new sleeve (26) to the
shaft using a press and press bars. Fit the sleeve with
the large chamfer facing outwards.
2. Fit the retaining ring (23) to the shaft. Lubricate and
fit a new oil seal (24). ccww
1. Second gear
2. Thrust washer
3. Circlip
6. Fit sixth gear (15) with the selector fork groove facing
away from the output sprocket end. Ensure that the
+ oil holes in the gear DO NOT align with the
corresponding oil hole in the output shaft.
If the oil holes in the sixth gear are aligned with the
corresponding hole in the output shaft, engine oil
ccsj
pressure and gear lubrication will be reduced.
3. Transfer the shaft to the vice and secure between soft engine damage and could also lead to engine seizure
jaws. Fit the sprocket (22), locktab (21) and nut (20>. resulting in loss of motorcycle control and an accident.
Tighten the nut to 13 2 Nm. Close the lock tab.
4. Withdraw the shaft from the vice and continue to
assemble from the opposite end to the output
sprocket.

Transmission
7. Fit a new circlip (14} to retain sixth gear. 9. Fit third gear (10> with the larger step side facing
away from the output sprocket.
10. Fit the thrust washer (9) and retain with a new
circlip (8).
ccvp
1. Sixth gear
2. Thrust washer
3. Circlip ccwe
8. Fit the thrust washer (13} to the rear of fourth gear. 1. Fourth gear
Fit the splined sleeve (12) for fourth gear, ensuring 2. Thrust washer
that the oil hole in the shaft DOES NOT align with 3. Circlip
the hole in the bush. Fit fourth gear (11) to the shaft 11. Fit the fifth gear (7) to the shaft with the selector fork
with the large step side facing towards the output groove facing towards the output sprocket Ensure
sprocket. that the oil holes in the gear DO NOT align with the
corresponding oil hole in the output shaft.
1 If the oil holes in the fifth gear are aligned with the
corresponding hole in the input shaft, engine oil
pressure and gear lubrication will be reduced.
engine damage and could also lead to engine seizure
ccwd
1. Third gear
2. Thrust washer

Transmission
12. Fit the first gear thrust washer and bearing (5 and 6). Starter Drive Gears/Sprag Clutch -
up to Engine Number 487366
A starter system parts kit (see parts catalogue for part
number) is available if any one of the following items
shown below need replacement.
6"'- - - - -- -- -- --:.7
1. Fifth gear
2. Thrust washer
3. Bearing
13. Fit first gear (4) to the shaft as marked during
disassembly.
1. Starter motor cover
2. Starter motor
3. Gear idler, 14/71 teeth
4. Right hand crankcase
S. Gear idler, 16/18 teeth
6. Hub and gear, 51 teeth
7. Needle roller bearing, sprag clutch
8. Sprag clutch
Note:
If the starter system parts kit is to be fitted, the
items indicated above, gaskets and the items
indicated below must be discarded when
removed.
- - - - - - - - - - - -;;
1. First gear
2. Thrust washer
14. Finally fit the thrust washer (3), needle roller bearing
(2)and bearing cap (1) to the end of the shaft.
1. Wave washer
2. Washer
3. Needle roller bearing
If the original components are to be refitted,
non of the components should be discarded.

Transmission
Removal 4. Withdraw the large starter idler gear noting the fitted
position of all components.
from the fuel tank.
1. Idler shaft
2. Wave washer
1. Front panel 3. Flat washer
2. Fixings 4. Idler gear
5. Bearing
2. Disconnect the battery, negative (black> lead first.
6. Flat washer
3. Remove the starter cover.
5. Remove the bolts securing the right hand crankshaft
cover.
Note:
There are two bolts located inside the cover in
the area behind the starter idler gear.
1. Starter cover
~ kajl
1. Right hand crankshaft cover

Transmission
6. Ease the cover from the crankcase and collect the 8. Slide the sprag clutch and gear from the crankshaft.
starter idler gear and wave washer, if fitted, again 9. Separate the sprag clutch, bearing and gear from
noting the position of all components. each other.
1. Idler shaft 1. Needle roller bearing

2. Starter idler gear 2. Sprag clutch and gear
3. Wave washer, up to Engine Number 496387 3. Plain washer
Z Using tool T3880017, prevent the sprag from 10. Recover the washer from the end of the crankshaft.
turning and remove the sprag fixing and washer
from the end of the cranksha~ Discard the fixing.
Inspection
1. Examine the sprag clutch for signs of slipping,

overheating (going blue) and for any other damage.
2. Examine all gears for chipped teeth, overheating
(going blue> and for any other damage.
3. Examine all bearings for chipped, broken or seized
rollers, overheating (going blue> and for any other
damage.
4. Examine the end of the crankshaft for damage.
kajk
1. Tool T3880017
2. Sprag fixing

Transmission
Installation 9. Tighten the cover bolts to 8 Nm.
Note:
To fit the starter system parts kit, see Starter
Drive Gears/Sprag Clutch - from Engine
Number 491324 on page 7-32.
If the original components are to be fitted,
continue from step 1.
1. Fit the sprag's washer to the crankshaft.

2. Assemble the needle roller bearing and sprag gear
to the sprag clutch.
3. Locate the sprag clutch assembly to the crankshaft.
Note:
The sprag clutch will only fit with the ~ ka]I
crankshaft when the master splines on both 1. Right hand crankshaft cover
components are aligned.
10. Lubricate then refit the large starter idler gear
ensuring that all components are located in the
positions noted on removal.
1. Sprag clutch
2. Crankshaft end
4. Prevent the sprag from turning using tool T3880017 1. Idler shaft
then fit and tighten a new sprag fixing and washer to 2. Wave washer
54Nm. 3. Rat washer
5. Lubricate the idler gear sha~ 4. Gear
Note: S. Bearing
6. Rat Washer
If a new starter idler gear is to be fitted, do not
fit the wave washer. 11. Thoroughly clean the starter cover..
If the original starter idler gear with a wave 12. Position a new gasket to the dowels then refit the
washer is to be fitted, the wave washer must starter cover.
also be fitted. 13. Fit and tighten the cover bolts to 8 Nm.
6. Fit the starter idler gear, shaft and wave washer, if 14. Reconnect the battery, positive <red) lead first
required (washer to the outside of the gear) to the 15. Refit the front panel to the fuel tank and tighten the
crankcase. fixings to 2 Nm.
Z Thoroughly clean the right hand crankshaft cover.
8. Position a new gasket to the crankcase dowels then
refit the right hand crankshaft cover.

Transmission
Starter Drive Gears/Sprag Clutch - Removal

from Engine Number 487367 to 1. Release the three fixings and remove the front panel
Engine Number 491323 from the fuel tank.
A sprag clutch parts kit (see parts catalogue for part

number) is available if any one of the following items
shown below need replacement.
1. Front panel
2. Fixings
2. Disconnect the battery, negative (black) lead first.
1. Sprag clutch 3. Remove the starter cover.
2. Needle roller bearing, sprag clutch
3. Hub and gear, 51 teeth
4. Wave washer
Note:
If the starter system parts kit is to be fitted, the
above items and those shown below must be
discarded when removed.
2. Fixings
1. Wave washer
2. Gear idler, 16/18 teeth
If the original components are to be refitted,
non of the components should be discarded.

Transmission
4. Withdraw the large starter idler gear noting the fitted Z Using tool T3880017, prevent the sprag from
position of all components. turning and remove the sprag fixing and washer
from the end of the crankshaft. Discard the fixing.
chjb kajk
1. Idler shaft
2. Idler gear 1. Tool T3880017
2. Sprag fixing
cover. 8. Slide the sprag clutch and gear from the crankshaft.
Note: 9. Separate the sprag clutch, bearing and gear from
each other:
There are two bolts located inside the cover in
the area behind the starter idler gear.
6. Ease the cover from the crankcase and collect the
starter idler gear and wave washer, if fitted, again
noting the position of all components.

2. Sprag clutch and gear
3. Plain washer
to. Recover the washer from the end of the crankshaft.

chja
1. Right hand crankshaft cover

2. Fixings

Transmission
Installation 6. Fit the starter idler gear, shaft and wave washer, if
required (washer to the outside of the gear) to the
Note:
crankcase.
To fit the sprag clutch parts kit, see Starter
Drive Gears/Sprag Clutch - from Engine
Number 491324 on page 7-32.
If the original components are to be fitted,

2. Assemble the needle roller bearing and sprag gear
to the sprag clutch.
Note:
The sprag clutch will only fit with the
crankshaft when the master splines on both
1. Idler shaft
2. Starter idler gear
3. Sprag clutch
8. Position a new gasket to the crankcase dowels then
refit the right hand crankshaft cover.
Note:
The right hand crankshaft cover fixings 1 and 2
are torqued twice as 14 and 15 respectively.
9. Tighten the cover bolts to 8 Nm in the sequence
shown below.
1. Sprag clutch
2. Crankshaft end
4. Prevent the sprag from turning using tool T38800l7
then fit and tighten a new sprag fixing and washer to
54Nm.
5. Lubricate the idler gear shaft.
Note:
fit the wave washer.
If the original starter idler gear is to be fitted,
the wave washer must be fitted.

Transmission
10. ensuring
Lubricate then refit th
that all c e large starter idler gear Starter Drive Gears/S
from Engine N prag Clutch -
positions noted on r~~~~:i~nts are located in the umber 491324
Removal
1. Release the three fi1xings

. and
rom the fuel tank remove the front panel
f
11. Thoroughly clean the starter

12. Position cover.
a new gasket to th e dowels then refit the
starter cover.
1. Front panel
Note: 2. Fixings
2.
3.
13.
14.
15.
7.30 Service Ma nua 1- Speed Tnp

· Ie and Speed Triple R
Transmission
4. Withdraw the large starter idler gear noting the fitted Z Using tool T3880017, prevent the sprag from
position of all components. turning and remove the sprag fixing and washer
from the end of the crankshaft. Discard the fixing.
chjb kajk
1. Idler shaft
2. Idler gear 1. Tool T3880017
2. Sprag fixing
cover. 8. Slide the sprag clutch and gear from the crankshaft.
Note: Note:
There are two bolts located inside the cover in Note the fitted condition of the components
the area behind the starter idler gear. for installation.
6. Ease the cover from the crankcase and collect the 9. Separate the sprag clutch, bearing and gear from
starter idler gear and wave washer, if fitted, again each other.
noting the position of all components.
chja 1. Washer
1. Right hand crankshaft cover 2. Bearing
2. Fixings 3. Gear
4. Retainer ring
S. Sprag clutch
6. Sprag clutch housing
10. Recover the washer from the end of the crankshaft.

Transmission
Installation Note:
fit the wave washer.
2. Assemble the sprag clutch, bearing and gear as If the original starter idler gear is to be fitted,
noted for removal. the wave washer must be fitted
6. Fit the starter idler gear, shaft and wave washer, if
required (washer to the outside of the gear) to the
crankcase.
1. Washer
2. Bearing
3. Gear
4. Retainer ring
1. Idler shaft
5. Sprag clutch
2. Starter idler gear
6. Sprag clutch housing
3. Sprag clutch
Note: 8. Position a new gasket to the crankcase dowels then
The sprag clutch will only fit with the refit the right hand crankshaft cover.
crankshaft when the master splines on both Note:
The right hand crankshaft cover fixings 1 and 2
are torqued twice as 14 and 15 respectively.
9. Tighten the cover bolts to 8 Nm in the sequence
shown below.
1. Sprag clutch
2. Crankshaft end
4. Prevent the sprag from turning using tool T3880017
then fit and tighten a new sprag fixing and washer to
54Nm.
5. Lubricate the idler gear shaft

Transmission
10. Lubricate then refit the large starter idler gear 13. Fit and tighten the cover bolts to 8 Nm in the
ensuring that all components are located in the sequence shown below.
positions noted on removal.
chjb
1. Idler shaft
14. Reconnect the battery, positive <red) lead first.
2. Gear
15. Refit the front panel to the fuel tank and tighten the
11. Thoroughly clean the starter cover. fixings to 2 Nm.
12. Position a new gasket to the dowels then refit the
starter cover.
Note:
The starter cover fixings 1 and 2 are torqued
twice as 6 and 7 respectively.

Transmission

8 Lubrication
Table of Contents
Exploded View - Sump. ............... .. .............. .. ........ . .................... ... ... 8.2
Exploded View - Oil Pump and Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Exploded View - Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Engine Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Engine Oil Circuit Description... ................. .. ......... . .. . . . ... .. ... ... ............... 8.6
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
Triumph Engine Oil ......... ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
Oil Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. 7
Oil and Oil Filter Change..... .......... .. .. ... .... .. ..... . ... ....... .. . .. ....... . ... .... ... 8.7
Disposal of Used Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
Removal ... . ... . ............................. .. ............................... .. ...... 8.9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
Low Oil Pressure Warning Light Switch..... .. ... ... ........ .......................... .. .. . .. 8.12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Sump .. ................... ..... ........................ . ......... . .................... . 8.13
Removal ... .. ........ . ....... .. .. .. ......... . .... . .................. . .. .. .. . . .. ...... . 8.13
Inspection.. .. . .......................... .. .. .. ..... .. ......... . ..... .. ......... . . ... .. 8.13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
Inspection.. .. . ..... .. . ... ... ................... . .... .. ........ ..... ................... 8.15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15

Lubrication
Exploded View - Sump

Lubrication
Exploded View - Oil Pump and Gears
15 Nm
Apply ThreeBond 1305

to the threads
12Nm
12 Nm
15 Nm

Lubrication
Exploded View - Oil Cooler
. I
' j
9Nm
9Nm
v

Lubrication
Engine Oil Circuit
Alternator Cooling Jet
r .......
~u a
l©I=
@=
H~ ~H __,
'-

Lubrication
Engine Oil Circuit Description Engine Oil

Oil is collected from the sump and is drawn through a
mesh strainer into the oil pump rotor. The oil pump is Specification
fitted with a single pumping rotor which supplies
Use semi or fully synthetic 10 W/40 or 15 W/50
pressurised oil to the lubrication circuit and the oil cooler.
motorcycle engine oil which meets specification API SH
Pressurised oil is delivered to the outside rim of the oil (or higher) and JASO MA, such as Castro! Power 1
filter near to where the oil pressure relief valve is fitted. Racing 4T, sold as Castrol Power RS Racing 4T in some
The relief valve is set to open at 75 lb/in 2 and when open, countries.
returns high pressure oil direct to the sump.
Filtered oil is then fed via the remote oil cooler (mounted
beneath the radiator) into the lower crankcase gallery and
from here is distributed around the engine:
A Caution
Triumph high performance fuel injected engines are
Cooled oil is fed to the main gallery located designed to use semi or fully synthetic motorcycle
under the crankshaft. Here it is delivered to the engine oil which meets specification API SH (or higher)
crankshaft main bearings and, via drillings in AND JASO MA
the crankshaft, to the big end bearings.
Do not add any chemical additives to the engine oil. The
Spray jets located in the upper crankcase, behind the engine oil also lubricates the clutch and any additives
main bearing shells, lubricate the pistons and could cause the clutch to slip.
connecting rod small ends. These jets are fed oil Do not use mineral, vegetable, non-detergent oil, castor
from the crankshaft oil feed. based oils or any oil not conforming to the required
Some oil is sent directly to the cylinder head via specification. The use of these oils may cause instant,
a drilling in the upper crankcase and an severe engine damage.
external link pipe. A low oil pressure warning Ensure no foreign matter enters the crankcase during an
light switch is located at the crankcase end of oil change or top-up.
the link pipe.
Oil that arrives at the cylinder head is fed to Triumph Engine Oil
both camshafts via a gallery in the cylinder
head casting that delivers oil directly to the Your Triumph Motorcycle is a quality engineered product
sprocket end camshaft bearings. Oil is then fed which has been carefully built and tested to exacting
through the hollow camshafts to the other standards. Triumph Motorcycles are keen to ensure that
camshaft bearings, the tappet buckets and the you enjoy optimum performance from your machine and
valves. with this objective in mind have tested many of the
engine lubricants currently available to the limits of their
Oil is fed to the gearbox via internal oil pipes
performance.
and drillings that supply oil directly to the end
of each sha~ Oil is circulated along the Castro! Power 1 Racing 4T (sold as Castrol Power RS
gearbox shafts to exit holes that feed directly to Racing 4T in some countries) consistently performed well
the bearings, gears and selectors. during our tests and has become our primary
recommendation for the lubrication of all current Triumph
Oil is fed to the alternator to aid cooling. The oil motorcycle engines.
is taken from the crankshaft oil feed and
Castro! Power 1 Racing 4T (sold as Castro! Power RS
directed to the alternator via a drilling in the
Racing 4T in some countries>, specially filled for Triumph,
alternator bolt.
is available from your authorised Triumph dealer..

Lubrication
Oil Level Inspection 3. With the motorcycle upright, remove the filler
plug/dipstick, wipe the blade clean and screw it fully
In order for the engine, transmission, and clutch to home.
function correctly, maintain the engine oil at the correct
level, and change the oil and oil filter in accordance with
scheduled maintenance requirements.
Motorcycle operation with insufficient, deteriorated, or

contaminated engine oil will cause accelerated engine
wear and may result in engine or transmission seizure.
Seizure of the engine or transmission may lead to loss of
motorcycle control and an accident. 1. Filler
2. Filler plug/dipstick
3. Upper marking
4. Remove the filler plug/dipstick.
Never start the engine or run the engine in a confined 5. The oil level is indicated by lines on the filler
area. Exhaust fumes are poisonous and can cause loss of plug/dipstick. When full, the indicated oil level must
consciousness and death within a short period of time. be level with the upper marking on the dipstick.
Always operate your motorcycle in the open-air or in an 6. If the oil level is too low, add oil a little at a time until
area with adequate ventilation. the correct level is reached.
Z Once the correct level is reached, re-fit the filler
A Caution
plug/dipstick.
Running the engine with insufficient oil will cause Oil and Oil Filter Change
engine damage. If the low oil pressure indicator remains
on, stop the engine immediately and investigate the
cause.
Note:
Prolonged or repeated contact with engine oil can lead
An accurate indication of the level of oil in the to skin dryness, irritation and dermatitis. In addition,
engine is only shown when the engine oil is at used engine oil contains potentially harmful
normal operating temperature, the motorcycle contamination which can cause cancer. Wear suitable
is upright (not on the side stand) and the filler clothing and avoid skin contact.
plug/dipstick has been fully screwed home. The engine oil and filter must be replaced in accordance
with scheduled maintenance requirements.
1. Start the engine and run at idle for approximately
five minutes. 1. Warm up the engine thoroughly, and then stop the
2. With the motorcycle upright, stop the engine and engine.
wait for three minutes to allow the oil to settle. 2. Place an oil pan beneath the engine.
The oil may be hot to the touch. Contact with hot oil
may cause the skin to be scalded or burned.

Lubrication
3. Remove the oil drain plug.
A Caution
Racing the engine before the oil reaches every part can
cause engine damage or seizure.
13. Ensure that the oil pressure warning light

extinguishes shortly after starting.
I
L___
Q 1 ~) ~ 2
A Caution
If the engine oil pressure is too low, the low oil pressure
warning light will illuminate. If this light stays on when
~1 the engine is running, stop the engine immediately and
investigate the cause. Running the engine with low oil
1. Oil filter pressure will cause engine damage.
2. Oil drain plug
14. Stop the engine and check the oil level. Adjust if
4. With the motorcycle on level ground, and on the
necessary.
sidestand, allow the oil to completely drain.
5. Unscrew and remove the oil filter using Triumph
service tool T3880313. Disposal of Used Engine Oil
To protect the environment, do not pour oil on the
ground, down sewers or drains, or into water courses.
Dispose of used oil sensibly. If in doubt contact your local
authority.
,.,._,
1. Oil filter
2. Tool T3880313
6. Dispose of the old oil filter in an environmentally

friendly way.
Z Pre-fill a new oil filter with clean engine oil.
8. Apply a smear of clean engine oil to the sealing ring
of the new oil filter.
9. Fit the oil filter and tighten to 10 Nm.
10. After the oil has completely drained out, fit a new
sealing washer to the drain plug. Fit and tighten the
plug to 25 Nm.
11. Fill the engine with new oil of the type and grade
listed previously and in the specification section.
12. Start the engine and allow to idle.

Lubrication
Oil Pump 4. Fit tool T3880371 to the drive dogs on the upper oil
pump drive sprocket. Hold the tool to prevent
rotation and release the bolt securing the oil pump
drive sprocket to the oil pump.

to skin dryness, irritation and dermatitis. Furthermore,
used engine oil contains potentially harmful
contaminants which can cause cancer.
When handling used engine oil, always wear protective
clothing and avoid any skin contact with the oil.
A Caution
Do not pour engine oil on the ground, down sewers or
drains, or into water courses. To prevent pollution of
water courses etc., dispose of used oil sensibly. If in
doubt contact your local authority.
1. Oil pump drive chain
Removal 2. Pump drive sprocket fixing
3. Pump drive sprocket
1. Release the three fixings and remove the front panel 4. Tool T3880371
from the fuel tank. 5. Upper oil pump drive sprocket
5. Remove the tool, upper and lower sprockets, upper

sprocket bearing and the drive chain by sliding all
components off the shaft together.
6. Release the bolts securing the oil pump to the
crankcase and withdraw the oil pump.
1. Front panel
2. Fixings

3. Remove the clutch (see page 4- n.
1. Pump bolts

Lubrication
Inspection Rotor Tip Clearance
1. Release the screw and withdraw the oil pump plate Standard: 0.15 mm
from the pump body. Service Limit: 0.20 mm
cert
1. Oil pump drive shaft 1. Rotor tip clearance

2. Oil pump plate 2. Pump body clearance
3. Oil pump body
4. Screw 3. Measure the pump body clearance using feeler
gauges.
A Caution Body Clearance
If any part of the oil pump is found to be outside the Standard: 0.15 - 0.22 mm
service lim it, the complete pump must be replaced. Service Limit: 0.35 mm
Severe engine damage may result from the continued
4. Measure the pump end clearance.
use of a faulty oil pump.
2. Measure the rotor tip clearance using feeler gauges. Pump End Clearance
Standard: 0.02 - 0.07 mm

5. Ca) If all clearances are within service limits, liberally
apply clean engine oil to all internal components and
refit the oil pump plate to the oil pump body.
Cb) If any clearance measured is outside the service
limits, renew the complete pump.
6. Inspect the sprocket and chain for wear and/or
damage. Replace the sprocket and chain if wear
and/or damage is found.

Lubrication
Installation 4. As an assembly, slide the upper drive sprocket

bearing, upper drive sprocket, drive chain and pump
sprocket onto the input shaft and oil pump.
A Caution
Before fitting the oil pump to the crankcase ensure the
pump internal surfaces have been 'wetted' with clean
engine oil. The pump may fail to pick-up oil from the
sump if the surfaces have not been 'wetted'. This will
cause the engine to run without engine oil pressure and
will lead to severe engine damage.
1. Fill the oil pump with new engine oil, turning the
pump rotor as the oil is poured in to ensure all
surfaces are coated with oil.
2. Position the oil pump to the crankcase and insert into
the opening provided.
Note:
Use the sprocket end of the oil pump shaft to 1. Oil pump drive chain
turn the drive peg into alignment with the 2. Pump drive sprocket fixing
drive on the water pump. 3. Pump drive sprocket
3. Fit the oil pump to the crankcase, ensure the water 4. Tool T3 8803 71
pump drive peg locates into the drive on the water 5. Upper oil pump drive sprocket
pump shaft. Tighten the bolts to 12 Nm. 5. Locate the pump drive sprocket onto the pump
ensuring that the drive engages correctly.
6. Refit tool T3880371 to the upper drive sprocket and
tighten a new oil pump drive sprocket centre bolt to
15 Nm. Remove the tool.
7. Assemble the clutch (see page 4-10).
8. Reconnect the battery, positive (red lead) first.
fixings to 2 Nm.
10. Refill the engine with oil (see page 8-7>.
Pump Insertion

Lubrication
Low Oil Pressure Warning Light Installation

Switch 1. Incorporating new copper washers on both sides of
The low oil pressure warning light switch is located at the the oil pipe union, fit the switch and tighten to
lower end of the camshaft oil feed pipe. 13 Nm.
2. Refit the electrical connection.
fixings to 2 Nm.
1. Oil feed pipe

2. Low oil pressure warning light switch

from the fuel tank.
1. Front panel
2. Fixings
2. Disconnect the battery, negative <black) lead first.
3. Disconnect the electrical connection to the switch.
4. Remove the switch and collect the copper washers.

Lubrication
Sump Z Release the bolts securing the sump to the lower

crankcase. noting the position of the wire guide for
the drain hose.
Removal 8. Detach the sump.

from the fuel tank.
l~L
i- ~
cezo_1
1. Transmission oil feed pipe fixings

cgfo ~
9. Remove the sump gasket.
1. Front panel 10. If necessary, remove the transmission oil feed pipe
2. Fixings and collect the sealing washer from either side of
each joint.
2. Disconnect the battery, negative <black> lead first.
3. If fitted, remove the bellypan <see page 16-14).
Inspection
4. Drain the engine oil (see page 8-TJ.
1. Inspect the transmission oil feed pipe for damage.

Renew as necessary.
2. Inspect the oil pick-up for correct fitment in the lower
The oil may be hot to the touch. Contact with hot oil crankcase.
may cause the skin to be scalded or burned.
Installation
1. If removed, fit the transm1ss1on oil feed pipe

incorporating new washers. Tighten the fixings to
8Nm.
to skin dryness, irritation and dermatitis. In addition used
which can cause cancer. Wear suitable clothing and
avoid skin contact.
5. Remove the exhaust system (see page 10-125).
The exhaust system will be hot if the engine has recently

been running. Always allow sufficient time for the
exhaust to cool before working on or near the exhaust
system.
Contact with a hot exhaust could result in burn injuries.
cezo_1
6. Remove the oil filter.
1. Transmission oil feed pipe fixings

Lubrication
2. Incorporating a new sump gasket, position the sump Oil Cooler

to the lower crankcase.
Note:
Removal
The sump fixings 1 and 2 are torqued twice as
21 and 22 respectively. 1. Release the three fixings and remove the front panel
• Apply a drop of ThreeBond 13 60 to the thread from the fuel tank.
of the fixing for the wire guide (item 10> only.
3. Fit the wire guide for the drain hose as noted for
removal and tighten the sump fixings to 12 Nm.
1. Front panel
2. Fixings
chiy
Sump Fixings Tightening Sequence 3. Drain the engine oil (see page 8- n.
4. Pre-fill a new oil filter with clean engine oil.
5. Apply a smear of clean engine oil to the seal of the
new oil filter.
6. Fit the oil filter and tighten to 10 Nm using I The oil may be hot to the touch. Contact with hot
tool T3880013. engine oil may cause skin to be scalded or burnt
Z Refit the exhaust system (see page 10-128).
Note:
Use new exhaust gaskets at the downpipe
connections with the cylinder head. Prolonged or repeated contact with engine oil can lead
to skin dryness, irritation and dermatitis. In addition used
8. Fill the engine with the correct grade of engine oil.
9. Reconnect the battery positive (red) lead first. which can cause cancer. Wear suitable clothing and
10. Start the engine and ensure that the low oil pressure avoid skin contact.
warning light goes out shortly after starting.
11. Stop the engine and adjust the engine oil level. 4. If fitted, remove the bellypan (see page 16-14).
fixings to 2 Nm.
13. If fitted, Refit the bellypan (see page 16-14).

Lubrication
5. Disconnect the oil cooler feed and return hoses from Inspection
the oil cooler and discard the fixings.
1. Inspect the oil cooler connection points for fractures
and signs of oil leakage.
2. Check the oil cooler fins for damage and leaks.
Installation
1. Position the oil cooler to the retaining brackets.

2. Refit and tighten the oil cooler fixings to 9 Nm.
3. Align the oil cooler pipes to the cooler and,
incorporating new 0-rings, tighten the new fixings to
9Nm.
4. Refill the engine with oil (see page 8-TJ.
5. Reconnect the battery, positive (red) lead first.
6. Start the engine and check for oil leaks. Once a leak
1. Oil cooler hoses check has been made, stop the engine and allow to
2. Fixings stand for 10 minutes.
6. Release the oil cooler fixings. Z Adjust the engine oil level (see page 8-TJ.
fixings to 2 Nm.
Z Remove the oil cooler.

Lubrication

9 Engine Removal/Refit
Table of Contents
Engine Removal/Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

Engine Removal/Refit
Engine Removal/Refit 15. Disconnect all electrical connections to the engine.

Noting the connection locations and the position of
cable-ties securing the harnesses in position.
Removal 16. Detach the throttle bodies from the cylinder head
(see page 10-115>.
Note:
It is not necessary to disconnect the throttle
Before staring work, ensure the motorcycle is stabilised cables. Instead, lay the throttle bodies over the
and adequately supported. This will help prevent it from frame during the period when the engine is
falling and causing injury to the operator or damage to separated from the frame.
the motorcycle.
lZ Remove the clutch cable (see page 4-S>.
1. Place the motorcycle on a paddock stand. 18. Place a support beneath the engine and ensure that
2. Remove the seat (see page 16-10>. the frame is still adequately and securely supported.
3. Remove the battery (see page 17-8). 19. Remove the frame to cylinder head bracket from the
left hand side of the motorcycle.
4. Remove the fuel tank (see page 10-93).
5. Remove the airbox (see page 10-100>. Note:
6. If fitted, remove the bellypan <see page 16-14). Note the position for each of the mounting
Z Drain the engine oil (see page 8-7>. bolts and washers for installation.
8. Remove the oil cooler <see page 8-14>. 20. Remove the engine mounting bolts, locknuts and
washers from the right hand side of the frame.
9. Remove the radiator <see page 11-rn. Discard the locknuts.
10. Remove the exhaust system <see page 10-125>.
Note:
11. Remove the coolant expansion tank (see
page 11-15>. Note the orientation of the frame rubbing
block on the left hand lower engine mounting.
Note:
21. Remove the engine mounting bolts and locknuts
Secure the coolant hoses to prevent damage as from the left hand side and collect the frame rubbing
the engine is removed. block from the lower engine mounting. Discard the
12. Set the drive chain adjustment to allow maximum locknuts.
free play in the chain (see page 13-6>.
13. Disconnect the gearchange linkage at the
gearchange shaft.
14. Remove the sprocket and harness covers.
cgwc
1. Rubbing block
Note:
The frame is fitted with four frame adjuster
sleeves, located on the right hand side of the
frame.
2. Harness cover
3. Fixings

22. Using tool T3880377 slacken the frame adjuster

sleeves.
A Caution
Unless the following engine mounting bolt tightening
sequence is precisely followed, severe frame damage
can occur.
Z Using tool T3880377 tighten the four adjusters in

the following sequence.
a) Remove the bolt and washer from the cylinder
head rear mounting and tighten the adjuster to
S Nm. Lubricate the threads of this bolt only
with a smear of proprietry high temperature
copper based grease. Refit the bolt and washer.
b) Remove the bolt and washer from the lower
crankcase mounting and tighten the adjuster to
cgwb 5 Nm. Refit the bolt and washer.
1. Cylinder head rear adjuster c) Remove the bolt and washer from the upper
2. Lower crankcase adjuster crankcase mounting and tighten the adjuster to
3. Upper crankcase adjuster 5 Nm. Refit the bolt and washer.
4. Cylinder head front adjuster
d) Remove the bolt and washer from the cylinder
5. Adjuster
head front mounting and tighten the adjuster to
3 Nm. Refit the bolt and washer.
A Caution ·
To prevent chain damage, do not allow the chain to
come into contact with dirt, road grit etc.
23. Lower the engine sufficiently to allow the drive chain

to be detached from the output sprocket.
24. Remove the engine from the frame.
A Caution
To prevent damage to components, lower the engine
very carefully.
Installation c gwb -------~

1. Cylinder head rear adjuster
1. Refit the frame to cylinder head bracket to the left 2. Lower crankcase adjuster
hand side of the engine, do not fully tighten at this 3. Upper crankcase adjuster
stage. 4. Cylinder head front adjuster
5. Adjuster
2. Position the engine beneath the frame.
3. Raise the engine, looping the drive chain over the 8. Remove the support from beneath the engine.
output sprocket as it is raised. 9. Fit new locknuts and tighten in the following
4. Align the engine to the frame and refit the engine sequence.
mounting bolts, washers and the rubbing block to
support the engine, as noted for removal. Left Hand Side Tightening Sequence
5. Tighten the frame to cylinder head bracket fixings to a) Upper crankcase mounting bolt to 80 Nm.
30Nm. b) Cylinder head rear mounting to 80 Nm.
6. Tighten the cylinder head front left hand mounting c) Cylinder head front mounting to 80 Nm.
to 20 Nm.
d) Lower crankcase mounting to 80 Nm.

Right Hand Side Tightening Sequence 16. Refit the radiator <see page 11-13).
a> Upper crankcase mounting bolt to 80 Nm. 1Z Refit the oil cooler (see page 8-15).
b) Lower crankcase mounting to 80 Nm. 18. Refit the coolant expansion tank (see page 11-16>.
c> Cylinder head front mounting to 80 Nm. 19. Refill the cooling system <see page 11-6>.
d) Cylinder head rear mounting to 80 Nm. 20. Fill the engine with oil of the correct grade and
viscosity (see page 8-7).
10. Refit the clutch cable (see page 4-6>.
21. Refit the airbox (see page 10-101>.
11. Refit the throttle bodies to the cylinder head (see
22. Refit the battery <see page 17-8) but do not
page 10-116>.
reconnect its leads at this stage.
12. Reconnect all electrical connections to the
23. Refit the fuel tank (see page 10-94).
engine.and secured as noted for removal
13. Refit the sprocket cover and the harness cover,
tighten the bolts to 8 Nm. 25. Refit the front panel to the fuel tank and tighten the
fixings to 2 Nm.
14. Refit the gearchange linkage.
15. Using new seals at the cylinder head, refit the
exhaust system (see page 10-128). 2Z Remove the motorcycle from the paddock stand and
place on the side stand.
28. Refit the seat (see page 16-1 n.
29. Adjust the drive chain (see page 13-6).
1. Cylinder head
2. Seals

10 Fuel System/Engine Management
Table of Contents
Exploded View - Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Exploded View - Fuel Pump...... ........................... . ............. ............... .. 10.9
Exploded View - Fuel Rail, Throttles and Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
Exploded View - Airbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
Exploded View - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
Exploded View - Evaporative System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
Exploded View - Secondary Air Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Fuel Requirements - all countries except USA............ ........................... .. ..... 10.15
Fuel Requirements - USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Oxygenated Gasoline....... .............. .... ........... ...... ............ .. .......... 10.15
Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Methanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
MTBE <Methyl Tertiary Butyl Ether)..................... .. ............ ............. . ...... 10.15
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Air temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Air temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
ATDC. .. .... ............................................................. ............ 10.15
Barometric pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
BTDC....... ....... ..... ..... .... ...... ........... .......... ... .................... .. 10.15
Catalyst. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Closed throttle position...... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Coolant temperature............ ......... ... ............... ...... ......... .... ......... 10.15
Coolant temperature sensor. .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Cooling fan status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
OTC ...................... .... ... . ....................... .... . ... ........... ... ...... 10.16
ECM .................. .... .......... .. ................. ...... .. . ......... ...... ..... 10.16
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Fall detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Freeze frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Idle fuel trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Idle fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Idle reference speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Ignition advance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

Ignition switch position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

Ignition timing...... ........... .. ..................... .... ............................ 10.16
Immobiliser and Tyre Pressure Monitoring System <TPMS> Control Module . . . . . . . . . . . . . . . . . . . . 10.16
Injector pulse time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Long term fuel trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
MAP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
MIL........ .................. . . . ............ . . . ................... ....... ......... . . 10.16
Neutral switch status.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Off idle fuel trim... ... .. ......... ... ..................... ...... ........... ... ....... .. 10.16
Open circuit... .............. ... ...... ... ............ .... .. ... ....... ... .............. 10.16
Over temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Oxygen Sensor ..... ...... ........... . . .... .............. . ................ .. .......... 10.16
Primary throttle position sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Primary throttle stepper motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Purge valve duty cycle.. ...... .. ............... . ........ .. ........................... . . 10.17
Road speed sensor .............. '. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Sensor reference Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Short term fuel trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Sidestand status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Target dwell time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Throttle position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Throttle Voltage........ .... .. .. .. ..... .... ......... .... .. .... .. .. ........ ......... .... 10.17
TDC...... ........... ....... ............. ........... ........ . ..... . . ....... .......... 10.17
TPMS. .......... .. ........... ........ ......... .................... ...... ..... ....... 10.17
Transponder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Vbatt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Engine Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
Sensor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
System Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
Actuator Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
Immobiliser System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
System Description. ............. ... .. ....... ....................... . ............ ... .. 10.22
System Components and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Further Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Components Location.... ............ .... . . ........................... ..... ..... ... ... 10.23
Tyre Pressure Monitoring System CTPMS> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
System Components and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
Further Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
Engine Management Circuit Diagram - Speed Triple with ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
Key to Wiring Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26

Engine Management Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27

Engine Management Circuit Diagram - Speed Triple without ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
Key to Wiring Circuit Diagram........... .................................... .... ....... 10.28
Engine Management Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
System Diagnostics. .... ..... ... ....... ................................ . ...... .... ....... 10.30
On-board Fault Detection System. ................... .. ........ . ................. ....... 10.30
Diagnostic Interface Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
Triumph Diagnostic software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
Build Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
Current Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
Sensor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 3
Injector Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
Ignition Data.. .. ... ... ....... ........... ............. .................. .............. 10.34
Idle Speed and Throttle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
Adaption Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 5
Function Tests. ....... ........ ...................... ................... ......... ...... 10.36
Adjust Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
Freeze Frame Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
lmmobiliserfTPMS Control Module Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
Electrical Connectors.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
Before Disconnection:. ........ ................... ... . .. . . ...... .. ......... .... ...... ... 10.41
When Disconnecting a Connector: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
When Inspecting a Connector... ....... ..... .. ........ ................... ....... ..... .... 10.41
When Connecting a Connector: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
Disconnection of ECM connectors........ ........ ... .............................. ....... 10.41
Reconnection of ECM connectors.................. ................................ ..... 10.42
Further Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
Crankshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
Pinpoint Tests... . ...... ........ ......... ................... ......... ..... ..... ...... . 10.43
Idle Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
Throttle Position Sensor. . ........ .. ................. ........... . ......................... 10.48
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
Purge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
Coolant Temperature Sensor. ........ ... .............................................. .... 10.54
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54
Inlet Air Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56

Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.58

Pinpoint Tests. ........ ..................... . ......................................... 10.58
System Voltage .................. .. ............. ......... .... . ..... .... ............. . ... 10.59
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.59
Cooling Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.60
Pinpoint Tests. .......... . ....... .. .............. ....... .. .. . . . . ..... .. ............ . . . 10.60
Oxygen Sensor ..................... .. .. ... ........ ... .... ........ ...... ........ ........ 10.61
Pinpoint Tests. ..... . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.61
Oxygen Sensor Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.62
Pinpoint Tests. ............................................................... .. ...... 10.62
Fall Detection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.63
Pinpoint Tests. ... ... ......... .. ............. .... .. .. . ......... .... . ................. . 10.63
Vehicle Speed/Wheel Sensor.. . ..... ............... .. .. .. . . ......... .. .................. .. 10.64
Pinpoint Tests. . . .... .... . ..... ....... .. ..... .... ......................... .. ...... . . .. 10.64
CAN Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.66
Instrument Communication <CAN>. ..... .. . ................... ....... ...... ...... .. .. ...... 10.67
Pinpoint Tests.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.67
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.68
Pinpoint Tests. ................ .... ... .... .. .......................................... 10.68
Ambient Pressure Sensor...... .................. . .. .. . .. ......... ... ..................... 10.69
Pinpoint Tests.... .... ....... ....... ........ ............. . ...... . ............... ...... 10.69
Manifold Absolute Pressure CMAP> Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.70
Pinpoint Tests. .. . ......................... .. ..................... ... .. . .. .... .. . .... . 10.70
Secondary Air Injection Valve. ...... . ............. ..... ..... . .. ..... .... . .... . ............ 10.71
Pinpoint Tests... ....................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.71
EMS Main Relay Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.72
Pinpoint Tests. .............. . ..... ... ........ ...... ......... .. ...... ..... .. .. ........ 10.72
EEPROM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.74
EMS Ignition Voltage Input Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75
Pinpoint Tests. .......... .. . . ................... ........ .. . . .. .......... ........ ...... 10.75
5 Volt Sensor Supply Circuit... ...... .. .............................. . ........ ............ 10.76
Pinpoint Tests.... .... . . . .................... ... ........ ...... ........... ...... ....... 10.76
Tune Lock. ... ... .................. . . .. .................................. . ...... . .. ..... 10.n
ECM or Tune ID Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.78
Pinpoint Tests. .................... ..... ... .. .................. . ...................... 10.78
Immobiliser and TPMS Control Module Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.79
Immobiliser and TPMS Control Module ID lncompatable... .... . .. ... ............. ....... ..... 10.80
ABS Modulator ID lncompatable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.81
ABS Modulator Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.82
Fault Finding - Non Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.83
Front Wheel Unit Sensor Battery Alert. ................ ....... .... .. ............ . ........... 10.84

Rear Wheel Unit Sensor Battery Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.85

Front Wheel Unit Sensor Fault Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.86
Rear Wheel Unit Sensor Fault Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.87
Front Wheel Unit Sensor Loss of Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.88
Rear Wheel Unit Sensor Loss of Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.89
lmmobiliser/TPMS Control Module Fault. ........................................ .... ....... 10.90
Invalid Key: Key Authentication Unsuccessful ......... . .. .................................... 10.91
Pinpoint Tests ........ ... . ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.91
Fuel Tank - Raising and Supporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92
Fuel Tank - Lowering and Securing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.93
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.93
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.93
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.94
Fuel Pump and Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.95
Removal........ .. ..... ....................... ..... ........ . . . ... ....... ............ 10.95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.96
Fuel Level Sender Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.97
Removal..... .... ... .......... ...... ........ ... ............ .. ... . ...... .. . .......... 10.97
Installation .............. .. ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.97
Fuel Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.98
Fuel Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.99
Airbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.100
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.100
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101
Air Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102
Ignition Coil Seal ......... .... ...... . . .. ... .. .. .. .. . ....................... .... ......... 10.103
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103
Engine Control Module CECM> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.104
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.104
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.106
Intake Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.107
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.107
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.107
MAP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.108
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.108
Barometric Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.109
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.109

Fall Detection Switch ..... . ............... . ...... . ..................................... . 10.110

Removal . . ................................................... . ... . ................. . 10.110
Installation . . .... . ................................................................. . . 10.110
Crankshaft position sensor . .. . .............................................. . ........... . 10.111
Removal ...... . .................... . . . .................................. . .......... . 10.111
Installation .......... . . . ... . ............................................. . .......... . 10.111
lmmobiliser/TPMS Control Module ............................................... . ...... . 10.112
Removal ....... .. ............................. . . . ... . ..... .. ............... . . .. .... . 10.112
Installation ......................................................... . ............ . .. . 10.112
Throttle Cable .......... . ......... ... .................................... .. ........... . 10.112
Adjustment ........... . ............................................... .. ........... . 10.112
Removal .... . ............ . ......... . ........ .. . . ....................... ... ......... . 10.113
Examination .................................. .. .. . .. . .. . ................. . ......... . 10.114
Installation .................... . ...... . .................... . ........................ . 10.114
Throttle Bodies/Injectors . . ....................... . ........................... .. .... . ... . 10.115
Removal . .. . ..... . . . ............................ . .............. . ............. . . . ... . 10.115
Inspection ........................................................ . ... . .......... .. . . 10.116
Installation ......................................................... . ... . ........ . . . . 10.116
Throttle Body Balancing .... . . . ....................................................... .. . . 10.117
Throttle Position Sensor . . ........ ............................................... . ....... . 10.119
Removal . ........... . .............................................................. . 10.119
Installation ................ . ........................................... . ............ . 10.119
Idle Speed Control Stepper Motor ........ . . . ........... . .......... . ..................... . 10.120
Removal ............. . ........... . .......................... . ...................... . 10.120
Installation . .... . ... . ............................................................... . 10.121
Engine Management Adaption ....................................... . ....... . ...... . ... . 10.124
General Information ................. .. .................................. . ........... . 10.124
Adaption Status ........ . .......... . ..... . ........................................... . 10.124
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.124
Typical Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.124
Forcing adaption to take place. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.124
Fault Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.125
Exhaust System ........ . .. . ............................................................ 10.125
Removal ................ . ........ . ................................... . ............. . 10.125
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.128
Secondary Air Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.131
System Purpose and Operation. .. . .............. .. .......................... . ....... . .. 10.131
Secondary Air Injection Solenoid Valve ..... . ... . .......................................... 10.132
Removal .. . .......... . .... . ........... . .......... . ..................... .. ........... 10.132
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.132
Secondary Air Injection Reed Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.133
Removal .......................................... . .................... . ............ 10.133
Inspection ............ . ................... . .............. . ........ . ........ .. ........ 10.133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.134

Evaporative Canister CWhere Fitted)......... ... ....................... ....... ............ . 10.134

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.134
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.135
Purge Control Valve............. ...... ................................................. 10.136
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.136
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.137
Evaporative Emissions Control System.................. .... .............. ...... .. ......... 10.138
Component Locations................ ............ ... ..... ......... ..... ...... . ....... . 10.138
Evaporative Control System - Engine Off. ....................... ....... ..... ....... ...... 10.139
Evaporative Control System - Engine Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.140

Exploded View - Fuel Tank
9Nm
4Nm
/
4Nm
@>
2Nm ~

Exploded View - Fuel Pump
9Nm

Exploded View - Fuel Rail, Throttles and lniectors

Exploded View - Airbox
'
10Nm
0
~
SNm ~
10Nm
e

Exploded View - Exhaust System
15 Nm
15 Nm
15 Nm 10Nm
See text
SNm

Exploded View - Evaporative System

Exploded View - Secondary Air lniection
9Nm

Fuel Requirements Glossary of Terms

The following terms and abbreviations will be found in
Fuel Requirements - all countries except USA this section. A brief explanation is given below of what
some of the more common terms and abbreviations
Outside America, this model must be run on 95 RON
mean.
unleaded fuel.
Air temperature
Fuel Requirements - USA
The air temperature in the airbox and intake system.
In the United States of America where the octane rating of
fuel is measured in a different way, the following
information may be applied: This model is designed to Air temperature sensor
run on unleaded gasoline with a CLC or AKI octane rating
Sensor located in the airbox to detect the temperature of
(R+M)/2 of 89 or higher.
the incoming air.
A Caution
ATDC
The use of leaded gasoline is illegal in some countries,
After Top Dead Centre.
states or territories and will invalidate the vehicle and
emissions control warranties. Additionally, leaded
gasoline will cause damage to emissions control Barometric pressure
components.
Pressure of the air in the atmosphere.
Oxygenated Gasoline
Battery Voltage
To help in meeting clean air standards, some areas of the
U.S. use oxygenated gasoline to help reduce harmful The voltage at the input to the Engine Control Module
emissions. This model will give best performance when CECM).
using unleaded gasoline. However, the following should
be used as a guide to the use of oxygenated fuels.
BTDC
A Caution Before Top Dead Centre <TDC>.
Because of the generally higher volatility of oxygenated

Catalyst
fuels, starting, engine response and fuel consumption
may be adversely affected by their use. Should any of Device placed in the exhaust system which reduces
these difficulties be experienced, run the motorcycle on exhaust emissions by stimulating secondary combustion
normal unleaded gasoline. of the exhaust gases.
Ethanol Closed throttle position

Ethanol fuel is a mixture of 100/o ethanol and 900/o Throttle position at idle <i.e. against end stop), measured as
gasoline and is often described under the names a voltage and expressed as a percentage.
'gasohol', 'ethanol enhanced', or 'contains ethanol'. This
fuel may be used in Triumph motorcycles.
Coolant temperature
Methanol The coolant temperature in the cylinder head.
A Caution Coolant temperature sensor
Fuels containing methanol should not be used in Sensor which detects coolant temperature.
Triumph motorcycles as damage to components in the
fuel system can be caused by contact with methanol. Cooling fan status
The 'on' or 'off' condition of the cooling fan.
MTBE <Methyl Tertiary Butyl Ether)
The use of gasolines containing up to 150/o MTBE <Methyl
Tertiary Butyl Ether) is permitted in Triumph motorcycles.

OTC Immobiliser and Tyre Pressure Monitoring

System <TPMS> Control Module
Diagnostic Trouble Code.
The control module for the Immobiliser and TPMS
system.
ECM
Engine Control Module.
lniector pulse time
The time during which an injector remains open {i.e.
Engine speed
delivering fuel>.
The crankshaft revolutions per minute.
Long term fuel trim

Fall detection
Fueling after adapting to the engine's long term fueling
The fall detection switch will detect if the motorcycle is on requirements (closed loop only>. See also short term fuel
its side and will cut power to the ECM immediately. trim.
Freeze frame MAP sensor

A data set captured at the time a Diagnostic Trouble Code Manifold absolute pressure (the air pressure in the intake
<DTO is set. ' system).
Idle fuel trim MIL

The percentage above or below the nominal fuel Malfunction Indicator Lamp.
requirement for the volume of air entering at idle. Illuminates when most Diagnostic Trouble Codes CDTCs)
are set.
Idle fueling
Adjustment of fueling at idle to suit the actual air inducted. Neutral switch status
The 'neutral' or 'in gear' status of the gearchange.
Idle reference speed
The target idle speed as determined by the Engine Off idle fuel trim
Control Module CECM>. Cit should be the same as the The percentage above or below the nominal fuel
actual idle speed if the motorcycle is operating correctly>. requirement for the volume of air entering at engine
speeds other than idle. This function is not currently used
Ignition advance in the Triumph system.
The timing of ignition at the spark plug relative to top

dead centre. Open circuit
A break in an electrical circuit - current cannot flow.
Ignition switch position
The 'ON' or 'OFF' position of either or both the ignition Over temp
switch and the engine stop switch. High temperature within the Engine Control Module
CECM> caused by an internal or external failure.
Ignition timing
Same as 'ignition advance'. 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.

Primary throttle position sensor Target dwell time

Sensor for the primary <lower) throttle position. The actual time from coil 'on' to coil 'off'.
Primary throttle stepper motor Throttle position

Stepper motor used to vary throttle opening at idle and The position of the throttle butterfly given as a percentage
when the engine is cold. of the movement range. When the data is displayed on
the tool, fully open need not be 1000/o nor fully closed 00/o.
Purge valve duty cycle

Throttle Voltage
The time the purge valve is open in an open/close cycle,
expressed as a percentage of the cycle time. Voltage at the throttle potentiometer.
Road speed sensor TDC

Gearbox mounted sensor which delivers information to Top Dead Centre.
the ECM that is converted to the road speed value that is
displayed on the speedometer.
TPMS
Tyre Pressure Monitoring System.
Sensor reference Voltage
Supply voltage to the system sensors (nominally 5 Volts).
Transponder
A transmitter-responder chip located in the ignition key.
Short circuit
The transponder is activated by a radio signal sent out by
A 'short cut' in an electrical circuit - current by-passes the the immobiliser and TPMS control module, via an
intended circuit (usually to earth). antenna located around the ignition switch. If the
immobiliser and TPMS control module does not receive
the correct code signal from the transponder, the
Short tenn fuel trim
immobiliser will remain active and the engine will not
A correction applied to the fuel mixture during closed start.
loop catalyst operation. This, in turn has an effect on the
long term fuel trim in that, if an engine constantly requires
Vbatt
mixture correction, the long term fuel trim will adapt to
this requirement thus reducing the need for constant Battery voltage.
short term adjustment.
Sidestand status
The 'up' or 'down' position of the side stand.

Engine Management System Crankshaft position sensor - situated in the

crankcase, near the alternator cover. The
crankshaft position sensor detects movement of
System Description a toothed wheel attached to the alternator rotor.
The Speed Triple is fitted with an electronic engine The toothed wheel gives a reference point from
management system which encompasses control of both which the actual crankshaft position is
ignition and fuel delivery. The Engine Control Module calculated. The crankshaft position sensor
CECM> is electronically paired to the immobiliser/TPMS information is used by the ECM to determine
control module to help prevent theft of the motorcycle engine speed and crankshaft position in relation
(see page 10-22). The ECM also draws information from to the point where fuel is injected and ignition
sensors positioned around the engine, cooling and air of the fuel occurs.
intake systems and precisely calculates ignition advance
Engine coolant temperature sensor -
and fueling requirements for all engine speeds and loads.
situated at the rear of the cylinder head, on the
In addition, the system has an on-board diagnostic left hand side. Coolant temperature
function. This ensures that, should a malfunction occur in information, received by the ECM, is used to
the engine management system, the malfunction type, optimise fueling at all engine temperatures and
and engine data at the time the malfunction occurred, are to calculate hot and cold start fueling
stored in the ECM memory. This stored data can then be requirements.
recovered using a special service tool which is mandatory
for all Triumph dealers. In this way, precise diagnosis of a Throttle position sensor - situated at the left
fault can be made and the fault quickly rectified. end of the throttle body. Used to relay throttle
position information to the ECM. Throttle
opening angle is used by the ECM to
System Sensors determine fueling and ignition requirements for
Intake air temperature sensor.- situated in all throttle positions.
the top of the airbox. As the density of the air Road speed sensor - for motorcycles without
<and therefore the amount of oxygen available ABS and motorcycles with ABS up to
to ignite the fuel> changes with temperature, an VIN 490000 it situated in the upper crankcase,
intake air temperature sensor is fitted. Changes on the left hand side, above the sprocket cover.
in air temperature (and therefore air density) The road speed sensor provides the ECM with
are compensated for by adjusting the amount data from which road speed is calculated and
of fuel injected to a level consistent with clean displayed on the speedometer.
combustion and low emissions. Motorcycles with ABS from VIN 490001 are
Barometric pressure sensor - situated on the not fitted with a road speed sensor. The rear
left hand side, at the front of the rear mudguard ABS wheel speed sensor provides the ECM
beneath the seat. The barometric pressure with data from which road speed is calculated
sensor measures atmospheric air pressure. With and displayed on the speedometer.
this information, the amount of fuel per Oxygen sensor - situated in the exhaust
iniection is adjusted to suit the prevailing header system upstream of the catalyst. The
conditions. oxygen sensor constantly feeds information to
Manifold Absolute Pressure <MAP> the ECM on the content of the exhaust gases.
sensor - situated to the left side of the airbox, Based on this information, adjustments to
connected to each of the three throttle bodies air/fuel ratio are made.
by equal length tubes. The MAP sensor Side stand switch - situated at the top of the
provides information to the ECM which is used sidestand leg. If the sidestand is in the down
at shallow throttle angles (very small throttle position, the engine will not run unless the
openings> to provide accurate engine load transmission is in neutral.
indications to the ECM. This degree of engine
load accuracy allows the ECM to make very Fall detection switch - situated beneath the
small adjustments to fuel and ignition which seat. The fall detection switch will detect if the
would otherwise not be possible from throttle motorcycle is on its side and will cut power to
angle data alone. the ECM immediately. This prevents the engine
from running and the fuel pump from
Clutch switch - situated on the clutch lever. delivering fuel. In the event of a fall, the switch
The clutch must be pulled in for the starter is reset by returning the bike to an upright
motor to operate. position and switching the ignition off then
back on again.

Sensor Locations
INTAKE AIR MANIFOLD

TEMPERATURE ABSOLUTE PRESSURE
SENSOR <MAP> SENSOR
FALL DETECTION
SWITCH
c:cps_1
CLUTCH SWITCH THROTTLE COOLANT TEMPERATURE

POTENTIOMETER SENSOR
BAROMETRIC
PRESSURE SENSOR
cgep_3
CRAN KS HAFT ROAD SPEED

SIDE STAND SWITCH SENSOR <MOTORCYCLES
POSITION SENSOR
WITHOUT ABS ON LY>

System Actuators Cooling fan - located behind the radiator. The

ECM controls switching on and off of the
In response to signals received from the sensors, the ECM
cooling fan in response to a signal received
controls and directs messages to a series of electronic and
from the coolant temperature sensor. When the
electro-mechanical actuators. The function and location of
coolant temperature rises to a level where the
the actuators is given below.
cooling effect of natural airflow is insufficient,
Throttle stepper motor - situated at the right the cooling fan is turned on by the ECM. When
end of the throttle bodies. The throttle stepper the coolant temperature falls sufficiently, the
actuates a cam/lever which causes variations in ECM turns the cooling fan off. The fan only
the closed throttle position. Although used becomes operational when the engine is
primarily to ensure target idle speed is running. It will not operate at any other time.
maintained, it also increases throttle opening
Secondary air injection solenoid - located
when the engine is cold.
on the rear of the airbox. The secondary air
Canister purge valve <certain markets injection solenoid controls airflow through the
only) - situated in the vapour return line secondary air injection system.
between the carbon canister and the throttle
bodies. The purge valve controls the return of Note:
vapour which has been stored in the carbon
• In this system, the starter lockout system
canister during the period when the engine is
(clutch switch, neutral switch, sidestand switch)
switched off. The valve is 'pulsed' by the ECM
all operate through the engine management
to give control over the rate at which the
ECM.
canister is purged.
Injectors - located in the cylinder head. The
engine is fitted with three injectors. The spray
pattern of the injectors is fixed but .the length of
time each injector can remain open is variable
according to operating conditions. The duration
of each injection is calculated by the ECM using
data received from the various sensors in the
system.
Ignition coils - plug-top coils are located in the
camshaft cover. There are three coils fitted, one
for each spark plug. The ECM controls the
point at which the coils are switched on and off.
In calculating the switch-on time, the ECM
allows sufficient time for the coils to charge to a
level where a spark can be produced. The coils
are switched off at the point of ignition, the
timing of which is optimised for good engine
performance.
Main power relay - situated under the seat
When the ignition is switched on, the main
power relay is powered up to provide a stable
voltage supply for the ECM.
Fuel pump - located inside the fuel tank. The
electric pump delivers fuel into the fuel system,
via a pressure regulator, at a constant 3 bar
pressure. The pump is run continuously when
the engine is operating and is also run briefly
when the ignition is first switched on to ensure
that 3 bar is available to the system as soon as
the engine is cranked. Fuel pressure is
controlled by a regulator also situated inside the
fuel tank.

Actuator Locations
IGNITION COILS INJECTORS FUEL PUMP
AIR INJECTION SOLENOID
THROTTLE STEPPER
MOTOR
STARTER SOLENOID
MAIN POWER RELAY COOLING FAN

Immobiliser System Keys

When the motorcycle is delivered from the factory it is
supplied with two keys. Keys can be deleted or added to
System Description
the immobiliser system using the Triumph diagnostic tool.
The Speed Triple and Speed Triple R are fitted with an A maximum of four keys can be added to the system.
electronic immobiliser system to help protect it against To ensure the immobiliser system functions correctly note
theft. This system has to be paired with the ECM and the the following:
ignition key which contains a transponder chip. If all the
components are correctly paired, the immobiliser will Do not put any magnetic materials on the same
allow the engine to start. The Triumph diagnostic tool is key ring as the motorcycle key;
the only way these components can be paired. Do not put any other ignition key with a
In addition, the system has an on-board diagnostic transponder chip fitted near the motorcycle key
function. This ensures that, should a malfunction occur in when in use;
the immobiliser system, a malfunction code is stored in
Do not modify the immobiliser system;
the immobiliser/tyre pressure monitoring system <TPMS)
control modules memory. This stored data can then be Do not submerge the key in water or any other
recovered using the Triumph diagnostic tool (see fluid;
page 10-30).
Do not drop or strike the key against hard
material.
System Components and Operation
Transponder chip - situated inside the ignition Diagnostics
key. The chip is activated by the antenna coil
To fully diagnose the immobiliser system it is necessary to
when the ignition switch is turned to the ON
check for fault codes in the immobiliser/TPMS control
position.
module using the Triumph diagnostic tool (see
Antenna coil - situated around the ignition page 10-30).
switch. When the ignition switch is turned to
the 0 N position, and the transponder chip is
activated, the signal from the chip is sent to the Further Diagnosis
immobiliser/TPMS control module. The tables that start on page 10-38, if used correctly, help
lmmobiliser/TPMS Control Module to pinpoint a fault in the system once a diagnostic trouble
situated on the back of the airbox. This control code has been stored.
module communicates with the transponder
chip in the key and the ECM and will only allow
the engine to start if a matching signal is
received.
Alarm/immobiliser warning indicator
light - situated in the instrument pack. The
light will flash on and off for 24 hours to show
that the engine immobiliser is on. When the
ignition switch is turned to the ON position the
immobiliser and the indicator light will be off. If
the indicator light remains on it indicates that
the immobiliser has a malfunction that requires
investigation. If an accessory alarm is fitted, the
immobiliser indicator light will only illuminate
when the conditions described in the accessory
alarm instructions are met.

Components Location
IMMOBILISER/TPMS ANTENNA COIL

CONTROL MODULE
ENGINE CONTROL
MODULE TRANSPONDER
CHIP

Tyre Pressure Monitoring System Tyre pressure sensor - Situated inside the
front and rear wheel. Each sensor has its own
<TPMS> unique ID number and must be recorded in
the spaces provided in the owner handbook.
These sensors measure the air pressure inside
System Description
the tyre and transmit pressure data to the
This Speed Triple can be fitted with the accessory tyre instruments. These sensors will not transmit the
pressure monitoring system ITPMS>. data until the motorcycle is travelling at a speed
When fitted the tyre pressures shown on the instrument greater than 12 mph <20 km>. Two dashes will
panel indicate the actual tyre pressure at the time of be visible in the display area until the tyre
selecting the display. This may differ from the inflation pressure signal is received.
pressure set when the tyres are cold because tyres · The wheel sensor is a sealed unit and must not
become warmer during riding, causing the air in the tyre be opened. The battery inside the sensor is not
to expand and the pressure to increase. The cold inflation replaceable and a new sensor must be fitted
pressures specified by Triumph take account of this. when the battery voltage becomes too low.
In addition, the system has an on-board diagnostic
function. This ensures that, should a malfunction occur in Compliance
the immobiliser system, a malfunction code is stored in
the immobiliser/tyre pressure monitoring system <TPMS> This device complies with part 15 of the FCC Rules.
control modules memory. This stored data can then be Operation is subject to the following two conditions:
recovered using the Triumph diagnostic tool (see
This device may not cause harmful interference;
page 10-30>.
Owners must only adjust tyre pressures when the tyres This device must accept any interference
are cold using an accurate tyre pressure gauge and must received, including interference that may cause
not use the tyre pressure display on the instruments. undesired operation.
Changes or modifications to the device could void the

user's authority to operate the equipment.
The tyre pressure monitoring system is not to be used
as a tyre pressure gauge when adjusting the tyre Diagnostics
pressures. For correct tyre pressures, always check the
tyre pressures when the tyres are cold and using an When a fault condition with the TPMS is detected, the red
accurate tyre pressure gauge. warning light in the instrument pack will illuminate and
the tyre symbol will flash repeatedly.
Use of the TPMS system to set inflation pressures may
lead to incorrect tyre pressures leading to loss of The red warning light and flashing symbol will also occur
motorcycle control and an accident. if the TPMS has been enabled in the instrument pack but
not in the immobiliserff PMS control module. Before
When fitting the TPMS, the installation flow-chart detailed proceeding to the diagnostics, check that the motorcycle
in the Triumph diagnostic tool user guide must be has wheel sensors fitted and that the option for the TPMS
followed. has been enabled in the immobiliserffPMS control
module.
System Components and Operation

Further Diagnosis
Instruments - Used to display the tyre
pressure value, the tyre symbol and the TPMS The tables that start on page 10-38, if used correctly, help
warning light. to pinpoint a fault in the system once a diagnostic trouble
code has been stored.
lmmobiliser/TPMS control module
Receives the data from the tyre pressure
sensors and sends the information to the
instrument pack.

Component Locations
TYRE SYMBOL
TYRE PRESSURE
DISPLAY
IMMOBI ISER/TPMS
CONTROL MODULE
TYRE PRESSURE
SENSOR

Engine Management Circuit Diagram - Speed Triple with ABS
Key to Wiring Circuit Diagram Key to Wiring Colour Codes

Code Wiring Colour
Key Item Description B Black
1 Engine Control Module
u Blue
2 Diagnostic Connector
N Brown
3 Vehicle Speed Sensor
G Green
4 Instrument Assembly
5 ABS Module s Slate/Grey
6 lmmobiliser/TPMS Control Module 0 Orange
7 Ignition Switch K Pink

8 Clutch Switch R Red
9 Side Stand Switch p Purple
10 Fuel Level Sender
w White
11 Fall Detection Switch
y Yellow
12 Barometric Pressure Sensor
LG Light Green
13 Intake Air Temperature Sensor
14 MAP Sensor LU Light Blue
15 Coolant Temperature Sensor ECM Connector Pin Numbering

16 Oxygen Sensor
Connector B CGrey) Connector A <Blackl
17 Throttle Position Sensor
18 Fuel Pump
19 Fuel Pump Relay
20 Cooling Fan
21 Cooling Fan Relay
The above illustration shows the pin numbering system
22 Idle Speed Control Stepper Motor used in the engine management circuit diagram.
23 Ignition Coils The black connector's pins are prefixed A and the grey
24 Sub Harness connector's pins B. As viewed on the mating face with the
ECM (as per the illustration), pins are numbered from
25 Secondary Air Injection Solenoid
right to left with number one in the top right corner.
26 330 Ohm Resistor
27 Neutral Switch
28 Crankshaft Sensor
29 Engine Management System Relay

Engine Management Circuit Diagram
,.
171-------UP - - - - - < Al
29 28 B2J BY
LJ---11! - ----< All 85
2
A24
27 A34 K Y -- - - - - + - - - - + - - - - - <
- - - - - - - - - -8w A31 _c-s 3
B2l!
4
827
- YKVR
'-+--+-- R
Um7
1
5
- -----1 A15
t-0< VP- ----! A14
YB - - - - - ! A1 3
~----------N K ------iM
, . - - -- - -- - NK
A33
23
, . . . . - - - - - - - NK ~ GK------1 A16
- - - - -- -- - NK ~GP-------1818
~------ NK ~ GB ------1 a17
22 A' l
ON - - - - - - 4 K<'l
OW- - - - - - 4 AZJ
8Z1 t----======K~-----fl
----KB==lJ
11
B2 OU A2<I
8'3 O K -- - - t A21
: i-------+--+------.KP~ 12
~ KB B~
21
IE
819
835 All --Fl

1 - - - - - + - + - - -KO
815
A35
----KB----tJ 13
8
_J___ __L_
B
,_______ ::---=fl 14
...-+---K===LJ
~-0-1 20
BY - - - - - - - - - - - - ! B30
19
16
~--BP ---------------j 829

18 '1 AlD GY---------lJ
.____ _ _ _f, l 17

Engine Management Circuit Diagram - Speed Triple without ABS
Key to Wiring Circuit Diagram Key to Wiring Colour Codes

Code Wiring Colour
u Blue
N Brown
3 Vehicle Speed Sensor
G Green
4 Instrument Assembly
5 lmmobiliserffPMS Control Module s Slate/Grey
6 Ignition Switch 0 Orange
7 Clutch Switch K Pink

8 Sidestand Switch R Red
9 Fuel level Sender p Purple
10 Fall Detection Switch
w White
11 Barometric Pressure Sensor
y Yellow
12 Intake Air Temperature Sensor
LG Light Green
13 MAP Sensor
14 Coolant Temperature Sensor LU Light Blue
15 Oxygen Sensor ECM Connector Pin Numbering

16 Throttle Position Sensor
Connector B <Grey> Connector A <Black>
17 Fuel Pump
B18~B01
~
18 Fuel Pump Relay
19 Cooling Fan
20 Cooling Fan Relay ~6 BN
21 Idle Speed Control Stepper Motor

22 Ignition Coils used in the engine management circuit diagram.
23 Sub Harness The black connector's pins are prefixed A and the grey
24 Secondary Air Injection Solenoid connector's pins B. As viewed on the mating face with the
ECM (as per the illustration), pins are numbered from
25 330 Ohm Resistor
right to left with number one in the top right corner.
26 Neutral switch
27 Crankshaft Sensor
28 Engine Management System Relay

Engine Management Circuit Diagram
28 27 CJ===!#'
2 ue
Al
A9
823
BS
A24
2
3 1
26 A34 KY
8W AJ1 _c-0 3
25
"'z
K
[~' 4
2
~
89
BB
828
B27
4
23
NK
---El~ 1
:
A15
A14
YB
NK
A13
NJ 6[}]
BG
"ill
R
B
6
5
10
S
w A32
80~7
91}
814
__Ls a
NK
BA ~B
l
.t.33
22 8
NK~GK
'.!<
NK
~
~
GP
GB
A18
818
817
84 BG
KB
rn 9
21
A4
A' l
ON
ON
A22
A23
821
w=t]
Kl!
K •
6
1Q
82
B' J
OU
OK
A2!l
A21
81
A27
820 KB
~
=tJ 1
8
20 "'1:1
~
819
3 1 2 s
B3S
816
A11
KO==[] 12
KB 2
AJS
~3
B B
__L_ __L_
K
KS 2 13
~-0--1
NK
~
19
BY 830
18
/\26 15
w
BP
17 'l 829
A10
016
System Diagnostics Note:

When a fault has been rectified, the MIL will
The engine management system has an on-board
remain illuminated until sufficient non-fault
diagnostics feature which allows service technicians to
warm-up cycles have taken place to turn it off.
retrieve stored data from the ECM using Triumph
The MIL will be immediately extinguished if,
diagnostic software. Full details of the Triumph
after first rectifying the fault, the OTC
diagnostic software operation and how to interpret
(diagnostic trouble code> that caused the MIL
the results are given in the Triumph Diagnostic Tool
illumination is erased from the ECM memory
User Guide.
using the Triumph diagnostic tool.
The software is connected, via an interface cable, to the
motorcycle using a dedicated diagnostic plug situated Note:
beneath the seat. By using a dedicated plug, no electrical In most cases, when a fault is detected, the
connectors associated with the system are disturbed, engine management system will revert to a
reducing potential connector damage. 'limp-home' mode. In this mode, the engine
The software allows the user to retrieve data associated will still function though the performance and
with the system sensors and actuators, test various fuel economy may be marginally affected. In
component functions, read build data and make minor some cases, the rider may not notice any
adjustments to the set-up of the system. The data and appreciable difference from normal operation.
tests available are described on the following pages.
On-board Fault Detection System

The on-board diagnostic system has two stages to fault
detection. When a fault is detected, the DSM <Diagnostic
Status Manager} raises a flag to indicate that a fault is
present and increments a counter. The counter checks the
number of instances that the fault is noted. For example, if
there is a fault in the crankshaft position sensor, the
counter will increment its count each time the crankshaft
turns through 3 60°, provided the fault is still present.
When the count begins, the fault is detected but not
confirmed. If the fault continues to be detected and the
count reaches a pre-determined threshold, the fault
becomes confirmed. If the fault is an emissions related
fault or a serious malfunction affecting engine
performance, a DTC <Diagnostic Trouble Code) and freeze
frame data will be logged in the ECM's memory and the
MIL <Malfunction Indicator Lamp) on the motorcycle
instrument panel is illuminated. Once a fault is confirmed,
the number of warm-up cycles made by the engine is
counted. If the fault clears, the warm-up cycle counter will
extinguish the MIL <Malfunction Indicator Lamp) at a pre
determined count, and erase the DTC and freeze frame
data from the ECM memory at another (higher) count.
A single warm-up cycle is deemed to have taken place
when the following criteria have been met:
The coolant temperature must be raised to
72°C or more.
The coolant temperature must have risen by
23°C or more from its start temperature, when
72°C is reached.
A controlled power-down sequence must take
place.

Diagnostic Interface Connection Triumph Diagnostic software

1. To connect the Triumph diagnostic interface to the Described on the following pages is the range of
motorcycle, remove the seat <see page 16-70) and information which can be retrieved from the ECM's
release the diagnostic connector from its locating memory and the adjustments which can be performed
tang. using the Triumph diagnostic software.
The tables indicate which tests are performed by the
on-board system and what information can be retrieved
0 by the Triumph diagnostic software.
Note:
Full details of how to operate the software can
be found in the Triumph Diagnostic Tool User
Guide, which can be downloaded by authorised
Triumph dealers from www.triumphonline.net.
Build Data
The Build Data screen will display the following
information:
1. Diagnostic connector Motorcycle model;
2. Plug the diagnostic interface directly into the Vehicle Identification Number <VIN);
diagnostic connector. ECM type;
ECM ID;
ECM serial number;
Tune number;
Date of last tune download;
Total tune downloads since manufacture;
The lock status of the ECM <ECM Locked,
Unlocked or Not Applicable>.
Diagnostic Interlace
3. When the diagnostic session is completed,
disconnect the Triumph diagnostic interface.
4. Refit the diagnostic connector to its locating tang and
refit the seat <see page 16-1 T>.

Current Data
The data available under Current Data is:
Function Examined Result Reported (Scale>
Fuel system status open or closed loop operation
Calculated load value %

Engine coolant temperature oc
Short term fuel trim %
Intake manifold absolute pressure mm/hg
Engine speed rpm

Vehicle speed km/h
Ignition timing advance degrees

Intake air temperature oc
Absolute throttle position %
Oxygen sensor Volts

Sensor Data
When using this function it is possible to check the status of various sensors and actuators.
The data sets are divided into seven groups - Sensor Voltages; Sensor Readings; Injector Data; Ignition Data; Idle Speed,
Throttle Data and Inputs and Adaption Status. Each of these screens is described on the following pages.
Sensor Voltages
The data available under Sensor Voltages is:
Item Checked Result Unit
Battery voltage Volts
Voltage from ignition switch to ECU Volts
Air temperature sensor voltage Volts
Coolant temperature sensor voltage Volts
Atmospheric pressure sensor voltage Volts
Manifold absolute pressure sensor voltage Volts
Throttle position sensor voltage Volts
Fuel level sensor voltage Volts
Oxygen sensor output voltage Volts
Sensor Readings
The data available under Sensor Readings is:
Air temperature oc
Coolant temperature oc
Atmospheric (barometric) pressure mm Hg
Manifold absolute pressure (one reading per cylinder) mm Hg
Low fuel light on/off
Oxygen sensor heater status on/off

lniector Data
The data available under iniector data is:

lniector 1 pulse time milliseconds
Injector 2 pulse time milliseconds
Injector 3 pulse time milliseconds
Ignition Data
The data available under ignition Data is:

Ignition timing cyl 1 degrees BTDC
Coil 1 dwell time milliseconds
Idle Speed and Throttle Data

Engine speed RPM
Idle reference speed RPM
Idle speed control current steps numeric
Idle speed control target steps numeric
Throttle position %open

Secondary air injection status SAi on/off

Inputs
The data available under Inputs is:
Function Examined Result Unit
EMS Main relay status relay on/off
Fuel pump relay status on/off
Starter relay status starter on/off
Starter switch status switch on/off
Side stand status up/down
Fall detection status normal/over
Clutch switch status release/grip
Neutral switch gear/neutral
Vehicle speed km/h
Malfunction indicator light status MIL on/off
Cooling fan status fan on/off
Calculated load %
Purge valve duty cycle %
Adaption Status
Because the fuel system is adaptive, the engine management system is able to automatically adjust to new working
conditions, such as changes in fuel quality, component wear, air leaks etc. This screen displays information on the adaption
status of the vehicle which will show if it has adapted or not
Function Examined Report Method
Closed throttle position adapted adapted/not adapted
Idle speed control adaption status %
Oxygen sensor adaption range (off idle) %
Oxygen sensor adaption range (idle) %
Oxygen sensor adaption status (off idle) %
Oxygen sensor adaption status (idle) %

Function Tests
The system allows the diagnostic software to perform a series of function tests on various actuators in the engine
management system. In some cases it is necessary to make a visual observation of a component and in others, if faults are
present, DTCs will be logged.
The Function Tests available are:

Instrument panel Observe instrument panel, refer to service manual
Idle air control stepper motor Observe throttle position/Stored fault code*
Purge valve Listen for valve operation/Stored fault code*
Fuel pump - priming Listen for fuel pump operation/Stored fault code*
Fuel pump - continuous operation Fuel pressure test/Listen for fuel pump operation/Stored fault code*
Cooling Fan Control Observe the cooling fan/Stored fault code*
Secondary air injection Listen for valve operation/Stored fault code*

* If a fault is detected.
Adiust Tune
Using the Triumph diagnostic software, it is possible to:
reset the adaptions;
balance the throttle bodies.
Further functions are provided to allow correct replacement and adjustment of the:
throttle position sensor;
idle speed control stepper motor.
These functions are needed as, after replacement of the parts concerned, adjustments have to be made to specific voltage
settings, with the throttles set in a specific position.
To reset the adaptions, see page 10-124.
To replace and adjust the throttle position sensor, see page 10-119.
To replace and adjust the ISC stepper motor, see page 10-120.
To balance the throttles, see page 10-117.

Freeze Frame Data

Freeze frame data is stored at the time a DTC is recorded (confirmed) by the ECM. If multiple DTCs are recorded, the
freeze frame data which is stored will relate to the first recorded DTC only.
By calling up freeze frame data associated with the first recorded DTC, the technician can check the engine condition at
the time the fault occurred. The data available is:

DTC Diagnostic Trouble Code <DTO number
Fuel system status open or closed loop operation
Calculated load %
Coolant temperature oc
Short term fuel trim %
Intake manifold absolute pressure mm/hg
Engine speed RPM

Vehicle speed km/h
Ignition advance degrees

Intake air temperature oc
Throttle position %
Oxygen sensor output voltage Volts
Oxygen sensor short term fuel trim %

Diagnostic Trouble Codes

Diagnostic trouble codes CDTCs) are logged in the ECM memory when there is a confirmed fault in the system.
The codes are reported to the Triumph diagnostic tool as a four digit code.
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 ECM also records this fact and will turn off the MIL when sufficient no-fault warm-up cycles
have taken place. Any fault codes will remain in the ECM memory until the required number of no-fault warm-up cycles
have taken place. The number of warm-up cycles required to extinguish the MIL will always be less than the number
required to remove a DTC from the ECM memory. DTCs can be removed at any time using the Triumph diagnostic tool.
The system will log the diagnostic trouble codes listed below/over:
Diagnostic Fault Description Number of Number of MIL

Trouble no-fault no-fault illuminated
Code <OTC> cycles cycles when fault
before before OTC is logged
turning off is erased
MIL
P0201 Injector 1 circuit malfunction 3 40 Yes
P0351 Ignition coil fault - coil 1 3 40 Yes
P0335 Crankshaft sensor circuit malfunction 3 40 Yes
P0032 Oxygen sensor heater short circuit to vBatt 3 40 Yes
P0031 Oxygen sensor heater open circuit/short to ground 3 40 Yes
P0030 Oxygen sensor heater circuit malfunction 3 40 Yes
P0130 Oxygen sensor circuit malfunction 3 40 Yes
P0122 Throttle position sensor low input 3 40 Yes
P0123 Throttle position sensor 1 short circuit to vBatt 3 40 Yes
P0107 Manifold absolute pressure sensor 1 short circuit to 3 40 Yes
ground
P0108 Manifold absolute pressure sensor 1 open circuit or short 3 40 Yes
circuit to 5 Volt sensor supply
P1105 Manifold absolute pressure sensor pipe malfunction 3 40 Yes
P1107 Ambient air pressure sensor circuit short circuit to ground 3 40 Yes
P1108 Ambient air pressure sensor circuit open circuit or short 3 40 Yes
POl12 Intake air temperature sensor short circuit to ground 3 40 Yes
P0113 Intake air temperature sensor open circuit or short circuit 3 40 Yes
to 5 Volt sensor supply
P0117 Engine coolant temperature sensor short circuit to ground 3 40 Yes
P0118 Engine coolant temperature sensor open circuit or short 3 40 Yes
Vehicle speed sensor malfunction - motorcycles with a
POSOO 3 40 Yes
vehicle speed sensor

Diagnostic Fault Description Number of Number of MIL

Trouble no-fault no-fault illuminated
Code <OTC> cycles cycles when fault
before beforeDTC is logged
turning off is erased
MIL
Rear wheel speed sensor malfunction - motorcycles
POSOO 3 40 Yes
without a vehicle speed sensor
P1552 Cooling fan relay short circuit to ground or open circuit 3 40 Yes
P1553 Cooling fan relay short circuit to vBatt or over temp 3 40 Yes
P1231 Fuel pump relay short circuit to ground or open circuit 3 40 Yes
P1232 Fuel pump relay short circuit to vBatt 3 40 Yes
P0444 Purge valve short circuit to ground or open circuit 3 40 Yes
P0445 Purge valve system short circuit to battery 3 40 Yes
P0617 Starter relay short circuit to vBatt 3 40 Yes
P0616 Starter relay short circuit to ground or open circuit 3 40 Yes
P0414 Secondary air injection short circuit to vBatt 3 40 Yes
Secondary air injection short circuit to ground or open

P0413 3 40 Yes
circuit
PO SOS Idle speed control system malfunction 3 40 Yes
P1631 Fall detection circuit short circuit to ground 3 40 Yes
P1632 Fall detection circuit short circuit to vBatt 3 40 Yes
POS60 System voltage - battery circuit malfunction 3 40 Yes
P1659 Ignition power supply malfunction 0 40 No
P1685 Main relay circuit malfunction 3 40 Yes
P0603 EEPROM fault 0 40 No
P1696 5 V sensor supply short circuit to ground 3 40 Yes
P1697 5 V sensor supply short circuit to vBatt 3 40 Yes
P1698 5 V sensor supply malfunction 3 40 Yes
Only if
P1605 ECM locked by the tunelock function Tunelock is N/A Flashing
unlocked
Only if
P1614 ECM or ID Incorrect Instrument NIA Flashing
ID Matching
P1690 CAN communication malfunction 3 40 Yes
P1695 Lost communication with the instrument panel 3 40 Yes
P1650 Lost communication with Immobiliser ECM 3 40 Yes
P1508 Unmatched Immobiliser ECM 3 40 Flashing
P1520 ABS modulator ID incompatable 3 40 Flashing
P1521 Lost communication with the ABS modulator 3 40 Yes
P0460 Fuel level sensor 3 40 Yes

lmmobiliser/TPMS Control Module Diagnostic Trouble Codes

Diagnostic trouble codes <DTCs) are logged in the immobiliserfTPMS control module memory when there is a confirmed
fault in the system.
The system will log the diagnostic trouble codes listed below:
Diagnostic Trouble Fault Description Warning Light/Information

Code <OTC>
LOOOl Front wheel sensor unit battery alert For low battery voltage - LO bAt
visible in the instrument display
screen. the TPMS symbol in the
display screen will indicate which
sensor has low battery voltage.
For zero battery voltage - Only
L0002 Rear wheel sensor unit battery alert
dashes will be visible in the
instrument display screen, TPMS
warning light ON and the TPMS
symbol in the display screen will
flash ON and OFF
L0003 Front wheel sensor unit fault alert
L0004 Rear wheel sensor unit fault alert
TPMS warning light ON and the
LOOOS Front wheel sensor unit loss of communication error TPMS symbol in the display screen
will flash ON and OFF
L0006 Rear wheel sensor unit loss of communication error
L0007 Immobiliser ECM fault
L0008 Invalid key: Key authentication unsuccessful Alarm/Immobiliser light ON

Electrical Connectors Disconnection of ECM connectors
Before beginning any diagnosis, the following connector Note:

related information should be noted: Two different coloured and shaped connectors
A major cause of hidden electrical faults can be traced to are used in the ECM, which ensures correct
faulty electrical connectors, for example: connection is always made. The connectors on
the ECM are coloured black and grey, and
Dirty/corroded terminals.
correspond with identical connectors on the
Damp terminals. main harness.
Broken or bent cable pins within multi-plugs.

A Caution
For example, the Engine Control Module <ECM) relies on
When disconnecting a connector, never pull directly on
the supply of accurate information to enable it to plan the
the wires as this may result in cable and connector
correct fuelling and ignition timing. One dirty terminal will
damage.
cause an excessive voltage drop resulting in an incorrect
signal to the ECM.
If, when carrying out fault diagnosis, a fault appears to
clear by simply disconnecting and reconnecting an
A Caution
electrical plug, examine each disconnected plug for the Never disconnect an ECM when the ignition switch is in
following. the 'ON ' position as this may cause multiple fault codes
to be logged in the ECM memory.
Always disconnect an ECM after disconnecting the
Before Disconnection:
battery, negative (black) lead first.
If testing with a Voltmeter, the voltage across a
connector should be virtually battery Volts 1. Turn the ignition to the OFF position and wait at least
(unless a resistor is fitted in the circuit). If there 1 minute for the ECM to complete its power down
is a noticeable change, suspect faulty/dirty sequence.
connections. 2. If fitted, the security bracket must be removed (see
page 10-104).
When Disconnecting a Connector: 3. Move the cover on the connector to access the
locking device.
Check for a security device that must be 4. Press down on the locking device and gently pull
released before the connector can be
back on the connector to release it from the ECM.
separated, e.g. barb, hook and eye etc.
When Inspecting a Connector:

Check that the individual pins have not been
bent
Check for dampness/dirt/corrosion.
Check cables for security.
Check cable pin joints for damage.
When Connecting a Connector:

Ensure there is no dirt around the
connector/seal.
1. Locking device
Push together squarely to ensure terminals are Note:
not bent or incorrectly located.
The ECM is located under the seat.
Push the two halves together positively.

Reconnection of ECM connectors Further Diagnosis
A Caution
The tables that follow will, if used correctly, help to
pinpoint a fault in the system once a diagnostic trouble
Damage to the connector pins may result if an attempt
to fit the connectors incorrectly is made.
1. Fit the connector into its socket and, whilst holding

the connector in place, insert it fully into the ECM
until the locking device retains it.
2. If fitted, refit the security bracket with a new fixing
(see page 10-106>.

Crankshaft Sensor
Fault Code Possible cause Action

P0335 Crankshaft sensor system fault View &. note diagnostic tool
1
freeze frame 1 data if available.
Ensure sensor is fitted correctly and
connector is secure.
Disconnect ECM and proceed to
pinpoint test 1.
Pinpoint Tests
Test Result Action

1 Check terminal and cable integrity: OK Disconnect sensor and proceed to
- ECM pin A01 test 2
- ECM pin A09
Faulty Rectify fault, proceed to test 6
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin AOl to earth Short circuit Locate and rectify wiring fault, proceed to
- ECM pin A09 to earth test 6
3 Check cable continuity: OK Proceed to test 4
- ECM pin AOl to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin A09 to sensor pin 2 test 6
4 Check cable for short circuit: OK Renew crankshaft sensor, proceed to test 5
- ECM pin AOl to ECM pin A09 Short circuit Locate and rectify wiring fault, proceed to
test 6
5 Check crank toothed wheel: OK Proceed to test 6

- Damage to teeth - magnetic debris
contamination
Faulty Clean/renew toothed wheel, proceed to test 6
6 Reconnect harness, clear fault code and run OK Action complete - quit test
engine to verify fault cleared
Fault still present Contact Triumph service
Circuit Diagram
Crankshaft Engine
Sensor Control Module
~uP-----fATl
LEJ--ue---E_J

Idle Speed Control

PO SOS ISC stepper motor/wiring fault View & note diagnostic tool
'freeze frame' data if available.
View & note diagnostic tool 'sensor'
data.
Ensure sensor connector is secure.
pinpoint test 1.
Pinpoint Tests
Test Result Action

1 Check cable and terminal integrity: OK Proceed to test 2
- ECM pin A22 Faulty Rectify fault, proceed to test 7
- ECM pin A23
- ECM pin A20
- ECM pin A21
2 Check resistance value: 40 to 120 Disconnect stepper motor and proceed to
test 3
- ECM pin A22 to ECM pin A23 Open circuit Proceed to test 4
- ECM pin A20 to ECM pin A21
Short circuit Disconnect stepper motor and proceed to
test 5
- ECM pin A2 2 to earth Short circuit Locate and rectify wiring fault, proceed to
- ECM pin A23 to earth test 7
- ECM pin A20 to earth
- ECM pin A21 to earth
- ECM pin A22 to stepper motor pin A4 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin A23 to stepper motor pin A1 test 7
- ECM pin A20 to stepper motor pin 82
- ECM pin A21 to stepper motor pin B3
- ECM pin A22 to ECM pin A23 Short circuit Locate and rectify wiring fault, proceed to
- ECM pin A20 to ECM pin A21 test 7
6 Check stepper motor resistance: 40 to 120 Proceed to test 7
- Motor pin A4 to motor pin AOl Faulty Renew stepper motor, proceed to test 7
- Motor pin 802 to motor pin B03
diagnostic tool function test to visually verify
operation of stepper motor

Circuit Diagram
Engine
Control Module
Idle Speed Control
Stepper Motor
ON A22
0 A23
OU A20
OK A21

Fuel lniectors

P0201/02/03 Injection system fault - Injector 112/3 View &. note diagnostic tool
1
- Misfire indicates open circuit freeze frame' data if available.
- Flooding indicates short circuit Ensure relevant injector connector is

secure. Disconnect ECM and proceed
to pinpoint test 1.
Pinpoint Tests
Test Result Action


- ECM pin A14
- ECM pin A13
2 Check resistance value: 12.50 to 14.00 Proceed to test 3

- ECM pin A06 to ECM pin A 15 <injector 1)
- ECM pin A06 to ECM pin A 14 (injector 2)
- ECM pin A06 to ECM pin A 13 (injector 3)
Open circuit Disconnect relevant injector and proceed to
test 4
Short circuit Disconnect relevant injector and proceed to

test 5
3 Check cable for short circuit to ground: OK Proceed to test 7
- ECM pin A 15 to earth Short circuit Locate and rectify wiring fault, proceed to
- ECM pin A 14 to earth test 7
- ECM pin A 13 to earth

- ECM pin A06 to relevant injector pin 2 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin A 15 to injector 1 pin 1 test 7
- ECM pin A 14 to injector 2 pin 1

- ECM pin A 13 to injector 3 pin 1
5 Check cable for short circuit to supply box: OK Proceed to test 6

- ECM pin A06 to ECM pin A 15 Cinj 1) Short circuit Locate and rectify wiring fault, proceed to
- ECM pin A06 to ECM pin A 14 Cinj 2) test 7
- ECM pin A06 to ECM pin A 13 Cinj 3)
6 Check relevant injector resistance: 12.SQ to 14.00 Proceed to test 7
- Injector pin 1 to injector pin 2 Faulty Renew relevant injector, proceed to test 7

Circuit Diagram
EMS Relay
ECM
3 2 1 5
Sub Harness Connector
YK 1 - - - -YK AIS
yp 1 - - - -yp A14
YB 1----YB AB
Fuel Injectors

Throttle Position Sensor

P0122 Throttle position sensor low input View & note diagnostic tool
P0123 voltage {short to ground or open 'freeze frame' data if available.
circuit) View & note diagnostic tool 'sensor'
Throttle position sensor 1 short circuit data.
to vBatt Ensure sensor connector is secure.
pinpoint test 1.
Pinpoint Tests
Test Result Action

1 Check cable and terminal integrity: OK Disconnect sensor and proceed to test 2
- ECM pin A10
- ECM pin 801
- ECM pin 820

- ECM pin A 10 to ground
Short circuit Locate and rectify wiring fault, proceed to

test 5
- ECM pin A 10 to sensor pin 1
- ECM pin 820 to sensor pin 2
Open circuit Locate and rectify wiring fault, proceed to

test 5
4 Check cable for short circuit: OK Renew throttle position sensor, proceed to
- ECM pin A 10 to ECM pin 801 test 5
- ECM pin A 10 to ECM pin 820

test 5

Circuit Diagram
ECM
Throttle
Position Sensor
D
GY AlO
KB 820
Bl

Purge Valve
P0444 Purge valve short circuit to ground or View & note diagnostic tool 'sensor'
open circuit data.
Ensure purge valve connedor is
secure.
Disconned ECM and proceed to
pinpoint test 1.
P0445 Short circuit to battery+ Disconned purge valve and proceed

to pinpoint test 5.
Pinpoint Tests
Test Result Action

- ECM pin 809 Faulty Rectify fault, proceed to test 7
2 Check resistance value: 24Q to 28Q Disconned purge valve and proceed to test 3
- ECM pin A06 to ECM pin 809 Open circuit Proceed to test 4
Short circuit Disconned purge valve and proceed to test 5
- ECM pin 809 to earth Short circuit Locate and redify wiring fault, proceed to
test 7
- ECM pin 809 to valve pin 2 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin A06 to valve pin 1 test 7

- ECM pin A06 to ECM pin 809 Short circuit Locate and rectify wiring fault, proceed to
test 7
6 Check purge valve resistance: 24Q to 28Q Proceed to test 7
- Valve pin 1 to valve pin 2 Faulty Renew purge valve, proceed to test 7
7 Reconned harness, clear fault code and run OK Adion complete - quit test
operation of purge valve
Fault Contad Triumph service

Circuit Diagram
EMS Relay
Sub Harness Connector
ECM
._______::=[]

Ignition Coils
P0351/52/53 Ignition system fault - lgn coil 1/2/3 View &. note diagnostic tool
'freeze frame' data if available.
Ensure relevant ign coil connector is
to pinpoint test 1.
Pinpoint Tests
Test Result Action
- ECM pin B17 Faulty Rectify fault, proceed to test 7

- ECM pin A18
- ECM pin B18
2 Check resistance value: 0.8Q to 1.2Q Proceed to test 3

ECM pin A06 to
- ECM pin Cign coil 1) A 18
- ECM pin Cign coil 2) B 18
Open circuit Disconnect relevant ignition coil and proceed

to test 4
Short circuit Disconnect relevant ignition coil and proceed

to test 5
- ECM pin to earth A 18 Short circuit Locate and rectify wiring fault, proceed to
- ECM pin to earth B 18 test 7
- ECM pin to earth B17
Power latch relay pin 5 to any ign coil pin 1 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin A 18 to ign coil 1 pin 2 test 7
- ECM pin B18 to ign coil 2 pin 2

- ECM pin B 17 to ign coil 3 pin 2
ECM pin A06 to Short circuit Locate and rectify wiring fault, proceed to
- ECM pin Cign coil 1) A 18 test 7
- ECM pin {ign coil 3) B 17
6 Check relevant ign coil resistance: 0.8Q to 1.2Q Proceed to test 7

- lgn coil pin 1 to ign coil pin 2 Faulty Renew relevant ignition coil, proceed to test 7

Circuit Diagram
EMS Relay
ECM
A6
----NK ~GK A18
K ~GP B18
NK ~GB B17
Ignition Coils

Coolant Temperature Sensor
P0118 Engine coolant temperature sensor View & note diagnostic tool
open circuit or short circuit to 5 Volt 'freeze frame' data if available.
sensor supply View & note diagnostic tool 'sensor'
data.
pinpoint test 1.
P0117 Engine coolant temperature sensor Disconnect sensor and proceed to
short circuit to ground test 6.
Pinpoint Tests
Test Result Action

- ECM pin 820
2 Check resistance value: OK Disconnect temp sensor and proceed to test 6
- ECM pin A29 to ECM pin 820 Open circuit Disconnect sensor and proceed to test 3
<Temperature dependent,-see below)
Short circuit Disconnect temp sensor and proceed to test 4
- ECM pin A29 to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin 820 to sensor pin 2 test 7

- ECM pin A29 to ECM pin 820 Short circuit Locate and rectify wiring fault, proceed to
test 7
5 Check sensor resistance: OK Proceed to test 7
- Sensor pin 1 to sensor pin 2 Faulty Renew temp sensor, proceed to test 7
<Temperature dependent - see below)
- ECM pin A29 to ground Short circuit Locate and rectify wiring fault, proceed to
test 7
7 Reconnect harness, dear fault code and run OK Action complete - quit test

Circuit Diagram
Resistance data under typical conditions:
Warm engine: . .... ..... ...... 200 to 400Q
Cold engine:
20°C ambient ....... .. ...... .. 2.35 to 2.65KQ
- 10°C ambient . .. . ............ 8.50 to 10.2SKQ
Coolant
ECM
T•~~~
L:J---KGLJ

Inlet Air Temperature Sensor
P0113 Intake air temperature sensor open View & note diagnostic tool
circuit or short circuit to 5 Volt sensor 'freeze frame' data if available.
supply View & note diagnostic tool 'sensor'
data.
pinpoint test 1.
P0112 Intake air temperature sensor short Disconnect sensor and proceed to
circuit to ground pinpoint test 6.
Pinpoint Tests
Test Result Action

- ECM pin 820
2 Check resistance value: OK Disconnect temp sensor and proceed to test 6

- ECM pin A 11 to ECM pin 820
(Temperature dependent-see below) Open circuit Disconnect temp sensor and proceed to test 3
Short circuit Disconnect temp sensor and proceed to test 4
- ECM pin A 11 to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin A 11 to ECM pin 820 Short circuit Locate and rectify wiring fault, proceed to
test 7
5 Check sensor resistance: OK Proceed to test 7
- Sensor pin 1 to sensor pin 2 Faulty Renew temp sensor, proceed to test 7
ITemperature dependent-see below)
- ECM pin A 11 to ground Short circuit Locate and rectify wiring fault, proceed to
test 7
Fault still present Contad Triumph service

Circuit Diagram
If engine is warm, remove sensor and allow time to cool to ambient prior to test
Resistance data:
Ambient temp .. . . . . ...... .... Resistance value
80°C .... ..... .. .. . .......... 200 to 400n
20°C ........................ 2.35 to 2.65Kn
-10°C. ...... ... .............. 8.50 to 10.25KQ
Inlet Air
Temperature
ECM Sensor
~KB-n
~Ko--LJ

Fuel Pump Relay

P1231 Fuel pump relay short circuit to Check if pump runs briefly when
ground or open circuit ignition is switched on.
Ensure fuel pump relay connector is
secure.
pinpoint test 1.
P1232 Fuel pump relay short circuit to vBatt Disconnect fuel pump relay and
proceed to pinpoint test 4.
Pinpoint Tests
Test Result Action

1 Check cable and terminal integrity: OK Disconnect fuel pump relay and proceed to
test 2
- ECM pin 829 to earth Short circuit Locate and rectify wiring fault, proceed to
test 5
- ECM pin 829 to fuel pump relay pin 2 Open circuit Locate and rectify wiring fault, proceed to
test 4
diagnostic tool function test to verify fault
cleared
Circuit Diagram
Fuel Pump Relay
ECM
.______,.---[]

System Voltage

P0560 Bike voltage system fault View & note diagnostic tool 'sensor'
data.
Ensure voltage across battery is
acceptable, note voltage.
pinpoint test 1.
Pinpoint Tests
Test Result Action

1
2 With Ignition 'ON check voltage at:
, Same as 'across Proceed to test 3
battery' voltage
- ECM pin A6 Less than 'across Locate and rectify wiring fault, proceed to
battery' voltage test 3
3 Reconnect harness, clear fa ult code and run OK Action complete - quit test
Circuit Diagram
EMS Relay
5 1 2 3
ECM
NK A6
f:
B35
816
A35

Cooling Fan Relay
P1552 Cooling fan relay short circuit to View &. note diagnostic tool 'sensor'
ground or open circuit data.
Ensure fan relay connector is secure.
pinpoint test 1.
P1553 Cooling fan relay short circuit to vBatt Disconnect fan relay and proceed to
or over temp pinpoint test 4.
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect fan relay and proceed to test 2
- ECM pin 830 to ground Short circuit Locate and rectify wiring fault, proceed to
test 5

- Fan relay pin 2 to ECM pin 830 Open circuit Locate and rectify wiring fault, proceed to
- Fan relay pin 1 to EMS relay pin 5 test 5
- ECM pin 830 to ECM pin A6 Short circuit Locate and rectify wiring fault, proceed to
test 5
operation of cooling fan
Circuit Diagram
EMS Relay Cooling Fan Relay
5 1 l 3 ECM

Oxygen Sensor

P0130 Oxygen sensor circuit fault View &. note 'freeze frame' data if
available.
1
View &. note 'sensor data.
pinpoint test 1.
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect oxygen sensor and proceed to
test 2
- ECM pin 820
- ECM pin A26 to ECM pin B20 Short circuit Locate and rectify wiring fault, proceed to
- ECM pin A26 to ECM pin A6 test 4

engine. Check adaptation status
Circuit Diagram
EMS Relay Lambda Sensor
3 1 2 4 ECM
._____ w 814
A26
.__-----KB 820
...._----------NK A6

Oxygen Sensor Heater
P0031 Oxygen sensor heater circuit short View &. note 'freeze frame' data if
circuit to ground or open circuit available.
View &. note 'sensor' data.
pinpoint test 1.
P0032 Oxygen sensor heater circuit, short Disconnect oxygen sensor and
circuit to vBatt proceed to pinpoint test 4.
Pinpoint Tests
Test Result Action

1 Check cable and terminal integrity: OK Disconnect oxygen sensor and proceed to
- ECM pin B14 test 2

- ECM pin B 14 to ground Short circuit Locate and rectify wiring fault, proceed to
test 5
- ECM pin B 14 to sensor pin 4 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin A06 to sensor pin 3 test 5
4 Check cable for short circuit: OK Renew oxygen sensor and proceed to test 5
- ECM pin B 14 to ECM pin A06

test 5
5 Reconnect harness, clear fault code and run OK Action complete, quit test
engine. Check adaption status
Circuit Diagram
EMS Relay 1..'3mbda Sensor
ECM
.....__ _ W B14
A26
....._-----KB B20
....._---------~NK A6

Fall Detection Switch

P1631 Fall detection circuit short circuit to View & note 'freeze frame' data if
ground available.
P1632 Fall detection switch high input View&. note 'sensor' data.
voltage or open circuit Ensure switch connector is secure.
pinpoint test 1.
Pinpoint Tests
Test Result Action

- ECM pin 821 to ECM pin A06 test 6

- ECM pin B1 to sensor pin 4 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin B20 to sensor pin 6

- Sensor pin 4 to sensor pin 5 Short circuit Locate and rectify wiring fault, proceed to
- Sensor pin 4 to sensor pin 6 test 6
5 Check voltage <with ignition on>: sv Renew fall detection switch and proceed to
test 6
- Sensor pin 4 Less than 4.8 V Locate and rectify wiring fault, proceed to
test 6
6 Reconnect harness, clear fault code OK Action complete, quit test
Circuit Diagram
Fall
ECM Detection
KB=t]
Switch
KU 5
K 4

Vehicle Speed/Wheel Sensor

POSOO - Motorcycles with vehicle Vehicle speed sensor circuit fault_ View & note 'freeze frame' data if
speed sensor motorcycles without ABS and available.
motorcycles with ABS 2011 model View & note 'sensor' data.
year
Ensure sensor connedor is secure.
pinpoint test 1.
Rear wheel speed sensor - Refer to C1613 (see page 14-64).

motorcycles with ABS from 2012
model year
Pinpoint Tests
Test Result Action

1 Check cable and terminal integrity: OK Disconnect ambient pressure sensor and
proceed to test 2

- Instrument pin 9
- ECM pin A34 to ground Faulty Locate and rectify wiring fault, proceed to
- ECM pin A34 to ECM pin B1 test 4
- ECM pin A34 to battery
3 Check cable for continuity: OK Renew vehicle speed sensor and proceed to
test 4
- ECM pin A34 to sensor pin 3 Open circuit Locate and redify wiring fault, proceed to
- Sensor pin 2 to ground test 4
- Instruments pin 9 to sensor pin 1
engine

Circuit Diagram
Rear Fuse Box

r -- - - - ,
5
I I
'--------WU E:=::J e
I lOA I
L __ ___ _J
ECM
Road KY - -- - - - - 1 A34
Speed Sensor

CAN Communication
P1690 Fault in CAN communication between View & note 'freeze frame' data if
ECM and other CAN nodes available.
(Immobiliser unit, instruments and Ensure ignition switch is in 'OFF
ABS module) position.
Proceed to pinpoint test 1.
Pinpoint Test
Test Result Action
1 Check cable and terminal integrity: OK Disconnect the ECM and proceed to test 2

- ECM pin 827
- Immobiliser pin 1
- Immobiliser pin 6
- Instrument pin 4
- Instrument pin 5
- ABS unit pin 1
- Diagnostic connector pin 6
- Diagnostic connector pin 14
- ECM pin B28 to ground Faulty Locate and rectify wiring fault, proceed to
- ECM pin B27 to ground test 4
3 Check cable resistance: More than 50.Q Contact Triumph service
- ECM pin B28 to ECM pin B27 Faulty (short circuit or Locate and rectify wiring fault, proceed to
less than SOQ) test 4
engine
Circuit Diagram
ECM Instruments
lmmobilser unit
R-f611
u--t..2_LJ
ABS unit
R---GTI
u--t.E.LJ
Diagnostic connector
R-f611
u~

Instrument Communication CCAN>
P1695 Fault in CAN communication between View & note 'freeze frame' data if
ECM and Instrument Assembly available.
View & note 'sensor' data.
Ensure Instrument connector is secure.
pinpoint test 1.
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect instruments and proceed to test 2

- ECM pin 827
- Instrument pin 4
- Instrument pin 5
- ECM pin B27 to ground test 4
3 Check cable continuity: OK Contact Triumph service
- ECM pin 828 to Instrument pin 5 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin 827 to Instrument pin 4 test 4
engine
Circuit Diagram
Instruments ECM
1151--R-f8281
~u~

Fuel Level Sensor

P0460 Fuel level sensor circuit fault View & note 'freeze frame' data if
available.
View & note 'sensor1 data.
pinpoint test 1.
Pinpoint Tests
Test Result Action

- ECM pin 820
- ECM pin B4 to ground Short circuit Locate and rectify wiring fault, proceed to
test 5
- ECM pin 84 to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed to
4 Check cable for short circuit: OK Renew fuel level sensor and proceed to test 5
- Sensor pin 1 to sensor pin 2 Short circuit Locate and rectify wiring fault, proceed to
test 5
5 Reconnect harness, clear fault code OK Action complete, quit test

Circuit Diagram
Fuel
Level
Sensor ECM
llll-sG---fs41
L__£_j--KB---E_J

Ambient Pressure Sensor
P1107 Ambient air pressure sensor circuit View & note 'freeze frame' data if
short circuit to ground available.
View & note 'sensor' data.
pinpoint test 1.
P1108 Ambient air pressure sensor circuit Disconnect ambient pressure sensor
open circuit or short circuit to 5 Volt and proceed to pinpoint test 4.
sensor supply
Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect ambient pressure sensor and
proceed to test 2
- ECM pin 820
- ECM pin 801
- ECM pin A27 to ECM 820 Short circuit Locate and rectify wiring fault, proceed to
test 5
3 Check cable for continuity: OK Renew ambient pressure sensor and proceed
to test 5
4 Check cable for short circuit: OK Renew ambient pressure sensor and proceed
- ECM pin A27 to ECM pin 801 to test 5

test 5
engine
Circuit Diagram
Ambient
Pressure
ECM Sensor
~:=t]

Manifold Absolute Pressure CMAP> Sensor
P0107 MAP sensor 1 short circuit to ground View &. note 'freeze frame' data if
available.
View &. note 'sensor' data.
pinpoint test 1.
P0108 MAP sensor 1 open circuit or short Disconnect MAP sensor and proceed
circuit to 5 Volt sensor supply to test 4.
P1105 MAP sensor pipe fault Check connection/condition of pipe
from MAP sensor to throttle body.
Pinpoint Tests
Test Result Action

1 Check cable and terminal integrity: OK Disconnect MAP sensor and proceed to test 2
- ECM pin 820
- ECM pin 801
- ECM pin A28 to ECM 820 Short circuit Locate and rectify wiring fault, proceed to
test 5
3 Check cable for continuity: OK Renew MAP sensor and proceed to test 5
4 Check cable for short circuit: OK Renew MAP sensor and proceed to test 5
- ECM pin A28 to ECM pin 801
test 5
engine
Circuit Diagram
MAP
ECM Sensor
lIJ=~=U

Secondary Air lniection Valve
P0413 Secondary air injection short circuit to View & note diagnostic tool 'sensor'
ground or open circuit data. Ensure SAi valve connector is
to pinpoint test 1.
P0414 Secondary air injection short circuit to Disconnect SAi valve and proceed to
vBatt pinpoint test 5.
Pinpoint Tests
Test Result Action

- ECM pin 80B Faulty Rectify fault, proceed to test 7
2 Check resistance value: 20.Q to 25.Q Disconnect SAi valve and proceed to test 3
- ECM pin BOB to ECM pin A06 Open circuit Proceed to test 4
Short circuit Disconnect SAi valve and proceed to test 5
- ECM pin 80B to ground Short circuit Locate and rectify wiring fault, proceed to
test 7
- ECM pin BOB to valve pin 2 Open Circuit Locate and rectify wiring fault, proceed to
- ECM pin A06 to valve pin 1 test 7

- ECM pin 80B to ECM pin A06

test 7
6 Check SAi valve resistance: 20Q to 25.Q Proceed to test 7
- Valve pin 1 to valve pin 2 Faulty Renew SAi valve, proceed to test 7
operation of SAi valve
Circuit Diagram
EMS Main Relay
NK~YO
Secondary Air Valve
' - - - - - - - - - NK
=fJ ECM
BOS
A06

EMS Main Relay Circuit

P1685 EMS Main Relay circuit fault Note that the Starter Motor cannot be
powered if a Main Relay fault exists.
Ensure the EMS Main Relay connector
is secure. Proceed to pinpoint test 1.
Pinpoint Tests
Test Result Action

1 Ensure ignition has been switched off for OK Proceed to test 2
greater than one minute. Identify EMS
Main Relay on the harness.
Check that relay operates when the ignition Faulty Disconnect ECM and proceed to test 4
is switched on.
2 Check Rear fuse box fuse 2 integrity. OK Disconnect ECM and proceed to test 4
Faulty Disconnect ECM and proceed to test 3
3 Check cable for short circuit: OK Replace fuse 6 and proceed to test 4
- ECM pin A06 to ground Short circuit Locate and rectify wiring fault, replace fuse 2
- EMS Main Relay pin 3 to ground and proceed to test 7
4 Check cable and terminal integrity: OK Disconnect Main Relay and proceed to test 5
- ECM pin B15
- EMS Main Relay pin 1
- ECM pin B15 to ground Short circuit Locate and rectify wiring fault, proceed to
test 7
6 Check cable continuity: OK Replace EMS Main Relay and proceed to
test 7
- ECM pin A06 to EMS Relay pin 5 Open circuit Locate and rectify wiring fault, proceed to
- ECM pin B15 to Relay pin 1 test 7
- EMS Main Relay pin 2 to ground
- EMS Main Relay pin 3 to Rear Fuse box
Fuse 2
7 Reconnect harness, clear fault code. Switch OK Action complete - quit test
ignition off for longer than one minute.
Switch ignition on and check that the EMS
Main Relay operates. Start engine as final
check

Circuit Diagram
Rear Fuse Box EMS Main Relay

r - - --,
I
I
2 I
3 2 1 5
20A I
I
ECM
._ _ __:=f]

EEPROM Error

P0603 EEPROM error View & note 'freeze frame' data if
available.
No tests available - contact Triumph
service.

EMS Ignition Voltage Input Circuit

P1659 Ignition power supply malfunction Disconnect ECM and proceed to
pinpoint test 1.
Pinpoint Tests
Test Result Action
1 Check Fuse box Fuse 1 integrity OK Proceed to test 3
Faulty Proceed to test 2
2 Check cable for short circuit: OK Replace Fuse 1 and proceed to test 3
- ECM pin A 19 to ground
Short circuit Locate and rectify wiring fault, replace Fuse 2

and proceed to test 5

- Alarm Connector pin 1
- Alarm Connector pin 2
- Right hand switch cube pin 4
- Right hand switch cube pin 5
- ECM pin A 19 to Fuse box Fuse 1, note Open circuit Locate and rectify wiring, immobiliser or
that the engine stop switch must be in the engine stop switch fault, proceed to test 5
'RUN' position and any Alarm fitted must
be disarmed
Circuit Diagram
Engine
Stop Alarm
Switch Control Unit
I
o
Rear Fuse Box
~--~--~
E:::::J
lOA
L ___ __ _J
I
WU
-0 Ignition
Switch
1 5 G- - - - - '
I ~LGR-EJ·~
GN_j

S Volt Sensor Supply Circuit

P1696, P1697, P1698 5 V sensor supply short circuit to View & note 'sensor' data. Note ECM
ground sensors requiring a power supply will
5 V sensor supply short circuit to v8att not be active. Disconnect ECM and
proceed to pinpoint test 1.
5 V sensor supply malfunction
Pinpoint Tests
Test Result Action

- ECM pin 820
2 Check cable for short circuit OK Proceed to test 4
- ECM pin B01 to ECM pin 820
3 Disconnect the following sensors in turn: OK Replace sensor last removed and proceed to
test 5
- MAP sensor Faulty Proceed to test 4
- Ambient pressure sensor
- Throttle position switch
- Fall detection sensor and retest for short
circuit
- ECM pin 801 to ECM pin 820
- ECM pin 820 to ground test 5
- ECM pin 801 ~o A06
- ECM pin 820 to A06
- ECM pin 801 to battery positive
- ECM pin 820 to battery positive
5 Reconnect harness, clear fault code and use OK Action complete - quit test
service tool to check for correct sensor
outputs and 5 V sensor supply voltage level
Circuit Diagram
Ambient
Pressure MAP Sensor Fall Detection Throttle
Sensor Switch Position
ECM
~KB
L_j-K TI IJ IJ II
Tune Lock

P1605 ECM locked by the tunelock function This is also identified by a fast flashing
MIL indication and a disabled engine
management system. Unlock the
ECM using the diagnostic software
and supplied unlock code from
Triumph service.

ECM or Tune ID Incorrect
P1614 ECM or tune is incorrect, causing the This is also identified by a fast flashing
ECM to be disabled to prevent the MIL indication and a disabled engine
motorcycle from being operated management system.
Pinpoint Tests
Test Result Action
1 Check ECM part number is correct for the OK Proceed to test 2

motorcycle
Faulty Replace ECM with correct part and proceed
to test 3
2 Check that the tune is correct for the OK Proceed to test 3
motorcycle, using the diagnostic software
Faulty Update the tune using the diagnostic
software, proceed to test 3
3 Clear fault code, check for normal operation OK Action complete - quit test

Immobiliser and TPMS Control Module Communication

P1650 Lost communication with View & note 'freeze frame' data if
Immobiliser ECM available.
Ensure immobiliser and TPMS control
module connedor is secure.
Ensure the ignition switch is turned to
the OFF position.
Pinpoint Tests
Test Result Action

1 Check cable and terminal integrity: OK Disconned ECM and proceed to test 2
- ECM pin 828 Faulty Redify fault, proceed to test 4
- ECM pin 827
- Immobiliser pin 1
- Immobiliser pin 6
2 Check cable for short circuit: OK Disconnect immobiliser, ignition switch and
proceed to test 3
- ECM pin 828 to ground Faulty Locate and rectify wiring fault, proceed to
3 Check cable continuity: OK Contad Triumph service

- ECM pin 828 to immobiliser pin 6 Fault still present Locate and redify wiring fault, proceed to
- ECM pin 827 to immobiliser pin 1 test 4
- Immobiliser pin 7 to ground

- Ignition switch pin 5 to immobiliser pin 2
- Ignition switch pin 5 to immobiliser pin 8
4 Reconned harness, clear fault code and run OK Adion complete, quit test
engine
Circuit Diagram
R~ECM
u-E_J
Immobiliser
GR----"'I'~
Unit
68 "I
1~111 I
'l_ ~~
L___J LJ Antenna
Ignition Switch

Immobiliser and TPMS Control Module ID lncompatable

P1508 Unmatched Immobiliser ECM, This is also identified by a fast flashing
causing the ECM to be disabled to MIL indication and a disabled engine
prevent the motorcycle from being management system.
operated
Pinpoint Tests
Test Result Action

1 Follow the Pair ECM and Immobilise OK Action complete, quit test
procedure as described in the Triumph
Diagnostic Tool user guide

ABS Modulator ID lncompatable

P1520 There is a mismatch between the Check ABS modulator part number is
ECM and the ABS modulator, causing correct for the motorcycle.
the ECM to be disabled to prevent the
motorcycle from being operated

ABS Modulator Communication

1
P1521 Fault in CAN communication between View &. note 'freeze frame data if
ECM and ABS modulator available.
Ensure ABS modulator connector is
secure.
Pinpoint Test
Test Result Action
1 Check cable and terminal integrity: OK Disconnect ECM and proceed to test 2

- ECM pin B27
- ABS modulator pin 1
- ABS modulator pin 17
2 Check cable for short circuit: OK Disconnect ABS modulator and proceed to
test 3
- ECM pin B28 to ABS modulator pin 1 Fault still present Locate and rectify wiring fault, proceed to
- ECM pin 827 to ABS modulator pin 17 test 4
engine
Circuit Diagram
ABS
Modulator
Q= R=[]28
u 827
ECM

Fault Finding - Non Electrical
Symptom Possible cause(s)

Poor throttle response at low RPM Low fuel pressure caused by filter blockage/leaks
Cutting out at idle Throttle bodies out of balance
!SC (Idle Speed Control) actuator inoperative
Low fuel pressure
Weak mixture caused by air leak at the throttle

body/transition piece to cylinder head face
Idle speed too low/high ISC <Idle Speed Control) actuator sticking
Incorrect closed throttle position setting
Mechanical fault with the throttle linkage
Diagnostic software malfunctions during tune download Low battery voltage

procedure
Throttle hang-up Incorrect closed throttle position setting
Motorcycle will start but cuts out immediately ISC motor stuck
Low fuel pressure caused by filter blockage/leaks
Abnormally high fuel pressure Fuel pressure regulator inoperative
Temperature gauge reads cooler than normal Cooling system air-locked resulting in coolant temperature
sensor operating in air instead of coolant
Motorcycle will not start Check the immobiliser system for faults
Ensure that the keys, ECM and immobiliser/TPMS control

module are all correctly paired

Front Wheel Unit Sensor Battery Alert

Note:
All the fault codes for the tyre pressure monitoring system and the immobiliser system can only be
viewed in the Safety/Security section of the Triumph diagnostic software.

L0001 Low battery voltage Replace the front wheel pressure
or sensor following the procedure
described in the Triumph diagnostic
The TPMS tyre symbol in the
tool user guide.
instrument pack will be on for
8 seconds with the 'F' symbol with 'lo Record the new sensor's ID number
bAtt' shown in the display screen into the owner handbook before
fitting.

Rear Wheel Unit Sensor Battery Alert
L0002 Low battery voltage Replace the rear wheel pressure

or sensor following the procedure
The TPMS tyre symbol in the
tool. user guide.
instrument pack will be on for
8 seconds with the 'F' symbol with 'lo Record the new sensor's ID number
bAtt1 shown in the display screen into the owner handbook before
fitting.

Front Wheel Unit Sensor Fault Alert

L0003 The front wheel pressure sensor has If the problem persists:
detected a hardware error Replace the front wheel pressure
Note: This OTC will automatically be sensor following the procedure
generated if OTC L0007 occurs described in the Triumph diagnostic
tool user guide.
Record the new sensor's ID number
into the owner handbook before
fitting.

Rear Wheel Unit Sensor Fault Alert

L0004 The rear wheel pressure sensor has If the problem persists:
detected a hardware error Replace the rear wheel pressure
Note: This DTC will automatically be sensor following the procedure
generated if DTC L0007 occurs described in the Triumph diagnostic
tool user guide.
fitting.

Front Wheel Unit Sensor Loss of Communication

Note:
Refer to the owner's handbook for the wheel pressure sensors ID numbers.

LOOOS lmmobiliserff PMS control module If the problem persists:
has lost communication with the front Using the Triumph diagnostic tool,
wheel sensor unit check that the correct ID number for
Low battery voltage the front wheel pressure sensor is
Wrong sensor ID number has been registered to the lmmobiliserffPMS
registered in the immobiliserffPMS control module.
control module Replace the front wheel pressure
sensor following the procedure
tool user guide.
fitting.

Rear Wheel Unit Sensor Loss of Communication

Note:

L0006 lmmobiliserffPMS control module If the problem persists:
has lost communication with the rear Using the Triumph diagnostic tool,
wheel sensor unit check that the correct ID number for
Low battery voltage the rear wheel pressure sensor is
Wrong sensor ID number has been registered to the lmmobiliserffPMS
registered in the immobiliserffPMS control module.
control module Replace the rear wheel pressure
sensor following the procedure
tool user guide.
fitting.

lmmobiliser/TPMS Control Module Fault

Note:
L0007 Immobiliser ECM fault Using the Triumph diagnostic tool,

lmmobiliserfTPMS control module check that the correct ID numbers for
has lost communication with the front the wheel pressure sensors are
and rear wheel sensor units registered to the lmmobiliser!TPMS
control module.
Low battery voltage
If the correct IDs are registered,
Wrong sensor ID numbers have been
replace the front and rear wheel
registered in the immobiliserfTPMS
pressure sensor following the
control module
procedure described in the Triumph
diagnostic tool user guide.
fitting.

Invalid Key: Key Authentication Unsuccessful

L0008 lmmobiliserfTPMS control module Check that the key has been
or cannot identify the transponder chip registered with the immobiliser!TPMS
in the key control module, if it is a new key or an
Alarm/immobiliser warning indicator
additional key.
light is on when the ignition switch is
at the ON position (only visible on Check that there are no additional
motorcycles without the accessory keys with a transponder chip fitted
alarm fitted) close to the ignition key and proceed
to pinpoint test 1.
Pinpoint Tests
Test Result Action

1 If available, try to start the motorcycle with OK Transponder chip in the key not functioning
the second registered key: correctly. Register a new key using the
Triumph diagnostic tool then proceed to
test 5
2 Check the condition of cable, connector OK Disconnect the ignition switch, proceed to
housing and terminals for the following: test 3
- Ignition switch Faulty Rectify fault, proceed to test 5

- Immobiliser and TPMS control module
3 Check antenna coil resistance: 70. to 130. Proceed to test 4
- Ignition switch pin 2 to ignition switch Faulty Replace the ignition switch, register new keys
pin 7 and proceed to test 5
- Ignition switch pin 7 to Immobiliser and Faulty Rectify fault, proceed to test 5
TPMS control module pin 10
- Ignition switch pin 2 to Immobiliser and
TPMS control module pin 5
engine
Circuit Diagram
. - - ---BG
I .-----B 10 Immobiliser
Unit
~ a>
I I
11 4568 271
I I I I I I I
S::z >- ~ ~ LJ:z
3::
Ignition
Switch LJ Antenna

Fuel Tank - Raising and Supporting 4. Remove the fuel tank support from its location under
the seat base.
Note:
The fuel tank may be raised without being
removed completely, for access to the battery
and the coolant expansion tank for topping-up.
1. Remove the seat (see page 16-10>.

from the fuel tank.
1. Seat
2. Fuel tank prop
5. Pivot the fuel tank upwards at the front. While
holding the fuel tank in the raised position, locate the
fuel tank prop into the support points on the airbox
and fuel tank.
cgfo " "
1. Front panel
2. Fixings
3. Remove the front fixings for the fuel tank.
1. Fuel tank prop

2. Fuel tank
3. Supporting point, fuel tank
4. Supporting point, airbox
1. Fixings
2. Fuel tank

Fuel Tank - Lowering and Securing Fuel Tank
1. Support the fuel tank and remove the tank support.

Removal
2. Lower the fuel tank into position and secure with the
two fixings. Tighten to 4 Nm.
fixings to 2 Nm. Observe the warning advice given in the general
4. Securely fit the fuel tank support to its location under information section on the safe handling of fuel and fuel
the seat base. containers.
5. Refit the seat (see page 16-1 n. A fire, causing personal injury and damage to property,
6. If a bellypan is fitted, ensure that the three drain could result from spilled fuel or fuel not handled or
hoses protrude below the lower edge of the stored correctly.
bellypan's side moulding, as shown below.
2. Raise and support the fuel tank (see page 10-92).
Note:
Before disconnection, note that the front
breather hose has a larger diameter than the
rear hose. Ensure they are returned to the
same locations when refitting the tank.
4. Disconnect the two breather hoses.
T1031
1. Side panel
2. Drain hoses
·A Caution
If the fuel tank is raised or removed, the fuel tank drain
hoses will be pulled above the lower edge of the
bellypan's side moulding. This may allow water and/or
fuel to drain onto the painted surface of the bellypan.
To prevent paint damage, ensure the three drain hoses cgtq
protrude below the lower edge of the bellypan's side 1. Front breather hose
moulding after the fuel tank has been lowered and 2. Rear breather hose
secured.
If the fuel rail is dismantled without first reducing

pressure, fuel may escape causing clothing and
components to be coated with fuel.
This would represent a serious fire hazard which could
lead to burn injuries and damage to property.

Note: 8. Remove the bolt and its tube securing the rear of the
fuel tank to the frame.
Because fuel stored in the fuel rail will be at
3 bar pressure, it is essential that the fuel 9. Remove the fuel tank from the frame.
pressure is reduced before any dismantling of
the fuel rail takes place. To reduce pressure, Installation
briefly crank the engine with the fuel pump
disconnected. 1. Position the fuel tank to the frame.
When disconnected, the fuel tank is self-sealing
2. Fit the bolt and its tube to secure the rear of the fuel
but a small amount of fuel may dribble from
tank to the frame and tighten to 9 Nm.
the hose.
3. Pivot the fuel tank upwards at the front. While
5. Ease the latch away from the fuel connector until the
holding the fuel tank in the raised position, locate the
release buttons are exposed.
fuel tank prop into the support points on the airbox
and fuel tank.
1. Locked position 1. Fuel tank prop

2. Unlocked position 2. Fuel tank
6. Disconnect the fuel hose by squeezing the sides of 3. Supporting point, fuel tank
the connector and pulling the hose free from the 4. Supporting point
spigot. 4. Reconnect the fuel feed hose by gently pushing
Z Disconnect the electrical connections to the fuel level inwards until the hose engages with a click.
sender and the fuel pump. 5. Slide the double check latch down (i.e. towards the
spigot) until the release buttons are covered. If the
latch will not slide into position, then the fuel hose is
not fully home on its spigot and must therefore be
refitted correctly.
6. Reconnect the fuel pump electrical connection.
Z Reconnect the fuel level sender electrical connection.
8. Reconnect the two breather hoses as noted for
removal.
9. Lower and secure the fuel tank (see page 10-93).
10. Securely fit the fuel tank support to its location under
the seat base.
cgub
1. Fuel hose
2. Fuel gauge connection
3. Fuel pump connection

Fuel Pump and Filter Assembly Z Remove the fixings securing the fuel pump
mounting plate to the tank Remove the plate.
Removal
Note:
The fuel pump and filter assembly is a sealed
for life unit and must be replaced as a
complete assembly.
1. Remove the seat (see page 16-10).

from the fuel tank.
1. Fuel pump
2. Fuel pump spigot
3. Mounting plate
4. Mounting plate fixings
8. Lift the fuel pump and filter assembly and

manoeuvre it from the fuel tank aperture.
9. Disconnect the fuel level sensor electrical connector
and remove the fuel pump and filter assembly.
1. Front panel
2. Fixings
3. Disconnect the battery, negative (black) lead first

5. Drain the fuel tank into a suitable container.
Observe the warning advice given in the general

information section on the safe handling of fuel and fuel
containers. '1: Fuel level sensor electrical connector
A fire, causing personal injury and damage to property, 10. Noting its orientation, remove and discard the
could result from spilled fuel or fuel not handled or sealing ring from the fuel pump assembly.
stored correctly.
6. Invert the fuel tank and place on a protective surface

to prevent paint damage.
Fuel Pump and Filter Assembly

Installation S. Tighten the fixings in the sequence shown below to

9Nm.
1. Install a new sealing ring into the fuel pump
assembly, with the seal lip facing uppermost, and
ensure that it is correctly seated.
-------~2
~1
cguc_2
Pump Mounting Plate Torque Sequence

1. Sealing ring
2. Seal lip 6. Refit the fuel tank (see page 10-96).
2. Taking care to ensure the sealing ring is not 7. Refill the fuel tank with the fuel drained earlier.
damaged or dislodged, manoeuvre the fuel pump 8. Reconnect the battery, positive (red) lead first.
assembly into the tank aperture.
3. Reconnect the fuel level sensor electrical connector fixings to 2 Nm.
and locate the fuel pump and filter assembly. 10. Start the engine and check carefully for fuel leaks.
4. Ensure the locating peg on the fuel pump assembly Rectify as necessary.
is located in the cut out on the mounting plate and 11. Refit the seat (see page 16-1 n.
the offset hole is positioned as shown below.
cguc_1
1. Offset hole position

2. Locating peg

Fuel Level Sender Assembly Installation
1. Refit the fuel level sender assembly to the fuel tank

Removal ensuring that the upper tang and two side tangs are
correctly attached to the bracket inside the fuel tank.
from the fuel tank.
cegy
1. Upper tang
2. Side tangs
2. Refit the fuel pump and filter assembly (see
1. Front panel page 10-96).
2. Fixings
3. Refill the fuel tank with the fuel drained earlier.
3. Disconnect the battery, negative (black) lead first 4. Reconnect the battery, positive (red) lead first.
4. Remove the fuel pump and filter assembly <see 5. Refit the front panel to the fuel tank and tighten the
page 10-95). fixings to 2 Nm.
5. Release the two side tangs securing the fuel level 6. Start the engine and check carefully for fuel leaks.
sender to the bracket inside the fuel tank and Rectify as necessary.
carefully withdraw the fuel level sender.
Z Refit the seat {see page 16-1 T>.
1. Fuel level sensor

2. Tangs

Fuel Pressure Checking 4. Connect the adapter hose to the fuel pump plate
outlet as shown in the illustration below.
Observe the fuel handling precautions given in the

general information system.
Fuel pressure is checked using service tool T3880001.
clac
1. Adaptor hose 'B'

2. Fuel pump plate outlet
DII 3. Extension cable T3880123
5. Connect the adapter between the fuel pump plate

cdgh
outlet and fuel hose as shown in the illustration
below. Insert the gauge to the adapter also as shown
Tool T3 880001 in the illustration.
1. Remove the fuel tank (see page 10-93) and place on

a suitable support, close to the motorcycle.
2. Using the extension cable T3880123, carefully
connect the fuel pump connection on the main
harness to the fuel tank. Connect the other end of
the extension cable to the motorcycle main harness. 5
3. Select the fuel pressure gauge adapter marked 'B'
from service tool T3880001.
Always use the correct fuel pressure gauge adapter

<adapter 'B' for 1050 cc Speed Triple from
VIN 305060> and Speed Triple R. Use of an 'II
cgwg fiJJ O
incorrect adapter will result in a fuel leak. A fuel leak can
1. Motorcycle fuel hose
result in a fire causing damage to property and injury to
2. Adaptor hose 'B'
persons.
4. Wiring extension T3880123
6. Fuel pump plate outlet

Note: Fuel Delivery System

To release the fuel pressure gauge from the Fuel is delivered to the injectors by a pump located inside
adapter, slide the outer ferrule downwards. the fuel tank. Fuel flows in the direction of the arrows
This will allow the gauge to spring upwards shown in the diagram below.
from the adapter.
Incorporated in the fuel pump assembly is a filter, a
To insert the gauge to the adapter, push the
pressure regulator and a pick-up strainer.
gauge spigot into the adapter until a click can
be heard.
6. Ensure the gauge is visible to the side of the
motorcycle.
7. Start the engine and observe the fuel pressure
reading on the gauge.
Note:
The fuel pressure should be 3.0 bar nominally.
8. When fuel pressure checking is complete, turn the
ignition to the OFF position, disconnect the fuel
pressure gauge adapter and wiring extension.
9. Refit the fuel tank (see page 70-96>.
~ f:
'-t
~
\
\
\\
~
Direction of Fuel Flow
Seavice Manual - Speed Triple and Speed Triple R 10.99

Airbox 9. Release the fixings and detach the

immobiliserfTPMS control module from the airbox.
Removal

from the fuel tank.
1. Immobiliser and TPMS module

2. Fixings
3. Air temperature sensor
Note:
1. Front panel Note the routing of the battery cables for
2. Fixings installation.
2. Disconnect the battery, negative (black) lead first 10. Remove the battery strap.
3. Remove the seat (see page 16-10>. 11. Remove fixings securing the air filter housing and
detach the battery cables from the airbox.
4. Remove the fuel tank <see page 10-93).
5. Remove the battery <see page 17-8>.
6. Disconnect the hose and multi-plug from the
secondary air iniection control valve.
cgsb
~
1. Air filter housing
2. Fixings
3. Battery cables
1. Hose
2. Multi-plug
3. Secondary air injection control valve
7. Remove the MAP sensor (see page 10-108).
8. Disconnect the multi-plug from the air temperature
sensor.

12. Remove and discard the front fixings of the airbox. Installation
1. Position the airbox to the forward location and push

home.
2. Press down on the rear of the airbox to locate the
intake rubbers to the throttle bodies.
A Caution
Always ensure that all 3 intake rubbers seal to the
throttles through 360° as poor performance and lack of
power can result from incorrect sealing.
3. Fit and tighten the airbox rear fixings to 5 Nm.

4. Fit new front fixings and tighten to 10 Nm.
5. Fit the breather drain hose to the rear of the airbox.
1. Fixings 6. Route the battery cables over the airbox as noted for
2. Airbox removal, refit the fixings for the air filter housing and
tighten to 3 Nm.
13. Disconnect the breather drain hose from the rear of
the airbox. 7. Attach the immobiliser and TPMS module to the
airbox, tighten the fixings to 2 Nm.
14. Remove the rear fixings of the airbox.
8. Connect the multi-plug to the air temperature
sensor.
9. Refit the MAP sensor (see page 10-708).
10. Reconnect the hose and multi-plug to the secondary
air injection control valve.
11. Fit the battery. Do not connect the battery cables at
this stage.
fixings to 2 Nm.
1. Breather drain hose

2. Fixings
15. Gently lift the rear of the airbox to release it from the
throttle bodies.
16. Once the airbox has cleared the throttle bodies, slide
it rearwards and fully remove.
Inspection
1. Inspect the intake rubbers for splits, damage and

distortion.
2. Inspect the intake rubber retaining rings for loss of
elasticity.
3. Check the airbox itself for damage.

Air Filter Element Z Lift the air filter housing out of the airbox and
remove the filter from its housing.
Removal

from the fuel tank.
1~ '.~
' ~j-
~
abdu_1
1. Airbox
3. Air filter element
cgfo" Installation
1. Front panel 1. Thoroughly clean the inside and outside of the

2. Fixings airbox.
3. Disconnect the battery, negative (black) lead first. 2. Seat the air filter element into its housing.
4. Remove the fuel tank (see page 10- 93 ). 3. With the battery leads routed as noted for removal,
locate the filter housing into the airbox, secure with
Note:
the fixings and tighten to 3 Nm.
Note the routing of the battery leads and how 4. Refit the fuel tank (see page 10-94).
they are secured to the airbox for installation.
5. Remove the battery strap.
6. Release the fixings securing the air filter housing to fixings to 2 Nm.
the airbox.
Z Refit the seat (see page 16-1 n.
cgsb

2. Fixings
3. Battery leads

Ignition Coil Seal 2. Using a clean cloth remove the powder lubricant and
any dirt/dust from the coil and its outer case.
Removal
The seal has a covering of a powder lubricant that could

get into the eyes or be inhaled. When removing or
fitting the seal always wear protective equipment for the
eyes and a mask to cover the nose and mouth.
Failure to follow the above warning may result in
personal injury.
A Caµtion
cfsk
Care must be taken when removing or fitting the seal.
Excessive force may damage the electrical connector of 1. Coil
the coil or the seal. 2. Outer case
Note:
Installation
The removal and installation of the new seal
must take place in a clean environment. Note:
Do not re-use the seal after it has been When removing the seal the outer case on the
removed from the coil, always fit. a new seal. coil will move out of position. For the correct
Do not use tools to remove the seal, the seal fitment of the seal, the outer case on the coil
must be removed by hand. must be put back to its original position.
An audible click can be heard when the outer
1. Using finger pressure only, slide the seal off the coil case is pushed back to its original position.
and its outer case.
1. Push the outer case up the coil until it clicks back into
its original position.
1~
I
cfsu_2
1. Coil
Cfsl
2. Seal
3. Outer case 1. Outer case

2. Using finger pressure only, fit the seal to the coil with Engine Control Module <ECM>
the two dimples on the seal positioned as shown
below and with the groove inside the seal aligned
with the lugs on the coil. Removal

from the fuel tank.
cfsu
1. Front panel
2. Fixings

Note:
Note the position of the relays for installation.
4. Remove the relay brace.
1. Seal
2. Dimples
3. Coil
4. Lugs
5. Seal groove
3. Check that the cap for the spark plug is fitted to the
coil correctly as shown below.
clsk_1
1. Cap
4. When the coil is fitted to the engine, ensure the seal

mates correctly with the camshaft cover.

5. Detach the relay connectors and the diagnostic 7. Remove and discard the two fir tree fasteners
connector from the underseat tray by lifting them securing the ECM cover to the underseat tray.
upwards.
8. Lift the back of the cover up to release the front

Note: locating tang from the under seat tray. Remove the
cover.
Some models may be fitted with a security
clamp around the black connector of the ECM.
Note the position and orientation of the
security clamp and bracket for installation.
6. For models with the security clamp only:
Without damaging the shear bolt guard and using a
suitable drill, carefully drill out the head of the shear
bolt from the ECM security clamp.
cgsk
~
1. Locating tang, ECM cover
2. Slot, underseat tray
A Caution
Care must be taken when moving the ECM to avoid
damaging the ambient air pressure sensor. Damage to
the ambient air pressure sensor may affect engine
performance.
2. Security clamp
3. Shear bolt guard 9. Disconnect the grey connector from the ECM.

10. For models with the security clamp only: All Models
Remove the security clamp and bracket from the 4. Fit the grey connector to the ECM and position the
ECM. ECM onto the under seat tray against its locating
tang.
~
~
ECM
1.
11. Disconnect the black connector and remove the 2. Locating tang
ECM. 5. Refit the ECM cover and secure using new fir tree
fasteners.
I nsta llatio n 6. For models with the security clamp only:
Tighten the shear bolt for the security clamp until the
1. Fit the black connector to the ECM. bolt head has sheared off.
Note: Z Attach the relays and the diagnostic connector to the
under seat tray as noted for removal.
For models with the security clamp continue
8. Refit the brace for the relays. Reconnect the battery,
from step 2.
positive (red) lead first.
For models without the security clamp,
fixings to 2 Nm.
Models With the Security Clamp Fitted 10. Refit the seat (see page 16-11).
2. Fit the bracket and security clamp to the ECM as If a new ECM is fitted it will need to be paired with the
noted for removal. immobiliserfTPMS control module as described in the
Safety/Security section of the Triumph diagnostic software.
3. Fit a new shear bolt to the security clamp. Do not
fully tighten at this stage.

Intake Air Temperature Sensor Installation
1. Fit the air temperature sensor to the airbox and

Removal tighten its fixing to 2 Nm.
2. Reconnect the air temperature sensor.
3. Refit the fuel tank <see page 10-96).
4. Reconnect the battery, positive <red} lead first.
from the fuel tank.
fixings to 2 Nm.
1. Front panel
2. Fixings
3. Disconnect the battery, negative (black> lead first
5. Disconnect the multiplug from the air temperature
sensor.
2. Fixing
3. Air temperature sensor
6. Release the fixing and remove the sensor from the
airbox.

MAP Sensor Installation
1. Refit the air hose.

Removal 2. Take a new 0-ring and lubricate it with a smear of
petroleum jelly. Fit the 0-ring to the sensor, then fit
1. Remove the seat (see page 76-10). the sensor to the airbox, tightening the screw to
2. Release the three fixings and remove the front panel 2Nm.
from the fuel tank. 3. Reconnect the multi-plug.
5. Reconnect the battery, positive (red> lead first.
fixings to 2 Nm.
Z Refit the seat (see page 76-1 n.
1. Front panel
2. Fixings

4. Remove the fuel tank (see page 10-95>.
5. Disconnect the multiplug from the MAP sensor.
~
1. Multi-plug
2. Air hose
3. MAP sensor
4. Airbox
6. Release the fixing securing the sensor to the airbox.

Z Raise the sensor, disconnect the air hose and remove
the sensor.

Barometric Pressure Sensor Installation
1. Fit the sensor and tighten its fixing to 4 Nm.

Removal 2. Reconnect the multi-plug.
3. Reconnect the battery, positive (red} lead first.
fixings to 2 Nm.
from the fuel tank.
1. Front panel
2. Fixings
4. Disconnect the multi-plug from the barometric
pressure sensor.
2
cgue \
1. Barometric pressure sensor

2. Multi-plug
3. Fixing
5. Release the fixing and remove the sensor.

Fall Detection Switch Installation
1. Fit the fall detection switch to the mounting bracket,

Removal fit new fixing screws and tighten to 3 Nm.
2. Connect the fall detection switch multiplug.
1. Remove the seat <see page 16-10>.
from the fuel tank.
fixings to 2 Nm.
1. Front panel
2. Fixings

4. Disconnect the fall detection switch multi-plug.
5. Release and discard the screws securing the switch to
the mounting bracket and remove the switch.
3. Screws

Crankshaft position sensor Installation
Note: 1. Check the sensor 0-ring for damage or

The air gap for the crankshaft position sensor is deterioration. Renew as necessary.
not adiustable.
Removal

from the fuel tank.
C<:Ny
1. Sensor
2. 0-ring
1. Apply a smear of oil to the sensor 0-ring to aid

assembly.
2. Refit the sensor taking care not to damage the
0-ring.
1. Front panel
3. Refit the sensor bracket. Fit and tighten a new fixing
2. Fixings
to 10 Nm.
2. Disconnect the battery, negative CblackJ lead first 4. Reconnect the sensor multi-plug.
3. Remove and discard the fixing securing the sensor 5. Reconnect the battery, positive (red) lead first.
bracket to the crankcase. Ease the sensor from the
crankcase.
fixings to 2 Nm.
1. Sensor
2. Sensor bracket
4. Disconnect the sensor multi-plug.

lmmobiliser/TPMS Control Module Throttle Cable
Removal Adiustment
Note:
1. To access the multi-plug for the immobiliserff PMS
control module, remove the airbox (see Minor adiustments to the opening cable can be
page 10-700>. made using the adiuster near the twist grip end
2. Disconnect the multi-plug and remove the of the throttle. Where a correct setting cannot
immobiliser!TPMS control module. be achieved this way, the adiusters at the
throttle end of both cables must be used. The
opening cable must be set first followed by the
closing cable.

from the fuel tank.
cgud
1. Multi-plug
Installation
1. Installation is the reverse of removal.

2. If a new immobiliserff PMS control module is fitted it
must be paired with the following items as described 1. Front panel
in the Safety/Security section of the Triumph 2. Fixings
diagnostic software:
ECM;
4. Set the 'opening' cable adjuster at the twist grip end
Ignition keys for the motorcycle; such that it has an equal amount of adjustment in
each direction. Tighten the locknut.
If fitted, the front and rear tyre pressure sensors.
1. 'Opening' cable adiuster <twist grip end)

6. Remove the airbox (see page 70- 100).

1
7. Set the opening' cable adjuster at the throttle end to Removal
give 2 - 3 mm of play at the twist grip. Tighten the
Note:
locknut.
Before beginning to remove the throttle
cables, note the exact routing and location of
both cables to help ensure that they are
returned to the same locations and routing on
assembly.

from the fuel tank.
ccwq
1. 10pening' cable adjuster (throttle end)

2. 'Closing' cable adjuster <throttle end>
8. With the throttle fully dosed, ensure that there is

1
2 - 3 mm of free play in the closing' cable. Adjust if
necessary, tightening the locknut to 2.5 Nm
afterwards.
Operation of the motorcycle with incorrectly adjusted, 1. Front panel

incorrectly routed or damaged throttle cables could 2. Fixings
interfere with the operation of the brakes, clutch or the 3. Disconnect the battery, negative (black) lead first.
throttle itself. Any of these conditions could result in loss
of control of the motorcycle and an accident.
6. Slacken the adjuster locknuts at the throttle body end
of the cables such that they will allow the outer
cables to be detached from the cable bracket.
Move the handlebars to left and right full lock while
checking that cables and harnesses do not bind. Cables 7. Detach the inner portion of the cables from the
or harness that bind will restrict the steering and may throttle cam.
cause loss of control and an accident.
Ensure that the adjuster locknuts are tightened. A loose

throttle cable adjuster could cause the throttle to stick
leading to loss of control and an accident.

fixings to 2 Nm.
1. Throttle cam
2. Closing cable
3. Opening cable

8. At the twist grip end, slide off the rubber boot and Installation
release the screws which secure the two halves of the
twist grip guide to each other. 1. Locate the cables to the frame following the routing
noted during removal.
2. Engage the inner cable nipples to the twist grip.
3. Assemble the two halves of the cable guide ensuring
that the outer cables are correctly located in the
guide and the guide is positioned on the handlebars
as prior to removal. Fit and tighten the screws to
3Nm.
0 0
cdgq_1 0 0
1. Twist grip
2. Twist grip guide
D 0
3. Screws
4. Rubber boot
9. Separate the two halves of the guide then release the
inner cables from the twist grip.
1. Closing cable
2. Opening cable
0 0
bJbJ
D a
1. Closing cable
2. Opening cable
cdgq_1
10. Detach the cables from the motorcycle.
1. Twist grip
2. Twist grip guide
Examination 3. Screws
4. Rubber boot
1. Check that both the throttle cables operate smoothly,
without sticking or binding. Replace the cables if
there is any doubt as to their correct operation.

4. Refit the boot. Throttle Bodiesllniectors

5. Attach the other end of the inner cables to the
throttle cam ensuring the opening cable is fitted to
the bottom of the cam and the closing cable to the Removal
top.
1. Remove the seat <see page 16-10).
6. Locate the outer cables to the bracket and secure
with the adjuster and locknuts. Tighten to 2.5 Nm. 2. Release the three fixings and remove the front panel
from the fuel tank.
Z Set the cable adjustment (see page 10-113).
8. Refit the airbox <see page 10-96).
fixings to 2 Nm.
12. Refit the seat (see page 16-10>.
1. Front panel
2. Fixings

5. Remove the airbox <see page 10-95).
6. Disconnect the throttle position sensor multi-plug.
Z Disconnect the stepper motor multi-plug.
8. Detach the MAP sensor hoses from the throttle
bodies.
9. Release both throttle cables from the throttle cam
<see page 10-95).
10. Release the clips securing the throttle bodies to the
transition pieces.
1. Throttle body
2. Transition piece <one per cylinder>
3. Clip Cone per cylinder>

11. Ease the throttle bodies from the transition pieces Installation
and lay the assembly on the crankcase.
12. Disconnect the electrical connector from each 1. Thoroughly clean the transition piece to cylinder
injector. head mating faces.
13. Release the bolts securing the fuel rail to its bracket. 2. Refit the transition pieces to the head incorporating
new 0-rings to the joint face. Tighten the transition
piece fixings to 12 Nm.
1. Fuel rail bolts

14. Ease the fuel rail and injectors from the cylinder
1. Transition piece
head.
2. 0-ring
15. To detach the injectors from the fuel rail, release the
clip at the fuel rail end of each injector and ease the 3. If the injectors have been removed from the fuel rail,
injector from the rail. refit them to the rail and secure with the clips.
4. Check the injector 0-rings for splits and other
damage. Replace as necessary.
5. Refit the injectors and fuel rail to the cylinder head.
Tighten the fuel rail fixings to 6 Nm.
1. Injector
2. Clip
3. Fuel rail
16. To detach the transition pieces from the head,
release the screws, raise the transition pieces and 1. Fuel rail bolts
collect the 0-rings. 6. Reconnect the electrical connector to each injector.
Z Refit the throttle bodies to the transition pieces and
Inspection secure with clips.
8. Reconnect the stepper motor.
1. Check all joints and seals for splits, cuts and damage.
9. Reconnect the throttle position sensor.
2. Check the throttles for sticking, loose or damaged
throttle plates.
3. Check the 0-rings for damage.

10. Reconnect the MAP sensor hoses. Throttle Body Balancing

11. Reattach and adjust the throttle cables (see
page 10-96). Note:
12. Refit the airbox (see page 70-96). The throttles cannot be balanced using
13. Refit the fuel tank <see page 10-96). equipment to measure vacuum in each
throttle. Instead, the Triumph diagnostic tool
must be used.
fixings to 2 Nm. 1. Remove the seat (see page 16-10).
16. Refit the seat (see page 16-11). 2. Release the three fixings and remove the front panel
from the fuel tank.
1. Front panel
2. Fixings
5. Remove the airbox (see page 10-95).
If the engine has recently been running, the

1
components beneath the fuel tank may be hot to the

touch.
6. Temporarily refit the fuel tank and reconnect the fuel

supply and fuel pump connection using tools
T3880001 (minus the fuel pressure gauge> and
T3880023 (see page 10-98).
Z Temporarily reconnect the battery, positive (red) lead
first
8. Attach exhaust extraction hoses to the silencers.
9. Attach the Triumph diagnostic tool start the engine
and navigate to 'ADJUST TUNE' (see page 70-30>.

10. Select 'BALANCE THROTTLES'. 12. When balanced, stop the engine and disconnect the
diagnostic tool.
Adjust Tune Procedure
14. Refit the airbox (see page 10-96).
Adjust the throttle balance as described in the service manual until
balanced 15. Refit the fuel tank (see page 10-96).
Press cancel to cancel the adjustment process
Press OK to finish 16. Reconnect the battery, positive (red) lead first.
Throttle Status: Throttles Balanced 17. Refit the front panel to the fuel tank and tighten the
fixings to 2 Nm.
Cylinder 1 MAP Pressure: 465 mmHg 18. Refit the seat (see page 16-1 n.
Cylinder 2 MAP Pressure: 464 mmHg
Cylinder 3 MAP Pressure: 465 mmHg
Q Adjusting parameter - Balance Throttles
Balance Throttles Screen

Note:
The balance throttle screens show the vacuum
value of each throttle in mm/Hg. In addition,
when the throttles are balanced to an
acceptable range of each other the word
'THROTTLES BALANCED' in green text will
appear on the right of the screen. At this point,
no further adjustment is necessary or
productive.
If the throttles are not balanced to each other
the word 'THROTTLES UNBALANCED' in red
text will appear on the right of the screen. At
this point adiustment will be necessary.
11. Using the throttle adiusters, make adiustments until
the word THROTILES BALANCED' appears.
1. Adjusters

Throttle Position Sensor Installation
1. Fit the replacement throttle position sensor ensuring

Removal the 0-ring is positioned correctly between the sensor
and throttle body.
2. Engage the new screws and washers supplied and
2. Release the three fixings and remove the front panel part tighten such that the sensor can still be rotated.
from the fuel tank.
3. Position the throttle body assembly near to its fitted
position and reconnect the sensor.
J~L
, t.
5. Attach the Triumph diagnostic tool to the dedicated
~··. "· ~\ ~ ~
1 plug.
6. Turn the ignition to the 'ON' position.
<'. \
.. ' . ' :::.-.._ ~ ,
Z Conned the diagnostic tool and navigate to, and
'\ select the 'ADJUST TUNE' option.
~
8. At the next screen, select the Throttle Position Sensor
Renew <see below) then press the adjust button.
9. On pressing the Adjust button, the diagnostic tool
will send a command which drives the throttle to the
fully closed position. The tool will also display the
voltage reading coming from the throttle position
cgfo " "
sensor.
1. Front panel
2. Fixings
Adjust the throttle position sensor as described in the service manual
4. Remove the fuel tank (see page 10-93). until the voltage reading is within the range shown below
Press OK when the adjustment is complete
5. Remove the airbox (see page 10-100). Press cancel to cancel the adjustment process
6. Remove the throttle body assembly <see

Throttle Voltage: 0.59V
page 10-115>.
Z Remove the throttle position sensor from the left
hand end of the throttle body. Coiled the 0-ring on Target Voltage Range: 0.58 v - 0.62 v
disassembly.
Q Adjusting parameter - Throttle Position Sensor Adjust
10. Gently rotate the throttle position sensor until the

voltage reading on the tool shows
0.6 Volts ±0.02 Volts. The reading on the screen will
turn green, indicating that the reading is correct.
Note:
This is a setting voltage only. Because of the
adaptive nature of the engine management
system, in-service voltage may vary from this
setting figure.
11. Tighten the sensor retaining screw to 2 Nm and
recheck the voltage reading shown on the tool.
1. Throttle position sensor
Repeat the adjustment if the reading is outside the
specified range.
12. Press the OK button to return the throttle to normal
control and return the diagnostic tool to the Adjust
Tune menu.

13. Disconnect the battery, negative (black) lead first. Idle Speed Control Stepper Motor
14. Check that the throttle opens and closes without
obstruction/sticking and has a smooth action
throughout the full range of its movement. Rectify as Removal
necessary.
from the fuel tank.
Operation of the motorcycle with an incorrectly adjusted
throttle position sensor, or a throttle position sensor that
causes the throttle to stick could result in loss of throttle
control. Loss of throttle control could result in loss of
control of the motorcycle and an accident.
Operation of the motorcycle with an incorrectly

adjusted, incorrectly routed or damaged throttle cable
could interfere with the operation of the brakes, clutch
or the throttle itself. Any of these conditions could result
in loss of control of the motorcycle and an accident.
15. Refit the throttle body assembly (see page 10-96>. cgfo " ' -
16. Refit the airbox (see page 10-96>. 1. Front panel

1Z Refit the fuel tank (see page 10-96). 2. Fixings
18. Reconnect the battery, positive Cred) lead first. 3. Disconnect the battery, negative (black) lead first.
19. Check and clear any stored faults using the Triumph 4. Remove the fuel tank <see page 10-93).
diagnostic tool.
20. Disconnect the diagnostic tool.
6. Remove the throttle bodies <see page 10-115>.
Z Remove the nylon nut, metal washer and plastic
fixings to 2 Nm.
washer attaching the idle control stepper arm to the
22. Refit the seat (see page 16-11>. idle speed control lever.
cdav
1. Idle control stepper arm

2. Idle speed control lever
3. Nut etc.

8. Remove the two screws securing the idle speed Installation

control stepper motor to its bracket, then remove the
stepper motor in the direction shown. 1. Ensure the idle speed control lever is correctly
positioned in relation to the throttle cam as shown.
cdaw
cdgr
1. Idle speed control stepper motor
2. Bracket
3. Fixings
4. Direction of removal
9. Leave the plastic collar and spring on the control
stepper arm.
cdgs
2. Loosely fit the spring and collar on the stepper arm.
cdax
1. Collar
2. Spring
cdax
1. Collar
2. Spring

3. Locate the stepper motor to its bracket and tighten 11. On pressing the Adiust button, the diagnostic tool
the fixings to 3.5 Nm. will send a command that drives the throttle to the
fully closed position. The tool will also display the
voltage reading coming from the throttle position
sensor which should be between the target voltage
range of 0.58 Volts and 0.62 Volts.
Adjust the throttle position sensor as described in the service manual

until the voltage reading is within the range shown below
Press OK when the adjustment is complete
Press cancel to cancel the adjustment process
Throttle Voltage: 0.59V
Target Voltage Range: 0.58 v - 0.62 v

cday
1. Idle speed control stepper motor

2. Bracket Q Adjusting parameter - Throttle Position Sensor Adjust
3. Fixings
4. Direction of fitting
12. Tighten the stepper arm until a clearance of 0.5 mm
4. Fit the plastic washer through the lever then fit the
can be measured between the idle speed control
metal washer and nut.
cam and the throttle roller.
5. Fit the throttle body onto the ~ngine (see
page 10-96).
6. Temporarily reconnect the battery, positive <red) lead
first.
Z Turn the ignition to the ON position.
8. Attach the Triumph diagnostic tool to the dedicated
plug; refer to the Triumph Diagnostic Tool User
Guide for additional information.
9. On the diagnostic tool navigate to Engine
Diagnostics and select the Adiust Tune button.
10. Select Idle Speed Control Stepper Renew then
press the Adiust button.
1. Idle speed control lever

2. Throttle roller
13. Check the voltage reading shown on the software. If

the reading is between the target voltage range,
then proceed to step 1Z If the reading is not within
this range, adjustment must be made as described in
steps 14 to 16.
14. Slacken the screws securing the throttle position
sensor to the throttle body.
15. Gently turn the throttle position sensor until the
voltage reading shown on the software is between
the target voltage range.

16. Tighten the sensor retaining screw to 2 Nm and 21. Turn the ignition to the OFF position.
recheck the voltage reading shown on the software. 22. Disconnect the diagnostic tool.
Repeat the adjustment if the reading is outside the
specified range.
24. Check and adjust the throttle cable settings (see
17. Press the OK button to progress to the next
page 70-173).
adjustment.
Note:
The diagnostic software will calculate the target
voltage range for when the throttle is in the
checking that the cables and harnesses do not bind. A
fully open position.
cable or harness which binds will restrict the steering
18. On pressing the OK button, the diagnostic tool will and may cause loss of control and an accident.
send a command that drives the throttle to the fully
open position. The tool will also display the voltage 25. Refit the airbox (see page 10-96).
reading coming from the throttle position sensor 26. Refit the fuel tank (see page 10-96>.
which should be between the target voltage range
calculated by the software and shown on the screen.
19. With the stepper fully opened, check the voltage
fixings to 2 Nm.
shown on the software and, if necessary, adjust the
nut on the top of the stepper arm until the software 29. Refit the seat Csee page 16-11>.
shows a voltage within the target voltage range
shown on the screen. The reading on the screen will
change from red to green, indicating that the
reading is correct.
cdba
1. Adjustment nut
20. Press the Adiust button to fully close the idle speed
control stepper motor. After a minimum of
15 seconds (the tool will show 'Adapting' and not
allow further actions to take place during this period),
press the OK button again to return the ECM to
normal control.
.A Caution
Do not operate the throttle while the stepper motor is
being adjusted, otherwise the incorrect value will be
adapted and the engine will not start.

Engine Management Adaption Terminology

Where the term 'status' is used, this indicates how far the
present operating parameter is from the stored (baseline)
General Information
value. The nearer these figures are to zero the better as it
The engine management system fitted to this model is indicates the motorcycle has adapted to its current
adaptive. This means that the system is able to learn about operating conditions.
new or changing operating conditions and continuously The term 'range' indicates how much (in percentage
adapt itself without needing to constantly make major terms) of the adjustment range has been used to reach
adjustments from a fixed baseline setting. the current operating status.
Adaptive changes can become necessary because of
changes in fuel quality, minor defects, or because a new
Status Range
part may have been fitted which has slightly different 100% - Not Adapted +100%
characteristics to the old part. All adaptive changes are
automatic and require no intervention by rider or dealer.
Adaption Status
To see if a motorcycle has fully adapted, a facility named
'ADAPTION STATUS' is provided on the diagnostic tool.
0%-Adapted
The following adaption details can be examined: 0%

-30%
Closed throttle position reference Adapted/not

status adapted
Idle speed control adaption status % -75%
Oxygen sensor adaption status (off % -100%

idle)
Oxygen sensor adaption range (off % Status versus Range
idle)
Oxygen sensor adaption status %
Typical Values
(idle)
In a correctly adapted motorcycle, the following will be
Oxygen sensor adaption range %
typical:
<idle)
Function Examined Read Out
Closed throttle position reference Adapted
status
Idle speed control adaption status Between + 100
and -1000/o
Oxygen sensor adaption status (off 0% +/- 100/o
idle>
Oxygen sensor adaption range (off Between + 100
idle> and -1000/o
Oxygen sensor adaption status 0% +/- 10%
(idle)
Oxygen sensor adaption range Between + 100
(idle) and -1000/o

Forcing adaption to take place Exhaust System

If the read-out indicates that the motorcycle is not
adapted, the following will force the system to make
Removal
adaptions:
If the engine has recently been running, the exhaust

Never start the engine or let it run for any length of time system will be hot. Before working on or near the
in a closed area. The exhaust fumes are poisonous and exhaust system, allow sufficient time for the exhaust
may cause loss of consciousness and death within a system to cool as touching any part of a hot exhaust
short time. Always operate the motorcycle in the open- system could cause burn injuries.
air or in an area with adequate ventilation.
1. Remove the seat <see page 16-10>.
Note: 2. Release the three fixings and remove the front panel
Resetting adaptions with the motorcycle from the fuel tank.
connected to an exhaust extraction system
may cause incorrect values to be set, causing
poor engine running. Always reset the
adaptions with the engine disconnected from
any exhaust extraction system whilst ensuring
the motorcycle is positioned in a well
ventilated area.
1. Ensure the engine is cold.

2. WITHOUT TOUCHING THE THROTTLE, start the
engine and allow it to warm up until the cooling fan
comes on.
3. Leave the engine to idle for a further 12 minutes.
Note: cglo " '
As an alternative to the above process, connect 1. Front panel

the diagnostic tool, select ADJUST TUNE (see 2. Fixings
the Triumph Diagnostic Tool User Guide) and
select RESET ADAPTIONS. This will force a fast 3. Disconnect the battery, negative (black) lead first
adaption routine to take place in around 4. Remove the oil cooler (see page 8-14).
S seconds. For this to happen, the engine 5. Remove the radiator (see page 11-1 n.
MUST be running, it must be at normal
6. Remove the rear panels <see page 16-11>.
operating temperature and in closed loop
control mode. Under any other conditions fast Z Remove the rear light moulding (see page 16-12).
adaption will not take place and may cause Note:
default values to be loaded, which may then
require a normal 12 minute adaption routine to Note the position and orientation of the
be run. exhaust clamps for installation.
Fault Indications
If 'range' figures at 100% are seen, then the adjustment
has reached maximum indicating a mechanical fault exists
on the motorcycle. This can be due to a number of faults
but the most likely causes will be low/high fuel pressure,
faulty injectors or air leaks at the throttle bodies or airbox.
In these circumstances, locate and rectify the fault, and
reset the adaptions as described above.

8. Release the clamps securing the silencers to the 11. Release the fixings and slide the heat shield
intermediate pipe. rearwards to remove it from the exhaust header
pipe.
cdga
1. Clamp fixing cgto
2. Silencer 1. Fixings
3. Intermediate pipe 2. Heat shield
9. Release the bolts securing the silencer mounting 12. Check, and if necessary refit, the rubber isolators
brackets to the rear frame. which are located on the heat shield as shown below.
-!--
cgrx
~
1. Bolt, right hand side shown 1. Rubber isolator, incorrectly fitted
2. Silencer mounting bracket 2. Rubber isolator, correctly fitted
3. Heat shield
10. Remove the silencers from each side and collect their
gaskets.

13. Release the clamp securing the intermediate pipe to 15. Release the fixings and remove the harness cover.
the header pipe.
1
cg we 1. Fixings
1. Clamp fixing 2. Harness cover
2. Intermediate pipe
16. Locate and disconnect the oxygen sensor multiplug
3. Header pipe
and release it from the wiring harness.
14. Release the fixing and remove the exhaust 1Z Detach the oxygen sensor harness from its clip on
intermediate pipe and collect its gasket. the crankcase and remove the oxygen sensor if
necessary.
=
1. Fixing
cgtm
2. Exhaust intermediate pipe 1. Clip
2. Harness
3. Oxygen sensor

18. Remove the bolt from the rear mounting point on 3. Fit the header pipe nuts loosely, then tighten nuts 2
the header pipe. and 4 hand tight to retain the header pipes in
position.
cgtn
1. Bolt
2. Header Pipe Header Pipe Hand Tightening Sequence
19. Release the header pipe fixings at the cylinder head. 4. Fit the rear mounting point bolt such that 1t is
20. Detach the header pipe assembly and collect the positioned to the top and front of the mounting lug.
seals from the head ports. Tighten the bolt to 25 Nm.
Installation
1. Fit new seals to the cylinder head.

Note:
A smear of grease may be used to retain the
seals in the cylinder head during assembly.
cgtn_1
1. Bolt
2. Header pipe
3. Mounting lug
caoy 2
1. Cylinder head
2. Seals
2. Locate the header pipe and align the flanges to the
cylinder head.

5. Tighten the header pipe fixings to the cylinder head 16. Tighten the silencer mounting bolts to 15 Nm.
in the following sequence.
cgll!
1. Bolt
Exhaust to Cylinder Head Tightening 2. Silencer mounting bracket
Sequence
1Z Tighten the intermediate pipe mounting bolt to
a) Tighten nuts 1 to 6 to 23 Nm in the order 15 Nm.
shown. 18. Refit and tighten the oxygen sensor to 25 Nm.
b) Retighten nuts 1 to 3 to 23 Nm in the order
shown.
6. Check the condition of the exhaust gasket, replace if
necessary, and fit to the header pipe.
Z Position the intermediate pipe clamp to the header
pipe.
8. Engage the intermediate pipe 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
stage.
9. Position the silencer clamps to the intermediate pipe
outlets.
10. Check the condition of the exhaust gaskets, replace if
necessary, and fit to the intermediate pipe.
11. Position and fully engage the silencers to the 1. Clip
intermediate pipe outlets. 2. Harness
12. Fit the silencer mounting bolts. Do not fully tighten 3. Oxygen sensor
the bolts at this stage.
19. Reconnect the oxygen sensor electrical connector
13. Orientate the clamps for the intermediate pipe and and attach the harness to its clip on the crankcase.
silencer as noted for removal.
14. Tighten the intermediate pipe to header pipe clamp
to 15 Nm.
15. Tighten the silencer clamps to 10 Nm.

20. Refit the harness cover and secure in place with its 25. Refit the rear panels (see page 76-12).
fixings. 26. Reconnect the battery, positive (red) lead first.
21. Align the heat shield to its locating tags on the 2Z Refit the front panel to the fuel tank and tighten the
header pipe. Fit the fixings and tighten to S Nm. fixings to 2 Nm.
22. Refit the radiator and refill the cooling system (see 28. Refit the seat <see page 76-1n.
page 11.1n.
29. Start the engine and check for exhaust leaks. Rectify
23. Refit the oil cooler (see page 8.14). if necessary.
24. Refit the rear light moulding <see page 16-13).

Secondary Air lniection
System Purpose and Operation
cgle
The secondary air iniection system is an aid to reducing levels of pollutants in the exhaust gases. It does this by
introducing a small amount of air into each exhaust port as the exhaust valve opens. The introduced air helps promote
further combustion of the fuel mixture in the exhaust system after it has left the combustion chamber.
At certain specific engine speeds above idle (determined by the factory programming of engine management system),
the secondary air iniection control valve is opened by the ECM and allows an air feed into the secondary air system
where, each time a pair of exhaust valves open, the exhaust gases in the exhaust port create a depression which causes
reed valves in the secondary air iniection system to open. When open, the depression in the exhaust port draws air from
the control valve, through the open reed valves, into the exhaust port. This air promotes secondary combustion of the
exhaust gases in the ports and the header system.
At other engine speeds, the system is disabled by closing the control valve in the system. This allows an oxygen sensor to
control air to fuel ratios. If air was fed to the exhaust system when the oxygen sensor was operational, the incoming air
would cause inaccuracies in the readings sensed by the oxygen sensor <which requires access to 'raw' combustion gases)
which would lead to rough running.

Secondary Air lniection Solenoid Installation

Valve 1. Carefully fit the solenoid valve to the airbox, ensure
that its seal remains fitted to the airbox.
Removal

from the fuel tank.
1. Seal
2. Airbox
2. Fit the screws and tighten to 2 Nm.

3. Reconnect the electrical connector and the hose to
the valve.
1. Front panel
2. Fixings
4. Remove the fuel tank (see page 10-93). fixings to 2 Nm.
5. Release the hose attached to the valve. Z Refit the seat (see page 16-1 n.
6. Disconnect the electrical connector, release the
screws and remove the valve.
1. Electrical connector
2. Screws
3. Valve

Secondary Air Injection Reed Valves 9. Detach the valves from the camshaft cover.
Removal

3. Remove the fuel tank (see page 10- 93).
5. Disconnect the electrical connections to the ignition
coils and remove the coils.
cbqx
1. Valves
Inspection
1. Check for cracks, bending or other damage to the

valve flaps. Replace as necessary.
2. Check for damage to the seal areas. Replace as
necessary.
3. Check the valve body to cylinder head seal for
1. Electrical connectors damage.
2. Ignition coils
6. Detach the secondary air injection feed hoses from

the reed valves on the camshaft cover.
2. Secondary air iniection hose
Z Release the bolts securing the valve covers to the

camshaft cover.
8. Ease the valve covers from the valves.

Installation Evaporative Canister <Where Fitted)

1. Fit the reed valves to the camshaft cover.
2. Refit the valve covers and tighten the fixings to
Removal
9Nm.
3. Refit the air hoses to the reed valves.
from the fuel tank.
'~
cguj ""R
2. Secondary air injection hose
1. Front panel
2. Fixings
4. Fit the ignition coils and reconnect.
4. Remove the fuel tank Csee page 10-93).
5. Disconnect the vacuum and purge pipe from the
carbon canister.
1. Coils
5. Refit the airbox Csee page 10-TOn.

6. Refit the fuel tank Csee page 10-94).
cgsu
Z Reconnect the battery, positive (red) lead first. 1. Purge pipe
8. Refit the seat (see page 16-11). 2. Vacuum pipe
3. Carbon canister

6. Cut the cable ties securing the canister to its bracket. 2. Fit the canister to its bracket in the orientation noted
for removal. Ensure the locating lugs on the canister
locate into their respective slots in the bracket.
1. Canister
2. Cable ties
Note:
Note the orientation of the carbon canister for 3. Large locating lug
installation. 4. Small locating lug
Z Remove the canister from the left hand side of the S. Large slot
motorcycle. 6. Small slot
3. Secure the canister in place with the cable ties and
Installation trim off any excess cable tie.
4. Refit the vacuum and purge pipes to the carbon
1. Fit the new cable ties to the mounting bracket for the canister.
carbon canister, as shown below.
1. Purge pipe
2. Vacuum pipe
2. Cable ties 3. Carbon canister
Z Refit the front panel to the fuel tank and tighten the
fixings to 3 Nm.

Purge Control Valve z Disconnect the electrical connector and hose from
the purge control valve.
Removal

from the fuel tank.
~I I
~
'·,'·.
1
. t .· ', }
2
' ;:;:,.__~
l 1
<@
1. Connector
2. Hose
8. Release fixings and remove the purge control valve
and bracket assembly.
cgfo " ' -
1. Front panel
2. Fixings

5. Remove the evaporative canister (see page 10-734).
6. Disconnect the electrical connector from the coolant
temperature sensor.
1. Fixings
2. Bracket
3. Purge valve
Note:
Note the routing of the cable tie and the
orientation of the purge control valve on the
bracket.
1. Connector
2. Coolant temperature sensor

9. Cut the cable tie and remove the purge control Installation
valve.
1. Fit the purge control valve to the bracket and secure
with a cable tie, as noted for removal.
2. Fit the purge control valve and bracket assembly to
the engine and tighten the fixings to 6 Nm.
3. Reconnect the electrical connector and hose to the
purge control valve.
4. Reconnect the electrical connector to the coolant
temperature sensor.
5. Fit the evaporative canister (see page 10-135).
6. Fit the fuel tank (see page 10-94).
Z Reconnect the battery, positive (red) lead first.
fixings to 2 Nm.
cgsw 9. Fit the seat (see page 16-1 n.
1. Purge control valve
2. Cable tie
3. Bracket

Evaporative Emissions Control System

If fitted, a carbon canister absorbs vapour while the engine is not running. When the engine is started, the vapour is
returned to the engine and burnt.
There are two distinct phases to the system's operation, engine off and engine running. These two conditions are
explained overleaf.
Component Locations
Carbon Canister - under the throttle bodies.
Purge Control Valve - attached to the underside of the bracket for the carbon canister (electronically controlled by the
ECM).
To throttle bodies
Carbon canister
Vacuum pipe

Evaporative Control System - Engine Off

When the engine is stationary any pressure increase in the fuel tank due to a rise in ambient temperature will cause the
fuel vapour to pass down the breather pipe A to a carbon filled canister which stores the vapour.
Once in the canister, vapour cannot return to the fuel tank because of a one-way valve in the canister.
Carbon canister

Evaporative Control System - Engine Running

When the engine is started, a vacuum is applied via pipe A to a vent valve on the canister, causing it to open.
Simultaneously, vacuum is applied along pipe B, via the purge control valve to the canister vent port.
Because the vent valve has been opened, the vacuum applied at point B begins to draw stored vapour from the carbon
filled area of the canister via the vent port and returns it to the throttle bodies for burning in the engine.
In order to control the speed at which vapour is purged from the canister, the engine management system regularly
shuttles the purge control valve between open and closed positions.
~~/ Purge control valve

\ I
;x' j
~, /
'~ Pipe A
Carbon canister ,~
~
~' //
~ / '
'~

11 Cooling
Table of Contents
Exploded View - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Coolant .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Radiator Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Radiator and Cooling Fan........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Coolant Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
Coolant Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
Drainage .................. ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. 7
Inspection ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
Coolant Pressure Cap and Coolant System Testing.. ........................................ . .. 11.9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
Expansion Tank. .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16

Cooling
Exploded View - Cooling System
2Nm
~
12 Nm - - - " ir
9Nm
10Nm
4Nm
ttt.
.,.: >4Nm
4Nm

Cooling
Coolant Radiator Hoses

A year-round, Hybrid Organic Add Technology (known as Regularly check all radiator hoses and hose clips for
Hybrid OAT or HOAD coolant is installed in the cooling cracks, leaks or deterioration in accordance with the
system when the motorcycle leaves the factory. It is scheduled maintenance chart.
coloured green, contains a 500/o solution of ethylene
glycol based antifreeze, and has a freezing point of -35°C
(-31°F>. Radiator and Cooling Fan
One of the two dyes used in HD4X Hybrid OAT Coolant Check the radiator fins for obstruction by insects, mud,
can break down at high temperatures. This indicates that leaves and general debris. Clean off any obstructions by
the coolant has been exposed to a higher than normal hand or with a stream of low pressure water.
temperature at some point and an investigation into the
cause should be carried out. The loss of colour is purely
cosmetic and is not indictive of any decrease in
performance of the product. The cooling fan operates automatically. To prevent
Always change the coolant at the intervals specified in the injury, keep hands and clothing away from the fan
Scheduled Maintenance chart. blades at all times.
The standard coolant mixture contains toxic chemicals

A Caution
Using high-pressure water sprays can damage the
that are harmful to the human body. Never swallow neat
radiator fins and impair the radiator's efficiency.
anti-freeze or any of the coolant mixture.
Do not obstruct or deflect airflow through the radiator
by installing unauthorised accessories in front of the
A Caution · radiator or behind the cooling fan. Interference with the
radiator airflow can lead to overheating and consequent
· The coolant anti-freeze contains a corrosion inhibitor engine damage.
which helps prevent damage to the metal surfaces inside
the cooling system. Without this inhibitor, the coolant
would 'attack' the metals and the resulting corrosion
would cause blockages in the cooling system leading to
engine overheating and damage.
Always use the correct anti-freeze as specified in the
owner's handbook. Never use a methanol based anti-
freeze as this does not contain the required corrosion
inhibition properties. I
Note:
HD4X Hybrid OAT coolant, as supplied by
Triumph, is pre-mixed and does not need to be
diluted prior to filling or topping up the cooling
system.

Cooling
Coolant Level Inspection Coolant Level Adiustment
Do not remove the coolant pressure cap when the Before starting work, ensure the motorcycle is stabilised
engine is hot. When the engine is hot, the coolant inside and adequately supported. This will help prevent it from
the radiator is hot and also under pressure. Contact with falling and causing injury to the operator or damage to
the pressurised coolant will cause scalds and skin the motorcycle.
damage.
1. Position the motorcycle on level ground and in an

upright position.
Do not remove the radiator pressure cap when the
2. The coolant level within the expansion tank can be
engine is hot. When the engine is hot, the coolant inside
inspected on the left hand side of the motorcycle
the radiator will be hot and also under pressure. Contact
without removing any covers.
with this hot, pressurised coolant will cause scalds and
3. Check the coolant level in the expansion tank. The skin damage.
coolant level must be between the MAX and MIN
level marks moulded into the expansion tank cover. 1. Allow the engine to cool.
If the coolant is below the minimum level, the 2. To access the expansion tank, raise and support the
coolant level must be adjusted. fuel tank <see page 70-92).
40 3. Remove the cap from the expansion tank and add

coolant mixture through the filler opening until the
level reaches the MAX mark on the expansion tank
cover.
/II
.
3 ,'/
1. Expansion tank cover

//
2. MAX mark
3. MIN mark
4. Expansion tank
cgeu_~
A Caution
1. Expansion tank
2. Tank cap
If the coolant level is found to be low, or if coolant has to 4. Refit the cap.
be added regularly, inspect the cooling system for
5. Lower and secure the fuel tank (see page 10-93).
coolant leaks. If necessary, pressure test the system to
locate the source of the leak and rectify as necessary. Note:
Loss of coolant may cause the engine to overheat and
• If the coolant level is being checked because
suffer severe damage.
the coolant has overheated, also check the
level in the radiator and top up if necessary.
In an emergency, distilled water can be added
to the cooling system. However, the coolant
must then be drained and replenished with
HD4X Hybrid OAT coolant as soon as possible.

Cooling
5. Detach the rear of the cowl from the stud on its

A Caution mounting bracket, disconnect the direction indicator
harness and remove the cowl.
If hard water is used in the cooling system, it will cause
scale accumulation in the engine and radiator and
considerably reduces the efficiency of the cooling
system. Reduced cooling system efficiency may cause
the eng ine to overheat and suffer severe damage.
Coolant Replacement
Drainage
Before starting work, ensure the motorcycle is stabilised

and adequately supported. This will help prevent it from cgvm
falling and causing injury to the operator or damage to 1. Fixings

the motorcycle. 2. Stud
3. Cowl
Note:
6. Repeat steps 4 and 5 for the right hand radiator
Prior to disassembly of the coolant hoses, note cowl.
the orientation and position of the hose clips to
help ensure that they are returned to the same
positions and orientation on assembly.
Do not remove the coolant pressure cap when the
1. Remove the seat (see page 16-10). engine is hot When the engine is hot, the coolant inside
2. Release the fixings and remove the front cover from the radiator is hot and also under pressure. Contact with
the fuel tank the pressurised coolant will cause scalds and skin
damage.
~l
Z Remove the coolant pressure cap on the radiator.
'· t ./.·.
·~---=- ·
/
cgfo~
1. Front cover
2. Fixings
3. Disconnect the battery, negative (black> lead first. cgvl_1
4. Release the fixings securing the left hand radiator 1. Radiator cap
cowl to the radiator.
8. Position a container to collect the displaced coolant.
Note:
Note the routing of the direction indicator
harness for installation.

Cooling
9. Slacken the clip then release the bottom hose from Filling
the water pump.
1. Reconnect the bottom hose and tighten the hose clip
to 2 Nm.
2. If removed, refit the drain plug with a new washer, to
cgvL2 - - -
1. Bottom hose
2. Water pump
10. To drain the crankcase completely, remove the drain

plug shown in the illustration below. Discard the
washer.
1. Bleed screw
4. Slowly add coolant mixture to the system, through

the filler opening in the radiator, until the system is
full. If the system has filled correctly and fully, there
should be coolant visible through the bleed screw
opening as well as in the filler opening.
5. If there is no coolant visible through the bleed screw
opening, but the filler side appears to be full, attach a
length of clear tubing to the bleed screw spigot and
syphon coolant into the bleed screw side of the
radiator.
Note:
A hand operated vacuum pump or similar
1. Crankcase coolant drain plug
should be used to syphon the coolant through
the system.
6. If necessary, top up the system through the filler and
refit the coolant pressure cap.
Z Fit and tighten the bleed screw to 1.5 Nm.

Cooling
9. Start the motorcycle and allow the engine to idle for Water Pump
a short period of time to allow any air to be expelled
from the system.
Removal
Note:
Do not remove the coolant pressure cap when the Prior to disassembly of the coolant hoses, note
engine is hot. When the engine is hot, the coolant inside the orientation and position of the hose clips to
the cooling system is hot and also under pressure. help ensure that they are returned to the same
Contact with the pressurised coolant will cause scalds positions and orientation on assembly.
and skin damage.
1. Release the fixings and remove the front cover from
10. Stop the engine and top up the coolant level as the fuel tank.
necessary.
11. Fit the coolant pressure cap.
12. Check the expansion tank level and top up if
necessary (see page 11-4).
13. Ensure the grommet is fitted to the cowl and the
direction indicator harness is routed as noted for
removal.
14. Fit the rear of the radiator cowl to the stud on its
mounting bracket
15. Thoroughly clean the fixings and apply a drop of
ThreeBond 1360 to the thread.
16. Fit the three fixings and tighten to 4 Nm.
2
1Z Repeat steps 13 to 15 for the other radiator cowl. cgfo "
18. Refit the front cover to the fuel tank and tighten the 1. Front cover
fixings to 2 Nm. 2. Fixings
19. Refit the seat (see page 16-11>. 2. Disconnect the battery, negative (black) lead first
3. Drain the coolant (see page 11-S>.

engine is hot When the engine is hot, the coolant inside
the radiator is hot and also under pressure. Contact with
the pressurised coolant will cause scalds and skin
damage.

Cooling
4. Disconnect the coolant hoses to the water pump. Installation
1. Fit a new 0-ring seal to the water pump.

2. Align the drive slot in the water pump with the drive
slot on the oil pump (inside the crankcase).
Note:
• The water pump will not engage fully into the
crankcase unless the drive slots are engaged.
1. Bottom hose
2. Bypass hose
3. Water pump
4. Water pump to crankcase bolts
S. Water pump cover bolt
Note:
Note the routing of the harnesses and drain gake
hose behind the water pump for installation. 1. Water pump slot
5. Release the bolts securing the water pump to the
3. Fit the pump and tighten the fixings to 10 Nm.
crankcase.
4. Refit the hoses to the water pump and tighten the
6. Withdraw the water pump.
clips to 2 Nm.
Z Remove and discard the 0-ring seal from the water
5. Refill the cooling system (see page 11-6).
pump.
Z Refit the front cover to the fuel tank and tighten the
Inspection fixings to 2 Nm.
1. Check the water pump shaft and shaft bearings for

side and end float. Renew if necessary.
2. Check for corrosion and scale build-up around the
impeller and in the pump body. Renew if necessary.

Cooling
Coolant Pressure Cap and Coolant Coolant Pressure Cap Test

System Testing
Inspection

engine is hot. When the engine is hot, the coolant inside
the pressurised coolant will cause scalds and skin
damage.
1. Allow the engine temperature to cool for at least

30 minutes. cgwp
2. Remove the coolant pressure cap. 1. Hand held pump

3. Check condition of the upper and lower seals of the 2. Bayonet type connector
coolant pressure cap. 3. Pressure cap test adaptor 44 mm
4. Pressure cap test adaptor 46 mm
1. Select the correct test adaptor and securely fasten to

the pressure cap.
2. Carefully connect the hand pump to the adaptor
ensuring an air tight seal is maintained.
cdbu
1. Lower seal
2. Upper seal
3. Spring
Note:
If there is any sign of damage or deterioration cgwq
replace the cap. 1. Pressure cap
4. Pressure test the cap to the blow off pressure of 2. Test adaptor
1.1 bar as described below using T388014Z 3. Hand held pump
Note: 3. Pressure test the coolant cap to its 1.1 bar blow off
pressure. If the coolant cap opens at a lower
It is recommended to carry out coolant
pressure, fails to open at the correct pressure or the
pressure cap and cooling system pressure test
seal leaks, replace the cap.
consecutively.

Cooling
Coolant System Pressure Test Thermostat

1. Select the bayonet type adaptor and securely fasten
to the radiator. Removal
2. Carefully connect the hand pump to the bayonet
connector ensuring an air tight seal is maintained. 1. Release the fixings and remove the front cover from
the fuel tank
~l
~-t- ·.
~
cgfo "'
1. Front cover
2. Fixings
2. Bayonet type connector
3. Hand held pump 2. Disconnect the battery, negative (black> lead first.
3. Pressurise the cooling system to its 1.1 bar operating 3. Drain the coolant (see page 11-5'.
pressure, using the hand pump taking care not to
exceed the maximum cap pressure.
4. Hold the pressure for a minimum of 10 minutes,
whilst visually inspecting the external components of
engine is hot When the engine is hot, the coolant inside
the coolant system for leaks.
5. Remove the engine oil filler cap/dipstick and check the pressurised coolant will cause scalds and skin
for contamination of the engine oil caused by damage.
coolant escaping into the engine sump.
Note:
4. Detach the top hose from the thermostat elbow.
If the engine oil is contaminated further

exploratory investigation will be required.
If the engine oil is contaminated rectify the
cause of the problem and then renew the oil
and filter.
1. Top hose
2. Thermostat housing
5. Release the fixings securing the thermostat housing

to the cylinder head.
6. Remove the thermostat housing. Discard the 0-ring.
7. Remove the thermostat from the cylinder head.

Cooling
Inspection Radiator
1. Inspect the thermostat at room temperature. If the
valve is open, the thermostat must be replaced. Removal
2. To check the valve opening temperature, suspend
the thermostat in a container of water and raise the 1. Remove the seat (see page 16-10).
temperature of the water until the thermostat opens. 2. Release the fixings and remove the front cover from
The thermostat should start to open at 88°C +/- 5°C. the fuel tank.
3. If the temperature at which thermostat opening
takes place is incorrect, replace the thermostat.
Installation
1. Locate the thermostat into the cylinder head.
cgfo " ' -
1. Front cover
2. Fixings
3. Remove the battery (see page 17-8).

4. Drain the coolant (see page 11-5>.
cdbv
1. Thermostat (face shown inserted into the head)

Z Note the position of the harness at the top of the
radiator and release it from two straps.
2. Fit a new 0-ring to the thermostat housing.
8. Disconnect the cooling fan connection from above
the camshaft cover.
9. Release the fixings securing the left hand radiator
cowl to the radiator.
Note:
• Note the routing of the direction indicator
harness for installation.
cash
1. 0-ring/groove
3. Tighten the bolts to 8 Nm.

4. Reconnect the top hose and tighten the clips 2 Nm.
5. Refill the cooling system (see page 11-6>.
6. Connect the battery, positive (red) lead first.
Z Refit the front cover to the fuel tank and tighten the
fixings to 2 Nm.

Cooling
10. Detach the rear of the cowl from the stud on its 14. Detach the clutch cable retaining clip from the
mounting bracket, disconnect the direction indicator radiator.
harness and remove the cowl.
\
1. Clip
r.rrvm
3 2. Clutch cable
1. Fixings
2. Stud 15. Disconnect the expansion tank, top and bottom
3. Cowl hoses at the radiator.
11. Repeat steps 9 and 10 for the right hand cowl.

12. Disconnect the electrical connectors from the horn.
13. Release the fixing and remove the horn.
cgvj_3
1. Top hose
\\~
2. Bottom hose
3. Expansion tank hose
16. Remove the three lower fixings securing the radiator.

1. Electrical connectors
2. Fixing
3. Hom
1. Fixings

Cooling
lZ Release the bolt securing the radiator to the upper Installation

mount bracket.
1. Align the radiator right hand upper mounting to the
stud on the bracket. Fit the bolt to the upper
mounting, do not fully tighten at this stage.
1. Bolt
18. Remove the radiator by moving it to the right of the

motorcycle until its upper mounting is clear of its
stud on the bracket.
2. Align the oil cooler to the radiator. Fit the three lower
Inspection mounting bolts and tighten to 9 Nm.
1. Check the radiator for stone damage.

2. Check the radiator core, for damage to fins or
obstructions to air flow.
3. Repair any damage and clear all obstructions.
A. Caution
To avoid overheating and consequent engine damage,
replace the radiator if the cores are blocked or if the fins
are badly deformed or broken.
4. Check that the fan spins freely and without tight

spots.
5. Check the fan blades for signs of heat distortion.
3. Tighten the left hand upper mounting to 9 Nm.

Cooling
4. Reconnect the expansion tank, top and bottom 8. Refit the horn and tighten its fixing to 15 Nm.
hoses. Tighten the hose clips to 2 Nm. 9. Reconnect the electrical connectors to the horn.
1. Top hose 1. Electrical connectors

2. Bottom hose 2. Fixing
3. Expansion tank hose 3. Horn
5. Attach the clutch cable retaining clip to the radiator. 10. Refit the airbox (see page 10- 1on.
12. Refill the cooling system (see page 11-6>.
13. Ensure the grommet is fitted to the cowl and the
direction indicator harness is routed as noted for
removal.
14. Fit the rear of the radiator cowl to the stud on its
mounting bracket.
15. Thoroughly clean the fixings and apply a drop of
ThreeBond 1360 to the thread.
16. Fit the three fixings and tighten to 4 Nm.
17. Repeat steps 15 to 17 for the other radiator cowl.
18. Refit the battery (see page 17-B>.
19. Refit the front cover to the fuel tank and tighten the
cgvh_ 1
fixings to 2 Nm.
1. Clip
2. Clutch cable 20. Refit the seat (see page 16-11>.
6. Position the harness on top of the radiator as noted

for removal. Secure it in place with the two straps.
7. Reconnect the cooling fan to the main harness above
the camshaft cover.

Cooling
Expansion Tank
Removal Do not disconnect the two coolant hoses from the

expansion tank when the engine is hot. When the
1. Remove the seat <see page 16- 70). engine is hot the coolant in the expansion tank will be
hot.
2. Release the fixings and remove the front cover from
the fuel tank Contact with hot coolant will cause scalds and skin
damage.
Z Disconnect the upper hose from the expansion tank

8. Release the fixing and manoeuvre the expansion
tank away from the frame and out of its lower
mounting.
cgfo " "

1. Front cover
2. Fixings

5. Release the two fixings, indicated below, from the
sprocket cover and remove the harness cover. 1. Fixing
2. Upper hose
3. Expansion tank
9. Release the clip, disconnect the lower hose and

remove the expansion tank.
1. Fixings
2. Harness cover
6. If fitted, remove the evaporative canister (see

page 10- 134).
2. Hose
3. Expansion tank

Cooling
Installation 3. Secure the expansion tank with its fixing and tighten
to 4 Nm.
1. Align the expansion tank to the frame, fit the lower 4. Check and adjust the coolant level as necessary (see
hose and secure in position with its clip. page 11-4).
2. Fit the locating stud on the bottom of the expansion 5. If removed, refit the evaporative canister (see
tank into its grommet on the engine bracket. page 10-135>.
Z Rec;onnect the battery, positive <red) lead first.
8. Refit the front cover to the fuel tank and tighten the
fixings to 2 Nm.
2. Grommet
3. Expansion tank

12 Front Suspension
Table of Contents
Exploded View - Front Fork - Speed Triple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Exploded View - Front Fork- Speed Triple R...................... ......... . . .............. ... 12.3
Exploded View - Handlebars................ ......... ...................................... 12.4
Front Suspension.......... .......... .......... ...... ........ ............... ............. . 12.S
Fork Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.S
Front Fork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.S
Removal . ..... ...... ... ............ .......... ........... .......... .. ................. 12.5
Installation ................ ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
Fork Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7
Oil Refilling.................. .................. ....... ..... ... ........................ 12.7
Fork Oil Level Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8
Front Fork - Speed Triple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8
Inspection.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
Front Fork - Speed Triple R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
Disassembly........... ................... ...... ......... ....... ..... ................. 12.15
Inspection .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
Handlebars.................. ............. ............. ......... ........................ 12.23
Removal.. ............ .............. ...... ............ ..................... ......... 12.23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24
Headstock Bearing Check/Adjustment.. ................ . ................ ................ ... 12.26
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.26
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.26
Headstock Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29

Front Suspension
Exploded View - Front Fork - Speed Triple
~---- 90Nm
~~ Seetext
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35Nm r-
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35Nm

Exploded View - Front Fork - Speed Triple R
Front Suspension
f § ; - - - - 90Nm
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Service Manual - StJeed Triple and Speed Triple R.
12.3
Front Suspension
Exploded View - Handlebars
3 Nm
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25 Nm
3 Nm
\.... ~
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7Nm

Front Suspension
Front Suspension Front Fork

The Speed Triple is equipped with hydraulic, adjustable,
telescopic front forks. Both forks are adjustable for spring Removal
pre-load, compression damping and rebound damping.
The Speed Triple R is equipped with hydraulic, adjustable,
telescopic front forks. The spring pre-load adjusters are
located at the top of each fork. The rebound damping Before starting work, ensure the motorcycle is stabilised
adjuster is located at the top of the right hand fork and the and adequately supported. This will help prevent it from
compression damping adjuster is located at the top of the falling and causing injury to the operator or damage to
left hand fork. the motorcycle.
Periodic inspection for damage and fluid leaks is essential
for safe riding. Always follow the inspection instructions at 1. Raise and support the front of the motorcycle.
the intervals stated in the scheduled maintenance chart. 2. ABS models only: Noting the routing of its harness,
detach the wheel speed sensor from the left hand
fork. Collect the washer from between the sensor
Fork Inspection
and fork leg and discard the bolt.
Examine each fork for any sign of damage or scratching
of the slider surface or for oil leaks.
If any damage or oil leakage is found, strip and repair as
described in this section or consult an authorised Triumph
dealer.
Check for smooth operation of the forks as follows:
Place the motorcycle on level ground.
While holding the handlebars and applying the
front brake, pump the forks up and down
several times.
If roughness or excessive stiffness is detected, repair as

described in this section or consult an authorised Triumph
dealer.
Riding the motorcycle with defective or damaged 3. Detach and support the front brake calipers (see
suspension can cause loss of motorcycle control and an page 14-19 for Speed Triple, see page 14-21 for
accident. Never ride with damaged or defective Speed Triple R>.
suspension.
Never allow the brake calipers to hang on the brake

hoses as this may damage the hoses. A damaged brake
hose can cause a reduction in braking efficiency leading
to loss of motorcycle control and an accident.
4. Remove the front wheel <see page 15-8).

5. Remove the front mudguard <see page 16-13).
Note:
If the forks are to be dismantled, slacken the
fork top caps after the top yoke clamp bolt has
been slackened.

Front Suspension
6. Slacken the top yoke clamp bolts. Installation
1. Position the fork within the yokes so that the groove

on the outer tube is 5 mm below the lower surface
of the top yoke.
~
cgrj
1. Top yoke clamp bolt
A Caution cg~_,
Smm/
I
Care must be taken when removing the forks, to ensure 1. Groove, Speed Triple shown Speed Triple R similar
that the outer surfaces do not become scratched. 2. Lower surface, top yoke
2. Tighten the top yoke clamp bolt to 20 Nm.

Z Slacken the bottom yoke clamp bolts.
3. Tighten the bottom yoke clamp bolts to 25 Nm in
the sequence shown below.
8. Using a downward, twisting action, withdraw the Tightening Sequence for the Clamp Bolts
forks from between the yokes.
4. Refit the front mudguard (see page 16- 13).
5. Install the front wheel <see page 15-9).
6. Refit the front brake calipers <see page 14-20 for
Speed Triple, see page 14-23 for Speed Triple R)_
Z ABS models only: Refit the front wheel speed
sensor (see page 14-37).
8. Lower the motorcycle to the ground and park it on
the side stand.

Front Suspension
Fork Oil Change 3. Set the scale on tool 3880160-T0301 to the level
specified for the model being worked on (see the
fork oil table or illustration below for the correct level
Draining setting).
Before starting work, ensure the motorcycle is stabilised Refer to fork oil level chart.
and adequately supported. This will help prevent it from
falling and causing injury to the operator or damage to
the motorcycle.
1. Remove the fork <see page 12-5).

2. Remove the top cap assembly <see page 72-9).
3. Remove the fork spring <see page 72-9).
4. Holding the inner and outer tubes together, invert
the fork and pour out the fork oil into a suitable
container. Pump the damper rod to remove all the
oil.
1. Tool 3880160-T0301
Oil Refilling 2. Adjustment plate
3. Scale area
The oil level is measured from the upper surface of the 4. Hole (zero position)
fork outer tube, with the fork fully compressed and the
Note:
spring removed.
Zero level on the tool is set at the small exit
hole in the side of the scale tube, NOT AT THE
END TIP. Do not attempt to block this side hole
For the measurement, refer

to the table below.
I 4.
5.
as this will cause the final fluid level to be
incorrect.
Insert the scale end of the tool into the fork inner
tube.
Hold the tool adjuster plate level with the upper
surface of the fork inner tube and draw fluid into the
syringe until fluid flow ceases (empty the syringe if
the body becomes full before fluid flow stops).
6. The fluid level in the fork is now set to the height set
on the tool scale. Check the tool scale setting and
repeat the process if incorrectly set.
Fork Oil Level (spring removed and the fork

fully compressed)
Incorrect fork oil levels could result in an unsafe riding
Model Oil Level condition leading to loss of control and an accident
Speed Triple 85 mm Z Assemble the fork (see page 12-12).

Speed Triple R 130mm 8. Refit the fork <see page 72-6>.
1. Fill the fork with the grade of oil specified in the fork
oil table, to a level above that which will finally be
required.
2. Pump the fork assembly and damper several times
to expel any trapped air then fully compress the fork
and support it in an upright position. Leave the fork
for a few minutes to allow the oil to stabilise.

Front Suspension
Fork Oil Level Chart Front Fork - Speed Triple
Speed Triple Disassembly

Oil Oil Oil Fork Pull
Level Volume Grade Through
85 mm 552 cc Showa Groove on outer
558 tube 5 mm Before starting work, ensure the motorcycle is stabilised
below the lower and adequately supported. This will help prevent it from
surface of the falling and causing injury to the operator or damage to
upper yoke the motorcycle.
Speed Triple R Note:

Oil Oil Oil Fork Pull Before removing the forks, release the top
Level Volume Grade Through yoke clamp bolt and slacken the top cap a little
130 mm 478 cc Ohlins Groove on outer to allow easier removal during strip-down.
fork oil tube 5 mm
01309-01 below the lower 1. Note the position of the rebound damping adjuster
surface of the to ensure the setting is retained on re-assembly.
upper yoke 2. Turn the spring preload adjuster fully anti-clockwise
to the softest setting. Make a note of the number of
turns to ensure the setting is retained on re-
assembly.
cgrj_2
1. Spring preload adiuster

2. Rebound damping adjuster
Do not change the fork adjustment settings. If they are

changed, this will change the handling of the motorcycle
from those which the rider is used to. Riding with
unfamiliar fork settings may cause unexpected handling
characteristics leading to loss of control and an accident.
3. Remove the forks (see page 12-5).

Note:
The fork seals can be renewed without
removal of the damping cylinder. Unless
removal of the damping cylinder is necessary,
omit steps 18 and 19 of this procedure.

Front Suspension
4. Very gently clamp the fork outer tube in a soft jawed 9. Using tool T3880067, manually compress the fork
vice to prevent it from turning, then unscrew the top spring and insert the spring holder as shown, below
cap from the outer tube. the damper locknut.
~2
L
ccut_1
1. Fork 1. Damper locknut

2. Soft jaws 2. Tool T3 88006 7
3. Top cap 3. Spring holder Cpart of T3880067)
10. Slacken the locknut, unscrew and remove the top

A Caution cap and the damper rod, taking care not to bend the
rod. The top cap assembly cannot be dismantled.
Never tightly clamp the outer tube as this will cause the
11. Recompress the fork spring to remove the holder.
tube to permanently distort. A distorted tube is not
serviceable and must be replaced. 12. Pump the damper rod to remove all the oil.
Note:
The top cap is not under spring tension and will
While compressing the fork spring and while the spring
not spring upwards when the threads
holder is in place always wear protective equipment for
disengage.
the face and eyes and never stand directly above or look
5. Holding the inner and outer tubes together, invert directly down on the fork. If the spring compressor or
the fork and pour out the fork oil into a suitable holder should dislodge or detach, the resulting release
container. of spring tension could cause parts to fly off resulting in
6. Return the fork to the soft jawed vice. injury to the user.
Z Allow the outer tube to slide down the inner to allow
access to the spring spacer.

directly down on the fork. If the spring compressor or
holder should dislodge or detach, the resulting release
of spring tension could cause parts to fly off resulting in
injury to the user.
8. Fit tool T3880067 over the top cap. Position the two
adjustable arms to the holes in the spring spacer.
Screw in the arms until they positively engage in the
spring spacer holes.

Front Suspension
13. Remove the nylon spacer, spring collar and spring. It 15. Invert and mount the fork assembly to
is not necessary to remove the bump rubber if still tool T3880153.
attached to the top cap.
cg rd
ccwz_1
1. Tool T3880153
1. Nylon spacer 2. Tool T3880159
2. Spring collar
16. Raise the inner tube and remove the dust seal and
3. Bump rubber
circlip from the outer tube.
14. Fit both halves of tool T3880159 to the outer tube as
shown below and hold in position.
ccuv 1
1. Dust seal
cgrc 2. Circlip
1. Outer tube
2. Tool T3880159

Front Suspension
17. Remove the fork from the tool and, using a slide 19. Remove the damper bolt from the bottom of the
hammer action to release the oil seal and bushes fork.
from the outer tube, separate the inner and outer
tubes leaving the seals and bushes in place on the
inner tube. Note the relative positions and
orientation of all bushes and seals before removal.
ccux_2
1. Damping cylinder bolt location
20. Remove the damping cylinder from the inner tube.
1. Inner tube
2. Outer tube
18. To allow the removal of the sea.ls and bushes,

carefully remove the upper bush from the inner
tube.
ccuy_ 1
1. Damping cylinder
Inspection
1. Inspect the inner tube for stone chips, scoring,

ccup_3 scratches, excessive wear and any other damage.
1. Inner tube
Renew as necessary.
2. Upper bush Note:
Small inclusions in the inner tube may be
removed using a fine grade stone or similar.
2. Inspect the spring for damage, cracks and
deformation. Renew the spring if necessary.
3. Inspect all the bushes and seals for damage. Renew
any damaged items if necessary.

Front Suspension
Assembly 3. Invert and position the fork tube outer to

tool T3880153.
4. Apply a smear of fork oil to the bushes and seals.
5. Position the seals and bushes to the inner tube as
The front forks comprise many precision machined noted prior to removal. Ensure the seal (item 3) is
parts. Total cleanliness must be observed at all times and position with the text end facing the circlip. Use a
assembly must take place in a dirt/dust-free new cirdip.
environment.
Dirt ingress may cause damage to the fork parts, leading
to incorrect operation, instability, loss of control or an
accident.
Note:
If the damper has not been removed, omit
operations 1 and 2.
1. Clean the threads of the damping cylinder bolt and

fit a new sealing washer. Prevent the cylinder from
turning while tightening the damping cylinder
securing bolt to 3 5 Nm.
ccup_2
1. Dust seal
2. Circlip
3. Seal
4. Washer
5. Lower bush
6. Upper -bush
6. Using a suitable tool, fit the upper bush to the fork

inner tube.
Z Position the inner tube assembly to the outer,
ensuring that the oil and dust seal lips do not
become damaged.
ccux_2
8. Using the narrow end of tool T3880003, guide the
lower bush, washer and seal into place.
1. Damping cylinder bolt location
2. Fit both halves of tool T3880159 to the outer tube as

1
shown below and hold in position.
ccuq_2
1. Tool T3880003
2. Seal
3. Washer
cgrd_1
4. Lower bush
1. Outer tube
5. Tool T3880153
2. Tool T3880159
6. Tool T3 880159
3. Tool T3880153

Front Suspension
9. Retain the bush, washer and seal with a new circlip. 16. Rethread the damping rod locknut to the bottom of
the threads.
1. Dust seal cdep_3
2. Circlip 1. Damping rod

3. Tool T3880153 2. Locknut
10. Position the dust seal to the outer tube.

11. Invert tool T3880003 and, using hand pressure only,
push the dust seal squarely into the outer tube.
While re-compressing the fork spring and while the
12. Fill the fork with oil (see page 12-TJ. spring holder is in place always wear protective
13. Position the fork assembly as for compression of the equipment for the face and eyes and never stand
fork spring during strip down. directly above or look directly down on the fork. If the
14. Refit the fork spring, close wound end uppermost, spring compressor or holder should dislodge or detach,
spring collar, nylon spacers and bump rubber. the resulting release of spring tension could cause parts
to fly off resulting in injury to the user.
lZ Turn the rebound damping adjuster such that its top

is 1.5 mm above the spring preload adjuster.
4
ccuu_2
1. Spring cap
2. Nylon spacer Clower
3. Spring>
4. Spacer <upper> cg re
5. Bump rubber 1. Rebound damping adjuster

2. Spring preload adjuster
15. Attach tool 3880085-T0301 to the threads of the
damper rod and pull the damper upwards.

Front Suspension
18. Refit tool T3880067 as previously described, Note:

compress the fork spring and refit the spring holder.
It is much easier to tighten the top cap when
the fork has been refitted.
24. Fit the fork (see page 12-6'J but do not fully tighten
the top yoke damp bolt at this stage.
25. Tighten the top cap to 35 Nm.
26. Tighten the top yoke clamp bolt to 20 Nm.
2Z Check that the rebound damping adjuster is as
noted for removal.
28. Turn the spring preload adjuster clockwise to the
number of turns noted for removal.
ccut_1
1. Damper locknut
2. Tool 13880067
3. Spring holder (part of T3880067)
A Caution
If removed, the damping rod locknut must be fitted with
the flat face facing to the top of the fork. .The slightly
tapered face must face the fork spring. Incorrect
orientation may lead to a loosening of the locknut
19. Inspect the 0-ring for the top cap for any damage, 1. Spring preload adjuster
replace if necessary. 2. Rebound damping adiuster
20. Fit the top cap by slowly turning by hand until some
resistance is felt.
21. Hold the top cap while tightening the damper rod
locknut to 20 Nm.

directly down on the fork. If the spring compressor or
holder should dislodge or detach, the resulting release
of spring tension could cause parts to fly off resulting in
injury to the user.
22. Recompress the spring to remove the spring holder.

23. Lubricate the 0-ring on the top cap with a smear of
fork oil then screw the top cap fully into the outer
tube.

Front Suspension
Front Fork - Speed Triple R 1. Turn the spring pre-load adjuster fully anti-clockwise
to the softest setting. Make a note of the number of
turns to ensure the setting is retained on re-assembly.
Disassembly

the motorcycle.
The front forks comprise many precision machined

parts. Total cleanliness must be observed at all times and
disassembly/assembly must take place in a dirt/dust-free
environment. cgzz
Dirt ingress may cause damage to the fork parts, leading 1. Spring pre-load adjuster
to incorrect operation, instability, loss of control or an j 2. Compression/rebound adjuster
accident. 1 2. Remove the forks (see page 12-Sl.
Note:
Before removing the forks, slack~n the top cap
a little (using service tool T3880161) to allow Do not change the fork adjustment settings. If they are
easier removal during the strip down. changed, this will change the handling of the motorcycle
The fork seals can be renewed without the from those which the rider is used to. Riding with
removal of the damping cylinder. Unless the unfamiliar fork settings may cause unexpected handling
removal of the damping cylinder is necessary, characteristics leading to loss of motorcycle control and
omit steps 1S to 20 of this procedure. an accident.
A Caution Note:
The top cap is not under spring tension and will
Care must be taken when turning the spring pre-load not spring upwards when the threads
adjuster to ensure that it does not become scratched. disengage.
Protect its surfaces with a suitable cloth or tape to
prevent scratching.

Front Suspension
3. Very gently clamp the fork in a soft jawed vice to 5. Remove the lock nut, upper seat and the spring.
prevent it from turning. Hold the outer tube and
using tool T3880161 unscrew the top cap from the
outer tube.
chab
1. Lock nut
. 31
1. Tool T3880161
2. Upper seat
3. Spring
2. Top cap 6. Using a length of steel wire with a hook in one end,
3. Outer tube remove the spring spacer.
4. Use a suitable 17 mm socket to hold the top cap and
use tool T3880162 to loosen the lock nut then
remove the top cap.
chap
1. Spring spacer
2. Outer tube
chac_ I Z Remove the fork from the vice.

1. Tool T3880162 8. Holding the inner and outer tubes together, invert
2. Top cap the fork and pour out the fork oil into a suitable
3. lock nut container. Pump the damper rod to remove all the
oil.
9. Return the fork to the soft jawed vice.
10. Carefully separate the inner and outer tube leaving
the seals and bushes in place on the outer tube.

Front Suspension
11. Using the handle of tool T3880162 remove the dust 14. Remove the washer.
seal from the outer tube as shown below. Use a
piece of cloth under the tool to prevent it from
damaging the outer tube.
chan
1. Washer
2. Outer tube
15. Insert tool T3881005 over the damping cylinder,

1. Tool T3880162
engage the lugs on the tool into the slots in the
2. Dust seal
damping cartridge inside the fork. Unscrew the
3. Cloth
cartridge and remove it from the fork.
4. Outer tube
12. Using a suitable small screwdriver, remove the

cirdip.
Note:
Note the orientation of the oil seal for
installation.
13. Using the handle of tool T3880162 remove the oil
seal. Use a piece of cloth under the tool to prevent it
from damaging the outer tube.
chai
1. Tool T388100S
2. Inner tube
1. Tool 13880162
2. Oil seal
3. Cloth

Front Suspension
16. Remove the adjustment rod, valve and spring from 18. Remove the E-clip and then the spring guide.
the damping rod. Discard the E-dip.
chak
1. Adjustment rod 1. E-clip

2. Valve 2. Spring guide
3. Spring
Note:
lZ Fit tool T3881003 approximately 20 mm from the
• Note one end of the rubber stop has a cut
threaded end of the damping cylinder. Secure the
away in it. Note orientation of the rubber stop
lower end of the tool into a soft jawed vice as shown
and washer for installation.
below.
19. Remove the E-clip, washer and rubber stop. Discard
the E-clip.
chaj
1. Tool T3881003
2. Cylinder tube
3. Soft jaws 1. E-clip
2. Washer
3. Rubber stop
4. Cutaway
Note:
• Note the orientation of the damping rod for
installation.

Front Suspension
20. Push the damping rod into the cylinder and remove 1. Carefully fit the damping rod into the damping
it from the other end. cylinder as noted for removal.
1. Damping cylinder 1. Damping cylinder

2. Damping rod 2. Damping rod
2. Fit the rubber stop and washer to the damping rod

Inspection as noted for removal. Secure in position with a new
E-clip.
1. Inspect the inner tube for stone chips, scoring,
scratches, excessive wear and any . other damage.
Renew as necessary.
Note:
Small inclusions in the inner tube may be
removed using a fine grade stone or similar.
2. Inspect the spring for damage, cracks and
deformation. Renew the spring if necessary.
3. Inspect the seals for damage. Renew any damaged
seals as necessary.
Assembly
1. E-clip
2. Washer
The front forks comprise many prec1s1on machined
3. Rubber stop
parts. Total cleanliness must be observed at all times and
4. Cutaway
disassembly/assembly must take place in a dirt/dust-free
environment.
Dirt ingress may cause damage to the fork parts, leading
to incorrect operation, instability, loss of control or an
accident.
Note:
If the damping cylinder has not been removed
omit steps 1 to 6.
Seavice Manual - Speed Triple and Speed Triple R 12.19

Front Suspension
3. Fit the spring guide and secure in to postion with a 6. Fit the damping cylinder into the inner tube and
new E-clip. tighten to 40 Nm using tool T3881005 and a
torque wrench.
chak
1. E-clip chai
2. Spring guide 1. T3881005

2. Inner tube
4. Fit the spring, valve and adjustment rod into the
damping rod as noted for removal. Z Fit the washer into the outer tube.
chan
1. Spring 1. Washer
2. Valve 2. Outer tube
3. Adjustment rod
5. Remove tool T3881003 and damping cylinder from

the vice and remove the tool from the cylinder.

Front Suspension
8. Using tool T3880080 fit a new oil seal to the outer 14. Fit the spring spacer into the outer tube.
tube in the orientation noted for removal.
chap
chae 1. Spring spacer

1. Tool T3880080 2. Outer tube
2. Outer tube
15. Very gently clamp the fork in a soft jawed vice.
9. Fit the circlip to the outer tube. 16. Fit the spring into the inner tube.
17. Attach tool T3880163 to the threads of the damping
rod and pull it fully upwards.
2--J
1. Circlip
2. Oil seal
chaq
3. Washer
1. Spring
4. Outer tube
2. T3880163
10. Press the dust seal back into the outer tube using 3. Damping rod
finger pressure only. 4. Outer tube
11. Carefully fit the outer tube over the inner tube.
12. Pour 500 ml of Ohlins fork oil into the inner tube.
Push the damping rod up and down until the fork is
filled with oil.
13. Compress the fork leg and damper rod completely
and adjust the fork oil level to 130 mm below the
upper edge of the outer tube (see page 12-7>.

Front Suspension
18. Using a suitable pair of pliers, carefully hold the 20. Turn the lock nut fully onto the damping rod. Ensure
damping rod in position without touching the outer that the spring remains seated to its upper seat as
tube. Remove tool T3880163. shown below.
char chat
1. T3880163 1. Spring
2. Damping rod 2. Upper seat
3. Pliers
21. Fit the top cap fully onto the damping rod. Tighten
19. While holding the damping rod, fit the upper seat the lock nut to 20 Nm.
and its lock nut to the damping rod, as shown below.
chbh
chas 1. Lock nut

1. Upper seat 2. Top cap
2. lock nut
Note:
3. Damping rod
It is much easier to finally tighten the top cap
when the fork has been fitted.

Front Suspension
22. Lift the outer tube and screw it fully on to the top Handlebars
cap.

I and adequately supported. This will help prevent it from
the motorcycle.
Removal

from the fuel tank.
chaa_1
1. Top cap
2. Outer tube
23. Refit the fork (see page 12-6).

24. Tighten the top cap to 20 Nm.
25. Adjust the spring preload as noted for removal.
26. Adjust the compression and damping rebound as
described in the owner's handbook. ·
1. Front panel
2. Fixings
3. Undo the fixing screws and remove the end weights
from the handlebars. Discard the fixings.
4. Undo the screws and free the left switch gear
assembly from the handlebar. Without disconnecting
any wiring, lay the switch aside.
5. Unscrew the bolts and remove the clamp from the
clutch lever assembly. Without disconnecting the
clutch cable, lay the lever aside.

Front Suspension
6. Slide off the rubber boot and release the screws 12. Unscrew the bolts and remove the clamp from the
which secure the two halves of the twist grip guide to front brake master cylinder. Taking care to not invert
each other. the brake fluid reservoir, lay the assembly aside.
13. Release the fixings securing the handlebar clamps to
the risers, detach the clamps and collect the
handlebar.
z
2
3~
r.tinn 1
1. Twist grip
2. Twist grip guide
3. Screws cgrg
4. Rubber boot 1. Upper Clamp
Z Note the position of the guide relative to the 2. Handlebar
handlebar then separate the two halves of the twist 3. Riser
grip guide. 14. Remove the left hand handlebar grip.
8. Note and mark the position of each cable relative to
the twist grip in order to correctly identify their
Installation
location during reassembly.
9. Release the inner cables from the twist grip. 1. Locate the handlebar in the lower halves of the
clamps. Fit the upper damps and bolts, do not fully
tighten at this stage.
2. Align the handlebar + mark with the front right hand
split line of the clamp/riser, then tighten clamp bolts,
front first, to 26 Nm.
1. Closing inner cable

2. Opening inner cable
10. Slide the twist grip off the handlebar.
11. Undo the screws and free the right hand switch gear
assembly from the handlebar. Without disconnecting
any wiring, lay the switch aside. 1. Handlebar + mark
2. Right hand front clamp split line
A Caution 3. Position the clutch lever to the handlebar. Fit the

clamp <UP arrow pointing upwards) and clamp bolts
To prevent body damage, do not spill brake fluid onto do not fully tighten at this stage.
any area of the bodywork.

Front Suspension
4. Align the split line of the clutch lever with the+ mark 10. Assemble the two halves of the cable guide ensuring
on the upper surface of the handlebar, then tighten that the outer cables are correctly located in the
the clamp bolts, upper first, to 12 Nm. guide and the guide is positioned on the handlebars
as prior to removal.
1. Handlebar + mark r.rlnn 1
2. Clamp split line 1. Twist grip

2. Twist grip guide
5. Align the left hand switch cube to the handlebar and 3. Screws
secure with the screws. Tighten the screws to 4. Rubber boot
2.5 Nm.
11. Tighten the cable guide fixings to 3 Nm.
6. Fit the left hand handlebar grip.
12. Position the front brake master cylinder assembly to
Z Position the right hand switch cube to the handlebar
the handlebar. Fit the clamp and clamp fixings do
and tighten the fixings to 2.5 Nm.
not fully tighten at this stage.
8. Slide the twist grip onto the right hand side of the
13. Align the split line of the master cylinder clamp to
handlebar.
the + mark on the upper surface of the handlebar
9. Reconnect the inner throttle cables as noted during and tighten the clamp fixings upper first to 8 Nm.
removal. Ensure that the positions of the opening
and closing cables are not transposed.
0 0
D 0
1. Handlebar + mark
2. Clamp split line
1. Closing inner cable
2. Opening inner cable 14. Fit the handlebar end weights, tightening the new
fixings to 3 Nm.
15. Check the throttle cable free play setting. Adjust as
necessary (see page 10-112>.

Front Suspension
16. Reconnect the battery, positive <red) lead first. Headstock Bearing
1Z Refit the front panel to the fuel tank and tighten the Check/Adiustment
fixings to 2 Nm.
18. Check for correct operation of the front brake and
clutch. Check that the throttle opens and closes Check
without sticking and that the cables do not bind or
restrict the steering when the handlebars are turned 1. Raise and support the front of the motorcycle.
from lock-to-lock Rectify as necessary.

Operation of the motorcycle with incorrectly adjusted, and adequately supported. This will help prevent it from
incorrectly routed or damaged throttle cables could falling and causing injury to the operator or damage to
interfere with the operation of the brakes, clutch or the the motorcycle.
throttle itself. Any of these conditions could result in loss
of control of the motorcycle and an accident.

checking that cables and harnesses do not bind or that
the steering feels tight or difficult to turn. A cable or
harness that binds, or steering that is tight/difficult to
turn will restrict the steering and may cause loss of
control and an accident.
Checking Headstock Bearing Adiustment

2. Move the handlebars from lock to lock whilst
checking for signs of tightness.
3. Hold the lower end of the front forks as illustrated
and 'rock' with a front-to-rear motion. If free play can
be detected, the headstock bearings require
adjustment.
Adiustment
1. Raise and support the front of the motorcycle.

2. Remove the handlebars (see page 12-23).
3. Slacken the top yoke clamp bolts.
If the lower yoke fixings are also slackened, the forks will
no longer support the weight of the motorcycle.
Do not slacken the lower yoke fixings as, in this
condition, the motorcycle could topple over causing
damage and/or risk of injury.

Front Suspension
4. Remove the headstock top nut.
~~~
0
;• • _. __---!. _
:.;;,.-:;.:: ._, .,-~ ~ .....
,. . A. fff ~ .• _.. \· . , ~ '•~
.v,.. •
.1r.~ ...... -._..-:.:::...,....-~
.......-.!. .....
It is essential that the adjuster nut is not over-tightened.

If the adjuster is over-tightened it will cause a pre-load
on the headstock bearings. This will introduce tight
steering, which could cause loss of control and an
accident.
1
cgfs_I
1. Headstock top nut
5. Ease the top yoke from the forks and support while
detached.
Note:
When adiusting the bearing free-play, ensure
that the threaded part of the stem is free from
grease. 1. Adiuster nut
6. Adjust the bearing free-play as follows, all using 2. Locknut
3. Tool T3880023
tool T3880023:
Remove the locknut and tab washer. Discard Z Refit the top yoke to the forks.
the tab washer. 8. Tighten the top nut to 90 Nm.
Slacken the adjuster nut then tighten to 9. Tighten the top yoke clamp bolts to 20 Nm.
40Nm. 10. Refit the handlebars (see page 12-24>.
Slacken the adjuster nut, then retighten to 11. Recheck the bearing adjustments (see page 12-26).
15 Nm.
Fit a new tab washer and locknut

Hold the adjuster nut in position while
tightening the locknut to 40 Nm.

Front Suspension
Headstock Bearing Removal 6. Using tool T3880023, remove the locknut and tab
washer. Discard the tab washer.

and adequately supported. This will help to prevent it
the motorcycle.

from the fuel tank.
/
cdbo
1. Locknut
2. Adjuster nut
3. Tool T3880023
Z Using the same tool, remove the adjuster nut.

8. Remove the bottom yoke from the frame.
cgfo "
Always wear eye, hand and face protection when using
1. Front panel a hammer and drift. Use of a hammer and drift can
2. Fixings cause bearings to fragment. Pieces of fragmented
bearing could cause eye and soft tissue injuries if
suitable protective apparel is not worn.
3. Remove both forks (see page 12-S>.
4. Remove the handlebars (see page 12-23>. 9. Using a suitable drift, evenly and progressively drive
the bearing races from the frame headstock.
5. Release the headstock top nut and remove the top
yoke. 10. Noting their orientation, remove the inner race and
dust seal from the bottom yoke using a press or
puller. Discard the dust seal.
Inspection
Only remove raised witness marks from within the

frame. Removal of material below any raised areas will
reduce the level of interference between the frame and
the bearings. Loss of interference could cause the
bearing to become loose in the frame leading to loss of
motorcycle control and an accident.
1
cg1s_1 1. Examine the frame for any raised witness marks
1. Headstock top nut caused by the removal process. Remove any such
marks with fine emery paper or a gentle file.

Front Suspension
Installation 3. Position a new upper bearing to the frame with the

bearing identification marks and larger radius facing
1. Fit a new dust seal to the steering stem on the downwards (into the frame aperture). Evenly and
bottom yoke as noted for removal. progressively drive the upper bearing into the frame
headstock.
4. Lubricate the lower bearing using multi-purpose
grease to NLGI 2 specification.
5. Drive a new lower outer bearing into the frame
headstock.
6. Insert the lower yoke to the frame, fit the upper
bearing and race, and retain with the adjuster nut
Z Adjust the headstock bearings (see page 12-26>.
8. Locate the upper yoke to the steering stem. Install
but do not fully tighten the headstock top nut at this
stage.
9. Fit the forks (see page 12-6).
10. Tighten the headstock top nut to 90 Nm.
cgrt 11. Check that no free play exists in the headstock
1. Bottom yoke bearings. Adjust as necessary <see page 12-26).
2. Dust shield 12. Refit the handlebars (see page 12-24).
A Caution
Protect the threads of the bottom yoke when using a
press or puller as damaged threads may mean replacing
the yoke completely.
2. Press a new lower bearing inner race onto the

steering stem of the bottom yoke.
1. Bearing
2. Bottom yoke
3. Press bed

Front Suspension

13 Rear Suspension
Table of Contents
Exploded View - Swinging Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
Exploded View - Rear Hub and Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
Exploded View - Rear Suspension Unit - Speed Triple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
Exploded View - Rear Suspension Unit - Speed Triple R............ ............. .. .. ........... 13.5
Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
Chain Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
Chain Free-movement Inspect.ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
Chain Free-movement adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
Chain Wear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
Rear Suspension Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8
Inspection................. ........................ ... ............. ................... 13.9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9
Drag Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
Drop Link Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
Swinging Arm/Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.13
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.17
Final Drive/Rear Hub and Bearings.............. .. .. ................ ............... ..... ... 13.19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.19
Inspection - All Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
Assembly - Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
Installation - All Parts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
Drive Chain Replacement. .......... ... .......................... ... ..................... . 13.23
Rivet link type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.23

Rear Suspension
Exploded View - Swinging Arm
SNm
SNm
r
I

Rear Suspension
Exploded View - Rear Hub and Wheel
33 Nm
146Nm

Rear Suspension
Exploded View - Rear Suspension Unit - Speed Triple
48Nm
/
- - ~~
o---
-- -- --
-- -- -- -- --
48Nm

Rear Suspension
Exploded View - Rear Suspension Unit - Speed Triple R
48Nm
48Nm
48Nm

Rear Suspension
Drive Chain Chain Adiustment

For safety and to prevent excessive wear, the drive chain Note:
must be checked, adjusted, and lubricated in accordance
The correct adiustment setting is 21 -30 mm.
with the scheduled maintenance chart. Checking,
adjustment and lubrication must be carried out more
frequently for extreme conditions such as salty or heavily Chain Free-movement Inspection
gritted roads.
If the chain is badly worn or incorrectly adjusted (either
too loose or too tight) the chain could jump off the
sprockets or break.
A chain that breaks or jumps off the sprockets could

snag on the engine sprocket or lock the rear wheel,
severely damaging the motorcycle and causing an
accident. Never neglect chain maintenance.
Note:
Checking and adiustment of the drive chain
must be carried out with the motorcycle held
in upright position with no additional weight on
it. 1. Maximum movement position
Chain Lubrication
Lubrication is necessary every 200 miles and also after Before starting work, ensure the motorcycle is stabilised
riding in wet weather, on wet roads, or any time that the and adequately supported. This will help prevent it from
chain appears dry. falling and causing injury to the operator or damage to
Use the special chain lubricant as recommended in the the motorcycle.
specification section.
1. Place the motorcycle on a level surface and hold it in
Correct application method is critical for chain lubricant. an upright position with no additional weight on it.
Apply the lubricant for one full chain revolution only, then
2. Rotate the rear wheel to find the position where the
leave for eight hours before riding. This allows the
chain has least slack. Measure the chain's vertical
lubricant's solvent <used to thin the oiD to evaporate and
movement, mid-way between sprockets.
the oil to 'soak' into all parts of the chain. If the lubricant is
applied and the motorcycle is ridden shortly afterwards, 3. If correct, the vertical movement of the drive chain
the lubricant is unlikely to reach all parts and the majority midway between the sprockets should be
will be flung off and wasted. Applying excessive amounts 21 -30 mm.
is not helpful under any circumstances.
It should be noted that the lubricant is applied to the chain
to lubricate its action across the sprockets. In an 0-ring or
X-ring chain, external lubrication does not penetrate to the
bushes and rollers as the 0-ring or X-ring seal prevents
this from happening.
A Caution
Do not use a power 'jet' wash to clean the chain as this
may cause damage to the chain components.

Rear Suspension
Chain Free-movement adjustment 4. Stretch the chain taut by hanging a 10 - 20 kg

(20 - 40 lb) weight on the chain.
1. Slacken the swinging arm/hub pinch bolt. 5. Measure a length of 20 links on the straight part of
2. Using the C-spanner from the motorcycle tool kit, the chain from pin centre of the 1st pin to pin centre
turn the eccentric adjuster clockwise to increase of the 21st pin. Repeat the test at various sections of
vertical movement, anticlockwise to take out vertical the chain to establish an average reading. This is
movement. because the chain may wear unevenly.
6. If the length exceeds the service limit of 320 mm,
the chain must be replaced.
A chain that breaks or jumps off the sprockets could

snag on the engine sprocket or lock the rear wheel,
severely damaging the motorcycle and causing loss of
Z Examine the whole length of the chain. If there are

any excessively tight or loose sections, loose pins or
damaged rollers, the chain should be replaced.
8. Inspect sprockets for unevenly or excessively worn
teeth. Also examine the sprockets for damaged
teeth.
1. Pinch bolt
2. C-spanner
3. Eccentric adjuster
3. Once the correct chain setting has been achieved, WORN TOOTH WORN TOOTH
tighten the swinging arm/eccentric adjuster pinch (ENGINE SPROCKET) (REAR SPROCKET)
bolt to 55 Nm.
Chain Wear Inspection

(; \)
._ a
(Sprocket wear exaggerated
for illustrative purposes)
ecol
The use of non-approved chains may result in a broken

chain or may cause the chain to jump off the sprockets.
Use a genuine Triumph supplied chain as specified in
the Triumph Parts Catalogue.
Never neglect chain maintenance and always have
chains installed by an authorised Triumph dealer.
1. Measurement across 20 links
2. 10 - 20 kg Weight 9. If there is any irregularity found in any of the
components, replace the drive chain and/or any
other damaged components.
Before starting work, ensure the motorcycle is stabilised 1

the motorcycle.

Rear Suspension
Rear Suspension Unit Note:

Both drop link plates are marked as shown
below. Both plates are identical and must be
Removal
fitted with the TOP marking at the top and
facing the outside of the motorcycle.

system will be hot. Before working on or near the
exhaust system, allow sufficient time for the exhaust
system to cool as touching any part of a hot exhaust
system could cause burn injuries.

the motorcycle.
1. Raise and support the rear of the motorcycle under

the frame or engine. Position a block to support the 1. Drop link plate
rear wheel. Note:
Note that the bolts for the drop plates and rear
from the fuel tank.
suspension unit are installed from the left hand
side.
5. Noting the orientation of the drop link plates, release
the three fixings, remove the plates and position the
'· drag link dear. Discard the locknuts.
/
. ·#
1. Front panel
2. Fixings

4. Remove the exhaust silencers and the intermediate cgrn 4
pipe (see page 10-125>. 1. Rear suspension unit, Speed Triple shown
2. Drop link plate
3. Drag link
4. Fixings
6. Remove the rear suspension unit upper mounting

nut and bolt, discard the nut. Manoeuvre the unit
upwards through the swinging arm and clear of the
motorcycle.

Rear Suspension
Inspection 6. Position the drop link plates as noted for removal

and insert the bolts from the left hand side.
1. Clean all components and inspect for damage/wear
to:
drag link, its bearings, sleeves and seals;
rear suspension unit lower mounting sleeve
and bearing;
drop link plates.
2. Renew as necessary.
Installation
1. Remove the sleeve from the drag link and pack the
bearing with fresh grease to NLGI 2 specification.
Refit the sleeve. cgrn 4
2. Remove the sleeve from the swinging arm and pack 1. Rear suspension unit, Speed Triple shown
2. Drop link plate
the bearing with fresh grease. Refit the sleeve.
3. Drag link
3. Apply grease to the seals. 4. Fixings
4. Remove the sleeve from the rear suspension lower
Z Fit new locknuts but do not fully tighten at this stage.
mounting and pack the bearing with fresh grease.
Refit the sleeve. 8. With the weight of the motorcycle on its wheels,
tighten the rear suspension unit upper mounting to
48Nm.
9. Tighten the three fixings for the drop link plates to
48Nm.
10. Refit the exhaust intermediate pipe and silencers <see
page 10-128).
11. Connect the battery, positive <red> lead first.
fixings to 2 Nm.
gagk_2
1. Rear suspension unit, Speed Triple shown

2. Drag link
3. Sleeves
4. Seal
5. Locate the rear suspension unit and loosely fit the

upper mounting bolt and new locknut.

Rear Suspension
Drag Link 4. Noting the orientation of the drop link plates, release
the three fixings, remove the plates. Discard the
locknuts.
Removal


falling and causing injury to the operator or damage to cgrn 4
the motorcycle. 1. Rear suspension unit, Speed Triple shown
2. Drop link plate
1. Raise and support the rear of the motorcycle under 3. Drag link
the frame or engine. Position a block to support the 4. Fixings
rear wheel.
5. Release the fixing securing the drag link to the frame
and remove the drag link. Discard the locknut.
from the fuel tank.
cgm_1
1. Drag link
1. Front panel
2. Fixings
2. Fixings
3. Disconnect the battery, negative {black) lead first.

Inspection
1. Clean all components and inspect for damage/wear:

drag link, its bearings, sleeves and seals;
rear suspension unit lower mounting sleeve
and bearing;
drop link plates.

Rear Suspension
2. Renew as necessary. Drop Link Plates
Removal

gagl_2 Before starting work, ensure the motorcycle is stabilised

1. Drag link and adequately supported. This will help prevent it from
2. Rear suspension unit, Speed Triple shown falling and causing injury to the operator or damage to
3. Seals the motorcycle.
4. Bearings
5. Sleeves 1. Raise and support the rear of the motorcycle under
6. Drop link plates the frame or engine. Position a block to support the
rear wheel.
Installation from the fuel tank.
1. Remove the sleeves from the drag link and pack the
bearings with fresh grease to NLGI 2 specification.
Refit the sleeve.
2. Remove the sleeve from the swinging arm and pack
3. Apply grease to the seals.
mounting and pack the bearing with fresh grease.
Refit the sleeve.
5. Fit the drag link to the frame, fit its bolt from the left
hand side and fit a new lock nut. Do not fully tighten
at this stage.
6. Position the drop link plates as noted for removal
7. Fit new locknuts but do not fully tighten at this stage. 1. Front panel
8. With the weight of the motorcycle on its wheels, 2. Fixings
tighten the drag link and drop link fixings to
48Nm.
fixings to 2 Nm.

Rear Suspension
3. Disconnect the battery, negative (black) lead first. Inspection
Note:
1. Clean all components and inspect for damage/wear
• Both drop link plates are marked as shown to:
below. Both plates are identical and must be
drag link, its bearing, sleeve and seals;
fitted with the TOP marking at the top and
facing the outside of the motorcycle. swinging arm, its bearing, sleeve and seals;
rear suspension unit lower mounting sleeve,
bearing and seals;
drop link plates.
2. Renew as necessary.
Installation
1. Remove the sleeve from the drag link and pack the
bearing with fresh grease to NLGI 2 specification.
Refit the sleeve.
2. Remove the sleeve from the swinging arm and pack
3. Apply grease to the seals.
1. Drop link plate
Note: mounting and pack the bearing with fresh grease.
Refit the sleeve.
Note that the bolts for the drop plates are
installed from the left hand side.
4. Noting the orientation of the drop link plates, release 6
the three fixings, remove the plates. Discard the nuts.
3
gagl_3
1. Drag link
2. Rear suspension unit, Speed Triple shown
3. Seals
cgrn 4 4. Bearings
1. Rear suspension unit, Speed Triple shown S. Sleeves
2. Drop link plate 6. Drop link plates
3. Drag link
4. Fixings

Rear Suspension
5. Position the drop link plates as noted for removal Swinging Arm/Drive Chain
Removal


cgrn 4 and adequately supported. This will help prevent it from
1. Rear suspension unit, Speed Triple shown falling and causing injury to the operator or damage to
2. Drop link plate 1
the motorcycle.
3. Drag link
4. Fixings 1. Release the three fixings and remove the front panel
from the fuel tank.
6. Fit new nuts but do not fully tighten at this stage.
7. With the weight of the motorcycle on its wheels,
tighten the three fixings for the drop link plates to
48Nm.
fixings to 2 Nm.
cgfo " '
1. Front panel
2. Fixings

3. Remove the rear wheel (see page 15-10).

Rear Suspension
4. Remove the sprocket and harness covers. 6. Release the three fixings and remove the rear brake
hose cover from under the swinging arm. Discard
the fixings.
2. Harness cover
3. Fixings
2. Brake hose cover
5. Release the two fixings and detach the chain rubbing
strip from the swinging arm. Collect the flanged Z Detach the brake hose and, if fitted, the ABS sensor
sleeve from the lower fixing and discard both fixings. harness from their clips under the swinging arm.
2. Lower fixing 2. ABS sensor harness, if fitted

3. Chain rubbing strip 3. Clips

Rear Suspension
8. Release the fixings and remove the lower chain 14. Release the fir tree and remove the covers for the
guard. swinging arm spindle.
cgwh cg rt
1. Fixings 1. Fir tree

2. Lower chain guard 2. Cover, left hand side shown
9. Remove the axle shaft and the final drive unit (see 15. Remove the swinging arm spindle nut and washer
page 13-19). from the right hand side. Discard the nut.
10. Place the axle shaft/brake disc assembly to one side. 16. Partialy withdraw the swinging arm spindle from the
11. Release the fixings and remove the hugger. left hand side, to allow access to the frame adjuster
on the right hand side of the frame.
cgrs
1. Fixings cg rm
2. Hugger 1. Spindle
12. Remove the rear suspension unit (see page 13-8)

and support the swinging arm.
13. Detach the chain from the output sprocket.

Rear Suspension
1Z Using tool T3880104, slacken the frame adjuster. 20. Remove the wheel bearing/hub from the left hand
side of the swinging arm.
CTN- 1
1. Tool T3880104 gagt_t
2. Frame adjuster 1. Circlip

2. Caliper carrier
18. Withdraw the swinging arm spindle from the left
3. Hub
hand side and remove the swinging arm, together
4. Swinging arm
with the drive chain.
S. Caliper bolt
Support the drive chain while the swinging arm
21. Remove the outer seal and bearing sleeve from the
is being removed to protect it from
left hand side.
contamination.
22. Remove the seal and spacer from the right hand
If the swinging arm is to be replaced, remove side.
the drive chain (see page 13-23).
23. Release the circlip and remove the two ball bearings
by drifting through from the left.
24. Remove the spacer tube.
Note:
The needle roller bearing and inner seal in the
right hand side of the arm cannot be removed
undamaged.
gaew_1
1. Swinging arm spindle
19. Remove the large circlip securing the caliper carrier

to the hub and remove the carrier.

Rear Suspension
25. Remove the right hand bearing and inner seal by Inspection
drifting through from the left.
1. Check all swinging arm bearings for damage, pitting,
and cracks. Replace as necessary.
2. Check the swinging arm for damage. Replace as
necessary.
3. Check the wheel/hub bearings for damage, pitting,
and cracks. Replace as necessary (see page 15-13).
4. Check all bearing seals for damage, splits etc.
Replace as necessary.
5. Check the chain for wear, damage etc. Replace as
necessary.
6. Check both sprockets for wear, damage etc. Replace
as necessary.
Z Check the inner drive chain rubbing strip for wear
and damage. Replace as necessary.
1. Seal 8. Check the top drive chain rubbing strip for wear and
2. Spacer damage. Replace if necessary.
3. Circlip
4. Ball bearings Assembly
5. Spacer tube
6. Inner seal 1. Install the bearings (marked faces outwards), sleeves
7. Bearing sleeve etc. into the swinging arm in the order shown on the
previous page. Use new seals throughout.
9. Outer seal
2. Fit the drive chain rubbing strip to the swinging arm
26. Remove the seals, Bearing sleeve and bearing from but do not fit its fixings at this stage.
the drop plates mounting. 3. Fit the drive chain to the swinging arm (see
page 13-23).
4. Refit the caliper carrier positioning stud and tighten
to 27 Nm.
5. Refit the hub with the circlip groove facing towards
the right hand side.
6. Refit the caliper carrier (logo side facing to the right)
and retain with the circlip.
Z Position the swinging arm to the frame.
gagn_2
1. Bearing sleeve
2. Seals
27 Remove the drive chain rubbing strip.

Rear Suspension
8. Refit the swinging arm spindle from the left hand 1Z Attach the brake hose and, if fitted, the ABS sensor
side such that it will support the swinging arm, but harness to their clips under the swinging arm.
not pass all the way through the frame adiuster. This 18. Refit the rear brake hose cover to the swinging arm
will allow tool T3880104 to engage in the slot of the and tighten the new fixings to 6 Nm.
frame adjuster.
19. Fit the flanged sleeve to a new fixing and secure the
lower end of the chain rubbing strip to the swinging
arm and tighten to S Nm.
20. Secure the upper end of the chain rubbing strip to
the swinging arm and tighten to S Nm.
gaew_1
1. Swinging arm spindle
9. Using tool T3880104, tighten the frame adjuster to

6Nm.
21. Grease the inner hub bearing (see page 75-15).

22. Refit the axle shaft and final drive assembly (see
page 73-21).
c-iaw 1
1. Tool T3 880104
2. Frame adjuster
10. Fully insert the swinging arm spindle.
11. Fit the washer and new nut to the swinging arm
spindle and tighten to 110 Nm.
12. Refit the covers for the swinging arm spindle.
13. Fit the drive chain to the output sprocket.
14. Fit the lower chain guard and tighten the fixings to 1. Axle shaft
4.SNm. 2. Final drive
15. Fit the rear suspension unit but do not fully tighten 3. Chain
the fixings at this stage (see page 73-9).
16. Fit the hugger and tighten the fixings to 3 Nm.

Rear Suspension
23. Refit the rear wheel (see page 15-10>. Final Drive/Rear Hub and Bearings
24. Lower the motorcycle to the ground and place on
the side stand.
Removal
25. With the weight of the motorcycle on its wheels,
tighten the rear suspension unit upper mounting to
48Nm.
from the fuel tank.
26. Tighten the three fixings for the drop link plates to
48Nm.
fixings to 2 Nm.
29. Pump the rear brake pedal several times to position
the brake pads in the caliper. Rectify as necessary if
correct brake operation is not restored (see
page 14-26).
cgfo ""
1. Front panel
2. Fixings

3. Raise and support the rear of the motorcycle under
the frame or engine.

the motorcycle.
4. Remove the rear wheel (see page 15-70>.

5. Models with ABS only: Detach the rear ABS wheel
speed sensor from the caliper carrier (see
page 74-40>.
A Caution
To prevent damage to the brake pipe and caliper, do not
allow the caliper to hang on the brake pipe.

Rear Suspension
6. Without disconnecting the brake hose, detach then Note:

support the rear brake caliper.
Collect the spacer fitted between the final
drive and the hub.
gaek_1
2 1 2
1. Rear brake caliper
2. Caliper mounting bolts
1. Axle shaft
7. Slacken the swinging arm/hub pinch bolt. 2. Final drive
8. Use the C-spanner from the motorcycle tool kit to 3. Chain
turn the hub and slacken the drive chain. Note:
Support the chain while the hub is removed to
prevent it from becoming contaminated.
If necessary, the brake disc can be removed at
this point.
12. Ease off the final drive hub, and capture the spacer.
1. Pinch bolt
2. C-spanner
3. Adjuster
4. Final drive nut
9. De-stake then slacken the nut securing the final drive

unit to the axle shaft.
1. Cush drive hub
10. Remove the staked nut (discard the nut), Belleville 2. Spacer
washer and stepped washer from the axle shaft. 3. 0-ring
11. Pull the axle shaft through the hub to the right hand 4. Cush drive rubbers
side such that the shaft clears the final drive S. Cush drive housing
assembly. Remove the final drive unit disconnecting 6. Sprocket
the chain at the same time.
13. Remove the cush drive rubbers.
14. If required, remove the securing nuts to release the
chain sprocket.
15. To detach the rear hub and bearings, remove the
large circlip securing the caliper carrier to the hub
and detach the carrier.

Rear Suspension
16. Remove the wheel bearing hub from the left hand Assembly - Final Drive
side of the swinging arm.
1. Position the sprocket, fit the bolts from the inside face
of the cush drive housing and secure with new nuts,
tightened to 3 3 Nm.
2. Fit the 0-ring to the cush drive hub.
3. Fit the cush drive rubbers.
4. Locate the spacer in the cush drive housing and fit
the hub.
Installation - All Parts
1. Refit the wheel bearing hub to the swinging arm,

with the circlip groove to the right hand side.
2. Grease the inner hub bearing (see page 15-15>.
gagt_l 3. Refit the caliper carrier (logo side facing to the right)
1. Circlip and the slotted hole over the positioning stud. Retain
2. Caliper carrier with the circlip.
3. Hub
4. Swinging arm
5. Caliper carrier positioning stud
Note:
Rear wheel bearing replacement procedure
can be found in section 15.
Inspection - All Parts
1. Thoroughly clean all components and inspect for

damage, wear etc. Renew as necessary.
2. Pay particular attention to the condition of the cush
rubbers, examining for splits, damage, softness etc.
3. Check the final drive bearing for wear or rough gagt_t
running, and the seal for damage. 1. Circlip

2. Caliper carrier
4. Inspect the 0-ring in the cush drive hub for damage.
3. Hub
5. Inspect the sprocket teeth for wear, damage and 4. Swinging arm
chips. 5. Caliper carrier positioning stud
6. Check the wheel/hub bearings for damage, pitting,
4. Refit the axle shaft and align the spacer to the final
and cracks. Replace as necessary.
drive side.
Z Check all bearing seals for damage, splits etc.
Replace as necessary. 5. Taking care not to damage the seals, locate the final
drive on the shaft then refit the drive chain to the
sprocket.

Rear Suspension
6. Fit: 8. Refit the rear brake caliper. Tighten the caliper bolts
to 40 Nm.
collar, stepped side inwards;
Belleville washer, convex side out;
a new stake nut.
gaek_1
2 1
1. Caliper
2. Caliper bolts
9. Models with ABS only: Fit the ABS sensor, harness
bracket and shim to the caliper carrier (see
1. Final drive unit page 14-41>.
2. Axle shaft
10. Refit the rear wheel <see page 15-10>.
3. Stepped washer
4. Belleville washer 11. Lower the motorcycle to the ground and place on
5. Stake-nut the side stand.
12. Adjust the chain tension <see page 73-6J.
Z Tighten the nut to 146 Nm, and stake to secure.
13. Tighten the swinging arm/hub pinch bolt to SS Nm.
14. Reconnect the battery positive (red) lead first.
fixings to 2 Nm.
16. Pump the rear brake pedal several times to position
the brake pads in the caliper. Rectify as necessary, if
the correct brake operation is not restored <see
page 14-26).
Staking the Nut

Rear Suspension
Drive Chain Replacement 3. Position the chain to the tool ensuring that the chain
link pin which is to be removed is aligned with the
holes in the chain cutting tail piece and the large
Rivet link type pressure screw. Tighten the large pressure screw by
hand to grip the chain.
As the drive chain passes through the swinging arm
casting, the chain must be split for removal from the
motorcycle. Removal of the swinging arm is not required
for drive chain replacement. The following instructions for
the replacement of rivet link type drive chains requires the
use of service tool T388002Z

the motorcycle.
1. Support the motorcycle on a stand so the rear wheel

is clear of the ground. cdqm_1
2. Insert the hollow chain cutting tail piece into the tool
1. Tool T3880027
body so its larger diameter end is facing towards the
2. Large pressure screw
large pressure screw as shown.
3. Chain
4. Chain cutting tail piece
4. Insert the small pressure screw into the larger

pressure screw as shown below, until the cutting pin
on the small pressure screw contacts the link pin.
Ensure that the cutting pin is centralised on the link
pin to be removed.
cdqk_1
1. ToolT3880027
3. Chain cutting tail piece
cdq1_1
1. Tool T3880027
2. Small pressure screw
5. Retain the tool body then tighten the small pressure
screw until the link pin is pressed out from the chain.
6. Repeat steps 3 to 5 on the remaining chain link pin.
Z Remove the tool and separate the two ends of the
chain.
8. Remove the chain cutting tail piece from the body.

Rear Suspension
Note: 12. Insert the link plate holder <marked PH5060R) into
the large pressure screw.
The replacement chain is supplied in a split
condition, complete with a link kit to ioin the
two ends.
A Caution
The component parts of the new link kit are coated with
a special grease which must not be removed. Removal
of this special grease will severely reduce the service life
of the cha in.
9. Use the old drive chain to pull the new chain into
position as follows: Temporarily attach the end of the
new chain to a free end of the old chain using the
old connedor link. Carefully pull the other end of the
old chain to pull the new chain around the sprockets.
cdqn_1
Note: 1. Tool body
Do not use the new connector link as the 2. Large pressure screw
special grease on it may be removed. 3. Link plate holder (marked PHS060R>
4. Riveting tail piece
10. Using the new link supplied with the chain kit, join
the two ends of the chain. Ensure that the 0-rings 13. Position the tool to the chain. Ensure the link plate
are positioned as shown below and the link plate is holder is correctly located in the large pressure
fitted with its markings facing outwards. screw.
V'~
1 3
1. 0-rings 1. Tool body

2. Link 2. Large pressure lever
3. Link plate 3. Link plate holder (marked PH S060R>
4. Riveting tail piece
11. Insert the riveting tail piece into the tool body so its
larger diameter end is facing towards the large
pressure screw as shown.
Note:
Tool T3880027 includes two link plate holders,
one is for riveted link plates (marked
PH5060R>, the other is for link plates retained
by a spring clip (marked PH4060C>. The holder
for riveted link plates has a shallow groove to
allow for chain link clearance, the holder for
clipped link plates has a deep groove to allow
for chain link clearance.

Rear Suspension
14. Locate the split link pins such that the pins will enter 20. Retain the tool body and tighten the large pressure
the groove in the link plate holder when the link screw until the split link end is riveted-over.
plate is pressed on to the link.
2 1
~~
3
?----\
cdqn_4
1. Tool body
1. Link plate holder 2. Large pressure screw
2. Link plate 3. Flare pin
3. Chain link
21. Back off the large pressure screw and rivet the
4. Link plate holder groove
remaining split link pin as described above.
15. Retain the tool body and tighten the large pressure 22. Remove the tool from the chain and check that both
screw until the link plate is pressed fu.lly onto the link. the split link pins are correctly riveted as shown
16. Back off the pressure screw, slide the tool assembly below.
to one side and check that the split link is correctly
assembled.
1Z Remove the link plate holder from the tool. Do not
remove the riveting tail piece from the tool
18. Insert the flare pin into the large pressure screw.
1 2
""
~ ~
3 4
,.
1. Correct riveting
2. Insufficient riveting
3. Excessive riveting
4. Riveting off-centre
cdqn_2
1. Tool body
3. Riveting tail piece If either split link pin is not correctly riveted, the split link
4. Flair pin must be removed and replaced with a new link. Never
operate the motorcycle with an incorrectly riveted split
19. Locate one of the split link pins into the riveting tail link as the link could fail resulting in an unsafe riding
piece and screw the large pressure screw in until the condition leading to loss of control and an accident
flare pin contacts the split link end. Ensure the split
link pin is centrally located on the flare pin.

Rear Suspension

14 Brakes
Table of Contents
Exploded View - Front Brake Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
Exploded View - Front Brake Caliper - Speed Triple. ............... .. ........ ..... .. . .. .. .. . .. . 14.5
Exploded View - Front Brake Caliper - Speed Triple R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
Exploded View - Rear Brake Master Cylinder . . . . . . . ... . .. .. . .................. . .............. 14.7
Exploded View - Rear Brake Caliper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
Exploded View -ABS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
Braking System Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
Fluid Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
Changing Brake Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
Brake Wear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 1
Breaking-in New Brake Pads and Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
Bleeding the Front Brakes, Renewing Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
Front Brake Pads - Speed Triple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
Front Brake Pads - Speed Triple R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
Removal .......... . ...... . ..... . .. . ....... . . .. ....................................... 14.16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
Front Brake Caliper - Speed Triple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
Front Brake Caliper - Speed Triple R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
Inspection ................ . ........ . ......................... . . . . .. ...... . . .. .... .... 14.22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23

Brakes
Front Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23

Wear ............................... . ...................... . ........................ 14.23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24
Front Brake Master Cylinder .............................................................. 14.25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
Bleeding the Rear Brakes, Renewing Brake Fluid. ...................... ..... .. . ..... ... .. . . . . 14.26
Rear Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.32
Rear Brake Disc .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.32
Wear. . ...... ....... ..... ......... .. ....................... .. .......... . ... ... . . .... 14.32
Removal. ...................... . .......... . ............ ..... ......... ........ ....... 14.32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.33
Rear Master Cylinder .... ........ ...... .. ........... . ................................. . .. 14.33
Removal ... ..... ....... .. ..................................................... .. ... . 14.33
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.34
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.35
Bleeding the Front Brakes, Renewing Brake Fluid - Motorcycles with ABS... .............. ...... . 14.35
Front ABS Wheel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.36
Removal ... . ...................... .. ..................... ..... ...................... 14.36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.37
Front ABS Pulser Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.38
Removal .......... . ....................................... . . .. ............... ... ... . 14.38
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.38
Bleeding the Rear Brake Fluid - Motorcycles with ABS ........................ . .. ... ....... . .. 14.39
Rear ABS Wheel Speed Sensor................................... .. . ... ................... 14.40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.41
Air Gap Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.42
Rear ABS Pulser Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.43
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.43

Brakes
ABS Hydraulic Modulator/ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.44

Removal.. ......... ..... ................................ . ... ... .... ...... ........... 14.44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.46
ABS .............. ... . .... ... ....... . .. ... ...... . ...................................... 14.48
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.48
Component Location... ........ . .............. ... ..................................... 14.49
ABS System Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.50
Key to Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.50
ABS System Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.51
System Diagnostics. ....................................................... . ............. 14.52
Diagnostic Tool Connection. ....................... .. .. .... ... .. . .. ..... ............... 14.52
Triumph Diagnostic Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.53
Build Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.53
Current Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.53
Bleed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.53
Diagnostic Trouble Codes. ........... ...... .... ............. ... .. . ........................ 14.54
Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.55
Electrical Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.57
Before Disconnection:.. ............ .... ........... .... . ..... .. ........................ 14.57
When Disconnecting a Connector: ........................... ... ..... ....... ............ 14.57
When Inspecting a Connector:.. . . .............. . .... . ..... . . . ........................ .. 14.57
When Connecting a Connector.. ................. . .......... ........................... . 14.57
Disconnection of ABS ECM Connector. .................................................. 14.57
Reconnection of ABS ECM Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.58
Further Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.58
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.58
ABS Warning Light ON <No DTCs Stored). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.59
ABS Warning Light Does Not Illuminate <No DTCs Stored)... ........ ..... ..................... 14.60
Front Wheel Sensor Open Circuit/Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.62
Rear Wheel Sensor Open Circuit/Short Circuit .... .... .. . . ..... .. ............ . . . ... . .. .. ... . . 14.64
Front Wheel Sensor Abnormal Input/losing Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.66
Rear Wheel Sensor Abnormal Input/Losing Contact .................. ... . .................... 14.67
Front Wheel Pulser Gear Missing Teeth .................................... ..... ............ 14.68
Rear Wheel Pulser Gear Missing Teeth. .. ... ..... . . . .. ..... ........ ..... ....... .... ....... .. 14.69
Front or Rear Input/Output Solenoid Open/Short Circuit .................... ... ............... 14.70
Front or Rear Wheel Actuator (Hydraulic Control> Wheel Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.71
Motor - Lock; Motor Stuck OFF; Motor Stuck ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.72
Power Source Voltage DropNoltage Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.73
Different Tyre Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.74
Abnormal ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.75
ABS Hydraulic Circuit Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.76

Brakes
Exploded View - Front Brake Master Cylinder
t---6Nm
~
~
~
L____ 6Nm
1 1
7Nm
I
25 Nm
25Nm
\
Brakes
Exploded View - Front Brake Caliper - Speed Triple
Seetex~
22Nm

Brakes
Exploded View - Front Brake Caliper - Speed Triple R
'-
'-
'-
'
~
......
'-
'-
'-
t
I
I ' ......
See text ' )
I
I
' I
r ' ) I
I I
I
I
I
I
I I I
I I
I I
I I
,)
I
,)
22Nm

Brakes
Exploded View - Rear Brake Master Cylinder
15 Nm
25Nm
~ - - - - - SNm
r
~ "
6Nm~j
<if? ~; .... ~
i I
f
6Nm ~
i
~6 Nm
....
~
25Nm / ~
18 Nm L-~ ts?
~ ~ 22Nm
())--- __JJ/ ~ ·e ~~ L
-0 - tJ

Brakes
Exploded View - Rear Brake Caliper
/"- /
/ ......... .........,,,
/
/
/
t~
/
/
~~
40Nm 18Nm
6Nm

Brakes
Exploded View - ABS System
25Nm 0
25 Nm
25Nm SNm
\
\
0
25Nm
I
I
9Nm I
.0. ~
1 .0.
25 Nm
9Nm ~\

Brakes
Braking System Maintenance Safety

Precautions
brake fluids other than those DOT 4 fluids listed in the
Brake fluid is hygroscopic which means it will absorb general information section may reduce the efficiency of
moisture from the air. The absorbed moisture will the braking system leading to an accident.
greatly reduce the boiling point of the brake fluid Failure to change the brake fluid at the interval specified
causing a reduction in braking efficiency. in the scheduled maintenance chart may reduce braking
Replace brake fluid in line with the scheduled efficiency resulting in an accident.
maintenance chart. A dangerous riding condition could
result if this important maintenance item is neglected.
Do not spill brake fluid onto any area of the bodywork
as this will damage any painted or plastic surface. Never use mineral based grease in any part of the
Always use new brake fluid from a sealed container and braking system or in any area where contact with the
never use fluid from an unsealed container or from one braking system is possible. Mineral based grease will
1
which has been previously opened. damage the hydraulic seals in the calipers and master
cylinders.
Do not mix different brands of fluid. Check for fluid
leakage around brake fittings, seals and joints. Damage caused by contact with mineral based grease
may reduce braking efficiency resulting in an accident.
Check regularly for brake hose damage. 1
FAILURE TO OBSERVE ANY OF THE ABOVE

WARNINGS MAY REDUCE BRAKING EFFICIENCY
LEADING TO AN ACCIDENT
If there has been an appreciable drop in the level of the

fluid in either brake fluid reservoir, consult your
authorised Triumph dealer for advice before riding.
If the brake lever or pedal feels soft when it is applied, or
if the lever/pedal travel becomes excessive, there may
be air in the brake lines or the brake may be defective.
It is dangerous to operate the motorcycle under such
conditions and remedial action must be taken by your
authorised Triumph dealer before riding the motorcycle.
Failure to take remedial action may reduce braking
efficiency leading to an accident.
14.1 0 Service Manual - Speed Triple and Speed Triple R

Brakes
Fluid Level Inspection Changing Brake Fluid

Brake fluid should be changed at the interval specified in
the scheduled maintenance chart.

and adequately supported. This will help prevent it from Brake Pads
the motorcycle. Front and rear pad wear is automatically compensated for
and has no effect on brake lever or pedal action.
In accordance with the scheduled maintenance chart,
inspect the brake fluid level in the front and rear master
cylinder reservoirs. Brake Wear Inspection
l. Ensure that the brake fluid level in the front and rear In accordance with the scheduled maintenance chart,
brake fluid reservoirs is between the upper and inspect the brake pads for wear. The minimum thickness
lower level lines (reservoir held horizontaD. of lining material is 1.0 mm for the front brake pad or
1.5 mm for the rear. If the lining thickness of any pad
(front or rear brakes> is at or below the minimum
1 thickness, replace all the pads on the wheel.
Note:
The brake pad groove should not be used as an
indication of brake pad wear. Always measure
the remaining brake pad lining thickness, and
replace all brake pads on any wheel which are
worn to, or below, the 1.0 mm (front> limit or
1. 5 mm Crear) limit.
1. Front rese1Voir upper level

2. Front rese1Voir lower level
ceyl
1. Brake pads <front caliper shown), Speed Triple shown
Do not replace individual brake pads, replace all pads in

the brake caliper. On the front where two calipers are
cdlg_2 mounted on the same wheel, all the pads in both
1. Rear rese1Voir upper level calipers must be replaced together. Replacing individual
2. Rear reservoir lower level pads will reduce braking efficiency and may cause an
accident.

Brakes
Breaking-in New Brake Pads and 2. Remove the rubber cap from the bleed nipple on
the right hand caliper.
Discs
3. Attach a transparent tube to the bleed nipple.
After replacement brake discs and/or pads have been
fitted to the motorcycle, we recommend a period of
careful breaking-in that will optimise the performance and
longevity of the discs and pads. The recommended
distance for breaking-in new pads and discs is 200 miles
<300 km).
After fitting new brake discs and/or pads avoid extreme
braking, ride with caution and allow for greater braking
distances during the breaking-in period.
Bleeding the Front Brakes, Renewing

Brake Fluid
1. Bleed nipple
Before starting work, ensure the motorcycle is stabilised 2. Spanner
and adequately supported. This will help prevent it from 3. Bleed tube
falling and causing injury to the operator or damage to 4. Container
the motorcycle.
4. Place the other end of the tube in a suitable
Note: receptacle containing new brake fluid.
5. Turn the handlebars to bring the fluid reservoir to a
The master cylinder should always be bled last.
level position.
Bleed each caliper in turn before bleeding the
master cylinder.
Models with ABS brakes: Refer to bleeding
ABS brakes later in this section <see
page 14-JS>.
1. Note the original setting of the brake lever adiuster

in order that it can be returned to the same position
when the bleeding operation is complete. Turn the
brake lever adiuster fully in.
abdL2
1. Front reservoir upper level

2. Front reservoir lower level
3. Screws
6. Remove the screws from the brake reservoir cover.
1. Brake lever
2. Adjusting screw

Brakes
16. Repeat the bleed procedure for the bleed nipple on

the master cylinder. Tighten the bleed nipple to
6Nm.
Ensure absolute cleanliness when adding brake fluid to
the brake fluid reservoir. Do not allow moisture or debris
to enter the cylinder as this will adversely affect the fluid
properties. Always use fluid from a sealed container and
do not use fluid from a container which has been
opened for any period of time. Always check for fluid
leakage around hydraulic fittings and for damage to
hoses.
A dangerous riding condition leading to an accident
could result if this warning is ignored .
.A Caution
To prevent body damage, do not spill brake fluid onto
1. Bleed nipple
l Carefully remove the reservoir cover taking care not 2. Spanner
to spill any fluid. 3. Bleed tube
8. Check the condition of the sealing diaphragm for the 4. Container
reservoir. Replace if necessary.
1Z When both calipers and the master cylinder have
9. Release the bleed nipple. been bled, ensure the brake lever operation has a
firm resistive feel to it, does not feel spongy and that
the lever cannot be pulled directly back to the
handlebar. Take remedial action as necessary.
18. Fill the reservoir to the upper level with new DOT 4
fluid.
general information section may reduce the efficiency of 19. Refit the reservoir diaphragm and cover. Secure the
the braking system leading to an accident. cap with its screws.
Observe the brake fluid handling warnings given earlier
in this section of the manual.
Note: Always return the lever adjuster to the original setting.

Operating the motorcycle with lever settings which are
During bleeding, do not allow the fluid level to unfamiliar may lead to loss of control or an accident.
fall below the lower level mark in the reservoir.
If the level is allowed to fall below this mar~ air 20. Reset the brake lever adjuster to the original setting.
may enter the system and the sequence of 21. Check that the brake operates correctly. Rectify as
bleeding must be repeated. necessary.
10. Slowly pull the brake lever to the handlebar and,
holding the lever fully in, close the bleed nipple.
11. Repeat steps 9 and 10 until no more air appears in
the bleed tube. It is dangerous to operate the motorcycle with defective
brakes; you must have your authorised Triumph dealer
12. When all air has been expelled from the system,
take remedial action before you ride the motorcycle
hold the lever in and close the bleed nipple. Tighten
again. Failure to take remedial action may result in
the nipple to 6 Nm.
reduced braking efficiency leading to loss of motorcycle
13. Fill the reservoir to the upper level with new DOT 4 control and an accident.
fluid.
14. Remove the transparent bleed tube.
15. Repeat the bleeding procedure for the left hand
caliper.

Brakes
Front Brake Pads - Speed Triple 4. Remove both brake pads and inspect for damage
and wear beyond the service limit.
Removal

the motorcycle.
1. Using finger pressure on the spring roller, press the

brake pad retaining spring inwards to release the
pin. Withdraw the pin with the other hand. Inspect
the pin for damage.
2. Remove the brake pad retaining spring and inspect
the spring for damage.
1. Brake pad
5. Repeat the removal of the remaining brake pads in

the caliper as described above.
Note:
Complete the assembly of the brake pads to
one caliper <see installation for details) before
removing the pads from the other caliper.
Installation
Never use mineral based grease in any part of the

braking system or in any area where contact with the
3. Brake pad retaining spring release direction
cylinders.
4. Pin removal direction
A. Caution
Never lever directly against the disc, caliper or the pad

lining material as this will damage these components.
Always use a levering tool made from a soft material If fitting new proprietary brakes pads, check that the
which will not cause damage to the load bearing carrier plate of the brake pad is at least 4.5 mm thick.
surfaces. Fitting brake pads with the carrier plate less than
Brake fluid will be displaced as the caliper pistons are 4.5 mm thick may result in brake failure due to the
compressed. To prevent body damage, ensure that the possible loss of the brake pad as it wears.
displaced fiuid does not come into contact with any part
of the bodywork. Brake pads for this model supplied by Triumph will have
the carrier plate at least 4.5 mm thick. Always have
3. Ease the brake pads apart to force the caliper pistons
back and allow withdrawal of the pads.

Brakes
replacement brake pads supplied and fitted by your 5. Ensure that the brake pad retaining spring is fully
Triumph dealer. engaged in both grooves in the pin.
4.Smm +
cezf
cezg_1
1. Carrier plate 1. Brake caliper

2. Brake pad 2. Pin
3. Pin groove
1. Fit new brake pads as an axle set or, if all the pads 4. Brake pad retaining spring
are in a serviceable condition, clean the pad grooves 5. Spring roller
before refitting all pads in their original positions.
6. Ensure the brake pad retaining pins are correctly
seated as shown below.
Do not apply more than a minimum coating of grease

to the pad retaining pins. Excess grease may
contaminate the brake pads, hydraulic seals and discs
causing reduced braking efficiency and an accident.
2. Lubricate the pad retaining pins using a minimum

amount of proprietary high temperature brake
grease.
3. Hook the end of the brake pad retaining pin into the
slot in the brake caliper as shown below. Ensure the
spring securely retains the brake pads.
cezl
Brake Pad Retaining Pins Incorrectly Seated
1. Caliper
2. Brake pad retaining spring
4. Press the spring roller inwards to allow the pin to cezi
slide through the spring. Brake Pad Retaining Pins Correctly Seated

Brakes
Z Repeat the installation of the remaining brake pads Front Brake Pads - Speed Triple R
in the caliper as described above.
8. Pump the brake lever to correctly position the caliper
pistons. Removal
Use only DOT 4 specification brake fluid as listed in the Before starting work. ensure the motorcycle is stabilised
general information section of this manual. The use of and adequately supported. This will help prevent it from
brake fluids other than those DOT 4 fluids listed in the falling and causing injury to the operator or damage to
general information section may reduce the efficiency of the motorcycle.
the braking system leading to an accident.
Do not allow the calipers to hang on the brake hoses as
9. Check the front brake fluid level and top up as
this may damage the hoses and could lead to loss of
required with new DOT 4 fluid.
motorcycle control and an accident
10. Check for correct brake operation. Rectify as
necessary. 1. Remove the caliper mounting bolts and slide the
caliper off the disc.
It is dangerous to operate the motorcycle with defective

control and an accident
chbg

2. Caliper
2. Release the brake pad retaining lug from its

mounting in the caliper and remove the brake pad.
C)
1. Brake pad retaining lug

Brakes
3. Repeat for the other brake pad.

Note:
Note the position and orientation of the anti- If fitting new proprietary brakes pads, check that the
rattJe spring for installation. carrier plate of the brake pad is at least 4.5 mm thick.
Note that the arrow on the anti-rattle spring is Fitting brake pads with the carrier plate less than
pointing in the same direction as the arrow on 4.5 mm thick may result in brake failure due to the
the caliper. possible loss of the brake pad as it wears.
Brake pads for this model supplied by Triumph will have

the carrier plate at least 4.5 mm thick. Always have
replacement brake pads supplied and fitted by your
Triumph dealer.
4.5 mm+
2. Arrow, front caliper
Inspection chbe
1. Carrier plate
1. Check the anti-rattle spring. Renew any component 2. Brake pad
which shows signs of damage or corrosion.
2. Check there is no sign of leakage from the piston
seals. Rectify any problems before installing the pads. A Caution
Note: Never lever directly against the disc, caliper or the pad
lining material as this will damage these components.
Complete the assembly of the brake pads to Always use a levering tool made from a soft material
one caliper Csee assembly for details) before which will not cause damage to the load bearing
removing the pads from the other caliper. surfaces.
Brake fluid will be displaced as the caliper pistons are
Installation compressed. To prevent body damage, ensure that the
displaced fluid does not come into contact with any part
of the bodywork.
1. If new pads are being installed, push the pistons fully

Never use mineral based grease (such as lithium or
back into the caliper body. Keep an eye on the fluid
copper based grease) in any area where contact with the :
level in the reservoir whilst retracting the pistons to
braking system hydraulic seals and dust seals is possible.
prevent fluid spillage.
Mineral based grease will damage the hydraulic seals
and dust seals in the calipers and master cylinders. 2. Ensure that the anti-rattle plate position and
Damage caused by contact with mineral based grease orientation is as noted for removal.

Brakes
3. Fit one of the brake pad's retaining lugs into its 11. Repeat the removal, inspection and installation
mounting in the caliper with its friction material process for the other caliper.
surfaces facing the other side of the caliper.

general information section may reduce the efficiency of
the braking system leading to loss of motorcycle control
and an accident
12. Check the front brake fluid level and top up as

required with new DOT 4 fluid.
~
necessary.
chaz ()
1. Anti-rattle spring
2. Retaining lug
3. Retaining lug mounting It is dangerous to operate the motorcycle with defective
4. Using finger pressure only, fit the pad's other brakes; you must have your authorised Triumph dealer
retaining lug into its mounting of the caliper. Ensure take remedial action before you ride the motorcycle
that both retaining lugs are fully fitted into their again. Failure to take remedial action may result in
mountings. reduced braking efficiency leading to loss of motorcycle
5. Repeat steps 2 to 4 for the other brake pad.
6. Thoroughly clean the threaded bolt holes for the
front fork brake caliper fixings.
Z Position the caliper over the disc.
8. Thoroughly clean the threaded part of the bolt and
smear the first four threads with a proprietary copper
based grease.
9. Secure the brake caliper with the bolts and tighten to
SS Nm.
10. Pump the brake lever to correctly position the caliper

pistons.

Brakes
Front Brake Caliper - Speed Triple Disassembly
Removal
To prevent injury, never place fingers or hands inside
the caliper opening when removing the pistons. Always
wear eye, hand and face protection when using
Before starting work, ensure the motorcycle is stabilised compressed air. Eye, face and skin damage will result
and adequately supported. This will help prevent it from from direct contact with compressed air.
the motorcycle.
A Caution Ensure that the caliper bores do not become scratched

during piston removal and assembly. Ensure that the
To prevent body damage, do not spill brake fluid onto pistons remain square to their bores during fitment
any area of the bodywork. otherwise damage to the caliper could result.
1. Disconnect the brake hose at the caliper, and place A dangerous riding condition leading to an accident
the free end of the hose(s) in a suitable container to could result if this warning is ignored.
collect brake fluid.
1. Cover the caliper with a clean, heavy cloth and, using
2. Remove the brake pads <see page 14-14). compressed air, remove the pistons one at a time.
3. Remove the two caliper bolts.
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 leak past the
seals resulting in a dangerous riding condition leading to
loss of motorcycle control and an accident.
2. Remove the old dust seals and piston seals then

thoroughly clean and dry the caliper bores. Discard
the old seals and pistons, these must not be re-used.
Always renew caliper seals and pistons after removal

from the caliper. An effective hydraulic seal can only be
cgva_1
1. Caliper bolts made if new components are used.

4. Manoeuvre the caliper clear of the disc, taking care
could result if this warning is ignored.
not to damage the wheel.
3. Check the caliper bores for corrosion, scoring and
damage. Renew as necessary.

Brakes
Assembly Installation
1. Apply a thin smear of propriety high temperature

brake grease to the threads of each caliper bolt.
Ensure that the caliper bores do not become scratched 2. Ensuring the mounting faces on the fork and caliper
during piston removal and assembly. Ensure that the are clean and dry, position the caliper over the disc.
pistons remain square to their bores during fitment Install the caliper bolts and tighten to.SS Nm.
otherwise damage to the caliper could result
Note:
The piston seals are slightly thicker than the
dust seals.

fluid.
Never use solvents, petrol (gasoline}, engine oil, or any
cgva_1
as this will cause deterioration of the hydraulic seals in 1. Caliper bolts
the calipers and master cylinders.
3. Fit the brake pads <see page 14-14).
motorcycle control and an accident could result if this 4. Connect the brake hose to the caliper incorporating
warning is ignored. new sealing washers on each side of the hose
connection.
1. Fit the piston seals and the dust seals to the caliper 5. Tighten the banjo bolt to ZS Nm.
bores as shown below.

6. Fill the master cylinder reservoir with new DOT 4

brake fluid from a sealed container.
Z Bleed the front brake lines (see page 14-12}.
8. Check for correct brake operation.
oozk
1. Piston seal groove

2. Dust seal groove
3. Piston seal I It is dangerous to operate the motorcycle with defective
4. Dust seal brakes; you must have your authorised Triumph dealer
5. Piston take remedial action before you ride the motorcycle
2. Carefully push the pistons fully into the caliper bores reduced braking efficiency leading to loss of motorcycle
by hand. control and an accident.

Brakes
Front Brake Caliper - Speed Triple R Disassembly
Removal
To prevent injury, never place fingers or hands inside
the caliper opening when removing the pistons. Always
wear eye, hand and face protection when using
compressed air. Eye, face and skin damage will result
from direct contact with compressed air.
falling and causing injury to the operator or damage to 1. Cover the caliper opening with a clean heavy cloth
the motorcycle. and using either compressed air or by reconnecting
the master cylinder and pumping the brake lever,
A Caution
remove the pistons one at a time.
To prevent paint damage, do not spill brake fluid onto

any area of the bodywork. Spilled brake fluid will
damage paintwork. i
1
2 3
Note:
Note the orientation of the brake hose on the oO(] 3
/. 2 1
CD06
caliper for installation.
1. Disconnect the brake hose at the caliper and place

00(])
7
2.
the free end of the hose in a suitable container to
collect the brake fluid.
Remove the brake pads (see page 14-76).
3 ClJ
7 0())
3
chbd
1. Piston seal
2. Dust seal
3. Pistons
4. Caliper
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 leak past the
seals resulting in a dangerous riding condition leading to
loss of motorcycle control and an accident.
2. Extract the dust seals and piston seals, taking care

not to damage the caliper bores. Discard the old
seals, these must not be re-used.

Brakes
Note: Assembly
The piston seals are slightly thicker than the
1. If all components are serviceable, obtain a piston seal
dust seals.
kit and reassemble the caliper as follows:
Never use mineral based grease (such as lithium or

copper based grease) in any area where contact with the
braking system hydraulic seals and dust seals is possible.
Mineral based grease will damage the hydraulic seals
and dust seals in the calipers and master cylinders.

1. Piston seals fluid.
2. Dust seals
3. Check the pistons, caliper and mounting bracket for other petroleum distillate on internal brake components
signs of damage, paying particular attention to the as this will cause deterioration of the hydraulic seals in
caliper bores and pistons. If damage is present, the calipers and master cylinders.
renew the worn component or the complete caliper A dangerous riding condition leading to loss of
assembly. motorcycle control and an accident could result if this
warning is ignored.
Inspection
2. Ensure all components are clean, then fit the new
seals to their grooves in the caliper bores.
1. Check the pistons and caliper bores for corrosion,
scoring and damage. 3. Lubricate the fluid seals, caliper bore and the outside
of the pistons with clean DOT 4 brake fluid.
4. Ease the pistons squarely back into the bores, taking
care not to displace the seals.
Always renew caliper seals and pistons after removal
made if new components are used.
2. Inspect the brake pads for damage and wear beyond

the service limit. Renew as necessary.

Brakes
Installation Front Discs

1. Remove the front wheel (see page 15-8).
2. Temporarily fit the calipers to the forks.
3. Connect the brake hoses to the calipers Before starting work, ensure the motorcycle is stabilised
incorporating new sealing washers on each side of and adequately supported. This will help prevent it from
the hose connections. falling and causing injury to the operator or damage to
4. Ensure the orientation of the brake hose is as noted the motorcycle.
for removal and tighten the banjo bolt to 25 Nm.
Wear
1. Replace any brake disc if it is worn beyond the

Do not allow the calipers to hang on the brake hoses as service limit or exceeds the disc run-out limit.
this may damage the hoses and could lead to loss of
motorcycle control and an accident. Front Disc Thickness
5. Detach the calipers from the front forks and refit the
Standard: 4.5 mm
wheel (see page 15-9).
Service Limit: 4.0mm
6. Fit the brake pads <see page 14-m. I
Disc Run-out
I Service Limit: 0.3 mm

general information section of this manual. The use of Measure disc run out using an accurate dial gauge
brake fluids other than those DOT 4 fluids listed in the mounted on a surface plate.
and an accident.
7. Fill the master cylinder with new, DOT 4 brake fluid

from a sealed container.
8. Bleed the front brake line (see page 14-12).
2
9. Check for correct brake operation.

brakes; you must have your authorised Triumph dealer gaeb

again. Failure to take remedial action may result in 1. Disc
2. Dial gauge
Removal
Do not renew front brake discs individually. Discs must

always be renewed in pairs even if one of a pair is
serviceable.

Brakes
2. Support the wheel on blocks as illustrated to avoid Installation

damage to the wheel centre.
1. Locate the first disc on the wheel (text OUTSIDE
facing outwards - Speed Triple only) as noted during
removal.
2. Fit new bolts and tighten to 22 Nm.
3. Fit the other disc in the same way.
4. Refit the wheel (see page 15-9).
necessary.

take remedial action before you ride the motorcycle I

1. Wheel reduced braking efficiency leading to loss of motorcycle
2. Support block control and an accident
Note:
Speed Triple only: Note that the disc carrier has
the text outside on it. This must be facing
outwards when the disc is fitted to wheel.
1. Brake disc carrier - Speed Triple shown

2. Brake disc
3. Remove and discard the bolts.
4. Detach the disc.
5. Repeat for the other disc.

Brakes
Front Brake Master Cylinder 6. Remove the mirror and the brake fluid reservoir
from the clamp for the front brake master cylinder.
Note: Support the brake fluid reservoir in an upright
The piston set inside the front brake master position.
cylinder is not se1Viceable. The master cylinder Z Release the clamp screws from the handlebar to
must be replaced in the event of a failure. remove the master cylinder.
Removal Disassembly
The following items can be replaced on the front brake
master cylinder:
Brake lever;
Before starting work, ensure the motorcyde is stabilised
and adequately supported. This will help prevent it from Bleed screw;
Brake light switch.
the motorcycle.
1. Release the three fixings and remove the front panel Installation
from the fuel tank.
1. Align the split line of the master cylinder clamp to
the+ mark on the upper surface of the handlebar.
~L
~-f ·
~
cgfo " '
1. Front panel
2. Fixings
2. Disconnect the battery, negative (black) lead first. 1. Handlebar + mark

2. Clamp split line
A Caution 2. Tighten the clamp bolts upper first to 8 Nm.

3. Fit the brake fluid reservoir and mirror to the front
To prevent paint damage, do not spill brake fluid onto
brake master cylinder. Tighten the mirror to 25 Nm.
any area of the bodywork. Spilled brake fluid will
damage paintwork. 4. Connect the brake hose to the master cylinder
incorporating new sealing washers. Tighten the
3. To drain the fluid from the master cylinder, attach a banjo bolt to 25 Nm.
tube to the right hand caliper bleed nipple, slacken 5. Connect the brake light switch.
the nipple and allow the fluid to drain into a suitable
container. Operate the brake lever until all fluid has
been expelled.
4. Note the setting of the brake lever adjuster to ensure Use only DOT 4 specification brake fluid as listed in the
it is returned to the same position when the overhaul general information section of this manual. The use of
operation is complete. brake fluids other than those DOT 4 fluids listed in the
5. Disconnect from the master cylinder: general information section may reduce the efficiency of
brake hose; and an accident.
brake light switch connections. Observe the brake fluid handling warnings given earlier

Brakes
6. Fill and bleed the front brakes (see page 14-12). Bleeding the Rear Brakes, Renewing
Brake Fluid
Always return the lever adiuster to the original setting

noted during removal. Operating the motorcycle with
lever settings which are unfamiliar may lead to loss of Before starting work ensure the motorcycle is stabilised
control or an accident. and adequately supported. This will help prevent it from
7. Reset the brake lever adiuster to the original setting. the motorcycle.
8. Examine the system for correct operation and fluid
leaks. Rectify as necessary. Note:
9. Connect the battery, positive (red> lead first. Models with ABS brakes: Refer to bleeding
10. Refit the front panel to the fuel tank and tighten the ABS brakes later in this section (see
fixings to 2 Nm. page 14-39>.
1. Remove the cap from the rear bleed nipple.
necessary.
2. Attach a transparent tube to the bleed nipple.

1. Bleed nipple
2. Spanner
3. Bleed tube
3. Place the other end of the tube in a suitable

receptacle containing new brake fluid.
A Caution

Brakes
4. Unscrew and remove the rear brake reservoir cover

taking care not to spill any fluid.

1
12. Fit the reservoir cover and diaphragm. Check for

correct diaphragm fitment before final tightening of
~Y the cover.
13. Remove the bleed tube from the nipple.
14. Replace the bleed nipple dust cap.
necessary.
1. Rear brake fluid reservoir
2. Upper level
3. Lower level

Ensure absolute cleanliness when adding brake fluid to again. Failure to take remedial action may result in
the brake fluid reservoir. Do not allow moisture or debris reduced braking efficiency leading to loss of motorcycle
to enter the cylinder as this will adversely affect the fluid control and an accident
properties. Always use fluid from a sealed container and
do not use fluid from a container which has been
opened for any period of time. Always check for fluid
leakage around hydraulic fittings and for damage to
hoses.
5. Check the condition of the sealing diaphragm.

Replace the diaphragm as necessary.
6. Release the bleed nipple.
Note:
During bleeding, do not allow the fluid level to
fall below the lower level mark in the reservoir.
If the level is allowed to fall below this mark, air
may enter the system and the sequence of
bleeding must be repeated.
Z Slowly depress the brake pedal and, holding the
pedal fully down, close the bleed nipple.
8. Repeat steps 6 and 7 until no more air appears in
the bleed tube.
9. Maintain the brake fluid level between the upper
and lower reservoir levels whilst bleeding is being
carried out
hold down the brake pedal and close the bleed
nipple. Tighten the nipple to 6 Nm.
11. Fill the reservoir to the maximum level with new
DOT 4 fluid.

Brakes
Rear Brake Pads 5. Remove the brake pads and inspect for damage or
wear beyond the service limit.
1. Remove the rear wheel (see page 15-10).
1. Brake pads
2. Anti-rattle spring
6. Remove the anti-rattle spring and inspect for

damage.
Installation
gaix 2 1 2
1. Pad retaining pins
Z. Caliper mounting bolts
2. Slacken the brake pad retaining pins. braking system or in any area where contact with the
cylinders.
Do not allow the caliper to hang on the brake hoses as Damage caused by mineral based grease may reduce
this may damage the hoses and could lead to an braking efficiency resulting in an accident.
accident.
3. Remove the caliper mounting bolts and position the

caliper to allow withdrawal of the pad retaining pins.
A. Caution
4. Press downwards on both pads and remove the pad Brake fluid will be displaced as the ca liper pistons are
retaining pins. compressed. To prevent body damage, ensure that the
displaced fluid does not come into contact with any part
of the bodywork or the rear wheel.
1. If fitting new pads, use hand pressure to compress

the caliper pistons fully into their bores.

Brakes
2. Install the anti-rattle spring into the caliper. 9. Check the brake fluid level and top-up as required
with new DOT 4 fluid.
10. Refit the rear wheel (see page 15-10>.
necessary.

akw
1. Anti rattle spring
3. Renew the brake pads as a pair or, if both pads are

in serviceable condition, clean the pad grooves
before fitting them.

4. Lubricate the pad retaining pins using a minimum

amount of proprietary high temperature brake
grease.
5. Position the caliper over the disc ensuring both pads
are correctly aligned.
6. Fit the caliper retaining bolts, and tighten to 40 N m.
Z Tighten the brake pad retaining pins to 18 Nm.
8. Pump the brake pedal to correctly position the
caliper pistons.
Use only DOT 4 specification brake fluid as listed in the 1

the braking system leading to an accident

Brakes
Rear Brake Caliper Disassembly
1. Press downwards on both pads and remove the

Removal retaining pins. Remove the brake pads.
Before starting work, ensure the motorcycle is stabilised To prevent injury, never place fingers or hands inside
and adequately supported. This will help prevent it from the caliper opening when removing the pistons. Always
falling and causing injury to the operator or damage to wear eye, hand and face protection when using
the motorcycle. compressed air. Eye, face and skin damage will result
from direct contact with compressed air.
A Caution 2. Cover the caliper opening with a clean, heavy cloth

and, using either compressed air or by reconnecting
To prevent body damage, do not allow brake fluid to the master cylinder and pumping the brake pedal,
contact any area of the bodywork or the rear wheel. remove the pistons one at a time.
1. Remove the rear wheel (see page 15-10>.

Inspection
2. Disconnect the rear brake hose at the caliper and
place the free end of the hose in a suitable container
1. Check the piston and caliper bore for corrosion,
to collect brake fluid.
scoring and damage. Renew as necessary.
3. Slacken the two pad retaining pins. - -
4.
5.
Remove the caliper mounting bolts.
Remove the brake caliper assembly. ~ Always renew caliper seals and pistons after removal
made if new components are used.
2. Inspect the brake pads for damage and wear beyond

the service limit. Renew as necessary.
Assembly

gaix 2 1 2 braking system or in any area where contact with the
1. Pad retaining pins braking system is possible. Mineral based grease will
cylinders.
Ensure that the caliper bores do not become scratched

during piston removal and assembly.

Brakes
~~~--.:~ 3. Lubricate the mounting bracket pins with silicone

, · ": r..f ! '. 'U·_fif~11h ~ i · · .' ;;, - ·~ based grease (such as T2022021 supplied by
I..---..~~ Triumph) then reassemble the bracket and caliper.
Before installation, all internal brake components should Ensure the pin gaiters are correctly located on both
be cleaned and lubricated with clean new DOT 4 brake the bracket and caliper.
fluid.
as this will cause deterioration of the hydraulic seals in
the calipers and master cylinders.
motorcycle control and an accident could result if this
warning is ignored.
1. Fit new fluid seals to the caliper. Apply brake fluid to

the outside of the caliper piston and fluid seal.
1. Caliper sliding pin

2. Caliper bracket sliding pin
4. Install the anti-rattle spring into the caliper.
gaec
1. Pistons
2. Dust seals
3. Piston seal
Ensure that the pistons do not tip during assembly as

this could damage the caliper.
A dangerous riding condition leading to an accident 1. Anti-rattle spring
~-----~7~~~~:~~~
2. Carefully push both pistons into the caliper by hand.

t~···. . - ' · .. ' ~ ff..~Cillffi . . ..
~
5. Position the brake pads in the caliper. Lubricate the

pad retaining pins using a minimum amount of
proprietary high temperature brake grease. Press
down on both pads and fit the pad retaining pins.

Brakes
Installation Rear Brake Disc

1. Position the caliper over the disc ensuring the pads
are correctly aligned on both sides of the disc. Wear
2. Fit the caliper retaining bolts, and tighten to 40 Nm.
~:~...
. _.. ·-··.· . , ""' ""•.,.... r.j_~
...- _ :fi-.... ~ _ ... '·•.·t·a
..
i _ _
3. Tighten the brake pad retaining pins to 18 Nm. .. · ~· '-1.LI i f_.:: . , _.--.:.=~, -..
,."''-~'""-·
4. Conned the brake hose to the caliper using new
washers on each side of the banjo bolt. and adequately supported. This will help prevent it from
5. Tighten the banjo bolt to 25 Nm. falling and causing injury to the operator or damage to
the motorcycle.
1. Replace any brake disc if it is worn beyond the

Use only DOT 4 specification brake fluid as listed in the service limit or exceeds the disc run-out limit (see
general information section of this manual. The use of below).
general information section may reduce the efficiency of Rear Disc Thickness
Observe the brake fluid handling warnings given earlier Standard: 6.0mm
in this sedion of the manual.
I Service Limit: S.Omm
6. Fill the master cylinder reservoir with new, DOT 4 Disc Run-out
brake fluid from a sealed container.
Z Bleed the rear brake (see page 14-26). I Service Limit: 0.15 mm
8. Refit the rear wheel (see page 15-10>. Measure disc run out using an accurate dial gauge
9. Check for correct brake operation. Rectify as mounted on a surface plate.
necessary.
---- --
~~.m~mn
fr:. . . . .. ·. . .·. ,,.' I \ . \If
-· .·'. 1 ~Y-':"r'tt" ... ~;-._- :- ·/; •{. ·""·"" - ~ ·-';
:\ 4c,.{~!0.1J.J.iJ.!!· . _\. ··-· _., _
I_ J._ ~ ~ ~ .• ~ .~·.~ .L-~ -~-·~-=~
take remedial adion before you ride the motorcycle
jahc_1
1. Disc
2. Dial gauge
Removal
1. Remove the rear axle shaft (see page 13-19).

2. Support the axle shaft carefully to avoid damage to
the disc or axle shaft threads.
3. Models with ABS only: Remove the pulser ring
and discard its fixings.
4. Remove and discard the 4 bolts and nuts to detach
the disc.

Brakes
Installation Rear Master Cylinder

Note:
For models with ABS, the brake disc and ABS Removal
pulser ring must be centred on the hub using
service tool T3880388. ABS operation may be ~--:·--~· ~ .... -~/, . ,:·. ~,,~;·, •lll>_~·: ~~i:-.--..- ..~~
affected if the ABS pulser ring and brake disc ~~::_4_~--'_.-
are not centred on the hub. Before starting work, ensure the motorcycle is stabilised
1. Models with ABS only: Position service falling and causing injury to the operator or damage to
tool T3880388 to the axle shaft so that the text' the motorcycle.
BRAKE DISC is visible.
A Caution
any area of the bodywork or wheels.
9. Drain the fluid from the master cylinder by bleeding

the system at the rear caliper until all fluid has been
expelled.
10. Remove the clip and washer from the clevis pin at
the lower end of the brake pushrod.
11. Remove the clevis pin.
12. Disconnect the rear brake hose from the master
cylinder.
13. Remove the screws securing the heel guard and
control plate to the frame.
1. Brake disc
2. Tool T3880355
2. All models: Locate the disc on the axle sha~ On

models with ABS the tool T3880388 will centre the
the brake disc on the axle shaft.
3. Fit new bolts and nuts, tighten to 22 Nm.
4. Remove service tool T3880388.
5. Thoroughly clean and degrease the disc.
6. Models with ABS only: Refit the pulser ring with new
fixings <see page 14-43). 3--:-----!....
Z Refit the axle shaft <see page 13-21>.
8. Check that the brake operates correctly.
cgwl
It is dangerous to operate the motorcycle with defective 1. Screws

brakes; you must have your authorised Triumph dealer 2. Heal guard
take remedial action before you ride the motorcycle 3. Master cylinder
again. Failure to take remedial action may result in 14. Disconnect the brake reservoir hose from the master
reduced braking efficiency leading to loss of motorcycle cylinder.

Brakes
15. Release the fixings and remove the brake master 1. Clean the master cylinder bore, piston and seals, with
cylinder from the control plate. new brake fluid.
2. Ensure all ports are clear of obstruction.
Ensure that the piston and piston seal are fitted facing
the same way as noted during removal. A dangerous
riding condition leading to an accident could result from
incorrect assembly of the master cylinder.

fluid.
cgwl Never use solvents, petrol (gasoline), engine oil, or any
1. Fixings other petroleum distillate on internal brake components
2. Control plate as this will cause deterioration of the hydraulic seals in
3. Master cylinder the calipers and master cylinders.
Disassembly motorcycle control and an accident could result if this
warning is ignored.
1. Remove the boot from the cylinder and pushrod.
3. Install the spring and piston set together.
2. Remove the circlip retaining the pushrod to the
4. Apply a small amount of brake grease to the
cylinder.
push rod.
3. Remove the pushrod and piston set from the master
5. Install the pushrod in the master cylinder and retain
cylinder bore noting the relative position of the seals
with a new circlip.
and piston components.
6. Refit the boot.
Inspection
1. Visually inspect the master cylinder bore for wear,

scratches or corrosion. Replace as necessary.
2. Check the piston and cylinder bore for damage,
wear or deterioration. Replace as necessary. Always
renew the piston seals if the cylinder has been
dismantled.
3. Examine the pushrod for bends and damage.
Replace as necessary.
~
Assembly \ ·~
4---
1 I
galb_1
2
Never use mineral based grease in any part of the 1. Clip
braking system or in any area where contact with the 2. Clevis pin
braking system is possible. Mineral based grease will 3. Reservoir hose
damage the hydraulic seals in the calipers and master 4. Dust boot
cylinders. 5. Circlip
6. Piston set

Brakes
Installation Bleeding the Front Brakes,

1. Fit the master cylinder to the control pate. Do not
Renewing Brake Fluid - Motorcycles
fully tighten the fixings at this stage. with ABS
2. Fit the reservoir hose to the master cylinder.
~-;;~-~~-.-~
3. Temporarily fit the control plate and master cylinder
assembly to the frame.
t..
~ 1-& ...
. .i..L~. ~~.!.J::1r-;I:J_~:_1
~-- • ....__-.:....6&.-- ~:...~..:.~
_ :- . :r
~~ -
1
4. Tighten the master cylinder to control plate fixings to Before starting work, ensure the motorcycle is stabilised
18Nm. and adequately supported. This will help prevent it from
falling and causing iniury to the operator or damage to
5. Remove the control plate fixings, fit the heal guard
the motorcycle.
and tighten the fixings to 27 Nm.
6. Connect the push rod to the brake pedal using a 1. Complete the brake bleed procedure as for models
new clevis pin and clip. without ABS brakes (see page 14-12).
Z Incorporating new washers, fit the brake hose to the 2. Connect the Triumph diagnostic tool <See
master cylinder. Ensuring correct orientation of the page 14-52>.
brake hose, tighten the banjo bolt to 25 Nm. 3. Follow the on screen menu to ABS Diagnostics. From
~~~7····-···-----~ the menu, select 'BLEED SYSTEM' <see page 14-53}.
••
~: .:w
·=- _;·: '.
: -' ~ • ~ • ; . -; I
j1 1 \ -"''"~e:r~,m:
' • ~~-- ~· ~
•
,·: - -• •-• '"
·
~~.-J- Note:
Use only DOT 4 specification brake fluid as listed in the On pressing the Start button, the diagnostic
general information section of this manual. The use of software will send a command to the ABS ECM
brake fluids other than those DOT 4 fluids listed in the to open the 2nd circuit solenoid.
The front brake lever travel will increase as
ABS modulator solenoids are opened and will
Observe the brake fluid handling warnings given earlier then decrease as the solenoids are
in this section of the manual. automatically closed.
Pressure must be applied to the front brake
8. Fill and bleed the rear brake system (see
lever before operating the bleed sequence on
page 14-26).
the diagnostic tool. An assistant will be
9. Check for correct brake operation. Rectify as required to open the bleed nipple while
necessary. pressure is applied to the brake lever.
4. Apply pressure to the front brake lever, press the
Start button to activate the bleed sequence on the
diagnostic tool, and with assistance, release one of
the bleed nipples.
take remedial action before you ride the motorcycle 5. Get an assistant to slowly pull the brake lever to the
again. Failure to take remedial action may result in handlebar.
reduced braking efficiency leading to loss of motorcycle 6. With the lever held fully against the handlebar, close
control and an accident. the bleed nipple. Once the bleed nipple is closed,
release the brake lever.
Z Repeat steps 5 and 6 until no more air appears in
the bleed tube, maintaining the brake fluid level
between the upper and lower reservoir levels whilst
bleeding is being carried out
8. The bleed sequence will run for a maximum of
90 seconds. Press the Stop button to end the bleed
sequence at any time. Once the bleed sequence has
completed the diagnostic tool will display a message
ABS system bleed complete.

Brakes
Front ABS Wheel Sensor

A Caution
The ABS modulator must be allowed to cool between Removal
bleeding operations. Always allow the ABS modulator to
cool for 5 minutes before starting the bleed procedure
again. Failure to follow this instruction may result in
damage to the ABS modulator.
9. Repeat the above procedure as necessary until all air and adequately supported. This will help prevent it from
is expelled from the system. falling and causing injury to the operator or damage to
the motorcycle.
apply pressure to the brake lever and close the bleed 1. Release the three fixings and remove the front panel
nipple. Tighten the nipple to 6 Nm. from the fuel tank.
11. Repeat the brake bleed procedure as for models
without ABS brakes (see page 14-12).
1. Front panel
2. Fixings
2. Disconnect the battery negative (black> lead first

Note:
Note the routing of the harness and its
retaining clips for installation.
5. Disconnect the wheel speed sensor multiplug,
Identified as the white connector.

Brakes
6. Release the wheel speed sensor harness from the Air Gap Measurement
brake hose clips. 10. Using feeler gauges, measure the air gap between
Z Release the bolt and remove the sensor. Collect the the wheel speed sensor and the pulser ring.
shim from between the sensor and fork leg and
discard the bolt
( i!
4
/ 11
ii
_.j ;.-
0.1 mm - 1.5 mm
cdhL1
1. ABS sensor
2. Shim
3. Pulser ring
4. Fixing
11. Rotate the wheel and repeat the measurement in
Installation several places to ensure the pulser ring is not
distorted or bent. Renew a damaged pulser ring.
Note:
12. Adjust the air gap using the correct shim to achieve
Check the condition of the shim before use. Do an air gap between 0.1 mm to 1.5 mm.
not use a shim which is bent or damaged.
Note:
1. Position the wheel speed sensor to the fork leg with Shims are available in the following sizes,
its shim between the sensor and fork leg. Fit a new 0.8 mm and 1.6 mm.
bolt and tighten to 9 Nm.
13. If necessary, remove the wheel speed sensor, fit the
2. Route the harness and secure to the brake hose clips correct thickness shim and refit the wheel speed
as noted for removal. sensor and tighten the new fixing to 9 Nm.
3. Connect the wheel speed sensor multiplug.
4. Refit the airbox <see page 10-101).
6. The air gap between the wheel speed sensor and the
pulser ring must be between 0.1 mm and 1.5 mm.
Check, and if necessary, adjust the air gap <see
page 14-3TJ.
Z Connect the battery, positive (red} lead first
( ii
9.
fixings to 2 Nm.
Check that the brakes operate correctly. 4
/ 11
ii
_.j ;.-
0.1 mm -1.5 mm
cdhL1
1. ABS sensor
2. Shim
3. Pulser ring
4. Fixing
14. Repeat the air gap measurement. Re-adjust as
necessary.

Brakes
Front ABS Pulser Ring 3. Remove and discard the five bolts and remove the
pulser ring.
Removal
~~
I
;. . : •: . •• i
~---
the motorcycle
1. Remove the front wheel {see page 15-8>.
Damage to the wheel centre could cause misalignment

cdhe_1
of the wheel when refitted. A dangerous riding
condition leading to an accident could result if this 1. Pulser ring
warning is ignored.
2. Support the wheel on blocks as illustrated below.

Inspection
1. Check the pulser ring for damage, m1ss1ng or

cracked teeth or distortion. Renew the pulser ring as
necessary.
Installation
1. Locate the pulser ring on to the wheel, fit new bolts

and tighten to 5 Nm.
2. Refit the front wheel (see page 15-9).
3. Check, and if necessary, adjust the air gap between
the front wheel speed sensor and the pulser ring
(see page 14-37>.
4. Check that the brakes operate correctly.
1. Wheel
2. Support block

Brakes
Bleeding the Rear Brake Fluid -

Motorcycles with ABS A Caution
The ABS modulator must be allowed to cool between
bleeding operations. Always allow the ABS modulator to
cool for 5 minutes before starting the bleed procedure
Before starting work, ensure the motorcycle is stabilised again. Failure to follow th is instruction may result in
and adequately supported. This will help prevent it from damage to the ABS modulator.
Z Repeat the above procedure as necessary until all air
the motorcycle.
is expelled from the system.
1. Complete the brake bleed procedure as for models 8. When all air has been expelled from the system,
without ABS brakes (see page 14-26). hold down the brake pedal and close the bleed
2. Connect the Triumph diagnostic tool (see nipple. Tighten the nipple to 6 Nm.
page 14-52). 9. Repeat the brake bleed procedure as for models
3. Follow the on screen menu to ABS Diagnostics. From without ABS brakes (see page 14-26).
the menu, select BLEED SYSTEM (see page 14-53).
Note:
On pressing the Start button, the diagnostic
software will send a command to the ABS ECM
to open the 2nd circuit solenoid.
The rear brake pedal travel will increase as
ABS modulator solenoids are opened and will
then decrease as the solenoids are
automatically closed.
Pressure must be applied to the rear brake
pedal before operating the bleed sequence on
the diagnostic tool. An assistant will be
required to open the bleed nipple while
pressure is applied to the brake pedal.
4. Apply pressure to the rear brake pedal, press the
Start button to activate the bleed sequence on the
diagnostic tool, and with assistance, release the bleed
nipple.
5. Slowly depress the brake pedal and, holding the
pedal fully down, close the bleed nipple. Repeat until
no more air appears in the bleed tube, maintaining
the brake fluid level between the upper and lower
reservoir levels whilst bleeding is being carried out
6. The bleed sequence will run for a maximum of
90 seconds. Press the Stop button to end the bleed
sequence at any time. Once the bleed sequence has
completed the diagnostic tool will display a message
ABS system bleed complete.

Brakes
Rear ABS Wheel Speed Sensor 5. Release the two fixings and detach the chain rubbing
strip from the swinging arm. Collect the flanged
sleeve from the lower fixing and discard the lower
Removal fixing.

the motorcycle.

from the fuel tank.
6. Release the three fixings and remove the rear brake

hose cover from under the swinging arm. Discard
the fixings.
1. Front panel
2. Fixings
4. Disconnect the wheel speed sensor multiplug
Identified as the white connector.
Note:
Note the routing of the ABS sensor harness for
installation.

Brakes
Z Detach the ABS sensor harness from its clips under Installation
the swinging arm.
Note:
Check the condition of the shim before use. Do
not use a shim which is bent or damaged.
1. Position the shim to the fixing such that it will be

installed between the wheel speed sensor and the
brake caliper carrier.
2. Fit the wheel speed sensor, harness bracket and
shim to the brake caliper carrier as noted from
removal and tighten the new fixing to 9 Nm.
3. The air gap between the wheel speed sensor and the
pulser ring must be between 0.1 mm and 1.5 mm.
Check, and if necessary, adjust the air gap (see
page 14-42>.
4. Attach the ABS sensor harness to its clips under the
swinging arm as noted for removal.
2. ABS sensor harness 5. Refit the rear brake hose cover to the swinging arm
3. Clips and tighten the new fixings to 6 Nm.
Note: 6. Fit the flanged sleeve to a new fixing and secure the
lower end of the chain rubbing strip to the swinging
Note the position of the bracket for the ABS arm and tighten to 5 Nm.
sensor and its shim.
Z Secure the upper end of the chain rubbing strip to
8. Release the fixing securing the wheel speed sensor the swinging arm and tighten to 5 Nm.
to the rear brake caliper carrier and remove the
sensor. Collect the shim and discard the fixing.
cguu_3
2. Lower fixing
1. Fixing 3. Chain rubbing strip
2. ABS harness bracket
3. ABS sensor 8. Connect the wheel speed sensor multiplug.
4. Shim 9. Refit the fuel tank (see page 10-94).
5. Caliper carrier 10. Refit the front panel to the fuel tank and tighten the
fixings to 2 Nm.

Brakes
Air Gap Measurement 5. Rotate the wheel and repeat the measurement in
several places to ensure the pulser ring is not
A Caution 6.
distorted or bent Renew a damaged pulser ring.
Adjust the air gap using the correct shim to achieve
Never lever directly against the disc, caliper or the pad an air gap between 0.1 mm to 1.5 mm.
lining material. Always use a levering tool made from a
Note:
soft material which will not cause damage to the load
bearing surfaces. Shims are available in the following sizes,
0.8 mm and 1.6 mm.
1. Carefully slide the caliper carrier towards the brake Z If necessary, remove the wheel speed sensor, fit the
disc to eliminate any play in the caliper carrier. correct thickness shim and refit the wheel speed
2. Using feeler gauges, measure the air gap between sensor and tighten the new fixing to 9 Nm.
the wheel speed sensor and the pulser ring.
0 0
.0
~nOn cguu_2
1. Fixing
ABS Wheel Speed Sensor Air Gap 2. ABS sensor
Measurement 3. Shim
3. Carefully slide the caliper carrier away from the 8. Repeat the air gap measurement Re-adjust as
brake disc to eliminate any play in the caliper carrier. necessary.
4. Repeat the air cap measurement.
~ II 0
ABS Wheel Speed Sensor Air Gap
nvn
Measurement

Brakes
Rear ABS Pulser Ring Inspection
1. Check the pulser ring for damaged, missing or

Removal cracked teeth or distortion. Renew the pulser ring as
necessary.
Installation
Before starting work, ensure the motorcyde is stabilised
and adequately supported. This will help prevent it from Note:
falling and causing injury to the operator or damage to The brake disc and ABS pulser ring must be
the motorcycle. centred on the hub using service
tool T3880388. ABS operation may be
1. Remove the rear axle shaft (see page 13-19).
affected if the ABS pulser ring and brake disc
2. Support the axle shaft carefully to avoid damage to are not centred on the hub.
the disc or axle shaft threads.
3. Remove and discard the four screw and remove the 1. Position service tool T3880388 to the axle shaft so
pulser ring. that the text 'PULSER RING' is visible.
1. Axle shaft 1. Pulser ring

2. Pulser ring 2. Tool T3880388
3. Brake disc
2. Locate the pulser ring over the tool and on to the
rear brake disc.
3. Install new screws and tighten to 5 Nm.
4. Remove the service tool T3880388.
5. Refit the rear axle shaft <see page 13-21>.
6. Check, and if necessary, adjust the air gap between
the rear wheel speed sensor and the pulser ring (see
page 14-42>.

Brakes
ABS Hydraulic Modulator/ECM Z Detach the rectifier/regulator harness from the right
hand side of the frame.
Note:
The rectifier/regulator is also attached to the
ABS modulator bracket.
Removal

the motorcycle.

from the fuel tank. cgtz
1. Clip
2. Rectifier/regulator harness
Note:
Note the routing of the rectifier regulator
harnesses for installation
8. Disconnect the rectifier/regulator harnesses from the
main harness.
1. Front panel
2. Fixings
page 11-15>. cgvr_1
6. If fitted, remove the evaporative canister (see 1. Connector, left hand side
page 10-134). 2. Connector, right hand side
A Caution
any area of the bodywork or wheels.

Brakes
9. Drain the fluid from the front and rear master 12. Release the two top fixings and one fixing at the
cylinders for front brake master cylinder see front of the bracket. Position the brake fight switch
page 14-12) for rear brake master cylinder see aside and carefully remove the ABS modulator,
page 14-26). rectifier/regulator and bracket assembly.
10. Disconnect the ABS modulator multiplug <See
page 14-57>.
Before the disassembly of any brake lines in the ABS

hydraulic circuit, always mark their position so that they
can be returned to the same position when assembled.
If the brake lines are incorrectly assembled the
performance of the ABS system will be seriously
compromised, leading to loss of motorcycle control and
an accident.
11. Remove the 4 brake line unions and, taking care not
to bend the brake lines, detach the lines from the
ABS modulator.
1. Top fixings
2. Front fixing
3. Bracket
13. Release the fixings and remove the
rectifier/regulator. Discard the locknuts.
1. ABS modulator
2. Brake line unions
t Note:
Note that the brake light switch is secured by cgvd
one of the fixings for the ABS modulator 1. Fixings
bracket. 2. Rectifier/regulator, up to VIN 499956 shown

Brakes
14. Release the three screws and remove the ABS 2. Align the rectifier/regulator to its bracket Fit the
modulator. Discard the screws. fixings with new locknuts and tighten to 3 Nm.
1
cgvb cgvd
1. Screws 1. Fixings
2. ABS modulator 2. Rectifier/regulator
3. Carefully manoeuvre the ABS modulator,

Installation rectifier/regulator and bracket assembly to the frame.
Fit the front fixing and washer but do not fully
1. Align the ABS modulator to its bracket, fit new tighten at this stage.
screws and tighten to 9 Nm. 4. Fit the two top fixings with the brake switch secured
to the ABS modulator bracket as noted for removal.
1
cgvb
1. Screws
2. ABS modulator 1. Top fixings
2. Front fixing
3. Bracket
5. Tighten all three fixings to S Nm.

6. Reconnect the rectifier/regulator harnesses to the
main harness.

Brakes
7. Attach the rectifier/regulator harness to the right 9. Reconnect the ABS modulator multiplug, ensure the
hand side of the frame. Ensure that the clip is behind locking device is fully engaged.
the ridge on the frame, as shown below. 10. Refit the coolant expansion tank <see page 11-16).
11. If removed. refit the evaporative canister <see
page 10-135).
13. Refit the fuel tank <see page 10-94>.
14. Reconnect the battery, positive (red} lead first.

cgtz
1. Clip
2. Rectifier/regulator harness 15. Bleed the front brakes (see page 14-35).
3. Ridge
16. Bleed the rear brakes (see page 14-39).
8. Taking care not to bend the brake lines, connect the
brake lines to the ABS modulator as noted for
removal. Incorporating new sealing washers and
tighten the banjo bolts to 25 Nm. It is dangerous to operate the motorcycle with defective
brakes; you must have your authorised Triumph Dealer
take remedial action. Failure to take remedial action may
reduce braking efficiency leading to loss of motorcycle
1Z Refit the front panel to the fuel tank and tighten the
fixings to 2 Nm.
1. ABS modulator
2. Brake line unions

Brakes
ABS The system has a self diagnostic function built-in which

monitors the fail safe relay, solenoid valves, motor relay,
wheel speed sensors, power supply and ground, as well as
System Description internal ECM functions. In the event of a malfunction
being detected, the ECM will illuminate the ABS warning
The ABS versions of the Speed Triple are fitted with an
light, and store a diagnostic trouble code in the system
electronic anti-lock brake system CABS) which is designed
memory. This stored data can then be recovered using a
to prevent the wheels from locking or skidding by
special service tool which is mandatory for all Triumph
reducing braking effort to the front or rear brake caliper
dealers. In this way, precise diagnosis of a fault can be
when wheel-lock is detected.
made and the fault quickly rectified.
The system consists of a hydraulic modulator and ECM
Under normal operation, the ABS warning light will flash
assembly mounted to a bracket beneath the fuel tank, a
on and off after ignition on until the vehicle speed
front wheel speed sensor mounted to the front fork, and a
exceeds 6 mph ( 10 km/h). If a trouble code is stored the
rear wheel speed sensor mounted to the rear brake
ABS warning light will stay illuminated and the ABS will
caliper carrier.
not function, however the brakes will operate normally. If
Both front and rear wheels have a pulser ring mounted on the ABS warning light does not extinguish, or illuminates
to the wheel, the front being mounted to the wheel hub, whilst the motorcycle is being ridden, refer to the ABS
the rear being mounted to the rear brake disc. system diagnostics <see page 14-52).
The front and rear master cylinders are connected via
lines to the modulator and from the modulator the pipes
connect to the brake calipers. The calipers and master
cylinders are identical to the non-ABS equipped
motorcycle.
The front and rear brake circuits operate as separate
systems. The front and rear brakes are not connected in
any way inside the modulator.
The modulator ECM continuously calculates the front and
rear wheel speeds, and from these inputs the ECM
calculates the estimated motorcycle speed, wheel
deceleration/acceleration, the wheel speed difference and
the wheel slip <skid) rate. This is calculated by comparing
the calculated wheel speeds with the calculated vehicle
speed, so that if one wheel speed deviates significantly
from the other two readings, this wheel is determined to
be skidding.
Under braking, if the modulator detects that either wheel
is about to slip, due to the brake force exceeding the
available traction between the tyre and road surface (the
wheel will begin to slip or 'skid'), the ECM very rapidly
releases and re-applies the brake pressure to prevent the
wheel from skidding.
This is felt through the brake pedal or lever as a rapid
'pulsing'.
If the rider reduces braking effort, or traction increases (so
that traction exceeds braking force, the wheel will rotate
once more) the wheel will no longer lock up. The ABS
system will detect this and stop controlling brake pressure,
and return to its monitoring state.

Brakes
Component Location
ABS
MODULATOR
FRONT PULSER FRONT WHEEL

RING SPEED SENSOR
FRONT
BRAKE LIGHT
SWITCH
REAR PULSER
RING

Brakes
ABS System Circuit Diagram
Key to Wiring Diagram Key to Wiring Colour Codes

Code Wiring Colour
1 Front Fuse Box CFuses 1and 2}
u Blue
2 Headlamp Relay
N Brown
3 ABS Modulator
G Green
s Slate/Grey
0 Orange
6 Front Wheel Speed Sensor
K Pink
7 Rear Wheel Speed Sensor
R Red
8 Instruments p Purple
9 Rear Brake Light Switch
w White
lO Right Hand Switch Cube y Yellow
11 Brake Light
LG Light Green
LU Light Blue
ABS ECM Connector Pin Numbering
cdhg

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.

Brakes
ABS System Circuit Diagram
r - - - - --1
I I
r
i I
20A 20~ I
I
5
4ot:r · 10
H
6 DJ==:~12
. - - - - GP - - - - - - - --
7 DJ==:_ l8
-------------1
"~10
GP - - - - t
' 11
'

Brakes
System Diagnostics 2. Plug the diagnostic interface directly in to the

diagnostic connector.
The ABS system has an on-board diagnostics feature
which allows service technicians to retrieve stored data
from the ECM using Triumph diagnostic software. Full
details of the Triumph diagnostic software operation
and how to interpret the results are given in the
Triumph Diagnostic Tool User Guide.
The software is connected, via an interface cable, to the
motorcycle using a dedicated diagnostic plug situated
under the seat. By using a dedicated plug, no electrical
connectors associated with the system are disturbed,
reducing potential connector damage.
The software allows the user to retrieve data associated
with the system sensors and actuators, test various
component functions, read build data and make minor
adjustments to the set-up of the system. The data and
tests available are described on the following pages.
Diagnostic Interface
Diagnostic Tool Connection 3. When the diagnostic session is completed,

disconnect the Triumph diagnostic interface.
1. To connect the Triumph diagnostic interface to the 4. Refit the diagnostic connector to its locating tang and
motorcycle, remove the seat (see page 16-10) and refit the seat (see page 16-1 T>.
release the diagnostic connector from its locating
tang.
cguw
1. Diagnostic connector

Brakes
Triumph Diagnostic Tool Current Data
Described on the following pages is the range of The Current Data screen will display the following
information which can be retrieved from the ECM's information:
memory and the adjustments which can be performed
Function Examined Result Reported (Scale)
using the Triumph diagnostic software.
The tables indicate which tests are performed by the on- Front wheel speed Kph
board system and what information can be retrieved by Rear wheel speed Kph
the Triumph diagnostic software.
Brake switch status On/Off
Note:
ABS warning light status On/Off
Full details of how to operate the software can
be found in the Triumph Diagnostic Tool User
Guide, which can be downloaded by authorised Bleed System
Triumph dealers from www.triumphonline.net. Using the Triumph diagnostic tool, it is possible to bleed
the ABS modulator of trapped air. This is necessary when
Build Data the hydraulic brake system has been dismantled, or the
ABS modulator renewed.
The Build Data screen will display the following
Full details of this procedure are provided on page 14-35
information:
for front brakes or page 14-39 for rear brakes.
Function Examined
ECM type
ECM ID number
Software version number

Brakes

Diagnostic trouble codes <DTCs) are logged in the ABS ECM memory when there is a confirmed fault in the system.
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
C1611 Front wheel sensor short circuit to ground or open circuit
C1612 Front Wheel Sensor Abnormal Input/Losing Contact
C1613 Rear Wheel Sensor Open Circuit/Short Circuit
C1614 Rear Wheel Sensor Abnormal Input/Losing Contact
C1621 Front Wheel Pulser Gear Missing Teeth
C1623 Rear Wheel Pulser Gear Missing Teeth
C1631 Front wheel input solenoid short circuit to ground or open circuit
C1632 Front wheel output solenoid short circuit to ground or open circuit
C1633 Rear wheel input solenoid short circuit to ground or open circuit
C1634 Rear wheel output solenoid short circuit to ground or open circuit
C1641 Front Wheel Actuator CHydraulic Control) Wheel Lock
C1643 Rear Wheel Actuator <Hydraulic Control> Wheel Lock
C1651 Motor - Lock
C1652 Motor - Stuck OFF
C1653 Motor - Stuck ON
C1654 Solenoid Relay - Stuck OFF/ON
C1661 Power Source Voltage Drop
C1662 Power Source Voltage Rise
C1671 Different Tyre Diameter
C1681 Abnormal ECM
14.54 Service Manual - Speed Tri pie and Speed Tri pie R
Brakes

Dependant on the DTC stored, the ABS ECM will act in one of two ways:
a) Inhibit ABS operation immediately, irrespective of the ABS operating mode;

or
b) Allow the ABS operation to complete before inhibiting the ABS.
Once the ABS ECM has inhibited ABS function, the ECM will act in one of three ways:
a) Allow the ABS to resume operation if the fault clears;

or
b) Allow ABS operation after an ignition cycle if the fault clears;
or
c) Inhibit the ABS function until the fault is rectified and the DTC erased.
The ABS system will act on the DTC stored according to the tables on the following pages:
Fault Description ABS warning ABS ABS continues ABS will resume operation
light operation is to operate if fa ult clears
illuminated inhibited when fault is
when fault is when fault is logged
logged logged (Only when ABS
is Active. When
ABS is no longer
active, operation
is inhibited)
Front Wheel Sensor Open Yes Yes No

Circuit/Short Circuit
Front Wheel Sensor Abnormal Yes Yes Yes Yes, if after ignition cycle, no
Input/Losing Contact fault is detected. DTC remains
stored
Rear Wheel Sensor Open Yes Yes No

Circuit/Short Circuit
Rear Wheel Sensor Abnormal Yes Yes Yes Yes, if after ignition cycle, no
Input/Losing Contact fault is detected. DTC remains
stored
Front Wheel Pulser Gear Yes Yes Yes, if after ignition cycle, no
Missing Teeth fault is detected for 1 second
and speed exceeds 30 km/h.
DTC remains stored
Rear Wheel Pulser Gear Yes Yes Yes, if after ignition cycle, no
Missing Teeth fault is detected for 1 second
and speed exceeds 30 km/h.
DTC remains stored
Front Wheel Input Solenoid Yes Yes No

Open/Short Circuit
Front Wheel Output Solenoid Yes Yes No

Open/Short Circuit
Rear Wheel Input Solenoid Yes Yes No

Open/Short Circuit
Rear Wheel Output Solenoid Yes Yes No

Open/Short Circuit

Brakes
Fault Description ABS warning ABS ABS continues ABS will resume operation
light operation is to operate if fa ult clears
illuminated inhibited when fault is
when fault is when fault is logged
logged logged (Only when ABS
is Active. When
ABS is no longer
active, operation
is inhibited)
Front Wheel Actuator Yes Yes Yes, if after ignition cycle, no
(Hydraulic Control) Wheel fault is detected. DTC remains
Lock stored
Rear Wheel Actuator Yes Yes Yes, if after ignition cycle, no
(Hydraulic ControD Wheel fault is detected. DTC remains
Lock stored
Motor - Lock Yes Yes No
Motor - Stuck OFF Yes Yes No
Motor - Stuck ON Yes Yes No
Solenoid Relay - Stuck Yes Yes No
OFF/ON
Power Source Voltage Drop Yes, Light will Yes Yes, if voltage rises above a
extinguish .if preset threshold for more
fault clears than 10 seconds
Power Source Voltage Rise Yes, Light will Yes Yes, if voltage drops below a
extinguish if preset threshold for more
fault clears than 10 seconds
Different Tyre Diameter Yes Yes No
Abnormal ECU Yes Yes No

Brakes
Electrical Connectors Disconnection of ABS ECM Connector
Before beginning any diagnosis, the following connector

related information should be noted: A Caution
Note: When disconnecting a connector, never pull directly on
the wires as this may result in cable and connector
A maior cause of hidden electrical faults can be
damage.
traced to faulty electrical connectors.
For example:
Dirty/corroded terminals. A Caution
Damp terminals. Never disconnect the ABS ECM when the ignition
switch is in the ON position as this may cause multiple
Broken or bent cable pins within multi-plugs. fault codes to be logged in the ECM memory.
Always disconnect an ECM after disconnecting the
For example, the ABS electronic control modulator (ABS
battery negative (black> lead first.
ECM> relies on the supply of accurate information to
enable it to monitor and control the brake system. One
1. Lift up the locking device and gently pull back on the
dirty terminal will cause an excessive voltage drop connector to release it from the ECM.
resulting in an incorrect signal to the ECM.
If, when carrying out fault diagnosis, a fault appears to
clear by simply disconnecting and reconnecting an
electrical plug, examine each disconnected plug for the
following.
Before Disconnection:
If testing with a voltmeter, the voltage across a
connector should be virtually battery volts K
<unless a resistor is fitted in the circuit>. If there K
is a noticeable change, suspect faulty/dirty
connections. ~D
2
When Disconnecting a Connector: cfyr_6
Check for a security device that must be 1. ABS modulator

released before the connector can be 2. Connector
separated. E.G. barb, hook and eye etc. 3. Locking device
Note:
When Inspecting a Connector: The ABS ECM is an integral part of the ABS
Check that the individual pins have not been modulator. Under no circumstances should the
bent ECM be removed from the ABS modulator. If a
new ECM is required, repair is by replacement
Check for dampness/dirt/corrosion.
of the ABS modulator and ECM as an assembly
Check cables for security. only.
Check cable pin joints for damage.
When Connecting a Connector.

Ensure there is no dirt around the
connector/seal.
Push together squarely to ensure terminals are
not bent or incorrectly located.
Push the two halves together positively.

Brakes
Reconnection of ABS ECM Connector Further Diagnosis
A. Caution
The tables that follow will, if used correctly, help to
pinpoint a fault in the system once a diagnostic trouble
Damage to the connector pins may result if an attempt
to fit the connectors incorrectly is made.
Pinpoint Tests
Before Starting Pinpoint Tests
1. Delete the stored DTCs.

2. Switch the ignition OFF and ON.
If the ABS is not functioning, the brake system will

continue to function as a non-ABS braking system. Do
not continue to ride for longer than is necessary with the
indicator light illuminated. Ride with extreme caution
when performing diagnostic troubleshooting on a non-
functioning ABS system. In this situation braking too
ctyr_7
hard will cause the wheels to lock resulting in loss of
1. ABS modulator motorcycle control and an accident
2. Connector
3. Locking device 3. Ride the motorcycle at a road speed in excess of
3 0 km/h. If the DTC is repeated proceed to the
1. Fit the connector into its socket and, whilst holding relevant pinpoint test.
the connector in place, push down gently on the 4. If the OTC is not repeated this indicates the DTC may
locking device until it locks. have been stored due to external influences such as
bad road surfaces or electrical interference.
After Completion of the Pinpoint Tests
1. Delete the stored DTCs.

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

Brakes
ABS Warning Light ON <No DTCs Stored}
ABS Warning Light ON CNo DTCs ABS Ignition supply fuse/circuit fault Ensure ABS ECM connector is secure.
Stored) ABS Warning light circuit fault Disconnect ABS ECM connector and
proceed to pinpoint test 1:-
Pinpoint Tests
Test Result Action
-ABS ECM connector pin 16 and Ground Faulty Rectify fault, proceed to test S
pin 24
2 Check cable continuity of the ABS ignition Same as 'across Proceed to test 3
supply circuit: With Ignition 'ON', check battery' voltage
voltage between
- ABS ECM connector pin 16 and Ground Less than 'across Locate and rectify wiring fault, proceed to
battery' voltage test S
3 Check cable continuity of the ABS warning Voltage greater than Proceed to test 4
light circuit: 1.5 v
Check voltage between:
- ABS ECM connector pin 21 and Ground Voltage less than Locate and rectify fault, proceed to test S
1.5 v
4 Check cable continuity of the ABS warning ABS warning light Proceed to test 5
light circuit: - Short ABS ECM connector 'OFF'
pin 21 and Ground pin 24 together:
Turn Ignition 'ON' ABS warning light Locate and rectify fault, proceed to test 5
'ON'
s Reconnect ABS ECM harness, clear fault OK Action complete - quit test
code and test ABS to verify fault cleared
Circuit Diagram
Front Fuse Box
2 I
I ABS
20A 2DA I Control Module
_J
y B
R 9
RU- 16
~
4 2 1 3
1111----
....________.__I 8 - 24
21
Instruments ~ "-- 8- 25
Headlamp Relay _l_

Brakes
ABS Warning Light Does Not Illuminate <No DTCs Stored>
ABS Warning Light OFF <No DTC's Warning light circuit fault Ensure ABS ECM connector is secure.
Stored) ABS ECM ground circuit fault Ensure ABS ECM ground connection
is secure.
Disconnect ABS ECM connector and
Pinpoint Tests
Test Result Action
- ABS ECM connector pin 16 and Ground Faulty Rectify fault, proceed to test 6
2 Check the ABS warning light circuit fuse OK Proceed to test 3

(front fuse box, fuses 1 and 2):
Faulty Replace fuse, proceed to test 6
3 Check cable for short to voltage: With ov Proceed to test 4

Ignition 'OFF', check voltage between
- ABS ECM connector pin 16 and Ground Above 3 V Locate and rectify wiring fault, proceed to
test 6
4 Check cable for short to ground: With Voltage greater than Proceed to test 5
ignition 'ON', Check the ABS warning light 1.5 v
circuit voltage between:
- ABS ECM connector pin 21 and Ground Voltage less than Locate and rectify fault, proceed to test 6
1.5 v
5 Check cable for continuity: ABS ECM OK Proceed to test 6
connector pin 24 and Ground:
Turn Ignition 'ON' Faulty Locate and rectify fault, proceed to test 6
6 Reconnect ABS ECM harness, clear fault OK Action complete - quit test

Brakes
Circuit Diagram
-·
Front Fuse Box
,- - - -
I
2 I
I ABS
20A 20A I Control Module
_J
y B
R 9
RU - 16
~HI----~
4 2 1 3
21
B - 24
Instruments ~ "-- 8 - 25
Headlamp Relay _L

Brakes
Front Wheel Sensor Open Circuit/Short Circuit
C1611 Front wheel sensor short circuit to Ensure ABS ECM connector is secure.
ground or open circuit Ensure wheel speed sensor connector
is secure.
Pinpoint Tests
Test Result Action
- ABS ECM connector pin 3 and ABS ECM Faulty Rectify fault, proceed to test 9
connector pin 12
- ABS ECM connector pin 12 and Ground Short circuit Proceed to test 3
3 Disconnect the front wheel speed sensor OK Replace the wheel speed sensor, proceed to
connector. Check cable for short circuit: test 9
Wheel speed sensor connector pin 2 Short circuit Locate and rectify wiring harness fault,
(motorcycle harness side) and Ground proceed to test 9
-ABS ECM connector pin 3 and Ground Short circuit Proceed to test 5
5 Check cable for short circuit: OK Replace the wheel speed sensor, proceed to
test 9
- Wheel speed sensor connector pin 1 Short circuit Locate and rectify wiring harness fault,
- ABS ECM connector pin 12 and Wheel Open circuit Locate and rectify wiring harness fault,
speed sensor connector pin 2 <motorcycle proceed to test 9
harness side)
-ABS ECM connector pin 3 and Wheel Open circuit Locate and rectify wiring harness fault,
harness side)
8 Reconnect the front wheel speed sensor 3 mA to 14 mA Proceed to test 9

connector. Check the wheel speed sensor
operation:
- Connect a suitable voltage supply Faulty Replace the wheel speed sensor, proceed to
between 4.5 V and 16 V between ABS test 9
ECM connector pin 12 (positive) and pin 3
(negative), and measure the current
consumption of the wheel speed sensor

Brakes
Circuit Diagram
Wheel speed sensor current consumption data under typical conditions:
Voltage Min Typical Max

Low (4.5 V> 3.1 mA 4.1 mA 5.3 mA
High (16 V> 8.1 mA 10.5 mA 13.6 mA
Front Wheel ABS

Speed Sensor Control Module
uw
I:I BG 1:, I

Brakes
Rear Wheel Sensor Open Circuit/Short Circuit
C1613 Rear wheel sensor short circuit to Ensure ABS ECM connector is secure.
ground or open circuit Ensure wheel speed sensor connector
is secure.
Pinpoint Tests
Test Result Action
- ABS ECM connector pin 2 and ABS ECM Faulty Rectify fault, proceed to test 9
connector pin 18
3 Disconnect the front wheel speed sensor OK Replace the wheel speed sensor, proceed to
connector. Check cable for short circuit: test 9
<motorcycle harness side) and Ground proceed to test 9
5 Check cable for short circuit: OK Replace the wheel speed sensor, proceed to
test9
-ABS ECM connector pin 2 and Wheel Open circuit Locate and rectify wiring harness fault,
harness side)
- ABS ECM connector pin 18 and Wheel Open circuit Locate and rectify wiring harness fault,
speed sensor connector pin 1 (motorcycle proceed to test 9
harness side)
8 Reconnect the front wheel speed sensor 3 mA to 14 mA Proceed to test 9

connector. Check the wheel speed sensor
operation:
- Connect a suitable voltage supply Faulty Replace the wheel speed sensor, proceed to
between 4.5 V and 16 V between ABS test 9
ECM connector pin 2 <positive) and pin 18
(negative), and measure the current
consumption of the wheel speed sensor

Brakes
Circuit Diagram
Wheel speed sensor current consumption data under typical conditions:
Voltage Min Typical Max

Low (4.5 V> 3.1 mA 4.1 mA 5.3 mA
High (16 V> 8.1 mA 10.5 mA 13.6 mA
Rear Wheel ABS

Speed Sensor Control Module
UR
I:I BG
I:. 1

Brakes
Front Wheel Sensor Abnormal Input/losing Contact
C1612 Front wheel speed sensor poor signal Ensure ABS ECM connector is secure.
Incorrect Wheel speed sensor air gap Ensure wheel speed sensor connector
Damaged or dirty pulser ring is secure.
Loose or incorrectly installed wheel Proceed to pinpoint test 1:-

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

speed sensor between the sensor and the
pulser ring:
-Air gap between 0.1 mm to 1.5 mm Faulty Rectify the fault and proceed to test 5
2 Check the pulser ring for damage or OK Proceed to test 3

contamination by road grime or ferrous
metal filings
Faulty Clean or replace the ABS pulser ring, proceed

to test 5
3 Check the wheel speed sensors for correct OK Proceed to test 4

installation, and the fixings for correct
torque
Faulty Rectify the fault and proceed to test 5

4 Check the wheel speed sensor circuit <see OK Contact Triumph service
page 14-62)
5 Clear fault code and test ABS to verify fault OK Action complete - quit test
cleared

Brakes
Rear Wheel Sensor Abnormal Input/Losing Contact

C1614 Rear wheel speed sensor poor signal Ensure ABS ECM connector is secure.
Incorrect Wheel speed sensor air gap Proceed to pinpoint test 1:-
Damaged or dirty pulser ring
Loose or incorrectly installed wheel
speed sensor
Pinpoint Tests
Test Result Action

pulser ring:
- Air gap between 0.1 mm to 1.5 mm Faulty Rectify the fault and proceed to test 5

metal filings

to test 5

torque:

4 Check the wheel speed sensor circuit <See OK Contact Triumph service
page 14-64)
cleared

Brakes
Front Wheel Pulser Gear Missing Teeth
C1621 Incorrect Wheel speed sensor air gap Ensure ABS ECM connector is secure.
Damaged or dirty pulser ring Proceed to pinpoint test 1:-
speed sensor
Damaged/incorrect wheels
Pinpoint Tests
Test Result Action

pulser ring:

metal filings

to test 5

torque:
4 Check the motorcycle wheel for OK Proceed to test 4

damage/incorrect size
cleared

Brakes
Rear Wheel Pulser Gear Missing Teeth
C1623 Incorrect Wheel speed sensor air gap Ensure ABS ECM connector is secure.
Damaged or dirty pulser ring Proceed to pinpoint test 1:-
speed sensor
Damaged/incorrect wheels
Pinpoint Tests
Test Result Action

pulser ring:
metal filings

to test 5
torque:

4 Check the motorcycle wheel for OK Proceed to test 4
damage/incorrect size

cleared.

Brakes
Front or Rear Input/Output Solenoid Open/Short Circuit

Front: C1631; C1632 Front wheel input solenoid short Ensure ABS ECM connector is secure.
Rear: C1633; C 1634 circuit to ground or open circuit Disconnect ABS ECM connector and
C1654 Front wheel output solenoid short proceed to pinpoint test 1:-
circuit to ground or open circuit
Rear wheel input solenoid short circuit
to ground or open circuit
Rear wheel output solenoid short
circuit to ground or open circuit
Pinpoint Tests
Test Result Action

- ABS ECM connector pin 9 and Ground Faulty Rectify fault, proceed to test 5
2 Check the ABS solenoid fuse {front fuse OK Proceed to test 3

box fuse 1);
Faulty Replace fuse, proceed to test 5
3 Check cable continuity: With Ignition 'ON', Same as 'across Proceed to test 4
check voltage between battery' voltage
4 Check cable for continuity: OK Proceed to test 5
- ABS ECM connector pin 24 and Ground Faulty Locate and rectify fault, proceed to test 5
cleared
Circuit Diagram
Front Fuse Box

r-------,
I
I
I
20A I
ABS
Control Module

Brakes
Front or Rear Wheel Actuator <Hydraulic Control> Wheel Lock
C1641; C1643 Binding brake Ensure ABS ECM connector is secure.

Incorrect Wheel speed sensor air gap Proceed to pinpoint test 1:
speed sensor
Pinpoint Tests
Test Result Action
1 Check the relevant wheel for brake bind caused OK Proceed to test 2
by caliper or master cylinder faults, or other
mechanical causes

2 Measure the air gap of the wheel speed sensor OK Proceed to test 3
between the sensor and the pulser ring:

installation, and the fixings for correct torque
cleared

Brakes
Motor - Lock; Motor Stuck OFF; Motor Stuck ON
C1651 ; C1652; Motor circuit fault Ensure ABS ECM connector is secure.
C1653 Motor runs continually Turn the ignition 'ON'.
Motor does not run at all Proceed to pinpoint test 1:
Pinpoint Tests
Test Result Action
1 Check the motor function: OK Proceed to test 2
Check that with the motorcycle stationary and the Motor runs Contact Triumph service
ABS ACM modulator connected, the motor does continually
not operate
2 Check the ABS motor circuit fuse front fuse box, OK Proceed to test 3
(fuse 2)
Faulty Replace fuse and proceed to test 5
3 Check cable continuity: With Ignition 'ON', check Same as 'across Proceed to test 4
voltage between: battery' voltage
4 Check cable for continuity: OK Proceed to test 5
- ABS ECM connector pin 25 and Ground Faulty Locate and rectify fault, proceed to test 5
5 Reconnect ABS ECM harness, clear fault code OK Action complete - quit test
and test ABS to verify fault cleared
Circuit Diagram
Front Fuse Box

r-------,
I I
I
I
I 20A
Control Module
Y- - - - 1 8

Brakes
Power Source Voltage DropNoltage Rise
Cl661; C1662 Power supply circuit fault Ensure ABS ECM connector is secure.
Battery charging circuit fault Disconnect ABS ECM connector and proceed to pinpoint
test 1:
Pinpoint Tests
Test Result Action
- ABS ECM connector pin 16 and Ground pin 24 Faulty Rectify fault, proceed to test 5
2 Check the cable for continuity: OK Proceed to test 3
-ABS ECM connector pin 24 and Ground Faulty Rectify wiring harness fault, proceed to test 5
3 Check battery voltage: With ignition 'ON', Check Voltage greater Proceed to test 4
the voltage between: than 10 V
-ABS ECM connector pin 16 and Ground pin 24 Voltage less Locate and rectify fault, proceed to test 5
than 10 V
4 Check battery voltage: Reconnect ABS ECM Voltage Proceed to test 4

connector and start the engine, Check the between 10 V
voltage between: and 16 V
- Battery positive <red) terminal and negative Voltage greater Check the battery charging circuit. Locate and
(black) terminal than 16 V rectify fault, proceed to test 5
cleared
Circuit Diagram
Front Fuse Box

I
I
2 I
I ABS
20A 20AI Control Module
_J
y 8
R 9
RU- 16
._____.___.11 1~ i~
Instruments "----
21
8 - 24
8 - 25
Headlamp Relay _l_

Brakes
Different Tyre Diameter
C1671 Incorrect diameter wheels installed Ensure ABS ECM connector is secure.
Incorrect tyre pressures Proceed to pinpoint test 1:
Incorrect wheel speed sensor air gap
Pinpoint Tests
Test Result Action
1 Check for installation of wheels and tyres of the OK Proceed to test 2

correct size
2 Check the tyre pressures OK Proceed to test 3

contamination by road grime or ferrous metal
filings

to test 5
4 Measure the air gap of the front wheel speed OK Proceed to test 5
sensor between the sensor and the pulser ring:
cleared

Brakes
Abnormal ECU
Fault Code I Possible cause Action

C1681 Abnormal ECM Ensure ABS ECM connector is secure.
Incorrect Wheel speed sensor air gap Proceed to pinpoint test 1:
.speed sensor
PinpGint Tests
Test Result Action

1 Measure the air gap of the wheel speed sensors OK Proceed to test 2
between the sensor and the pulser ring:
2 Check the pulser rings for damage or OK Proceed to test 3
contamination by road grime or ferrous metal
filings
to test 4
inst~, and the fixings for correct torque
4 Clear fault code aAd test ABS to verify fault OK Action complete - quit test
deared

Brakes
ABS Hydraulic Circuit Layout
A. Front Brake Circuit from Master

Cylinder to ABS Modulator
B. Front Brake Circuit from ABS

Modulator to Front Calipers
C. Rear Brake Circuit from Master

Cylinder to Modulator
D. Rear Brake Circuit from ABS

Modulator to Rear Calipe-r
E. ABS Modulator
14.76 Service Manual - Speed Tripre and Speed Triple R

15 Wheels/Tyres
Table of Contents
Exploded View - Front Wheel - Speed Triple... ............................................. . . 15.2
Exploded View - Front Wheel - Speed Triple R......................... . ...................... 15.3
Exploded View - Rear Wheel 8. Final Drive - Speed Triple. ................................ ... . .. 15.4
Exploded View - Rear Wheel 8. Final Drive - Speed Triple R. ....................... . ............ 15.5
Tyres .............. . ....................... ........ ........ . ............................ 15.6
Tyre Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6
Tyre Wear/Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6
Important Tyre Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7
Tyre Remove/Installation on Wheels with a TPMS Sensor. ..... .. ............ .. .............. 15.8
Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8
Removal. ... . ... ... ............................. . ..................... ........... .... 15.8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9
Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
Removal.... ..................... ...... ........ ....... ...... .. ....................... 15.10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
Front Wheel Bearing ... . .. .. ........ ... ......... ....... ......... ..... ........... ...... ... 15.11
Removal...... ..................................... .. ............ ...... .............. 15.11
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
Rear Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
Inspection..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
Rear Hub Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15

Wheels/Tyres
Exploded View - Front Wheel - Speed Triple
65Nm

Wheels/Tyres
Exploded View - Front Wheel - Speed Triple R
65 Nm

Wheels/Tyres
Exploded View - Rear Wheel & Final Drive - Speed Triple
6Nm
\
146Nm

Wheels/Tyres
Exploded View - Rear Wheel & Final Drive - Speed Triple R
146Nm

Wheels/Tyres
Tyres Tyre Pressures
This model is equipped with tubeless tyres, valves, and The corect tyre pressures are shown below. The tyre
1
wheel rims. Only tyres marked 'TUBELESS and tubeless pressures must always be checked and adjusted when the
type tyre valves mounted on rims marked 'TUBELESS' tyres are cold.
can be used. Front - 2.3 5 bar (34 psi>
Rear - 2.90 bar (42 psi>
Incorrect tyre inflation will cause abnormal tread wear

and instability problems which may lead to loss of
Under-inflation may result in the tyre slipping on, or
coming off the rim. Over-inflation will cause instability
and accelerated tread wear.
Both conditions are dangerous as they may cause loss of
control leading to an accident.
Tyre Wear/Wheel Inspection

As the tyre tread wears down, the tyre becomes more
Typical Wheel Marking
susceptible to puncture and failure. It is estimated that
900/o of all tyre failures occur during the last 100/o of tread
life (90% worn). It is false economy and unsafe to use
tyres until they are worn to their minimum.
All tyres are fitted with tread wear indicators. When the
tyre becomes worn down as far as the top of a tread wear
indicator, the tyre is worn beyond its service life and must
be replaced.
ccom
----
Typical Tyre Marking
Tyres that have been used on a rolling road

dynamometer may become damaged. In some cases,
gafj
the damage may not be visible on the external surface
of the tyre. 1. Tread Wear Indicator
Tyres must be replaced after such use as continued use
In accordance with the scheduled maintenance chart,
of a damaged tyre may lead to instability, loss of control
measure the depth of the tread with a depth gauge, and
and an accident.
replace any tyre that has worn to, or beyond the
minimum allowable tread depth.
Inspect wheels for cracks, splits and kerb damage. Always
replace wheels that are suspected of having become
damaged.

Wheels/Tyres
r~~~~·~~~.7~ r-;:-~·~... -.~~~;~~·-:;-:···'''.Jf.

. .. / 1 , ~ _c-t~.rn h ... J.. . .• I • / • \. • •\ filo1h (! .t ' ~ •.: ' .'.. ·~
i;__:,..__~~~~
· -~-~·-~
.. -----~~~--~ ~~.~..:..a......:.-~-=::==::-~~--==-~--~~
Operation with excessively worn tyres is hazardous and The use of tyres other than those listed in the
will adversely affect traction, stability and handling which specification section of the owner's handbook may
may lead to loss of control or an accident. adversely affect handling leading to loss of control or an
When tubeless tyres become punctured, leakage is accident.
often very slow. Always inspect tyres very closely for Use the recommended tyre options only in the
punctures. combinations given in the owner's handbook.
Check the tyres for cuts, embedded nails or other sharp Do not mix tyres from different manufacturers or tyres
objects. from the same manufacturer but from another option.
Check the rims for dents or deformation. Operation with
damaged or defective wheels or tyres is dangerous and ~~·i·f.~-~
loss of control or an accident could result. ~h' ... :_ / ! '. i_ ~t:ilflJ. fnlj }· '-. . ·, ;... ~. ~ ._ :~ _;
L~----~.i::i.......~
Always consult your Triumph dealer for tyre Always check tyre pressures before riding when the
replacement, or for a safety inspection of the tyres. tyres are cold. Operation with incorrectly inflated tyres
may affect handling leading to loss of control and an
Minimum Recommended Tread Depth accident.
The following chart can be used as a guide to the
minimum safe tread depth.
Under 80 mph (130 km/h) 2 mm C0.08 in)

Operation with excessively worn or damaged tyres will
Over 80 mph <130 km/h) Rear 3 mm <0.12 in) adversely affect handling and control leading to loss of
Front 2 nim <0.08 in) control or an accident
Triumph motorcycles must not be operated above the Do not install tube-type tyres on tubeless rims. The bead
legal road speed limit except in authorised closed course will not seat and the tyres could slip on the rims, causing
conditions. tyre deflation that may result in a loss of vehicle control
and an accident.
Important Tyre Information Do not install an inner tube inside a tubeless tyre. This
All Triumph motorcycles are carefully and extensively may cause instability and excessive heat build-up may
tested in a range of riding conditions to ensure that the cause the tube to burst resulting in rapid tyre deflation,
most effective tyre combinations are approved for use on loss of vehicle control and an accident.
each model. It is essential that approved tyre combinations
are used when purchasing replacement tyres as the use of
non approved tyres or approved tyres in non approved
combinations may lead to motorcycle instability. Always Accurate wheel balance is necessary for safe, stable
refer to the owner's handbook data section for details of handling of the motorcycle. Do not remove or change
approved tyres and tyre combinations. any wheel balance weights. Incorrect wheel balance may
,-,-.~--~7\-T~~---..-.~ . . -.--. -,~-.~---.~. -. cause instability leading to loss of control and an
.
- •. f
"'""f"'"':'fi~·..-:'\
/ '• '·, . ''_1'-... G.! ..~J.,J)J.j.! f. . . . ' ..' accident.
•1o;_··-.. . . . ~
- - --
~-~
When wheel balancing is required, such as after tyre
If a tyre sustains a puncture, the tyre must be replaced.
replacement, see your authorised Triumph dealer.
Failure to replace a punctured tyre, or operation with a
repaired tyre can lead to instability, loss of control or an Only use self-adhesive weights. Clip on weights will
accident. damage the wheel and tyre resulting in tyre deflation,
loss of control and an accident.
Never use an inner tube to repair a punctured tyre. The
rough surface inside the tyre can chafe the tube leading
to instability, rapid deflation, loss of control and an
accident.

Wheels/Tyres
Front Wheel
When replacement tyres are required, consult your Removal

authorised Triumph dealer who will arrange for the tyres
to be fitted according to the tyre manufacturers
instructions.
When tyres are replaced, allow time for the tyre to seat Before starting work, ensure the motorcycle is stabilised
itself to the rim (approximately 24 hours). During this and adequately supported. This will help prevent it from
seating period, ride cautiously as an incorrectly seated falling and causing injury to the operator or damage to
tyre could cause loss of control or an accident. Initially, the motorcycle.
the new tyre will not produce the same handling
characteristics as the worn tyre and the rider must allow 1. Position the motorcycle on a paddock stand.
adequate riding distance (approximately 100 miles) to 2. Detach both brake calipers (see page 14-19 for
become accustomed to the new handling characteristics. Speed Triple, see page 14-21 for Speed Triple R>.
After both 24 hours and 100 miles, the tyre pressures
Note:
should be checked and adjusted and the tyre examined
for correct seating and rectified as necessary. It is not necessary to disconnect the brake
Use of a motorcycle when not accustomed to its hoses.
handling characteristics may lead to loss of control and
an accident
Do not allow the calipers to hang on the brake hoses as

Tyre Remove/Installation on Wheels with a this may damage the hoses.
TPMS Sensor
Damaged hoses could cause brake failure leading to loss
of control and an accident
A Caution
3. Raise and support the front of the motorcycle.
To prevent damage to the TPMS sensor, care must be 4. Slacken both pinch bolts at the lower end of the right
taken for the remova l/installation of tyres by ensuring hand fork.
that the tyre lever/install tool does not make contact with
the TPMS sensor.
When removing and installing a tyre, the tyre lever/install

tool must start 30° away from the tyre valve and move
away from the valve.
©
©
©
1. Fork pinch bolts
5. Release and remove the wheel spindle, which is

threaded into the left hand fork.
T0913
1. Position of tyre lever/install tool
2. Tyre valve
3. Tyre pressure sensor
4. Direction of wheel rotation

Wheels/Tyres
6. Remove the wheel and the wheel spacers. Installation
1. Lightly smear the wheel spacers with grease and

locate in the hubs.
2. Position the wheel between the forks ensuring the
spacers remain in position on both sides.
1. Wheel spacer (right hand shown>
Z Place the wheel on wooden blocks.
Do not allow the wheel to rest on either brake disc as 1. Wheel spacer <right hand shown>
this may damage the disc and could lead to an accident 3. Refit the wheel spindle from the right hand side and
tighten to 65 Nm.
A caution 4. Lower the motorcycle to the ground and pump the

front suspension to allow the right hand fork to 'float'
To prevent wheel and bearing damage, observe to its natural position on the wheel spindle.
absolute cleanliness and ensure there is no dirt ingress 5. Tighten the fork pinch bolts to 22 Nm.
to the wheel bearings wh ile the wheel is removed.
8. Thoroughly clean all components and inspect for

wear or damage.
1. Fork pinch bolts
6. Thoroughly clean and degrease the brake discs.

Z Fit the brake calipers <see page 14-20 for
Speed Triple, see page 14-23 for Speed Triple R.>.
8. Models with ABS: Check the air gap between the
wheel speed sensor and the pulser ring <see
page 14-J TJ.

Wheels/Tyres
Rear Wheel Installation
1. Fit the wheel, aligning with the 5 location dowels.

Removal 2. Hold the wheel squarely in position while fitting:
conical spacer;
plain washer;
Belleville washer, convex side outwards;
falling and causing injury to the operator or damage to nut.
the motorcycle.
3. Tighten the wheel retaining nut to 146 Nm, and fit
1. Raise and support the rear of the motorcycle to allow the clip.
removal of the rear wheel.

1. Rear wheel, Speed Triple shown

2. Conical spacer
3. Plain washer
4. Belleville washer
S. Nut
6. Clip
2. To release the wheel, remove:

clip;
nut;
Belleville washer;
plain washer;
conical spacer.
3. Remove the wheel (at a slight angle to avoid contact

with the rear footrest and hugger).

Wheels/Tyres
Front Wheel Bearing 4. Using a suitable pin punch, through the centre of the
wheel, drift out the right hand wheel bearing. Collect
the centre sleeve. Remove the left hand wheel
Removal bearing in the same way.
A Caution
Do not allow the wheel to rest on the brake disc, as this
may damage the disc. Support the wheel on wooden
blocks, equally spaced around the rim, such that the
brake disc is raised above the ground.
2. Place the wheel on wooden blocks to prevent

damage to the discs.
3. Remove and discard the seals and the bearing cirdip.
~~:7: ---~ -·\--;:~- ~.·-~ -· ·. _-·~~~~~
~!~· .~ : · , 1 . ~~
Ar= 1!'u1! 1~ . ?
~ • • I
Always wear eye, hand and face protection when using Wheel Bearing Removal
a hammer and dri~ Use of a hammer and drift can
cause bearings to fragment. Pieces of fragmented Inspection
bearing could cause eye and soft tissue iniuries if
~.-.-.--~~
:~·.. · .- -. n
/ 1 · \ 11 ~ ;:-, ;"' j n~ - -·;.
<i· _- .-~
~~· IL~.~~~~~--~-·~· ---~ ·.~: ~'..-~it:- I~ ....
A Caution Only remove raised witness marks from within the

wheel. Removal of material below any raised areas will
To prevent wheel damage and to aid bearing removal, reduce the level of interference between the wheel and
always apply force evenly on both sides of the bearing the bearings. Loss of interference could cause the
to prevent it from 'tipping' and becoming stuck. bearing to become loose in the wheel leading to loss of
Application of uneven force will lead to difficulty in motorcycle control and an accident.
removing the bearing and to a damaged wheel.
1. Examine the wheel for any raised witness marks
caused by the removal process. Remove any such
marks with fine emery paper or a gentle file.

Wheels/Tyres
Installation Rear Wheel Bearing

Note:
Refer to the chart below for the correct tool Removal
and tool face when inserting bearings. Bearings
are inserted by means of a draw-bolt acting on 1. Remove the rear hub <see page 13-19).
the insertion tool. A support tool is located on 2. Transfer the hub to a workbench.
the opposite side of the wheel to the insertion 3. Remove the bearing retaining ring from the right
tool and as the bolt is tightened, the bearing is hand side of the hub.
drawn in to the wheel.
Bearing Support tool

insertion tool
Left bearing T3880053 3880075 - T0301
Small face to Large face to wheel
bearing
Right bearing T3880053 3880075 - T0301
Small face to Large face to wheel
bearing
1. Fit the wheel bearing to the left hand side of the

wheel using the method described above.
1. Bearing retaining ring
Note:
The right hand circlip will remain within the
hub until the bearing is removed.
Working through the hole in the centre of the
left hand bearing, detach the right hand inner
circlip using circlip pliers.
A Caution
Always support the hub as instructed because fully
closing the vice onto the hub or supporting the hub on
any other area than that specified above (particularly the
Tool T3880053 in Position on Wheel
eccentric adjuster slots) will cause damage and may also
2. Fit a new circlip. lead to premature wear of the new bearing once it is
3. Fit the centre sleeve and the bearing to the left hand fitted.
side using the method described on the previous
4. Fit soft jaw-clamps to a vice and position the hub
page.
with the right hand side facing downwards. Do not
4. Lubricate and fit new seals to the front wheel. damp the hub in the vice. Close the vice only
Lubricate the seal's knife-edge with grease to NLGI 2 sufficiently to fully support the broadest possible area
specification. of the hub.
5. Fit the front wheel (see page 15-9).

a hammer and drift. Use of a hammer and drift can
cause bearings to fragment Pieces of fragmented

Wheels/Tyres
A. Caution A. Caution
To prevent hub damage and to aid bearing removal, To prevent hub damage and to aid bearing removal,
always apply force evenly on both sides of the bearing always apply force evenly on both sides of the bearing
to prevent it from 'tipping' and becoming stuck. to prevent it from 'tipping' and becoming stuck.
Application of uneven force will lead to difficulty in Application of uneven force will lead to difficulty in
removing the bearing and to a damaged hub. removing the bearing and to a damaged hub.
5. Working through the hole in the centre of the left 8. Working through the hole in the centre of the hub,
hand bearing, use a pin punch to drift out the right use a pin punch to drift out the left hand bearing.
hand bearing.
Inspection
~..,~ ~--.........,·---;-;·-...·~--...--;~-"-~~
r-. / !· '/" 1 r.-r~J.1Jie!; .. · ... ·~

~~~~~~~.·~-·-~~~~·~·~· ·~~
Only remove raised witness marks from within the hub.
Removal of material below any raised areas will reduce
the level of interference between the hub and the new
bearing. Loss of interference could cause the bearing to
become loose in the hub leading to loss of motorcycle
Examine the hub for any raised witness marks caused
by the removal process. Remove any such marks with
fine emery paper or a gentle file, taking care to ensure
I that filings do not contaminate the bearings.
1. Punch
2. Bearing Installation
6. Remove the inner circlip from the hub. 1. Lubricate and place a new inner hub seal within the
Z Remove the bearing retaining ring from the left hub. Lubricate the seal's knife-edge with grease to
hand side of the hub. N LG I 2 specification.
2. Fit a new inner circlip. Ensure the circlip is retained in
the groove through its entire circumference.
cdfz

cbaw
1. Inner circlip

a hammer and drift. Use of a hammer and drift can
cause bearings to fragment. Pieces of fragmented
Service Manual - Speed Triple and Speed Triple R 15. 13

Wheels/Tyres
3. Open the vice to a distance that will accept the hub, 6. Retain the new bearing by fitting a new retaining
new right hand bearing and service tool 3880065- ring to the groove inside the hub. Ensure the ring is
T0301 all aligned together inside the soft vice jaws. retained in the groove through its entire
Align the large end of tool 3880065-T0301 to the circumference.
new bearing.

1. Hub
Z Open the vice to a distance that will accept the hub,
2. Right hand bearing
new left hand bearing and service tool 3880075-
3. Service Tool 3880065-T0301
T0301 all aligned together inside the soft vice jaws.
4. Progressively close the vice until the outer cage of Align the small end of tool 3880075-T0301 to the
the new bearing is pushed fully up to the inner new bearing.
circlip inside the hub. Open the vice and collect the
hub and tool then place the tool aside.
A. Caution
Ensure the hub, new bearing and tool remain in
alignment throughout the assembly process.
Misalignment of any of these items could cause damage
to the bearing and/or the hub.
5. Should misalignment occur at any point, remove the

components, check and rectify any damage and then
repeat the bearing installation process.
edge
1. Hub
2. Left hand bearing
3. Service Tool 3880065-T0301
8. Progressively close the vice until outer race of the left

hand new bearing is pushed fully up to the inner
flange inside the hub. Open the vice and collect the
hub and tool then place the tool aside.

Wheels/Tyres
Rear Hub Bearing Lubrication

A Caution
Ensure the hub, new bearing and tool remain in
alignment throughout the assembly process.
Misalignment of any of these items could cause damage Ensure the motorcycle is stabilised and adequately
to the bearing and/or the hub. supported, to prevent it falling and causing damage or
Should misalignment occur at any point, remove the injury.
components, check and rectify any damage and then
1. Remove the rear wheel axle shaft <see page 13-19).
repeat the bearing installation process.
2. Remove as much of the old grease and debris as
9. Retain the new bearing by fitting a new retaining possible and check the needle roller bearing for
ring to the groove inside the hub. Ensure the ring is damage, replace as necessary.
retained in the groove through its entire 3. Fit the greasing tool, T3880340, into the needle
circumference. roller bearing on the right hand side of the hub.
cdfz
1. Bearing retaining ring 1. Rear hub

10. Thoroughly clean the hub-bore in the swinging arm. 2. Greasing tool, T3880340
11. Refit the hub (see page 13-21). 4. Attach a grease gun, containing grease to NLGI 2
12. Lubricate the inner hub bearing <see page 15-15>. specification, to the grease nipple.
5. Pump grease into the greasing tool until clean grease
is seen to come out of the two holes adjacent to the
grease nipple.
6. Remove the greasing tool and check that the bearing
is adequately covered with clean grease.
Z Refit the rear wheel axle shaft (see page 13-21>.

Wheels/Tyres

16 Frame and Bodywork
Table of Contents
Exploded View - Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Exploded View - Rear Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
Exploded View - Rear Panels ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
Exploded View - Front and Rear Mudguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.S
Exploded View - Footrests and Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
Exploded View - Bellypan Cif fitted>.. ................ ... ..................... .......... ...... 16.7
Exploded View - Flyscreen Cif fitted> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8
Exploded View - Seat Cowl (if fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9
Frame, Footrests and Fixings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
Seat .... .. ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
Removal ......... ... ................. ... .......... . .............. . ...... ... .......... 16.10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.12
Rear Light Moulding....... ..................................... . ............... ....... .. 16.12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.13
Front Mudguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.13
Bellypan Cif fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14
Flyscreen Cif fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14
Removal .......................................... . .................................. 16.14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14

Frame and Bodywork
Exploded View - Frame
See text
See text
See text
See text
3Nm
6Nm
SNm

Frame and Bodywork
Exploded View - Rear Subframe
58Nm

Frame and Bodywork
Exploded View - Rear Panels
SNm
SNm
I
I
/
I
&

Frame and Bodywork
Exploded View - Front and Rear Mudguards
SNm
\" 23Nm
4Nm
~) 6Nm
~
6Nm ~
~

Frame and Bodywork
Exploded View - Footrests and Mountings
I .,
I
I
I
~
I
I I
ti v
I
/11
27Nm 27Nm ~ I
c,.
o-~> 27Nm
()
--
~/~
9Nm

Frame and Bodywork
Exploded View - Bellypan (if fitted)
7Nm
cglz

Frame and Bodywork
Exploded View - Flyscreen (if fitted)
7Nm
3 Nm

Frame and Bodywork
Exploded View - Seat Cowl Cif fitted)
3 Nm
3Nm

Frame and Bodywork
Frame, Footrests and Fixings Seat
Inspection Removal
1. Inspect the frame footrests and bodywork for

damage, cracks, chafing and other dangerous
A Caution
conditions. Check bodywork and frame fixings for To prevent damage to the seat or cover, care must be
security. taken not to drop the seat. Do not lean the seat against
2. Inspect the bank angle indicators on the rider's the motorcy~le or any surface which may damage the
footrests for wear. The bank angle indicators are seat or cover. Instead, place the seat, with the seat cover
worn out when 5 mm of the bank indicator remains. facing upwards, on a clean, flat surface which is covered
with a soft cloth.
Do not place any item on the seat which may cause
damage or staining to the seat cover.
Note:
The seat lock is situated on the left hand side of
the motorcycle, in the frame, below the seat.
1. Insert the ignition key into the seat lock and turn the
key anti-clockwise while pressing down on the rear
part of the seat.
1. Bank angle indicator
Use of a motorcycle with footrests worn beyond the

maximum limit will allow the motorcycle to be banked
to an unsafe angle.
Banking to an unsafe angle may cause instability, loss of
1. Seat lock
If the motorcycle is involved in an accident or collision it 2. To detach the seat, lift the rear and disengage the
must be taken to an authorised Triumph dealer for front lip from below the fuel tank.
repair or inspection.
Any accident can cause damage to the motorcycle
which, if not correctly repaired, may cause loss of
The frame must not be modified as any modification to

the frame such as welding or drilling may weaken the
frame resulting in loss of motorcycle control and an
accident.

Frame and Bodywork
Installation Rear Panel

1. Position the seat to the fuel tank, engage the front
tags to the side of the fuel tank and the seat's tongue Removal
under the fuel tank.
Note:
An audible click can be heard when the seat is from the fuel tank.
correctly engaged in the lock.
2. Position it to the seat lock and press down at the rear
to engage it in the lock.
y- ·~~~-~:-·-~~·~
· ·. / I
~~·:. -,<"~-I 1iniJ:!~i
~~-..:~.:.:: __ -- · .. - · ..
._;,;.~~ ~
~
To prevent detachment of the seat during riding, after

fitting always grasp the seat and pull firmly upwards. If
the seat is not correctly secured it will detach from the
lock. A loose or detached seat could cause loss of
3. Grasp the seat and ensure that it is securely retained.
1. Front panel
2. Fixings

4. Remove the rear panel fixings.

Frame and Bodywork
5. Detach the rear panel stud from the grommet and Rear Light Moulding
remove from the motorcycle. Ensure the grommet
remains fitted to the rear light moulding.
Removal

from the fuel tank.
1. Stud
2. Grommet
3. Rear light moulding
Installation
1. Front panel
1. Ensure the grommet is correctly fitted to the rear 2. Fixings
light moulding. 3. Disconnect the battery, negative (black> lead first.
2. Align the side panel to the motorcycle and push the 4. Remove the rear panels (see page 16-1 n.
stud into the grommet.
5. For models without the mudguard extension
3. Refit the fixings and tighten to S Nm. fitted ony: Remove and discard the fixings securing
4. Reconnect the battery, positive (red) lead first. the rear light moulding to the splash guard.
fixings to 2 Nm.
6. Refit the seat <see page 16-1 T>.
~" ~~ r
1. Fixing, right hand side shown
~
6. For models with the mudguard extension fitted
only: Remove and MS x 16 mm screws securing the
rear light moulding to the splash guard.
16.12 Sesvice Manual - Speed Triple and Speed Triple R

Frame and Bodywork
Z Release the screw and slide the rear light moulding Front Mudguard
rearwards to remove.
Removal
1. Release the four fixings that secure the mudguard to

the fork leg.
1. Screw
0
Installation o@
0 ,.-.,.
1. Mudguard
1. Align the rear light moulding to the motorcycle.
2. Fixings, left hand side shown
2. Refit the screw and tighten to 5 Nm.. 3. Fork protector
2. Capture the fork protector panels from each side
before sliding the mudguard forward to remove it.
Installation
1. Position the mudguard to the forks, locating the fork

protector panels at the same time.
2. Fit and tighten the mudguard fixings to 6 Nm.
3. For models without the mudguard extension

fitted ony: Fit new fixings securing the rear light
moulding to the splash guard.
4. For models with the mudguard extension fitted
only: Tighten the fixings to 4 Nm.
5. Refit the rear panels (see page 16-12).
Z Refit the front panel to the fuel tank and tighten the
fixings to 2 Nm.

Frame and Bodywork
Bellypa n (if fitted} Flyscreen (if fitted>
Removal Removal
1. Release the four fixings that secure the bellypan to its 1. Release the four fixings that secure the flyscreen to
mountings. its infill panel.
cgmb_1
2
cgpc
1. Fixings 1. Fixings
2. Bellypan 2. Infill panel
3. Flyscreen
2. Carefully slide the bellypan forward and down to
remove from the motorcycle. 2. Slide the flyscreen forward to remove from the
motorcycle.
Installation
Installation
1. Position the bellypan onto its mountings and tighten
the fixings to 4 Nm. 1. Position the flyscreen onto its infill panel and tighten
the fixings to 3 Nm.

17 Electrical
Table of Contents
Exploded View - Instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
Exploded View - Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4
Exploded View - Rear light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5
Exploded View - Direction Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
Exploded View - Alternator, Starter and Rectifier/Regulator... ..... .... ..................... . ... 17.7
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8
Battery Installation .......... ·. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8
New Battery Commissioning......... ....................... ...... ....................... 17.9
Battery Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9
Battery Already in Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9
Table of Battery Charging Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
Relay identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
Fuse Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.11
Instrument Assembly....... .................. ....... . ...... ..... ... ........ ... .......... . 17.12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15
Headlight Adjustment... ................... ............. ................. ........ .. .... 17.15
Headlight Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.16
Position Lamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17
Rear Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17
Rear Light Unit Replacement. ..... . .. .. ....... ..... .......... ..... ...................... 17.17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.18
Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
Licence Plate Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19

Electrical
Starter Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20

Removal. ........... . ................................................................ 17.20
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.21
Alternator............... ... ... . . . .................... .... .................. .. .... ... ... 17.21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.23
Alternator Rectifier/Regulator ................................ ... ......... r. • • • • • • • • • • • • • • • 17.24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
Alternator Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.26
Pinpoint Tests. ................... .... ..................................... ... ........ . 17.26
Rectifier/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.28
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.28
Lighting Circuit - Motorcycles with ABS Up To VIN 485952 and Motorcycles without ABS
Up To VIN 490000.. ..... ... ... ......................................................... 17.30
Key to circuit diagram. ..... ... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30
Key to wiring colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30
Lighting Circuit - Motorcycles with ABS From VIN 485953 and Motorcycles without ABS
From VIN 490001 .. ..... .. .. ... ........ ....... .. ... .. .. ... .... .......................... 17.32
Key to circuit diagram... . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.32
Starting and Charging Circuit .. ........ .... ............................... ~ . . . . . . . . . . . . . . . 17.34
Key to circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.34
Auxiliary and Accessory Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.36
Complete System - Speed Triple without ABS - Up To VIN 485952 ......... .. .... .... .......... 17.38
Key to circuit diagram. ... . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.38
Complete System - Speed Triple without ABS - From VIN 485953.... ......... ..... .. ... ....... 17.40
Complete System - Speed Triple with ABS - Up To VIN 490000. ............................... 17.42
Complete System - Speed Triple with ABS - From VIN 490001. ....... .... ..................... 17.44

Electrical
Exploded View - Instruments
3Nm

Electrical
Exploded View - Headlight
~
\}
15 Nm
3Nm
rJ>15Nm
•
3 Nm
~
~-\
~30Nm

Electrical
Exploded View - Rear light
4Nm
, 1
2Nm
/

Electrical
Exploded View - Direction Indicators
r
3Nm
3 Nm

Electrical
Exploded View - Alternator, Starter and Rectifier/Regulator
--
!
--- -- -- -- --- - - - - - ---- -- -
Up to VIN 499573 without ABS From VIN 499 5 74 without ABS
Up to VIN 499956 with ABS From VIN 499957 with ABS
J
I
I
I
I I I
' --- --- --- -- --- -- --- -- -- -- ~ '- ---- -- ---- -- ---- ---- - ---
(@~105Nm
~ 12Nm
10Nm ~
~

Electrical
Battery
Ensure that the battery terminals do not touch the

motorcycle frame as this may cause a short circuit or
The battery gives off explosive gases; keep sparks, spark which would ignite battery gases causing a risk of
flames and cigarettes away. Provide adequate ventilation personal injury.
when charging or using the battery in an enclosed
space.
The battery contains sulphuric acid (electrolyte>. Contact
with skin or eyes may cause severe burns. Wear
protective clothing and a face shield.
If electrolyte gets on your skin, flush with
water immediately.
If electrolyte gets in your eyes, flush with
water for at least 15 minutes and SEEK
MEDICAL ATIENTION IMMEDIATELY
If electrolyte is swallowed, drink large
quantities of water and SEEK MEDICAL
ATIENTION IMMEDIATELY
cgfg_l
KEEP ELECTROLYTE OUT OF THE REACH OF
CHILDREN. 1. Battery
2. Battery strap
3. Negative (-) terminal
4. Positive C+> terminal
5. Brace
The battery contains harmful materials. Always keep
children away from the battery whether or not it is fitted
in the motorcycle. Battery Installation
Do not jump start the battery, touch the battery cables
together or reverse the polarity of the cables as any of
these actions may cause a spark which would ignite
battery gases causing a risk of personal injury. Ensure that the battery terminals do not touch the
motorcycle frame as this may cause a short circuit or
spark which would ignite battery gases causing a risk of
personal injury.
The battery electrolyte is corrosive and poisonous. Never 1. Fit the battery.
swallow battery electrolyte or allow to come into contact
2. Route the battery cables as noted for removal.
with the skin. Always wear eye and skin protection when
adjusting the electrolyte level. 3. Reconnect the battery, positive (red) lead first.
4. Apply a light coat of grease to the terminals to
prevent corrosion.
Battery Removal
5. Cover the terminals with the protective caps.
1. Raise and support the fuel tank <see page 10-92). 6. Refit the battery brace and strap.
Note: Z Lower and secure the fuel tank <see page 10-93).
Note the routing of the battery leads for

installation.
3. Remove the battery brace and strap.
4. Remove the battery.

Electrical
New Battery Commissioning 13. Fit the battery to the motorcycle, positive <red) lead
first.
In order to correctly and safely commission a new battery,
the battery commissioning procedure listed below must
be carefully followed. This is the only battery Battery Maintenance
commissioning procedure that Triumph recommends.
The battery is a sealed type and does not require any
The procedure is designed to ensure that the battery is at
maintenance other than checking the voltage and routine
its best when fitted to the motorcycle, and will provide the
recharging such as during storage.
best possibf e performance and reliability.
It is not possible to adjust the electrolyte level in the
Failure to comply with this procedure may lead to reduced
battery.
battery performance and/or shorten the life of the battery.
Note:
The charge level in the battery must be
maintained to maximise the battery life.
The battery electrolyte is corrosive and poisonous. Never
swallow battery electrolyte or allow it to come into With normal use of the motorcycle, the charging system
contact with the skin. To help reduce the risk of injury, will keep the battery charged. If the motorcycle is unused
always wear eye and skin protection when filling and the battery will gradually discharge due to battery self
sealing the battery. discharge and the continuous current drain for the clock,
immobiliser and the engine control module memory.
1. Read the instructions and warnings delivered with The rate of battery discharge can be greatly increased by
the battery! the addition of electrical security systems or other
2. Place the battery on a flat level surface and remove accessories.
the sealing foil. Allowing a battery to discharge, or leaving it discharged
3. Remove the battery sealing strip from the electrolyte over a period of time, causes sulphation of the lead plates
container (if applicable) and save for ·use later in this within the battery.
procedure. Do not break the seal on the electrolyte Sulphation is a normal chemical reaction inside the battery
container. and over a period of time sulphate will crystallise on to the
4. Place the electrolyte container and adapter (if lead plates making charging difficult or impossible. The
applicable) on the battery and fill the battery result is a permanently damaged battery, which would not
according to the manufacturers instructions. be covered by the motorcycle warranty.
5. After starting to fill the battery with electrolyte, allow Keeping a battery at full charge reduces the chance of it
the battery to stand for 30 minutes with the filling freezing in cold conditions. Allowing a battery to freeze
container in place. can cause serious internal damage to the battery.
6. Check that all of the electrolyte has drained from the When leaving the motorcycle standing for more than a
container. Do not remove container at this point. If few days, regularly check the battery voltage using a
the container has not completely drained, tap the digital multimeter. Should the battery voltage fall below
sides of the container to start the electrolyte flowing 12.8 V, charge the battery using the BatteryMate 150-9.
again. Refer to the instructions supplied with the
Z After all of the electrolyte has drained into the BatteryMate 150-9.
battery, allow the battery to stand, with the For extended periods of storage (beyond two weeks) the
electrolyte container in place, for a further battery should be removed and the battery voltage
30 minutes for batteries 3Ah - 12Ah or 1 hour for checked regularly and charged when below 12.8 V.
batteries greater than 12Ah.
8. Remove the electrolyte container and adapter Battery Already in Service
carefully, and dispose of both immediately.
Use the guidelines in the table on the following page for
9. Place the sealing cap strip LOOSELY over the filling
charging. Always verify the battery condition before
holes of the battery.
charging, and 30 minutes after charging.
10. Charge the battery using BatteryMate 150-9. Refer
to the instructions supplied with BatteryMate 150-9. Note:
11. After charging is complete, press down firmly with A fully charged battery should read 12.8 Volts
both hands to seat the caps (do not use tools or force or higher after the battery has been off the
the caps into position). charger for 3 0 minutes or more.
12. Disconnect the charger and allow the battery to
stand for 1 hour before fitting to the motorcycle.

Electrical
Table of Battery Charging Times
State of charge Voltage Action Charge time <using

BatteryMate 150-9)
1000/o 12.8 v - 13.0 v None. Check at 6 months from None required
date of manufacture
750/o - 1000/o 12.5 v - 12.8 v May need slight charge. If no 3 - 6 hours

charge given, check in
3 - 4 months
500/o- 750/o 12.0 v - 12.5 v Needs charge 5 - 11 hours
250/o - 500/o 11.5 v - 12.0 v Needs charge at least 13 hours
00/o - 25% 11.5 V or less Needs recovery using 20 hours

BatteryMate 150-9. Re-test after
recovery
Relays Fuses
The relays are located under the seat. To gain access to If a fuse fails during operation, inspect the electrical
the relays, remove the seat (see page 16-10). system to determine the cause, and then replace it with a
new fuse of the correct current rating.
Relay identification
1. Front fuse box

2. Rear fuse box
The two fuse boxes are located under the seat.
4. Engine management system relay

5. Starter relay
6. Direction indicator relay Always replace blown fuses with new ones of the correct
current rating (as specified on the fuse box cover) and
never use a fuse of higher rating.

Electrical
Fuse Identification Motorcycles with ABS from VIN 485953 and

Motorcycles with ABS from VIN 490001
A blown fuse is indicated when all of the systems
protected by that fuse become inoperative. When
checking for a blown fuse, use the table below to establish
which fuse has blown. en
~1
..a. I\) (N ~ U1
m m U'I
m
...... U'I
s:: > > > s:
0
The fuse identification numbers listed correspond with s:::
""D ..,, ""D m
-I -f ff.. l
0
those printed on the fuse box cover. Spare fuses are -< -< i '6' ~
z
located at right angles to the main fuses and should be
tl Vi~
replaced if used.
Front Fuse Box

Note:
For motorcycles without ABS, fuse positions 1
and 2 will be empty.
Motorcycles without ABS up to VIN 485952 and

Motorcycles with ABS up to VIN 490000 1. Fuse box
2. Fuse box cover
3. Spare fuses
..... ~ en
~1
I\) (N U1
N N
m
...... ...... U'I
> > > > > s::

0 0 0 0
Fuse No. Circuits Protected Fuse
0 ""D m
J> J>
aJ
en
i>CIJ
en
-f
»: "°" ~ -<
z Rating
Vi~
1 ABS 20
ti 2
3
ABS
Tail light
Licence plate light
20
5
4 Side lights 10
Direction indicators
5 Alarm 5
Instrument lights
cebw_3
1. Fuse box 6 Empty -

2. Fuse box cover
3. Spare fuses

Rating
1 ABS 20
2 ABS 20
3 Tail light 10
Licence plate light
Side lights
4 Direction indicators 10
s Alarm 5
Instrument lights
6 Empty -

Electrical
Rear Fuse Box - All Models Instrument Assembly
~ I\) w +:ii CJ1 O') Removal

N N ...... ...... ...... m 0
C) C) c.n C) C)
)> )> )> )> )> 3: "'tJ
m
•
~
~
~ 0 -< z
0 ~ -I from the fuel tank.
- -- - - ·--·-
- - -~-
- -- - -
cebw_2
1. Fuse box
2. Fuse box cover
3. Spare fuses

Rating
1. Front panel
1 Dip and main beam 20 2. Fixings
headlights
2 Engine management 20
syatem 3. If fitted, remove the flyscreen (see page 16-14).
3 Cooling fan 15 4. Remove the cover and gasket attached to the rear of
the instruments.
4 Fuel pump 10
Note:
5 Ignition switch 10
6 Empty - The cover is held in place by bayonet type
fixings. Gently pull on the cover to release it.
Main Fuse
The 30 Amp main fuse is located in front of the battery.
To allow access to this fuse, the front panel on the fuel
tank must be removed.
3. Instrument assembly
cgfg__2
1. Main fuse
2. Battery

Electrical
5. Disconnect the electrical connector from the Installation

instruments.
6. Remove the screw securing the instrument assembly 1. Position the instrument assembly to the bracket
to its bracket, collect the washer. 2. Insert the bayonet fixings into the grommets.
Z Release the instrument assembly from the bayonet 3. Refit the screw with its washer and tighten to 3 Nm.
fixings.
4. Connect the electrical connector to the instruments.
5. Install the cover and gasket to the rear of the
instruments. Ensure that the headlight harness is
covered and the bayonet fixings are fully inserted
into the grommets on the bracket.
2. Screw
3. Washer
4. Bayonet fixings
2. Screw
3. Washer
4. Bayonet fixings
5. Grommets
Z If fitted, refit the flyscreen (see page 16-14).
fixings to 2 Nm.

Electrical
Headlights 5. Disconnect the headlight multi-pin electrical

connector.
Removal

from the fuel tank.
~
1. Multi-pin electrical connector
6. Loosen the bolt at the rear of the headlight clamp.
7. While supporting the headlight assembly, remove
cgfo~
both bolts, the clamp and the headlight assembly.
1. Front panel
2. Fixings
2. Disconnect the battery, negative <black) fead first.

3. If fitted, remove the flyscreen (see page 16-14).
4. Remove the cover and gasket attached to the rear of
the instruments.
Note:
The cover is held in place by bayonet type
fixings. Gently pull on the cover to release it.
1. Rear bolt
2. Front bolt
3. Clamp
3. Instruments

Electrical
Installation Horizontal Adiustment

Note:
1. Align the headlight assembly to its bracket.
2. Fit the clamp and and tighten the clamp bolts, front The horizontal beams of both headlights can
first, to 15 Nm. be adiusted individually. The same procedure is
used to adiust either headlight.
3. Reconnect the headlight multi-pin electrical
connector.
4. Install the cover and gasket to the rear of the
instruments. Ensure that the headlight harness is
covered and the bayonet fixings are fully inserted
into the grommets on the bracket.
5. Reconnect the battery, positive (red> lead first.
6. If fitted, refit the flyscreen (see page 16-14>.
fixings to 2 Nm.
8. Check and, if necessary, adjust the headlight
alignment (see page 17-15>.
Headlight Adiustment
cgfc_2
r---
1. Horizontal beam adiusters
Vertical Adiustment
7. Switch the headlight dipped beam on.
Note:
8. Slacken the headlight mounting nut.
The vertical beams of the left hand and right
9. Adjust the horizontal position of the headlight to give
hand headlights can only be adiusted together.
the required beam setting.
Independent adiustment is not possible.
10. Tighten the nut to 30 Nm.
11. Repeat for the second headlight
12. Re-check the headlight beam settings.
13. Switch the headlights off when both beam settings
are satisfactorily set
Adjust road speed to suit the visibility and weather

conditions in which the motorcycle is being operated.
Ensure that the headlight beam is adjusted to illuminate
the road surface sufficiently far ahead without dazzling
oncoming traffic. An incorrectly adiusted headlight may
impair visibility causing an accident.
1. Vertical adiuster fixings
1. Switch the headlight dipped beam on.

2. Slacken the clamp bolts, rear first, sufficiently to allow
restricted movement of the headlights.
3. Adjust the position of the headlights to give the
required beam setting.
4. Tighten the clamp bolts, front .first to 15 Nm.
5. Re-check the headlight beam settings.
6. Switch the headlights off when both beam setting is
satisfactorily set.

Electrical
Headlight Bulb Replacement 3. While supporting the headlight, remove the fixings
and detach the headlight from its bowl.
Each headlight bulb can be replaced as follows:
~-~
~
The bulb becomes hot during use. Always allow
sufficient time for the bulb to cool before handling.
Avoid touching the glass part of the bulb. If the glass is
touched or gets dirty, dean with alcohol before re-use.
Do not reconnect the battery until the assembly process

has been completed. Premature battery reconnection
could result in ignition of the battery gases causing risk
of injury.
1. Release the three fixings and remove the front panel 1. Fixings
from the fuel tank. 2. Headlight bowl
4. Disconnect the multi-pin electrical connector from

the headlight bulb, then remove the headlight.
1. Front panel
2. Fixings
2. Disconnect the battery, negative (black) lead first. 1. Multi-pin connector

5. Disconnect the multi-pin electrical connector from
the bulb and remove the rubber cover.

Electrical
6. Detach the wire retainer from its clip (do not remove Rear Light
the screw) then remove the bulb from the light unit
Note:
The rear light is sealed for life and must be
replaced in the event of a failure.
Rear Light Unit Replacement

from the fuel tank.
cgln_1
1. Headlight bulb
2. Bulb clip
3. Position lamp bulb
Z Installation is the reverse of the removal procedure.
8. Tighten the fixings for the headlight bowl to 3 Nm.
fixings to 2 Nm.
Note:
When reconnecting the battery, connect the 1. Front panel
positive <red> lead first. 2. Fixings
Position Lamp Bulb Replacement 4. Remove the rear panels (see page 16-1 n.
Position lamp bulbs are fitted to both headlight units. To 5. Remove the rear light moulding <see page 16-12>.
replace a position light bulb, remove the headlight unit
from the headlight bowl to gain access for position light Note:
bulb replacement. Note the position of the three locating lugs on
the splash guard for installation.

Electrical
6. Release the screw then remove the splash guard 8. Release the fixings securing the rear light unit to the
from the mudguard. rear subframe. Note the routing of its harness and
remove the rear light unit.
cgvq
1. Screw
2. Locating tangs
I 1. Rear light unit
3. Splash guard 2. Fixings
Note:
Installation
• Note the routing of the rear light harness for
installation.
1. Position the rear light unit to the subframe with its
7. Disconnect the rear light harness. harness routed as for removal. Secure with the two
fixings and tighten to 4 Nm.
2. Reconnect the electrical connector and position the
harness as noted for removal.
3. Refit the splash guard, fit the screw and tighten to
4Nm.
4. Refit the rear light moulding (see page 16-13>.
5. Refit the rear panels (see page 16-12).
6. Reconnect the battery, positive Cred) lead first
fixings to 2 Nm.
cgvp I
1. Rear light harness, viewed under the mudguard
2. Connector

Electrical
Indicator Light Licence Plate Light
Bulb Replacement Bulb Replacement

from the fuel tank.
celc
1. Indicator lens
2. Screw
1. Front panel
The lens on each indicator light is held in place by a screw
2. Fixings
located in the lens of the light.
Release the screw and remove the lens to gain access to 2. Disconnect the battery, negative (black) lead first.
the bulb for replacement
A Caution
Do not pull the licence plate bracket more than is
necessary to access the light's inside fixing nut. Damage
to the bracket will result from pulling it too far.
3. Remove the fixings for both rear indicators.
1. Fixing, left hand side shown

2. Licence plate bracket
4. Carefully raise the licence plate bracket to gain

access to the locknut.
5. Counter-hold the locknut to prevent it from turning
and remove the licence plate light fixing screw.
Collect the locknut.

Electrical
6. Detach the light from the license plate bracket. It is Starter Motor
not necessary to disconnect the licence plate light
electrical connectors.
Removal
A Caution 1. Remove the seat (see page 16-10>.
To avoid cable damage, do not pull the bulb holder 2. Release the three fixings and remove the front panel
using the cables. Pull only on the bulb holder. from the fuel tank.
Z Carefully remove the bulb holder from the back of

the licence plate light unit and remove the bulb.
1. Front panel
2. Fixings
1. licence plate light 3. Disconnect the battery, negative (black) lead first.
2. Bulb holder 4. Remove the fuel tank see page 70-93>.
Installation is the reverse of the removal procedure, noting 5. If fitted, remove the evaporative cannister (see
the following: page 10-134).
Tighten the licence plate lamp fixing to 2 Nm. 6. Remove the low oil pressure warning light switch
<see page 8-12).
Tighten the rear indicator fixings to 3 Nm.
Z Ease the rubber boot from the starter cable and then
Reconnect the battery, positive (red) lead first. release the cable nut.
Refit the front panel to the fuel tank and tighten 8. Detach the cable.
the fixings to 2 Nm. 9. Release the bolts securing the starter to the
crankcase.
1. Starter motor
2. Bolts

Electrical
10. Ease the starter motor from the right hand engine Alternator
cover while gently moving the camshaft oil feed pipe
out of the way.
Removal
Inspection
1. Ensure the starter turns freely and without binding. 2. Release the three fixings and remove the front panel
from the fuel tank.
2. Check the starter 0-ring for damage and
deterioration. Replace as necessary.
Installation
1. Fit the starter motor to the right hand engine cover

ensuring that the 0-ring does not become damaged
during installation.
2. Fit the starter motor bolts, then, whilst firmly holding
the starter motor in position against the crankcase,
tighten the starter motor bolts to 10 Nm.
3. Refit the lead and secure with the nut. Tighten to
7Nm.
4. Refit the rubber boot.
5. Refit the low oil pressure warning light switch (see
page 8-12). 1. Front panel
2. Fixings
6. If removed, refit the evaporative cannister (see
page 10-135>. 3. Disconnect the battery, negative (black> lead first
Z Refit the fuel tank (see page 10-94). 4. Release the bolts securing the left hand engine cover
8. Refit the front panel to the fuel tank and tighten the to the engine.
fixings to 2 Nm.
9. Reconnect the battery positive <red) lead first.
fixings to 2 Nm.
11. Refit the seat (see page 16-1 T>.
1. Left hand engine cover
5. Withdraw the cover from the crankcase against the

pull of the alternator magnet.

Electrical
6. To remove the stator from the cover, release the 9. With the rotor bolt removed, insert tool T3880203
three bolts in the centre of the cover and release the to the centre of the alternator.
bolt securing the cable bracket.
1. Rotor
t. Stator 2. Tool T3880375
2. Stator bolts 3. Tool T3880203
3. Cable bracket
4. Cable bracket bolt 10. Tighten tool T3880203, while preventing the
crankshaft from turning with tool T3880375, to
Z Withdraw the stator. release the taper seating of the rotor from the
8. To remove the rotor, prevent the crankshaft from crankshaft.
rotating using tool T3880375, and ·remove the 11. Withdraw the rotor and tool as an assembly and then
centre bolt from the crankshaft. separate the tool from the rotor.
1. Rotor
2. Tool T3880375

Electrical
Assembly Note:
The engine cover fixings 1 and 2 are torqued
1. Assemble the rotor to the keyway on the crankshaft.
twice as 14 and 1S respectively.
2. Refit tool T3880375 to prevent the crankshaft from
9. Refit the left hand engine cover incorporating a new
rotating.
gasket. Tighten the cover fixings to 8 Nm in the
3. Tighten the rotor retaining bolt to 105 Nm. sequence shown below.
1. Rotor
2. Tool T3880375 Engine Cover Tightening Sequence
4. Remove tool T3880375. 10. Reconnect the battery positive (red) lead first.
5. Locate the stator to the engine cover. 11. Refit the front panel to the fuel tank and tighten the
fixings to 2 Nm.
6. Apply silicone sealer to the cable grommet and align
the cable to the exit slot. 12. Refit the seat <see page 16-1 T>.
7. Fit the cable retainer bracket and tighten the bolt to
8Nm.
8. Tighten the stator bolts to 12 Nm.

Electrical
Alternator Rectifier/Regulator Note:

Note the routing of the rectifier regulator
Note:
harnesses for installation
For models with ABS, the rectifier/regulator is Z Disconnect the rectifier/regulator harnesses from the
mounted on the same bracket as the ABS main harness.
hydraulic modulator. To remove the
rectifier/regulator see page 14-44).
For models without ABS, the rectifier/regulator
is mounted on its own bracket.

from the fuel tank.
~L
\t/
·· ~~ ··
1. Connector, left hand side

~ 2. Connector, right and side
Note:
rectifier/regulator for installation.
cgfo " ' -
8. Release the screws and remove the rectifier/regulator
and bracket assembly.
1. Front panel
2. Fixings

page 11-15).
6. Detach the rectifier/regulator harness from the right
hand side of the frame.
cgtx
1. Screws, 2 of 3 shown
2. Rectifier/regulator
3. Bracket
Note:
rectifier/regulator for installation.
9. Release the fixings and remove the
cgtz rectifier/regulator.
1. Clip

Electrical
10. From VIN 499 5 74 only: Disconnect the 5. Attach the rectifier/regulator harness to the right
subharness from the rectifier regulator. hand side of the frame. Ensure that the clip is behind
the ridge on the frame, as shown below.
1. Sub harness connectors cgtz

1. Clip
Installation
3. Ridge
Note:
6. Refit the coolant expansion tank <see page 11-75>.
For models with ABS, see page 14-28 for the Z Refit the fuel tank <see page 10-93).
installation of the rectifier regula~or.
8. Conned the battery, positive <red) lead first.
1. From VIN 499574 only: Conned the subharness 9. Refit the front panel to the fuel tank and tighten the
to the rectifier regulator. fixings to 2 Nm.
2. Fit the rectifier/regulator to its bracket as noted for 10. Refit the seat (see page 16-1 n.
removal and tighten the fixings to 3 Nm.
3. Position the rectifier/regulator and bracket assembly
to the frame with the harnesses routed as noted for
removal. Secure with the screws and tighten to
SNm.
4. Reconnect the harnesses to the main harness.

Electrical
Alternator Stator
The stator is an assembly of 18 coils, arranged into three phases. It is possible to check for continuity, and short circuits
through the coils to earth.
Note:
Only repairs to the stator harness between the connector and the harness entry point into the crankcase
are permitted.
Do not attempt to repair the stator coils.
If the battery is not fully charged, the charging voltage may be lower than specified when checking at
2000 rpm.
Ensure all additional accessories (auxiliary lights, heated grips etc.> are switched off.
Battery not charging Main fuse in front of the battery Check the condition of fuse.
Battery Check the condition of the battery.

Test the battery using the
BatteryMate 150-9. Refer to the
instructions supplied with the
BatteryMate 150-9. Ensure the battery
is serviceable:-
Alternator Proceed to pinpoint test 1.
Rectifier/Regulator Test the rectifier/regulator (see

page 17-28).
Pinpoint Tests
Test Result Action

- Battery positive (+) Faulty Rectify fault, proceed to test 6
- Battery negative (-)
- Rectifier/regulator to main wiring harness
connector pin 1
connector pin 2
connector pin 3
connector pin 4
2 Check cable and terminal integrity: OK Disconnect the battery leads, negative (black)
- Rectifier/regulator to alternator harness lead first. Disconnect rectifier/regulator to
connector pin 1 main wiring harness connector (4 pin).
Proceed to test 3
- Rectifier/regulator to alternator harness
connector pin 2 Faulty Rectify fault, proceed to test 6
- Rectifier/regulator to alternator harness
connector pin 3

Electrical
Test Result Action
3 Check cable continuity: OK Reconnect the battery leads, positive (red)

- Rectifier/regulator main harness connector lead first. Reconnect the rectifier/regulator to
pin 1 to battery lead negative main wiring harness connector (4 pin).
Disconnect the rectifier/regulator to alternator
- Rectifier/regulator main harness connector
harness connector C3 pin). Proceed to test 4
pin 2 to battery lead negative
- Rectifier/regulator main harness connector Open circuit Locate and rectify wiring fault, proceed to
pin 3 to battery lead positive test 6
- Rectifier/regulator main harness connector
pin 4 t-0 battery lead positive
4 Check resistance through the coils: 0.4Q to 0.6Q Proceed to test 5
- Alternator harness pin 1 to 2 Open circuit or short If the fault is between the connector and the
- Alternator harness pin 2 to 3 circuit crankcase, repair the harness. Proceed to
- Alternator harness pin 3 to 1 test 6
If the fault is after the crankcase, replace the
unit Proceed to test 6
5 Check for short to earth: Open c:ircuit Proceed to test 6
- Alternator harness pin 1 to metal frame Short circuit Replace unit Proceed to test 6
- Alternator harness pin 2 to metal frame
-Alternator harness pin 3 to metal frame
6 Reconnect the harness an_d run the engine. 13.5 V to 15 V Action complete - quit test
Check the charging voltage at 2000 rpm:
Fault still present Test rectifier/regulator (see page 17-28}
If rectifier/regulator is serviceable, contact
Triumph service
Alternator connector
Stator pin numbers
Main fuse 30 A
," C-:J.---.----+-----~ :------,

~¥'
Y YY
I I I
BBRR
I I I I
Battery
1 '2 3 1 2 4 3
Rectifier/regulator
Regulator/rectifier main wiring harness

connector pin numbers
alterna!or_ l

Electrical
Rectifier/Regulator
Internally the rectifier/regulator consists of:
six diodes;
a voltage controller and three thyristors.
The diodes are arranged with one diode connected between each yellow input wire and each pair of red an~ black output
wires.
The diodes convert the ac voltage to de voltage.
Each yellow input wire is also connected to a thyristor which is in turn connected to ground. When the de voltage at the
battery reaches the required level, the voltage controller sends a signal to all three thyristors. The thyristors then conduct
and effectively short circuit the stator until the de voltage drops to an acceptable level.
It is possible for any number of these diodes to fail, reducing the power output of the unit This may not be obvious until
maximum power is required by the ignition, lighting and accessories etc.
The diodes can be checked using a multimeter on DIODE setting.
Note:
This test does not check for voltage regulation.
Battery not charging Main fuse in front of the battery Check the condition of the fuse:
Battery Check the condition of the battery.
Test the battery using the
BatteryMate 150-9. Refer to the
instructions supplied with the
BatteryMate 150-9. Ensure the battery
is serviceable.
Rectifier/Regulator Disconnect the rectifier regulator
connectors from the main wiring
harness and the alternator harness.
Alternator Test the alternator stator (see
page 17-26).
Pinpoint Tests
Test Result Action
1 Check the earth and power for continuity: OK Proceed to test 2

- Rectifier/regulator connector pin 1 to Open circuit Rectify wiring fault. Proceed to test 6
pin 2
If no wiring fault found, replace unit. Proceed
- Rectifier/regulator connector pin 3 to to test 5
pin 4
2 Check diodes forward bias: 0.4 V to 0.7 V Proceed to test 3
- Positive (+) probe to Rectifier/regulator Open or short circuit Replace unit. Proceed to test 6
connector pin 1 to:
Negative (-) probe to alternator connector
pin 1
pin 2
pin 3

Electrical
Test Result Action

3 Check diodes forward bias: 0.4 V to 0.7 V Proceed to test 4
- Negative (-} probe to Rectifier/regulator Open or short circuit Replace unit. Proceed to test 6
connector pin 4 to:
Positive(+) probe to alternator connector
pin 1
pin 2
pin 3
4 Check diodes reverse bias: Open circuit or 'OL' Proceed to test 5

- Positive (+) probe to Rectifier/regulator on meter
connector pin 4 to: A voltage reading or Replace unit. Proceed to test 6
Negative (-) probe to alternator connector short circuit
pin 1
Negative (-} probe to alternator connector
pin 2
pin 3
5 Check diodes reverse bias: Open circuit or 'OL' Proceed to test 6

- Negative (-) probe to Rectifier/regulator on meter
connector pin 1 to: A voltage reading or Replace unit. Proceed to test 6
Positive(+) probe to alternator connector short circuit
pin 1
Positive (+) probe to alternator connector
pin 2
Positive (+) probe to alternator connector
pin 3
6 Reconnect the harness and run the engine. 13.5 V to 15 V Action complete - quit test
Check the charging voltage at 2000 rpm:
Fault still present Test alternator stator (see page 17-26)
If rectifier/regulator is serviceable, contact

Triumph service
Ai
Diode
Rectifier/regulator
R 3
connector
B 2
B 1
Alternator Voltage
connector controller
Alternator connector Rectifier/regulator

pin numbers Thyristor pin numbers

Electrical
Lighting Circuit - Motorcycles with ABS Up To VIN 485952 and

Motorcycles without ABS up to VIN 490000
Key to Circuit Diagram Key to Wiring Colours
Key Item Description Key Wiring Colour
1 Rear fuse box (fuse 1 and 5) B Black
2 Ignition switch u Blue
3 Front fuse box (fuse 3) N Brown
4 Starter relay G Green
5 Headlamp relay s Slate/Grey
6 Number plate lamp 0 Orange
7 Tail light K Pink
8 Left hand switch cube assembly R Red
9 Main/dip beam switch p Purple
10 Pass switch w White
11 Instrument assembly y Yellow
12 Oil pressure warning light LG Light Green
13 Main beam warning light LU Light Blue
14 Engine sub-harness
15 Headlight 1
16 Headlight 2

Electrical
r--- - 1
I
1I
I 2
I
I
r - - - - - - - - - - - - - - - - RU
- - - - au
3 I 3
I
I
L
T . '~
8
8
~7
9
11
14
10
B-s
.__-+-----+-------+----uw B 1------1
_[ ~ B ~
2 4 1 3 3 1 4 2
16 15
~ ~ CE~~

Electrical
Lighting Circuit - Motorcycles with ABS From VIN 485953 and

Motorcycles without ABS from VIN 490001
1 Rear fuse box (fuse 1 and 5) B Black
3 Front fuse box (fuse 3) N Brown
4 Starter relay G Green
5 Headlamp relay s Slate/Grey
6 Number plate lamp 0 Orange
7 Tail light K Pink
8 Left hand switch cube assembly R Red
9 Main/dip beam switch p Purple
10 Pass switch w White
11 Instrument assembly y Yellow
12 Oil pressure warning light LG Light Green
13 Main beam warning light LU Light Blue
14 Engine sub-harness
15 Headlight 1
16 Headlight 2

Electrical
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16 15

Electrical
Starting and Charging Circuit
1 Battery) B Black
2 Starter solenoid u Blue
3 Starter motor N Brown
4 Engine control module G Green
5 Starter relay s Slate/Grey
6 Main fuse (30 Amp) 0 Orange
7 RegulatorI rectifier K Pink
8 Front fuse box (fuses 1, 2, 4 and 5) R Red
9 Rear fuse box <fuses 1, 2, 3, 4 and 5) p Purple
10 Engine control module relay w White
11 Cooling fan relay y Yellow
12 Fuel pump relay LG Light Green
13 Instruments LU Light Blue
14 Alarm
15 Starter switch
16 Engine stop switch
17 Immobiliser module
18 Ignition switch

Electrical
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17

Electrical
Auxiliary and Accessory Circuit
1 Front fuse box <Fuses 4 & 5) B Black
3 Indicator relay N Brown
4 Front brake light switch G Green
5 Horn switch 5 Slate/Grey
6 Direction indicator switch 0 Orange
7 Horn K Pink
8 Rear brake light switch R Red
9 Brake light p Purple

10 Instrument assembly w White
11 Diagnostic connector y Yellow
12 Direction indicator (Instruments) LG Light Green

13 Alarm LED LU Light Blue
14 Front right direction Indicator

15 Front left direction Indicator
16 Alarm unit
17 Rear right direction indicator
18 Rear left direction indicator

Electrical
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18

Electrical
Complete System - Speed Triple without ABS - up to VIN 485952
Key to Circuit Diagram
Key Item Description 36 Rear brake lever switch
1 Instrument assembly 37 Right hand rear indicator
2 Vehicle speed sensor 38 Rear light
3 Front brake lever switch 39 Number plate light
4 Engine kill switch 40 LH rear indicator
5 Starter button 41 Alarm connector (accessory)
6 Engine control module 42 Starter motor ~
7 Oxygen sensor 43 Battery
8 Oil pressure switch 44 Starter solenoid
9 Purge valve 45 Main fuse
10 Fuel injector 3 46 Starter relay
11 Fuel injector 2 47 Rectifier/regulator
12 Fuel injector 1 48 Alternator stator
13 Secondary air injection solenoid 49 Rear fuse box
14 Fuel level sender 50 Front fuse box
15 Idle speed control actuator 51 Immobiliser
16 Fall detection switch 52 Ignition switch
17 Air temperature sensor 53 Headlight dip/main relay
18 Coolant temperature sensor 54 Clutch lever switch
19 Throttle potentiometer 55 Horn switch

20 Ambient pressure sensor 56 Direction indicator switch
21 MAP sensor 57 Pass light switch

22 Engine management relay 58 Headlamp dip switch
23 Neutral switch 59 LH front indicator
24 Resistor (330 Q) 60 Left hand Position light
25 Ignition coil 3 61 Left hand main light
26 Ignition coil 1 62 Right hand main light
27 Ignition coil 2 63 Right hand position light
28 Fuel pump relay 64 Horn
29 Fuel pump 65 Right hand front indicator
30 Cooling fan relay 66 Direction indicator unit
31 Cooling fan
32 Sidestand switch
33 Engine earth
34 Crankshaft sensor
35 Diagnostic connector

. ~"'
(::( ·. Circuit Diagram - Complete System - Models without ABS- up to VO 485952
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Electrical
Complete System - Speed Triple without ABS - from VIN 485953

1 rnstrument assembly 37 Right hand rear indicator
4 Engine kill switch 40 LH rear indicator
6 Engine control module 42 Starter motor
1l Fuel injector 2 47 Rectifier/regulator
14 Fuel level sender so Front fuse box
17 A ir temperature sensor 53 Headlight dip/main relay
18 I Coolant temperature sensor 54 Clutch lever switch

22 I Engine management relay 58 Headlamp dip switch
23 Neutral switch 59 LH front indicator
24 Resistor (330 Q) 60 Left hand Position light
25 , -Ignition coil 3 61 Left hand main light
26 Ignition coil 1 62 Right hand main light
27 Ignition coil 2 63 Right hand position light
28 ~ ~uel pump relay 64 Horn
2:9 Fuel pump 65 Right hand front indicator
30 Cooling fan relay 66 Direction indicator unit
31 Cooling fan
32 Sidestand switch
33 Engine earth
17.40 Se1Vice M _
anual - Speed Triple and Speed Triple R
Circuit Diagram - Comp~ete System - Moclle~s without ABS -from V~ 485953
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Electrical
Complete System ~ Speed Triple with ABS - up to VIN 490000 rr~~

. ·:.·. ·- ..-
~-
1 Instrument assembly 37 Right hand rear indicator

4 Engine kill switch 40 Left hand rear indicator
10 Fuel injector 1 46 Starter relay ~T ---1

··...~::·
_
17 Air temperature sensor 53 Headlight dip/main. relay
22 Engine management relay 58 Headlamp dip switch

{
59 Front whel speed sensor '·. : ___,,..
23 Neutral switch
24 Resistor (330 .Q) 60 Rear wheel speed sensor
25 Ignition coil 3 61 ABS modulator
26 Ignition coil 1 62 Left hand front indicator
27 Ignition coil 2 63 Left hand position light
28 Fuel pump relay 64 Left hand main beam
29 Fuel pump 65 Right hand main beam
30 Cooling fan relay 66 Right hand position light
31 Cooling fan 67 Horn
32 Sidestand switch 68 Right hand front indicator
33 Engine earth 69 Direction indicator unit
35 · Diagnostic connector

Circuit Dnagram - Complete Syst e m - Mode~s with ABS - up to VON 490000
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Electrical
r.--· -.. . .
Complete System - Speed Triple with ABS - from VIN 490001
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Key Item Description 36 Right hand rear indicator

1 Instrument assembly 37 Rear light
3 Engine kill switch 39 Left hand rear indicator
14 Idle speed control actuator so Immobiliser
16 Air temperature sensor 52 Headlight dip/main relay
19 Ambient pressure sensor SS Direction indicator switch
21 Engine mana~ement relay 57 Headlamp dip switch
22 Neutral switch 58 Front whel speed sensor
23 Resistor (330 m 59 Rear wheel speed sensor
24 Ignition coil 1 60 ABS modulator
25 Ignition coil 1 61 Left hand front indicator
26 Ignition coil 2 62 Left hand position light
27 Fuel pump relay 63 Left hand main beam
28 Fuel pump 64 Right hand main beam
29 Cooling fan relay 65 Right hand position light
30 Cooling fan 66 Horn
31 Sidestand switch 67 Right hand front indicator
32 Engine earth 68 Direction indicator unit
35 Rear brake lever switch

65f'
:"··:-:·
Circuit Diagram - Complete System - Models w ith ABS - from VD 490001
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57 56 55

Speed Triple Vin 461332 Onwards Speed Triple R

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Speed Triple Vin 461332 Onwards Speed Triple R

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SPEED TRIPLE

VIN 461332 ONWARDS

Part Number 3856544 issue 1, 11.2011

Engine Removal and Refit

Fuel System/Engine Management

Frame and Bodywork

Seivice Manual - Speed Triple and Speed Triple R iii

iv Seivice Manual - Speed Triple and Speed Triple R

Service Manual - Speed Triple and Speed Triple R v

vi Seivice M anual - Speed Triple and Speed Triple R

Tampering with Noise Control Repairs and Replacements

Service M anual - Speed Triple and Speed Triple R VII

This page intentionally left blank

viii Service Manual - Speed Triple and Speed Triple R

Service Manual - Speed Triple and Speed Triple R 1.1

Electrical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

1.2 Seivice Manual - Speed Triple and Speed Triple R

Clutch Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.49

Seivice Manual - Speed Triple and Speed Triple R 1.3

Ignition System Safety Precautions Third Party Products

1.4 Seivice Manual - Speed Triple and Speed Triple R

Oils Environmental Protection Precautions

Burning of used engine oil in small space heaters or

Any risk of eye injury must be avoided. Always wear eye

Setvice Manual - Speed Triple and Speed Triple R 1.5

Use only DOT 4 specification brake fluid as listed in the

Before installation, all internal brake components should

1.6 Service Manual - Speed Triple and Speed Triple R

Jacking and Lifting

Coolant mixture, which is blended with anti-freeze and

Do not remove the radiator cap when the engine is hot.

Seivice Manual - Speed Triple and Speed Triple R 1.7

Cleaning Components Liquid Gasket, Non-permanent Locking Agent

Joints and Joint Faces

1.8 Service M anual - Speed Triple and Speed Triple R

Locking Devices Oil and Grease Seals

Chassis Bearing Lubrication

Failure to replace an encapsulated bolt could lead to a Note:

Seivice Manual - Speed Triple and Speed Triple R 1.9

General Below/overleaf several common bearing types and the

3. Rotate the bearing to ensure that the grease is

Lubrication and Checks While Seivicing a Bearing

1. Disassemble parts as necessary to access the

1.10 Service Manual - Speed Triple and Speed Triple R

2. Rotate the bearing to ensure that the grease is

1. Disassemble the parts as necessary to access the

Seivice Manual - Speed Triple and Speed Triple R 1.11

Draining or extraction of petrol/gasoline from a vehicle

1. 12 Seivice Manual - Speed Triple and Speed Triple R

Connectors and Harness - The engine of a motorcycle is a Disciplines

reconnecting the battery, always connect the positive

Always ensure that battery leads are routed correctly and

Seivice Manual - Speed Triple and Speed Triple R 1.13

Electrical Testing For example, if a battery of 12 V is connected to a bulb

The ftow of current in a circuit (I) is measured in

1.14 Service Manual - Speed Triple and Speed Triple R

Circuit Diagrams Glossary of Circuit Diagram Symbols

A fuse is a device which protects a circuit in the event of a

Seivice Manual - Speed Triple and Speed Triple R 1.15

Ground or Earth Point Resistor

A relay is effectively an electromagnetic switch. To close

1.16 Seivice Manual - Speed Triple and Speed Triple R

Tracing Circuits To Check Continuity: