SMT-TN 160 1 Nov

Technical News 160
November 2014
Strictly Confidential
Contents
Item
Subject
Model Affected
Item 1.
Frame Bolt Tightening Sequence
Tiger Explorer and Tiger Explorer XC
Item 2.
New Harness and Harness/Gear Position
Sensor Parts Kit
Tiger Explorer and Tiger Explorer XC
Item 3.
Panniers
Trophy SE
Item 4.
Instrument Pack Washer
Various
Item 5.
Side Stand Fixing
All Thunderbird 1600 cc and
Thunderbird 1700 cc Models
Item 6.
Lower Yoke Pinch Bolt Tightening Sequence
All Models With Two Lower Yoke Pinch Bolts Per
Fork Leg
Item 7.
Update to Service Manual Full Specifications
Speed Triple, Speed Triple R from VIN 461332,
Sprint ST, Sprint GT, Tiger 1050 and Tiger Sport
Item 8.
Crankcase Spares Kit - Update to VIN
ranges specified in Technical News 151,
Item 11
Speed Triple, Speed Triple R, Sprint GT and
Tiger 1050
Item 9.
Sliding Caliper Seal Kit
Various
Technical News 160
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Item 1.
Description:
Frame Bolt Tightening Sequence
Models affected:
Tiger Explorer and Tiger Explorer XC
The frame bolt tightening sequence and torque figures have been updated for the above models. When
refitting an engine to the above models, follow the new frame bolt tightening sequence as described in the
procedure below:
Note:
•
When carrying out the cylinder head rework described in Technical News 144 (April 2013), the following
frame tightening procedure should be used when refitting the engine to the frame.
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it
from falling and causing injury to the operator or damage to the motorcycle.
Note:
•
•
Before starting this procedure, complete steps 1 to 6 of the engine installation procedure as described in
the Service Manual.
The swinging arm’s right hand pivot pin must be loosened before the frame bolts can be tightened.
1.
Carefully remove the cover from the swinging arm's right hand pivot pin.
2.
Using the service tool Lock Ring Wrench, 38 mm T3880062, remove the locking ring from the right hand
pivot pin.
1
2
T1053
1. Lock Ring Wrench, 38 mm T3880062
2. Locking ring
3.
Loosen the right hand pivot pin but do not fully remove.
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Note:
•
The following steps assume that the front cylinder head bolts are still temporarily fitted as described in
step 3 of the engine installation procedure in the Service Manual.
4.
Raise the rear of the engine and align the engine to the frame.
Frame Bolts Exploded View
2
4
1
5
3
6
1.
2.
3.
4.
5.
6.
Left hand front cylinder head bolt
Left hand rear cylinder head bolt
Right hand front cylinder head bolt
Right hand rear cylinder head bolt
Upper crankcase bolt
Lower crankcase bolt
5.
Temporarily fit the crankcase mounting bolts and washers to the left hand side of the frame.
6.
Remove the right hand front cylinder head bolt and washer and temporarily refit to the left hand side of
the mounting point.
7.
Lubricate the threads of the new rear cylinder head bolts only with a smear of proprietary high
temperature copper-based grease.
8.
Fit the new right hand rear cylinder head bolt ensuring that the spacer is fitted between the cylinder
head and frame. Do not fully tighten at this stage.
9.
Fit the new left hand rear cylinder head bolt. Do not fully tighten at this stage.
10.
Fit a new lock nut to the left hand front cylinder head bolt and tighten to 24 Nm.
11.
Tighten the left hand rear cylinder head bolt to 85 Nm.
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12.
Using tool Engine Mounting Adjuster Wrench T3880377, tighten the three adjusters in the following
sequence.
•
Tighten the lower crankcase adjuster to 5 Nm then, remove the lower crankcase bolt and washer and
refit to the right hand side of the frame.
•
Tighten the upper crankcase adjuster to 5 Nm then, remove the upper crankcase bolt and washer and
refit to the right hand side of the frame.
•
Tighten the cylinder head right hand front adjuster to 3 Nm then, remove the right hand front cylinder
head bolt and washer and refit to the right hand side of its mounting.
3
2
4
1
chma
1.
2.
3.
4.
Lower crankcase adjuster
Upper crankcase adjuster
Cylinder head front right adjuster
Adjuster
13.
Remove the support from beneath the engine.
14.
Fit new lock nuts and tighten in the following sequence:
•
Upper crankcase mounting lock nut to 100 Nm.
•
Lower crankcase mounting lock nut to 100 Nm.
•
Right hand rear cylinder head bolt to 85 Nm.
•
Left hand front cylinder head bolt and lock nut to 115 Nm.
•
Right hand front cylinder head bolt and lock nut to 100 Nm.
Note:
•
Continue from step 11 of the engine installation procedure as described in the Service Manual, omitting
the steps describing the removal of the swinging arm’s right hand pivot pin cover and locking ring (these
are completed by steps 1 and 2 of this procedure).
When ordering replacement parts, always refer to EPC.
Please mark your copy of the Service Manual and Technical News 144 (April 2013) with this information.
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Item 2.
Description:
New Harness and Harness/Gear Position Sensor Parts Kit
Models affected:
Tiger Explorer and Tiger Explorer XC
A new harness has been released for the above models from:
•
Engine number 679707 - All markets except Brazil
•
Engine number 680149 - Brazil market only.
This new harness is now connected directly to the gear position sensor without the use of a fly lead.
A harness and gear position sensor parts kit has also been released for use when replacing the harness on
the above models up to engine number 596480 that do not have the fly lead gear position sensor fitted.
Note:
•
•
•
•
From engine number 596481 a new gear position sensor and fly lead was introduced to the above models,
see Technical News 143 dated March 2013. A parts kit was also released, for earlier engines.
The new harness is retrofittable to earlier models without the fly lead fitted only when fitted together
with parts kit T2501116.
The new harness is retrofittable to earlier models fitted with the fly lead by removing the fly lead and
connecting the harness to the gear position sensor.
Refer to the following table when replacing either the harness or the gear position sensor on the above
models:
When Replacing
Gear position
sensor
Harness
On Tiger Explorer and Tiger Explorer XC Models
Use
Up to engine number 596480 without the fly lead for
the gear position sensor
Fly lead and gear position
sensor kit T1298294
From engine number 596481 with the fly lead for the
gear position sensor fitted
Gear position sensor
T1290660
Up to engine number 596480 without the fly lead for
the gear position sensor
Harness and gear position
sensor kit T2501116
From engine number 596481 with the fly lead for the
gear position sensor fitted
Harness T2501095
T2501116 - Kit, Harness and Gear Sensor - Tiger Explorer and Tiger Explorer XC up to engine number 596480
Parts Kit Contents
Parts Kit
T2501116
T1298294
Technical News 160
Parts Kit Contents
Part Numbers
Harness, Main
T2501095
Sensor, Gear Position
T1290660
Sensor, Gear Position
T1290660
Fly Lead, Gear Position Sensor
T25109955
O-ring
T3600267
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The gear position sensor pinpoint test procedure has also changed. The pinpoint test procedure for the new
gear position sensor and old gear position sensors with a fly lead is as follows:
Pinpoint Tests
Test
Result
Action
1
Check cable and terminal integrity:
OK
Disconnect sensor and proceed to test 2
- ECM pin B44
Faulty
Rectify fault, proceed to test 5
OK
Proceed to test 3
Short circuit
Locate and rectify wiring fault, proceed
to test 5
OK
Proceed to test 4
Open circuit
Locate and rectify wiring fault, proceed
to test 5
OK
Renew gear position sensor and contact
pin and proceed to test 5
Short circuit
Locate and rectify wiring fault, proceed
to test 5
OK
Action complete, quit test and run
engine
Fault still present
Contact Triumph service
- ECM pin B18
- ECM pin B23
- ECM pin B34
2 Check cable for short circuit:
- ECM pin B44 to ground
- ECM pin B34 to ground
- ECM pin B23 to ground
3 Check cable continuity:
- ECM pin B44 to sensor pin 1
- ECM pin B23 to sensor pin 2
- ECM pin B34 to sensor pin 4
- ECM pin B18 to sensor pin 3
4 Check cable for short circuit:
- ECM pin B34 to ECM pin B23
- ECM pin B34 to ECM pin B18
- ECM pin B34 to ECM pin B44
- ECM pin B23 to ECM pin B18
- ECM pin B23 to ECM pin B44
- ECM pin B44 to ECM pin B18
5 Reconnect harness, clear fault code
Circuit Diagrams
Old Gear Position Sensor with Fly Lead
Engine Electronic
Control Module
Gear Position
Sensor
1
2
3
4
3
1
2
BW
BK
KB
BW
BK
KB
B44
B23
B18
K
K
KB
GY
B34
B18
B36
New Gear Position Sensor
Gear Position
Sensor
K
K
KB
GY
1
2
3
4
BW
BK
KB
K
Engine Electronic
Control Module
BW
BK
KB
K
B44
B23
B18
B34
MAP Sensor
When ordering replacement parts, always refer to the EPC.
Please mark your copy of the Service Manual with this information.
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Item 3.
Description:
Panniers
Models affected:
Trophy SE
Panniers will not be supplied with the above models in the packing crate from VIN 657579. The panniers will
be delivered to the dealers separately.
The panniers will be supplied assembled with only the lock barrel to be fitted. To fit the lock barrel, follow the
procedure described below:
Note:
•
The lock barrel will only fit one way.
1.
Take a lock barrel and key (supplied with the motorcycle), insert the key into the barrel and push the
barrel into position in the pannier until it clicks into place.
2.
Check the operation of the lock barrel.
3.
Turn the key to the LOCK position and remove the key.
4.
Fit the lock barrel to the remaining panier in the same manner.
4
3
2
1
1.
2.
3.
4.
Key slot, shown in the locked position
Lock position symbol
Unlock position symbol
Release position symbol
To fit the panniers to the motorcycle, refer to the Motorcycle Assembly Guide.
Please mark your copy of the Service Manual with this information.
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Item 4.
Description:
Instrument Pack Washer
Models affected:
Various
Model
From VIN
Speed Triple and Speed Triple R - All Models
679575
Street Triple, Street Triple R, Street Triple 70 kW version and Street Triple 660 cc All Models
680475
Tiger Explorer and Tiger Explorer XC - All Models
678630
Tiger Sport
679575
A revised washer with an increased outside diameter has been introduced on the above models and is
retrofittable. If the instrument pack is removed or replaced for any reason, a larger 18 x 1.6 mm washer
should be fitted.
When ordering replacement parts, always refer to the EPC.
Note:
•
Models already in service need not be replaced unless the instruments have been loosened or removed.
1
2
1. Washer 18 x 1.6 mm
2. Grommet
Please mark your copy of the Service Manual with this information.
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Item 5.
Description:
Side Stand Fixing
Models affected:
All Thunderbird 1600 cc and Thunderbird 1700 cc Models
The torque figure for the side stand bolt on the above models has changed to 20 Nm and the side stand lock
nut has changed to 9 Nm.
Note:
•
Models already in service need not be retightened unless the fixings have been loosened or removed.
9 Nm
2
20 Nm
1
1. Bolt
2. Lock nut
Please mark your copy of the Service Manual with this information.
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Item 6.
Description:
Lower Yoke Pinch Bolt Tightening Sequence
Models affected:
All Models With Two Lower Yoke Pinch Bolts Per Fork Leg
A new lower yoke pinch bolt tightening sequence has been released for all models with two lower yoke pinch
bolts per fork leg.
The new tightening sequence is as follows:
1.
Tighten the upper pinch bolt to the torque specified in the Service Manual.
2.
Tighten the lower pinch bolt to the torque specified in the Service Manual.
3.
Retighten the upper pinch bolt to the torque specified in the Service Manual.
1
2
1. Upper pinch bolt
2. Lower pinch bolt
Please mark your copy of the Service Manual with this information.
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Item 7.
Description:
Update to Service Manual Full Specifications
Models affected:
Speed Triple, Speed Triple R from VIN 461332, Sprint ST, Sprint GT, Tiger 1050 and
Tiger Sport
We have identified that the following specifications detailed in the Service Manuals for the above models are
incorrect:
Tiger 1050 and Tiger Sport
•
Exhaust valve stem diameter.
Speed Triple and Speed Triple R from VIN 461332
•
Inlet valve guide bore diameter
•
Exhaust valve stem diameter
•
Exhaust valve guide bore diameter.
Sprint ST and Sprint GT
•
Exhaust valve stem diameter
•
Exhaust valve guide bore diameter.
The correct specifications for the items listed above are as follows:
Item
Exhaust valve stem diameter
Service limit
Inlet valve guide bore diameter
Service Limit
Exhaust valve guide bore diameter
Service Limit
All Models
4.995 - 4.970 mm
4.945 mm
5.000 - 5.015 mm
5.043 mm
5.000 - 5.015 mm
5.063 mm
Note:
•
The valve stem to guide clearance specifications are correct as detailed in the Service Manuals for all
models listed above.
Please mark your copy of the Service Manual with this information.
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Item 8.
Description:
Crankcase Spares Kit - Update to VIN ranges specified in Technical News 151, Item 11
Models affected:
Speed Triple, Speed Triple R, Sprint GT and Tiger 1050
The VIN range specified in Technical News 151, Item 11 has changed. When ordering crankcase spares kit
T1169090, refer to the VIN ranges listed below.
Crankcase Spares Kit
A new crankcase spares kit incorporating the components necessary for the sliding selector shaft
mechanism has been released for use with:
•
Speed Triple and Speed Triple R models from VIN 537881 up to VIN 562631.
•
Sprint GT and Tiger 1050 models from VIN 535379 up to VIN 562631.
The new crankcase spares kit has been released to ensure continued parts support for the models listed in
the VIN ranges above. The kit enables the conversion of non-sliding selector shaft models to the current
condition, where crankcase replacement is required.
Parts will no longer support old condition, non-sliding selector shaft crankcases and any replacement will be
the new condition.
Note:
•
•
New condition crankcases can be installed as described in the Service Manual.
The sliding selector shaft can be installed as described in Technical News 139, Item 1.
Crankcase Spares Kit Contents
Kit Part Number
Kit Contents
Part Numbers
Quantity
T1169090
Crankcase spares assembly
T1169111
1
Detent arm assembly
T1190115
1
Detent lever spring
T1190666
1
Keeper plate
T1190207
1
Dry seal plug, N.P.S.I. 3/8
T3450005
1
E-clip
T3500044
2
Selector shaft, sliding
T1191424
1
When ordering replacement parts, always refer to EPC.
Please mark your copy of the Service Manual with this information.
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Item 9.
Description:
Sliding Caliper Seal Kit
Models affected:
Various
A parts kit containing sliding caliper pin gaiters has been released. The kit can be used to replace sliding pin
gaiters on the calipers identified for the following models:
Models
Front
Caliper(s)
Rear
Caliper
America and Speedmaster EFI - All Models
•
•
Bonneville T100 EFI - All Models
•
•
Bonneville and Bonneville SE EFI from VIN 380777 - All Models
•
•
Scrambler and Thruxton EFI - All Models
•
•
Speed Triple and Speed Triple R from VIN 461332 - All Models
•
Sprint GT
•
Street Triple, Street Triple 70 kW version and Street Triple 660 cc from VIN 560477
•
Tiger 800 and Tiger 800XC - All Models
•
Tiger XRx and Tiger XCx
•
Tiger Explorer and Tiger Explorer XC
•
Tiger Sport
•
Trophy and Trophy SE
•
When servicing the brake calipers identified for the models listed above, inspect the sliding pin gaiters for
damage and replace if necessary using parts kit T2021707.
1
1
2
1. Sliding pin gaiters - Street Triple left hand front caliper shown
2. Kit T2021707
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Note:
•
•
Removal, disassembly, inspection, assembly and installation of brake calipers is as described in the
Service Manual for each model.
Always check for correct brake operation after installation of new braking system parts.
Warning
It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph
dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result
in reduced braking efficiency leading to loss of motorcycle control and an accident.
When ordering replacement parts, always refer to the EPC.
Please mark your copy of the Service Manual with this information.
Circulation
Initial and date when read and return to central file holder
Service
Manager
Parts Manager
Technical News 160
Sales Manager
Workshop
Supervisor
Technician 1
Technician 2
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