Académique Documents
Professionnel Documents
Culture Documents
Introduction
General Information
Scheduled Maintenance
Cylinder Head
Clutch
Crankshaft
Bevel Box and Drive Shaft
Balancer
Transmission
Lubrication
Engine Removal and Refit
Fuel System/Engine Management
Cooling
Rear Suspension
Front Suspension
'.,
Brakes
WheelslTyres
ii
Introduction
iii
Introduction
This manual is designed primarily for use by trained
technicians in a properly equipped workshop.
However, it contains enough detail and basic
information to make it useful to the owner who desires
to perform his own basic maintenance and repair
work. The work can only be carried out if the owner
has the necessary hand and special service tools to
complete the job.
A basic knowledge of mechanics, including the proper
use of tools and workshop procedures is necessary in
order to carry out maintenance and repair work
satisfactorily. Whenever the owner has insufficient
experience or doubts his ability to do the work, an
authorised Triumph dealer must undertake all
adjustments, maintenance, and repair work.
In order to perform the work efficiently and to avoid
costly mistakes, read the text and thoroughly
familiarise yourself with procedures before starting
work.
All work should be performed with great care and in a
clean working area with adequate lighting.
Aiways use the correct special service tools or
equipment specified. Under no circumstances use
makeshift tools or equipment since the use of
SUbstitutes may adversely affect safe operation.
Where accurate measurements are required, they
can only be made using calibrated, precision
instruments.
For the duration of the warranty period, an authorised
Triumph Dealer must perform all repairs and
scheduled maintenance.
To maximise the life of your Motorcycle:
iv
Note:
Introduction
Tampering with Noise Control
System Prohibited
References
References to the left-hand or right-hand side given in
this manual are made when viewing the motorcycle
from the rear.
Operations covered in this manual do not always
include reference to testing the motorcycle after
repair. It is essential that work is inspected and tested
after completion and if necessary a road test of the
motorcycle is carried out particularly where safety
related items are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with service limits where applicable.
During the period of running-in from new, certain
adjustments may vary from the specification figures
given in this manual. These will be reset by the dealer
at the 500 mile/BOO km service, and thereafter should
be maintained at the figures specified in this manual.
Edges
Watch for sharp edges, especially during engine
disassembly and assembly. Protect the hands with
industrial quality gloves.
When replacement parts are required, it is essential
that only genuine Triumph parts are used.
Safety features and corrosion prevention treatments
embodied in the motorcycle may be impaired if other
than genuine Triumph parts are fitted. In certain
territories, legislation prohibits the fitting of parts not
to the manufacturer's specification.
Tightening procedure
Generally, when installing a part with several bolts,
nuts or screws, they should all be started in their
holes and 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 (in 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.
Force
Common sense should dictate how much force is
necessary in assembly and disassembly. If a part
seems especially difficult to remove or install, stop
and examine what may be causing the problem.
Never lever a component as this will cause damage
both to the component itself and to the surface being
levered against.
~.
Introduction
vi
1 General Information
Table of Contents
Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-3
Dangerous Susbstances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-3
Fluoroelastomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-3
Oils............................................................................
1-3
1-3
1-4
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-4
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-5
1-5
1-5
1-5
1-6
1-6
1-6
1-6
1-6
1-6
1-7
1-7
1-7
1-7
1-7
1-7
1-7
1-7
1-7
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Petrol - Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Fuel tank removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Chassis repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7
1-8
1-8
1-8
Electrical Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-9
1.1
General Information
Replacement Parts . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service data
Specification
.........................................................
Service tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special service tools:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. ..
. ..
. ..
. ..
1-10
1-10
1-10
1-11
1-11
1-20
1.2
1-25
1-25
1-26
1-27
1-28
1-29
1-30
1-31
1-32
1-33
General Information
Ignition System Safety Precautions
Fluoroelastomers
Dangerous Susbstances
Oils
Many liquids and other substances used in motor
vehicles are poisonous and should under no
circumstances be consumed and should, as far as
possible, be kept from contact with the skin. These
substances among others include acid, anti-freeze,
asbestos, brake fluid, fuel, lubricants, and various
adhesives.
Always pay close attention to the
instructions printed on labels and obey the
instructions contained within. These instructions
are included for your safety and well-being.
NEVER DISREGARD THESE INSTRUCTIONS!
1.3
General Information
be aware of who your nearest first-aider is and
where the medical facilities are kept.
Brakes
Environmental Protection
Precautions
1.4
General Information
Coolant
Safety Instructions
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.
~.
1.5
General Information
Cleaning components
Lubrication
The majority of engine wear occurs while the engine
is warming up and before all the rubbing surfaces
have an adequate lubrication film. During assembly,
011 or grease (whichever is more suitable) should be
applied to any rubbing surface, which has lost its
lubrication film. Old grease and dirty 011 should be
cleaned off. This is because used lubricants will have
lost some lubrication qualities and may contain
abrasive foreign particles.
Use recommended lubricants. Some oils and greases
in particular should be used only in certain
applications and may be harmful if used in an
application for which they are not intended. This
manual makes reference to molybdenum disulphide
grease in the assembly of certain engine and chassis
parts. Always check manufacturer recommendations
before using such special lubricants.
Screw Threads
Metric threads to ISO standard are used.
Damaged nuts, bolts and screws must always be
discarded.
Castellated nuts must not be slackened back to
accept a split-pin, except in those recommended
cases when this forms part of an adjustment.
Do not allow 011 or grease to enter blind threaded
holes. The hydraulic action on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can
affect the torque reading.
Unless specified, threaded fixings must always be
fitted dry (no lubrication).
Gaskets, a-rings
1.6
General Information
Locking Devices
Always release locking tabs and fit new locking
washers, do not re-use locking tabs.
Always fit new split-pins of the correct size for the hole
in the bolt or stud. Do not slacken back castle nuts
when fitting split pin, except in those recommended
cases when this forms part of an adjustment.
Press
A part installed using a press or driver, such as a
wheel bearing, should first be coated with oil or
grease on its outer or inner circumference so that it
will locate smoothly.
Ball beari ng
When installing a ball bearing, the bearing race which
is an interference fit should be pushed by a suitable
driver. This prevents severe stress or damage to the
load carrying components. Press a ball bearing until it
touches the shoulder in the bore or on the shaft.
Press or drift seals to the depth of its housing, with the
sealing lip facing the lubricant to be retained if the
housing is shouldered, or flush with the face of the
housing where no shoulder is provided.
Encapsulated bolt
)
General
1.7
General Information
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 than air and will always fall to the
lowest ievel. It can readily be distributed throughout
any indoor environment by air currents, consequently,
even a small spillage of petrol (gasoline) is potentially
very dangerous.
Chassis repairs
1.8
General Information
Electrical Precautions
The following guidelines are intended to ensure the
safety of the operator whilst preventing damage to the
electrical and electronic components fitted to the
motorcycle. Where necessary, specific precautions
are detailed in the relevant sections of this manual
which should be referred to prior to commencing
repair operations.
Equipment - Prior to commencing any test procedure
on the motorcycle ensure that the relevant test
equipment is working correctly and any harness or
connectors are in good condition, in particular mains
leads and plugs.
Battery disconnecting
Before disconnecting the battery, switch off all
electrical equipment.
The ignition system produces extremely high
voltages. Do not touch any part of the ignition
system or any cables while the engine is running.
An electric shock caused by contact with the ignition
system may lead to illness, injury or death.
Disciplines
The battery contains harmful materials. Always
keep children away from the battery whether or not it
is filled in the motorcycle.
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 gasses causing a risk of
personal injury.
High Voltage Circuits - Whenever disconnecting live
H.T. circuits always use insulated pliers. Exercise
caution when measuring the voltage on the coil
terminals while the engine is running, high voltage
spikes can occur on these terminals.
1.9
General Information
Electrical wires
All the electrical wires are either single-colour or twocolour and, with only a few exceptions, must be
connected to wires of the same colour. On any of the
two-colour wires there is a greater amount of one
colour and a lesser amount of a second colour. A
two-colour wire is identified by first the primary colour
and then the secondary colour. For example, a yellow
wire with thin red stripes is referred to as a 'yellow!
red' wire; it would be a . red!yellow' wire if the colours
were reversed to make red the main colour.
Inspection
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, scratches, colour changes, deterioration,
seizure or damage of any nature.
Service data
The service data listed in this manual gives
dimensions and specifications for brand new, original
parts. Where it is permissible to allow a part to exceed
these figures, then the service limit is given.
The terms of the motorcycle warranty will be
invalidated by the fitting of other than genuine Triumph
parts.
Replacement Parts
1.10
Specification
Triumph are constantly seeking to improve the
specification, design and production of their
motorcycles and alterations take place accordingly.
While every effort has been made to ensure the
accuracy of this Manual, it should not be regarded as
an infailible guide to current specifications of any
particular motorcycle.
Authorised Triumph Dealers are not agents of
Triumph and have no authority to bind the
manufacturer by any expressed or implied
undertaking or representation.
General Information
Service tools
Special service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical
components in a practical manner without causing damage. Some operations in 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.
jali
~'
gahc
1.11
General Information
T3880250 - Diagnostic tool
"',,
T3880201 - Anti-rotation jig - alternator
1.12
General Information
T3880063 - Castle wrench - 31 mm
C=:::r=:::::RIliII!lilII@IIIIIIIIiIIIE:I!=:1:==J
""!l'
~'
""!l'
1.13
General Information
Full Specification
Rocket III
Engine
Arrangement
In line, longitudinal,
Displacement
2294 cc
Bore x Stroke
. ...
Compression Ratio
8.7:1
Cylinder Numbering
Number 1 at front
Firing order
1-2-3
Max. Torque
. . 101.6 x 94.3 mm
Cylinder Head
Vaive Head Dia
Valve Lift.
Valve Stem Dia
In
37.90 mm
Ex
32.30 mm
In
8.30 mm
Ex
8.30 mm
In
Ex
. . . . . . . . . .. .
1.982.26 mm (std)
90 0 inclusive
.43.2 mm (std)
Valve Clearance
In
Ex
In
0.10 - 0.15 mm
Ex
0.150.20 mm
28.015 - 28.035 mm
Ex
28.015 - 28.035 mm
In
27.97827.993 mm
Ex
27.978 - 27.993 mm
open
12 BTDC
close
28 ABDC
duration
220
Exhaust
open
.41 0 BBDC
close
11 0 ATDC
duration
232 0
1.14
General Information
Full Specification
Rocket III
Camshaft Run-out.
0.015 mm (std)
73.7 mm
Clutch/Primary Drive
Primary Drive
Type
Type
Wet, multi-plate
10
0.30 mm
3.72 - 3.88 mm
3.5 mm
Cable
2-3 mm
Piston/Crankshaft
Piston Diameter
Top
Second
Top
Second
Oil
Top
Second
Oil
~.
1.15
General Information
Full Specification
Rocket III
Crankshaft run-out
0.04 mm (std)
0.07 mm (service limit)
Transmission
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Gear Ratios
Primary
1.034:1
1sI.
2.929:1
2nd
1.947:1
3rd
1.435:1
4th
1.160:1
5th
0.964:1
Secondary
1.043:1
Final Drive
Final Drive Type. . . . . . . . . . . . . . . . . . . . .. .
Drive system
. . . . . . . . . . . . . . . . . . .. .
2.846:1
0.17 litres
Lubrication
Oil Capacity (incl. filter, dry fill). . . . . . . . . .. .
5.9 litres
5.4 litres
1.16
General Information
Full Specification
Rocket III
5.1 litres
Viscosity
10W/40 or 15W/50
Type
Ignition System
Type
Digital, inductive
Electronic Rev-Limiter
6,500 rpm
0.56 KO
0.9 mm
Fuel System
Fuel Type
25 litres
Submerged, electric
3.0 Bar
Modulated, vacuum
Idle Speed
800 rpm
Injector Type
Single nozzle
Throttle
Twin butterlly
Stepper motor
Control Sensors
Cooling System
Coolant Mixture
Anti-Freeze Type
Mobil Antifreeze
~'
1.17
General Information
Full Specification
Rocket III
3.2 litres
1.2 bar
. '"
85 C
Suspension
Front Fork Travel
. .............. . 120 mm
. .............. .89 mm
RearVVheeITravel
. .............. . 105 mm
Brakes
Front type. . . . . . . . . . . . . . . . . . . . . . . . . .. .
33.96 mm/30.23 mm
Disc Dia
"
320 mm
Disc Thickness. . . . . . . . . . . . . . . . . . . . . .. .
0.3 mm
14 mm
Recommended Fluid
"
DOT 4
Rear Type
"
"
.
32 mm
Disc Dia
316 mm
Disc Thickness. . . . . . . . . . . . . . . . . . . . . .. .
0.15 mm
12.7 mm
Recommended Fluid. . . . . . . . . . . . . . . . .. .
DOT 4
MT 3.5 x 17
0.5 mm
0.5 mm
150/80 R17
34 Ib/in'
1.18
MT 7.5 x 16
General Information
Full Specification
Rocket III
0.5 mm
0.5 mm
240/50 R16
42 Ib/in'
Frame
Frame Type
Tubular steel
Overall Length
2480 mm
Overall Width
880 mm
Wheelbase
1690 mm
Seat Height
740 mm
Castor
32
Trail
152 mm
Dry Weight
320 kg
Max. Payload
(rider, passenger, luggage & accessories)
235 kg
Electrical Equipment
Battery Rating
Alternator Rating
~.
1.19
General Information
Torque Wrench Settings
Cylinder head area
Application
Torque (Nm)
10
See text
15
18
See text
See text
10
Clutch
Application
Torque (Nm)
9
105
10
Application
Connecting rod big end bolts
See text
See text
See text
See text
45
Engine Covers
Torque (Nm)
Application
Clutch cover to crankcase
28 (M8)
9 (M6)
18
1.20
General Information
Transmission
Application
Torque (Nm)
12
12
23
9
27
12
145
Lubrication System
Application
Torque (Nm)
12
25
12
Sump to crankcase
Sump plugs (front and rear)
Oil pick up strainers to sump
25
15
10
12
15
Cooling System
Application
Torque (Nm)
10
Radiator to frame
4
2
10
~.
1.21
General Information
Fuel System, Exhaust System and Airbox
Application
Torque (Nm)
9
9
5
2
12
19
22
27
27
10
3
9
Rear Suspension
Torque (Nm)
Application
Swinging arm pivot bolt - fixed (left hand)
Swinging arm pivot bolt - adjustable (right hand)
Swing arm pivot bolt lock ring (right hand)
Rear suspension unit upper mounting bolt
Rear suspension unit lower mounting bolt
100
15
100
28
28
Front Suspension
Torque (Nm)
Application
20
22
30
65
45
35
26
3
Wheels
Application
Torque (Nm)
1.22
65
22
110
General Information
Front Brakes
Torque (Nm)
Application
Disc to wheel
40
18
5
25
15
25
22
Calliper to fork
Pad retaining pin (hexagon drive)
Calliper bleed screw
Hose to calliper
Master cylinder to handlebar
Hose to master cylinder
Rear Brakes
Torque (Nm)
Application
8
25
27
7
25
15
30
22
Application
27
27
40
20
25
10
1.23
General Information
Bodywork
Application
Torque (Nm)
See text
27
See text
Electrical
Application
Torque (Nm)
28
120
12
Indicators to brackets
2
15
20
1.24
General Information
Routings
Clutch Cable Routing
ccjy
~'
1.25
General Information
Handlebar Cable Routing
(
\
1.26
General Information
Main Wiring Harness Routing
1.27
General Information
Rear Mudguard Harness Routing
--------.........................
.-:--------
......
"\\\\
\'
ccjn
1.28
0\'
General Information
Front Brake Hose Routing
1.29
General Information
Rear Brake Pipe and Hose Routing
1.30
General Information
Throttle Cable Routing
~.
1.31
General Information
. . control versions)
.
Fuel Hose and Fuel Tank Breather Hose Routin 9 ( non-evaporative emISSion
1.32
General Information
Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing
~'
1.33
General Information
1.34
2 Scheduled Maintenance
Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . ..
2-2
2-3
2.1
Scheduled Maintenance
Introduction
To maintain the motorcycle in a safe and reliable
condition, the maintenance and adjustments outlined
in this section must be carried out as specified in the
schedule of daily checks, and also in line with the
scheduled maintenance chart.
Weather, terrain and geographical location affects
maintenance. The maintenance schedule should be
adjusted to match 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.
2.2
Triumph
Motorcycles
cannot
accept
any
responsibility for damage or injury resulting from
incorrect maintenance or improper adjustment
carried out by the owner.
Since incorrect or neglected maintenance can lead
to a dangerous riding condition, always have an
authorised Triumph dealer carry out the scheduled
maintenance of this motorcycle.
Scheduled Maintenance
2.4
Scheduled Maintenance
Scheduled Maintenance Chart
Odometer Reading in Miles (Krns) or time period,
whichever comes first.
Operation Description
Every
500
(800)
1 month
Engine - check for leaks
Day
10,000
(16000)
1 year
20,000
(32000)
30,000
(48000)
40,000
(64000)
50,000
(80000)
60,000
(96000)
2 years
3 years
4 years
5 years
6 years
Day
Coolant - renew
Fuel system - check for leaks
Day
Day
Day
Day
Day
Day
Every 2 years
Day
Day
Day
Day
Day
Day
2,3
3-2
3-3
3-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3-5
Cam Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
3-5
3-6
3-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
3-6
3-7
3-7
Camshafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3-9
Camshaft identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Cam sprocket orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
3-10
3-10
3-11
3-12
Valve Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14
, '" .. .. . . . ..
3-14
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-15
"
Inspection. .. .. . . .. . . . . . .. . . .. .. .. . . . . . . . .. .. . . .. .. . .. . . . ..
Installation .... " .. . . . . . .. . . .. .. .. .. .. .. . . . . . .. .. . . . .. ... ..
.. . . . . . . . .
.. . . . . . .. .
3-16
3-16
3-17
3-17
3-17
Cam Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3-18
Inspection
"
" ..
. . . . . . .. . . . .. .. ..
3-18
3.1
Cylinder Head
Exploded View - Cam Cover
r
'"
3.2
10Nm
Cylinder Head
Exploded View - Camshaft and Cam Drive
'(O~
18Nm
r2~
~'
(j
27Nm
/
~
3.3
Cylinder Head
Exploded View - Cylinder Head
SEE TEXT
SEE TEXT
10Nm
/)
i .r
10Nm
8Nm
@~
10Nm
3.4
Cylinder Head
7.
Description
1. Cam cover
2. Cam cover bolts
3. Bolt seals
8. Remove all the bolts and bolt-seals from the cam
cover.
9. Raise the cover and manoeuvre it towards the
right hand side of the engine, where it can be
removed.
Cam Cover
Removal
1.
2.
3.
4.
5.
6.
3.5
Cylinder Head
Installation
1.
2.
Removal
1.
2.
1. 'D' sections
3.
4.
5.
6.
7.
8.
9.
",q,
1. Inspection plug
3.
1
CbpS
1. Camshafts
2. Lobes
3. Valves
4.
Remove the center nut and washer from the cam
chain tensioner.
3.6
Cylinder Head
Installation
5.
1.
2.
1. Tensioner
2. Tensioner plunger
3. Pawl
3. Look into the inspection hole.
Rotate the
crankshaft clockwise (as viewed from the front),
until No. 1 cylinder is at TOC. No. 1 cylinder is at
TOC when a 'dot' mark on the crank gear is in
alignment with the line in the upper crankcase.
Inspection
1.
2.
~.
3.7
Cylinder Head
In addition, timing marks on the camshaft
sprockets should point downwards at a point
level with the cylinder head. If they do not align
as shown, turn the camshafts until they do align.
7.
cbpy
1. Tensloner
8. Fit a new washer to the tensioner's centre nut.
9. Fit the spring to the tensioner body. Fit the
centre nut and tighten to 23 Nm.
1. Tool T3BB0202
2. Cam sprocket holes
5. Fit the tensioner to the crankcase (ratchet teeth
facing upwards) ensuring the gasket is not
damaged during the process.
6. Fit and tighten the tensioner fixings to 9 Nm.
3.8
as
Cylinder Head
12. When the timing checks have been satisfactorily
completed, refit the inspection plug tightening it
to 18 Nm.
13. Refit the cam cover (see page 3.6).
3.
Camshafts
1.
Note:
1. Top pad
","
1. Camshafts
2. Lobes
3. Valves
2.
~.
1. Cam ladder
2. Cam ladder flxings (2 of 16)
3.9
Cylinder Head
Camshaft identification
6.
Note:
7.
,bqb
1. Removing a camshaft
8. Repeat for the second camshaft.
1. Sprocket
2. IN marking
3. EX marking
To fit a sprocket to an inlet cam, position the sprocket
to the cam and align the hole marked 'IN' with one of
the threaded holes in the camshaft. If both bolt-holes
in the cam line up correctly with the holes in the
sprocket, the sprocket is in the correct place. If the
holes do not line up, then the sprocket should be
rotated by a half-turn.
3.10
Cylinder Head
g) Finger-tighten the cam ladder bolts until the
under-head areas are in contact with the cam
ladder.
h) In the sequence shown below evenly and
progressively tighten the cam ladder bolts,
approximately half a turn each, until the cam
ladder is in full contact with the head.
Inspection
1.
2.
3.
4.
3.11
Cylinder Head
6.
Standard
0.040 - 0.091 mm
Service limit
0.13 mm
7.
I Standard
I 22,93 - 22.96 mm
8.
6.
Installation
1.
2.
3.
Located camshafts
Lubricate the cam bearing areas of the cam
ladder with a 50/50 solution of engine oil and
molybdenum disulphide grease.
""h
1. Cam ladder
2. Cam bearing areas
7.
8.
9.
4.
5.
3.12
Cylinder Head
10. In the sequence shown below evenly and
progressively tighten the cam ladder bolts,
approximately half a turn each, until the cam
ladder is in full contact with the head.
~.
14. Ease the cam chain away from the sprockets and
position the cams so that the timing marks align
as shown below. Allow the cam chain to drop
back onto each sprocket after positioning each
cam.
1. TooIT3880202
2. Cam sprocket holes
16. Refit and assemble the cam chain tensioner
plunger, spring and centre nut (see page 3.7).
17. Remove tool T3880202.
18. Turn the engine over at least four times, then
check the cam timing again. Reset as necessary
19. Check all valve clearances (see page 3.14).
Adjust as necessary to give the correct
clearances.
20. Refit the cam cover (see page 3.6).
3.13
Cylinder Head
Valve Clearances
Note:
1.
2.
3.
4.
Inlet
0.10 to 0.15 mm
Exhaust
0.15 to 0.20 mm
5.
Note:
1.
2.
3.
4.
5.
be
Note:
3.14
Cylinder Head
9.
Cylinder Head
1. Top hose
2. Bypass hose
8. Disconnect the coolant temperature sensor and
low oil pressure switch connections.
In-fill panel
10. Identify the position of each of the tappet buckets
and shims before removing them from the head.
11. Remove the sound suppression bolt from the
cam chain chest.
12. Progressively release the cylinder head bolts in
the order shown below.
"'"
~.
3.15
Cylinder Head
Inspection
Installation
1.
1.
2.
2.
3.
4.
of the
liner to
position
position
0.030 mm
3.16
.",,"
1. Dowels
5. Position a new cylinder head gasket to the
crankcase.
6. Lower the cylinder head over the cam chain
rubbing blades and locate it onto the dowels.
Cylinder Head
7.
2.
"""
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
collets
valve spring
Installation
1.
2.
3.
Note:
4.
5.
~.
3.17
Cylinder Head
7.
8.
Cam Chain
Inspection
An in-situ check can be made as follows:
1.
2.
3.
4.
""1'
3.18
1.
2.
3.
Cylinder Head
6.
4.
5.
~.
3.19
Cylinder Head
3.20
4 Clutch
Table of Contents
Exploded View - Clutch Controls .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4.2
4.3
4.4
Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
4.5
4.6
4.6
Clutch Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4.7
Removal. . ..
Installation
...
.. .. . .. .. .. .. . . . . . . .
. . . . .. .. .. . .. .. . . . .
. . . ..
4.7
4.7
Clutch. . ... .. . . ..
...
.. ..
.. .. .. .. .. . ..
..
4.7
.. ..
. . . ..
..
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4.7
4.9
Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9
4.9
~.
4.1
Clutch
Exploded View - Clutch Controls
15NmZ::
e~~
"
4.2
3Nm
3Nm
~
~-----'O
3Nm
Clutch
Exploded View - Clutch
4.3
Clutch
Exploded View - Clutch Cover
00
4.4
Clutch
4.
Clutch Cable
Removal
5.
1. Clutch Cable
2. Adjuster
1. Locknut
2. Lever adjuster
4.5
Clutch
6.
Installation
1.
2.
3.
Note:
4.
5.
1. Nut/locknut Slots
2. Cable Release Point
7. Remove the cable from the motorcycle noting the
cable routing, particularly where it passes
through steering area.
6.
7.
Note:
Examination
1.
2.
3.
4.6
1. Clutch Lever
2. Correct Setting, 2-3 mm
8. Reconnect the battery positive (red) lead first.
g. Refit the rider's seat.
Clutch
Clutch Cover
Clutch
Removal
Removal
1.
2.
3.
4.
5.
6.
7.
2.
Installation
Thoroughly clean the cover and crankcase
mating faces.
Position a new gasket to the crankcase.
Refit the cover ensuring that the gasket does not
become dislodged.
1.
2.
3.
Note:
4.
5.
6.
7.
1. Llfler piece
2. Needle bearing
3. Thrust washer
4.7
Clutch
4.
6.
7.
cl""
1. Friction Plates
2. Steel Plate
3. Anti-judder Seat Washer
4. Anti-judder Spring
Note:
5.
1. Centre Nut
2. Belleville washer
3. Plain washer
4. Inner Drum
5. Thrust Washer
8. Slide the clutch outer drum outwards from the
engine, collecting the bearing sleeve on removal
of the drum.
1. Outer drum
2. Bearing sleeve
4.8
Clutch
Friction Plate Inspection
Thickness
1.
1. Friction Plate
2. Feeler Gauge
3. Surface Plate
Assembly
3.72 - 3.88 mm
Service limit
3.5 mm
2.
I 0.30 mm
1.
2.
~.
4.9
Clutch
3.
1. Primary gear
2. Backlash eliminator
3. Crank gear
4. Arrowed; alignment hole
Note:
When the outer drum is correctly fitted and
the gears are pre-Ioaded correctly, the
bearing sleeve will be a flush fit with the
clutch drum face. In addition, a groove
around the input shaft will be visible.
4.
1.3880025-T0301
8. Disengage second gear and check for free
rotation of the clutch inner drum.
9. Coat all clutch friction plates in clean engine oil
10. Fit the friction plates, steel plates, anti-judder
seat and spring to the clutch basket, in the same
order as noted during removal.
Note:
1. Thrust washer
5. Fit the clutch inner drum.
6. Refit the plain washer, fit a new Belleville washer
('out' mark facing outwards), and refit the centre
nut.
4.10
Clutch
11. Refit the clutch pull rod.
Note:
4.11
Clutch
4.12
5 eran kshaft
Table of Contents
Exploded View - Crankshaft, Connecting Rod and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5-2
5-3
5-4
Crankcases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5-5
5-5
5-7
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5-9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
5-9
5-9
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10
Removal.. ..
. . .. ... .. .. ... . . . . .. . ... .. .. .. .. . . . . ... .. .. .. . . .. ... ... . . ..
Installation
..........................................................
Right hand (exhaust) side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10
5-10
5-11
5-12
5-13
5-13
5-13
5-14
5-15
Disassembly. . . . . . . . . . . . . . . . . . .
Piston Wear Check. . . . . . . . . . . . . .
Piston Rings/Ring Grooves. . . .. . ..
Piston Ring Gap. . . . . . . . . . . . . . . .
Piston Assembly. . . . . . . . . . . . . . . .
Cylinder Wear.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
.. ... .. .. .. .. .. ... ... .. .. .. . .... .. .. ...
. . ... .. .. .. .... ... ... .. . . .. ... .. .. . .. ..
.......................................
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5-15
5-15
5-16
5-16
5-16
5-18
Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
5-18
5-19
~'
.....
.....
. .. ..
.....
.....
5.1
Crankshaft
Exploded View - Crankshaft, Connecting Rod and Piston
cC
::
<:
<:
">
:>
LL
~~~
""
5.2
SEE TEXT
Crankshaft
Exploded View - Crankcase Fixings
====: :====
0
Itl
5.3
Crankshaft
Exploded View - Crankcase and Liners
~45Nm
Co
fj
fj
fj
lX:gi
5.4
Crankshaft
Crankcases
1.011 pipes
2. Remove the non-return valve from the scavenge
oil pump, by gently pUlling it outwards from its
location.
Note:
Removal
1.
2.
3.
4.
5.
10.2).
6.
7.
8.
1. Non-return valve
3. In the sequence shown below, release the bolts
securing the main bearing ladder to the
crankcases.
6
Disassembly
1.
~.
5.5
Crankshaft
4.
6.
5.
Note:
14
~~~"
Lk-!l<--"'IIU
___
7.
32
~-13
30
"
"
35
15
11
1. Dowel locations
8.
5.6
Crankshaft
Assembly
1.
2.
1. Dowels
3.
Sealer areas
""p
1. Main bearing ladder
2. Baffle
3. Baffle lugs
5.
5.7
Crankshaft
Stage 3
34
"
32
13
30
24
22
"
23
31
12
I.
25
"
20
35
27
19
10
15
11
5.8
Crankshaft
Installation
Crankshaft
Removal
1.
2.
3.
2.
3.
4.
""
Removing the balancer
4.
5.
5.
6.
7.
8.
~.
5.9
Crankshaft
Connecting Rods
Installation
Note:
Removal
Note:
The connecting rods and cap are etchmarked on one side to identify their
correct orientation. However, the cylinder
from which they are individually removed
should also be identified, using a laundry
marker or similar.
1.
2.
3.
4.
1.
2.
6.
7.
10.2).
3.
4.
5.
cbye
8.
9.
5.10
1. Liner
2. Sealer Area
Crankshaft
8.
9.
1. Piston
3880105-T0301.
2. Arrow
'M
1. Crankpin
2. Big End
5.11
Crankshaft
Connecting Rod Big End Bearing
Selection/Crankpin Wear Check
1.
3.
4.
5.
6.
7.
Crankpin diameter
Note:
2.
Note:
Standard
40.946 - 40.960 mm
Service limit
40.922 mm
Note:
0.065 - 0.035 mm
Service Limit
0.100 mm
5.12
Crankshaft
Connecting Rod Bearing Selection
Note:
White
Red
Crankpin
diameter
40.960 to
40.954
40.953 to
40.946
For Instance:
Crankpin diameter
40.958
Required Bearing
White
0.018 - 0.041 mm
Service limit
0.100 mm
2.
Note:
measurements for
all
Repeat the
connecting rods and their respective
crankpins. It is normal for the bearings
selected to differ from one connecting rod
to another.
43.092 - 43.108 mm
Service limit
43.068 mm
Note:
2.
Note:
5.13
Crankshaft
Compare the data found with the chart above to select bearings individually by journal.
Shell
Colour
White
Red
Red
Blue
Blue
Green
Crankcase
bore
diameter
46.105 to
46.097
46.105 to
46.097
46.114 to
46.106
46.114 to
46.106
46.123 to
46.115
46.123 to
46.115
Crankshaft
journal
diameter
43.108 to
43.100
43.099 to
43.092
43.108to
43.100
43.099 to
43.092
43.108to
43.100
43.099 to
43.092
For example:
Crankcase Bore
46.099 mm
43.095 mm
Bearing Required
BLUE
Standard
0.05 - 0.20 mm
Service limit
0.40 mm
Note:
Note:
5.14
Crankshaft
Note:
Pistons
Disassembly
1.
1.
Note:
2.
~/
7:::::S1iiiiiOi~==:;;;;::j-'h1iilOmm
Service limit
101.511 mm
3.
All cylinders
Note:
4.
5.
5.15
Crankshaft
Piston Rings/Ring Grooves
1.
2.
3.
",,,
3.
0.20 - 0.35 mm
0.55 mm
Second - standard
0.30 - 0.50 mm
0.675 mm
0.20 - 0.70 mm
0.875 mm
0.02 - 0.06 mm
0.16 mm
Second - standard
0.02 - 0.06 mm
0.16 mm
4.
1.
2.
service
Piston Assembly
1.
Note:
5.16
Crankshaft
7.
...
FRONT
=3
2.
3.
1. Top Ring
2. Second Ring
3. Steel Oil Control Rings
8. Oil Control Ring Expander
Note:
9.
1. Piston
2. Direction arrow
4.
5.
6.
5.17
Crankshaft
Cylinder Wear
1.
Cylinder Liners
Service limit
101.659 mm
Removal
1.
2.
3.
'///////////'
---
--
---+-
3
~/////~
Cbxz
gaep
2.
1. Tool T3880061
2. Locking nut
3. Extraction nut
5.18
Crankshaft
4.
Installation
1.
2.
3.
1. Cylinder liner
2. Studs
3. Head-bolt holes
5. Fully engage the bolt threads in the head bolt
holes. It is not necessary to fully tighten the
bolts.
6. Turn the locking nut clockwise until the rubber
sleeve on the tool tightly grips the bore of the
liner.
7. Turn the extraction nut clockwise sufficient to
raise the liner and break the seal between the
liner and crankcase.
Note:
8.
9.
1. Liner
2. Sealer Area
4. Apply a thin bead of silicone sealer to the liner to
crankcase mating face.
1ri-----L
1. Liner
2. Sealer area
5.19
Crankshaft
5.
Note:
6.
Note:
5.20
6.2
6.3
6.3
6.3
6.4
Bevel Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
6.4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
6.4
6.4
Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
6.5
6.1
6.2
1.
)
1. Bevel box
2. Flller/level plug
~.
2.
3.
4.
6.3
Removal
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.
1.
2.
3.
4.
5.
)
1. Bevel box
2. Drain plug
2. Remove the drain plug and allow the oil to fully
drain out.
3.
Installation
Note:
Note:
4.
5.
6.
7.
'5
\ (
ob"
1. Drive shaft
2. Swinging arm
3. Sleeve
1.
2.
6.4
Note:
Note:
4.
5.
6.
7.
Drive shaft
Drive shaft details can be found in the rear
suspension section on page 13.5.
6.5
6.6
7 Balancer
Table of Contents
Exploded View - Balancer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
7-2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3
Removal
, .. .. . . .. . . . . . . . . . . . . . . .. ..
Inspection.. . . .. .. . .. .. .. . . .. . . . . . .. .. . . .. .. .. .. .. .. . . . . . .. . . . . .. .. .. .. .. ...
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
7-3
7-4
7-4
7.1
Balancer
Exploded View - Balancer
7.2
Balancer
Introduction
In an engine with an even number of cylinders (i.e. 2,
4, 6 etc.), a piston on an upward stroke is always
counter-balanced by one on a descending stroke.
However, in an engine with an odd number of
cylinders, such as that fitted to the Rocket Ill, this
natural state of balance does not occur. Therefore a
balancer is fitted to the engine in order to control
irregular pulses caused by the odd number of
cylinders. Without a balancer, the engine would 'pulse'
each time the crankshaft rotated. This 'pulsing' would
be felt as a vibration which would amplify as engine
speed increases.
The balancer has the ellect 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.
1. Balancer
2. Crankshaft
4.
Removal
1. Balancer
2. Bearing
Note:
7.3
Balancer
Note:
Inspection
1.
2.
Assembly/lnstallation
Note:
Note:
Note:
1. Balancer shaft
2. Slot marks
1.
cbrh
7.4
Balancer
2.
3.
re,
1. Bearing dowels
2. Upper crankcase slots
1. Circlips
2. Grooves
4. Check that the balancer and crank dot marks are
still in alignment.
5. Assemble the crankcase halves as described on
page 5.7.
6. Refit the engine to the frame as described on
page 10.5.
7.5
Balancer
7.6
8 Transmission
Table of Contents
Exploded View - Input and Output Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
8-2
8-3
8-4
8-5
8-6
8-7
8-7
8-9
8-9
8-11
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
8-11
8-12
8-12
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
8-12
8-13
Output Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-14
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-15
8-15
8-16
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-18
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-19
8-20
8-20
8.1
Transmission
Exploded View - Input and Output Shafts
a~~
~oo
@.
000~
'~~Qb
~~
8.2
Transmission
Exploded View - Gear Change Mechanism
12Nm
8.3
Transmission
Exploded View - Gear Selector Mechanism
27Nm
9Nm
,~
6)
\
\,~
9Nm
cclg
8.4
Transmission
Exploded View - Torsional Damper Shaft Housing
28Nm
L~
28Nm
~lt
28Nm
~,
ti
28Nm
9Nm
TI@9H'
8.5
Transmission
Exploded View - Torsional Damper Shaft
185Nm
8.6
Transmission
Selector Shaft, Selector Forks and
Drum
6.
Removal
Note:
1.
2.
3.
4.
1. Selector shaft
2. 'c' clip
5. Insert an M6 bolt, hand tight only, into the thread
at the front end of the selector shaft.
8.7
Transmission
9.
cbyj
1. Selector drum
2. Detent wheel
1. Actuator shaft
Note:
8.8
Transmission
5.
Inspection
Inspect all springs for over-extension (Le.
abnormal gaps between coils). Replace as
necessary.
Inspect all seals for damage and distortion.
Renew as necessary.
Check the selector forks and selector grooves for
Renew
wear beyond the service limits.
components as necessary.
1.
2.
3.
Item
Standard
Selector fork
thickness
5.90
mm
6.00
5.80 mm
Selector
groove width
6.05
mm
6.15
6.30 mm
Fork to groove
clearance
0.05
mm
0.25
0.50 mm
Service Limit
Installation
1.
2.
1. Inner bearing
2. Selector drum
3. Fit the selector drum outer bearing, bearing
keeper plate and retain the plate using a new
screw. Tighten the screw to 12 Nm.
4. Apply Loctite 1305 to the threads of the spring
abutment bolt (if removed). Fit and tighten it to
23Nm.
1. Detent wheel
2. Selector Drum
3. Pin
4. Recess
6.
7.
1. Detent arm
2. Spring eye
3. Shaft
8. Position the assembly to the crankcase and part
engage it in its hole.
9. Locate and hold the ball-end of the gear change
actuator arm in the actuator.
8.9
Transmission
10. Feed the gear change shaft through the
crankcase, engaging it in the actuator arm and
also attaching the free end of the detent arm
spring over the spring abutment bolt. Ensure that
the gear change return spring also engages over
the spring abutment bolt.
The
13. Place the transmission in neutral.
transmission is in neutral when the wheel of the
detent arm rests in a tooth on the detent wheel
that has a V-shaped cut-out.
=="'='=="'==-
Note:
If a new bolt cannot be sourced, clean the
threads of the old bolt and apply a spot of
three-bond 1305 to the threads before
fitting it.
12. Refit the input shaft as described on page 8. 13.
Note:
1. Selector forks
2. Selector drum
3. Selector shaft
16. Feed the selector shaft through the selector forks
and secure it with a new 'C' clip.
17. Assemble the crankcases as described on page
5.7.
18. Refit the engine as described on page 10.5.
8.10
Transmission
Torsional Damper Shaft
5.
6.
Removal
1.
2.
3.
8.11
Transmission
Installation
1.
Note:
Note:
2.
3.
4.
5.
6.
Removal
Note:
1.
2.
Note:
3.
4.
Note:
8.12
Transmission
5.
4.
5.
1. Torx fixings
2. Notches
3. Stake marks
6. Refit the selectors and shaft as described on
page 8.9.
7. Refit the output shaft to the crankcase ensuring
the snap-ring on the outside of the inner bearing
locates in their corresponding groove in the
crankcase.
1. M6 bolts
2. Bearing housing
7. With the bearing housing released, withdraw the
input shaft through the aperture for the bearing
housing.
Installation
1.
2.
3.
8.
~.
9.
8.13
Transmission
Output Shaft
1. Ball bearing
2. Thrust washer
3. First gear
4. Needle roller bearing
5. Thrust washer
6. Fifth gear
7. Clrcllp
8. Thrust washer
9. Fourth gear
10. Third gear
11. Spllned bush
12. Thrust washer
13. Circlip
8.14
Transmission
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to the
hand, arms or other parts of the anatomy.
Disassembly
Note:
13.
-...--...
1. Press
2. Output shaft
3. Centre bearing
15. Press the shaft through the bearing.
Inspection
1.
~.
8.15
Transmission
Assembly
Note:
Note:
1. Output shaft
2. Bearing
3. Clrclip groove
4. Press bars
2. Locate the output shaft (19) to the bearing, with
the threaded end pointing through the bearing
(i.e. away from the press).
3. Press the output shaft through the bearing until
the shoulder in the centre of the shaft contacts
the bearing face.
4.
1.
5.
6.
8.16
Transmission
7.
8.
ttbh
1. Second gear
2. Circlip
9. Fit the splined dog ring (14) to the shaft.
10. Retain the dog ring with a new circlip (13),
orientating the circlip as shown below.
13. Fit the thrust washer (8), then a new circlip (7),
orientating the circlip as shown below.
1. Third/fourth gear
2. Circllp
14. Fit fifth gear (6) to the shaft, followed by the
thrust washer (5).
15. To complete assembly of the output shaft, fit the
needle roller bearing (4), first gear (3), thrust
washer (2) and bearing (1).
1. Dog ring
2. Clrclip
11. Fit the thrust washer (12) and splined bush (11).
12. Slide third and fourth gears (10 and 9) onto the
splined bush.
~.
8.17
. n
Transmisslo
Input Shaft
12
/)0 9.
~~
ccbk
8.18
8 Fifth gear
g. Fifth gear bush
. Thrust wa sher
10.
11 Circlip
r
12.. Thirdlfourth gea
13. Circllp
14. Se C ond gear
15. Circlip
Transmission
9.
Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
Note:
=~><
1. Press bars
2. Bearing/housing
10. Remove the snap-ring from the bearing housing.
""m
Pressing out the bearing
8.19
Transmission
Inspection
1.
2.
Caution
Assembly
Note:
Note:
The circlips used on the input shaft have a
flat side and an angled side. Illustrations
throughout the assembly text indicate
which orientation of each circlip is correct.
1. Bearing housing
2. Bearing
3.
When using a press, always wear overalls, eye face
and hand protection. Objects such as bearings
frequently break-up under ioad and the debris
caused during break-up may cause damage and
injury to unprotected parts of the body.
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to the
hand, arms or other parts of the anatomy.
8.20
1. Shaft
2. Bearing/housing
3. Press bars
5.
Transmission
6.
7.
1. Thrust washer
2. Belleville washers
3. Bush
8. Fit fifth gear (8) and the fifth gear thrust washer
(10).
9.
1. Thircllfourth gear
2. Circlip
12. Slide on second gear (14).
13. Retain second gear with a new circlip (13),
orientating the circlip as shown below.
1. Second gear
2. Circllp
1. Fifth gear
2. Fifth gear thrust washer
3. Circllp
10. Fit the third/fourth gear (12) to the shaft.
~.
8.21
Transmission
8.22
9 Lubrication
Table of Contents
Exploded View - Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
9-2
9-3
9-4
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Scavenge System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
9-4
9-4
9-4
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
9-6
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Triumph Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Inspection
Oil and Oil Filter Change. .. .. . . .. . .. .. .. .. . . . . . .. .. . . . .. . . .. . .. . .. .. .. .. . ..
Disposal of Used Engine Oil and Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6
9-6
9-6
9-7
9-8
9-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Installation
9-10
Sump. . . .. .. . . .. . . ..
.. .
.. .. . .. .. .. . . . .. . . ..
.. .. .. .
.. . . . . . ..
.. ..
9-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
.................................
9-10
9-10
9-11
Oil Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-11
~~~
~11
Inspection. . . . .. . . .. .. . . . .. .. .. . .. . . .. . . ..
.. ..
.. .. . ..
.. ..
'" . .. .. ..
.. . .. .. . .
Installation
Oil Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
'" .. . . . ..
.. .. . .
Oil Pressure Relief Valve
9-13
9-14
9-15
9-15
Oil Tank
'" .. .. .. . . . . . .. .. . . . .. .. .. .. . .. .. . . . . . . ..
. . .. . .. ..
Removal
,
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
Oil Transfer Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
9-16
9-16
9-16
9-16
9-16
9.1
Lubrication
Exploded View-Sump
..
..
i
12Nm
~
q
..
..
sb6J~~ . . o: : : : :~<;"')
..
jffo@
25Nm
@f((t)
22 Nm
12Nm
}~
12 Nm
9.2
25 Nm
'\
25Nm
Lubrication
Exploded View - Oil tank, filter and pumps
28Nm
/~
13 Nm
~'
~~~\
12Nm
9.3
Lubrication
Oil Circuit
General Description
The Rocket III utilises a dry sump iubrication system
whereby a pressure pump takes oil from an oil tank
and delivers oil under pressure to the engine and
transmission. A scavenge pump coliects oil from the
sump and returns it to the oil tank.
The oil tank is attached to the upper crankcase on the
ieft hand side of the motorcycle. Situated within the
lower crankcase, the pressure pump is gravity fed
from the oil tank via an internal drilling. An oil tank
drain plug is situated at the lowest point in the drilling,
in the sump itself.
Scavenge System
Pickups from the double-ended scavenge pump
coliect oil from the front and rear of the sump and
return it to the oil tank. Further drain plugs are fitted to
the front and rear of the sump to drain residual oil
from the sump.
Pressure System
9.4
Lubrication
PRESSURE SYSTEM
SCAVENGE SYSTEM
~'
9.5
Lubrication
Oil Level Inspection
Engine Oil
Specification
Use a semi or fully synthetic 10W/40 or 15W/50
motorcycle engine oil which meets specification API
SH (or higher) and JASO MA, such as Mobii 1 Racing
4T (fully synthetic) or MobilExtra 4T (semi synthetic).
l~~~~
""
--\---j
1. Oil tank
2. Oil tank cap
3. Dipstick
4. Maximum mark
5. Minimum mark
2.
Note:
3.
9.6
~.
Lubrication
4.
5.
6.
2.
Note:
1.
3.
4.
7.
9.7
Lubrication
8.
1. Oil filter
2. Oil filter cover
9. Position the oil drain pan beneath the oil filter.
10. Unscrew and remove the oil filter using Triumph
service tool T3880312. Dispose of the old filter
in an environmentally friendly way.
)
Disposal of Used Engine Oil and Oil Filters
To protect the environment, do not pour oil on the
ground, down sewers or drains, or into watercourses.
Db not place used oil filters in with general waste. If in
doubt contact your local authority.
1. Tool T3880312
9.8
Lubrication
Low Oil Pressure Warning Light
Switch
6.
Note:
7.
8.
11.104.
9.
~.
9.9
Lubrication
Installation
1.
Sump
Removal
1.
2.
7.
8.
4.
Inspection
If the oil pick-ups are removed, always use new pickup bolts during reassembly. Use of the original bolts
may lead to pick-up detachment leading to severe
engine damage.
9.10
Lubrication
1.
Oil Pumps
Note:
Two oil pumps are fitted to this model. A
pressure pump to supply oil under
pressure to various parts of the engine,
and a twin-rotor scavenge pump to return
oil to the oil tank from the sump.
"""
1. Oil pick-ups
Installation
1.
2.
3.
4.
5.
Note:
1.
2.
9.11
Lubrication
3.
6.
1. Mesh filter
7. Separate the crankcase halves as described on
page 5.5.
8. Release the screws that secure the scavenge
pump to the lower crankcase.
P"""":P)~~ab'~~
I~~~
G
)
9.12
L.
~@~
~,I
Lubrication
9.
1. Scavenge pump
1.
2.
Inspection
Standard
Service limit
0.15 mm
0.30 mm
0.15
mm
0.22
0.02
mm
0.07
0.35 mm
0.10 mm
5.
9.13
Lubrication
Installation
4.
Fill the oil pumps with new engine oil, turning the
pump rotors as the oil is poured into the pump.
Position the scavenge pump to the crankcase
and engage it to the mounting dowels. Ensure
the drive blade is facing towards the front of the
engine.
1. Scavenge pump - drive blade
1. Mounting dowels
3. Fit and tighten the scavenge pump screws to
12Nm.
1. Mesh filler
6. Fit and tighten the pressure pump and spray bar
screws to 12 Nm.
7. Assemble the crankcase halves as described on
page 5.7.
9.14
Lubrication
8.
1. Pump sprocket
2. Drive sprocket
3. Chain
4. "OUT" mark
9.
~.
9.15
Lubrication
Oil Tank
Installation
1.
Removal
1.
2.
3.
2.
3.
4.
5.
6.
7.
8.
6.
Inspection
1.
2.
3.
9.16
Tb_v'
~
10.2
10.5
10.1
2.
3.
4.
5.
6.
7.
8.
system
1. Heel guard
2. Heel guard flxings
17. Remove the clip from the rear brake pedal c1evis
pin. Remove the clevis pin.
as
Note:
9.
1. Pedal
2. Pushrod
3. Clevis
10.2
=-----=!~
Note:
It is not necessary to disconnect the brake
pipe from the master cylinder.
19. Unclip the brake pipe.
/fL
\ 11
1. Brake Pipe
2. Clips
20. Remove the heat shield from the brake pipe joint.
r-,.
10.3
its
cbsi
1. Breather hose
2. Clip
Note:
Battery earth
10.4
Installation
Note:
1.
2.
Battery earth
5.
3.
10.5
cbue
"'"'
1. Selector rod
2. Gear change crank
3. Pinch bolt
1. Pedal
2. Pushrod
3. Clevis
4. Clip
10.6
lr---\-~
"
Z))
H~~
1. Heel guard
2. Heel guard IIxlngs
---_!J>
- ~~i!=j~,"~~~~:={
1. Brake pipe
2. Clip
~'
10.7
10.8
11.7
11.8
11.9
11.10
11.11
11.12
Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.13
11.13
11.13
Oxygenated Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.13
Ethanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.13
Methanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.13
11.13
Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
Air temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
ATDC
11.14
Barometric pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
Battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
BTDC
11.14
Catalyst. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
Coolant temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
11.14
DTC
11.14
ECM
11.14
Engine speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
Freeze frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
Idle fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
Ignition advance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
11.1
Ignition timing
"
11.16
System Description
System Sensors
Sensor Locations
11.16
11.16
11.17
11.18
11.19
System Actuators
Actuator Locations
11.21
11.22
Current Data
Freeze-frame Data
Function Tests
Checks/Adjustments
Adjustments
Adaption status
Build data
Checks
11.22
11.22
11.23
11.23
11.24
11.24
11.24
11.24
11.24
11.25
11.26
11.28
11.28
11.2
11.20
11.28
Electrical Connectors
11.58
Before Disconnection:
11.58
11.58
11.58
11.58
11.58
11.59
Further Diagnosis
11.59
Crankshaft Sensor
11.60
11.60
11.62
11.62
11.64
11.64
11.66
11.66
11.68
11.68
11.70
11.70
11.72
11.72
11.74
11.74
11.76
11.76
11.77
11.77
11.78
11.78
Tachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
11.79
Pinpoint Tests
Idle Speed Conrol
Pinpoint Tests
Fuel Injectors
Pinpoint Tests
Throttle Position Sensor
Pinpoint Tests
Purge Valve
Pinpoint Tests
Ignition Coils
Pinpoint Tests
Coolant Temperature Sensor
Pinpoint Tests
Inlet Air Temperature Sensor
Pinpoint Tests
Fuel Pump Relay
Pinpoint Tests
System Voltage
Pinpoint Tests
Cooling Fan Relay
Pinpoint Tests
Pinpoint Tests
Coolant Temperature Indication
Pinpoint Tests
Vehicle Speed Output.
Pinpoint Tests
Lambda Sensor
Pinpoint Tests
Lambda Sensor Heater.
11.79
11.80
11.80
11.81
11.81
11.82
11.82
11.83
11.3
11.83
EEPROM Error
11.84
11.85
Pinpoint Tests
11.85
11.86
11.86
11.88
11.88
11.90
Pinpoint Tests
11.90
11.91
Pinpoint Tests
11.91
Pinpoint Tests
11.92
11.93
Pinpoint Tests
11.93
11.94
Pinpoint Tests
11.94
11.95
11.95
11.96
11.96
11.97
Fuel Tank
11.98
11.98
11.99
11.100
11.101
11.101
.
"
Inspection
Assembly
Installation
Electrical connections
'.'
Installation
Air Filter
"
Assembly
11.105
11.106
11.109
11.111
Removal.
11.101
11.103
11.103
11.104
11.105
Removal.
11.4
11.92
11.111
11.112
11.112
Removal
Installation
11.112
11.112
11.113
Removal
Installation
11.113
11.113
11.113
Removal
Installation
11.113
11.113
11.114
Removal
Installation
11.114
11.114
11.115
Removal
Installation
11.115
11.115
11.116
Removal
Installation
11.116
11.116
Throttle Cables
11.117
Removal
Examination
Installation
11.117
11.118
11.118
11.119
11.121
11.121
11.122
Installation
11.122
11.123
11.125
Removal
Assembly/installation
11.125
11.126
11.126
Removal
Installation
11.126
11.127
11.128
Removal
Installation
11.128
11.128
11.130
Removal
Installation
11.130
11.130
11.133
11.133
~.
11.5
Terminology
Typical Values
Fault Indications
Exhaust System
11.134
Removal.
Installation
11.134
11.136
11.138
Component Locations (all situated behind the left hand side cover)
11.138
11.138
11.139
11.140
11.6
11.133
11.133
11.133
11.134
11.7
tftc
~
1--'
15
;!
Nrr.-! L
..
L...
11.8
*4a
~r--,
---J
"-5Nm
5Nm
3.5Nm
6Nm
~'
11.9
~~.
9Nm
1-1.5 Nm
11.10
~~ee
7Nm
11.11
00
11.12
Fuel Requirements
Fuel Requirements - all countries except USA
Outside America, the Rocket III must be run on 95
RON unleaded fuel.
Oxygenated Gasoline
To help in meeting clean air standards, some areas of
the U.S. use oxygenated gasoline to help reduce
harmful emissions. The Rocket III will give best
performance when using unleaded gasoline.
However, 'the following should be used as a guide to
the use of oxygenated fuels.
Ethanol
Ethanol fuel is a mixture of 10% ethanol and 90%
gasoline and is often described under the names
'gasohol', 'ethanol enhanced', or 'contains ethanol'.
This fuel may be used in Triumph motorcycles.
11.13
DTC
The following
this section.
what some
abbreviations
ECM
Engine Control Module.
Air temperature
The air temperature in the air box and intake hose.
Engine speed
The crankshaft revolutions per minute.
Freeze frame
A data set captured at the time a Diagnostic Trouble
Code (DTC) is set.
ATDC
Idle fuel trim
Barometric pressure
Pressure of the air in the airbox.
Idle fueling
Battery voltage
BTDC
Before Top Dead Centre (TDC).
Catalyst
Ignition advance
Coolant temperature
Ignition timing
11.14
MIL
Short circuit
Neutral switch status
The 'neutral' or 'in gear' status of the gearchange.
Open circuit
A break in an electrical circuit - current cannot flow.
Sidestand status
The 'up' or 'down' position of the side stand.
Over temp
High temperature within the Electronic Control
Module (ECM) caused by an internal or external
failure.
Throttle position
Throttle voltage
Vbatt
Battery voltage.
11.15
System Description
The Rocket III is fitted with an electronic engine
management system which encompasses control of
both ignition and fuel delivery. The electronic control
module (ECM) draws information from sensors
positioned around the engine, cooling and air intake
systems and precisely calculates ignition advance
and fueling requirements for all engine speeds and
loads.
In addition, the system has an on-board diagnostic
function. This ensures that, should a malfunction
occur in the engine management system, the
malfunction type, and engine data at the time the
malfunction occurred, are stored in the ECM memory.
This stored data can then be recovered using a
special service tool which is mandatory for all Triumph
dealers. In this way, precise diagnosis of a fault can
be made and the fault quickly rectified.
System Sensors
11.16
CLUTCH SWITCH
PRIMARY THROTTLE
POSITION SENSOR
\
SECONDARY THROTTLE
POSITION SENSOR
ooJi
COOLANT
TEMPERATURE
SENSOR
SIDE STAND
SWITCH
MANIFOLD ABSOLUTE
PRESSURE SENSOR
INTAKE AIR
TEMPERATURE SENSOR
oolh
CRANKSHAFT
POSITION SENSOR
11.17
11.18
Note:
INJECTORS
FALL DETECTION
~~~~~~SWITCH
~x:
.=
o
"'~
MAIN POWER
RELAY
CANISTER PURGE
VALVE
""'i
FUEL PUMP
\~
COOLING FAN
~~
ccdg
IGNITION COILS
11.19
Key
Item Description
Code
Wiring Colour
Black
Diagnostic Connector
Blue
Brown
Sidestand Switch
Green
Instrument Assembly
Slate/Grey
Orange
7
8
Clutch Switch
Pink
Starter Relay
Red
10
Purple
11
White
12
MAP Sensor
Yellow
13
LG
Light Green
14
Lambda Sensor
LU
Light Blue
15
Cooling Fan
16
17
18
19
20
Ignition Coils
21
22
23
24
25
26
27
Fuel Injectors
28
29
30
Crankshaft Sensor
11.20
B
B9
A
lkB1
:~:~~~~~
If\i5000000000
B34 -=-(JOoogoooy
I'
B26
A7Ji
11
Al
~~~~A8
Ooooooclflll A14
ooooooOif/1f
\~!TA20
A26
16
,-----17
r8-~
AlO
30
[J}=up-
-A14
UB- -AB
A18
NK-
"
GK-
3
21-KB-
23
c--- GN-
11
13
817
816 - O B
16
81' f--R
8" f--VW
15
811
f - - o w - 807
f - - O I I - 811
12 I - - - O K - 803
KG-
14 t - - K G - A09
IIW-
16
22
L.--BY-
17
>--KO -
t---GY~
AOO
A26
A25
KG
~7
f--BJ(
f--80~8
8
19 :
I
I
I~
;,;
111
,
1 6
11
.,.
.1
~'
I~l
816
1
2
1
All f--KP
A07
A2'
Aex,
11
KB-2
12
\KB
An
f--'O
Bll
,,-
802
BY-
810
15
-W
IlOB - 8
809 - 8
~ 13
1
All - 8
PW
10
l~~=~
001
I-KG-
K-l
"1
8"
AOl f--KS
16
"T
~~
r-'ID
Bl1
20
N,J7
GP-
NK~GB-
18
,---<B'
~:~GK~
K
I
I
I
7 I
----[[=:J 6
AIO
19 f - - ' -
~~K-----4:Zr-YR -
,---
83<1 f--KG
21
I
I
18 f--KB-
,-
--'-
/'
18
81' f--YN
GY-
.l
A19 I---BW->---BW- 11
A02
~I--K-
3
2 l-KB-
Bl2 -110
C---GW- 8"
c---IIW-
..
9 t - - - O N - B2l
10
OK-
BB
80S
KB-
2
1
24
-yp-
7 t - - - G U - 812
8 t - - - G K - B04
lA'O N
OW-25 8
OUD'
-YI(-
S
6
lA'G N
-GW
D'
, C---YD-
GU-
1 -NK-
3
1
2
28
26
40-
1
2
l
14
r"'- ,
1
11.21
System Diagnostics
The engine management system has an on-board
diagnostics feature which allows service technicians
to retrieve stored data from the ECM using a Triumph
service tooi. Full details of the tool's operation and
how to interpret the results are given elsewhere in
this section.
The tooi is connected to the motorcycle using a
dedicated diagnostic plug situated beneath the seats.
By using a dedicated plug, no electricai connectors
associated with the system are disturbed, reducing
potential connector damage.
The tool 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.
Note:
11.22
Freeze-frame Data
Function Examined
Engine speed
Result Reported
(Scale)
RPM
Calculated load
Coolant temperature
QC
Throttle Position
QC
Vehicle speed
Ignition Advance
km/h
degrees
volts
mm/hg
RPM
Calculated load
Coolant temperature
QC
Throttle Position
QC
Vehicle speed
Ignition Advance
Result Reported
(Scale)
km/h
degrees
volts
mm/hg
11.23
Adaption status
Function Examined
Report Method
Instrument panel
Visual
inspection
instruments
Function Examined
adaptedlnot adapted
control
Idle
speed
stepper motor
control
Cooling fan
Stored fault
operation
2nd
throttle
stepper motor
If a fault
IS
controi
of
code'/fan
Idle
speed
adaption status
Report Method
Build data
The following items of build data can also be read .
detected.
Function Examined
Vehicle identification Number (VIN)
Checks/Adjustments
11.24
Result Unit
numeric
numeric
milliseconds
milliseconds
milliseconds
milliseconds
degrees BTDC
degrees BTDC
degrees BTDC
degrees BTDC
Item Checked
Result Unit
% open
pressure
Volts
pressure
sensor
Atmospheric pressure
Volts
mmHg
Volts
mmHg
Battery voltage
Volts
Volts
Coolant
voltage
temperature
sensor
Volts
milliseconds
milliseconds
milliseconds
milliseconds
'othe~
is:
Volts
Item Checked
Volts
MIL off/on
Volts
Fan offlon
Volts
Starter on/off
Normal/over
% open
Heater on/off
Volts
SAlon/off
Volts
Engine rpm
RPM
Volts
Vehicle speed
kmlh
Volts
2nd throttle
voltage
position
sensor
Calculated load
Idle reference speed
Idle speed control target steps
Purge valve duty cycle
Result Unit
+1-100%
%
RPM
numeric
Gear position
numeric value
Neutral switch
Gear/neutral
On/off
11.25
Fault Description
MIL
Number of
no-fault
cycles
before
DTCis
erased
Number of
no-fault
cycles
before
turning off
MIL
illuminated
when fault
is logged
P0201
40
Yes
P0202
40
Yes
P0203
40
Yes
P1201
40
Yes
P1202
40
Yes
P1203
40
Yes
P0335
40
Yes
P0032
40
Yes
P0031
40
Yes
P0030
40
Yes
P0136
40
Yes
P0122
40
Yes
P0123
40
Yes
P0107
40
Yes
P0108
40
Yes
P1105
40
Yes
P1107
40
Yes
P1108
40
Yes
P0112
40
Yes
P0113
40
Yes
P0117
40
Yes
P0118
40
Yes
P0500
40
Yes
11.26
Number of
no-fault
cycles
before
turning off
Fault Description
MIL
Number of
no-fault
cycles
before
DTCis
erased
MIL
illuminated
when fault
is logged
P1552
40
Yes
P1553
40
Yes
P1231
40
Yes
P1232
40
Yes
P0444
40
Yes
P0445
40
Yes
P0617
40
Yes
P0616
40
Yes
P0414
40
Yes
P0413
40
Yes
P0222
40
Yes
P0223
40
Yes
P0638
40
Yes
P0505
40
Yes
P1631
40
Yes
P1632
40
Yes
P0560
40
Yes
P1500
40
No
P0654
40
No
P1115
40
No
P0460
40
No
P0705
40
No
P0656
40
No
P1610
40
No
P0630
EEPROM fault
40
No
11.27
6 7
34~\\~~
2>s:~ ,,)A~,,/'
-=-~~A
~
~"~~
,<~".
./
\ ~y
Tool Keys
In most cases, the Return key (.J) enables the user to
return to the screen last displayed.
go,
1. Memory card
2. Screen
3. Return key
4. Up key
5. Down key
6. Validate key
7. Help key
Diagnose faults
Obtain data
Return key
a
[
R G N
U R R E N T
R E R D
...
F U N [
5 T I
D T [
D R T R
5 T D R E
T f
T E 5 T 5
11.28
gaeg
gaes
Help key
Test Procedure
The following describes the procedure to follow when
using the service diagnostic tool. It does not cover
the further diagnosis that must be carried out once a
fault area has been identified. For details of the
procedure to follow when a fault area or fault code has
been identified, refer to the diagnosis details later in
this section.
Note:
gaef
Validation key
11.29
CONNECT BIKE
SELF TEST
SYSTEM ERROR
False
CHECK CARD
Absent
Present
SELECT LANGUAGE
ENGLISH
FRANCAIS
DEUTSCH
ESPANOL
NEDERLANDS
TRIUMPH MOTORCYCLES
DIAGNOSTIC TOOL
SOFTWARE VERSION
2004_01
VALIDATE
False
Main Menu
SERVICE DATA
DEALER 555555
11.30
SERVICE DATA
DATE 15/06/04
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Quit
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Error Count
STORED ERRORS
FAULT COUNT 02
IGNITION COIL 1 OPEN CIRCUIT
INJECTOR 3 OPEN CIRCUIT
Diagnostics
Starred DTC
DIAGNOSTICS
CURRENT DATA
FAULT CODES
FUNCTION TESTS
QUIT
Fault codes
STORED ERRORS
FREEZE FRAME DATA
CLEAR DTCS
Current data
CURRENT DATA
ENGINE SPEED
CALCULATED LOAD
COOLANT TEMPERATURE
SHORT TERM FUEL TRIM
THROTTLE POSITION
INTAKE AIR TEMPERATURE
VEHICLE SPEED
IGNITION ADVANCE
OXYGEN SENSOR OUTPUT VOLTAGE
INTAKE MANIFOLD ABSOLUTE PRESSURE
FUEL SYSTEM STATUS
STORED ERRORS
Return
RETURN TO DTCS
CLEAR DTCS
STOP ENGINE
Clear
STORED ERRORS
ERASE ALL DTC DATA
YES
NO
No
RESETDTCS
Yes
11.31
Diagnostics
DIAGNOSTICS
CURRENT DATA
FAULT CODES
FUNCTION TEST
QUIT
Function test
FUNCTION TEST
DTes present
.J
FUNCTION TEST
INSTRUMENT PANEL
IDLE SPEED CONTROL STEPPER MOTOR
PURGE CONTROL VALVE
FUEL PUMP RELAY
FUEL PUMP OPERATION
COOLING FAN
2ND THROTTLE CONTROL STEPPER MOTOR
Cancel
Error Count
Screen
FUNCTION TEST
"TEST NAME"
PROCEED
CANCEL
Proceed
FUNCTION TEST
TEST NAME
TESTING......
OBSERVE
..
TESTDTCS
DTe present
Zero DTes
FUNCTION TEST
TEST NAME
TEST FAILED Pllll
SIC TQ VBATT
FUNCTION TEST
TEST NAME
TEST COMPLETE
CLEAR DTC
Yes
FUNCTION TEST
PERFORM ANOTHER TEST
YES
NO
No
11.32
Main Menu
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Check/Change
Check/Adjust menu
CHECK/ADJUST
Quit
CHECK
Adjust menu
ADJUST
QUIT
Check
CHECK/ADJUST
ADJUST TUNE
UPDATE TUNE
QUIT
Adjust
Check menu
CHECK
READ BUILD DATA
READ SENSORS
READ ADAPTION STAlUS
QUIT
Quit
Adjust menu
Read sensors
ADJUST
THROTILE BALANCE
ADAPTION RESET
REPLACETPS
REPLACE Ise STEPPER
TUNE UPDATE
QUIT
VOLTAGES
THRonLES/COILS/INJECTORS
OTHER
f--
f--
~
Build data
THROTILE BALANCE
THROTILE 1 1234 MM/HG
THROTILE 2 1234 MM/HG
THROTILE 3 1234 MM/HG
I----
No
Yes
ADAPTION RESET
CONFIRMY/N
BUILD DATA
VIN
XXXXXXXXXXXxx
TRIUMPH ECU PART NUMBER
XXXXXX
KEfHIN EGU PART NUMBER
XXXXXXXXXXXXX
ECU SERIAL NO
XXXXXXXXXXXX
SOFTWARE VERSION NUMBER
XXXXXXXXXXX
DATE OF MANUFACTURE
XXXXXXXXXXX
CALIBRATION ID
XXXXXXXXXXX
Adaption status
ADAPTION STATUS
ECU RESET CLOSED THROTILE POSITION REF STATUS
IDLE SPEED CONTROL ADAPTJON STATUS
02 SENSOR ADAPTION STATUS - OFF IDLE
02 SENSOR ADAPTION RANGE - OFF IDLE
02 SENSOR ADAPTION STATUS -IDLE
02 SENSOR ADAPTION RANGE - IDLE
11.33
Main menu
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Check/Adjust
ChecklAdjusl menu
CHECK/ADJUST
ADJUST TUNE
UPDATE TUNE
QUIT
Quit
.
UPDATE TUNE
SELECT MODEL
ROCKET III
Update tune
ROCKET III
TUNE XXXXX
TUNE XXXXX
TUNE XXXXX
UPDATE TUNE
???????
UPDATE TUNE
TUNEXXXX
CONFIRM
CANCEL
QUIT
Confirm
Cancel
Pass
TEST PASSWORD
UPDATE TUNE
DOWN LOADING. ...
10% COMPLETE
Fail
SECURITY
ACCESS DENIED
DOWNLOAD OK?
Yes
11.34
No
UPDATE TUNE
UPDATE TUNE
DOWNLOAD COMPLETE
5 E L E
~
E N G L I
5 H
F R R N [
R I 5
0 E U T 5
E 5 P R N
oL
L R N G U R G E
T R L I
R N 0
" "
" "
"
N E 0 E R L R N 0 5
1. Tool
2. Connection to Main Harness
Connect the tool to the dedicated rnulliplug under the
seat.
(gJ]
I~!
~.
11.35
T R jl lu l'I!p HI
,
,i a"I ,IR!G
I N!a
E!,,
a F !f1;'
R'TR
i
I
1'1
5
/l
"'!a
a!~
@I
! I i
a T
T
ER
a
- -
!Tl[
galu
8'
If
@I
a,N
;'0
11.36
i
!
I r! ID!
5!1J!'
"r1
/
10
ID!,
'*'.
R T R
L I
N K
E R L E R
(81]
19J]
I~f
g.,
If the above is displayed, check that the ignition is
switched on.
5 5 5 5 5 5
~
I~
R T R
F R U L T
R E T R !I ;>
@I
'*' to
'*'
g.,
I~!
'*'.
'*'.
~.
11.37
,, i
i5 E
R 1/ 1
le
/ ai~
8. MAIN MENU
E
aiR
I
1'1
~I-
I I
[IH E [
K /
aiu
@I
ailI R G
R
[
5 T
Ra
NI
5!
5
10
($1
iTi
!
,
j
IT
11'
1 E N U
;
10
I~(
12>(
Enter the date using the 'Up' and 'Down' keys in the
same way that the Dealer number was entered.
Note:
'DIAGNOSTICS'
'CHECK/ADJUST
11.38
selected)
0 I
R G N
5 T I
5 T R R T
?
R E R 0
U R R E N T
0 R T R
5 T 0 R E 0
R L [
gall!
1'2>
N E
oR
2 9 96
1 5
T E fI P
19JJ
19JJ
@I
R T R
0 T [ 5
~
I cJ
E N G I
U L R T E 0
T E N G I N E
U R R E N T
<$1
galll
Iz::, (
'*'.
I t1
IZ>
.~
Iz::, ~
'*'
~.
11.39
is T
,i
!
a PI
--,'
E N G 1 IN E
I,
1'1 R I iN
il7 EiN U
IRIG N
as
T I
![lHiE:C
,
I
'
I I'i
~:~i+-'
I R
a J UiS
T
i
+-+-+-!-+-+..
_;-- -
io il
---
,i
I 1
U I
,is
I<DZ:>(
Switch off the engine.
@I
ID
I @I lz:, {
Use the 'Up' and 'Down' keys to position the cursor
opposite DIAGNOSTICS.
Press the
Validation
'DIAGNOSTICS' menu.
key
'*'
to
dispiay
11.40
i' P 0 1 1 1
"p
0 U N T
0 T
5 T 0 R E 0
0 2
"
0 2 0 1
F R E E Z E
[
L E R R
0 T [
0 R T R
(gJ]
19J1
~
F R R fI E
9"
0 T [
/~
/~
I~~
I~(
9"
Align 'FREEZE FRAME DATA' with the cursor, and
to display 'FREEZE
press the validation key
FRAME' (see 15.).
'*'
'*'
P01l7
Help text
MAP SENSOR
LOW VOLTAGE
'*'
to continue (operation
IMPORTANT:
If a DTC has an asterisk (*) to its right, this indicates
that a snap shot of engine data at the time the DTC
was stored is available to aid your fault diagnosis. To
access this information, press the Validation key
to
go to operation 14. and open 'FREEZE FRAME
DATA'.
'*'
~.
11.41
II
I< E E
Z iE
F I< R f'I El
i i
I
R T E
la
T E f'I P
9 %
1 5
"I< E T
[
L E
I< E
UIRH
RIl<l
,a
,
'
TI[ 5
<$"1
I~(
10
I~(
'*'
'*' to go on to operation
Note:
'*'
11.42
5 T
R L L
0 T
0 T
0 I
0 R T R
N 0
R E R 0
I~
5 T 0 R E 0
L E R R
0 T
0 T [ 5
(gJl
/J JE>!,
galu
Scroll to position either 'YES' or 'NO' opposite the
cursor.
0 R T R
llSUl
@I
U R R E N T
R G N 0 5 T 1 [ 5
QIIIU
I~!
Note:
~.
11.43
T 5
p RIE 5 E N
Tic
8 E F
[]
[]
R E
,IT
E 5 T
R C T
F U N C T 1 OiN
I
f
TI
6"1
I @I
is!r
i
i
@!
'*'
Note:
The fault(s) which caused the DTC's to be
set must be rectified and cleared before
continuing the Function Tests.
A full list of all the possible DTCs can be
found earlier in this section.
'*'
P RIN E L
E'P p E R
! @I
5 C
I~Q
13.).
N 5 T R U 1'1 E N T
lE> (
T E 5 T
10
1E>!
Instrument panel.
Idle speed control stepper.
Purge valve.
Fuel pump prime.
Cooling fan operation.
Fuel pump operation.
Second throttle controi stepper motor.
11.44
N 5 T R U 1'1 E N T
T E 5 T
P R N E L
P R 0 C E E 0
C R N C E L
Note:
lGDJ
<$1
gO"
I <$]
I~
ID(
11.45
F U N [
I
N S r
Riu
I
nlE
r E
sir
I IN G
0 8 SiE
Rill
,
r E
N r
@I
/I
E L
sirlR
IF U N [
Rlu
OIN
E N r
[
rES r
RN
E L
0 fI P L E r E
G E S
:~
@I
t~!
10
j1 Iz:.(
11.46
'*'
T E 5 T
R N 0 T H E R
T E 5 T
F U N [
P E R F
~
R 1'1
!J E 5
F U N [
T I
N 5 T R U 1'1 E N T
T E 5 T
F R I
0 N
T E 5 T
P R N E L
L E 0
P 1 1 1 1
N 0
(gJ]
~
(gJ]
.~
I~(
<$"1
11:)
/~
I~!
g""
This display allows you to decide whether you wish to
test another component.
g""
If the test selected at operation 22. is unsatisfactory, a
DTC will be displayed on line 3 of this display.
'*'
'*'
'*'
'*'
~.
11.47
27. CHECK/ADJUST
!
I7R!/jN
G NOS T I
1[1 5
171ENU
!
!
--+--~I
I
H E
H E
0 U I
IT
R 01J U liS T
!
-tI
1:0
I~I
10
I @ IE:>!
Use the 'Up' and 'Down' keys to position the cursor
opposite 'CHECK/ADJUST'.
Press the Validation key '*'; the 'CHECK/ADJUST'
menu will be displayed.
11.48
K /
R 0 J U 5 T
@I
<$1
to return
to 'MAIN
MENU'
28. CHECKS
[
~
R E R
R E R
R
a
a
5 E N 5
R p T I
a
a
B UI L
H E [ K 5
5 T R T U 5
gall!
/<$!
19JJ
/~
@I
12>(
galu
E [ U
T T R I U 1'1 P H
19JJ
I~
R T R
X X X X X X X X X X X X X X X X X X
R T R
~
cl
tJ I N
R 5
12>
.~
/<I.J2>(
Tune Number
11.49
ia iR
5 E N 5 ,
'
E N !6
i
? R
aiR T R
iR
51 E NI5 0 R
5 tJ
!R
I
TIE
nip
5 [
5 T
T E 1'1 P
0 N
!R
T U 5
alUiT
I
R R N 6 E
P!L iE RI5 E
IJ R
@I
1:--2>
gaiu
Note:
The help information shows the likely
range of readings for a correctly
functioning system at normal operating
temperature.
11.50
iI N!E
I~I
!R 0 R P T
'*'
J~(
to return to 'CHECK!
L 0 5 E 0
0 2
R 0 R P T I 0 N
0 R T R
T H R 0 T T L E
N 0
R 0 R P T I 0 N
5 E N 5 0 R
R 0 R P
/;
96
5 1 96
19J1
~
I~~
Function Examined
Report Method
adapted/not adapted
Idle
speed
control
adaption status
Oxygen
adaption
idle)
sensor
status (off
Oxygen
adaption
idle)
sensor
range (off
Oxygen
sensor
adaption status (idle)
Oxygen
sensor
adaption range (idle)
Note:
11.51
R 0 JUS T
T
R E 5 E
TUN E
, ,;
,
i
I
ri; IR
0 R P T I
T H R 0 T T L E
I
sf
T H R 0 TIT LTE
II
0 N
8 R L R N [lE
~
IT ui N E
i
R 0 J U 5 T
! '
si
ElfJ
iR EiN
I
!
P 0 T
51TiE P P E R
N]E
R!E
;
lJl
l~l
I~(
'*'
'*'
gall!
I~(
11.52
D N F I
!:J
E 5
R E 5 E T
R I?
N D
I 2 3
I? I? I H G
T H R D T T L E
I 2 3
I? I? I H G
T H R D T T L E
1 2 3
I? I? I H G
(lgJJ
6$'1
I)
I~(
galu
~.
E D
19JJ
gaiu
T H R D T T L E
<$1
B R L R N
T H R D T T L E 5
10
I~(
11.53
U P 0 R T E
T!UIN E
IT
U N E
i
i
5 5 5 515
,
[ E 5 5
DiN N E
@I
I <I IDI
I<I
R E T R
&
,0
IDI
'*'
11.54
01
0 E N
uP
5 E L E
~R
K E T
D R T E
R D
T U N E
fI D D E L
T U N E
2 X X X X
T U N E
2 X X X X
T U N E
2 X X X X
galu
1'2)
<$1
I~(
galu
19J1
K E T
(gJl
<$1
10
.~
I~(
11.55
T UIN Ei
u p a RirlE
. ,
21 x x x x
[i a N F
[lA N
@l
I @I
,
i
T U N E
R /'I
0 IJ!N
!
i
U paR TIE
N G
,i
iT U ,N E
I
I.'
a
I~+!.+++-i
-l;i +[+0+/'I+p-I LE' TIE I
L i 0 !R
r-144-+-+a
,
f-'
Ii
E L
i~
@I
iZ>.
i~r
Iz::, (
'*'.
'*'
'*' to
Note:
11.56
U 1'1 P H
0 f
~.
5 0 F T
(,J
1'1
T 0 R [
R G N 0 5 T I
R R E
tJ E R 5 I
':I
L E 5
T 0 0 L
0 N
2 0 0 'I - 0 1
From this screen, use the following button press
sequence:
HELP (?) HELP (?) - RETURN (.J) - HELP (?)
VALIDATE (*).
The dealer log-in screen will then be displayed. From
that screen, download can be restarted in the normal
way.
Note:
11.57
Note:
Note:
11.58
Further Diagnosis
The tables that follow will, if used correctly, help to
pinpoint a fault in the system once a diagnostic
trouble code has been stored.
1.ECM
2. Large connector
3. Small connector
2.
~.
11.59
Possible cause
Action
P0335
Pinpoint Tests
Test
1 Check terminal and cable integrity:
- ECM pin A13
- ECM pin A14
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
Proceed to test 6
Faulty
11.60
Crankshaft
Sensor
Engine
Control Module
lI1l--u,------jAi4l
U.1--U8~
~'
11.61
Possible cause
Action
P0505
Pinpoint Tests
Result
Action
OK
Proceed to test 2
Faulty
40 to 120
Open circuit
Proceed to test 4
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
40 to 120
Proceed to test 7
Faulty
Test
1 Check cable and terminal integrity:
2
ECM
ECM
ECM
ECM
pin
pin
pin
pin
B23
B07
B11
B03
ECM
ECM
ECM
ECM
pin
pin
pin
pin
B23 to earth
B07 to earth
B11 to earth
B03 to earth
pin
pin
pin
pin
A
A1
B
B1
11.62
Sub ~arness
~w----IN
10
ON
OW
OU
11
OU
Bll
8'
OK
12
OK
803
~'
Engjne
Control Module
Engine
B23
807
11.63
Possible cause
Action
P0201/02/03
Pinpoint Tests
Test
2
Check
- ECM
- ECM
- ECM
resistance
pin A20 to
pin A20 to
pin A20 to
A20 to
B05 to
B06 to
B17 to
Action
OK
Proceed to test 2
Faulty
12.50 to 14.00
Proceed to test 3
Open circuit
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
12.50 to 14.00
Proceed to test 7
Faulty
value:
ECM pin B05 (injector 1)
ECM pin B06 (injector 2)
ECM pin B17 (injector 3)
- ECM
- ECM
- ECM
- ECM
Result
11.64
ECM
A20
En~ine
Sub- arness
Fuse Box
Fuse6
NK
2 1
2 2
2 3
NK
YK
YP
VB
YK
BOS
YP
B06
VB
817
Fuel Injectors
~.
11.65
Possible cause
P0122
P0123
Throttle
voltage
circuit)
Throttle
voltage
supply)
Action
position sensor low input View & note diagnostic tool 'freeze
(short to ground or open frame' data if available.
View & note diagnostic tool 'sensor'
position sensor high input data.
(short circuit to sensor Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test 1
Pinpoint Tests
Test
1 Check
- ECM
- ECM
- ECM
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short ci rcu it
11.66
Engine
Sub-Harness
Connector
ECM
Throttle
Position Sensor
D=:=GY
2
~'
KB _____KB
E
17
GY
18
KB
A07
19
AOl
A10
11.67
Possible cause
P0444
Open circuit or short circuit to earth View & note diagnostic tool 'sensor'
data.
Ensure purge valve connector is
secure.
Disconnect ECM and
proceed to pinpoint test 1
P0445
Action
Disconnect
purge
valve
proceed to pinpoint test 5
and
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin 831
2 Check resistance vaiue:
- ECM pin A20 to ECM pin 831
Result
Action
OK
Proceed to test 2
Faulty
24Qt028Q
Open circuit
Proceed to test 4
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
24Q to 28Q
Proceed to test 7
Faulty
11.68
~.
EMS Relay
=EJ
ECM
Purge Valve
NK~/~VR
"--------NIK
83.
AlO
Fuse Box
fuse6
~.
11.69
Possible cause
Action
P0351 152/53
Pinpoint Tests
Result
Action
OK
Proceed to test 2
Faulty
1.4l1 to 1.8l1
Proceed to test 3
Open circuit
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
1.4l1 to 1.8l1
Proceed to test 7
Faulty
Test
1 Check cable and terminal integrity:
11.70
EMS Relay
ECM
'----,,----------IN'
A20
Bl9
B16
Fuse Box
B01
Fuse6
Ignition Coils
11.71
Possible cause
P0118
Open circuit, or short circuit to View & note diagnostic tool 'freeze
battery+
frame' data if available.
Action
P0117
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
OK
Short circuit
OK
Proceed to test 5
Open circuit
OK
Proceed to test 5
Short circuit
OK
Proceed to test?
Faulty
OK
Proceed to test?
Short circuit
11.72
200 to 4000
Cold engine:
20C ambient
2.35 to 2.65KO
-10C ambient
8.50 to 10.25KO
Coolant
Temperature
Sensor
f2l-KB
L0-KG ---~
~'
m- =f
Engine
Sub-Harness
Connector
ECM
18
KB
A07
14
KG
A09
11.73
Possible cause
Action
P0113
Open circuit, or short circuit to View & note diagnostic tool 'freeze
frame' data if available.
battery+
View & note diagnostic tool 'sensor'
data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test 1:-
P0112
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
OK
Open circuit
Short circuit
OK
Proceed to test 5
Open circuit
OK
Proceed to test 5
Short circuit
OK
Proceed to test?
Fauity
OK
Proceed to test?
Short circuit
11.74
Resistance value
80 0 G
20 0 G
200 to 4000
2.35 to 2.65KO
8.50 to 10.25Kn
-1OoG
Inlet Air
ECM
Temperature
Sensor
~KB~
~KO~
~.
11.75
Fault Code
Possible cause
P1231
Fuel pump relay open circuit, or Check if pump runs briefly when
ignition is switched on.
short circuit to ground
Ensure fuel pump relay connector
is secure.
Disconnect ECM and proceed to
pinpoint test 1:-
P1232
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
OK
Proceed to test 5
Short circuit
Circuit Diagram
Fuel Pump Relay
EMS Relay
ECM
:==~_'K==~~----,~:=EJ
Fuse Box
Fuse 6
11.76
Possible cause
Action
P0560
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
Circuit Diagram
EMS Relay
KM
NK
Fuse Box
Fu,e6
~'
f:
AlO
A06
608
609
11.77
Possible cause
Action
P1552
Fan relay open circuit, or short View & note diagnostic tool 'sensor'
circuit to ground
data.
Ensure fan relay connector is
secure.
Disconnect ECM and proceed to
pinpoint test1:
P1553
Pinpoint Tests
Test
1 Check cable and terminal integrity:
ECM pin 810
2 Check cable for short circuit:
ECM pin 810 to ground
3 Check cable continuity:
Fan relay pin 4 to ECM pin 810
- Fan relay pin 6 to EMS relay pin 8
4 Check cable for short circuit:
- ECM pin 810 to ECM pin A20
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Proceed to test 5
Short circuit
Circuit Diagram
EMS Relay
P.-+"'='-':-,-+I,
ECM
LBY-J:l
L-----------iNK-t:j
Fuse Box
Fuse6
11.78
Possible cause
Action
P0654
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin 814
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
Circuit Diagram
Instruments
~
J
Fuse Box
FuseS
G
LGN
GR
R
10
c=::::J
KM
'It:
814
A06
BOB
Bog
11.79
Possible cause
P1115
Temperature Indication system fault View & note 'freeze frame' data if
available.
View & note 'sensor' data.
Ensure instrument connector is
secure.
Disconnect ECM and proceed to
pinpoint test 1:-
Action
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
Circuit Diagram
Instruments
~
~
LGN
GRJ
15
10
11.80
ECM
YW
'1 F:
63'
A06
B08
809
Fuse Box
Fuse 5
==:J
Possible cause
Action
P1500
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin 832
- ECM pin 808
- ECM pin 809
- ECM pin A06
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
Circuit Diagram
~
J
Instruments
Fuse Box
Fuse 5
G
LGN
ECM
GR
RO
13
10
81
E==:J
f:
832
A06
808
809
11.81
Possible cause
Action
P0130
Pinpoint Tests
Test
1 Check cable and terminal integrity:
ECM pin A11
- ECM pin AO?
2 Check cable for short circuit:
ECM pin A11 to ECM pin AO?
- ECM pin A11 to ECM pin A20
3 Check cable continuity:
- ECM pin A11 to sensor pin 1
- ECM pin A11 to sensor pin 2
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
Circuit Diagram
EMS Relay
Lambda Sen'or
ECM
'---w
B3,
11
~----K6
Fuse Box
L----------NK
Fu,e6
11.82
07
A2a
Possible cause
Action
POO31
Lambda sensor heater circuit short View & note '1reeze frame" data if
available.
circuit to ground or open circuit.
View & note "sensor" data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test 1:
POO32
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- Ecm pin 833
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 5
Open circuit
OK
Circuit Diagram
EMS Relay
Lambda Sensor
ECM
w BB
11
Fuse Box
KB
A07
NK
AlO
Fuse6
~.
11.83
Possible cause
Action
P0603
EEPROM error
11.84
Possible cause
P1631
P1632
Action
switch
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A04
2 Check cable for short circuit:
- ECM pin A04 to ground
ECM pin A04 to ECM pin A20
3 Check cable continuity:
- ECM pin A01 to sensor pin 4
- ECM pin A04 to sensor pin 5
ECM pin AO? to sensor pin 6
4 Check cable for short circuit:
- Sensor pin 4 to sensor pin 5
- Sensor pin 4 to sensor pin 6
5 Check voltage (with ignition on):
- Sensor pin 4
6 Reconnect harness, clear fault code.
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Proceed to test 5
Short circuit
12V
voltage)
OK
Circuit Diagram
KM
fall
Detection
Switch
r:l=:=fl
L;}-K----U
11.85
Possible cause
P0222
2nd throttle position sensor low View & note "freeze frame" data if
voltage. (short circuit to ground or available.
open circuit)
View & note "sensor" data
Ensure sensor connector is secure.
2nd throttle position sensor high Disconnect ECM and proceed to
voltage. (short circuit to sensor pinpoint test1 :
supply)
P0223
Action
Pinpoint Tests
Test
11.86
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
ECM
Sub- arness
Connector
2nd Throttle
Position Sensor
rn=:=~
2
~.
K8 ------KB
8
16
A02
18
KB
A07
19
AOI
11.87
Possible cause
Action
P0638
2nd throttle actuator motor / wiring View & note "freeze frame" data if
fault
available.
View & note "sensor" data
Ensure
secure.
actuator
connector
is
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
- ECM pin
- ECM pin
- ECM pin
- ECM pin
Faulty
4n to Ion
Open circuit
Proceed to test 4
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
4n to Ion
Proceed to test 7
B21
B22
B12
B04
pin
pin
pin
pin
B21 to
B22 to
B12 to
B04 to
ground
ground
ground
ground
11.88
2nd Throttle
Control Module
GN
GN
A'
GW
'21
GW
822
GU
GU
812
8'
GK
GK
804
[g
~.
Engine
Sub Harness
Connector
Actuator
11.89
Possible cause
Action
P0500
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A21
- Instrument pin 18
2 Check cable for short circuit:
- ECM pin A21 to ground
- ECM pin A21 to ECM pin A01
- ECM pin A21 to battery
3 Check cable for continuity:
- ECM pin A21 to sensor pin 3
- Sensor pin 2 to ground
- Instruments pin 18 to sensor pin 1
Result
Action
OK
Faulty
OK
Proceed to test 3
Faulty
OK
Open circuit
Circuit Diagram
Alarm
Control Unit
Instruments
Il-GR
LT'Y
Kill
Switch
J~LGN
KY -
Fuse Box
Fuse 5
G--EE=:J===c3--
ECM
---jA1l
Road
Speed Sensor
11.90
Possible cause
Action
P110?
Ambient pressure sensor circuit View & note '~reeze frame" data if
short circuit to ground
available.
View & note "sensor" data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test1 :
P1108
ambient
pressure
Ambient pressure sensor circuit! Disconnect
short circuit to supply or open sensor and proceed to pinpoint test
circuit
4.
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A23
- ECM pin AO?
- ECM pin A01
2 Check cable for short circuit:
- ECM pin A23 to ECM AO?
3 Check cable for continuity:
- ECM pin A23 to sensor pin 3
- ECM pin AO? to sensor pin 2
- ECM pin A01 to sensor pin 1
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Open circuit
OK
Short circuit
sensor and
Circuit Diagram
Ambient
Pressure
Sensor
ECM
AD7
A23
A01
KO={]
KP
11.91
Possible cause
Action
P01O?
MAP sensor circuit short circuit to View & note "freeze frame" data if
ground
available.
View & note "sensor" data
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test1:
P0108
P1105
sensor
and
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A03
- ECM pin AD?
- ECM pin AD1
2 Check cable for short circuit:
- ECM pin AD3 to ECM AD?
3 Check cable for continuity:
- ECM pin AD3 to sensor pin 3
- ECM pin AD? to sensor pin 2
- ECM pin AD1 to sensor pin 1
Result
Action
OK
Fauity
OK
Proceed to test 3
Short circuit
OK
Open circuit
OK
Short circuit
Circuit Diagram
MAP
ECM
'07
AOl
A01
11.92
Sensor
"=tJ
K5
Possible cause
Action
P0705
Pinpoint Tests
Test
1 Check cable and terminal integrity:
ECM pin A26
2 Check cable for short circuit:
ECM pin A26 to ground
3 Check cable continuity:
ECM pin A26 to sensor pin 1
ECM pin A19 to sensor pin 2
4 Check cable for short circuit:
Sensor pin 1 to sensor pin 2
5 Reconnect harness, clear fault code.
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
Circuit Diagram
Gear
PosH",on
Sensor
KM
II1l--BK -------JA26l
~BW~
~.
11.93
Possible cause
Action
P0460
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A24
- ECM pin A06
2 Check cable for short circuit:
- ECM pin A24 to ground
3 Check cable continuity:
- ECM pin A24 to sensor pin 4
- ECM pin A06 to sensor pin 3
4 Check cable for short circuit:
- Sensor pin 3 to sensor pin 4
5 Reconnect harness, clear fault code.
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
Circuit Diagram
Fuel
level
Sensor
[CM
DJ= -fAMl
8G
11.94
B~
Possible cause
Action
P1610
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A30
- Instrument pin 4
2 Check cable for short circuit:
- ECM pin A30 to ground
3 Check cable continuity:
- ECM pin A30 to instrument pin 4
- Instrument pin 10 to ground
- Instrument pin 2 to alarm control
unit pin 1
Result
Action
OK
Proceed to test 2
Faulty
OK
Disconnect instrument
proceed to test 3
Short circuit
OK
Open circuit
assembly
and
Circuit Diagram
Alarm
Control Unit
Instruments
Kill
Switch
~
J
Fuse Box
Fuse 5
LGN
GR
4
10
ECM
:
1f
BG
c::==J
830
AM
BOB
BOO
11.95
Possible cause
PD656
Accessory fuel level gauge circuit Ensure fuel level gauge connector
is secure.
fault
Disconnect ECM and proceed to
pinpoint test1:
Action
Pinpoint Tests
Test
1 Check cabie and terminal integrity:
- ECM pin ADS
- Gauge pin 1
2 Check cable for short circuit:
ECM pin ADS to ground
- ECM pin ADS to ECM pin A2D
3 Check cable continuity:
- ECM pin ADS to gauge pin 1
- Gauge pin 2 to earth
- Gauge pin 3 to alarm controi unit pin 1
4 Reconnect harness, clear fault code.
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Open circuit
OK
Circuit Diagram
Alarm
Control Unit
Access0J'
Fuel Leve
Gauge
Kill
Switch
~
~
LGN
ECM
GRJ
BG
'1 f:
11.96
A08
A06
BOB
B09
Fuse Box
Fuse 5
c==J
Possible cause(s)
11.97
Fuel Tank
Note:
The fuel tank may be raised without being
removed completely, for access to the top
of the engine. ignition coils, spark plugs
etc.
,""
5.
iI@
Remove the intake cover from the left hand side
of the tank as follows, release the two screws
from its front and rear edges and then slide it
downwards to release it from two support studs
in its centre.
1. Fixing
11.98
1. Coil bracket
2. Fuel tank prop
8. Locate the plain end of the prop in the fuel tank
fixing hole and the spherical end in the fixing
bracket on the tank.
2.
"-...~~~e
~~~
1. Coil bracket
2. Fuel tank prop
3. Lower the tank into position and secure with the
forward fixing. Tighten the fixing to 9 Nm.
4.
5.
6.
7.
11.99
2.
cb'p
1. Fuel hose
2. Electrical connection
4. Disconnect the electrical connection from the
fuel pump plate.
5. Support the fuel tank while removing the rear
mounting bolt.
1. Fuel tank
2. Breather hoses
The fuel pipe will contain fuel under pressu re. When
releasing the fuel pipe union, wear eye protection
and protective clothing and ensure that the
pressurised fuel is not exposed to naked flames,
light bulbs, etc. A fire, causing personal injury and
damage to property, may result from fuel exposure
to naked flames, light bulbs and any other source of
Ignition.
Note:
Cbrq(\
7.
11.100
3.
4.
ob"
~.
11.101
7.
6.
1. Pressure regulator
2. Hose clips
3. Link pipe
4. Pump mounting plate
Note:
8.
"'"Screw
1.
2. Pressure regulator
Note:
1. Filler
2. Clip
3. Inlet hose
4. Filler arrow
11.102
""'"
1. Fuel pump
2. Fuel pump clamp
3. Mounting bar
13. The pump may now be removed.
Inspection
1.
2.
Assembly
1.
1. Fuel pump
2. Electrical connection
11. Release the clip securing the remaining fuel
hose to the pump, then ease the fuel pipe away
from the filter.
1. Fork
2. Isolator feet
00pI
1. Fuel pipe
2. Pump
11.103
'b",
1. Fuel pump
,bp<
5.
6.
1. Fuel pump
2. Electrical connection
12. Check that the fuel levei sender arm moves
freely along its full range of travel, and comes to
rest on the pump plate. Rectify as necessary.
Installation
1.
2.
3.
1. Filter
2. Clip
3. Inlet hose
4. Filter arrow
7. Position the hose clip to the filter inlet.
8.
9.
11.104
Removal
1.
2.
3.
11.100.
4.
5.
6.
7.
1. Evaporative canister
2. Hoses
3. Cable ties
11. Remove the canister.
12. Disconnect the electrical connections to the fall
detection switch and alternator rectifier.
\
1. Relay pack
2. Airbox
3. Screws
4. Roll-over valve
8. Ease the relay pack from the airbox.
Note:
9.
11.105
..............,
/1
ctnv
1. Fuse box
2. Fir-tree pi ugs
Electrical connections
17. Place the ECM to one side.
18. Remove the three screws from the ECM bracket,
then detach the bracket.
-=====
,~.
1. ECM bracket
19. Ease the two relay connectors from the battery
box by pushing them upwards.
1. Relays
2. Battery box
1. ECM
2. Screws
11.106
..
"'
1. Seat Lock
2. Screws
23. Release the two screws securing the battery box
assembly to the frame.
"'''
....
1. Battery box
2. Screw (left hand shown)
24. Maneouvre the battery box assembly from the
motorcycle and place aside.
~.
1. Throttle bodies
2. Clips
26. Noting their orientation, release the two clips
securing the intake plenum to the intake duct.
1. Intake plenum
2. Intake duct
3. Clips
27. Carefully detach the intake plenum from the
throttle bodies and intake duct. Place the intake
plenum aside.
11.107
1. Intake hose
2. Intake duct
3. Clip
1. Intake duct
2. Fixing
pressure
1. MAP sensor
2. Air temperature sensor
3. Connectors
Note:
11.108
1. Airbox
2. Fixings
1.
Installation
Reconnect the
sensors.
MAP
and
air temperature
1. MAP sensor
2. Air temperature sensor
3. Connectors
6.
1. Airbox
2. Semi-circular feature
3. Frame cross tube
2.
3.
~.
11.109
1. Relays
2. Battery box
11. Arranging the cables to the rear of the ECM
bracket as noted prior to removai, refit the ECM
bracket and tighten its screws to 3 Nm.
4~~~ti
1. ECM bracket
2. Cables
12. Locate the ECM to its bracket and tighten its
screws to 3 Nm.
13. Reconnect both multi-plugs to the ECM.
11.110
2. Airbox
3. Screws
4. Roll-over valve
17. Reattach the roll over valve to its bracket.
18. Position the fuse box to the battery box. Retain
the fuse box with new fir-tree plugs.
19. Reconnect the fall
alternator rectifier.
detection
switch
and
Air Filter
Removal
1.
2.
3.
4.
1. Evaporalive canister
2. Hoses
3. Cable lies
21. Refit the rear mudguard as described on page
17.13.
22. Refit the rear wheel as described on page 16.9.
23. Refit and reconnect the battery as described on
page 18.10.
24. Refit both side covers as described on page
17.9.
25. Refit the fuel tank as described on page 11.101.
26. Refit the rider's seat as described on page 17.9.
\ . .m
1. Filter element
6. Inspect the cover seal for damage.
~.
11.111
Assembly
1.
2.
3.
4.
5.
6.
Removal
1.
2.
3.
4.
5.
Installation
1.
2.
11.112
3.
4.
5.
Removal
1.
2.
3.
4.
1.
2.
3.
4.
ob"
1. MAP sensor
2. MUlti-plug
5. Unscrew the bolt securing the sensor to the
intake duct.
6. Raise the sensor in order to disconnect the hose
from below it.
Instal.lation
Installation
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
11.113
1.
Removal
1.
2.
3.
Note:
4.
3.
4.
5.
"':'S::~-.../
2.
6.
7.
Fit a new O-ring to the sensor. Lubricate the 0ring with a smear of petroleum jelly.
Position the sensor to the engine and route the
wiring as noted prior to removal.
Retain the sensor with the two screws, tightening
them to 9 Nm.
Connect the sensor to the main wiring harness.
Reattach the connector to the bracket.
Position the left hand engine infill panel to the
frame. Align the screw hoies in the panel with
those in the connector bracket and frame. Fit
and tighten the screws to 3 Nm.
Reconnect the battery, positive (red) lead first.
Refit the rider's seat as described on page 17.9.
\\
6.
11.114
Installation
1.
Removal
1.
2.
3.
Note:
4.
2.
3.
4.
5.
6.
7.
Fit a new O-ring to the sensor. Lubricate the 0ring with a smear of petroleum jelly.
Position the sensor to the engine and route the
wiring as noted prior to removal.
Retain the sensor with the screw then tighten the
screw to 9 Nm.
Connect the sensor to the main wiring harness.
Reattach the connector to the bracket.
Position the left hand engine infill panel to the
frame. Align the screw holes in the panel with
those in the connector bracket and frame. Fit the
screws and tighten to 3 Nm.
Reconnect the battery, positive (red) lead first.
Refit the rider's seat as described on page 17.9.
5.
Note:
6.
11.115
Installation
Fit a new O-ring to the sensor. Lubricate the 0ring with a smear of petroleum jelly.
Position the sensor to the engine and route the
wiring as noted prior to removal.
Retain the sensor with the screw, tightening it to
9Nm.
1.
Removal
Remove the rider's seat as described on page
17.9.
Disconnect the battery negative (black) lead first.
Remove the engine infill panel from the left hand
side of the engine (see page 17.10).
1.
2.
3.
2.
3.
Note:
Note:
4.
4.
5.
6.
7.
5.
Note:
6.
11.116
Throttle Cables
9.
Removal
Note:
1.
2.
3.
4.
5.
6.
""w
1. Throllle cables
2. Screw
3. Union
~'
"'"Opening cable adjuster
1.
2. Closing cable adjuster
3. Locknuts
~.
11.117
Installation
Note:
1.
2.
3.
4.
5.
1. Master cylinder
2. Screws
12. Ease the master cylinder away from the
handlebar to allow space for the throttle cables to
be detached from the twist grip. Detach the
cables from the twist grip.
o
cbsz
1. Split line
2. Dot mark
6. Tighten the master cylinder clamp bolts, upper
first and then the lower to 15 Nm.
7.
1. Twist grip
2. Throttle cables
13. Note the routing of the throttle cables, then
remove them from the frame.
8.
Examination
1.
1. Throttle cables
2. Retainer screw
3. Union
11.118
~'
11.119
2.
3.
4.
5.
6.
7.
11.120
1.
2.
3.
T H R 0 T T L E 5
B R L R N
E 0
T H R 0 T T L E
1 i! 3
1'1 1'1 / H G
T H R 0 T T L E
i!
1 i! 3
1'1 1'1 / H G
T H R 0 T T L E
1 i! 3
1'1 1'1 / H G
1. Adjuster 1
2. Adjuster 2
5.
4.
11.121
Throttle Body
Removal
1.
2.
3.
4.
1. Intake hose
2. Intake duct
3. Clip
8. Disconnect the manifold absolute pressure
(MAP) and air temperature sensors from the
wiring harness.
1. Throttle bodies
2. Clips
5. Release the two clips securing the intake plenum
to the intake duct.
1. MAP sensor
2. Air temperature sensor
3. Connectors
1. Intake plenum
2. Intake duct
3. Clips
6. Carefully detach the intake plenum from the
throttle bodies and intake duct. Place the intake
plenum aside.
11.122
Note:
Installation
1. Intake duct
2. Fixing
the injectors.
1.
2.
1. Transition piece
2.0-ring
3.
4.
5.
Note:
1. Throllle body
2. Clips
6.
~.
11.123
8.
each injector.
9.
~1
1. Intake duct
2. Fixing
11.124
1. Intake plenum
2. Intake duct
3. Clips
13. Reconnect the MAP and air temperature sensor
connections.
Removal
1.
2.
3.
4.
""
1. Fuel rail
2. Screws
Note:
5.
1. Fuel rail
2. Injectors
11.125
Removal
"'"
1. Clips
2. Injectors
7. Ease each injector from the fuel rail.
8. Recover the upper and lower O-rings from each
injector.
1.
2.
3.
4.
Assembly/installation
1.
2.
3.
4.
5.
6.
7.
8.
11.126
cbi;
Installation
1.
2.
P R I
rt R R !J
T H R 0 T T L E
[ UR R E N T
9.
11 0 L T 5
T P 5
L 0 5 E 0
5 6 11
Note:
10.
1. Sensor Insertion position (dolled line)
2. Sensor Initial filled position (solid line)
3. Insert the Torx screw to secure the throttle
potentiometer, but do not fully tighten the screw
yet.
4. Refit the throttle bodies as described on page
11.123.
5. Temporarily reconnect the battery, positive (red)
lead first.
6. Connect the diagnostic tool and scroll through to,
and select the 'ADJUST TUNE' option.
7. At the next screen, align the cursor with
THROTTLE POT RENEW (see below) then press
the validation key which is marked "'.
R 0 J U 5 T
R E 5 E T
~
P 0 T
5 T E P P E R
12.
13.
14.
T U N E
R 0 R P T I 0 N 5
T H R 0 T T L E
11.
R E N E IJ
R E N E IJ
~.
11.127
Removal
1.
2.
3.
4.
Gblj
5.
Installation
1.
2.
11.128
"noe
01 lt$ II'KM!menl.
Rec:1jy as~.
ill(:()O.llCIl~
11110:11.
5tic:t. COl*!
IJIOIOlqdeand an :odt;i .
1.
2.
~in_.ion
4.
5.
6.
7.
~~!.
et !he
Arry ot these
cO~l!ol of the
leed lir$l.
8.
Note:
.. r- ,"" , ", ,,
, " , , , ,
", , , ,
,
,
I
, , , , ,11 ,
,i
[;
"
H q
new
III
oesctled
on
page
.,J
l:l'''
.-
lhrQllIe po5lbO/l
5eO$Of
t 1.129
7.
Removal
1.
2.
3.
4.
{}
ccai
/~...
=-
Installation
1.
2.
3.
1. Collar
2. Spring
4. Fit the plastic washer through the lever then fit
the metal washer and nut.
1. Collar
2. Spring
5.
6.
7.
8.
11.130
R 0 R P T I 0 N 5
T H R 0 T T L E
~I
5 [
T U N E
P 0 T
5 T E P P E R
R E N E IJ
R E N E IJ
T H R 0 T T L E
[ UR R E N T
tJ 0 L T 5
5 T E P P E R
[
L 0 5 E 0
0
5 8 tJ
T H R 0 T T L E
O'--l'-~~I:~~
[ UR R E N T
tJ 0 L T 5
5 T E P P E R
0 P E N
0
1 2 tJ
1~~2
O.5mm
1. Idle speed control cam
2. Throttle roller
12. Check the voltage reading on the tool. If the
reading is 0.6 volts +/- 0.02 volts, MAKE A NOTE
OF THE EXACT VOLTAGE READING then
proceed to step 18. If the reading is not within
this tolerance band, adjustment must be made
as described in steps 13 to 15.
13. Slacken the retaining screw on the primary
throllle position sensor.
11.131
1. Adjustment nut.
11.132
Typical Values
General Information
Function Examined
Closed throttle position reference
status
Idle speed
status
Report Method
control
adaption
adapted/not
adapted
Between +100
and -100%
Between +100
and -100%
0% +/- 10%
Between +100
and -100%
1.
2.
Note:
Terminology
adaption
0% +/-10%
3.
%
control
Adapted
Read Out
~.
11.133
Fault Indications
If 'range' figures at 100% are seen, then the adjusted
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,
use the RESET ADAPTIONS facility on the diagnostic
tool (found under the adjust tune menu) and begin the
adaption process described above.
Removal
Note:
1.
1. Heat ShieId
2. Heat shield fixings
2.
11.134
9.
0/
"'"
____~@;;;;.--~1
1. Lower heat shield
2. Isolator brackets
3. Isolators
4. Upper heat shields
10. Release the clamp securing the headers to the
catalyst box.
11. At the cylinder head, release the nuts securing
the header pipes to the head.
- - ) ~~::::::=
----r// ""
~~:::;;=:
1. Silencer bracket
2. Fixings
5. Detach the silencers from the catalyst box.
6. Collect the silencer gaskets.
7. Disconnect the oxygen sensor connection from
the wiring harness.
8. Remove the upper heat shields from the exhaust
headers.
1. Header downpipe
2. Fixings
12. Detach and remove the header assembly.
13. Collect the header gaskets from the head and
catalyst box entry.
Note:
~.
11.135
1. Catalyst box
2. Fixing
15. Detach the catalyst box by easing it to the right
hand side of the motorcycle.
Note:
2.
1. Catalyst box
2. Right hand mounting
3. BolVwasher
3. Fit new gaskets to the cyiinder head ports.
--\
\\~:::
,
11
"-
cl",
1. Cylinder head ports
2. Gaskets
Note:
4.
5.
6.
11.136
15.
e/
~4
1.
2.
3.
4.
11.137
1. Carbon canister
2. Purge valve
3. Canister ties
11.138
~PIPEA
~ ROLL OVER VALVE
CANISTER
THROTTLE BODIES
PIPE C
\,-f
\
~PIPEB
11.139
~PIPEA
~ ROLL OVER VALVE
CANISTER
THROTTLE BODIES
PIPE C
\-f
\
~PIPEB
11.140
12 Cooling
Table of Contents
Exploded View - Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2
12-3
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4
Radiator Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4
12-4
12-5
12-5
Coolant Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-6
Drainage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling
" .. . . . . . .. .. .. . . . . . . . .. .. .. .. .. . . .. .. .. .. . .. .. . . .. . . . . .
12-6
12-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-7
Removal
" .. .. . .
. . .. .. . . .. .. . . ..
.
...
.
.
.. ..
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
12-7
12-8
12-8
12-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-9
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Inspection. . .. .. .. .. .. . .. . . .. .. .. .. .. . . .. . . .. . .. .. .. .. . . .. . .. . . .. .. . .. . . . . 12-10
Installation
12-10
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
12-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
12-11
12-13
12-13
12.1
Cooling
" tor
- Ra d la
Exploded V"ew
I
~3Nm
~~~
)P~
-3Nm
/J
2 5Nm
~~
..J'A{l'iUlIIIl
~"I
"
9Nm
~gm
--------~~~~~al
12.2
Service Manu
- Rocket III
"\
7 Nm
Cooling
Exploded View - Water Pump, Expansion Tank and Hoses
4Nm
1/ ~
~/
12Nm
~~
~~
~'
12.3
Cooling
Coolant
Using high-pressure water, as from a pressurewasher, can damage the radiator fins and impair the
radiator's efficiency.
Do not obstruct or deflect airflow through the
radiator by installing unauthorized accessories in
front of the radiator or behind the cooling fan.
Interference with the radiator airflow can lead to
overheating and consequent engine damage.
Radiator Hoses
Regularly check all radiator hoses and hose clips for
cracks, leaks or deterioration.
12.4
Cooling
Coolant Level Inspection
Note:
2.
1. Intake cover
2. Intake cover screws
3. Remove the cap from the expansion tank, and
add coolant mixture through the filler opening
until the level reaches the 'MAX' mark. Refit the
cap.
Note:
1. Expansion tank
2. MAXmark
3. MIN mark
4. Fluid level
3. If the coolant is below the minimum level, or
exceeds maximum, the coolant level must be
adjusted.
4.
12.5
Cooling
2.
Coolant Replacement
Drainage
1. Radiator cap
2. Security screw
3.
4.
Note:
1. Radiator cover
CbKg
12.6
Cooling
Water Pump
Filling
1.
2.
3.
Removal
1. Bleed screw
4.
5.
6.
7.
1.
2.
3.
cbxi
6.
Note:
7.
~.
12.7
Cooling
Inspection
1.
2.
3.
Installation
Replace the water pump '0' ring seal.
1.
cbxk
5.
6.
7.
cbxj
coxk
Note:
12.8
Cooling
Coolant Pressure Cap
Thermostat
Inspection
Removal
2.
1. Lower Seal
2. Upper Seal
3. Spring
Note:
3.
4.
1. Top hose
2. Bypass hose
5. Release the fixings securing the thermostat
housing to the cylinder head.
6. Withdraw the housing and collect the thermostat.
12.9
Cooling
4.
Inspection
1.
2.
3.
Installation
ccei
1.
2.
1. Coring/groove
5.
6.
7.
8.
9.
1. Thermostat
2. Jiggle pin
3. Rotate the thermostat until the jiggle pin is in the
fully upright position.
Note:
12.10
Cooling
Radiator
Removal
6.
~
1
~I
7.
1. Top hose
2. Bypass hose
5.
12.11
Cooling
8.
12.12
Cooling
Inspection
Installation
1.
2.
1.
3.
2.
3.
4.
5.
T8&!!!JB'
12.13
Cooling
12.14
13 Rear Suspension
Table of Contents
Exploded View - Swinging Arm
" ..
.. ..
.. ..
. .. . . . .. . . . . .
13.2
13.3
13.4
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suggested Suspension Settings. . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
..............................
.. . . . ..
..
..
..
..
..
13.4
13.4
13.4
13.5
13.5
13.5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
13.5
13.6
13.6
13.8
Removal
Installation
~.
...............
...............
...............
...............
...............
..
..
..
..
..
.........
.........
.........
.........
.........
,.
13.8
13.8
13.1
Rear Suspension
Exploded View - Swinging Arm
69Nm
ffu/~
_-~
-~
15 Nm
100Nm
13.2
Rear Suspension
Exploded View - Rear Suspension Units
28Nm
~'
13.3
Rear Suspension
Rear Suspension Units
Note:
The details given in the table are to be
used as a guide only where the rider and
passenger each weigh 90 kg or less.
Selting requirements should be increased
for heavier riders and passengers and
according to personal preferences.
Adjustment
The rear suspension is adjustable for pre-Ioad only.
To change the rear suspension spring pre-Ioad
setting, insert the adjustment tool supplied in the tool
kit into the hole provided in the adjuster ring.
Removal
1.
Note:
2.
Suspension Preload
Selting
Rider only
Position 1
Position 2
Position 5
13.4
Rear Suspension
Inspection
1.
2.
3.
Removal
Installation
1.
2.
1.
2.
3.
4.
5.
Note:
3.
4.
1. Brake pipe
2. Clips (rear of two shown)
3. Rearward clip location on swinging arm
13.5
Rear Suspension
6.
1. Locking ring
2. Swinging arm pivot
1. Drive shaft
2. Gearbox output shaft
3. Tool T3880062
7.
Inspection
Note:
8.
9.
1.
2.
3.
Installation
Note:
1. Swinging arm
1.
2.
2. Drive shaft
13.6
Rear Suspension
3.
1. Pivots
2. Frame
1. Swinging arm
2. Bearing
4.
5.
6.
7.
8.
9.
10.
1. Tool T3880062
11. Apply a smear of general purpose grease to the
drive shaft sleeve, inside and out.
~.
13.7
Rear Suspension
Swinging Arm Bearings
Removal
~~~~~~:~
\)
1.
Note:
1. Drive shaft
2. Swinging arm
3. Sleeve
14. Align the two brake pipe clips to the right hand
side of the SWinging arm. Tighten the clip fixings
t07 Nm.
2.
Note:
3.
Installation
Note:
1.
13.8
Rear Suspension
2.
3.
13.9
Rear Suspension
13.10
14 Front Suspension
Table of Contents
Exploded View - Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-2
14-3
Fork Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14-4
Front Fork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
14-4
14-5
14-5
Oil refilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14-7
Front Fork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
Inspection.. . . .. .. . . .. . .. .. . . . .. . . .. .. . . .. . . .. ... .. . . . . . .. . . . . . . . . . . . ..
14-12
Assembly ... , . . .. ... . . .. ... . .. . .. .. . . . ... . . .. . . . .. ... . . . . . . .. .. . . . . . ..
14-12
Steering Head Bearing Check and Adjustment.. . . . .. . . . .. . . . .. .. . .. . . ..
.. . . . . . .. ..
14-15
Check
'" .. . .. . . ..
. . .. .. . . . ..
Adjustment...............................................................
Bottom Yoke and Headstock Bearings. . . . .. .. . .. .. .. . .. . . . .. .. .. . . . .. .. . .. . .. ..
Yoke Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Bearing removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
,
,
'" .. .. . . . .
14-15
14-15
14-17
14-17
14-17
14-18
~.
14.1
Front Suspension
Exploded View - Front Fork
SEE TEXT
~r
20Nm
--
22Nm--.
o ~2Nm
~5Nm
ccgi
14.2
Front Suspension
Exploded View - Top and Bottom Yokes/Steering Head Bearings
3Nm
1\
26Nm
26Nm
~l1d
11 'fi
~-~~5Nm
9Nm
14.3
Front Suspension
Fork Inspection
Front Fork
Removal
4.
5.
14.4
"I'D_uo'
1a~
Front Suspension
6.
1.
2.
Installation
1.
2-
1. Fork
2. Caliper mounting
1. Outer tube
2. Outer tube lip
3. Top yoke
2.
3.
4.
5.
6.
7.
~.
3.
Note:
4.
5.
14.5
Front Suspension
6.
"""
1. Spacer
2. Spring cap
3. Spring
Note:
""'k
1. Damper locknut
2. TooIT3880067
3. Spring holder
8.
14.6
Front Suspension
Note:
Oil refilling
4.
5.
89~
6.
2.
3.
ob"
1. Tool 3880160-T0301
2. Adjuster plate
3. Scale area
4. Hole (zero position)
1. Tool 3880085-T0301
10. Refit the spring spacer.
14.7
Front Suspension
13. Refit the top cap to the damper rod.
14. Hold the top cap while tightening the damper rod
locknut to 16 Nm.
While recompressing the fork spring and while the
spring holder is in place always wear protective
equipment for the face and eyes and never stand
directly above or look directly down onto the fork. If
the spring compressor or hoider should dislodge or
detach, the resulting release of spring tension could
cause parts to fly off resulting in injury to the user.
11. Refit tool T3880067 as previously described,
compress the fork spring and refit the spring
holder.
Note:
1. Tool T3880067
2. Spring holder
~15.5mm
\
CO,,"
14.8
Front Suspension
Front Fork
Before starting work, ensure the motorcycle is stabilised and adequately supported.
from falling and causing injury to the operator or damage to the motorcycle.
Disassembly
"'ob
1. Top cap
2.0-ring
3. Spacer
4. Spring seat
5. Spring
6. Damper rod/cylinder
7. Inner tube
8. Dust seal
~.
Fork components
9. Circlip
10. Oil seal
11. Washer
12. Bush
13. Outer tube
14. Sealing washer
15. Damper rod bolt
14.9
Front Suspension
1.
2.
000'
1. Fork
2. Caliper mounting
",,'
1. Damper locknut
2. TooIT3880067
3. Spring holder
7. Slacken the locknut, unscrew and remove the top
cap. Recompress the fork spring to remove the
holder.
Note:
3.
Note:
4.
5.
14.10
Front Suspension
8.
1. Tool 3880090T0301
1. Spacer
2. Spring cap
3. Spring
9. Holding both the outer and inner tubes together,
invert the fork and pour out the fork oil into a
suitable container. Pump the damper rod to
remove all oil.
2. Damping cylinder
13. Remove the tool, then the damping cylinder from
the inner tube.
~1
1. Damping cylinder
2. Inner tube
14. Using finger pressure, remove the dust seal from
the outer tube.
~1
""'m
1. Inner tube
2. Outer tube
12. Remove the damper rod locknut then insert the
square end of tool 3990090-T0301 over the
damper rod and engage the square in the
damping cylinder cup inside the fork. Hold the
hexagonal end of the tool to prevent the cylinder
from turning while removing the damper bolt from
the bottom of the fork.
1. Dust seal
2. Outer tube
~.
14.11
Front Suspension
15. Remove the circlip from above the seal.
Assembly
Note:
1. Circlip
1.
2.
1. Seal removal
1. Outer tube
2. Washer
Inspection
1.
2.
3.
14.12
Front Suspension
3.
1. Seal
2. Tool 3880080T0301
4. Refit the dust seal, using finger pressure only.
5.
1. Inner tube
2. Outer tube
6. Fit the damper to the inner tube and engage tool
3880090-T0301 to the damper cup (as for
removal).
7. Clean the threads of the damping cylinder bolt
and fit a new sealing washer. Apply a drop of
three-bond 1342 to the threads then install the
bolt. Prevent the cylinder from turning by holding
the hexagonal end of tool 3880090T0301 while
tightening the damping cylinder bolt to 45 Nm.
ob,,,
1. Dust seal
2. Outer tube
1. Tool 3880090T0301
2. Cylinder
~.
14.13
Front Suspension
6.
~15.5mm
\
",,!::-.--~--'-------'
1. TooIT3BB0067
2. Spring holder
0"'''
1. TooI3BBOOB5T0301
13. Refit the spring spacer.
Note:
14.14
Front Suspension
Steering Head Bearing Check and
Adjustment
Adjustment
1.
1.
2.
3.
2.
1. Upper cover
2. Screws
14.15
Front Suspension
3.
Note:
7.
1. Top nut
Note:
4.
1. Top nut
8. Check that the free play has been eliminated and
that the steering can be turned freely from lock to
lock without any sign of tightness. Re-adjust if
necessary.
1. Locknut
2. Adjuster nut
5. Slacken the locknut and adjuster nut.
6. Adjust the bearing free play as follows:
a) Tighten the adjuster nut to 40 Nm.
b) Slacken the adjuster nut fUlly.
c) Re-tighten the adjuster nut to 6 Nm.
d) Loosen the adjuster nut by 90. Note that
there will now be free-play present.
e) Hold the adjuster nut in that position while
tightening the locknut to 40 Nm.
14.16
Front Suspension
Bottom Yoke and Headstock Bearings
5.
Yoke Removal
1. Locknut
2. Adjuster nut
6.
7.
Bearing removal
1.
1. Upper cover
2. Screws
3.
4.
2.
1. Top nut
14.17
Front Suspension
3.
Installation
1.
--;---1
obwm
1. Headstock
2. Bearing outer race
3. Bottom yoke Installation
1. Steering stem
2. Dust shield
2.
4.
5.
6.
7.
1. Bearing
2. Press
3. Press bed
1. Top nut
14.18
Front Suspension
8.
14.19
Front Suspension
14.20
15 Brakes
Table of Contents
Exploded View - Front Brake Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-3
15-4
15-5
15-6
15-7
15-8
15-8
Brake Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-8
15-8
15-9
15-11
Removal.................................................................
Installation
... ... . .. . .... . ... .. .. ... ... .. ... .. . .... ..
15-11
15-11
Removal. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
. ...
15-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
... . ... .. .. . .... .. .. .. ... ... ... .. ... . ..
.... ... . .. . .. ... .. .. ... ... .. ... .. ... ...
.......................................
.......................................
15-13
15-13
15-14
15-14
15-14
15-15
Wear....................................................................
Removal.... . . .. . . . . . .. .. . . .. . . ... . . . . . . . .... . .. ... .. . .. .. ... ... ... . . .. ..
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
15-15
15-15
15-16
...
.. . .
15-16
15-16
15-17
15-17
15-18
15-18
15-20
15-22
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-22
Removal . . . . . . . . . . . . . . . . . . . . . .
Disassembly.. . . . . .. .... . . . . ...
Inspection. . . . . . . . . . . . . . . . . . . . .
Assembly.. ..
. .. .
.
Installation
~'
15.1
Brakes
Installation
15-24
15-24
Wear
Removal.
Installation
.
.
.
.
.
.
.
.
15-24
15-25
15-25
15-25
Removal.
Disassembly
Inspection
Assembly
Installation
15.2
15-23
15-25
15-26
15-27
15-27
15-28
Brakes
i
2Nm_
C?
i-r
;e;
~
15Nm~
"
~.
6Nm
15.3
Brakes
Exploded View - Front Brake Caliper and Disc
5Nm
;r
\
~@
40Nm~
SEE TEXT
~22 Nm
15.4
~ONm
Brakes
Exploded View - Rear Brake Master Cylinders
2Nm
it
"'"
15.5
Brakes
Exploded View - Rear Brake Caliper and Disc
~ ~8Nm
~~
r'V
SEETE~
22Nm
~
"""
15.6
"I'b_'
.~
Brakes
Braking System Maintenance
Safety Precautions
~.
15.7
Brakes
Brake Fluid Level Inspection
Brake Pads
Front and rear brake pad wear is automatically
compensated for and has no effect on brake lever or
pedal action.
15.8
Brakes
Bleeding the Front Brakes,
Renewing Brake Fluid
4.
5.
6.
I
o
1. Diaphragm
9. Release the bleed nipple.
1. Bleed Nipple
2. Spanner
3. Bleed Tube
4. Container
~.
15.9
Brakes
15.10
Brakes
Front Brake Pads
4.
Removal
Installation
"'"
1. Retaining Pin
2. Anti-rattle Spring
3. Brake Pads
1.
2.
~.
15.11
Brakes
1.
3.
4.
5.
15.12
Brakes
Disassembly
2.
3.
4.
1. Caliper
2. Fluid supply
1. Caliper
2. Wheel
15.13
Brakes
Inspection
1.
2.
2.
3.
Installation
Assembly
1.
1.
2.
3.
4.
5.
1. Caliper bore
2. Fluid seal
6.
7.
8.
15.14
Brakes
Removal
Front Discs
1.
2.
Wear
Standard
5.0 mm
Service limit
4.0 mm
Disc Run-out
Standard
0.1 mm
Service limit
0.3 mm
cbzh
1. Wheel
2. Support block
3.
4.
5.
du.
1. Disc
2. Dial Gauge
15.15
Brakes
Installation
1.
2.
3.
4.
5.
Removal
3.
4.
5.
1. Lever
2. Adjuster wheel
3. Triangular mark
6. Disconnect the brake hose and brake light switch
connections to the master cylinder.
7. Release the clamp screws from the handlebar to
remove the master cylinder.
15.16
Brakes
Disassembly
1.
2.
4.
1. Piston Set
Inspection
"'''
1. Dust cover
3. Remove the circlip from beneath the dust cover.
cbzj
1. Circlip
1.
"",
1. Cylinder bore (1)
2. Dust cover (2)
3. Spring (3)
4. Piston (4)
5. Pivot Bolt (5)
Note:
~.
15.17
Brakes
2.
2.
cb~m
1. Piston
2. Seal (in correct orientation)
3. Refit the master cylinder dust cover.
1. Ports
Assembly
Installation
1.
2.
3.
2~
\II.:".,....--;~
1. Split line
2. Dot mark
4. Tighten the clamp bolts, upper first and then the
lower to 15 Nm.
15.18
Brakes
5.
15.19
Brakes
Bleeding the Rear Brakes,
Renewing Brake Fluid
1. Bleed Nipple
2. Spanner
3. Bleed Tube
3. Place the other end of the tube in a suitable
receptacle containing new brake fluid.
15.20
Brakes
5.
1. Diaphragm
6.
Note:
7.
8.
9.
~.
15.21
Brakes
Rear Brake Pads, Rear Brake
Caliper
4.
Removal
1.
1. Caliper
2. Caliper carrier
6.
1. Wheel spindle
2. Caliper carrier
3.
""
1. 'R' Clips
2. Pad retaining pin
7.
1. Torque reaction bolt
2. Spacer
15.22
8.
Brakes
4.
Installation
5.
Never use mineral based grease in any part of the
braking system or in any area where contact with
the braking system is possible. Mineral based
grease will damage the hydraulic seals in the
calipers and master cylinders. Damage caused by
mineral based grease may reduce braking efficiency
resulting in loss of motorcycle control and an
accident.
2.
1. Wheel hub
2. Spacer
6.
7.
8.
9.
3.
~.
15.23
Brakes
11. If the brake hose has been disconnected, bleed
the rear brake as described on page 15.20.
12. Pump the brake pedal to correctly position the
caliper pistons.
Standard
7.5 mm
Service limit
6.5 mm
Disc Run-out
Service limit
0.15 mm
\
cbzy
1. Disc
2. Dial Gauge
15.24
Brakes
Rear Master Cylinder
Removal
Removal
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.
1.
2.
3.
Installation
1.
2.
3.
4.
"
'1
3.
1. Heel guard
2. Heel guard fixings
~.
15.25
Brakes
4.
~3~~~'~j==='T\I~1==~,~,rl==;;;
1. Pedal
2. Pushrod
3. Clevis
5.
7.
Disassembly
1.
2.
6.
1. Circllp
1. Brake pipe
15.26
Brakes
3.
i ..
n -n-n--
Assembly
1. Piston
Inspection
1.
~5
Fit the new piston and seal set into the master
cylinder.
\ l-{HH\"",
1. Cylinder bore
2. Dust cover
3. Spring
4. Piston
5. Pivot bolt
2. Examine the push rod for distortion and other
damage. Replace as necessary.
~.
1. Piston
2. Seals (in correct orientation)
3. Apply a small amount of brake grease to the
push rod.
4. Install the pushrod in the master cylinder,
compress the spring and retain the assembly
with a new circlip.
15.27
Brakes
5.
1. Pushrod
2. Circlip
5.
Installation
1.
2.
3.
4.
6.
1. Reservoir hose
2. Clips
1. Heel guard
2. Fixings
15.28
Brakes
7.
~.
15.29
Brakes
15.30
16 WheelslTyres
Table of Contents
Exploded view - Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.2
16.3
Tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.4
Tyre Pressures. . . . . . . . . . . . . . . . . . .
Tyre WearlWheel Inspection. . . . . . . . .
Minimum Recommended Tread Depth.
Important Tyre Information. . . . . . . . . .
......
......
......
......
..
..
..
..
....
....
....
....
....
....
....
....
...
...
...
...
...
...
...
...
...
...
...
...
....
....
....
....
.............
.............
.............
.............
Front Wheel
16.4
16.4
16.5
16.5
16.6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
16.6
16.7
Rear Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.8
Removal.. . .
Installation
. . .. .. . . . . .. . . . .. . . .. .. .. .. .. . . ..
.. ..
.. . . .. . .. . .
..
Cush Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal... . . .. . . . .
Installation
'l\qgJB'
. . . . .. .. . . . . . . . . .. . . .. . . . . . .. .. . .
.. . . . .. ..
.. .
16.8
16.9
16.10
16.10
16.11
16.1
WheelslTyres
Exploded view - Front Wheel
16.2
WheelslTyres
Exploded View - Rear Wheel and Cush Drive
,
\
,
\
"'ll'
~'
110 Nm
16.3
WheelslTyres
Tyres
This model is equipped with tubeless tyres, valves,
and wheel rims. Only tyres marked 'TUBELESS' and
tubeless type tyre valves mounted on rims marked
'SUITABLE FOR TUBELESS TYRES' can be used.
1. Wheel Marking
2. Tyre Marking
Tyre Pressures
The correct tyre pressures for Rocket III are shown in
the table below. The tyre pressures must always be
checked and adjusted when the tyres are cold.
Loading
condition
Front
Rear
Rider only
2.34 Bar
(34 Ib/in 2)
2.90 Bar
(42Ib/in 2)
Rider,
passenger and
luggage
2.34 Bar
(34 Ib/in 2)
2.90 Bar
(42Ib/in 2)
16.4
WheelslTyres
Important Tyre Information
2 mm (0.08 in)
16.5
WheelslTyres
Front Wheel
Removal
Accurate wheel balance is important for safe, stable
handling of the motorcycle. Do not remove or
change any wheel balance weights. Incorrect wheel
balance may cause instability leading to loss of
motorcycle control and an accident.
When wheel balancing is required, such as after tyre
replacement, see your authorised Triumph dealer.
Only use self-adhesive weights. Clip-on weights will
damage the wheel and tyre potentially resulting in
tyre deflation, loss of motorcycle control and an
accident.
Note:
v
1. Fork pinch bolts
16.6
WheelslTyres
4.
Installation
1.
""'
1. Wheel spindle
5.
o
o
o
"'wo
1. Spacer
6.
1. Spacer
2. Hub
2. Position the wheel between the forks.
3. Raise the wheel until it is in alignment with the
spindle holes in both forks. Take care to not
dislodge the spacer.
4. Refit the wheel spindle from the left hand side
and tighten to 65 Nm.
5. Check that the brake disc is centrally located to
the caliper on the left hand side. If not, apply
gentle pressure to the fork to ensure the disc is
centred with the caliper.
6. Maintaining the above position, tighten the fork
pinch bolts to 22 Nm.
7. Thoroughly clean and degrease the brake discs.
8. Fit the brake calipers, tightening the mounting
bolts to 40 Nm.
9. Check the operation of the front brake. Rectify
as necessary.
16.7
WheelsITyres
Rear Wheel
4.
Removal
1. Wheel
2. Caliper carrier
3. Spacer
Note:
5.
6.
1. Wheel spindle
2. Bevel box
3.
7.
8.
16.8
WheelslTyres
Installation
6.
1.
2.
7.
3.
4.
1. Spacer
8.
1. Wheel
2. Bevel box
5.
1. Wheel spindle
2. Bevel box
1\@9R'
16.9
WheelslTyres
11. Pump the brake pedal to correctly position the
caliper pistons.
12. Check the operation of the rear brake. Rectify as
necessary.
Cush Drive
Removal
2.
1. Wheel centre
2. Driven Flange
3. Circlip
3. Withdraw the driven flange from the wheel,
recovering the spacer from the cush rubber side
of the flange.
Note:
16.10
WheelslTyres
4.
3.
-----,
1. Wheel
2. Cush Drive Rubbers
1. Driven flange
4. Retain the assembly with a new bold circlip.
Installation
1.
2.
1. Wheel centre
2. Driven Flange
3. Circlip
5. Refit the rear wheel as described on page 16.8.
1. Driven flange
2. Spacer
16.11
WheelslTyres
16.12
, . . .. ..
17-2
,. .. . . .. ..
17-3
, . . .. . . . ..
17-4
17-5
17-6
17-7
17-8
Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Rider's seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat lock
, .. . . .. . .. . .. . .. . .. .. .. .. .. . .. .. .. . . .. . . . ..
Rear Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17-9
17-9
17-9
17-9
Side Covers .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
,
" ., . .
. . ..
17-9
17-9
17-9
17-10
17-10
17-10
.
.. . . . . . .. .. .. ..
Front Mudguard. "
,
...
. . . . . . .. .. .. .. .. .. . .. . . .. .
Removal
, .. .. . . ..
Mudguard embellisher removal
Embellisher assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation..............................................
17-10
17-10
17-11
17-11
17-11
Rear Mudguard.
.. .. .. . . . . .. . . .. .. . .. .. .. .. .. ..
.. ..
..
.. .. . . . .. .. .. ..
Removal
,
, ..
Wiring connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
, .. . . .. . .. .
. . . ..
. . . . ..
.. . . . . . .
17-12
17-12
17-12
17-13
"
.. . . . .. .. .. . .. ..
, ..
. ..
17-15
17-15
17-16
Side Stand
, ..
. . . . .. . . . . . ..
.. .. .
.. .. . .. .. . .
Removal.................................................................
Installation...............................................................
17-17
17-17
17-17
Handlebars
Removal
Installation
, .. . .. .. .. ..
"
.. . .
17.1
.cO
SEETEXT---
17.2
~/
~
I~
27Nm
5Nm
64Nm
14Nm
26Nm
~"
17.3
3Nm
'Y
~~-~-
17.4
- ~~----~~
3Nm
9Nm
10Nm
~.
:I
17.5
9Nm
17.6
17.7
" 5mm
17.8
Seats
Removal
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.
Rider's seat
The seat lock is located at the rear of the right hand
side cover. To remove the rider's seat, insert the
ignition key into the seat lock and turn it anti-clockwise
while pressing down on the rear of the seat. This will
release the seat from its lock and allow it to be slid
upwards for complete removal from the motorcycle.
1. Screws
2. Side covers
Seat lock
Note:
4.
Installation
1.
2.
Rear Seat
Remove the rider's seat and release the fixings
securing the rear seat to the mudguard.
To refit the rear seat, position it to the rear mudguard
and tighten the three fixings to 9 Nm. Refit the rider's
seat.
3.
4.
5.
17.9
Front Mudguard
Removal
Removal
1.
1. Mudguard shroud
2. Mudguard shroud fixings
3. Fork leg
2. Detach both shrouds.
1. Infill panel
2. Withdraw the infill panel.
3.
Note:
<:
Installation
2.
3.
1.
Note:
17.10
1. Mudguard Flxlngs
2. Mudguard
1.
2.
1. Sticker
2. Screw head
3. Release the screw to allow detachment of the
embellisher.
Embellisher assembly
Installation
1.
1. Embellisher
2. Star washers
~.
2.
3.
4.
5.
17.11
Rear Mudguard
Removal
4.
6.
Wiring connections
1. Mudguard cover
2. Grommet
Note:
17.12
g.
--=
1. Mudguard
2. MUdguard brace
1. Mudguard flxlngs
8.
Installation
1.
2.
3.
1. Locating arms
2. Frame cross tube
4.
17.13
1. MS fixing
2. M10 fiXing
1. Fixings
6.
7.
8.
9.
1. Cover
2. Grommet
17.14
Handlebars
Removal
1.
1. Upper cover
2. Screws
8. Pivot the instruments forward to reveal the
handlebar clamp bolts.
1. Handlebar
2. Spacer
3. End weight
4. Fixing
2. Release the wiring and brake hose from its clips
on either side of the handlebar.
3. Undo the screws and free the left switchgear
assembly from the handlebar.
4. Unscrew the bolts and remove the clamp from
the clutch lever assembly.
5. Undo the screws and free the right switchgear
assembly from the front brake master cylinder.
Free the switch wiring from the handlebars.
6. Unscrew the bolts and remove the clamp from
the master cylinder.
17.15
Installation
1.
2.
lliJ
--r7"~~"ie----...
II,-y---_
1A
o
Cbsz
8.
9.
3.
4.
5.
<:::::::>
\I\\\\\\\\
1~
/e
~~-,-
1. Handlebar
2. Spacer
3. End weight
4. Fixing
6.
17.16
'lEli'
'lEli'
o od'
Installation
1.
2.
3.
4.
17.17
17.18
18 Electrical System
Table of Contents
Exploded View - Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
18-3
18-4
18-5
18-6
18-7
18-8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18-9
18-10
18-11
18-11
18-11
Fuse Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
18-12
18-12
'" . . ..
.. ..
.. .. . .. . .
. .. .. . . . . .
.. .. . . . .. .
18-14
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . .. . . .. . . . .
.. . . . .. ..
Indicator Lights
,
, . .. . .
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator.. ..
.. .. . . .. ... .. ..
.. . . ..
18-15
Removal.
. . .. .. . .. ..
.. .. . . . . .
. . . ... . .. .
.. . . ..
.. . . ..
Inspection
,.....
. . . .. . .. . .
Assembly. . .. .. .. .. . .. ..
.. . .. .
. . .. .. .. .. . . . . ... .. .. ... . . .
.. .. ..
. ..
...
18-15
18-16
18-16
Alternator Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
18-17
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
18-17
18-1 7
..
18-18
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation
18-18
18-1 8
Starter Motor
~.
"
. .. . .
.. ..
... . .. . .. .
18-14
18-14
18-14
.. . . ..
.. .
.. .. .. .. . .. . .
18-12
18-13
18-13
.. .. .. ..
.. .. .. .
18.1
Electrical System
Relays
Identification and location
Relay identification - left hand side
Relay identification - right hand side
ECM Connector Pin Numbering
Lighting Circuit
.
.
.
.
Complete System
18-25
18-26
18-23
18-24
18-21
18-22
18-19
18-19
18-19
18-19
18-20
18.2
18-19
18-26
Electrical System
Exploded View - Instruments
2Nm
~'
18.3
Electrical System
Exploded View - Alternator
9Nm
9Nm
~,
r
rD """'nJ
120Nm
18.4
Electrical System
Exploded View - Starter Motor
""
27 Nm
18.5
Electrical System
Exploded View - Headlight
c;:::::::'
3Nm
2~
)-'
~-------
~15Nm
CB \g)
\g)
(
4Nm
18.6
Electrical System
Exploded View - Rear Light and Indicators
9Nm
2Nm
"--.....
""~"'"
Jill
.,~ ~
:
~~
~
PUSH FIT
:~O,
I
I
I)
~O"
,7
2 Nm
"
'-"';j
2Nm
18.7
Electrical System
Exploded View - Battery, Horn and Wiring
PUSH FIT
1\
27Nm
/"'~
9Nm
L~
4Nm
J\
.-
9Nm
~/
~'"
18.8
Electrical System
Battery Removal
Battery
Battery Disposal
1. Battery
2. Battery strap
3. Poslllve (red) terminal
4. Negative terminal
1.
2.
3.
4.
5.
~.
18.9
Electrical System
Battery Installation
1.
2.
3.
4.
5.
6.
7.
18.10
Electrical System
Fuses
Terminal
Voltage
Measured
ChargeTime
(hours)
Charge Cutoff
Voltage
12.8
14.5
12.7
14.5
12.6
14.5
12.5
14.5
8-10
14.5
2
6
10
000000
000000
~'2345
2
11
fii1rol
WW,;.,....".....
ITIJ ~~J
1. Fuse box
2. Spare fuses
Note:
Numbers
shown
in
the
diagram
correspond to the fuse position numbers
in the table below.
Battery Maintenance
Clean the battery using a clean, dry, cloth. Be sure
that the cable connections are clean.
18.11
Electrical System
Fuse Identification
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.
Circuit Protected
Rating
(Amps)
Position
15
30
1
2
socket,
Accessory
instrument memory,
heated grips, ciock
10
Alarm,
diagnostic
connector, indicators,
brake lights
15
Instruments,
fuel
pump relay, starter
relay, main power
relay, fall detection
switch
10
Engine management
system
20
Cooling fan
15
5
7
8
Upper
and
lower
headlight
beams,
starter solenoid
20
Position lights
5
30
Accessory lights
Ignition switch main
feed
Instrument
illumination,
lights
Main fuse
Note:
position
10
11
Headlights
1.
2.
3.
4.
18.12
5.
6.
7.
8.
Electrical System
Headlight Horizontal Adjustment
1.
2.
3.
"'"'
4.
5.
1.
6.
2.
7.
3.
4.
8.
g.
5.
6.
7.
8.
",,'
1. Headlight bulb
2. Bulb clip
3. Position light bulb
~.
18.13
Electrical System
Rear Light
Indicator Lights
Bulb Replacement
Bulb Replacement
1. Lens
2. Lens screw
3. Bulb
Note:
2.
3.
4.
5.
6.
1.
18.14
Electrical System
7.
Alternator
Removal
1.
2.
3.
4.
1. Starter motor
2. Starter motor fixings
3. Alternator cover
5. Release the bolts securing the alternator cover to
the rear of the engine.
6. Withdraw the alternator cover from the
crankcase.
1. Rotor
2. Rotor bolt
3. Tool T3880201
8. Screw tool T3880200 into the rotor centre.
9. Prevent the rotor from turning using tool
T38B0201 while tightening tool T3880200. This
will release the taper seating of the rotor to the
crankshaft.
Note:
1. Rotor
2. TooIT3880200
3. Tool T3880201
10. Withdraw the rotor and tool as an assembly and
then separate the tool from the rotor.
Note:
18.15
Electrical System
11. To remove the stator, release the two bolts
securing the cable retainer to the crankcase.
Assembly
1.
2.
3.
1. Cable retainer
2. Bolts
12. Release the three bolts securing the stator to the
crankcase.
1. Stator
2. Cable retainer bracket
3. Fixings
4. Tighten the stator bolts to 12 Nm.
5. Assemble the rotor to the keyway on the
crankshaft.
6.
7.
8.
1. Stator
2. Stator bolts
13. Withdraw the stator from the crankcase.
Inspection
1.
2.
3.
18.16
Electrical System
9. Remove tool T3880201 .
10. Incorporating a new gasket, refit the alternator
cover to the rear of the engine.
11. Tighten the alternator cover bolts to 9 Nm.
12. Incorporating a new a-ring seal, fit the starter
motor and tighten the starter fixings to 27 Nm.
13. Refit the engine as described on page 10.5.
14. Reconnect the battery positive (red) lead first.
15. Refit the rider's seat.
Alternator Rectifier
Note:
Removal
1.
2.
3.
4.
1. Rectifier
2. Multi-plugs
5.
Installation
1.
2.
3.
4.
5.
18.17
Electrical System
Installation
Starter Motor
1.
Removal
1.
2.
3.
4.
5.
Arrowed - O-ring
2.
3.
4.
5.
6.
7.
8.
1. Boot
2. Cable
3. Starter motor
6.
1. Starter motor
2. Bolts
7.
18.18
Electrical System
Relays
Note:
B9
A
/k;B1
:~:,==~~
~oOOOOOOD
B34 ~JOOOp,ooor
/:
B26
A7~
lk
A1
~~~~A8
Doooooclflll A14
DoooooGDi1lf
~~?tA20
A26
1. Starter Relay
2. Flasher Unit
~.
18.19
Electrical System
Lighting Circuit
Key To Wiring Colour Codes
Code
Wiring Colour
Black
Ignition Switch
Blue
Instrument Assembly
Brown
Instrument Illumination
Green
Warning Lights
Slate/Grey
Orange
Tail Lamp
Pink
Red
10
Headlamp 2
Purple
11
Headlamp 1
White
Key
Item Description
12
Starter Relay
Yellow
13
LG
Light Green
14
LU
Light Blue
18.20
Electrical System
Circuit Diagram - Lighting
~---~UY
RO
,-
1-------,
1
1
10
1
L
1
_ _ _ _ _ -J
14
__I}-u-------,
\\
13
1Oec:E
~
~'
7 e6 e-
18.21
Electrical System
Starting and Charging Circuit
Key to circuit diagram
Key
Item Description
Code
Wiring Colour
Battery
Black
Starter Motor
Blue
Fuse 11
Brown
Starter Relay
Green
Slate/Grey
Clutch Switch
Orange
Sidestand Switch
Pink
Red
10
Purple
11
Instrument Assembly
White
12
Yellow
13
Alarm Control
Connector
LG
Light Green
14
Starter Switch
LU
Light Blue
15
16
Ignition Switch
17
18
19
Regulator / Rectifier
20
Alternator
18.22
Unit
Or
Harness
Link
Electrical System
Circuit Diagram - Starting and Charging
'I
+
z
~ -I~I~
1
1
1
1
_ J
----jB24
YN
20
~8K
~BW
A26
A19
A25
~BR
1
A18
9
19
,1
1
1
1
1
.2
L>'-
-.
~l
6
1
61
118
1
1
--'
~
'--GR
'--NK
R-EJ
112
,.
<t>
<:0
""
CD
13
--l5'l
p
16
15
14
2
18.23
Electrical System
Auxiliary and Accessory Circuit
Key to circuit diagram
Key
Item Description
Code
Wiring Colour
Black
Ignition Switch
Blue
Brown
Green
Slate/Grey
Diagnostic Connector
Orange
Pink
Red
10
Purple
11
White
12
Yellow
13
Instrument Assembly
LG
Light Green
14
LU
Light Blue
15
Horn Switch
16
Horn
17
Indicator Relay
18
Accessory Lights
19
20
Accessory Clock
21
Accessory Socket
18.24
Electrical System
Circuit Diagram - Auxiliary and Accessory
r - - - - - - - - - - - - - - -
21
I
I
I
I
I
I
I
[Th-p
20
~I
,
I
---
D D: t = PRU
I
I
~
--
- -
,\~J
19
[J}fP
8 :1
18
DJ=RU
6
P
00p
1~ I
5~
4f-<>
~UY
5!
OG
~/
RU
1~1t:~
i!;
(Ho
4 r-P8
15
81--8~
5!
l--GP-
-4
3
2
r
3 r-GW-
11
2~
14
1~1
-GR- 3
I f-----GR
-OG
16
6f-<>
8f-<>
-----------
13
4<l-
r--
7 -GR
GR
12 -
"
8---i
8~GW
"'"
"
~
r8~2
2 f--GR
17
~I
8U
61---8~
2f-<>
ffi
17
FU
GW
10
~'
18.25
Electrical System
Complete System
Key to Circuit Diagram
Key
Item Description
39
Rear Light
40
41
LH Rear Indicator
42
43
44
Battery
45
Starter Relay
46
Rectifier / Regulator
47
Alternator
48
Fuse Box
49
Ignition Switch
50
51
Accessory Socket
52
Handlebar
Heated
(Accessory)
53
16
54
17
2 nd Throttle Potentiometer
55
Horn Button
18
Throttle Potentiometer
56
19
57
20
58
21
59
LH Front Indicator
22
60
Position Light 1
23
MAP Sensor
61
Headlamp 1
24
Purge Valve
62
Position Light 2
25
Ignition Coil 1
63
Headlamp 2
26
Ignition Coil 2
64
Horn
27
Ignition Coil 3
65
RH Front Indicator
28
29
30
31
32
Cooling Fan
33
Diagnostic Connector
34
Sidestand Switch
35
Engine Earth
36
Crankshaft Sensor
37
38
RH Rear Indicator
Key
Item Description
Instrument Assembly
Starter Button
Lambda Sensor
10
Fuel Injector 1
11
Fuel Injector 2
12
Fuel Injector 3
13
2 nd Throttle Actuator
14
15
18.26
Grips
Connector
asI
~ ii~~2 na x
~ i i ~ ~~ g ~,!a ~ ~
III
.:
! l;
N
~~ .
~ .~
7
~I ~
I!.
::: 0
o
.
15
!ii
!i~
-...l-.-f...-th
.~.
:: 23
~~
la
2 ~ ~
29
""
-l-A
35- U
Jg~r:~11:~i
~
'..
11 12
36
1fu
I;
17 18 1- }O
32
~=t[]37
p
i,
,
r
- ---
---
;ID
JI ,_,,,
c. _ _
.-
-I
L-_ _
I
!
63QFj[. '
0;
61
__
......
. f
" 8~
Ej
58
I- - ,
~~
53 52 51 50
. !
O~!a::)
,
>
>
:I.:I~ ~ ~ :1 .
49
I- _ _
I ()
~
....l
_;~:;,;,;;;;;;;;:;.;:;.;;;_------
=:B 2
-J'-JJI'r
U!!tf=::::;---,
"I
12
B 4
" z > ,
'v
~_.C20~XB~ ~
B 7
_ _
640=:
60~:.
-~ID:j=oo39
~
~ :::::::t 40
0041
f-- OR-==W=
B ..",. B
!
-
I-=-ow= W =-~~4:00"" 38
~Booc::J:::IoIoB
.---- B
42
B 1
B 10
B 11
'.
.!
z
I1
~~~"'
M.. ~~
\
1"
"
44
,M
43
Bl
-=-36
""" Z"
M
46
-=-36
--
--;1&:"
18.27~,