tb194 en 01 · model affected: tiger 800 xr, tiger 800 xrx, tiger xrx - lrh, tiger 800 xcx, tiger...

1 of 39Technical Bulletin 194 Issue 1

Technical Bulletin 19401.2019

ContentsItem Subject Model Affected

194.1 Front Master Cylinder Reservoir Cap Screws Street Triple S, Street Triple S 35kw, Street Triple S660cc

194.2 Windscreen Support Fixings Tiger 800 XR, Tiger 800 XRX, Tiger XRX - LRH, Tiger800 XCX, Tiger 800 XRT and Tiger 800 XCA

194.3 Keyless Ignition Speed Triple RS, Tiger 1200 XRX, Tiger 1200 XRX-LRH, Tiger 1200 XRT, Tiger 1200 XCX, Tiger 1200 XCA,Scrambler 1200 XC, Scrambler 1200 XE

194.4 Clutch Cover Removal and Installation Tiger 800 XR, Tiger 800 XRX, Tiger 800 XCX, Tiger800 XRT and Tiger 800 XCA, Tiger 800 XRX-LRH

194.5 Rider's Seat (single seat) Thruxton 1200, Thruxton 1200R

194.6 Side Stand Spring Peg Street Cup, Street Twin, Bonneville T100 models fromVIN 759204, Street Scrambler, Thruxton 1200, Thrux-ton 1200R, Bonneville T120 models

194.7 Cylinder Head Installation Tiger XCX, Tiger 800 XR, Tiger 800 XRT, Tiger XRX,Tiger XRX - LRH and Tiger 800 XCA

194.8 Alternator Oil Feed Spray Jet Speed Triple 1050 from VIN 735438 to VIN 846800,Speed Triple 1050R from VIN 735337 to VIN 858022,Speed Triple S from VIN 867685, Speed Triple RSfrom VIN 867601

194.9 Headlight and Indicator Wiring HarnessRouting

Bonneville Bobber, Bonneville Bobber Black, Bon-neville Speedmaster

194.10 Transmission Output Shaft Tiger Explorer, Tiger Explorer XC, Tiger Explorer XC(from VIN 740277), Tiger Explorer XCA, Tiger ExplorerXCX, Tiger Explorer XR, Tiger Explorer XRA, TigerExplorer XRT, Tiger Explorer XRX, Tiger 1200 XR, Ti-ger 1200 XRX, Tiger 1200 XRX-LRH, Tiger 1200 XRT,Tiger 1200 XCX, Tiger 1200 XCA

194.11 Horn Wire Routing Street Triple RS from VIN 800262, Street Triple Sfrom VIN 803572, Street Triple R from VIN 806646,Street Triple R - LRH from VIN 822626 and StreetTriple S 660 cc from VIN 800262


Technical Bulletin 19401.2019

Contents194.12 Instrument Downloads - 900cc and 1200cc

Modern Classic Models with Analogue/LCDInstruments

Bonneville T100 from VIN 759204, Bonneville T120,Bonneville Bobber, Bonneville Bobber Black, Bon-neville Speedmaster, Speed Twin, Street Cup, StreetScrambler, Street Twin, Thruxton from VIN 743684,Thruxton R

194.13 Pinpoint Test - Engine Start/Stop SwitchCorrelation Error

Tiger 1200 XRX, Tiger 1200 XRX-LRH, Tiger 1200XRT, Tiger 1200 XCX, Tiger 1200 XCA

194.14 Diagnostic Trouble Code (DTC) P2138 - TwistGrip Position Sensor 1 Correlation Error withTwist Grip Position Sensor 2

All models with ride by wire throttle

194.15 Electronic Systems Commissioning andMotorcycle Unlocking

Scrambler 1200 XC, Scrambler 1200 XE

194.16 Battery Anti-Tamper Label All models


Item: 194.1

Description: Front Master Cylinder Reservoir Cap Screws

Model Affected: Street Triple S, Street Triple S 35kw, Street Triple S 660cc

The torque figure has changed. If loosened or removed for any reason the fixing(s) must be torqued asrequired.

WarningIf the master cylinder reservoir cap screws are over tightened this can result in a brake fluid leak.A dangerous riding condition leading to loss of motorcycle control and an accident could result if thiswarning is ignored.

Tighten the fixings to 1 Nm.

1

1. Front master cylinder reservoir cap screws

• Models already in service need not be re-tightened unless the fixings have been loosened or removed.When ordering replacement parts, refer to the EPC.Please mark your copy of the Service Manual with this information. For electronic service manuals, storethis information in a readily accessible place and refer to it when working on the relevant Triumphmotorcycle. This information will be included in the next service manual update.


Item: 194.2

Description: Windscreen Support Fixings

Model Affected: Tiger 800 XR, Tiger 800 XRX, Tiger XRX - LRH, Tiger 800 XCX, Tiger 800 XRT andTiger 800 XCA

The torque figure has changed. If loosened or removed for any reason the fixing(s) must be torqued asrequired.Tighten the fixings to 1.5 Nm.

L0617

2

3 3

1

1. Instrument cowl2. Windscreen support3. Fixings

• Models already in service need not be re-tightened unless the fixings have been loosened or removed.When ordering replacement parts, refer to the EPC.

Note:

• Please mark your copy of the Service Manual and Motorcycle Assembly Guide with this information. Forelectronic service manuals and assembly guides, store this information in a readily accessible place andrefer to it when working on the relevant Triumph motorcycle. This information will be included in thenext updates.


Item: 194.3

Description: Keyless Ignition

Model Affected: Speed Triple RS, Tiger 1200 XRX, Tiger 1200 XRX-LRH, Tiger 1200 XRT, Tiger 1200XCX, Tiger 1200 XCA, Scrambler 1200 XC, Scrambler 1200 XE

If you receive a customer query relating to a potential security vulnerability with the Triumph Keylesssystem the following explains how to manually disable the smart key using the On/Off button.Once the smart key has been deactivated the radio frequency between itself and the motorcycle is disableduntil it is reactivated by the rider.

Note:

• A single press of the On/Off button will display the current status.• The status LED momentarily illuminates when the On/Off button is pressed it will not remain

illuminated.

Although the motorcycle sensor has a maximum range of one metre the smart key will continue tocommunicate with the motorcycle and is able to transmit a signal up to approximately 15 metres.

5

42

1

3

6

1. Smart key2. On/Off button3. Status LED4. Smart key range (15 metres)5. Motorcycle sensor range (1 metre)6. Standard ignition key


To Deactivate the Wireless Signal:• Press and hold the On/Off button - the status LED will illuminate green and then red, this indicates the

smart key is now disabled.

1

2

3

1. Smart key2. On/Off button3. Status LED

To Reactivate the Wireless Signal:• Press and hold the On/Off button - the status LED will illuminate red and then green, this indicates the

smart key is now enabled and will communicate with the motorcycle.

1

2

3

1. Smart key2. On/Off button3. Status LED


Item: 194.4

Description: Clutch Cover Removal and Installation

Model Affected: Tiger 800 XR, Tiger 800 XRX, Tiger 800 XCX, Tiger 800 XRT and Tiger 800 XCA,Tiger 800 XRX-LRH

When removing the clutch cover on some of the motorcycles listed above it may be necessary to loosen theengine on its mountings and rotate it to allow access to the clutch cover fixings. If the clutch cover and it'sfixings cannot be removed and tightened as described in the Service Manual the following procedure mustbe followed.

WarningBefore starting work, ensure the motorcycle is stabilised and adequately supported. This will help preventit from falling and causing injury to the operator or damage to the motorcycle.

• Raise and support the motorcycle.• Remove the riders seat, refer to the Service Manual.• Disconnect the battery negative black lead first, refer to the Service Manual.• Remove the fuel tank, refer to the Service Manual.• Remove the exhaust silencer, refer to the Service Manual.

1. Working on the right hand side of the motorcycle, release the radiator lower mounting.

1

cgxr

1. Radiator lower mount fixing


2. Remove the two fixings and remove the heel guard.

21

1. Right hand heel guard2. Fixings

3. Remove the clip from the clevis pin at the lower end of the rear brake master cylinder push rod andremove the clevis pin.

3

cgyv_2

1

2

1. Clip2. Clevis pin3. Push rod


4. Remove the E-clip at the lower end of the pivot pin for the right hand footrest, raise the rear brakepedal to allow clearance and remove the pivot pin. Retain the E-clip and pivot pin for reuse.

2 1

3

4

1. E-clip2. Pivot pin3. Footrest4. Return spring

5. Remove the brake pedal and discard the fixing.

2

1

1. Brake pedal2. Fixing

6. Support the engine on proprietary lifting jacks, at the front and rear. Position the jacks under the sumpguard, directly under the four fixings.

7. Secure the engine to the jacks, using suitable straps, to prevent it from moving or falling.8. Set the drive chain adjustment to allow maximum free play in the chain, refer to the Service Manual.

Note:

• The swinging arm finisher plates are held into position by a compressed rubber bush into the frameaperture.


9. Release the tension from the fixings and gently ease the finisher plates from both sides of the frame.

2

1

L0574

1. Fixing2. Finisher

10. Remove the swinging arm spindle nut. Discard the nut.11. Remove the rear brake light switch, refer to the Service Manual.

Note:

• Do not fully withdraw the swinging arm spindle.• Withdrawing the swinging arm spindle approximately 270 mm will allow the swinging arm to remain

aligned with the right hand side of the frame whilst allowing the engine to rotate anticlockwise.

12. Partially withdraw the swinging arm spindle from the right hand side approximately 270 mm until it isno longer in contact with the lower rear engine mounting. Do not fully remove the swinging armspindle.

13. Release the nut securing the rear lower engine mounting bolt. Collect the hardened washer from underthe nut and discard the nut.

14. Remove the rear lower engine mounting bolt and hardened washer.15. Using service tool T388166, loosen and unscrew the left and right hand frame adjusters to allow

clearance between the frame and engine.

1

2

cgyk

1. Rear lower frame adjuster sleeve2. Service tool T3880166


CautionDo not fully remove the rear cylinder head bolts.Removing the rear cylinder head bolts will allow the engine to move beyond a predetermined positionwithin the frame.If the engine exceeds the predetermined position personal injury and damage to the engine assembly andit's ancillaries will be caused.

16. Loosen but do not remove the rear cylinder head mounting bolts.

Note:

• Note the position of the spacer installed between the left hand side front cylinder head and frame.

17. Remove the front cylinder head mounting bolts. Collect the spacer from between the left handmounting and the frame, and the washer from under the right hand bolt head.

CautionDamage to painted surfaces, such as the frame, cylinder head or crankcases, could result from inadequatecare during this process.

18. Carefully rotate the engine by raising the engine at the front and lowering it at the rear to allow accessto the clutch cover bolts.

cglb

Engine rotation

19. Release the clutch cable from the actuating arm, refer to the Service Manual.


20. Remove the clutch cover. Discard the clutch cover gasket.

1cglb

1. Clutch cover

21. Clean and refit the clutch cover incorporating a new gasket.22. Tighten the clutch cover fixings to 10 Nm in the sequence shown below.

11

2

6

10

3 7

1

5

9

48

Clutch Cover Tightening Sequence

23. Retighten fixings one and two to 10 Nm.24. Refit the clutch cable to the actuating arm at the clutch end and set the clutch adjustment, refer to

the Service Manual.

Note:

• Rotate the engine counterclockwise until the engine mounting bolts can be inserted fully through theframe.

25. Raise the rear of the engine until the engine and frame mounting points are aligned.26. Fit the right front cylinder head bolt and washer from the outside. Fit a new nut but do not fully

tighten at this stage.


27. Fit the spacer to the left hand front cylinder head mounting as noted during removal and then fit theleft front cylinder head bolt from the outside. Fit a new nut but do not fully tighten at this stage.

3 2 1

1. Left hand front cylinder head bolt2. Spacer3. Left hand front cylinder head nut

CautionUnless the following engine mounting bolt installation/tightening sequence is precisely followed, severeframe damage can occur.

28. Fully insert the lower rear engine mounting bolt (6) from the left hand side.29. Fit the swinging arm spindle (1).30. Tighten the swinging arm spindle nut to 110 Nm.31. Tighten the right hand rear cylinder head (2) bolt to 48 Nm.32. Tighten the right hand front cylinder head (3) bolt to 48 Nm.33. Tighten the left hand rear cylinder head bolt (4) to 48 Nm.


34. Tighten the left hand front cylinder head bolt (5) to 48 Nm.

3

8

4

8

5

4

3

6

2

1

2

7

1

1. Swinging arm spindle2. Right hand rear cylinder head bolt3. Right hand front cylinder head bolt4. Left hand rear cylinder head bolt5. Left hand front cylinder head bolt6. Rear lower engine mounting bolt7. Rear lower engine mounting nut8. Spacer

35. Using service tool T3880166, tighten the frame adjuster for the left hand lower rear engine mounting to3 Nm.

1

2

cgyk


36. Remove the lower rear engine mounting bolt (6) from the right hand side.


37. Using service tool T3880166, tighten the frame adjuster for the right hand lower rear engine mountingto 3 Nm.

1

2


38. Insert the lower rear engine mounting bolt (6) and washer from the right hand side.39. Fit the hardened washers and a new locknut to the rear engine mounting bolt, hold the locknut and

tighten the bolt to 48 Nm.40. Refit the brake pedal and tighten the new fixing to 22 Nm.

2

1

1. Brake pedal2. Fixing

41. Refit the right hand footrest, raise the rear brake pedal to allow clearance and refit the footrest pivotpin.


42. Secure the pivot pin with the E-clip.

2 1

3

4

1. E-clip2. Pivot pin3. Footrest4. Return spring

43. Refit the clevis pin to the lower end of the rear brake master cylinder push rod and secure using theclip.

3

cgyv_2

1

2

1. Clip2. Clevis pin3. Push rod

44. Refit the rear brake light switch, refer to the Service Manual.


45. Refit the heel guard, tighten the fixings to 12Nm .

21

1. Right hand heel guard2. Fixings

46. Refit the radiator lower mounting, tighten the fixing to 6 Nm.

1

cgxr

1. Radiator lower mount fixing

47. Adjust the drive chain, refer to the Service Manual.Perform the following operations:

• Refit the exhaust silencer, refer to the Service Manual.• Refit the fuel tank, refer to the Service Manual.• Connect the battery negative black lead first, refer to the Service Manual.• Refit the riders seat, refer to the Service Manual.• Lower the motorcycle to the ground and park it on the side stand.

When ordering replacement parts, refer to the EPC.

Note:

• Please mark your copy of the Service Manual and Motorcycle Assembly Guide with this information. Forelectronic service manuals and assembly guides, store this information in a readily accessible place andrefer to it when working on the relevant Triumph motorcycle. This information will be included in thenext updates.


Item: 194.5

Description: Rider's Seat (single seat)

Model Affected: Thruxton 1200, Thruxton 1200R

A replacement rider's seat is supplied with the centre seat foot fitted in either location A or B. If the centreseat foot is fitted at location A remove the seat foot and fit to location B.

CautionTo prevent damage to the seats or seat covers, care must be taken not to drop the seats.Do not lean the seats against the motorcycle or any surface which may damage the seats or seat covers.Instead, place the seats, with the seat cover facing upwards, on a clean, flat surface which is covered witha soft cloth.Do not place any item on the seats which may cause damage or staining to the seat covers.

1. Turn the seat over and place on a clean, flat surface which is covered with a soft cloth.2. Identify the location of the central seat foot.

A A

B B

1

2

3

1. Location identifiers2. Central foot locations3. Seat, underside


1. If necessary remove the central seat foot from locationA.2. Install the central seat foot to location B.

12

1. Location identifier (B)2. Central seat foot

Please mark your copy of the Service Manual with this information. For electronic service manuals, storethis information in a readily accessible place and refer to it when working on the relevant Triumphmotorcycle. This information will be included in the next service manual update.


Item: 194.6

Description: Side Stand Spring Peg

Model Affected: Street Cup, Street Twin, Bonneville T100 models from VIN 759204, Street Scrambler,Thruxton 1200, Thruxton 1200R, Bonneville T120 models

The side stand spring peg is encapsulated, therefore if it is loosened or removed it must be replaced with anew one.Tighten the fixing to 7 Nm.

cjfq

1

3

2

1. Side stand spring peg2. Side stand spring3. Side stand



Item: 194.7

Description: Cylinder Head Installation

Model Affected: Tiger XCX, Tiger 800 XR, Tiger 800 XRT, Tiger XRX, Tiger XRX - LRH and Tiger 800XCA

During engine manufacture the threaded area of the cylinder head bolts are lubricated with clean engine oilprior to installation.Therefore during cylinder head installation dealers are required to follow the same procedure.

CautionUsing the correct procedure to fit and tighten the cylinder head bolts will ensure the long term reliability ofthe cylinder head gasket.Clean each new bolt, paying particular attention to the threads and under the bolt head areas. If any ofthe threads or bolt head areas are damaged, replace the bolt(s).Lubricate the threaded area of the cylinder head bolts with clean engine oil.Tighten the bolts using the four-stage procedure described in the Service Manual.Failure to observe these important items may lead to engine damage.

1. Lubricate the threaded area of the new cylinder head bolts with clean engine oil.2. Fit the bolts and washers to the cylinder head and tighten until finger tight.

3

1

2

1. Cylinder head bolt2. Washer3. Threaded area

Note:

• The cylinder head bolt tightening sequence remains as described in the Service Manual.

When ordering replacement parts, refer to the EPC.Please mark your copy of the Service Manual with this information. For electronic service manuals, storethis information in a readily accessible place and refer to it when working on the relevant Triumphmotorcycle. This information will be included in the next service manual update.


Item: 194.8

Description: Alternator Oil Feed Spray Jet

Model Affected: Speed Triple 1050 from VIN 735438 to VIN 846800, Speed Triple 1050R from VIN735337 to VIN 858022, Speed Triple S from VIN 867685, Speed Triple RS from VIN867601

The torque figure has changed. If loosened or removed the encapsulated alternator oil feed spray jet mustbe replaced.Fit the alternator oil feed spray jet and tighten to 4 Nm.

ckjt

2

1

1. Alternator oil feed spray jet2. Crankshaft



Item: 194.9

Description: Headlight and Indicator Wiring Harness Routing

Model Affected: Bonneville Bobber, Bonneville Bobber Black, Bonneville Speedmaster

The headlight wiring harness is protected from rubbing on the headlight bowl by a split grommet. If for anyreason the headlight bulb, bowl or harness are removed the grommet must be fitted with the split facing tothe right hand side. The harness is routed along the left hand side of the frame and secured into positionas shown.1. Position the harness and secure using the bracket, tighten the fixings to 2.5 Nm.

1

2

L0169

3

1. Harness2. Split grommet3. Bracket

2. Secure the indicator lead to the clutch cable and position the rubber band 50mm+/-10 mm from thebracket as shown below.

2

1

L0169

3

50 mm +/-10 mm

1. Rubber band2. Indicator lead3. Clutch cable


3. Position the grommet so that the split faces to the right hand side.

ckbt

41

2

3

1. Split grommet2. Harness3. Headlight bowl4. Grommet split line

4. Position the harness so that the spare cables are positioned to the right hand side of the headlightbowl.

ckbd

2

1

1. Harness2. grommet

Refit the headlight and rim assembly as described in the Service Manual.Please mark your copy of the Service Manual with this information. For electronic service manuals, storethis information in a readily accessible place and refer to it when working on the relevant Triumphmotorcycle. This information will be included in the next service manual update.


Item: 194.10

Description: Transmission Output Shaft

Model Affected: Tiger Explorer, Tiger Explorer XC, Tiger Explorer XC (from VIN 740277), TigerExplorer XCA, Tiger Explorer XCX, Tiger Explorer XR, Tiger Explorer XRA, TigerExplorer XRT, Tiger Explorer XRX, Tiger 1200 XR, Tiger 1200 XRX, Tiger 1200 XRX-LRH, Tiger 1200 XRT, Tiger 1200 XCX, Tiger 1200 XCA

During manufacture the output shaft E-clip is no longer required, therefore the groove in the shaft is alsono longer required.The latest condition output shaft is retrofittable to previous models and can be installed in either direction.

21

1. Old condition (with E-clip groove)2. Latest condition (retrofittable)

Note:

• The latest condition output shaft can be used in conjunction with the original fitment selector forks.


When ordering a replacement part the new shaft will be supplied and an E-clip will not be required.

1

chms

1. Output shaft

If the shaft with E-clip groove is reused it must be fitted in the orientation noted during removal and a newE-clip fitted.

1

chms

1. E-Clip



Item: 194.11

Description: Horn Wire Routing

Model Affected: Street Triple RS from VIN 800262, Street Triple S from VIN 803572, Street Triple Rfrom VIN 806646, Street Triple R - LRH from VIN 822626 and Street Triple S 660 ccfrom VIN 800262

If removing or replacing the horn, make sure the horn wire is secured in the clips and the harness ispositioned away from the exhaust header pipes.

Note:

• If fitted remove the blue identification tape from the horn wire.• Do not allow any slack between lower and upper clipping features

1. Without allowing any slack between lower and upper clipping features, route the horn wire around theedge of the fan cowl and secure it into the clipping features.

2. Ensure the horn wire does not touch the radiator and that there is no slack between the hornconnectors and the lower clipping feature of the fan cowl.

ckjy

1

3

2

1. Horn wire2. Header pipe3. Clipping feature



Item: 194.12

Description: Instrument Downloads - 900cc and 1200cc Modern Classic Models with Analogue/LCD Instruments

Model Affected: Bonneville T100 from VIN 759204, Bonneville T120, Bonneville Bobber, BonnevilleBobber Black, Bonneville Speedmaster, Speed Twin, Street Cup, Street Scrambler,Street Twin, Thruxton from VIN 743684, Thruxton R

Internal investigations have identified that the ABS fuse must be removed while performing instrumentdownloads on the above models.Instrument downloads started when the ABS fuse is fitted may fail due to a high load placed on themotorcycle’s CAN bus.Removing the ABS fuse serves to reduce the load on the CAN bus, allowing the diagnostic tool to reliablycomplete the instrument download.When downloading to the instruments on the above models, dealers are requested to follow the proceduredetailed below:

Note:

• Refer to the Service Manual for the location of the ABS fuse.

1. Turn the ignition OFF.2. Remove the ABS fuse.3. Make sure the engine start/stop switch is in the STOP position.4. Turn the ignition ON and connect the Triumph diagnostic tool.5. Perform the required instrument download as described in Technical Bulletin 179, item 10.6. When the download has completed, turn the ignition OFF and refit the ABS fuse.7. Turn the ignition ON.8. Using the diagnostic tool, check all ECMs for stored DTCs and erase as necessary.


Item: 194.13

Description: Pinpoint Test - Engine Start/Stop Switch Correlation Error

Model Affected: Tiger 1200 XRX, Tiger 1200 XRX-LRH, Tiger 1200 XRT, Tiger 1200 XCX, Tiger 1200XCA

A pinpoint test has been released for fault codes C1156, C1157 and C1158 on the above models.The new pinpoint test will be added to the Service Manual at the next update.The pinpoint test is described below.

Fault Code Possible Cause Action

C1156C1157C1158

Right hand switch housingmalfunction - Engine start/stopswitch correlation error

Disconnect right hand switchhousing, engine ECM connectorB and keyless ECM and proceedto pinpoint test 1:

Pinpoint Tests

Test Result Action

1 Check cable and terminal integrity:- Right hand switch housing blackconnector pin 1- Right hand switch housing blackconnector pin 3- Right hand switch housing blackconnector pin 4- Right hand switch housing blackconnector pin 6- Right hand switch housing greyconnector pin 1- Right hand switch housing greyconnector pin 3- Switch housing subharness in lineconnector pin 1- Switch housing subharness in lineconnector pin 2- Switch housing subharness in lineconnector pin 4- Switch housing subharness in lineconnector pin 5- Switch housing subharness in lineconnector pin 12- Engine ECM pin B01- Chassis ECM pin A14- Chassis ECM pin A37- Chassis ECM pin A39- Chassis ECM pin A40- Alarm connector pin 1- Alarm connector pin 2- Alarm connector pin 4- Ignition master switch linkconnector pin 1- Ignition master switch linkconnector pin 2

OK Proceed to test 2

Faulty Rectify fault, proceed to test 5


Test Result Action

2 Check cable for short circuit:- Chassis ECM pin A39 to batterypositive terminal- Chassis ECM pin A40 to batterypositive terminal- Engine ECM pin B01 to batterypositive terminal


Short circuit Rectify fault, proceed to test 5

3 Note, for the following tests:The engine stop switch must be inthe RUN positionFor all markets except US, the ignitionmaster switch link connector must befittedFor US markets only, the ignitionmaster switch must be in the ONpositionCheck cable continuity:- Chassis ECM pin A39 to right handswitch housing black connector pin 3- Chassis ECM pin A40 to right handswitch housing grey connector pin 1- Chassis ECM pin A14 to right handswitch housing black connector pin 6- Chassis ECM pin A37 to right handswitch housing black connector pin 4- Engine ECM pin B01 to right handswitch housing black connector pin 4Right hand switch housing blackconnector pin 1 to battery positive (+)terminalRight hand switch housing greyconnector pin 3 to battery positive (+)terminal


Open circuit Locate and rectify wiring fault, proceedto test 5

4 Check cable for short circuit:- Chassis ECM pin A39 to pin A40


Short circuit Locate and rectify wiring fault, proceedto test 5

5 Reconnect harness, clear fault codeand run engine to verify fault cleared

OK Action complete - quit test

Fault still present Contact Triumph service


Circuit Diagram

1 34 6 13

R WB G NR

5 42 1 12

B01 12

A14

A37

A39

A40

1

2

4

95A

O BGN G N

BB

B

OBO G G

G

BO

B

N

1

6

18

30

42

5

17

29

41

53

40

1

16

713

1 3

4 6

1 3

4 6

23

4

1 5

6 12

2 4

2 1

2 1

12

G G

BR

G G

9

8

1 2

1163248

1733

6

57

39 37

14

1. Chassis ECM - Connector A2. Right Hand Switch Housing Grey Connector3. Right Hand Switch Housing Black Connector4. Switch Housing Subharness5. Alarm6. Engine ECM Connector B7. Fuse Box8. Ignition Master Switch (US markets only)9. Ignition Master Switch Link Connector (all markets except US)


Item: 194.14

Description: Diagnostic Trouble Code (DTC) P2138 - Twist Grip Position Sensor 1 Correlation Errorwith Twist Grip Position Sensor 2

Model Affected: All models with ride by wire throttle

Electrical pinpoint tests for DTC P2138 contain a voltage check of the 5 V power supply that is delivered tothe twist grip position sensors by the engine ECM.Below is a guide of how to perform this voltage check on models fitted with twist grip position sensors.The 5 V sensor supply is delivered to the twist grip position sensors by the following engine ECM connectorpins:

Twist grip position sensor Engine ECM pin Description

1 B17 + 5V

B35 Ground

2 B33 + 5V

B19 Ground

This voltage check is shown on each pinpoint test as follows:

Test Result Action

Turn the ignition on and measurethe Voltage between:- ECM pin B33 and ECM pin B19- ECM pin B17 and ECM pin B35

Ok - 5V DC Proceed

Faulty Rectify fault and proceed

To carry out this test:1. Make sure the engine ECM is connected.2. Disconnect the twist grip position sensor.3. Turn the ignition ON.4. Using a suitable multimeter set to DC voltage, measure the voltage between the ECM pins detailed

above by probing the corresponding twist grip position sensor connector pins on the main wiringharness.

Note:

• The twist grip position sensor pin numbers shown in the following illustration are an example and maydiffer from model to model. Refer to the Service Manual for pinpoint test and connector pin details foryour model.

• The engine ECM connector pin numbers detailed are the same for all models fitted with twist gripposition sensors.


2

B35

B21

B17

B28

B19

B33

B

R

W

B

R

W

3

1

6

5

7

4

85

1 2 3

6 7

5.0 V DC

12

5 V Power Supply Check - Twist Grip Position Sensor 21. Engine ECM2. Twist grip position sensor connector (harness side)


Item: 194.15

Description: Electronic Systems Commissioning and Motorcycle Unlocking

Model Affected: Scrambler 1200 XC, Scrambler 1200 XE

When performing a Pre-Delivery Inspection on the above models, the motorcycle’s electronic systems mustbe commissioned and the motorcycle unlocked before the engine can be started.

WarningFailure to download the latest calibrations to the above model(s) may cause an unsafe riding conditionleading to loss of motorcycle control and an accident.

Dealers are requested to commission the electronic systems and unlock the motorcycle by performing thefollowing operations in order:

• Keyless ECM calibration download• Instrument calibration download• Engine ECM calibration download• Unlock the engine ECM.

Initial Steps

WarningBefore starting work, ensure the motorcycle is stabilised and adequately supported. This will help preventit from falling and causing injury to the operator or damage to the motorcycle.

Note:

• Before starting the setup procedure, ensure the battery voltage is at least 12.8 Volts.• An approved battery charger suitable for use with maintenance free batteries, may be used to

maintain battery charge during the setup process.

1. Unpack the motorcycle as described in the Motorcycle Unpacking Guide.2. Assemble the motorcycle as described in the Motorcycle Assembly Guide.3. Ensure that the motorcycle battery is fully charged and installed as described in the service manual.4. Download and install the latest version of the Triumph Diagnostic Tool Software to your computer as

described in the Triumph Diagnostic Tool Installation Guide. Diagnostic tool version 2019-01 or later isrequired to complete this process.

Note:

• The motorcycle is supplied with one smart key and two passive keys.• The smart key has two modes of operation, active mode and passive mode.• With the smart key in active mode, the motorcycle can be powered ON when the smart key is

positioned within 1 metre (3 feet) of the Low Frequency (LF) antenna.• There is an LF antenna located under the seat, and another located in the headlight unit.• With the smart key in passive mode, the key must be positioned against the LF antenna located under

the seat to power the motorcycle ON.• Passive keys must be positioned against the LF antenna located under the seat to power the

motorcycle ON.• The smart key should be set to active mode and kept within 1 metre (3 feet) of the LF antenna for the

duration of this procedure.

5. To check the smart key is in active mode, press the smart key button and ensure the LED flashesgreen. If the LED flashes red, press and hold the button until the LED changes to green.

6. Remove the left hand side panel as described in the Service Manual.7. Connect the Triumph Diagnostic tool.


8. US markets Only: Turn the master ignition switch to the ON position.

Master Ignition Switch

Note:

• The smart key may be placed in the steering lock to ensure it is kept in range throughout thisprocedure.

9. Position the smart key in range of the LF antenna and press the Power ON/OFF button to power themotorcycle ON.

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1. Power ON/OFF button

Core Activity

WarningAlways use Automatic Model Selection when downloading calibrations.Manual model selection must only be used when attempting to restart an interrupted or failed download,or if an incorrect model is detected by Automatic Model Selection.Always ensure that the correct model is detected or selected before selecting a calibration for downloadand never attempt to download calibrations listed for an incorrect model.Downloading calibrations for an incorrect model will cause a dangerous riding condition which may lead toloss of motorcycle control and an accident.


CautionIf the download is cancelled or interrupted (either by accidental disconnection of the interface, adischarged battery, or by turning the ignition off) before it has completed, it will prevent the instruments/ECM from operating in the normal way. This is because the instrument’s/ECM’s operating system has beenerased from memory and has not yet been fully replaced. The download must be restarted using ManualModel Selection.

Note:

• The current password for all downloads can be found at www.triumphonline.net.• It is normal for DTCs to be stored after a download has completed. This is due to the download process

interrupting CAN communications between the ECMs.• After a download has completed, you will be prompted to check and erase any stored Chassis ECM,

Immobiliser, TPMS, Engine ECM and ABS DTCs. This must be completed after all downloads arecomplete.

Keyless ECM Calibration Download1. On the diagnostic tool, navigate to DOWNLOAD - KEYLESS ECM DOWNLOAD.2. Enter the password and click Next.3. Click Automatic Model Selection. On the Motorcycle Connection Instructions screen, click Connect.4. Check that the motorcycle is correctly detected then click Next.5. Select the available calibration and click Next.6. In the download confirmation screen, check the selected calibration is correct for the motorcycle and

click Confirm.

Note:

• Upon clicking confirm to start the download, the diagnostic tool will prompt you the turn the ignitionOFF.

7. Press the Power ON/OFF button to turn the ignition OFF. Click Next, the download will begin.

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1. Power ON/OFF button

Note:

• The calibration download has two stages. When the first download stage has completed, the diagnostictool will prompt you to present a paired key to the LF antenna and press the Power ON/OFF button tostart the second download stage.

• For this process, the smart key should be used to start the second stage of the download.

8. When prompted by the diagnostic tool, ensure the smart key is still in range of the LF antenna andpress the Power ON/OFF button.


Note:

• Multiple files are transferred during the download. The progress bar displayed on the diagnostic toolmay repeatedly rise from 0% to 100% as each file is downloaded.

• Always wait for the Verifying Download screen to appear to confirm the download has successfullycompleted.

9. Click Finish when the download has completed.

Instruments Calibration Download1. Disconnect the Triumph diagnostic tool.2. Power the motorcycle OFF, wait 10 seconds, then power the motorcycle back ON.3. Connect the Triumph diagnostic tool.4. Navigate to DOWNLOAD - INSTRUMENT DOWNLOAD.5. Enter the password and click Next.6. Click Automatic Model Selection. On the Motorcycle Connection Instructions screen, click Connect.7. Check that the motorcycle is correctly detected then click Next.8. Select the available calibration and click Next.9. In the download confirmation screen, check the selected calibration is correct for the motorcycle and

click Confirm. The Download will begin.

Note:

• During the download, the instrument display will turn off and the red immobiliser/alarm LED will flash.• Multiple files are transferred during the download. The progress bar displayed on the diagnostic tool

may repeatedly rise from 0% to 100% as each file is downloaded.• Do not assume the download has completed when the instrument display turns back on. Always wait

for the Verifying Download screen to appear to confirm the download has successfully completed.

10. Click Finish when the download has completed.

Engine ECM Download1. Switch the engine stop switch to the RUN (ON) position.

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1. Engine stop switch2. RUN (ON) position

2. Download the latest calibration as normal, using automatic model detection.

Unlock the Engine ECM1. Unlock the engine ECM as described in the Triumph Diagnostic Tool User Guide.

Note:

• There is a small delay while the instruments and keyless ECM are checked for up to date calibrations.


Note:

• The software will report if any calibrations are out of date and will prevent unlocking until the correctcalibrations are installed.

• The unlock code can be found at www.triumphonline.net.

Final Steps• Check and erase all stored immobiliser, Engine ECM and ABS DTCs.• Disconnect the Triumph Diagnostic Tool.• Refit the rider’s seat and passenger seat.• Check that the motorcycle can be powered ON and started using each key.• Set the instruments to display the correct language and units for your region, as described in the

Owners Handbook.

39 of 39Technical Bulletin Issue 1

Item: 194.16

Description: Battery Anti-Tamper Label

Model Affected: All models

The battery anti-tamper label has been removed from all models from VIN 908031.Motorcycles received after this VIN will no longer have the anti-tamper label fitted to the battery.

Circulation

Initial and date when read and return to central file holder

Service Manager Parts Manager Sales Manager WorkshopSupervisor

Technician 1 Technician 2

tb194 en 01 · model affected: tiger 800 xr, tiger 800 xrx, tiger xrx - lrh, tiger 800 xcx, tiger...

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