Fit the header pipe to the catalytic converter.

4

2

1

4

0mm
3

ckgz

1.
2.
3.
4.

Exhaust gasket
Catalytic converter
Exhaust header pipe
Exhaust header pipe flange (illustration sectioned for clarity)

Technical Bulletin 192 Issue 2

9 of 20

Note:
•

The compression slots on the exhaust header pipe must be visible to allow correct clamping of the
header pipe to the catalytic converter.

3.

Position the exhaust clamp to the exhaust header pipe as shown below and tighten the fixing to 10 Nm.

1

2

1

1

2

ckgy

1.
2.

Compression slots
Exhaust clamp

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

Technical Bulletin 192 Issue 2

10 of 20

Item:

192.8

Description:

Alternator Diagnosis

Model Affected:

Explorer XR, Explorer XRX, Explorer XRX-LRH, Explorer XRT, Explorer XC, Explorer
XCX, Explorer XCX-LRH, Explorer XCA, Tiger 1200 XR, Tiger 1200 XRX, Tiger 1200
XRX-LRH, Tiger 1200 XRT, Tiger 1200 XCX, Tiger 1200 XCA

The pinpoint test for Alternator Diagnosis has changed for the above models. This information amends the
current Service Manual procedure.

Alternator Diagnosis Procedure
If the charging circuit does not operate correctly, the following basic checks must be carried out before
further diagnosis is performed:
• Check the battery terminals are clean and tight.
• Check the engine earth connections are clean, tight and free from corrosion.
• Ensure the battery is fully charged and in good condition.
• Check that any fuse in the circuit is not blown and is of the correct rating.
Rectify any defects as necessary.
To check the alternator output, carry out the alternator pinpoint tests as described below.
Note:
•

•
•
•
•
•
•

The alternator is located under the fuel tank. To allow access to the alternator connections and
terminals, It is recommended that the fuel tank is mounted remotely and connected using service tool
T3880001 and service tool T3880123. Refer to the Fuel Pressure Checking section of the Service
Manual.
The Alternator does not contain any serviceable parts and must be replaced if faulty.
The alternator and regulator/rectifier are integrated in the same unit. It is not possible to check for
continuity and short circuit through the coils and to ground.
Do not attempt to open the alternator.
A multimeter is required to perform the pinpoint tests detailed below. The multimeter must be set to
DC voltage for all voltage measurements.
If the battery is not fully charged, the charging Voltage may be lower than specified when checking at
2,000 rpm.
Before starting, make sure all additional accessories (auxiliary lights, heated grips etc.) are switched
off.

Fault
Battery not charging

Technical Bulletin 192 Issue 2

Possible Cause

Action

Battery

Check the condition of the
battery
Test the battery using the
BatteryMate 150-9. Refer to the
instructions supplied with the
BatteryMate 150-9
Ensure the battery is serviceable

Alternator/Rectifier/Regulator

Proceed to pinpoint test 1

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Pinpoint Tests - Tiger Explorer XR, Tiger Explorer XRX, Tiger Explorer XRX-LRH, Tiger Explorer
XRT, Tiger Explorer XC, Tiger Explorer XCX, Tiger Explorer XCX-LRH, Tiger Explorer XCA, Tiger
1200 XR
Test
1

Check cable and terminal integrity:
- Battery positive (+) terminal
- Battery negative (-) terminal
- Alternator control connector pin 2
- Alternator output terminal
- Crankcase negative (-) terminal

Result

Action

OK

Proceed to test 2

Faulty

Rectify fault, proceed to test
2

2 Check fuses:
- Main fuse 40 A
- Fuse No 6, main fuse box

OK

Proceed to test 3

Faulty

Replace fuse, proceed to test 3

3 Check alternator control Voltage:
- Disconnect alternator control
connector
- Turn ignition ON
- Make sure the engine stop switch is in
the RUN position
- Disarm the alarm if fitted
- Make sure the instruments turn on
and the gear position is displayed
- Measure the Voltage between
alternator control pin 2 and battery
negative (-) terminal

Same as
battery
Voltage (12.5 V
+/- 0.5 V)

Turn the ignition off, reconnect the
alternator control connector. Proceed to
test 4

Faulty

Turn the ignition off, proceed to test 4

4 Disconnect the battery and check cable
continuity:
- Battery negative (-) cable ring terminal
to alternator metal housing (ground)
- Battery positive (+) cable ring terminal
to alternator output terminal
- Alarm connector 1 to Alternator
control connector pin 2
- Engine ECM Connector B, pin B01 to
Alternator control connector pin 2

OK

Reconnect the battery leads, positive (red)
lead first and proceed to test 5

Open circuit

Locate and rectify wiring fault.
Reconnect the battery leads, positive (red)
lead first and proceed to test 5

5 Ensure the alternator control connector
is plugged and secured. Run the engine.
Check the charging Voltage at 2,000
rpm between:
- Alternator output terminal and
alternator metal housing (ground)
- Alternator output terminal and
battery negative (-)
- Battery positive (+) and battery
negative (-)

13 V - 15 V

Action complete - quit test

Fault still
present

Proceed to test 6

Technical Bulletin 192 Issue 2

12 of 20

Test
6 Measure voltage drop in the charging
circuit.
Run the engine at 2,000 rpm.
Turn all loads on (including heated grips,
heated seats and fog lights if fitted).
Measure the voltage between:
- Battery negative (-) cable ring terminal
and alternator metal housing (ground)
- Battery positive (+) cable ring terminal
and alternator output terminal

Technical Bulletin 192 Issue 2

Result
OK - Voltage
drop less than
0.5 V
Faulty Voltage drop
greater than
0.5 V

Action
Contact Triumph service
Provide details of results and
observations of any test steps that have
failed.

13 of 20

Circuit Diagram

9

16
32
48

1
17
33

1

2

3

4

12

1

5
1 2

8

5

B01

BO

BO

10

2

12

6

17

6

29

18

41

30

37

42

53

1

7

B

2
BO

11

A37

GN

6
2

4

5
1

4

G

1

GB

2

5A

N
40A
N
+

5
10

2

1

3

6

-

B

1

1

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

1

4

5

8

Battery
Main fuse
Alternator
Main fuse box - fuse 6
Ignition switch connector
Right hand switch housing connector (10 way)
Alarm
Engine ECM
Engine ECM connector B
Alternator control
Chassis ECM
Chassis ECM connector A

Technical Bulletin 192 Issue 2

14 of 20

Pinpoint Tests - Tiger 1200 XRX, Tiger 1200 XRX-LRH, Tiger 1200 XRT, Tiger 1200 XCX, Tiger 1200
XCA
Test
1

Check cable and terminal integrity:
- Battery positive (+) terminal
- Battery negative (-) terminal