Service Bulletin 484

Strictly Confidential

March 2013
Affected Models....................005- Daytona 675, Daytona 675R, Daytona 675 ABS,
Daytona 675R ABS
VIN Range. ........ 0... cece ec eee eee eee VIN 564948 to VIN 586561
Markets ..... 00... cece eee cece renee ence All
Subject... 0.2.2.2... 0c eee eee ee ee eee Exhaust Butterfly Valve Cables

Background Information

We have identified a need to replace the exhaust butterfly valve cables on the above models, Dealers are
requested to remove and replace the exhaust butterfly valve cables.

Customer Contact Instructions

Motorcycles in the affected VIN range must be modified prior to delivery to the customer, or at the next
service/visit to the dealership.

Identification of Affected Motorcycles

Daytona 675, Daytona 675R, Daytona 675 ABS and Daytona 675R ABS motorcycles listed in the VIN range
above.

Warranty Claim Instructions

Fault code... 0. ee eee 01249791
Repair code . 0... cc cette ee 99484
Repair time allowance .................0..0.. 0.51 hrs Gndudes admin allowance)

Genuine Parts Information

Genuine Parts... 0.000. ec ccc eee eee 1 x 172202069 - Cables, Exhaust Valve

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Genuine Parts Ordering Instructions. .......For Triumph Subsidiary and Overseas Distributor
dealers using Triumph Warranty On-Line with Parts
Auto Ordering Flag switched on: Order all repair parts
by submitting a New Prior through the Warranty On-Line
system, Entering the above repair code in a New Prior will
automatically add the parts required and labour times for
this Service Bulletin.

For Overseas Distributor dealers NOT using Triumph
Warranty On-Line or for Overseas Distributor dealers
using Triumph Warranty On-Line with Parts Auto
Ordering Flag switched off: Orders should be placed
using the normal parts ordering procedure,

Parts Return Instructions................... Dealer to retain parts for 90 days. All parts must be stored
in a secure, non-public accessed area and correctly
identified with a completed warranty label. Thereafter the
parts must be rendered unusable prior to scrapping.

Other Instructions

Once completed, please mark the service record book that the requirements of this bulletin have been
complied with.

Replacement Procedure
Note:

* The exhaust butterfly valve cables must be replaced following the procedure listed in this
models service manual. However, the cables must be checked and adjusted at the correct
stage of installation, following the procedure detailed below.

Remove and replace the exhaust butterfly valve cables following the procedure listed in this model's service

manual. Check and adjust the cables at the correct stage of installation following the procedure detailed below.

Throughout this procedure, ensure that the motorcycle is stabilised and adequately supported to
risk of injury from the motorcycle falling.

prevent the

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If the engine has recently been running, the exhaust system will be hot. Before working on or near the
exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust
system could cause burn injuries.

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To help accurately check and set the adjustment of the control cables for the exhaust butterfly valve, use the
Triumph diagnostic tool as described below.

Check the Control Cables

1. Remove the rider's seat, as described in the service manual.

2. Attach the Triumph diagnostic tool to the dedicated plug and turn the ignition switch to the ON position,
refer to the Triumph Diagnostic Tool User Guide.

3. Open the Engine Diagnostics menu.

Engine Diagnostics Menu

4. Select the Function Test option.

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Clicking the 'Start’ button will cause the exhaust butterfly valve to move several times. To prevent injury,
never place loose clothing, fingers or hands near the exhaust valve actuator, cables or the valve on the
silencer, until the actuator has moved to the adjustment position. Loose clothing, fingers or the hands could
become trapped during valve/actuator movement and cause crushing injury to the fingers, hands or other
parts of the anatomy.

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5. Select Exhaust Butterfly Valve Actuator then click the ‘Start’ button. The software will also show the
message ‘Cable adjustment checks will be made while the valve operates’.

6. ‘Typically, the software will operate the valve several times and will then report its cable adjustment findings
near the bottom of the PC screen. In some circumstances, particularly if the cables are not correctly
adjusted, the test result will be shown immediately without running a test. This is because the software
recovers data from the ECU on initiation and does not need to run the function test to determine a result.
The software will display four possible results as follows:

* Cables too tight.
* — Cables too loose.
« Cables not evenly adjusted.
* — Cables correctly adjusted.
Engine Diagnastics
Function Test Menu

Note:

* Do not adjust the cables in the Function Test screen. With the diagnostic software in the
Function Test screen, one cable will be under tension and the other will be slack. This will
prevent the cables from being evenly adjusted.

7. If the test fails, do not adjust the cables while the diagnostic software is in the Function Test screen. Select

the Adjust Tune option then adjust the cables as described in Adjustment of the Control Cables.

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Adjustment of the Control Cables

Do not rotate the pulley on the exhaust butterfly valve actuator. Rotating the pulley will damage the internal
components of the actuator.
Note:

* The adjustment procedure must be followed to give a preliminary cable setting. Correct cable
adjustment must be confirmed by the diagnostic software.

1. On the diagnostic software navigate to and select the Adjust Tune option.

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Clicking the 'Adjust' button will cause the exhaust valve actuator to move to the adjustment position. To
prevent injury, never place loose clothing, fingers or hands near the exhaust valve actuator, cables or the
valve on the silencer, until the actuator has moved to the adjustment position. Loose clothing, fingers or the
hands could become trapped during valve/actuator movement and cause crushing injury to the fingers,
hands or other parts of the anatomy.

2. Select Exhaust Butterfly Valve Cable Adjust then click the ‘Adjust’ button.

Note:

* The cable adjustment must only be made when the exhaust butterfly valve is in its middle
position.

3. Click the ‘Adjust’ button a second time. The diagnostic software will send a command which drives the
exhaust valve actuator to the middle position. The diagnostic software will then show ‘Adjust cable - press
OK to continue’ on the screen. Do not click the 'OK' button until the cable adjustment is completed.

4. The exhaust butterfly cables can now be adjusted as follows:

5. Taking care not to scratch the frame with the control plate, release the adjuster lock nut on each exhaust
butterfly valve cable.

1. Lock nuts
2. Adjusters, control plate removed for clarity

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Note:

* The dosing cable is uppermost and has the silver coloured end.

6. Adjust the dosing cable adjuster until the arrow on the butterfly valve pulley is aligned with the upper
edge of the butterfly valve stop.

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1. Arrow, before adjustment
2. Butterfly valve stop
3. Closing cable

j. Arrow, after adjustment :
2. Butterfly valve stop
3. Closing cable

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7. With the arrow aligned with the upper edge of the butterfly valve stop, adjust the opening cable until it
has the same amount of thread showing as the closing cable.

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1. Threaded area

2. Adjusters, control plate removed for clarity

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Clicking the 'OK' button will cause the exhaust valve actuator to move to the closed position and then the
fully open position. To prevent injury, never place loose clothing, fingers or hands near the exhaust valve
actuator, cables or the valve on the silencer, until the actuator has stopped. Loose clothing, fingers or the
hands could become trapped during valve/actuator movement and cause crushing injury to the fingers,
hands or other parts of the anatomy.

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8. When the adjustment of the cable is complete, click the 'OK' button. The exhaust butterfly valve will now
move to the closed position and then the fully open position.

9. Click the ‘OK’ button again to finish.

10. If the adjustment is not correct, ‘Cables too loose - Adjust cables’ or 'Cables too tight - Adjust cables’ will
be displayed. Repeat steps 6 to 9 to tighten or loosen the cables evenly as required.

11. On the diagnostic software, click the Adjust button to check the cable adjustment. If necessary, repeat the
adjustment procedure.

12. Once adjustment is correct, tighten the adjuster lock nuts to 5 Nm.

Note:

* If the adjustment is not correct, the Malfunction Indicator Light (MIL) will be illuminated,
indicating the presence of DTCs (Diagnostic Trouble Codes).

* The following will be displayed: ‘Exhaust butterfly cables adjust DTCs present - Read and erase
DTCs'.

13. Rectify the DTCs as necessary by repeating the adjustment procedure.

14. On the diagnostic software, select READ STORED DITCS, erase any stored DTCs.
15. Close the software and disconnect the Triumph diagnostic tool.

16. Refit the rider's control plate, as described in the service manual.

17. Refit the silencer heat shield, as described in the service manual.

18. Refit the rider's seat, as described in the service manual.

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Note:

¢ Some affected motorcycles listed in the VIN range will have been modified and repaired by
Triumph prior to their release from the factory.

* The modified motorcycles can be identified by checking the ‘Outstanding Service Bulletins’ on
Warranty On-Line.

Circulation

(Initial and date when read and return to central file holder)

Service Parts Sales Workshop Technician 1 Technician 2
Manager Manager Manager Supervisor

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