TRIUMPH

Service Bulletin 521
Issue 1 - January 2015

Subject: Alternator De-coupler

Bulletin Models Affected VIN Range Markets Affected
Number
521 Tiger Explorer From | 683888 All

Tiger Explorer XC

Trophy SE To 694924

Background Information
We have identified a need to carry out the following additional checks at PDI or at the motorcycles
next visit to the dealership:

* To check the torque of the six M4 screws on the alternator de-coupler.

Customer Contact Instructions

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

Identification of Affected Motorcycles
Tiger Explorer, Tiger Explorer XC and Trophy SE listed in the VIN range above.

Service Bulletin 521 lof 5

Warranty Claim Instructions

Bulletin Fault Code Repair Description Repair Time
Number Code Allowance
521 01301091 99521 Tiger Explorer and Tiger Explorer XC: 1.5 hours
To check and retighten the six M4 screws
on the alternator de-coupler
Trophy SE: To check and retighten the six 3.0 hours
M4 screws on the alternator de-coupler
Genuine Parts Information
For Tiger Explorer and Tiger Explorer XC
Bulletin Part Number Description Quantity
Number
521 T1302207 Rubber Cap, De-coupler 1
73350124 Nut, M10 x 125 mm 1
73205081 Balt, HHFE, LGHTD, M6 x 1.0 x 28 mm, Encapsulated 2
13330649 Screw, PAN/HD, TX, MS x 0.8 x 72 mm, SLV 1
T3331042 Screw, PAN/HD, TX, M6 x 1.0 x 30 mm, Encapsulated 2
73331726 Screw, BUT/HD, M6 x 1.0 x T2 mm, SLV 2
73330728 Screw, PAN/HD, TX, M5 x 0.8 x 7.6 mm. SLV 4
For Trophy SE
Bulletin Part Number Description Quantity
Number
521 T1I302207 Rubber Cap, De-coupler 1
73350124 Nut, M10 x 1.25 mm 1
T2020609 Bolt, Disc, M8 x 1.25 x 30 mm, SLV, Encapsulated 3
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.
Genuine 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.

Service Bulletin 521 e2of5

Other Instructions

Before returning the motorcycle to the customer, download the latest calibration to the engine
control module using the current version of the Triumph diagnostic software.

Once completed, please mark the Service Record Book that the requirements of this bulletin have
been complied with.

Checking Procedure
Complete the checks as described in the procedures detailed below.

: tr __ oe —
A torque wrench of known accurate calibration must be used when tightening the six M4 screws
on the alternator de-coupler, Failure to tighten the alternator de-coupler screws to the correct

torque specification may result in loss of motorcycle control and an accident.

ghout the
supported to prevent the risk of injury from the motorcycle falling.

All Models

1. Remove the alternator as described in the relevant Service Manual.
2. Remove and discard the rubber cap from the alternator de-coupler and drive gear assembly.

3. Fit Alternator Wrench T38806Ce2 to the splines of the alternator de-coupler and drive gear
assembly.

Alternator Wrench T3880602

Service Bulletin 521 3of 5

4. Prevent the alternator from turning using a spanner on the Alternator Wrench T3880602, and

logsen the de-coupler and drive gear assembly nut using an 8 mm Allen key.

Alternator de-coupler
. Alternator Wrench T3880602
. & mm Allen key

wn

5. Remove the Alternator Wrench T3880602 and fully remove the nut. Discard the nut.
6 Remove the de-coupler and drive gear assembly from the alternator spline.
7

Place the service tool, Alternator Wrench T3880602, into a soft jaw vice with the splines
uppermost.

1. Service tool, Alternator Wrench T3880602
2. Soft jaws

Service Bulletin 521 4 of 5

8. Fit the alternator de-coupler to the service tool with the six M4 screws facing upwards.

1. De-coupler

2. M& screws {four shown)

9. Tighten the drive gear to de-coupler M4 screws to 3 Nm.

10. Remove the alternator de-coupler and service tool from the vice.

Tl Fit the de-coupler to the alternator and fit a new nut.

t2. Fit the Alternator Wrench T3880602 to the splines of the alternator de-coupler and drive gear
assembly,

13. Prevent the alternator from turning using a spanner on the Alternator Wrench T388060e and
tighten the new nut to 45 Nm,

oN

1. Alternator de-coupler
2. Alternator Wrench T3880602
3. 8 mm Allen key

14. Refit the alternator to the motorcycle, as described in the relevant Service Manual.

Circulation
Initial and date when read and return to central file holder

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

Service Bulletin 521 Sof 5