NHTSA ID Number: 10192906
Manufacturer Communication Number: SMT-TN-143
TSB/Document Date: 2021-05-10
Summary
A new gear position sensor and fly lead have been introduced to the above models from engine number 596481. If replacing the gear position sensor or fly lead from engine number 596481, refer to the EPC for the part numbers. If replacing the gear position sensor up to engine number 596480, a fly lead must also be fitted to enable the new sensor to be connected to the main harness. To facilitate this, a parts kit (part number T1294242) is available.
Triumph
Motorcycles
Normandy Way
Hinckley
Leicestershire LE10 3BZ
United Kingdom
Technical News
Issue 143
Strictly Confidential
April 2013
Contents
Item 1.
Gear Position Sensor - Daytona 675 (all models) and Street Triple (all models)
Item 2.
Gear Position Sensor - Trophy and Trophy SE
Item 3.
Gear Position Sensor - Tiger Explorer
Item 4.
Gear Position Sensor - Thunderbird 1600, Thunderbird 1600 - ABS, Thunderbird 1700,
Thunderbird 1700 - ABS, Thunderbird Storm, Thunderbird Storm - ABS
Item 5.
Gear Position Sensor - Tiger 800, Tiger 800 - ABS, Tiger 800XC and Tiger 800XC - ABS
Item 6.
Gear Position Sensor - Rocket III, Rocket III Classic, Rocket III Touring, Rocket III Touring SE,
Rocket III Touring - ABS and Rocket III Roadster
Item 1.
Description:
Gear Position Sensor
Models affected:
Daytona 675 (all models) and Street Triple (all models)
A new gear position sensor and fly lead have been introduced to the above models from engine number 596481.
If replacing the gear position sensor or fly lead from engine number 596481, refer to the EPC for the part numbers.
If replacing the gear position sensor up to engine number 596480, a fly lead must also be fitted to enable the new sensor
to be connected to the main harness. To facilitate this, a parts kit (part number T1294242) is available. The parts kit
consists of:
•
Gear position sensor
•
•
Fly lead.
For the installation of the parts kit up to engine number 596480, carry out the following procedure.
Removal
1.
Remove the seat as described in the Service Manual.
2.
Disconnect the battery, negative (black) lead first.
3.
Remove the fuel tank, as described in the Service Manual.
Note:
•
Note the position of the wire guide secured by the upper fixing of the gear position sensor for
installation.
4.
Remove the gear position sensor as described in the Service Manual.
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Technical News
Installation
1.
Fit two new O-rings to the new gear position sensor. Lubricate the O-rings with a smear of petroleum jelly.
2.
Fit the new gear position sensor to the engine as shown below. Ensure that the locating pin on the sensor fits into the
hole in the end of the gear selector drum.
3
2
1
4
3
cief
1.
2.
3.
4.
3.
Gear position sensor
Wire guide
Fixings
Gear position sensor harness
Fit the wire guide and fixings as noted for removal and tighten to 5 Nm.
4.
Route the harness of the gear position sensor through the wire guide and up into the fuel tank area.
5.
Attach the four pin multiplug of the fly lead to the gear position sensor and the three pin multiplug to the main
harness.
2
1
ciaa
1. Multiplug, gear position sensor
2. Multiplug, main harness
6.
Route the fly lead across the top of the engine to the throttle position sensor. Ensure the fly lead does not interfere
with routing of the fuel lines and breather hoses for the fuel tank.
7.
Disconnect the main harness from the throttle position sensor and connect it to the male multiplug of the fly lead.
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Technical News
8.
Connect the other multiplug on the fly lead to the throttle position sensor.
1
2
cieh
1. Throttle position sensor multiplug
2. Main harness multiplug
9.
If removed, refit the frame's left-hand finisher as described in the Service Manual.
10. Refit the fuel tank, as described in the Service Manual.
11.
Reconnect the battery, positive (red) lead first.
12. Turn the ignition to the ON position and select through the gears. Check that the instruments display each gear as it
is selected. Rectify any faults as necessary.
Please mark your copy of the Service Manual with this information.
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Technical News
Item 2.
Description:
Gear Position Sensor
Models affected:
Trophy and Trophy SE
A new gear position sensor and fly lead have been introduced to the above models from engine number 596481.
If replacing the gear position sensor or fly lead from engine number 596481, refer to the EPC for the part numbers.
If replacing the gear position sensor up to engine number 596480, a fly lead must also be fitted to enable the new sensor
to be connected to the main harness. To facilitate this a parts kit, part number T1298395 is available. The parts kit consists
of:
•
Gear position sensor
•
•
Fly lead.
For the installation of the parts kit up to engine number 596480, follow the procedure below.
Removal
Warning
Throughout the following procedure, ensure that the motorcycle is stabilised and adequately supported to prevent the
risk of injury from the motorcycle falling.
1.
Disconnect the battery, as described in the Service Manual.
2.
Remove the fuel tank, as described in the Service Manual.
Note:
•
Note the orientation of the gear position sensor’s electrical connector on its bracket for installation.
3.
Detach the gear position sensor multiplug from its mounting bracket and disconnect it from the main harness.
4.
Remove the two fixings and remove the gear position sensor.
1
3
2
cidw
1. Multiplug
2. Fixings
3. Gear position sensor
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Technical News
Installation
1.
Fit a new O-ring to the new gear position sensor. Lubricate the O-ring with a smear of petroleum jelly.
2.
Position the sensor to the selector cover, ensuring the pin on the sensor engages with the slot in the selector drum
shaft.
3.
Fit the two fixings and tighten to 5 Nm.
4.
Route the end of the fly lead with the multiplugs for the gear position sensor (3 and 4 pins) between the main
harness guide and the alternator, then down to the gear position sensor.
3
1
2
cidx
1. Main harness guide
2. Fly lead
3. Alternator
5.
Attach the three pin multiplug of the fly lead to the main harness then attach it to the mounting bracket as noted for
removal.
6.
Attach the new gear position sensor to the other multiplug on the sub-harness.
1
2
3
cidz
1. Bracket
2. Main harness
3. Gear position switch multiplug
7.
Disconnect the main harness from the MAP sensor and connect it to the male multiplug of the fly lead.
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Technical News
8.
Connect the other multiplug on the fly lead to the MAP sensor.
2
3
1
cidy
1. Fly lead
2. Fly lead multiplug
3. Main harness multiplug
9.
Refit the fuel tank as described in the Service Manual. Do not refit the body panels at this stage.
10. Reconnect the battery, as described in the Service Manual.
11.
Turn the ignition to the ON position and select through the gears. Check that the instruments display each gear as it
is selected. Rectify any faults as necessary.
12. Refit the body panels, as described in the Service Manual.
Please mark your copy of the Service Manual with this information.
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Technical News
Item 3.
Description:
Gear Position Sensor
Models affected:
Tiger Explorer
A new gear position sensor and fly lead have been introduced to the above models from engine number 596481.
If replacing the gear position sensor or fly lead from engine number 596481, refer to the EPC for the part numbers.
If replacing the gear position sensor up to engine number 596480, a fly lead must also be fitted to enable the new sensor
to be connected to the main harness. To facilitate this, a parts kit (part number T1298294) is available. The parts kit
consists of:
•
Gear position sensor
•
•
Fly lead.
For the installation of the parts kit up to engine number 596480, carry out the following procedure.
Removal
1.
Remove the rider's seat, as described in the Service Manual.
2.
Disconnect the battery, negative (black) lead first.
Note:
•
Note the routing of the harness for the gear position sensor for installation.
3.
Remove the following items as described in the Service Manual:
4.
•
Gear position sensor
•
Fuel tank infill panels
•
Radiator infill panels
•
Side fairings
•
Seat infill panels.
Remove the fixings securing the rear of the fuel tank to the frame.
1
chjy
1. Fixing, left-hand side shown
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Technical News
5.
With the aid of an assistant, raise the rear of the fuel tank to access the manifold absolute pressure (MAP) sensor and
disconnect its multiplug.
1
2
cift
1. MAP sensor
2. Multiplug
6.
Lower the fuel tank onto the frame.
Installation
1.
Fit a new O-ring to the new gear position sensor. Lubricate the O-ring with a smear of petroleum jelly.
2.
Position the sensor to the engine, ensuring the pin on the sensor engages with the slot in the selector drum shaft.
3.
Fit the two fixings and tighten to 5 Nm.
4.
Route the harness of the gear position sensor as noted for removal.
5.
Attach the four pin multiplug of the fly lead to the gear position sensor and the other multiplug to the main harness.
3
1
2
cifs
1. Main harness multiplug
2. Gear position sensor multiplug
3. Fly lead
6.
Route the other end of the fly lead up to the top of the engine near the MAP sensor.
7.
With the aid of an assistant, raise the rear of the fuel tank and connect the female multiplug to the MAP sensor.
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Technical News
8.
Connect the other multiplug of the fly lead to the main harness.
1
2
cifu
1. Fly lead multiplugs
2. Main harness
9.
Lower the rear of the fuel tank onto the frame, fit the two fixings and tighten to 12 Nm.
10. Refit the coolant expansion tank as described in the Service Manual.
11.
Reconnect the battery, as described in the Service Manual.
12. Turn the ignition to the ON position and select through the gears. Check that the instruments display each gear as it
is selected. Rectify any faults as necessary.
13. Refit the following items, as described in the Service Manual.
•
Seat infill panels
•
Side fairings
•
Radiator infill panels
•
Fuel tank infill panels
•
Rider's seat.
Please mark your copy of the Service Manual with this information.
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Technical News
Item 4.
Description:
Gear Position Sensor
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- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
- Formulated for engines with 75,000 miles or more, Valvoline...
- Delivers 20% better wear protection and 15% better sludge...
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TSB/Document ID: SMT-TN-143
Replacement Service Bulletin Number:
MFR Communication Date: 2013-04-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT ADAPTIVE/MOBILITY
MFR Component System:
MFR Component Subsystem:
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