Triumph Motorcycles
Normandy Way
Hinckley
Leicestershire LE10 3BZ
United Kingdom

Technical News
Issue 146

Strictly Confidential

May 2013

Contents
Item 1.

Throttle Balance - Daytona 675 from VIN 564948 and Daytona 675R from VIN 564948

Item 2.

Camshafts - Tiger 800, Tiger 800 ABS and Tiger 800XC ABS

Item 3.

Clutch and Brake Lever Pivot Pins - Tiger Explorer XC

Item 4.

Centre Stand Up Stop Rubber - Trophy, Trophy SE, Tiger Explorer and Tiger Explorer XC

Item 5.

Rear Subframe Lower Fixings - Tiger 1050 Sport

Item 6.

Rear Brake Disc - Tiger 800, Tiger 800 ABS, Tiger 800XC and Tiger 800XC ABS

Item 7.

Support Bracket, Rear Body Panel - Daytona 675 from VIN 564948 and Daytona 675R from
VIN 564948

Item 8.

Brake Line Unions to ABS Modulator - Daytona 675 from VIN 564948 and Street Triple from
VIN 560477

Item 9.

Front Brake Hose Fixing - Tiger 800XC and Tiger 800XC ABS

Item 10.

Harness Guide Fixings - Trophy and Trophy SE

Item 11.

Selector Fork Shaft - Tiger Explorer, Tiger Explorer XC, Trophy and Trophy SE

Item 12.

Breather Cover Tightening Sequence - Tiger Explorer, Tiger Explorer XC, Trophy and
Trophy SE

Item 13.

Secondary Air Injection to Airbox Hose Spring Clip - Street Triple from VIN 560477

Item 14.

Front Fork Protectors and their Fixings - Rocket III Roadster

Item 15.

Clutch Assembly - Tiger Explorer, Tiger Explorer XC, Trophy and Trophy SE

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Technical News

Item 1.
Description:

Throttle Balance

Models affected:

Daytona 675 from VIN 564948 and Daytona 675R from VIN 564948

The throttle balance procedure described in the above models’ Service Manuals is correct for the Street Triple and
Street Triple R only.
For the correct method of throttle balance for the above models, carry out the following procedure.

Warning
Do not disconnect the fuel line from the injectors in the airbox upper section. If this fuel line is disconnected during the
throttle balance procedure, fuel will be pumped from the fuel tank via the fuel pump which may lead to a fire hazard
which could result in personal injury.
Note:
•

The throttles cannot be balanced using equipment to measure vacuum in each throttle. Instead, the
Triumph diagnostic software must be used.

1.

Remove the seat and fuel tank, as described in the Service Manual.

2.

Release the three fixings and detach the engine control module (ECM) and its bracket from the airbox.

2
1

3

1

1

cian_3

1. Fixings
2. ECM
3. ECM bracket

Note:
•
•

The immobiliser ECU is attached to the inside surface of the airbox upper section. Note the routing of its
harness for installation.
When detaching the airbox upper section from the lower section, the air filter element will be attached
to the upper section.

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Technical News

3.

Release the eight fixings and detach the airbox upper section from the lower section.

2

1

2

2
chyu_1

1. Airbox upper section
2. Fixings

Note:
•

Note the orientation of the air filter for installation.

4.

Remove the air filter element from the airbox upper section and position the upper section to one side.

5.

Remove the airbox lower section as described in the Service Manual.

Warning
When carrying out the throttle balance procedure, do not raise the engine speed above 3,500 rpm. If the engine speed
exceeds 3,500 rpm the injectors in the airbox upper cover may start to inject fuel which may lead to a fire hazard which
could result in personal injury.
Note:
•

Do not disconnect the multiplugs from any of the injectors in the airbox upper section. If these injectors
are disconnected, the relevant injector in the throttle bodies will also be inoperative.

6.

The connection of the extension cable T3880123, fuel pressure gauge adapter marked 'B' and the adjustment of the
throttle balance are as described in the Service Manual.

7.

When the throttles are balanced, stop the engine and disconnect the diagnostic tool.

Note:
•

Because fuel stored in the fuel line will be at 3.5 bar pressure, it is essential that the fuel pressure is
reduced before any dismantling of the fuel rail takes place. To reduce pressure, briefly crank the engine
with the fuel pump disconnected.

8.

Disconnect the fuel pressure gauge adapter and wiring extension.

9.

Refit the airbox and fuel tank, as described in the Service Manual.

10. Remove the exhaust extraction hoses from the silencer.
11.

Refit the seat, as described in the Service Manual.

Please mark your copy of the Service Manual with this information.

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Technical News

Item 2.
Description:

Camshafts

Models affected:

Tiger 800, Tiger 800 ABS and Tiger 800XC ABS

New camshafts have been introduced to the above models from engine number 602078 and are not retrofittable.
The difference between the original and new camshafts are as follows:
•

The camshaft end, opposite the sprocket, has a slot which is used for timing.

•

The sprocket for the new camshaft has elongated holes for timing.

•

The crankcase has a hole for the timing pin.

•

The crankshaft has a hole for the timing pin.

2

1

id

1. Slot
2. Elongated slots

The removal, installation and timing of the new camshafts is different to that described in Service Manual, see Removal Camshaft on page 4.
The removal and installation of the camshaft drive chain tensioner is also different to that described in the Service Manual,
see Removal - Camshaft Drive Chain Tensioner on page 10.
Removal - Camshafts
1.

Remove the camshaft cover and the crankcase cover, as described in the Service Manual.

2.

Remove the spark plugs to reduce compression resistance when turning the engine.

3.

Rotate the engine using the bolt fitted to the end of the crankshaft so any two camshaft sprocket fixings are
accessible.

Note:
•
•
•

The camshaft sprocket fixings need only be loosened sufficiently to allow the sprockets to rotate on the
camshafts.
The camshaft sprocket fixings must never be re-used if loosened or removed; however new fixings
should only be installed during final tightening after the timing procedure has been completed.
If the sprockets are to be removed from the camshafts, temporarily refit the sprockets for timing
adjustment using the old fixings, and only install new fixings during final tightening.

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Technical News

4.

Loosen the two camshaft sprocket fixings. Do not remove the fixings at this stage.

1

1

chei

1. Fixings

5.

Rotate the crankshaft until the remaining two fixings are accessible.

Caution
Do not rotate the crankshaft further once the four camshaft sprocket bolts have been loosened. Rotation of the
crankshaft with the four sprocket bolts loose will result in valve to piston contact and serious engine damage.
6.

Loosen the two remaining camshaft sprocket fixings. Do not remove the fixings at this stage.

7.

Evenly release the hydraulic tensioner mounting bolts until the plunger spring tension has been released.

8.

Remove the hydraulic tensioner and discard the O-ring and gasket.

9.

Remove the camshaft ladder and camshafts as described in the Service Manual.

10. Remove the camshaft drive chain and if necessary the tensioner blade and rubbing strip, as described in the Service
Manual.
11.

Rotate the crankshaft clockwise (the normal direction of rotation), using the bolt fitted to the end of the crankshaft.
Stop rotation when number 1 cylinder is at Top Dead Centre (TDC), that is when the 'dot' mark on the primary gear
aligns with the line on the crankcase.

12. Insert the Crankshaft Timing Pin T3880601 into the timing holes in the crankcase and crankshaft.

2

1

cidu

1. Crankshaft Timing Pin T3880601
2. Timing hole in crankcase

13. At this stage the camshafts and sprockets can be separated if required.

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Technical News

Camshaft and Sprocket Identification
Note:
•

The inlet and exhaust camshafts are different. They can be identified by a raised feature in the centre of
the exhaust camshaft, which is machined off on the inlet camshaft. The camshafts can be further
identified with a letter 'I' for inlet or 'E' for exhaust stamped on the end of the sprocket boss.

2

1

3

gabo1

1.
2.
3.
4.

4

Inlet camshaft
Machined section
Exhaust camshaft
Raised section

The same sprocket is used for both inlet and exhaust camshafts, and is attached to the camshaft using slotted bolt holes.
The same holes are used when fitting the sprocket to either camshaft.
Note that the mark on the camshaft boss is not a timing mark, it is used as a visual aid during the timing adjustment
procedure.
Accurate camshaft timing can only be obtained using the correct timing method and service tools as described below.
Camshaft and Bearing Cap Inspection
The camshaft and sprocket inspection is the same as described in the Service Manual.
Camshaft Installation and Timing

Caution
The camshaft sprockets are attached to the camshafts using slotted bolt holes. This allows for very accurate valve timing
and therefore improved performance and fuel economy.
Never fit the camshaft sprockets without correctly setting the camshaft timing using the service tools and timing
procedure described below. Severe engine damage will result from incorrect valve timing adjustment.
1.

Check that the 'dot' mark on the primary gear is still aligned with the line on the crankcase and the Crankshaft
Timing Pin T3880601 is installed. Ensure the crankshaft cannot rotate.

2.

Thoroughly clean the camshafts and journals. Inspect the ends of the camshafts for correct fitment of the sealing
plugs. Lubricate the camshafts with clean engine oil before fitting to the head.

3.

If removed, refit the camshaft sprockets noting their orientation, and secure using the original bolts. DO NOT tighten
the fixings at this stage; the sprockets must be free to rotate.

4.

Refit the camshaft drive chain and, if removed, the tensioner blade and rubbing strip, as described in the Service
Manual.

Note:
•

Locate each camshaft to the head ensuring the camshafts are correctly identified (inlet and exhaust) and
are also correctly located over their respective valve banks.

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Technical News

5.

Refit the exhaust camshaft to the cylinder head, hooking the camshaft drive chain over the sprocket as you do so.

6.

Ensure there is no slack between the crankshaft and exhaust sprocket when the sprocket fixings are centrally located
within the slotted holes. Ensure alignment marks on the end of the camshaft journals are pointing inwards.

7.

Refit the inlet camshaft to the cylinder head, hooking the chain over the sprocket as you do so.