Triumph Motorcycles
Normandy Way
Hinckley
Leicestershire LE10 3BZ
United Kingdom

Technical News
Issue 148

Strictly Confidential

August 2013

Contents
Item 1.

Exhaust Butterfly Cables and Motor Assembly - Daytona 675 and Daytona 675R from
VIN 564948

Item 2.

Headstock Washer and Bearing Adjustment - Tiger Sport

Item 3.

Second and Sixth Output Gears - Speed Triple 1050, Speed Triple 1050 R, Sprint GT,
Tiger 1050 and Tiger Sport

Item 4.

Coolant Inlet Cover - Tiger 800, Tiger 800 with ABS, Tiger 800XC and Tiger 800XC with
ABS

Item 5.

Ignition Coil Fixings - Rocket III Touring and Rocket III Roadster

Item 6.

Tyre Pressure Monitor - All Models

Item 7.

Brake Hose Elbow - America and Speedmaster

Item 8.

Throttle Assembly - All Models with Temporary Handlebars

Item 9.

Transition Piece - Tiger 800 and Tiger 800XC from engine number 617517

Item 10.

ABS Modulator - Speed Triple 1050 with ABS up to VIN 499000

Item 11.

Sprocket Cover Fixings M6 x 16 mm - Tiger 1050 from VIN 595279, Speed Triple 1050
from VIN 595279 and Tiger Sport

Item 12.

Alternator - Street Triple models from VIN 560477

Item 13.

Selector Drum and Neutral Light Switch Parts Kits - Speed Triple 1050, Speed Triple 1050 R
from engine number 539023, Sprint GT from engine number 536533, Tiger 1050 ABS from
engine number 536533 and Tiger Sport from engine number 569533

Item 14.

Alternator - Tiger 800, Tiger 800 ABS and Tiger 800XC ABS

Item 15.

Instrument Fixings - Rocket III Touring and Rocket III Touring ABS

Item 16.

Windscreen Adjustment Mechanism Spares Assemblies - Trophy and Trophy SE

Item 17.

Tyre Noise - Tiger Explorer and Tiger Explorer XC

Item 18.

Service Manual Correction (Brazil ONLY) - Daytona 675 and Daytona 675R from
VIN 564948, Street Triple and Street Triple R from VIN 560477

Item 1.
Description:

Exhaust Butterfly Cables and Motor Assembly

Models affected:

Daytona 675 and Daytona 675R from VIN 564948

Triumph has begun to receive an increase in warranty claims for exhaust butterfly cables and motor assemblies fitted to
the above models.
During inspection, it has been recognised that the components are serviceable and no faults have been found.
Therefore we seek to remind dealers to refer to Technical News 142 dated March 2013 (Item 12) and follow the revised
adjustment procedure prior to replacing any components.
Please mark your copy of the Service Manual with this information.

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Technical News

Item 2.
Description:

Headstock Washer and Bearing Adjustment

Models affected:

Tiger Sport

A washer (part number T3551551) has been introduced between the top yoke and the headstock top nut on the above
model.

2
1
3

1. Washer
2. Headstock top nut
3. Top yoke

At the same time, the method for adjusting the headstock bearings has also changed.
Headstock Bearing Adjustment
The adjustment procedure of the headstock bearings in the Service Manual requires updating as described below:
Adjustment
1.

Remove the top yoke, as described in the Service Manual.

Adjust the bearing free-play as follows, using the relevant tool described in the Service Manual:

Warning
It is essential that the adjuster nut is not over-tightened. If the adjuster is over-tightened it will cause a pre-load on the
headstock bearings. This will introduce tight steering, which could cause loss of control and an accident.
•

Remove the lock nut, tab washer and adjuster nut.

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Technical News

•

Thoroughly clean the threads on the steering stem.

3

2

1

4
1.
2.
3.
4.

Adjuster nut
Lock nut
Stem threads
Tab washer

•

Refit the adjuster nut and tighten to 40 Nm.

•

Slacken the adjuster nut, then tighten to 8 Nm.

•

Refit the tab washer and lock nut.

•

Hold the adjuster nut in position while tightening the lock nut to 40 Nm.

2.

Refit the top yoke to the forks.

3.

Fit the washer and the headstock top nut. Tighten the top nut to 90 Nm.

2
1
3

2
1. Washer
2. Headstock top nut
3. Top yoke

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

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Technical News

Item 3.
Description:

Second and Sixth Output Gears

Models affected:

Speed Triple 1050, Speed Triple 1050 R, Sprint GT, Tiger 1050 and Tiger Sport

The second and sixth output gears have changed on the above models from the engine numbers listed in the table
below.
If for any reason the second or sixth output gears are replaced, a spares kit is available as the two gears must always be
replaced as a pair.
The table below identifies the model range and engine number that require the spares kit.
Model

From Engine
Number

To
Engine
Number

Speed Triple 1050

539023

598091

Speed Triple 1050 R

520032

598091

Sprint GT

536533

598091

Tiger 1050

536533

598091

Tiger Sport

569553

598091

Spares Kit T1186777
Description

Part Number

Quantity

Second output
gear

T1187812

1

Sixth output
gear

T1187817

1

For motorcycles that are not listed in the table above parts can be replaced as required.
When ordering replacement parts, always refer to the EPC.
Please mark your copy of the Service Manual with this information.

Item 4.
Description:

Coolant Inlet Cover

Models affected:

Tiger 800, Tiger 800 with ABS, Tiger 800XC and Tiger 800XC with ABS

The torque figures for the coolant inlet cover on the above models have changed as follows:
•

8 Nm for the two M6 x 20 mm fixings

•

9 Nm for the M6 x 25 mm fixing.

Note:
•

Models already in service need not be re-tightened unless the fixings have been loosened or removed.

1

3

2

1. Fixing, M6 x 20 mm
2. Fixing, M6 x 25 mm
3. Coolant inlet cover

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

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Technical News

Item 5.
Description:

Ignition Coil Fixings

Models affected:

Rocket III Touring and Rocket III Roadster

The torque figure for the fixings securing the ignition coils to the mounting bracket has changed to 9 Nm on the above
models.
Models already in service need not be re-tightened unless the bolts have been loosened or removed.

3
2
1

1

1. Fixings
2. Ignition coil (front shown)
3. Bracket

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

Item 6.
Description:

Tyre Pressure Monitor

Models affected:

All Models

We have been made aware that in certain circumstances puncture repair fluid has been used to repair punctures on
motorcycles with Tyre Pressure Monitoring System (TPMS) fitted.
If for any reason puncture repair fluid comes into contact with a TPMS pressure sensor and the sensor’s orifice becomes
blocked, the warning light on the instrument panel will become illuminated indicating a TPMS sensor fault. Triumph will
not allow warranty claims for damaged TPMS sensors where there are signs of puncture repair fluid being used. We also
remind dealers that the only replacement TPMS sensors approved for use are those obtained from Triumph
Genuine Parts. Use of any others will invalidate the motorcycle warranty.
The following caution will be added to future Owner’s Handbooks.

Caution
Do not use puncture repair fluid or any other item likely to obstruct air flow to the TPMS sensor’s orifices. Any blockage
to the air pressure orifice of the TPMS sensor during operation will cause the sensor to become blocked, causing
irreparable damage to the TPMS sensor assembly. Damage caused by the use of puncture repair fluid or incorrect
maintenance is not considered a manufacturing defect and will not be covered under warranty. Always have your tyres
fitted by your authorised Triumph dealer and inform them that tyre pressure sensors are fitted to the wheels.
Please mark your copy of the Service Manual with this information.

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Technical News

Item 7.
Description:

Brake Hose Elbow

Models affected:

America and Speedmaster

Dealers are reminded that the correct orientation of the front brake hose elbow on the above models is above the stop
feature on the brake reservoir and not below as on other models.
If removed for any reason the brake hose elbow must be positioned as shown below.
1.

Position a new sealing washer on each side of the brake hose end fitting then secure the hose to the master cylinder
with the banjo bolt.

2.

Whilst counter-holding the brake hose elbow, tighten the banjo bolt to 25 Nm.

1

2

ciig

1. Front brake hose
2. Brake reservoir stop feature

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

Item 8.
Description:

Throttle Assembly

Models affected:

All Models with Temporary Handlebars

Dealers are reminded to ensure that during the motorcycle assembly procedure:
•

The throttle assembly is positioned correctly

•

The throttle operation is smooth and unobstructed

•

The throttle returns to its fully closed position when released

•

The throttle grip free play is set to 2 - 3 mm

•

To install or adjust the throttle assembly, always refer to the motorcycle assembly guide.

Note:
•

The alignment marks on the handlebars are a guide only, therefore always check the throttle operation
prior to riding the motorcycle.

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

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Technical News

Item 9.
Description:

Transition Piece

Models affected:

Tiger 800 and Tiger 800XC from engine number 617517

Revised transition pieces have been introduced to the above models and are NOT retrofittable. The removal and
installation of the transition pieces is as described in the Service Manual noting the following:
•

The new transition pieces have a built-in rubber bead so the original O-rings are no longer required.

New encapsulated fixings have also been introduced. These must be replaced and tightened to 8 Nm if they are
loosened or removed.
If a transition piece has been removed for whatever reason, check the rubber bead for damage before refitting. If
damaged fit a new transition piece.
For the removal and installation of the transition pieces, refer to the Service Manual.
When replacing parts, always refer to the EPC.

1
2

3
cdvt

1. Transition piece
2. Rubber seal
3. Fixings

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

Item 10.
Description:

ABS Modulator

Models affected:

Speed Triple 1050 with ABS up to VIN 499000

This information was originally issued as a www.triumphonline.net notice in December 2011.
When fitting a new ABS modulator (part number T2024104) to the above models, the engine management tune software
must be replaced.
Using the latest Triumph diagnostic software, select the tune as appropriate for the market/motorcycle condition from the
folder for Speed Triple from VIN 499001 onwards.
Note:
•

The engine management software must be updated for the speedometer to operate correctly.

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

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Technical News

Item 11.
Description:

Sprocket Cover Fixings M6 x 16 mm

Models affected:

Tiger 1050 from VIN 595279, Speed Triple 1050 from VIN 595279 and Tiger Sport

The sprocket cover fixing torque has been reduced on the above models. In addition the length of the fixing has been
increased to 16 mm.
The revised torque is 7 Nm.
When ordering replacement parts, always refer to the EPC.
Note:
•
•