Technical News 161
January 2015
Strictly Confidential
Contents
Item

Subject

Model Affected

Item 1.

Clutch Cable

Thunderbird - All Models Except
Thunderbird Commander and Thunderbird LT

Item 2.

Pannier Strap Parts kit

Sprint GT, Tiger 800 (All Models), Tiger Sport,
Tiger Explorer, Tiger Explorer XC, Trophy and
Trophy SE

Item 3.

Main Wiring Harness

Trophy SE

Item 4.

Throttle Body Intake Rubbers

All Models With Push Fit Throttle Body Intake
Rubbers

Item 5.

Side Stand Fixing

Speed Triple 1050 ABS, Speed Triple 1050 R ABS
and Tiger Sport from VIN 670401

Item 6.

Front and Rear Direction Indicator Fixings

Thunderbird Commander, Thunderbird LT and
Rocket III Touring ABS

Item 7.

Throttle Position Sensor

Tiger XCX and Tiger XRX

Item 8.

Regulator Rectifier Bracket Fixing

Thunderbird ABS, Thunderbird Commander,
Thunderbird LT and Thunderbird Storm ABS

Item 9.

Gear Change Return Spring Abutment Bolt

Various

Item 10.

Coolant Filler Neck

Thunderbird ABS, Thunderbird Commander,
Thunderbird LT and Thunderbird Storm ABS

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Item 1.
Description:

Clutch Cable

Models affected:

Thunderbird - All Models Except Thunderbird Commander and Thunderbird LT

A new clutch cable has been introduced to the above models from VIN 693388 and is retrofittable. Parts no
longer support the original clutch cable.
The difference between the original and new condition clutch cable is that the inner cable's free length at the
clutch actuation lever is 18 mm longer than the original. The additional length is to allow the repositioning of
the clutch actuation lever to eliminate any possibility of clutch drag.
The fitting of the new condition clutch cable is the same as for Thunderbird Commander as described in the
Service Manual and Technical News 158 issued 07/2014.

2

1

cimx_2

1. Clutch cable free length
2. Clutch actuation lever

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

Item 2.
Description:

Pannier Strap Parts kit

Models affected:

Sprint GT, Tiger 800 (All Models), Tiger Sport, Tiger Explorer, Tiger Explorer XC,
Trophy and Trophy SE

New pannier lid retaining straps have been introduced to the panniers on the above models.
Note:
•
•

The new pannier lid retaining straps feature buckles that are not compatible with the old condition
straps.
Parts will no longer support old condition pannier lid retaining straps.

Parts kit T2357006 has been released for use when replacing old condition pannier lid retaining straps.
T2357006 - Spares Kit, Lid Straps, Panniers
Kit Contents

Quantity

T2357004 - Strap, Female, Lid Limit, Pannier

1

T2357005 - Strap, Male, Lid Limit, Pannier

1

T3350010 - Lock nut, M5

2

T3330648 - Screw, M5 x 20 mm

2

T3550249 - Washer

2

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Installation

Caution
Care must be taken during the assembly of the pannier lid retaining straps. Damage to the pannier
surfaces could result from inadequate care during the assembly process.
1.

Remove the pannier from the motorcycle as described in the Owner’s Handbook or Accessory Fitting
Instructions.

2.

Open the pannier and lay it flat on a clean soft surface, with the inside of the pannier facing upwards.

Note:
•

Note the position and orientation of the old male and female pannier lid retaining straps before removal.

Caution
Only drill through the rivet head when removing the pannier lid retaining strap rivets. Take care not to drill
into any other part of the pannier lid retaining strap mounting points as this would result in irreparable
damage to the pannier.
3.

To remove the old pannier lid retaining straps, using a suitable drill, drill through the head of the rivets
securing the pannier lid retaining straps to their mounting points. Remove and discard the straps, rivets
and washers.

1

2

cirt

1. Pannier lid retaining strap (male shown, female similar)
2. Rivet

4.

Carefully remove any swarf or debris created during drilling.

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5.

Align the new pannier lid retaining straps to their mounting points as noted during removal and secure
with the fixings as shown.

3
4

1

2
5

cirt

1.
2.
3.
4.
5.

Pannier lid retaining strap (male shown, female similar)
Mounting point
Screw
Washer
Nut

6.

Ensuring that the straps remain correctly aligned, tighten the fixings to 1.5 Nm.

7.

Partially close the lid and join the lid retaining strap buckles together, then fully close the lid.

1

cghr

1. Buckle

8.

Fit the pannier to the motorcycle as described in the Owner’s Handbook or Accessory Fitting
Instructions.

When ordering replacement parts, always refer to EPC.
Please mark your copy of the Service Manual with this information.

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Item 3.
Description:

Main Wiring Harness

Models affected:

Trophy SE

A new main wiring harness has been introduced to the above model from engine number 693353. The new
main harness has the four-pin multiplug for the gear position sensor and can be connected to it without the
use of a fly lead.
The new harness is retrofittable to earlier models as described below.
Models with Engines Built from Engine Number 596481 to Engine Number 693352
Note:
•

For engines built from engine number 596481 to engine number 693352 a new gear position sensor and
fly lead was introduced to the above models (see Technical News 143 dated April 2013). This gear position
sensor has the four-pin multiplug.

For the replacement of the main harness, the fly lead connecting the gear position sensor to the main
harness is to be removed and discarded. The gear position sensor can remain on the engine as the new
harness can connect directly to it.
Models with Engines Built up to Engine Number 596480
Note:
•

It is also possible that models with an engine built up to engine number 596480 may have had a new gear
position sensor fitted with a fly lead, as described in Technical News 143 dated April 2013.

If a new gear position sensor is required only, refer to Technical News 143 dated April 2013.
If a new main wiring harness is required, a harness parts kit (part number T2500837) is available and consists
of the following components.
Model

Parts Kit Number

Parts Kit Contents

Trophy SE

T2500837

T2500857, Main Wiring Harness
T1290666, Gear Position Sensor
T3700015, Cable Tie

Prior to ordering the parts kit, check to see if the gear position sensor has the four-pin multiplug. If it has the
four-pin multiplug only the new main wiring harness (part number 2500857) is required.
To check to see if the gear position sensor has a four-pin multiplug, follow the procedure described below.
1.

Disconnect the battery, as described in the Service Manual.

2.

Remove the left hand upper and lower fairings, as described in the Service Manual.

Remove the gear linkage cover, as described in the Service Manual.

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3.

Check to see if the gear position sensor has the three-pin or four-pin multiplug.

1

4
3

2

1.
2.
3.
4.

Three-pin multiplug (up to engine number 596480)
Four-pin multiplug (from engine number 596480 to engine number 693352)
Fly lead
Fly lead three-pin multiplug

If the gear position sensor has the four-pin multiplug, only replace the main wiring harness.
If the gear position sensor has the three-pin multiplug, the gear position sensor must also be replaced using
the parts kit T2500837.
After fitting the new main wiring harness and the gear position, cable tie the gear position multiplug to the
ABS modulator bracket. Trim off any excess cable tie.
The gear position sensor pinpoint test procedure has also changed. The pinpoint test procedure for the new
gear position sensor and old gear position sensors with a fly lead is as follows:
Pinpoint Tests
Test

Result

Action

1

Check cable and terminal integrity:

OK

Disconnect sensor and proceed to test 2

- ECM pin B44

Faulty

Rectify fault, proceed to test 5

OK

Proceed to test 3

Short circuit

Locate and rectify wiring fault, proceed
to test 5

OK

Proceed to test 4

Open circuit

Locate and rectify wiring fault, proceed
to test 5

- ECM pin B18
- ECM pin B23
- ECM pin B34
2 Check cable for short circuit:
- ECM pin B44 to ground
- ECM pin B34 to ground
- ECM pin B23 to ground
3 Check cable continuity:
- ECM pin B44 to sensor pin 1
- ECM pin B23 to sensor pin 2
- ECM pin B18 to sensor pin 3
- ECM pin B34 to sensor pin 4

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