Service Bulletin 604
Issue 1 - 02.2023
Subject: Hydraulic Clutch System Bleed
Bulletin Number
604

Models Affected

VIN Range

Tiger 1200 GT

Markets Affected

Up to BJ1925

All Markets

Tiger 1200 GT Pro
Tiger
Pro

1200

Tiger
1200
Explorer
Tiger 1200
Explorer

Rally
GT
Rally

Background Information
Dealers are requested to bleed the hydraulic clutch system as described in the procedure below.

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 1200 GT, Tiger 1200 GT Pro, Tiger 1200 Rally Pro, Tiger 1200 GT Explorer and Tiger 1200 Rally Explorer
motorcycles in the above VIN range.
Note:
•
•

Some affected motorcycles listed in the VIN range will have been modified and repaired by Triumph
prior to their release from the factory.
Unmodified motorcycles can be identified by checking the ‘VIN Enquiry’ on www.triumphonline.net.

Warranty Claim Instructions
Bulletin Number

Model

Fault Code

Repair Code

Description

Repair
Allowance

604

Tiger 1200 GT,
Tiger 1200 GT
Pro, Tiger 1200
Rally Pro

011731904

99604

Bleed Clutch

0.35 Hrs

604

Tiger 1200 GT
Explorer, Tiger
1200
Rally
Explorer

011731904

99604

Bleed Clutch

0.40 Hrs

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Genuine Parts Information
Bulletin Number
604

Model
Tiger
1200
GT,
Tiger 1200 GT Pro,
Tiger 1200 Rally
Pro

Part Number
T1174222

Description
Spares Kit, Clutch
Bleed

Quantity
1

Consisting of:
Screw,
Csk,
M6x1.0x50,Slv, Enc
- Qty 1
Screw,
Cap/HD,
M6x1x20, Slv, Enc Qty 1

604

Tiger
1200
GT
Explorer,
Tiger
1200 Rally Explorer

T1174333

Spares Kit, Clutch
Bleed

1

Consisting of:
Screw,
Csk,
M6x1.0x50,Slv, Enc
- Qty 1
Screw,
Cap/HD,
M6x1x20, Slv, Enc Qty 1
Screw,
Btn/HD,
M10x50, Enc - Qty
1
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 OnLine 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

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.

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Other Instructions
Once completed, please mark the Service Record Book that the requirements of this bulletin have been
complied with.
Before returning the motorcycle to the customer, download the latest calibration using the current version
of the Triumph diagnostic software to the following:
• Engine electronic control module
• Chassis electronic control module (if fitted)
• Keyless electronic control module (if fitted)
• Suspension electronic control module (if fitted)
• Connectivity module (if fitted)
• Instruments (if applicable).

Bleed the Hydraulic Clutch System

WARNING
Make sure the motorcycle is stabilised and adequately supported.
Do not support the motorcycle on any ancillary component, the exhaust system or any other non
structural parts of the motorcycle frame.
A correctly supported motorcycle will help prevent it from falling.
An unstable motorcycle may fall resulting in motorcycle damage, serious injury or death.

NOTICE
Renew locking devices where specified, refer to Fixings.
Before tightening a fixing using a crow foot spanner adapter, refer to Use of Crow Foot Spanner Adapters
with Torque Wrenches.
Observe all torque wrench tightening procedures, refer to Tightening procedure.

WARNING
Make sure absolute cleanliness when adding clutch fluid to the clutch fluid reservoir.
Do not allow moisture or debris to enter the cylinder as this will adversely affect the fluid properties.
Always use fluid from a sealed container and do not use fluid from a container which has been opened for
any period of time.
Always check for fluid leakage around hydraulic fittings and for damage to hoses.
A dangerous riding condition leading to loss of motorcycle control and an accident could result if this
warning is ignored.

WARNING
Use only DOT 4 specification brake and clutch fluid as listed in the General Information section of this
manual. The use of brake and clutch fluids other than those DOT 4 fluids listed in the General Information
section may reduce the efficiency of the clutch system leading to an accident.

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CAUTION
To prevent body damage, do not spill brake and clutch fluid onto any area of the bodywork or the brake
and clutch reservoirs.
Perform the following operations:
• If the motorcycle is fitted with blind spot radar, remove the rider's seat and remove the battery as
described in the Service Manual.
• Remove the left hand side mirror as described in the Service Manual.
• Remove the left hand side handguard as described in the Service Manual.
1.
Note the original setting of the clutch lever adjuster in order that it can be returned to the same
position when the bleeding operation is complete. Set the clutch lever adjuster to give maximum lever
travel.
2. Turn the handlebars to bring the fluid reservoir to a level position.
3. Clean the reservoir cap before removing.
4. Remove the reservoir cap, plastic plate and the diaphragm seal. Check the condition of the diaphragm
seal fitted, replace the diaphragm if necessary.

1
2
3

4
5

B02119

1.
2.
3.
4.
5.

5.

Reservoir cap
Plastic plate
Diaphragm seal
MAX mark
MIN mark

Release the fixings and detach the clutch slave cylinder bracket from the clutch cover. Do not remove
the hydraulic hose from the clutch slave cylinder.

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6.

Remove and discard the fixing on the clutch lifter arm and slide the clutch lifter arm from the splined
clutch lifter shaft.

5
4

2
1

3
B02121

1.
2.
3.
4.
5.

7.

Fixing
Lifter arm
Fixings
Bracket
Clutch slave cylinder

Remove the dust cap from the bleed screw on the slave cylinder.

NOTICE
Due to the small size of the bleed screw nipples, we recommend a syringe type bleed kit suitable for
bicycles is used.
8.
9.
10.

Place a suitable clean transparent plastic tube on to a proprietary brake bleed syringe.
Draw new clutch fluid into the syringe until the syringe is half full.
Attach the other end of the transparent plastic tube to the clutch slave cylinder bleed screw.

3
4

2

1
1.
2.
3.
4.

11.

Dust cover
Clutch slave cylinder bleed screw
Syringe
Transparent tube

Loosen the clutch slave cylinder bleed screw by ¾ of a turn.

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NOTICE
Clutch fluid must still be present in the syringe during the bleed process. Failure to keep clutch fluid in the
syringe may introduce air into the clutch system.
12.

Using the syringe, slowly push the clutch fluid through the clutch system into the clutch fluid reservoir
until the fluid reaches the maximum fluid level line.

NOTICE
Clutch fluid must still be present in the clutch fluid reservoir during the bleed process. Failure to keep
clutch fluid in the clutch fluid reservoir may introduce air into the clutch system.
Whilst drawing clutch fluid from the clutch fluid reservoir, the syringe must be held vertically to allow air to
travel up through the syringe.
13.
14.
15.
16.
17.
18.
19.

Slowly pull back the syringe piston until the fluid level in the clutch fluid reservoir almost reaches the
bottom.
Using the syringe, pump the clutch fluid into the system again until the fluid reaches the maximum
fluid level line of the clutch fluid reservoir.
Repeat steps 12 to 14 at least three times until no more air appears in the syringe or clutch fluid
reservoir.
Close the clutch slave cylinder bleed screw and tighten to 4 Nm.
Reinstall the slave cylinder bleed screw dust cap.
Check tighten the slave cylinder hydraulic hose union to 5 Nm.
Fit the clutch lifter arm to the clutch lifter shaft, lining up the split line of the lifter arm with the
alignment mark on the lifter shaft. Fit a new fixing and tighten to 10 Nm.

5
4

2
1

3
B02121

1.
2.
3.
4.
5.

Fixing
Lifter arm
Fixings
Bracket
Clutch slave cylinder

20. Refit the clutch slave cylinder bracket to the clutch cover and tighten the fixings to 10 Nm.

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21.

Check and, if necessary adjust the free play at the lifter arm. The difference between the clutch lifter
arm in its resting position and the clutch lifter arm rotated fully clockwise should be 2 - 5 mm. This can
be adjusted using the adjuster on the slave cylinder.

1

1.

Slave cylinder adjuster

CAUTION
Make sure the end of the transparent tube is secured to the master cylinder reservoir. Failure to secure
the transparent tube may cause clutch fluid to be spilt, causing damage to the motorcycle.
22. Remove the hose from the syringe and attach one end to the clutch lever master cylinder bleed screw.
Place the loose end of the hose into the master cylinder reservoir.

1
2

3

clcx

1.
2.
3.

Clutch master cylinder reservoir
Transparent tube
Clutch master cylinder bleed screw

NOTICE
Pressure applied to the clutch lever during the clutch fluid renew process must be applied and removed
smoothly and slowly. It must take a minimum of five seconds between lever positions (from fully released to
stop).
Failure to do this slowly can allow air to be drawn in to the system through the bleed screw threads.
23. Actuate the clutch lever slowly up to when the clutch lever touches the handlebar and release fully
four times. On the fifth time, apply a small amount of pressure to the lever until resistance is felt, hold
the clutch lever in this position and open the bleed screw at the master cylinder by ¾ turn.

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NOTICE
If the clutch lever is released whilst the bleed screw is open, this can allow air to be drawn in to the system
through the bleed screw threads.
24. Keeping pressure on the clutch lever so resistance is still felt, close the bleed screw. Release the clutch
lever fully.
25. Repeat process at the master cylinder until no air exits at the master cylinder bleed screw.
26. Tighten the clutch master cylinder bleed screw to 4 Nm.
27. Reinstall the master cylinder bleed screw dust cap.
28. Check the clutch lever to make sure there is minimal free play, rectify as necessary.
29. Reinstall the clutch reservoir cap, plastic plate and the diaphragm seal.

1
2
3

4
5

B02119

1.
2.
3.
4.
5.

30.
31.
32.
33.
34.
35.

Reservoir cap
Plastic plate
Diaphragm seal
MAX mark
MIN mark

Check the clutch for correct operation and fluid leaks. Rectify as necessary.
Refit the left hand side handguard as described in the Service Manual.
Refit the left hand side mirror as described in the Service Manual.
If blind spot radar is fitted to the motorcycle, refit the battery as described in the Service Manual.
Connect the Triumph diagnostic tool as described in the Service Manual.
Refit the rider's seat as described in the Service Manual, with the Triumph diagnostic tool still
connected. Make sure the diagnostic cable is not trapped by the seat.

WARNING
Exhaust fumes are poisonous, always operate a motorcycle in the open-air or in an area with adequate
ventilation.
Do not operate a motorcycle in an enclosed area without adequate ventilation.
Operating a motorcycle in an enclosed area without adequate ventilation can cause loss of consciousness
and death within a short period of time.

WARNING
The following check requires the motorcycle to be started and in gear. Make sure the motorcycle remains
adequately supported and the brakes are applied.
Failure to follow the advice above could lead to loss of motorcycle control which could result in serious
injury or death.

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36. Start the motorcycle and select first gear. Apply the brakes to keep the motorcycle stationary.
37. With the aid of an assistant and using the engine ECM sensor data on the Triumph diagnostic tool
software:
• Check the clutch switch status changes from Grip to Release before the clutch reaches its biting
point. Set the clutch lever adjuster to give minimum lever travel and repeat the check.
• If rectification is necessary, the dealer should re-bleed the clutch system and retest using the
Triumph diagnostic tool.
• If the re-bleed process is satisfactory, check the microswitch on the clutch lever assembly for
damage.
38. Stop the engine and remove the Triumph diagnostic tool.
39. Refit the rider's seat as described in the Service Manual.

WARNING
Always return the lever adjuster to the original setting as noted in step 1. Operating the motorcycle with
lever settings which are unfamiliar may lead to loss of control or an accident.
40. Reset the adjuster on the clutch lever to the original setting.

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