Triumph Scrambler 1200 XC Service Manual
Service Manual - Scrambler 1200
XC
Introduction
Introduction
This manual is designed primarily for use by trained technicians in a properly
equipped workshop. However, it contains enough detail and basic information to
make it us eful to the owner who desires to perform his own basic maintenance and
repair work. The work can only be carried out if the owner has the necessary hand
and special service tools to complete the job.
A basic knowledge of mechanics , including the proper use of tools and workshop
procedures is necess ary in order to carry out maintenance and repair work
satis factorily. Whenever the owner has ins ufficient experience or doubts regarding his
ability to do the work, an authoris ed Trium ph dealer mus t undertake all adjus tments,
maintenance, and repair work.
In order to perform the work efficiently and to avoid costly m istakes, read the text and
thoroughly familiarise yourself with procedures before starting work.
All work should be performed with great care and in a clean working area with
adequate lighting.
Always us e the correct special service tools or equipment specified. Under no
circum stances use makeshift tools or equipm ent since the use of subs titutes may
adversely affect safe operation.
Where accurate measurements are required, they can only be made using
calibrated, precis ion ins trum ents.
For the duration of the warranty period, an authorised Triumph dealer mus t perform
all repairs and scheduled maintenance.
To maximis e the life of your motorcycle:
Accurately follow the maintenance requirem ents of the periodic maintenance
chart in the Service Manual.
Do not allow problems to develop. Inves tigate unus ual nois es and changes in
the riding characteristics of the motorcycle. Rectify all problems as soon as
pos sible (im mediately if safety related).
Use only genuine Trium ph parts as lis ted in the electronic parts catalogue (EPC).
Follow the procedures in this manual carefully and completely. Do not take short
cuts.
Keep complete records of all maintenance and repairs with dates and any new
parts installed.
Service Manual - Scrambler 1200 XC 1 of 640
Use only approved lubricants, as specified in the Owner's Handbook, in the
maintenance of the motorcycle.
How to use this manual
To as sis t in the us e of this manual, the section title is given at the top.
Each major section starts with a contents page, listing the inform ation contained in
the section.
The individual steps com pris ing repair operations are to be followed in the sequence
in which they appear.
Adjustment and repair operations include reference to service tool numbers and the
ass ociated illustration depicts the tool.
Where us age is not obvious , the tool is shown in us e.
Adjustment and repair operations als o include reference to wear limits, relevant data,
torque figures, specialis t information and useful assem bly details .
Warnings, Cautions and Note s
Particularly im portant information is presented in the following form:
WARNING
This warning symbol identifies special instructions or procedures which, if not
correctly followed, could result in pers onal injury, or loss of life.
CAUTION
This caution symbol identifies special instructions or procedures which, if not
strictly observed, could result in damage to or des truction of equipment.
Note
This note symbol indicates points of particular interest for more efficient and
convenient operation.
Tampering with Noise Control Syste m Prohibited
Owners are warned that the law may prohibit:
The removal or rendering inoperative by any person other than for purposes of
maintenance, repair or replacement, of any device or element of design
incorporated into any new vehicle for the purpos e of nois e control prior to its sale
or delivery to the ultimate purchaser or while it is in use; and
The use of the vehicle after such device or elem ent of design has been removed
or rendered inoperative by any pers on.
Service Manual - Scrambler 1200 XC 2 of 640
Refe re nces
References to the left hand or right hand side given in this manual are made when
viewing the motorcycle from the rear.
Operations covered in this manual do not always include reference to testing the
motorcycle after repair. It is essential that work is ins pected and tested after
completion and, if necessary, a road test of the motorcycle is carried out particularly
where safety related items are concerned.
Dimensions
The dim ensions quoted are to des ign engineering specification with service limits
where applicable.
During the period of running-in from new, certain adjus tments may vary from the
specification figures given in this manual. These will be reset by the dealer at the 500
mile/800 km service, and thereafter should be maintained at the figures specified in
this manual.
Repairs and Replace ments
Before rem oval and disas sem bly, thoroughly clean the motorcycle. Any dirt entering
the engine or other parts will work as an abras ive and shorten the life of the
motorcycle. Particular attention should be paid when installing a new part, that any
dus t or metal filings are cleared from the immediate area.
Force
Com mon sens e should dictate how much force is necess ary in assembly and
dis ass embly. If a part seem s especially difficult to remove or install, stop and
exam ine what may be causing the problem . Never lever a com ponent as this will
caus e damage both to the component itself and to the surface being levered against.
Whenever tapping to aid removal of an item is necess ary, tap lightly using a hide or
plastic faced mallet.
Edge s
Watch for sharp edges , es pecially during engine disassem bly and assembly. Protect
the hands with industrial quality gloves.
When replacement parts are required, it is es sential that only genuine Triumph parts
are us ed.
Safety features and corrosion prevention treatments em bodied in the motorcycle may
be im paired if parts other than genuine Trium ph parts are fitted. In certain territories ,
legis lation prohibits the fitting of parts not to the manufacturer's specification.
Tightening procedure
Service Manual - Scrambler 1200 XC 3 of 640
Generally, when ins talling a part with several bolts, nuts or screws, they should all be
started in their holes and tightened to a snug fit, evenly and in a cros s pattern. This is
to avoid distortion of the part and/or gas or oil leakage. Conversely, bolts, nuts, or
screws, should all be loosened (in sequence if specified) by about a quarter of a turn
and then rem oved.
Where there is a tightening sequence specified in this Service Manual, the bolts,
nuts, or screws must be tightened in the order and by the method indicated.
Torque wrench setting figures given in this manual must be observed. The torque
tools used must be of accurate calibration.
Torque Tolerance
Torque
Tolerance
0 Nm to 25 Nm
+/- 10%
26 Nm to 100 Nm
+ 10% -0%
101 Nm to 200 Nm
+10% -0%
Locking devices, where specified, must be fitted. If the efficiency of a locking device is
impaired during removal it must be renewed. This applies particularly to micro-
encaps ulated fixings which must always be replaced if disturbed. Where neces s ary,
the text in this manual will indicate where such a fixing is us ed.
Use of Crow Foot Spanner Adapters with Torque Wrenches
The use of a crow foot spanner adapter will effectively lengthen the lever arm of a
torque wrench. The amount of torque applied to a fas tener is increas ed as the torque
wrench lever arm is extended, therefore the torque wrench setting must be adjus ted
in order to achieve the correct tightening torque.
Before tightening a fixing using a crow foot spanner adapter, measure the normal
length of the torque wrench from the centre of the drive square to the centre of the
handle (dim ens ion L1). Fit the crow foot spanner adapter to the torque wrench as
shown below. Meas ure the extended length of the torque wrench from the centre of
the crow foot spanner head to the centre of the handle (dimens ion L2).
Use the following formula to calculate the correct torque wrench setting to achieve the
required tightening torque.
Note
The example shown below is calculated using a crow foot spanner measuring
25 mm from the centre of the spanner head to the centre of the drive square.
Service Manual - Scrambler 1200 XC 4 of 640
ciyj
L2
L1
M1 = M2 x L1 / L2
Example
M2 is the required tightening torque to be applied
90 Nm
L1 is the normal length of the torque wrench,
measured from the centre of the drive square to the
centre of the handle
300 mm
L2 is the extended length of the torque wrench,
measured from the centre of the crow foot spanner
head to the centre of the handle
325 mm
M1 is the calculated torque wrench setting
83 Nm
General Information
Ignition System Safety Precautions
WARNING
The ignition sys tem produces extrem ely high voltages . Do not touch any part of the
ignition sys tem or any cables while the engine is running.
An electric shock caus ed by contact with the ignition system may lead to illness,
injury or death.
WARNING
Wearers of surgically implanted heart pacemaker devices should not be in close
proximity to ignition circuits and or diagnos tic equipment.
The ignition sys tem and any diagnostic equipm ent may interrupt the normal
operation of such devices causing illnes s or death.
Dangerous Substance s
Service Manual - Scrambler 1200 XC 5 of 640
WARNING
Many liquids and other substances used in motor vehicles are poisonous and
should under no circumstances be consum ed and should, as far as pos sible, be
kept from contact with the skin. Thes e subs tances am ong others include acid,
antifreeze, asbestos, brake fluid, fuel, lubricants, and various adhesives. Always
pay close attention to the instructions printed on labels and obey the instructions
contained within. These instructions are included for your safety and well-being.
NEVER DISREGARD THESE INSTRUCTIONS!
Third Party Products
WARNING
Many proprietary products, such as chemicals, solvents and cleaning agents, will
caus e damage to components if used incorrectly or inappropriately. Always follow
the manufacturer’s ins tructions printed on the product container’s labels and obey
the ins tructions given. Thes e instructions are included for your safety and well-
being.
Dam age to the motorcycle components caus ed by the incorrect or inappropriate
use of chemicals, solvents and cleaning agents may reduce the components
efficiency, resulting in los s of motorcycle control and an accident.
Fluoroe lastomers
WARNING
Fluoroelastomer material is us ed in the manufacture of various seals in Triumph
motorcycles.
In fire conditions involving temperatures greater than 315°C this material will
decompose and can then be potentially hazardous. Highly toxic and corrosive
decomposition products, including hydrogen fluoride, carbonyl fluoride, fluorinated
olefins and carbon monoxide can be generated and will be present in fumes from
fires.
In the presence of any water or humidity, hydrogen fluoride may dis solve to form
extremely corrosive liquid hydrofluoric acid.
If such conditions exist, do not touch the material and avoid all skin contact. Skin
contact with liquid or decomposition res idues can cause painful and penetrating
burns leading to perm anent, irreversible skin and tis s ue damage.
Oils
Service Manual - Scrambler 1200 XC 6 of 640
WARNING
The engine oil may be hot to the touch. Contact with hot oil may caus e the skin to
be scalded or burned.
WARNING
Prolonged or repeated contact with engine oil can lead to skin dryness , irritation
and derm atitis. In addition, used engine oil contains potentially harmful
contam inants which can cause cancer. Wear suitable clothing and avoid skin
contact.
Health Prote ction Precautions
Avoid prolonged and repeated contact with oils , particularly used engine oils.
Wear protective clothing, including impervious gloves where practicable.
Do not put oily rags in pockets.
Overalls must be cleaned regularly. Dis card heavily soiled clothing and oil
impregnated footwear.
First aid treatment should be obtained im mediately for open cuts and wounds .
Always be aware of who your nearest First Aider is and where the medical
facilities are kept.
Use barrier creams , applying before each work period to protect the skin from the
effects of oil and greas e and to aid removal of the same after completing work.
Wash with soap and water to ensure all oil is rem oved (skin cleansers and nail
brus hes will help). Preparations containing lanolin replace the natural skin oils
which have been removed.
Do not use petrol, kerosene, dies el fuel, gas oil, thinners or solvents for cleaning
skin.
If skin disorders develop, obtain medical advice without delay.
Where practicable, degrease components prior to handling.
WARNING
Any ris k of eye injury mus t be avoided. Always wear eye protection when using a
ham mer, air line, cleaning agent or where there is ANY ris k of flying debris or
chem ical splashing.
Environmental Protection Precautions
Service Manual - Scrambler 1200 XC 7 of 640
CAUTION
Do not pour oil on the ground, down sewers or drains, or into water courses . To
prevent pollution of water cours es etc., dis pose of us ed oil sensibly. If in doubt
contact your local authority.
Burning of used engine oil in small space heaters or boilers can be recommended
only for units of approved des ign. If in doubt, check with the appropriate local authority
and/or manufacturer of the approved appliance.
Dispos e of used oil and used filters through authorised waste dis pos al contractors,
to licensed waste disposal sites, or to the was te oil reclam ation trade. If in doubt,
contact your local authority for advice on disposal facilities.
Brakes
WARNING
Brake fluid is hygroscopic which means it will absorb mois ture from the air. Any
abs orbed moisture will greatly reduce the boiling point of the brake fluid causing a
reduction in braking efficiency.
Replace brake fluid in line with the routine maintenance schedule. A dangerous
riding condition could result if this important maintenance item is neglected!
Do not spill brake fluid onto any area of the bodywork as this will dam age any
painted or plas tic surface.
Always us e new brake fluid from a sealed container and never use fluid from an
uns ealed container or from one that has been previous ly opened.
Do not mix different brands of fluid. Check for fluid leakage around brake fittings,
seals and joints.
Check regularly for brake hos e damage.
FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING
EFFICIENCY LEADING TO AN ACCIDENT.
WARNING
If there has been an appreciable drop in the level of the fluid in either brake fluid
reservoir, consult your authorised Triumph dealer for advice before riding.
If the brake lever or pedal feels soft when it is applied, or if the lever/pedal travel
becomes excessive, there may be air in the brake lines or the brake may be
defective.
It is dangerous to operate the motorcycle under such conditions and rem edial
action must be taken by your authorised Trium ph dealer before riding the
Service Manual - Scrambler 1200 XC 8 of 640
WARNING
motorcycle.
Failure to take remedial action may reduce braking efficiency leading to an
accident.
WARNING
Use only DOT 4 specification brake fluid as listed in the General Information
section of this manual. The use of brake fluids other than those DOT 4 fluids listed
in the General Information section may reduce the efficiency of the braking sys tem
leading to an accident.
Failure to change the brake fluid at the interval specified in the routine
maintenance schedule may reduce braking efficiency resulting in an accident.
WARNING
Never use mineral-based greas e in any part of the braking system or in any area
where contact with the braking system is possible. Mineral-based grease will
dam age the hydraulic seals in the calipers and master cylinders.
Dam age caus ed by contact with mineral-based grease may reduce braking
efficiency resulting in an accident.
WARNING
Before installation, all internal brake components should be cleaned and
lubricated with clean new DOT 4 brake fluid.
Never use solvents, petrol (gasoline), engine oil or any other petroleum distillate
on internal brake components as this will caus e deterioration of the hydraulic
seals in the calipers and master cylinders.
A dangerous riding condition leading to loss of motorcycle control and an accident
could res ult if this warning is ignored.
Safety Instructions
Jacking and Lifting
WARNING
Always ensure that any lifting apparatus has adequate load and safety capacity for
Service Manual - Scrambler 1200 XC 9 of 640
WARNING
the weight to be lifted. Ensure the motorcycle is well supported to prevent any
pos sibility of the machine falling prior to lifting or jacking or while repairs and
servicing are carried out.
Never rely on a single means of support when working with the motorcycle. Use
additional safety supports and straps to prevent toppling.
Do not leave tools, lifting equipment, s pilled oil, etc. in a place where they could
become a hazard to health. Always work in a clean, tidy area and put all tools away
when the work is finished.
Precautions Against Damage
Avoid spilling brake fluid or battery acid on any part of the bodywork. Was h spillages
off with water imm ediately.
Disconnect the battery earth lead before starting work, see
ELECTRICAL
PRECAUTIONS
.
Always us e the recom mended service tool where specified.
Protect exposed bearing and sealing surfaces , and screw threads from damage.
Coolant
WARNING
Coolant mixture, which is blended with antifreeze and corrosion inhibitors
contains toxic chemicals which are harmful to the hum an body. Never swallow
antifreeze, corrosion inhibitors or any of the motorcycle coolant.
WARNING
Do not remove the radiator cap when the engine is hot. When the engine is hot,
the coolant inside the radiator is hot and als o under pres s ure. Contact with the
pres surised coolant will caus e scalds and skin damage.
CAUTION
The coolant antifreeze contains a corrosion inhibitor which helps prevent dam age
to the metal surfaces ins ide the cooling system . Without this inhibitor, the coolant
would 'attack' the metals and the resulting corrosion would caus e blockages in
the cooling sys tem leading to engine overheating and damage. Always use the
correct antifreeze as specified in the Owner's Handbook. Never use a methanol
Service Manual - Scrambler 1200 XC 10 of 640
CAUTION
bas ed antifreeze as this does not contain the required corrosion inhibition
properties.
CAUTION
Distilled water must be used with the antifreeze (see specification for antifreeze) in
the cooling sys tem.
If hard water is used in the system , it causes scale accumulation in the water
pas sages, and considerably reduces the efficiency of the cooling system .
Reduced cooling sys tem efficiency may lead to the engine overheating and engine
dam age.
Cleaning Components
A high flas hpoint solvent is recommended to reduce fire hazard.
Always follow container directions regarding the use of any solvent.
Always us e the recom mended cleaning agent or equivalent.
Do not use degreasing equipm ent for components containing items which could be
dam aged by the use of this process . Whenever pos s ible, clean components and the
area surrounding them before removal. Always observe scrupulous cleanliness
when cleaning dismantled components.
Lubrication
The majority of engine wear occurs while the engine is warming up and before all the
rubbing surfaces have an adequate lubrication film. During ass embly, oil or greas e
(whichever is more suitable) should be applied to any rubbing surface, which has
los t its lubrication film . Old grease and dirty oil should be cleaned off. This is
becaus e used lubricants will have lost som e lubrication qualities and may contain
abrasive foreign particles.
Use recomm ended lubricants. Some oils and greases in particular should be us ed
only in certain applications and may be harmful if us ed in an application for which
they are not intended. This manual makes reference to molybdenum disulphide
grease in the assem bly of certain engine and chassis parts. Always check
manufacturer recommendations before us ing such special lubricants.
Joints and Joint Faces
As sem ble joints dry unles s otherwise specified in this manual.
If gas kets and/or jointing com pound is recommended for use; remove all traces of
old jointing material prior to reassembly. Do not use a tool which will dam age the
Service Manual - Scrambler 1200 XC 11 of 640
joint faces and smooth out any scratches or burrs on the joint faces using an oil
stone. Do not allow dirt or jointing material to enter any tapped holes.
Gaskets, O-rings
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces
around the gasket should be free of foreign matter and perfectly sm ooth to avoid oil or
compress ion leaks .
Liquid Gasket, Non-permanent Locking Agent
Follow manufacturer's directions for cleaning and preparing surfaces where these
compounds will be used. Apply sparingly as excessive amounts of sealer may block
engine oil pass ages and cause serious dam age.
Prior to reas sem bly, blow through any pipes, channels or crevices with compressed
air.
WARNING
To prevent injury, always us e eye, face and ear protection when using compressed
air. Always wear protective gloves if the com pres sed air is to be directed in
proximity to the skin.
Screw Threads
Metric threads to ISO standard are used.
Dam aged nuts, bolts and screws mus t always be discarded.
Cas tellated nuts must not be loosened back to accept a split pin, except in those
recom mended cases when this forms part of an adjustment.
Do not allow oil or grease to enter blind threaded holes . The hydraulic action on
screwing in the bolt or stud could split the housing.
Always tighten a nut or bolt to the recom mended torque figure. Dam aged or corroded
threads can affect the torque reading.
Unles s specified, threaded fixings mus t always be fitted dry (no lubrication).
WARNING
Never lubricate a thread unless instructed to do so.
When a thread of a fixing is lubricated, the thread friction is reduced. When the
fixing is tightened, reduced friction will caus e over tightening and possible fixing
failure.
A fixing which fails in service could caus e component detachment leading to los s
of control and an accident.
Service Manual - Scrambler 1200 XC 12 of 640
Locking Devices
Always release locking tabs and fit new locking was hers . Do not reuse locking tabs.
Fitting a Split Pin
Always fit new split pins of the correct size for the hole in the bolt or stud. Do not
loosen back castle nuts when fitting a split pin, except in thos e recom mended cases
when this forms part of an adjus tment.
Always fit new roll pins of an interference fit in the hole.
Circlips, Retaining Rings
Replace any circlips and retaining rings that are rem oved. Rem oval weakens and
deform s circlips causing looseness in the circlip groove. When installing circlips and
retaining rings, take care to compres s or expand them only enough to install them.
Always us e the correct replacement circlip as recommended in the Trium ph parts
catalogue.
Self-Locking Nuts
Self-locking nuts can be reus ed, provided resistance can be felt when the locking
portion passes over the thread of the bolt or stud.
DO NOT reuse self-locking nuts in critical locations, e.g. s uspens ion components.
Always us e the correct replacement self-locking nut.
Encapsulated Bolts
An encapsulated bolt can be identified by a coloured section of thread which is
treated with a locking agent.
Unles s a specified repair procedure states otherwise, encapsulated bolts cannot be
reus ed and MUST be replaced if disturbed or rem oved.
WARNING
Failure to replace an encapsulated bolt could lead to a dangerous riding
condition. Always replace encapsulated bolts.
Oil and Grease Seals
Replace any oil or grease seals that are rem oved. Removal will cause damage to an
oil seal which, if reused, would cause an oil leak.
Ensure the surface on which the new seal is to run is free of burrs or scratches.
Renew the component if the original sealing surface cannot be completely res tored.
Service Manual - Scrambler 1200 XC 13 of 640
Protect the seal from any surface which could cause damage over which it has to
pas s when being fitted. Use a protective sleeve or tape to cover the relevant surface
and avoid touching the sealing lip.
Lubricate the sealing lips with a recom mended lubricant. This will help to prevent
dam age in initial use. On dual lipped seals, smear the area between the lips with
appropriate grease.
When pressing in a seal which has manufacturer's marks, press in with the marks
facing out.
Seals mus t be pressed into place us ing a suitable driver. Use of im proper tools will
dam age the seal.
Press
A part installed us ing a pres s or driver, such as a wheel bearing, should first be
coated with oil or grease on its outer or inner circum ference so that it will locate
smoothly.
Ball Bearing
When installing a ball bearing, the bearing race which is an interference fit should be
pus hed by a suitable driver. This prevents severe stress or dam age to the load
carrying components. Press a ball bearing until it touches the shoulder in the bore or
on the shaft.
With the sealing lip facing the lubricant, press or drift a seal to the depth of its
housing, if the housing is shouldered, or flush with the face of the housing where no
shoulder is provided.
Chassis Bearing Lubrication
Note
This information relates only to bearing lubrication. For the procedures
necessary to replace a bearing, always refer to the relevant section of this
Service Manual.
Bearings installed in engine and transmission applications are not covered by
this information. Refer to the Lubrication chapter or the relevant engine
chapter for additional information.
General
For a bearing to be serviceable for its anticipated life span it must be checked,
adjus ted and lubricated at regular intervals, as specified in the service schedules
given in the Owner’s Handbook and this Service Manual.
A correctly lubricated bearing will have a film of lubrication that separates the moving
parts, dis perses heat and protects the bearing surfaces from corrosion.
Service Manual - Scrambler 1200 XC 14 of 640
Note
In all cases, use the lubricant recommended.
Grease the bearing, not the cavity where it is located.
A bearing that is not regularly checked and lubricated will have a reduced life
span.
New Bearings
New bearings are typically protected with an oil pres ervative to prevent corrosion etc.
during storage. This is NOT the lubrication for the bearing but DOES NOT need to be
was hed off prior to assem bly and in-service lubrication.
When lubricating a new bearing with grease the following steps should be taken:
Do not clean off the oil preservative.
1.
Grease must be forced between the roller elements and the roller cage.
2.
Rotate the bearing to ens ure that the grease is distributed over the entire
circum ference of the internal parts.
3.
Any excess grease should be smeared on the outside of the rollers .
4.
Lubrication and Checks While Servicing a Bearing
Disass emble parts as necess ary to access the bearing.
1.
Inspect the old grease covering the bearing, looking for signs of bearing damage,
i.e. flakes or specks of metal.
2.
Rem ove the old grease.
3.
Check the bearing for smooth operation and vis ually check for corros ion, dents
and flaking in the bearing race, rollers or cage. Replace if neces sary.
4.
Below/overleaf several com m on bearing types and the lubrication procedures for
each are identified:
ceon
Service Manual - Scrambler 1200 XC 15 of 640
Sealed Bearings
Note
Sealed bearings can be identified by their integrated seals.
Sealed bearings are lubricated for life by the manufacturer.
Any attempt to change the grease in a sealed bearing will damage the
integrated seals. If the seals are damaged, dirt and water will ingress and the
life of the bearing will be greatly reduced.
ceon
Taper Bearings
Grease must be forced between the inner race and the roller carrier.
1.
Rotate the bearing to ens ure that the grease is distributed over the entire
circum ference of the internal parts.
2.
Any excess grease should be smeared on the outside of the rollers .
3.
Service Manual - Scrambler 1200 XC 16 of 640
ceon
Angular Contact and Ball Bearing
Grease the bearing races and the ball bearing carrier.
1.
Rotate the bearing to ens ure that the grease is distributed over the entire
circum ference of the internal parts.
2.
ceop
Needle Roller Bearings
Coat the needle rollers with grease.
1.
Ensure the needle rollers turn so that the grease is distributed over the entire
circum ference of the internal parts.
2.
As sem ble the parts, adjus t and check as neces sary.
3.
Metal Bushes
Disass emble the parts as necess ary to access the bus h.
1.
Rem ove the old grease.
2.
Apply fresh grease to the metal bush.
3.
Fuel Handling Precautions
General
The following information provides basic precautions which must be observed if
Service Manual - Scrambler 1200 XC 17 of 640
petrol (gas oline) is to be handled safely. It also outlines other areas of risk which
mus t not be ignored. This inform ation is iss ued for basic guidance only and, if in
doubt, appropriate enquiries should be made to your local Fire Officer.
Petrol – Gasoline
When petrol (gasoline) evaporates it produces 150 times its own volum e in vapour
which when diluted with air becom es a readily ignitable mixture. The vapour is
heavier than air and will always fall to the lowes t level. It can readily be distributed
throughout any indoor environment by air currents, consequently, even a small
spillage of petrol (gas oline) is potentially very dangerous.
WARNING
Petrol (gasoline) is highly flam m able and can be explosive under certain
conditions. When opening the fuel tank cap always observe all the following items:
Turn the motorcycle ignition switch OFF.
Do not sm oke.
Always have a fire extinguisher containing FOAM, CO2, HALON or POWDER close
at hand when handling or draining fuel or fuel system s. Fire extinguishers must
als o be present in areas where fuel is stored.
Always disconnect the vehicle battery, negative (black) lead first, before carrying
out, dism antling or draining work on a fuel sys tem .
Whenever petrol (gasoline) is being handled, drained, stored or when fuel
systems are being dis mantled, make sure the area is well ventilated. All potential
forms of ignition must be extinguis hed or removed (this includes any appliance
with a pilot light). Any lead-lamps must be flame-proof and kept clear of any fuel
spillage.
Warning notices mus t be posted at a safe distance from the site of the work to
warn others that petrol (gasoline) is being openly handled. The notice must
ins truct the reader of the precautions which mus t be taken.
Failure to obs erve any of the above warnings may lead to a fire hazard which could
result in pers onal injury.
WARNING
No one should be permitted to repair components associated with petrol
(gas oline) without first having specialis t training on the fire hazards which may be
created by incorrect installation and repair of items associated with petrol
(gas oline).
Repairs carried out by untrained personnel could bring about a safety hazard
leading to a risk of personal injury.
Service Manual - Scrambler 1200 XC 18 of 640
WARNING
Draining or extraction of petrol (gasoline) from a vehicle fuel tank mus t be carried
out in a well ventilated area.
The receptacle used to contain the petrol (gas oline) must be more than adequate
for the full amount of fuel to be extracted or drained. The receptacle should be
clearly marked with its contents, and placed in a safe storage area which meets
the requirements of local authority regulations.
When petrol (gasoline) has been extracted or drained from a fuel tank, the
precautions governing naked lights and ignition sources should be maintained.
Failure to obs erve any of the above warnings could bring about a safety hazard
leading to a risk of personal injury.
Fuel Tank Removal
Fuel tanks should have a 'PETROL (GASOLINE) VAPOUR' warning label attached to
them as soon as they are removed from the vehicle. In all cases, they must be stored
in a secured, marked area.
Chassis Repairs
WARNING
If the motorcycle is involved in an accident or collis ion it mus t be taken to an
authoris ed Triumph dealer for repair or inspection. Any accident can caus e
dam age to the motorcycle, which if not correctly repaired, may caus e a second
accident which may res ult in injury or death.
The frame mus t not be modified as any modification to the frame such as welding
or drilling may weaken the frame resulting in an accident.
Electrical Precautions
The following guidelines are intended to ensure the safety of the operator whils t
preventing dam age to the electrical and electronic components fitted to the
motorcycle. Where necessary, specific precautions are detailed in the relevant
sections of this manual which should be referred to prior to commencing repair
operations.
Equipm ent - Prior to commencing any test procedure on the motorcycle ens ure that
the relevant test equipment is working correctly and any harnes s or connectors are in
good condition, in particular mains leads and plugs.
WARNING
Service Manual - Scrambler 1200 XC 19 of 640
WARNING
The ignition sys tem produces extrem ely high voltages . Do not touch any part of the
ignition sys tem or any cables while the engine is running.
An electric shock caus ed by contact with the ignition system may lead to illness,
injury or death.
WARNING
Wearers of surgically implanted heart pacemaker devices should not be in close
proximity to ignition circuits and/or diagnos tic equipment.
The ignition sys tem and any diagnostic equipm ent may interrupt the normal
operation of such devices causing illnes s or death.
WARNING
The battery contains harmful materials . Always keep children away from the
battery whether or not it is fitted in the motorcycle.
Do not jump start the battery, touch the battery cables together or reverse the
polarity of the cables as any of these actions may cause a spark which would
ignite battery gas es caus ing a risk of personal injury.
High Voltage Circuits - Whenever disconnecting live H.T. circuits always use insulated
pliers . Exercise caution when meas uring the voltage on the coil terminals while the
engine is running. High voltage spikes can occur on these terminals.
Connectors and Harness - The engine of a motorcycle is a particularly hostile
environm ent for electrical com ponents and connectors. Always ensure thes e items
are dry and oil-free before dis connecting and connecting test equipm ent. Never force
connectors apart either by us ing tools or by pulling on the wiring itself. Always ensure
locking mechanis ms are disengaged before rem oval and note the orientation to
enable correct reconnection. Ensure that any protective covers and substances are
replaced if disturbed.
Having confirmed a component to be faulty, switch off the ignition and disconnect the
battery negative (black) lead first. Rem ove the component and support the
dis connected harness. When replacing the com ponent keep oily hands away from
electrical connection areas and push connectors home until any locking mechanism
becomes fully engaged.
Battery Disconnecting
Before disconnecting the battery, switch off all electrical equipment.
Service Manual - Scrambler 1200 XC 20 of 640
WARNING
To prevent the risk of a battery exploding and to prevent damage to electrical
components ALWAYS dis connect the battery negative (black) lead first. When
reconnecting the battery, always connect the pos itive (red) lead first, then the
negative (black) lead. Always disconnect the battery when working on any part of
the electrical system .
Failure to obs erve the above warnings may lead to electrical dam age and a fire
hazard which could cause personal injury.
Always ensure that battery leads are routed correctly and are not close to any
potential chafing points.
Disciplines
Switch off the ignition prior to making any connection or disconnection in the system.
An electrical surge can be caus ed by disconnecting 'live' connections which can
dam age electronic com ponents.
Ensure hands and work surfaces are clean and free of grease, swarf, etc. as grease
collects dirt which can cause tracking or high-resis tance contacts.
Prior to comm encing any test, and periodically during any tes t, touch a good earth to
dis charge body static. This is because some electronic components are vulnerable
to static electricity.
Electrical Wires
All the electrical wires are either single-colour or two-colour and, with only a few
exceptions , must be connected to wires of the sam e colour. On any of the two-colour
wires there is a greater am ount of one colour and a less er amount of a second
colour. A two-colour wire is identified by first the primary colour and then the
secondary colour. For example, a yellow wire with thin red stripes is referred to as a
'yellow/red' wire; it would be a 'red/yellow' wire if the colours were reversed to make
red the main colour.
Electrical Testing
For any electrical system to work, electricity must be able to flow in a complete circuit
from the power source (the battery) via the components and back to the battery. No
circuit means no electrical flow. Once the power has left the positive side of the
battery and run through the component it must then return to the battery on its
negative side (this is called earth or ground). To save on wiring, connections and
space, the negative side of the battery is connected directly to the frame or engine.
Around the frame and engine will be various other ground points to which the wiring
coming from com ponents will be connected. In the cas e of the starter motor it bolts
directly to the engine, which is bolted to the frame. Therefore the frame and engine
Service Manual - Scrambler 1200 XC 21 of 640
als o form part of the earth return path.
Ohm’s Law
The relationship between voltage, current and resistance is defined by Ohm’s Law.
The potential of a battery is measured in volts (V).
The flow of current in a circuit (I) is measured in amperes.
The power rating of a consumer is measured in watts (W).
The resistance (R) of a circuit is meas ured in Ohms.
Ohm’s law, for practical work can be described as -
Power is calculated by multiplying Volts x Amps -
By trans pos ing either of thes e formulae, the value of any unit can be calculated if the
other two values are known.
For example, if a battery of 12 V is connected to a bulb of 60 W:
the current flowing in the circuit can be calculated by using -
the bulb res istance can be calculated by using -
Service Manual - Scrambler 1200 XC 22 of 640
To us e either of the following triangles, put your finger over the value you want to find.
Multiply the remaining values if side by side, or divide if one is over the other.
Basic Electrical Circuits
Basic Circuit Diagram
In the above circuit an electrical reservoir (the battery) is connected via a cable to a
terminal on the controlling device (the switch) whos e contacts are either open or
clos ed. The other terminal on the switch is connected via a cable to the consumer
(the bulb), and the other side of the bulb filament is connected to ground (earth) by
another cable. The ground point is us ually a part of the frame or engine, to which the
battery negative terminal is also connected.
When the switch contacts are open (as shown in the diagram), the circuit is broken
and no current flows. When the switch contacts are closed, the circuit is made and
current flows from the battery positive terminal through the switch contacts and bulb
filam ent to ground. The frame completes the circuit to the battery negative terminal
and the bulb illuminates .
Although som e circuits on the circuit diagram may at firs t seem more com plicated, it
will generally be found that they can be broken down into sections which do not differ
greatly from the basic circuit above.
Circuit Diagrams
Circuit diagram s are created to provide a 'picture' of the electrical system and to
identify the route taken by each individual wire through the system , in order to identify
which com ponents it feeds and which connectors the wire runs through. Circuit
diagrams are an essential tool for fault finding, as it is possible to locate start and
finis h points for a circuit without having to manually trace the wire through the
motorcycle itself. Circuits diagrams may look confus ing at first but when they are
studied closely they soon become logical.
Service Manual - Scrambler 1200 XC 23 of 640
Due to the com plex circuits and the num ber of individual wires, Trium ph uses two
types of circuit diagram in its Service Manuals.
Within the manual, conventional circuit diagrams are used to show the layout of
the main circuits of the motorcycle. Thes e are: Engine managem ent/ignition,
Lighting, Starting and Charging and Auxiliary and Access ory. In thes e diagram s
no attempt is made to show the components of the system in any particular order
or pos ition in relation to the motorcycle.
At the back of the Service Manual a full colour layout circuit diagram is used to
show the main electrical com ponents in a pos ition similar to the actual position
on the motorcycle.
Both of these circuit diagrams us e sim ilar symbols to illus trate the various sys tem
components and will be accompanied by a key indicating circuit diagram
components and wiring colour codes.
Circuit diagram s als o depict the inner workings of a switch hous ing (i.e. which wire
connects to which when a switch is turned from one pos ition to another) so that a test
of that switch can be made us ing the wire term inals in the connector instead of
dis ass embling the switch itself.
Tracing Circuits
The following is a description of two types of common electrical failures , and som e of
the methods which may be used to find them .
Open Circuit
A break in an electrical circuit - current cannot flow. Us ually caused by a break in a
wire or cable or by a loose connection. Open circuits can often be intermittent, making
diagnosis difficult.
Short Circuit
A 'short cut' in an electrical circuit - current bypasses the intended circuit, either to
Service Manual - Scrambler 1200 XC 24 of 640
ground or to another, different circuit. Often caused by failure of the cable ins ulation
due to chafing or trapping of the wire. There are two different types of short circuit -
short to ground and short to battery Voltage.
A short to ground means that the current is going to ground before it reaches the
component it is supposed to feed. These are often caus ed by chafing of the harness
to the fram e or wires trapped between a bolted com ponent, and will often blow the
fuse on that circuit.
A short to battery voltage (12 Volts) is caused by a live power supply wire contacting
an adjacent cable. Note that it is also possible for a 5 Volt sensor reference voltage to
short to an adjacent circuit, which can also cause electrical failures and DTCs
(Diagnostic Trouble Code) to be stored.
When tracing a wire that is suspect, carefully check the circuit diagram before
starting. Remember:
a wire may diverge at a splice and go off to feed other circuits. If these circuits are
working, check for wiring faults from the splice onwards .
the circuit diagram is not an accurate guide to the actual location of the parts
when fitted on the motorcycle. It is a schematic diagram of the circuits.
particularly where engine management items are concerned, the circuit is only
completed by the ECM. If the ECM is not connected, the circuit may register as
open.
To Check Continuity:
CAUTION
Ensure the circuit being tested is switched off before measuring continuity.
Dam age to the Digital Multi Meter (DMM) may res ult from testing a 'live' circuit with
the meter set to resistance (Ω).
In the example below, the ground circuit continuity is being tested from the battery to
the frame.
Ω
0.0
Service Manual - Scrambler 1200 XC 25 of 640
Locate each end of the wire.
Set the Digital Multi Meter (DMM) to res istance check Ohms.
Probe each end of the wire.
If there is continuity, the meter will usually bleep or regis ter the resis tance of the
cable.
A high resistance figure could indicate a dirty or corroded connection.
If there is a break in the wire, the meter will not bleep or regis ter a resis tance.
By probing the wire in various places, the position of a high resistance or break in
the wire (open circuit) can be narrowed down until it is found.
To Measure Voltage:
In the example below, the circuit voltage is being meas ured at the bulb positive (+)
terminal.
V
12.7
Turn the circuit to be tested 'ON'.
Set the Digital Multi Meter (DMM) to Voltage Check (V). Ensure the multi meter is
set to DC Volts for direct current circuits (mos t circuits) or AC Volts for alternating
current circuits (typically alternator output voltage tests).
Set the range of the DMM to the range best suited to the voltage of the circuit
being tested (typically 20 Volts for most DMMs). Refer to the DMM manufacturers
ins tructions.
Connect the black (ground) lead of the DMM to a reliable ground connection
(usually the battery or frame ground).
Locate the pos itive terminal of the wire or component to be tested.
Service Manual - Scrambler 1200 XC 26 of 640
Connect the red (positive) lead of the DMM to the positive terminal.
Read the voltage from meter.
Splices
Splices are probably the most com m on cause of wiring faults after connectors .
Splices are made where two or more wires com e together and diverge in different
directions, usually to feed a different circuit.
To locate a splice, it is necessary to peel back the insulation and examine the splice
for its integrity. The mos t comm on fault is where one of the wires at the joint has
come adrift usually causing the circuit it feeds or grounds to becom e 'dead'.
Switches
To check a switch, set the multimeter to resistance/continuity and probe the two pins
that form a closed circuit when the switch is pus hed. If the switch is working correctly,
the resistance should register or the meter will bleep.
Relays
All relay cases have a circuit path engraved on them showing the circuit path across
the electromagnet and the switch. Before making any checks , first note the pin
des ignations, current paths, and whether or not there is a diode in either circuit path.
Make continuity checks across the electromagnet first, us ually from pin 86 (positive)
to pin 85 (negative). If a diode appears in the circuit use the diode check on the
multimeter (Volts scale) in the direction of current flow. If there is no diode, use the
resistance check facility. An open circuit or unus ually high resistance value indicates
a faulty relay.
To check the switch side, apply a 12 Volt supply between pins 86 and 85. With the
Service Manual - Scrambler 1200 XC 27 of 640
supply connected, the relay should be heard to click and there should be continuity
between pins 30 and 87. An open circuit indicates a faulty relay.
CAN (Controller Are a Networking)
CAN (som etimes called CANbus ) is a protocol for data communication between
Electronic Control Modules (ECMs). Each ECM on the network is connected by a
single pair of twisted wires (or bus) which are used for the transm iss ion of vehicle
sensor data. By us ing CAN, the overall num ber of sys tem sens ors, and the am ount of
cabling required to allow ECMs to communicate with each other is greatly reduced.
This saves cost, weight and space, and makes the sys tem more reliable, as the
physical number of wires and connections is reduced.
4
5
16
R
U
B28
B27
A34
B
KY
1
3
2
CAN works by each ECM sending out 'packets' of information (such as engine speed
or fuel consum ption inform ation) on to the network bus (note that the network must
be free of data before any ECM is allowed to transm it). This data is given a priority
according to its im portance (for example 'engine speed' may have a higher priority
than 'low fuel level'), so that even if two ECMs send data at the sam e time, high
priority information is always sent first. Lower priority data is then res ent after the high
priority data has been received by all ECMs on the network.
The receiving ECM confirms the data has been received correctly and that the data is
valid, and this information is then used by the ECM as necessary. Specific data not
required by an ECM will still be received and acknowledged as correct but then
dis regarded (for example if an ECM does not require 'clutch switch pos ition'
inform ation, this data packet would be ignored).
This allows for a very high speed system of comm unication, which is also very
reliable. Should one ECM fail or trans mit corrupted or otherwis e incorrect messages,
none of the other ECMs on the network will be affected, and after a certain time that
ECM will be prevented from trans mitting further messages until the fault is rectified.
This stops the ECM from clogging the network with incorrect data and preventing
Service Manual - Scrambler 1200 XC 28 of 640
other messages from getting through. The fault would then be reported by a DTC
(Diagnostic Trouble Code).
Triumph currently us es CAN for comm unication between the following ECMs :
Engine ECM
Instruments
ABS ECM
Immobiliser or Chassis ECM
Diagnostic connector
Inertial Measurement Unit (if fitted)
Audio sys tem (if fitted)
Electronic steering lock (if fitted)
LED Headlights (if fitted).
LIN (Local Interconnect Network)
LIN (Local Interconnect Network) is a serial network protocol used for communication
between components in vehicles. The bus is a single master/multiple slave bus that
uses a single wire to transmit data.
By us ing LIN, the am ount of cabling required to allow components to communicate
with each other is greatly reduced. This saves cost, weight and space, and makes
the system more reliable, as the physical num ber of wires and connections is
reduced.
The ins truments us e som e of this data internally and also broadcasts it on the
CANbus (Controller Area Networking) for use on the motorcycle as necess ary.
Information (such as headlight main beam) is being requested continuously by the
Instruments, once a confirm ation of the reques t is recognised the instruments will
react accordingly.
7 4
25
34
17
9 1
10
18
26
1
1
3
4
6
2
Service Manual - Scrambler 1200 XC 29 of 640
Instruments
1.
Switch housing (left hand side)
2.
Example
Press ing the headlight main beam button on the switch housing (left hand
handlebar) confirms to the instruments that headlight main beam is required.
The ins truments confirm the data has been received correctly and that the data is
valid.
Once confirm ed the headlight main beam is switched on.
Triumph currently us es LIN on certain models for communication between the
ins truments and the following components:
Fog light button
Heated seat
Dip beam/Daytime running lights (DRL) switch (if equipped)
Mode button
Turn signal switch
Joystick button
Horn button
High beam button
Service Tools
Serv ice Tools
Special service tools have been developed to facilitate rem oval, dis mantling and
ass embly of certain mechanical com ponents in a practical manner without causing
dam age. Some operations in this Service Manual cannot be carried out without the
aid of the relevant service tools . Where this is the case, the tools required will be
des cribed during the procedure.
Special Service Tools:
Service Manual - Scrambler 1200 XC 30 of 640
Loading...