Triumph 197.1 Service manual

1 of 9Technical Bulletin197Issue1
Technical Bulletin197
09.2019
Contents
Item Subject Model Affected
197.1 Alternator Cover Installation - Addition of
Sealant
Street Triple models from VIN 800262
197.2 Steering Head Bearings - Adjustment Scrambler 1200 XC, Scrambler 1200 XE
197.3 Gear Change Selector Mechanism Kit Street Cup, Street Twin, Bonneville T100 models from
VIN 759204, Street Scrambler, Thruxton 1200, Thrux-
ton 1200R, Bonneville T120 models, Bonnevile Bobber,
Bonneville Speedmaster from VIN 739143 and Bon-
neville Bobber Black
197.4 Fork Seal Cleaner All models

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Item: 197.1
Description: Alternator Cover Installation - Addition of Sealant
Model Affected: Street Triple models from VIN 800262
When installing the alternator cover to the crankcase on the above models, ThreeBond 1216E sealant is used
in addition to the gasket in the area of the alternator harness grommet.
Removal
Removal of the alternator cover is described in the relevant Service Manual.
Installation
1. Apply ThreeBond 1216E sealant to the grommet on the path shown below. The bead of sealant should
extend around the grommet perimeter (including the underside) and be approximately 3.5 mm wide.
Alternator Cover Grommet Sealant Path
2. Position the grommet to the alternator cover.
3. Position a new gasket to the crankcase dowels then refit the alternator cover.
4. Tighten the cover bolts to 10 Nm in the sequence shown below.
5. Re-tighten the fixings one and two to 10 Nm.
11
7
3
9
6
L0236
10
8
5
1
4
12
2
Alternator Cover Fixings Tightening Sequence
6. Route the alternator harness to the regulator/rectifier as noted for removal.
7. Connect the grey connector to the regulator/rectifier.
8. Route the crankshaft position sensor harness to the main harness as noted for removal.

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9. Connect the crankshaft position sensor the main harness.
L0332
1
1. Crankshaft position sensor connector
10. Connect the ground cables to the frame and tighten the fixing to 10 Nm. Refit the rubber boot over the
battery ground cable.
11. Attach the two harness brackets to the engine breather cover and tighten the fixings to 10 Nm.
L0328_1
1
21
3
4
5
1. Harness brackets
2. Fixings
3. Rubber boot
4. Ground cable fixing
5. Purge valve bracket
12. If removed, secure the purge control vale to its bracket with a cable tie.
Perform the following operations as described in the service manual:
• Coolant Expansion Tank - Installation
• Front Sprocket Cover - Installation
• Throttle Bodies/Injectors - Installation
• Airbox - Installation
• Fuel Tank - Installation
• Battery - Installation
• Seat - Installation
When ordering replacement parts, refer to the EPC.
Please mark your copy of the Service Manual with this information. For electronic service manuals, store
this information in a readily accessible place and refer to it when working on the relevant Triumph
motorcycle. This information will be included in the next service manual update.

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Item: 197.2
Description: Steering Head Bearings - Adjustment
Model Affected: Scrambler 1200 XC, Scrambler 1200 XE
The procedure for the adjustment of the steering head bearings on the above models has changed. A new
service tool (T3880750) must be used to complete this operation.
When you adjust the steering head bearings, follow the procedure described below.
Warning
Make sure the motorcycle is stabilised and adequately supported.
A correctly supported motorcycle will help prevent it from falling.
An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
1. Remove the seat as described in the Service Manual.
2. Disconnect the battery as described in the Service Manual.
Warning
If the lower yoke fixings are also loosened, the forks will no longer support the weight of the motorcycle.
Do not loosen the lower yoke fixings as, in this condition, the motorcycle could topple over causing damage
and/or risk of injury.
3. Remove the upper yoke as described in the Service Manual.
4. Adjust the bearing free play as follows:
• Use service tool T3880023 to remove the lock nut.
• Remove the tab washer.
• Use service tool T3880023 to remove the adjuster nut.
• Thoroughly clean the threads on the steering stem.
• Refit the adjuster nut and tighten to 40 Nm.
• Loosen the adjuster nut, then tighten to 15 Nm.
• Fit the tab washer.
• Fit the lock nut.
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 motorcycle
control and an accident.

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• With the bearing free play correctly set, use service tool T3880750 to hold the adjuster nut
stationary, then use service tool T3880023 to tighten the lock nut to 40 Nm.
c
j
b
u
1
2
3
4
5
1. T3880023 - 50 mm Socket
2. Lock nut
3. Tab washer
4. Adjuster nut
5. Dust seal
Warning
Make sure you torque the adjustment nut in an anticlockwise direction in the step that follows.
If you do not, the headstock bearings can become loose.
Note:
• Keep the torque wrench at 90 degrees to the centre line of the tool when you tighten the adjustment
nut in the stage that follows. This will apply the correct torque to the adjustment nut.
• Use service tool T3880750 to tighten the adjustment nut in an anticlockwise direction to 45 Nm.
Keep the torque wrench at 90 degrees to the centre line of the tool.

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Note:
• The adjustment nut can turn up to 90 degrees when you tighten it anticlockwise. This is usual.
1
2
90°
1. T3880750 - Headstock service tool
2. Torque wrench
Warning
Operation of the motorcycle with incorrectly adjusted steering head bearings, either too loose or too tight,
may cause a dangerous riding condition leading to loss of motorcycle control and an accident.
5. Check that the free play has been eliminated and that the steering can be turned freely from lock-to-
lock without any sign of tightness. Readjust if necessary.
6. Install the upper yoke as described in the Service Manual.
7. Connect the battery as described in the Service Manual.
8. Install the seat as described in the Service Manual.
Please mark your copy of the Service Manual with this information. For electronic service manuals, store
this information in a readily accessible place and refer to it often. This information will be included in the
next service manual update.

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Item: 197.3
Description: Gear Change Selector Mechanism Kit
Model Affected: Street Cup, Street Twin, Bonneville T100 models from VIN 759204, Street Scrambler,
Thruxton 1200, Thruxton 1200R, Bonneville T120 models, Bonnevile Bobber,
Bonneville Speedmaster from VIN 739143 and Bonneville Bobber Black
A gear change selector mechanism kit has been introduced for the above models and is retrofittable to the
start of production.
Parts will no longer support the old condition gear change selector mechanism or the individual
components included in the kit, and any replacement will be to the new condition.
Parts kit T1191968 has been released for use when replacing the gear change selector mechanism kit. The
kit consists of a fully assembled selector mechanism.
Note:
• The washer at the splined end of the selector shaft is retained by an O-ring for transportation
purposes. The O-ring must be removed and discarded before installing the selector shaft.
1
1. O-ring
When ordering replacement parts, refer to the EPC.
Please mark your copy of the Service Manual with this information. For electronic service manuals, store
this information in a readily accessible place and refer to it when working on the relevant Triumph
motorcycle. This information will be included in the next service manual update.

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Item: 197.4
Description: Fork Seal Cleaner
Model Affected: All models
The following service tools have been introduced to clean the front fork oil seal:
• T3880215 - Fork Seal Cleaner, Small
• T3880216 - Fork Seal Cleaner, Large
Service tool T3880215 is to be used on front suspension forks with a diameter between 35 to 45mm.
Service tool T3880216 is to be used on front suspension forks with a diameter between 45 to 55mm.
To clean the oil seal and dust seal, follow the procedure described below.
Warning
Make sure the motorcycle is stabilised and adequately supported.
A correctly supported motorcycle will help prevent it from falling.
An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
1. Clean the area around the dust seal then carefully detach the dust seal from the fork outer tube.
2. Wipe away any visible dirt or water from the oil seal.
Note:
• The fork seal cleaner has two cleaning hooks. The one with the OIL SEAL text is for the oil seal, the
other cleaning hook is for the dust seal.
• When cleaning the oil seal with the fork seal cleaner it is possible that a small amount of fork oil may
seep out.
3. Clean the fork seal cleaner before use.
4. Fit the fork seal cleaner to the fork inner tube. Make sure that the cleaning hook, with the text OIL
SEAL below it, is pointing towards the oil seal.
ckpd
3
1
2
1. Cleaning hook
2. OIL SEAL text
3. Oil seal location

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5. Slide the cleaning hook carefully under the seal lip. Rotate the fork seal cleaner 360° in the direction
shown then remove the cleaning hook from the oil seal.
ckpd_1
Direction of Rotation
6. Slide the fork seal cleaner down to use the other cleaning hook to clean the dust seal. Rotate the fork
seal cleaner 360° in the direction shown then remove the cleaning hook from the dust seal.
ckpd_1
2
1
Direction of Rotation
1. Dust seal
2. Cleaning hook
7. Refit the dust seal into the outer tube.
Circulation
Initial and date when read and return to central file holder
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