Braking System Maintenance Safety Precautions Warning: Brake fluid is hygroscopic which means it will absorb moisture from the air. The absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction in braking efficiency. Replace brake fluid in line with the...
Front Brake Fluid Level Inspection Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. In accordance with the scheduled maintenance chart,...
Rear Brake Fluid Level Inspection Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. In accordance with the scheduled maintenance chart,...
Changing Brake Fluid and Brake Pads Changing Brake Fluid Brake fluid should be changed at the interval specified in the scheduled maintenance chart. Brake Pads Front and rear pad wear is automatically compensated for and has no effect on brake lever or pedal action.
Brake Wear Inspection In accordance with the scheduled maintenance chart, inspect the brake pads for wear. The minimum thickness of lining material for any front or rear brake pad is 1.5 mm. If any pad has worn to the bottom of the groove in the pad centre, replace all...
Bleeding the Front Brakes, Renewing Brake Fluid Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Note the original setting of the brake lever...
Front Brake Pads — removal and installation Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Unscrew the pad retaining pin plug from...
Front Brake Caliper — removal, installation and disassembly Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Caution: To prevent paint damage, do not...
Front Discs — removal and installation Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Wear 1. Replace any brake disc if worn beyond the...
Bleeding the Rear Brakes, Renewing Brake Fluid Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Remove the cap from the rear bleed nipple. 2....
Rear Brake Pads — installation Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Push the brake caliper inwards towards the wheel...
Rear Brake Caliper — removal, installation, disassembly, inspection and assembly Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Caution: To prevent paint damage, do not...
Rear Brake Disc Wear Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Replace any brake disc worn beyond the...
Rear Master Cylinder — removal, installation, disassembly, inspection and assembly Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Remove the rider's seat (see page 16-13 )....
Bleeding the Front Brakes — Motorcycles with ABS Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Complete the brake bleed procedure as for models...
Front ABS Wheel Sensor — removal and installation Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Disconnect the battery negative (black)...
Front ABS Pulser Ring — removal, installation and inspection Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Remove the front wheel (see page 15-10 )....
Bleeding the Rear Brake Fluid — Motorcycles with ABS Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to. the operator or damage to the motorcycle. 1. Complete the brake bleed procedure as for models...
Rear ABS Wheel Speed Sensor — removal and installation Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Remove the rider's seat (see page 16-13 )....
Rear ABS Pulser Ring — removal, installation and inspection Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Remove the rear wheel (see page 15-12 )....
Air Gap Measurement — Front and Rear Wheel Speed Sensors 1. Using feeler gauges, measure the air gap between the wheel speed sensor and the pulser ring. 1. ABS sensor; 2. Shim; 3. Pulser ring; 4. Fixing 2. Rotate the wheel and repeat the measurement in several places to ensure the pulser ring is not...
ABS Hydraulic Modulator/ECM — removal and installation Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Remove the rider's seat (see page 16-13 )....
ABS System Description and Component Location System Description The ABS versions of the Tiger 800 and Tiger 800XC are fitted with an electronic anti-lock brake system (ABS) which is designed to prevent the wheels from locking or skidding by reducing braking effort to the front or rear brake...
ABS System Diagnostics The ABS system has an on-board diagnostics feature which allows service technicians to retrieve stored data from the ECM using Triumph diagnostic software. Full details of the Triumph diagnostic software operation are given in the Triumph Diagnostic...
Triumph Diagnostic Tool Described on the following pages is the range of information which can be retrieved from the ECM's memory and the adjustments which can be performed using the Triumph diagnostic software. The tables indicate which tests are performed by the onboard...
Diagnostic Trouble Codes Diagnostic trouble codes (DTC) are logged in the ABS ECM memory when there is a confirmed fault in the system. The codes are reported to the Triumph diagnostic tool as a four digit code. DTCs can be removed at any time using the Triumph diagnostic...
Electrical Connectors Before beginning any diagnosis, the following connector related information should be noted: Note: A major cause of hidden electrical faults can be traced to faulty electrical connectors. For example: Dirty/corroded terminals. Damp terminals. Broken...
Further Diagnosis The tables that follow will, if used correctly, help to pinpoint a fault in the system once a diagnostic trouble code has been stored. Pinpoint Tests Before starting pinpoint tests 1. Delete the stored DTCs. 2. Switch the ignition OFF and ON....
ABS Warning Light ON (No DTCs Stored) Fault Code Possible cause Action ABS Warning Light ON (No DTCs Stored) ABS Ignition supply fuse/circuit fault ABS Warning light circuit fault Ensure ABS ECM connector is secure. Disconnect ABS ECM connector and proceed to pinpoint test 1: Pinpoint...
ABS Warning Light Does Not Illuminate (No DTCs Stored) Fault Code Possible cause Action ABS Warning Light OFF (No DTCs Stored) Warning light circuit fault ABS ECM ground circuit fault Ensure ABS ECM connector is secure. Ensure ABS ECM ground connection is secure. Disconnect ABS ECM connector and proceed...
Front Wheel Sensor Open Circuit/Short Circuit Fault Code Possible cause Action C1611 Front wheel speed sensor circuit fault Ensure ABS ECM connector is secure. Ensure wheel speed sensor connector is secure. Disconnect ABS ECM connector and proceed to pinpoint test 1: Pinpoint Tests Test Result...
Rear Wheel Sensor Open Circuit/Short Circuit Fault Code Possible cause Action C1613 Rear wheel speed sensor circuit fault Ensure ABS ECM connector is secure. Ensure wheel speed sensor connector is secure. Disconnect ABS ECM connector and proceed to pinpoint test 1: Pinpoint Tests Test Result...
Front Wheel Sensor Abnormal Input/losing Contact Fault Code Possible cause Action C1612 Front wheel speed sensor poor signal Incorrect Wheel speed sensor air gap Damaged or dirty pulser ring Loose or incorrectly installed wheel speed sensor Ensure ABS ECM connector is secure. Ensure wheel speed...
Rear Wheel Sensor Abnormal Input/Losing Contact Fault Code Possible cause Action C1614 Rear wheel speed sensor poor signal Incorrect Wheel speed sensor air gap Damaged or dirty pulser ring Loose or incorrectly installed wheel speed sensor Ensure ABS ECM connector is secure. Proceed to pinpoint...
Front Wheel Pulser Gear Missing Teeth Fault Code Possible cause Action C1621 Incorrect Wheel speed sensor air gap Damaged or dirty pulser ring Loose or incorrectly installed wheel speed sensor Damaged/incorrect wheels Ensure ABS ECM connector is secure. Proceed to pinpoint test 1:...
Rear Wheel Pulser Gear Missing Teeth Fault Code Possible cause Action C1623 Incorrect Wheel speed sensor air gap Damaged or dirty pulser ring Loose or incorrectly installed wheel speed sensor Damaged/incorrect wheels Ensure ABS ECM connector is secure. Proceed to pinpoint test 1:...
Front or Rear Input/Output Solenoid Open/Short Circuit Fault Code Possible cause Action Front: C1631; C1632 Rear: C1633; C1634 C1654 ABS solenoid circuit fault Ensure ABS ECM connector is secure. Disconnect ABS ECM connector and proceed to pinpoint test 1: Pinpoint Tests Test Result Action 1. Check...
Front or Rear Wheel Actuator (Hydraulic Control) Wheel Lock Fault Code Possible cause Action C1641; C1643 Binding brake Incorrect Wheel speed sensor air gap Loose or incorrectly installed wheel speed sensor Ensure ABS ECM connector is secure. Proceed to pinpoint test 1: Pinpoint Tests Test Result Action 1....
Motor — Lock; Motor Stuck OFF; Motor Stuck ON Fault Code Possible cause Action C1651; C1652; C1653 Motor circuit fault Motor runs continually Motor does not run at all Ensure ABS ECM connector is secure. Turn the ignition 'ON'. Proceed to pinpoint test 1: Pinpoint Tests Test Result Action 1....
Power Source Voltage Drop/Voltage Rise Fault Code Possible cause Action C1661; C1662 Power supply circuit fault Battery charging circuit fault Ensure ABS ECM connector is secure. Disconnect ABS ECM connector and proceed to pinpoint test 1: Pinpoint Tests Test Result Action 1. Check cable...
Different Tyre Diameter Fault Code Possible cause Action C1671 Incorrect diameter wheels installed Incorrect tyre pressures Incorrect wheel speed sensor air gap Damaged or dirty pulser ring Ensure ABS ECM connector is secure. Proceed to pinpoint test 1: Pinpoint Tests Test...
Abnormal ECU Fault Code Possible cause Action C1681 Incorrect Wheel speed sensor air gap Damaged or dirty pulser ring Loose or incorrectly installed wheel speed sensor Ensure ABS ECM connector is secure. Proceed to pinpoint test 1: Pinpoint Tests Test Result...
ABS Hydraulic Circuit Layout ABS Hydraulic Circuit Layout A. Front Brake Circuit from Master Cylinder to ABS Modulator B. Front Brake Circuit from ABS Modulator to Front Calipers C. Rear Brake Circuit from Master Cylinder to Modulator D. Rear Brake Circuit from ABS Modulator to...