Thruxton R

Motorcycle Service Manual

This document is protected by copyright and may not, in whole or part be stored in a retrieval system, or
transmitted in any form or by any means, copied, photocopied, translated or reduced to any machine-
readable form without prior consent in writing from Triumph Motorcycles Limited.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior
notice and without incurring an obligation to make such changes to products manufactured previously. See
your authorised Triumph dealer for the latest information on product improvements incorporated after this
publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations in this publication are intended for reference use only and may not depict actual
model component parts.
© Triumph Motorcycles Ltd. 02.2016 issue 1

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Street Twin

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2 Thruxton R
 Table Of Contents

TABLE OF CONTENTS

Introduction 1
General Information 2
Service Tools 3
Specifications 4
Torque Wrench Settings 5
Routings 6
Routine Maintenance 7
Engine Covers 8
Cylinder Head 9
Barrels and Pistons 10
Clutch 11
Crankshaft 12
Balancer 13
Transmission 14
Starter Drive and Sprag Clutch 15
Lubrication 16
Engine Removal and Installation 17
Fuel System and Engine Management 18
Cooling 19
Front Suspension 20
Rear Suspension 21
Brakes 22
Wheels and Tyres 23
Final Drive 24
Frame and Bodywork 25
Electrical 26

Thruxton R 3
Introduction

INTRODUCTION How to use this manual

To assist in the use of this manual, the section title
is given at the top.
Introduction Each major section starts with a contents page,
listing the information contained in the section.
This manual is designed primarily for use by trained
The individual steps comprising repair operations
technicians in a properly equipped workshop.
are to be followed in the sequence in which they
However, it contains enough detail and basic
appear.
information to make it useful to the owner who
desires to perform his own basic maintenance and Adjustment and repair operations include reference
repair work. The work can only be carried out if the to service tool numbers and the associated
owner has the necessary hand and special service illustration depicts the tool.
tools to complete the job. Where usage is not obvious, the tool is shown in
A basic knowledge of mechanics, including the use.
proper use of tools and workshop procedures is Adjustment and repair operations also include
necessary in order to carry out maintenance and reference to wear limits, relevant data, torque
repair work satisfactorily. Whenever the owner has figures, specialist information and useful assembly
insufficient experience or doubts regarding his details.
ability to do the work, an authorised Triumph dealer
must undertake all adjustments, maintenance, and Warnings, Cautions and Notes
repair work.
Particularly important information is presented in
In order to perform the work efficiently and to the following form:
avoid costly mistakes, read the text and thoroughly
familiarise yourself with procedures before starting
work. Warning
All work should be performed with great care and This warning symbol identifies special instructions
in a clean working area with adequate lighting. or procedures which, if not correctly followed,
Always use the correct special service tools or could result in personal injury, or loss of life.
equipment specified. Under no circumstances use
makeshift tools or equipment since the use of
substitutes may adversely affect safe operation. Caution
Where accurate measurements are required, they
can only be made using calibrated, precision This caution symbol identifies special instructions
instruments. or procedures which, if not strictly observed, could
For the duration of the warranty period, an result in damage to or destruction of equipment.
authorised Triumph dealer must perform all repairs
and scheduled maintenance. Note:
To maximise the life of your motorcycle: • This note symbol indicates points of particular
• Accurately follow the maintenance interest for more efficient and convenient
requirements of the periodic maintenance chart operation.
in the Service Manual.
• Do not allow problems to develop. Investigate Noise Control System
unusual noises and changes in the riding
characteristics of the motorcycle. Rectify all Tampering with the noise control system is
problems as soon as possible (immediately if prohibited.
safety related). Owners are warned that the law may prohibit:
• Use only genuine Triumph parts as listed in the 1. The removal or rendering inoperative by any person
electronic parts catalogue (EPC). other than for purposes of maintenance, repair or
replacement, of any device or element of design
• Follow the procedures in this manual carefully
incorporated into any new vehicle for the purpose of
and completely. Do not take short cuts.
noise control prior to its sale or delivery to the
• Keep complete records of all maintenance and
ultimate purchaser or while it is in use and,
repairs with dates and any new parts installed.
2. the use of the vehicle after such device or element of
• Use only approved lubricants, as specified in
design has been removed or rendered inoperative by
the Owner's Handbook, in the maintenance of
any person.
the motorcycle.

4 Thruxton R
 Introduction

References Tightening procedure

References to the left hand or right hand side Generally, when installing a part with several bolts,
given in this manual are made when viewing the nuts or screws, they should all be started in their
motorcycle from the rear. holes and tightened to a snug fit, evenly and in a
Operations covered in this manual do not always cross pattern. This is to avoid distortion of the part
include reference to testing the motorcycle after and/or gas or oil leakage. Conversely, bolts, nuts, or
repair. It is essential that work is inspected and screws, should all be loosened (in sequence if
tested after completion and, if necessary, a road specified) by about a quarter of a turn and then
test of the motorcycle is carried out particularly removed.
where safety related items are concerned. Where there is a tightening sequence specified in
this Service Manual, the bolts, nuts, or screws must
Dimensions be tightened in the order and by the method
indicated.
The dimensions quoted are to design engineering
specification with service limits where applicable. Torque wrench setting figures given in this manual
must be observed. The torque tools used must be
During the period of running-in from new, certain
of accurate calibration.
adjustments may vary from the specification
figures given in this manual. These will be reset by Locking devices, where specified, must be fitted. If
the dealer at the 500 mile/800 km service, and the efficiency of a locking device is impaired during
thereafter should be maintained at the figures removal it must be renewed. This applies
specified in this manual. particularly to micro-encapsulated fixings which
must always be replaced if disturbed. Where
necessary, the text in this manual will indicate
Repairs and Replacements where such a fixing is used.
Before removal and disassembly, thoroughly clean
the motorcycle. Any dirt entering the engine or
other parts will work as an abrasive and shorten
the life of the motorcycle. Particular attention
should be paid when installing a new part, that any
dust or metal filings are cleared from the
immediate area.

Force
Common sense should dictate how much force is
necessary in assembly and disassembly. If a part
seems especially difficult to remove or install, stop
and examine what may be causing the problem.
Never lever a component as this will cause damage
both to the component itself and to the surface
being levered against.
Whenever tapping to aid removal of an item is
necessary, tap lightly using a hide or plastic faced
mallet.

Edges
Watch for sharp edges, especially during engine
disassembly and assembly. Protect the hands with
industrial quality gloves.
When replacement parts are required, it is essential
that only genuine Triumph parts are used.
Safety features and corrosion prevention
treatments embodied in the motorcycle may be
impaired if parts other than genuine Triumph parts
are fitted. In certain territories, legislation prohibits
the fitting of parts not to the manufacturer's
specification.

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Introduction

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6 Thruxton R
 2 General Information
Table of Contents
Ignition System Safety Precautions........................................................................................................................................................ 9
Dangerous Substances ................................................................................................................................................................................. 9
Third Party Products ..................................................................................................................................................................................... 9
Fluoroelastomers.............................................................................................................................................................................................. 9
Oils ........................................................................................................................................................................................................................... 9
Health Protection Precautions................................................................................................................................................................. 10
Environmental Protection Precautions ................................................................................................................................................ 10
Brakes................................................................................................................................................................................................................... 10
Safety Instructions.......................................................................................................................................................................................... 11
Chassis Bearing Lubrication ...................................................................................................................................................................... 14
Fuel Handling Precautions ......................................................................................................................................................................... 15
Electrical Precautions ................................................................................................................................................................................... 16
Glossary of Circuit Diagram Symbols..................................................................................................................................................... 17
Electrical Testing ............................................................................................................................................................................................. 19
Circuit Diagrams.............................................................................................................................................................................................. 20
Tracing Circuits................................................................................................................................................................................................ 20
CAN (Controller Area Networking) .......................................................................................................................................................... 22

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General Information

8 Thruxton R
 General Information

Ignition System Safety Precautions Fluoroelastomers

Warning Warning
The ignition system produces extremely high Fluoroelastomer material is used in the
voltages. Do not touch any part of the ignition manufacture of various seals in Triumph
system or any cables while the engine is running. motorcycles.
An electric shock caused by contact with the In fire conditions involving temperatures greater
ignition system may lead to illness, injury or death. than 315°C this material will decompose and can
then be potentially hazardous. Highly toxic and
corrosive decomposition products, including
Warning hydrogen fluoride, carbonyl fluoride, fluorinated
olefins and carbon monoxide can be generated
Wearers of surgically implanted heart pacemaker and will be present in fumes from fires.
devices should not be in close proximity to ignition
In the presence of any water or humidity,
circuits and or diagnostic equipment.
hydrogen fluoride may dissolve to form extremely
The ignition system and any diagnostic equipment corrosive liquid hydrofluoric acid.
may interrupt the normal operation of such
If such conditions exist, do not touch the material
devices causing illness or death.
and avoid all skin contact. Skin contact with liquid
or decomposition residues can cause painful and
Dangerous Substances penetrating burns leading to permanent,
irreversible skin and tissue damage.
Warning
Oils
Many liquids and other substances used in motor
vehicles are poisonous and should under no
circumstances be consumed and should, as far as Warning
possible, be kept from contact with the skin. These
The engine oil may be hot to the touch. Contact
substances among others include acid, antifreeze,
with hot oil may cause the skin to be scalded or
asbestos, brake fluid, fuel, lubricants, and various
burned.
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.
Warning
NEVER DISREGARD THESE INSTRUCTIONS! Prolonged or repeated contact with engine oil can
lead to skin dryness, irritation and dermatitis. In
addition, used engine oil contains potentially
Third Party Products harmful contaminants which can cause cancer.
Wear suitable clothing and avoid skin contact.
Warning
Many proprietary products, such as chemicals,
solvents and cleaning agents, will cause damage
to components if used incorrectly or
inappropriately. Always follow the manufacturer’s
instructions printed on the product container’s
labels and obey the instructions given. These
instructions are included for your safety and well-
being.
Damage to the motorcycle components caused by
the incorrect or inappropriate use of chemicals,
solvents and cleaning agents may reduce the
components efficiency, resulting in loss of
motorcycle control and an accident.

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General Information

Health Protection Precautions Burning of used engine oil in small space heaters or
boilers can be recommended only for units of
• Avoid prolonged and repeated contact with oils,
approved design. If in doubt, check with the
particularly used engine oils.
appropriate local authority and/or manufacturer of
• Wear protective clothing, including impervious the approved appliance.
gloves where practicable.
Dispose of used oil and used filters through
• Do not put oily rags in pockets. authorised waste disposal contractors, to licensed
• Overalls must be cleaned regularly. Discard waste disposal sites, or to the waste oil reclamation
heavily soiled clothing and oil impregnated trade. If in doubt, contact your local authority for
footwear. advice on disposal facilities.
• First aid treatment should be obtained
immediately for open cuts and wounds. Always Brakes
be aware of who your nearest First Aider is and
where the medical facilities are kept.
• Use barrier creams, applying before each work Warning
period to protect the skin from the effects of oil Brake fluid is hygroscopic which means it will
and grease and to aid removal of the same absorb moisture from the air. Any absorbed
after completing work. moisture will greatly reduce the boiling point of
• Wash with soap and water to ensure all oil is the brake fluid causing a reduction in braking
removed (skin cleansers and nail brushes will efficiency.
help). Preparations containing lanolin replace
Replace brake fluid in line with the routine
the natural skin oils which have been removed.
maintenance schedule. A dangerous riding
• Do not use petrol, kerosene, diesel fuel, gas oil, condition could result if this important
thinners or solvents for cleaning skin. maintenance item is neglected!
• If skin disorders develop, obtain medical advice
Do not spill brake fluid onto any area of the
without delay.
bodywork as this will damage any painted or
• Where practicable, degrease components prior plastic surface.
to handling.
Always use new brake fluid from a sealed
container and never use fluid from an unsealed
Warning container or from one that has been previously
opened.
Any risk of eye injury must be avoided. Always
wear eye protection when using a hammer, air Do not mix different brands of fluid. Check for fluid
line, cleaning agent or where there is ANY risk of leakage around brake fittings, seals and joints.
flying debris or chemical splashing. Check regularly for brake hose damage.
FAILURE TO OBSERVE ANY OF THE ABOVE
Environmental Protection WARNINGS MAY REDUCE BRAKING EFFICIENCY
Precautions LEADING TO AN ACCIDENT.

Caution
Do not pour oil on the ground, down sewers or
drains, or into water courses. To prevent pollution
of water courses etc., dispose of used oil sensibly.
If in doubt contact your local authority.

10 Thruxton R
 General Information

Warning Warning
If there has been an appreciable drop in the level Before installation, all internal brake components
of the fluid in either brake fluid reservoir, consult should be cleaned and lubricated with clean new
your authorised Triumph dealer for advice before DOT 4 brake fluid.
riding. Never use solvents, petrol (gasoline), engine oil or
If the brake lever or pedal feels soft when it is any other petroleum distillate on internal brake
applied, or if the lever/pedal travel becomes components as this will cause deterioration of the
excessive, there may be air in the brake lines or hydraulic seals in the calipers and master
the brake may be defective. cylinders.
It is dangerous to operate the motorcycle under A dangerous riding condition leading to loss of
such conditions and remedial action must be motorcycle control and an accident could result if
taken by your authorised Triumph dealer before this warning is ignored.
riding the motorcycle.
Failure to take remedial action may reduce braking Safety Instructions
efficiency leading to an accident.
Jacking and Lifting
Warning Warning
Use only DOT 4 specification brake fluid as listed in
the General Information section of this manual. Always ensure that any lifting apparatus has
The use of brake fluids other than those DOT 4 adequate load and safety capacity for the weight
fluids listed in the General Information section to be lifted. Ensure the motorcycle is well
may reduce the efficiency of the braking system supported to prevent any possibility of the
leading to an accident. machine falling prior to lifting or jacking or while
repairs and servicing are carried out.
Failure to change the brake fluid at the interval
specified in the routine maintenance schedule may Never rely on a single means of support when
reduce braking efficiency resulting in an accident. working with the motorcycle. Use additional safety
supports and straps to prevent toppling.
Do not leave tools, lifting equipment, spilt oil, etc.
Warning in a place where they could become a hazard to
health. Always work in a clean, tidy area and put
Never use mineral-based grease in any part of the all tools away when the work is finished.
braking system or in any area where contact with
the braking system is possible. Mineral-based Precautions Against Damage
grease will damage the hydraulic seals in the
Avoid spilling brake fluid or battery acid on any part
calipers and master cylinders.
of the bodywork. Wash spillages off with water
Damage caused by contact with mineral-based immediately.
grease may reduce braking efficiency resulting in Disconnect the battery earth lead before starting
an accident. work, see ELECTRICAL PRECAUTIONS.
Always use the recommended 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 human body. Never
swallow antifreeze, corrosion inhibitors or any of
the motorcycle coolant.

Thruxton R 11
General Information

has lost its lubrication film. Old grease and dirty oil
Warning should be cleaned off. This is because used
lubricants will have lost some lubrication qualities
Do not remove the radiator cap when the engine and may contain abrasive foreign particles.
is hot. When the engine is hot, the coolant inside
Use recommended lubricants. Some oils and
the radiator is hot and also under pressure.
greases in particular should be used only in certain
Contact with the pressurised coolant will cause
applications and may be harmful if used in an
scalds and skin damage.
application for which they are not intended. This
manual makes reference to molybdenum disulphide
grease in the assembly of certain engine and
Caution chassis parts. Always check manufacturer
The coolant antifreeze contains a corrosion recommendations before using such special
inhibitor which helps prevent damage to the metal lubricants.
surfaces inside the cooling system. Without this
inhibitor, the coolant would 'attack' the metals and Joints and Joint Faces
the resulting corrosion would cause blockages in Assemble joints dry unless otherwise specified in
the cooling system leading to engine overheating this manual.
and damage. Always use the correct antifreeze as If gaskets and/or jointing compound is
specified in the Owner's Handbook. Never use a recommended for use; remove all traces of old
methanol based antifreeze as this does not jointing material prior to reassembly. Do not use a
contain the required corrosion inhibition tool which will damage the joint faces and smooth
properties. 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.
Caution
Gaskets, O-rings
Distilled water must be used with the antifreeze
Do not reuse a gasket or O-ring once it has been in
(see specification for antifreeze) in the cooling
service. The mating surfaces around the gasket
system.
should be free of foreign matter and perfectly
If hard water is used in the system, it causes scale smooth to avoid oil or compression leaks.
accumulation in the water passages, and
considerably reduces the efficiency of the cooling Liquid Gasket, Non-permanent Locking Agent
system. Reduced cooling system efficiency may Follow manufacturer's directions for cleaning and
lead to the engine overheating and engine preparing surfaces where these compounds will be
damage. used. Apply sparingly as excessive amounts of
sealer may block engine oil passages and cause
Cleaning Components serious damage.
A high flashpoint solvent is recommended to Prior to reassembly, blow through any pipes,
reduce fire hazard. channels or crevices with compressed air.
Always follow container directions regarding the
use of any solvent. Warning
Always use the recommended cleaning agent or
equivalent. To prevent injury, always use eye, face and ear
Do not use degreasing equipment for components protection when using compressed air. Always
containing items which could be damaged by the wear protective gloves if the compressed air is to
use of this process. Whenever possible, clean be directed in proximity to the skin.
components and the area surrounding them before
removal. Always observe scrupulous cleanliness Screw Threads
when cleaning dismantled components. Metric threads to ISO standard are used.
Damaged nuts, bolts and screws must always be
Lubrication discarded.
The majority of engine wear occurs while the Castellated nuts must not be loosened back to
engine is warming up and before all the rubbing accept a split pin, except in those recommended
surfaces have an adequate lubrication film. During cases when this forms part of an adjustment.
assembly, oil or grease (whichever is more suitable)
should be applied to any rubbing surface, which

12 Thruxton R
 General Information

Do not allow oil or grease to enter blind threaded Encapsulated Bolts

holes. The hydraulic action on screwing in the bolt An encapsulated bolt can be identified by a
or stud could split the housing. coloured section of thread which is treated with a
Always tighten a nut or bolt to the recommended locking agent.
torque figure. Damaged or corroded threads can Unless a specified repair procedure states
affect the torque reading. otherwise, encapsulated bolts cannot be reused
Unless specified, threaded fixings must always be and MUST be replaced if disturbed or removed.
fitted dry (no lubrication).
Warning
Warning
Failure to replace an encapsulated bolt could lead
Never lubricate a thread unless instructed to do to a dangerous riding condition. Always replace
so. encapsulated bolts.
When a thread of a fixing is lubricated, the thread
friction is reduced. When the fixing is tightened, Oil and Grease Seals
reduced friction will cause over tightening and Replace any oil or grease seals that are removed.
possible fixing failure. Removal will cause damage to an oil seal which, if
A fixing which fails in service could cause reused, would cause an oil leak.
component detachment leading to loss of control Ensure the surface on which the new seal is to run
and an accident. is free of burrs or scratches. Renew the component
if the original sealing surface cannot be completely
Locking Devices restored.
Always release locking tabs and fit new locking Protect the seal from any surface which could
washers. Do not reuse locking tabs. cause damage over which it has to pass when
being fitted. Use a protective sleeve or tape to
Fitting a Split Pin cover the relevant surface and avoid touching the
sealing lip.
Always fit new split pins of the correct size for the
hole in the bolt or stud. Do not loosen back castle Lubricate the sealing lips with a recommended
nuts when fitting a split pin, except in those lubricant. This will help to prevent damage in initial
recommended cases when this forms part of an use. On dual lipped seals, smear the area between
adjustment. the lips with appropriate grease.
Always fit new roll pins of an interference fit in the When pressing in a seal which has manufacturer's
hole. marks, press in with the marks facing out.
Seals must be pressed into place using a suitable
Circlips, Retaining Rings driver. Use of improper tools will damage the seal.
Replace any circlips and retaining rings that are
removed. Removal weakens and deforms circlips Press
causing looseness in the circlip groove. When A part installed using a press or driver, such as a
installing circlips and retaining rings, take care to wheel bearing, should first be coated with oil or
compress or expand them only enough to install grease on its outer or inner circumference so that
them. it will locate smoothly.
Always use the correct replacement circlip as
recommended in the Triumph parts catalogue. Ball Bearing
When installing a ball bearing, the bearing race
Self-Locking Nuts which is an interference fit should be pushed by a
Self-locking nuts can be reused, provided suitable driver. This prevents severe stress or
resistance can be felt when the locking portion damage to the load carrying components. Press a
passes over the thread of the bolt or stud. ball bearing until it touches the shoulder in the
bore or on the shaft.
DO NOT reuse self-locking nuts in critical locations,
e.g. suspension components. Always use the With the sealing lip facing the lubricant, press or
correct replacement self-locking nut. 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.

Thruxton R 13
General Information

Chassis Bearing Lubrication 2. Inspect the old grease covering the bearing,
looking for signs of bearing damage, i.e. flakes
Note: or specks of metal.
• This information relates only to bearing 3. Remove the old grease.
lubrication. For the procedures necessary to
4. Check the bearing for smooth operation and
replace a bearing, always refer to the relevant
visually check for corrosion, dents and flaking
section of this Service Manual.
in the bearing race, rollers or cage. Replace if
• Bearings installed in engine and transmission
necessary.
applications are not covered by this
information. Refer to the Lubrication chapter Below/overleaf several common bearing types and
or the relevant engine chapter for additional the lubrication procedures for each are identified:
information.

General
For a bearing to be serviceable for its anticipated
life span it must be checked, adjusted 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,
disperses heat and protects the bearing surfaces
from corrosion.
Note:
ceon

• In all cases, use the lubricant recommended.

• Grease the bearing, not the cavity where it is Sealed Bearings
located.
• A bearing that is not regularly checked and Note:
lubricated will have a reduced life span. • Sealed bearings can be identified by their
integrated seals.
New Bearings • Sealed bearings are lubricated for life by the
New bearings are typically protected with an oil manufacturer.
preservative to prevent corrosion etc. during • Any attempt to change the grease in a sealed
storage. This is NOT the lubrication for the bearing bearing will damage the integrated seals. If
but DOES NOT need to be washed off prior to the seals are damaged, dirt and water will
assembly and in-service lubrication. ingress and the life of the bearing will be
When lubricating a new bearing with grease the greatly reduced.
following steps should be taken:
1. Do not clean off the oil preservative.
2. Grease must be forced between the roller
elements and the roller cage.
3. Rotate the bearing to ensure that the grease
is distributed over the entire circumference of
the internal parts.
4. Any excess grease should be smeared on the
outside of the rollers.

Lubrication and Checks While Servicing a

Bearing
ceon
1. Disassemble parts as necessary to access the
bearing.
Taper Bearings

1. Grease must be forced between the inner race

and the roller carrier.

14 Thruxton R
 General Information

2. Rotate the bearing to ensure that the grease 2. Remove the old grease.
is distributed over the entire circumference of 3. Apply fresh grease to the metal bush.
the internal parts.
3. Any excess grease should be smeared on the Fuel Handling Precautions
outside of the rollers.
General
The following information provides basic
precautions which must be observed if petrol
(gasoline) is to be handled safely. It also outlines
other areas of risk which must not be ignored. This
information is issued 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 volume in vapour which when diluted
with air becomes a readily ignitable mixture. The
ceon vapour is heavier than air and will always fall to the
lowest level. It can readily be distributed
Angular Contact and Ball Bearing throughout any indoor environment by air
currents, consequently, even a small spillage of
1. Grease the bearing races and the ball bearing
petrol (gasoline) is potentially very dangerous.
carrier.
2. Rotate the bearing to ensure that the grease
is distributed over the entire circumference of
the internal parts.

ceop

Needle Roller Bearings

1. Coat the needle rollers with grease.

2. Ensure the needle rollers turn so that the
grease is distributed over the entire
circumference of the internal parts.
3. Assemble the parts, adjust and check as
necessary.

Metal Bushes
1. Disassemble the parts as necessary to access
the bush.

Thruxton R 15
General Information

Warning Warning
Petrol (gasoline) is highly flammable and can be contents, and placed in a safe storage area which
explosive under certain conditions. When opening meets the requirements of local authority
the fuel tank cap always observe all the following regulations.
items: When petrol (gasoline) has been extracted or
Turn the motorcycle ignition switch OFF. drained from a fuel tank, the precautions
Do not smoke. governing naked lights and ignition sources should
be maintained.
Always have a fire extinguisher containing FOAM,
CO2, HALON or POWDER close at hand when Failure to observe any of the above warnings
handling or draining fuel or fuel systems. Fire could bring about a safety hazard leading to a risk
extinguishers must also be present in areas where of personal injury.
fuel is stored.
Always disconnect the vehicle battery, negative Fuel Tank Removal
(black) lead first, before carrying out, dismantling Fuel tanks should have a 'PETROL (GASOLINE)
or draining work on a fuel system. VAPOUR' warning label attached to them as soon
as they are removed from the vehicle. In all cases,
Whenever petrol (gasoline) is being handled,
they must be stored in a secured, marked area.
drained, stored or when fuel systems are being
dismantled, make sure the area is well ventilated.
Chassis Repairs
All potential forms of ignition must be
extinguished or removed (this includes any
appliance with a pilot light). Any lead-lamps must Warning
be flame-proof and kept clear of any fuel spillage.
If the motorcycle is involved in an accident or
Warning notices must be posted at a safe collision it must be taken to an authorised Triumph
distance from the site of the work to warn others dealer for repair or inspection. Any accident can
that petrol (gasoline) is being openly handled. The cause damage to the motorcycle, which if not
notice must instruct the reader of the precautions correctly repaired, may cause a second accident
which must be taken. which may result in injury or death.
Failure to observe any of the above warnings may The frame must not be modified as any
lead to a fire hazard which could result in personal modification to the frame such as welding or
injury. drilling may weaken the frame resulting in an
accident.

Warning
Electrical Precautions
No one should be permitted to repair components The following guidelines are intended to ensure the
associated with petrol (gasoline) without first safety of the operator whilst preventing damage to
having specialist training on the fire hazards the electrical and electronic components fitted to
which may be created by incorrect installation and the motorcycle. Where necessary, specific
repair of items associated with petrol (gasoline). precautions are detailed in the relevant sections of
Repairs carried out by untrained personnel could this manual which should be referred to prior to
bring about a safety hazard leading to a risk of commencing repair operations.
personal injury. Equipment - Prior to commencing any test
procedure on the motorcycle ensure that the
relevant test equipment is working correctly and
Warning any harness or connectors are in good condition, in
particular mains leads and plugs.
Draining or extraction of petrol (gasoline) from a
vehicle fuel tank must be carried out in a well
ventilated area.
The receptacle used to contain the petrol
(gasoline) must be more than adequate for the full
amount of fuel to be extracted or drained. The
receptacle should be clearly marked with its

16 Thruxton R
 General Information

Battery Disconnecting
Warning Before disconnecting the battery, switch off all
electrical equipment.
The ignition system produces extremely high
voltages. Do not touch any part of the ignition
system or any cables while the engine is running. Warning
An electric shock caused by contact with the
To prevent the risk of a battery exploding and to
ignition system may lead to illness, injury or death.
prevent damage to electrical components ALWAYS
disconnect the battery negative (black) lead first.
When reconnecting the battery, always connect
Warning the positive (red) lead first, then the negative
(black) lead. Always disconnect the battery when
Wearers of surgically implanted heart pacemaker
working on any part of the electrical system.
devices should not be in close proximity to ignition
circuits and/or diagnostic equipment. Failure to observe the above warnings may lead to
electrical damage and a fire hazard which could
The ignition system and any diagnostic equipment
cause personal injury.
may interrupt the normal operation of such
devices causing illness or death.
Always ensure that battery leads are routed
correctly and are not close to any potential chafing
Warning points.

The battery contains harmful materials. Always Disciplines

keep children away from the battery whether or Switch off the ignition prior to making any
not it is fitted in the motorcycle. connection or disconnection in the system. An
Do not jump start the battery, touch the battery electrical surge can be caused by disconnecting
cables together or reverse the polarity of the 'live' connections which can damage electronic
cables as any of these actions may cause a spark components.
which would ignite battery gases causing a risk of Ensure hands and work surfaces are clean and free
personal injury. of grease, swarf, etc. as grease collects dirt which
can cause tracking or high-resistance contacts.
High Voltage Circuits - Whenever disconnecting live Prior to commencing any test, and periodically
H.T. circuits always use insulated pliers. Exercise during any test, touch a good earth to discharge
caution when measuring the voltage on the coil body static. This is because some electronic
terminals while the engine is running. High voltage components are vulnerable to static electricity.
spikes can occur on these terminals.
Connectors and Harness - The engine of a Electrical Wires
motorcycle is a particularly hostile environment for All the electrical wires are either single-colour or
electrical components and connectors. Always two-colour and, with only a few exceptions, must
ensure these items are dry and oil-free before be connected to wires of the same colour. On any
disconnecting and connecting test equipment. of the two-colour wires there is a greater amount
Never force connectors apart either by using tools of one colour and a lesser amount of a second
or by pulling on the wiring itself. Always ensure colour. A two-colour wire is identified by first the
locking mechanisms are disengaged before removal primary colour and then the secondary colour. For
and note the orientation to enable correct example, a yellow wire with thin red stripes is
reconnection. Ensure that any protective covers referred to as a 'yellow/red' wire; it would be a 'red/
and substances are replaced if disturbed. yellow' wire if the colours were reversed to make
Having confirmed a component to be faulty, switch red the main colour.
off the ignition and disconnect the battery negative
(black) lead first. Remove the component and Glossary of Circuit Diagram Symbols
support the disconnected harness. When replacing
The following is a description of the symbols found
the component keep oily hands away from
in the circuit diagrams used in all Triumph Service
electrical connection areas and push connectors
Manuals.
home until any locking mechanism becomes fully
engaged.

Thruxton R 17
General Information

Connector Ground Point

1
2
3
4

This illustration is used to show all multiplug type This symbol is used to show ground points. This is
electrical connectors on Triumph circuit diagrams. the negative connection to either the frame or
The numbers in the box relate to the terminal engine, and is a common cause of intermittent
numbers of the connector pins. On ECMs with two faults due to loose or corroded connections.
connectors, the number would be prefixed with the
letters 'A' or 'B' to identify each connector. An Lamp or Bulb
additional number outside the box will identify the
component. 3 2

Diode

This symbol is used to show all types of light bulbs.

The numbers in the box relate to the terminal
numbers of the connector pins. An additional
number outside the box will identify the
An electrical one-way valve. Diodes allow current to component.
flow in one direction but will not allow it to return.
The arrow, which forms part of the diode symbol, LED (Light Emitting Diode)
indicates the direction of current flow.

Electromagnetic Winding (solenoid)

Triumph use LEDs for the alarm warning light,

instrument illumination and warning lights, gear
change lights and rear light/brake lights on various
An electromagnetic winding (or solenoid) is used to models.
convert an electrical current into a lateral
movement. This can then be used to operate Motor
switches (as used in relays) or other components
such as fuel injectors or secondary air injection
solenoids.
M
Fuse

3 An electric motor. This could be the starter motor

2 or a motor within an actuator, for example within
the ABS modulator.

Relay
A fuse is a device which protects a circuit in the
event of a fault. The fuse will 'blow' should a short
circuit occur, protecting that circuit from further
damage. The number next to the fuse on the 1 6 4 8

circuit diagram indicates the position of the fuse in

the fuse box.

18 Thruxton R
 General Information

A relay is effectively an electromagnetic switch. To engine. Around the frame and engine will be
close the relay contacts and complete the circuit, various other ground points to which the wiring
an electromagnet in the relay is energised which coming from components will be connected. In the
causes the relay contacts to close, making the case of the starter motor it bolts directly to the
circuit complete. engine, which is bolted to the frame. Therefore the
Relays are used when the electrical current is too frame and engine also form part of the earth
great for a mechanical switch, usually when the return path.
switching must be done quickly to prevent arcing
across the switch contacts. If a mechanical switch Ohm’s Law
were used, the mechanical switch contacts would The relationship between voltage, current and
quickly burn away. resistance is defined by Ohm’s Law.
• The potential of a battery is measured in volts
Resistor (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 measured in
Ohms.
A device placed in a cable to reduce a voltage or Ohm’s law, for practical work can be described as -
restrict the maximum current a device can draw.

Splice Voltage
Current
= Resistance

Power is calculated by multiplying Volts x Amps -

A hard cable joint where two or more cables are

joined in the wiring harness. A potential source of Watts = Volts x Amps
both open and short circuits.

Switches By transposing either of these 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 -
A mechanical device for completing or breaking a
circuit. There are three common types of switch:
normally open, normally closed and changeover. 60
W
V
= I
12
=5
Electrical Testing
For any electrical system to work, electricity must
be able to flow in a complete circuit from the power • the bulb resistance can be calculated by using -
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 V 12
battery and run through the component it must
I
=R 5
= 2.4
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

Thruxton R 19
General Information

To use either of the following triangles, put your Due to the complex circuits and the number of
finger over the value you want to find. Multiply the individual wires, Triumph uses two types of circuit
remaining values if side by side, or divide if one is diagram in its Service Manuals.
over the other. • Within the manual, conventional circuit
diagrams are used to show the layout of the
main circuits of the motorcycle. These are:
Engine management/ignition, Lighting, Starting
W V
and Charging and Auxiliary and Accessory. In
V I I R these diagrams no attempt is made to show the
components of the system in any particular
order or position in relation to the motorcycle.
Basic Electrical Circuits • At the back of the Service Manual a full colour
layout circuit diagram is used to show the main
electrical components in a position similar to
the actual position on the motorcycle.
Both of these circuit diagrams use similar symbols
to illustrate the various system components and
will be accompanied by a key indicating circuit
diagram components and wiring colour codes.
Basic Circuit Diagram Circuit diagrams also depict the inner workings of a
In the above circuit an electrical reservoir (the switch housing (i.e. which wire connects to which
battery) is connected via a cable to a terminal on when a switch is turned from one position to
the controlling device (the switch) whose contacts another) so that a test of that switch can be made
are either open or closed. The other terminal on the using the wire terminals in the connector instead
switch is connected via a cable to the consumer of disassembling the switch itself.
(the bulb), and the other side of the bulb filament is
connected to ground (earth) by another cable. The Tracing Circuits
ground point is usually a part of the frame or
The following is a description of two types of
engine, to which the battery negative terminal is
common electrical failures, and some of the
also connected.
methods which may be used to find them.
When the switch contacts are open (as shown in
the diagram), the circuit is broken and no current
Open Circuit
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 filament to ground. The frame completes the
circuit to the battery negative terminal and the
bulb illuminates.
Although some circuits on the circuit diagram may
at first seem more complicated, it will generally be A break in an electrical circuit - current cannot
found that they can be broken down into sections flow. Usually caused by a break in a wire or cable or
which do not differ greatly from the basic circuit by a loose connection. Open circuits can often be
above. intermittent, making diagnosis difficult.

Short Circuit
Circuit Diagrams
Circuit diagrams 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 components it feeds and
which connectors the wire runs through. Circuit
diagrams are an essential tool for fault finding, as it
A 'short cut' in an electrical circuit - current
is possible to locate start and finish points for a
bypasses the intended circuit, either to ground or
circuit without having to manually trace the wire
to another, different circuit. Often caused by failure
through the motorcycle itself. Circuits diagrams
of the cable insulation due to chafing or trapping of
may look confusing at first but when they are
studied closely they soon become logical.

20 Thruxton R
 General Information

the wire. There are two different types of short In the example below, the ground circuit continuity
circuit - short to ground and short to battery is being tested from the battery to the frame.
Voltage.
A short to ground means that the current is going 0.0

to ground before it reaches the component it is

supposed to feed. These are often caused by
chafing of the harness to the frame or wires Ω
trapped between a bolted component, 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 • Locate each end of the wire.
feed other circuits. If these circuits are working, • Set the Digital Multi Meter (DMM) to resistance
check for wiring faults from the splice onwards. check Ohms.
• the circuit diagram is not an accurate guide to • Probe each end of the wire.
the actual location of the parts when fitted on • If there is continuity, the meter will usually
the bike. It is a schematic diagram of the bleep or register the resistance of the cable.
circuits.
• A high resistance figure could indicate a dirty
• particularly where engine management items or corroded connection.
are concerned, the circuit is only completed by
• If there is a break in the wire, the meter will not
the ECM. If the ECM is not connected, the
bleep or register a resistance.
circuit may register as open.
• By probing the wire in various places, the
position of a high resistance or break in the
To Check Continuity:
wire (open circuit) can be narrowed down until
it is found.
Caution
Ensure the circuit being tested is switched off
before measuring continuity. Damage to the
Digital Multi Meter (DMM) may result from testing
a 'live' circuit with the meter set to resistance (Ω).

Thruxton R 21
General Information

To Measure Voltage: Relays

In the example below, the circuit voltage is being All relay cases have a circuit path engraved on
measured at the bulb positive (+) terminal. them showing the circuit path across the
electromagnet and the switch. Before making any
12.7 checks, first note the pin designations, current
paths, and whether or not there is a diode in either
circuit path.
V
Diode
86
87
Electromagnet

85 30

• 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 (most circuits)
or AC Volts for alternating current circuits Make continuity checks across the electromagnet
(typically alternator output voltage tests). first, usually from pin 86 (positive) to pin 85
• Set the range of the DMM to the range best (negative). If a diode appears in the circuit use the
suited to the voltage of the circuit being tested diode check on the multimeter (Volts scale) in the
(typically 20 Volts for most DMMs). Refer to the direction of current flow. If there is no diode, use
DMM manufacturers instructions. the resistance check facility. An open circuit or
unusually high resistance value indicates a faulty
• Connect the black (ground) lead of the DMM to
relay.
a reliable ground connection (usually the
battery or frame ground). To check the switch side, apply a 12 Volt supply
between pins 86 and 85. With the supply
• Locate the positive terminal of the wire or
connected, the relay should be heard to click and
component to be tested.
there should be continuity between pins 30 and 87.
• Connect the red (positive) lead of the DMM to An open circuit indicates a faulty relay.
the positive terminal.
• Read the voltage from meter.
CAN (Controller Area Networking)
Splices CAN (sometimes called CANbus) is a protocol for
data communication between Electronic Control
Splices are probably the most common cause of
Modules (ECMs). Each ECM on the network is
wiring faults after connectors. Splices are made
connected by a single pair of twisted wires (or bus)
where two or more wires come together and
which are used for the transmission of vehicle
diverge in different directions, usually to feed a
sensor data. By using CAN, the overall number of
different circuit.
system sensors, and the amount of cabling
To locate a splice, it is necessary to peel back the required to allow ECMs to communicate with each
insulation and examine the splice for its integrity. other is greatly reduced.
The most common fault is where one of the wires
at the joint has come adrift usually causing the
circuit it feeds or grounds to become '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 pushed. If
the switch is working correctly, the resistance
should register or the meter will bleep.

22 Thruxton R
 General Information

This saves cost, weight and space, and makes the incorrect data and preventing other messages from
system more reliable, as the physical number of getting through. The fault would then be reported
wires and connections is reduced. by a DTC (Diagnostic Trouble Code).
Triumph currently uses CAN for communication
between the following ECMs:
• Engine control module
R • Instruments
B28 4
U • ABS module
B27 5
• Immobiliser control module
16
• Diagnostic connector
• Audio system (if fitted).

1
KY
A34 3
2
B

CAN works by each ECM sending out 'packets' of

information (such as engine speed or fuel
consumption information) on to the network bus
(note that the network must be free of data before
any ECM is allowed to transmit). This data is given a
priority according to its importance (for example
'engine speed' may have a higher priority than 'low
fuel level'), so that even if two ECMs send data at
the same time, high priority information is always
sent first. Lower priority data is then resent 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 disregarded (for example if an ECM does
not require 'clutch switch position' information, this
data packet would be ignored).
This allows for a very high speed system of
communication, which is also very reliable. Should
one ECM fail or transmit corrupted or otherwise
incorrect messages, none of the other ECMs on the
network will be affected, and after a certain time
that ECM will be prevented from transmitting
further messages until the fault is rectified. This
stops the ECM from clogging the network with

Thruxton R 23
General Information

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24 Thruxton R
 3 Service Tools
Table of Contents
Service Tools and Garage Equipment ................................................................................................................................................... 27

Thruxton R 25
Service Tools

26 Thruxton R
 Service Tools

Service Tools and Garage Equipment

Special service tools have been developed to facilitate removal, dismantling and assembly of certain
mechanical components in a practical manner without causing damage. 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 described during the procedure.

Special Service Tools:

cdgh

T3880001 - Fuel Pressure Gauge T3880016 - Balancer Gear C-Spanner

T3880023 - 50 mm Socket T3880057 - Triumph Diagnostic Interface

Thruxton R 27
Service Tools

T3880039 T3880041

T3880039 - Idler Gear Timing Pin T3880041 - Idle Gear Timing Wrench

T3880109
cdoa

T3880104 - Swinging Arm Adjuster Wrench T3880109 - Bearing Separator

cgwp

3880105-T0301 - Torque Angle Gauge T3880147 - Radiator and Cap Tester Kit

28 Thruxton R
 Service Tools

ccha

3880160 -T0301 - Fork Oil Filler/Evacuator T3880176 - Radiator Pressure Test (use with
3880147)

ccmi

T3880307 - Clutch Anti-rotation Jig T3880308 - Cylinder Barrel Clamps

cczh

T3880313 - Oil Filter Wrench T3880365 - Alternator Housing Puller

Thruxton R 29
Service Tools

cjgu

T3880375 - Alternator Rotor Holder T3880391 - Fuel Pump Extension Cable

T3880601 - Camshaft Timing Pin T3880603 - Oil Pump Restraint

T3880606 - Flywheel Restraint Handle T3880609 - Timing Torque Limiter

30 Thruxton R
 Service Tools

cjar

T3880649 - Timing Chain Tensioner Socket T3880650 - Camshaft Timing Plate

cjas cjax

T3880651 - Timing Chain Tensioner T3880809 - Rear Balancer Timing Tool

cjav

cjat

T3880652 - Dead Shaft Key Tool T3880656 - Pulley Wrench Pin Set

Thruxton R 31
Service Tools

cczb
cjay

T3880811 - Front Balancer Timing Tool T3880053 - Wheel Bearing Extraction Kit

cczb

T3880075 - Bearing Installer BatteryMate Battery Charger - See Latest Parts

Catalogue for Part Number Information

cdoa2

T3880377 - Engine Mounting Adjuster T3880207 - Hose Clip Pliers

32 Thruxton R
 Service Tools

cjix

T3880171 - Fork Holding Tool T3880635 - Final Drive Chain Cut and Rivet

T3880184 - 45 mm Octagonal Socket T3880634 - Wrench Damper Cylinder

T3880003 - Front fork Seal Installer

Thruxton R 33
Service Tools

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34 Thruxton R
 4 Specifications
Table of Contents
Cylinder Head and Valves........................................................................................................................................................................... 37
Camshafts .......................................................................................................................................................................................................... 38
Clutch and Primary Drive ........................................................................................................................................................................... 39
Engine ................................................................................................................................................................................................................. 40
Piston .................................................................................................................................................................................................................... 41
Crankshaft ......................................................................................................................................................................................................... 42
Transmission..................................................................................................................................................................................................... 43
Final Drive .......................................................................................................................................................................................................... 44
Lubrication......................................................................................................................................................................................................... 45
Ignition System................................................................................................................................................................................................ 46
Fuel System....................................................................................................................................................................................................... 47
Emmisions Control System ....................................................................................................................................................................... 48
Cooling System ................................................................................................................................................................................................ 49
Suspension ........................................................................................................................................................................................................ 50
Brakes................................................................................................................................................................................................................... 51
Frame ................................................................................................................................................................................................................... 52
Wheels and Tyres........................................................................................................................................................................................... 53
Electrical Equipment ..................................................................................................................................................................................... 54

Thruxton R 35
Specifications

36 Thruxton R
 Specifications

Cylinder Head and Valves

Cylinder head Flatness tolerance 0.030 mm
Valve Head Diameter Inlet 35.60 mm
Exhaust 29.70 mm
Valve Lift Inlet 10.3 mm
Exhaust 9.2 mm
Valve Stem Diameter Inlet 4.975 - 4.990 mm (standard)
4.965 mm (service limit)
Exhaust 4.970 - 4.980 mm (standard)
4.960 mm (service limit)
Valve Guide Bore Diameter Inlet 5.000 - 5.015 mm (standard)
5.043 mm (service limit)
Exhaust 5.000 - 5.015 mm (standard)
5.043 mm (service limit)
Valve Stem to Guide Clearance Inlet 0.010 - 0.040 mm (standard)
0.078 mm (service limit)
Exhaust 0.020 - 0.045 mm (standard)
0.083 mm (service limit)
Valve Seat Width (in head) Inlet 1.000 - 1.100 mm (standard)
1.500 mm (service limit)
Exhaust 1.200 - 1.300 mm (standard)
1.700 mm (service limit)
Valve Seat Width (valve) 1.50 - 1.85 mm
Valve Seat Angle 90° inclusive
Valve Spring Length 49.9 mm
Inlet/Exhaust Valve Spring 'Load at Length' 214 N +/- 10 at 39.5 mm
Valve Clearance Inlet 0.05 - 0.13 mm
Exhaust 0.08 - 0.18 mm

Thruxton R 37
Specifications

Camshafts
Camshaft Timing (at 1 mm lift) Inlet Open 5.0° ATDC
Close 41.0° ABDC
Duration 216°
Exhaust Open 39.0° BBDC
Close 4.0° BTDC
Duration 215°
Camshaft Journal Diameter 22.930 - 22.960 mm
Camshaft Journal Clearance 0.040 - 0.091 mm (standard)
0.130 mm (service limit)
Camshaft Journal Bore Diameter 23.000 - 23.021 mm
Camshaft End Float 0.05 - 0.20 (standard)
Camshaft Run-out 0.015 mm (standard)

38 Thruxton R
 Specifications

Clutch and Primary Drive

Primary Drive Type Gear
Reduction Ratio 1.26:1 (93/74)
Clutch Type Wet multi-plate
No. of Friction Plates 8
Steel Plate Flatness Limit 0.15 mm
Friction Plate Flatness Limit 0.20 mm
Friction Plate Thickness (new) 2.90 - 3.10 mm
Friction Plate Thickness (service limit) 2.80 mm
Clutch Pack Height 38.00 mm + 0.34/-0.66 mm
Clutch Actuation Method Cable
Cable Free Play (at lever) 2.0 - 3.0 mm

Thruxton R 39
Specifications

Engine
Engine Configuration Liquid cooled parallel twin, 270° firing
angle
Arrangement Transverse in-line
Displacement 1200 cc
Bore x Stroke 97.6 x 80 mm
Compression Ratio 10.00:1
Cylinder numbering Left to right
Firing Order 1-2

40 Thruxton R
 Specifications

Piston
Cylinder Barrel Diameter - 97.585 - 97.601 mm (standard)
10 mm from the top of the barrel
Cylinder Barrel Diameter - 97.600 - 97.615 mm (standard)
97 mm from the top of the barrel
Piston Diameter 97.570 - 97.580 mm (standard)
97.530 mm (service limit)
Piston Ring to Groove Clearance Top 0.02 - 0.07 mm (standard)
0.085 mm (service limit)
Second 0.02 - 0.06 mm (standard)
0.075 mm (service limit)
Piston Ring Groove Width Top 1.21 - 1.24 mm (standard)
Second 1.01 - 1.03 mm (standard)
Oil 2.51 - 2.53 mm (standard and service limit)
Piston Ring End Gap Top 0.183 - 0.383 mm (standard)
0.503 mm (service limit)
Second 0.353 - 0.553 mm (standard)
0.673 mm (service limit)
Oil 0.153 - 0.703 mm (standard)
0.843 mm (service limit)
Gudgeon Pin Bore Diameter In Piston 21.004 - 21.012 mm (standard)
21.040 mm (service limit)
Gudgeon Pin Diameter 20.995 - 21.000 mm (standard)
20.985 mm (service limit)
Connecting Rod Small End Diameter 21.016 - 21.029 mm (standard)
21.039 mm (service limit)
Connecting Rod Big End Diameter 41.000 - 41.009 mm (standard)
Connecting Rod Big End Side Clearance 0.15 - 0.30 mm (standard)
0.50 mm (service limit)

Thruxton R 41
Specifications

Crankshaft
Crankshaft Big End Journal Diameter 38.000- 37.984 mm (standard)
37.9469 mm (service limit)
Crankshaft Big End Bearing Clearance 0.036 - 0.061 mm (standard)
0.100 mm (service limit)
Crankshaft Main Journal Diameter 43.108 - 43.092 mm (standard)
43.052 mm (service limit)
Crankshaft Main Bearing Clearance 0.018 - 0.042 mm (standard)
0.100 mm (service limit)
Crankshaft End Float 0.05 - 0.20 mm (standard)
0.50 mm (service limit)
Crankshaft Run-out 0.02 mm (standard)
0.035 mm (service limit)

42 Thruxton R
 Specifications

Transmission
Type 6 Speed, Constant Mesh
Gear Ratios Primary 1.26:1 (93/74)
1st 3.50:1 (49/14)
2nd 2.50:1 (45/18)
3rd 1.85:1 (37/20)
4th 1.48:1 (37/25)
5th 1.30:1 (35/27)
6th 1.17:1 (34/29)
Gear Selector Fork Thickness 5.90 - 6.00 mm (standard)
5.80 mm (service limit)
Gear Selector Groove Width 6.10 - 6.20 mm (standard)
6.30 mm (service limit)
Gear Selector Fork to Groove Clearance 0.1 - 0.3mm (standard)
0.50 mm (service limit)

Thruxton R 43
Specifications

Final Drive
Final Drive Type Chain - DID 520 VM2, 102 links
Final Drive Ratio 2.41:1 (41/17)
Drive Chain Slack See Final Drive Chain Adjustment, page 613

44 Thruxton R
 Specifications

Lubrication
Oil Capacity (including filter, dry fill) 3.80 litres
Oil and Filter Change 3.40 litres
Oil Change only 3.20 litres
Recommended Oil Approval Rating API SH (or higher) and JASO MA
Viscosity 10W/40 or 10W/50
Type Semi or fully synthetic
Oil Pressure (in main gallery) 3.00 - 3.60 bar at 3,500 rpm
Oil Pump Rotor Tip Clearance 0.15 mm (standard)
0.20 (service limit)
Oil Pump Body Clearance 0.15 - 0.239 mm (standard)
0.369 mm (service limits)
Oil Pump Rotor End Float 0.04 - 0.09 mm (standard)
0.12 mm (service limit)

Thruxton R 45
Specifications

Ignition System
Type Digital electronic
Electronic Rev-Limiter 7,000 rpm
Pick up Coil Air Gap Fixed, not adjustable
Primary Coil Resistance 0.185 Kohms
Ignition Coil Type Inductive, plug top
Spark Plug Type NGK LMAR8A-9
Spark Plug Gap 0.9 mm +0.0/-0.1 mm

46 Thruxton R
 Specifications

Fuel System
Fuel Type Unleaded, 91 RON (CLC or AKI octane rating (R+M)/2 of 87 or higher)
Fuel Tank Capacity 14.0 litres
Low Level Warning Lamp 3.5 litres remaining
Fuel Pump Type Submerged, electric
Fuel Pressure (nominal) 3.5 bar
Purge Control System Modulated, vacuum

Thruxton R 47
Specifications

Emmisions Control System

Type Multi point sequential
Idle Speed 1,000 rpm
Injector Type Multi hole, solenoid operated plate valve
Throttle Electronically controlled throttle bodies
Idle Speed Control Electronic
Control Sensors Atmospheric air pressure, throttle position, twist grip position,
coolant temperature, crankshaft position, oxygen sensor, intake
air temperature, gear position, MAP, vehicle speed (from ABS)
Catalysts One, in the catalytic converter box
Oxygen Sensor One per cylinder, heated, in header pipe
Evaporative Control Activated carbon canister (certain markets only)

48 Thruxton R
 Specifications

Cooling System
Coolant Mixture Pre-mixed
Antifreeze Type Triumph HD4X Hybrid OAT coolant
Cooling System Capacity 1.56 litres
Radiator Cap Opening Pressure 1.2 bar
Thermostat Opening Temperature 88°C
Cooling Fan Switch On Temperature 103°C
Temperature Gauge Sensor Resistance 173 Ohms (+/- 10%) at 100°C

Thruxton R 49
Specifications

Suspension
Front Fork Travel 120 mm
Recommended Fork Oil Grade Showa SS47
Oil Level (spring, spring seat and spacer 68 mm
removed and fork fully compressed)
Oil Volume (dry fill) 582 cc
Front Fork Pull Through upper surface of the fork top cap flange 23.5 mm from lower edge
of top yoke to the top of the outer tube (not the top cap)
Fork Spring Rate K = 8.1 N/mm
Rear Wheel Travel 120.3 mm

50 Thruxton R
 Specifications

Brakes
Front Type Four piston monobloc calipers acting on twin discs
Front Caliper Piston Diameter 34 mm
Front Disc Diameter 310 mm
Front Disc Thickness 4.5 mm (standard)
4.0 mm (service limit)
Front Disc Run-out Max. 0.25 mm
Front Master Cylinder Diameter 18 mm
Recommended Fluid DOT 4
Rear Type Twin piston sliding caliper acting on single disc
Rear Caliper Piston Diameter 27 mm
Rear Disc Diameter 220 mm
Rear Disc Thickness 5.0 mm (standard)
4.5 mm (service limit)
Rear Disc Run-out Max. 0.5 mm
Rear Master Cylinder Diameter 12.7 mm
Recommended Fluid DOT 4

Thruxton R 51
Specifications

Frame
Frame Type Tubular steel
Rake 22.8°
Trail 92.1 mm
Maximum. Payload (rider, passenger, 210 kg
luggage and accessories)

52 Thruxton R
 Specifications

Wheels and Tyres

Front Wheel Size MT 17 x 3.5
Front Wheel Rim Axial run-out 0.6 mm
Front Wheel Rim Radial Run-out 0.6 mm
Rear Wheel Size MT 17 x 5.0
Rear Wheel Rim Axial run-out 0.6 mm
Rear Wheel Rim Radial Run-out 0.6 mm
Approved Tyres A list of approved tyres specific to these models is available from
your authorised Triumph dealer, or on the Internet at
[Link].

Thruxton R 53
Specifications

Electrical Equipment
Battery Type YTX12-BS
Battery Rating 12 V - 10 Amp. Hour
Alternator Rating 25 Amps at 1000 rpm
46.5 Amps at 3000 rpm
Headlight 12 volt, 60/55 watt H4 halogen
Tail/Brake Light LED
Directional Indicator Lights 12 volt, 10 watt

54 Thruxton R
 5 Torque Wrench Settings
Table of Contents
Cylinder Head ................................................................................................................................................................................................... 57
Clutch ................................................................................................................................................................................................................... 58
Balancer, Crankshaft and Crankcase ................................................................................................................................................... 59
Engine Covers ................................................................................................................................................................................................. 60
Transmission...................................................................................................................................................................................................... 61
Lubrication System........................................................................................................................................................................................ 62
Final Drive .......................................................................................................................................................................................................... 63
Cooling System ................................................................................................................................................................................................ 64
Fuel System, Exhaust System and Airbox ......................................................................................................................................... 65
Front Suspension ........................................................................................................................................................................................... 67
Rear Suspension............................................................................................................................................................................................ 68
Wheels ................................................................................................................................................................................................................. 69
Front Brakes..................................................................................................................................................................................................... 70
Rear Brakes........................................................................................................................................................................................................ 71
ABS System....................................................................................................................................................................................................... 72
Frame, Footrests, Control Plates and Engine Mountings........................................................................................................... 73
Electrical ............................................................................................................................................................................................................. 74

Thruxton R 55
Torque Wrench Settings

56 Thruxton R
 Torque Wrench Settings

Cylinder Head
Application Torque (Nm) Notes
Camshaft cover to cylinder head 14 Nm See Camshaft Cover -
Installation, page 103
Camshaft drive chain tensioner to cylinder barrel 16 Nm
Camshaft drive chain tensioner blade to cylinder head 10 Nm Fit new fixing(s) if loosened or
removed
Camshaft frame to cylinder head 10 Nm See Camshaft - Installation, page
129
Camshaft sprocket to camshaft 22 Nm Fit new fixing(s) if loosened or
removed
Cylinder head to crankcase * See Cylinder Head - Installation,
page 135
Camshaft idler shaft bolt 10 Nm Fit new fixing(s) if loosened or
removed
Flanged plug to cylinder head 22 Nm Fit new fixing(s) if loosened or
removed
Spark plugs 12 Nm
Exhaust stud to cylinder head 10 Nm Fit new fixing(s) if loosened or
removed
Timing torque limiter 0.6 Nm

Thruxton R 57
Torque Wrench Settings

Clutch
Application Torque (Nm) Notes
Clutch centre nut 98 Nm Fit new fixing(s) if loosened or
removed
Fit new Belleville washer
Clutch pressure plate to centre 10 Nm
Clutch lever nut 3.5 Nm
Clutch lever clamp bolts 12 Nm
Switch housing screws 2.5 Nm
Clutch switch to switch housing 2.5 Nm
Clutch cable lower lock nut 3 Nm
Clutch cable bracket 1.5 Nm

58 Thruxton R
 Torque Wrench Settings

Balancer, Crankshaft and Crankcase

Application Torque (Nm) Notes
Crankcase to crankcase bolts * See Crankcase - Assembly, page
171
Oil level sight glass 30 Nm
Oil filler cap 3 Nm
Dry seal plug 23 Nm Fit new fixing(s) if loosened or
removed
Flanged plug 10 Nm
Breather plate to crankcase 12 Nm Fit new fixing(s) if loosened or
removed
Crankcase breather pipes to crankcase 9 Nm Fit new fixing(s) if loosened or
removed
Connecting rod big end bolts * See Connecting Rod -
Installation, page 178
Sprag thrust washer fixings 12 Nm Fit new fixing(s) if loosened or
removed
Sprag clutch housing fixings 16 Nm See Starter Drive/Sprag Clutch -
Installation, page 234
Plug, front balancer shaft adjuster clamp 23 Nm
Rear dead shaft retaining washer 12 Nm Fit new fixing(s) if loosened or
removed
Dead shaft clamp pinch bolt 10 Nm
Dead shaft clamp retaining bolt 10 Nm Fit new fixing(s) if loosened or
removed
Dead shaft pre load * See Balancer Shafts Dynamic
Adjustment, page 195

Thruxton R 59
Torque Wrench Settings

Engine Covers
Application Torque (Nm) Notes
Clutch cover to crankcase 10 Nm Fit new fixing(s) if loosened or
removed
See Clutch Cover - Installation,
page 98
Clutch cover embelisher to clutch cover 4 Nm Fit new fixing(s) if loosened or
removed
Clutch cover plug 3 Nm
Sound suppression to clutch cover fixings 6 Nm Fit new fixing(s) if loosened or
removed
Cable cover to alternator cover 6 Nm Fit new fixing(s) if loosened or
removed
Alternator cover embelisher to cover 4 Nm Fit new fixing(s) if loosened or
removed
Front sprocket cover to crankcase 9 Nm
Mesh cover to sprocket cover 4 Nm
Alternator cover to crankcase 10 Nm
Sump to crankcase 10 Nm
Sump plug 25 Nm Fit new sealing washer(s)
Baffle to sump 6 Nm

60 Thruxton R
 Torque Wrench Settings

Transmission
Application Torque (Nm) Notes
Front sprocket to output shaft nut 180 Nm Fit new fixing(s) if loosened or
removed
Input shaft bearing retainer 7 Nm Fit new fixing(s) if loosened or
removed
Input selector fork plug 22 Nm
Detent wheel to selector drum 12 Nm Fit new fixing(s) if loosened or
removed
Detent arm fixing 12 Nm Fit new fixing(s) if loosened or
removed
Detent arm spring fixing 12 Nm
Selector drum bearing retaining screw 12 Nm Fit new fixing(s) if loosened or
removed
Output selector shaft retainer 12 Nm Fit new fixing(s) if loosened or
removed
Gear change pedal pinch bolt 8 Nm
Starter drive flywheel * See Starter Drive/Sprag Clutch -
Installation, page 234

Thruxton R 61
Torque Wrench Settings

Lubrication System
Application Torque (Nm) Notes
Oil pressure relief valve plug 10 Nm
Oil pressure switch 15 Nm Fit new sealing washer(s)
Oil filter adapter 10 Nm
Oil filter 10 Nm Apply clean engine oil to the
seal(s)
Oil pump to crankcase 10 Nm Fit new fixing(s) if loosened or
removed
Oil cooling jet (pistons) 9 Nm Fit new fixing(s) if loosened or
removed
Oil pump drive chain guide fixings 9 Nm Fit new fixing(s) if loosened or
removed
Sump baffle plate to sump 6 Nm
Oil pump drive sprocket to oil pump 12 Nm
Oil pump rotor cover to oil pump body 10 Nm
oil pump auxilary chain guard 9 Nm Fit new fixing(s) if loosened or
removed

62 Thruxton R
 Torque Wrench Settings

Final Drive
Application Torque (Nm) Notes
Rear sprocket to cush drive 55 Nm See Rear Sprocket - Installation,
page 621

Thruxton R 63
Torque Wrench Settings

Cooling System
Application Torque (Nm) Notes
Radiator to frame upper 6 Nm
Thermostat housing to cylinder head 9 Nm
Coolant expansion tank mounting 7 Nm
Coolant expansion tank 3 Nm
Coolant temperature sensor 18 Nm Apply ThreeBond 1374 to the
threads
Coolant return elbow to crankcase 12 Nm Fit new fixing(s) if loosened or
removed
Coolant manifold to crankcase 9 Nm Fit new fixing(s) if loosened or
removed
Coolant filler neck 3 Nm
Radiator Grille 5 Nm

64 Thruxton R
 Torque Wrench Settings

Fuel System, Exhaust System and Airbox

Application Torque (Nm) Notes
Fuel tank to frame (pivot nut) 8 Nm
Fuel pump mounting plate to fuel tank 5 Nm
Fuel pump mounting bracket to fuel pump plate 7 Nm Fit new fixing(s) if loosened or
removed
Fuel hose bracket to fuel pump mounting bracket 4 Nm
Fuel pump baffle clamp 3 Nm
Fuel hose to fuel pump 15 Nm Fit new sealing washer(s)
Exhaust intermediate pipe to catalytic converter clamp 8 Nm
Right hand exhaust intermediate pipe to frame 19 Nm
Left hand exhaust intermediate pipe to frame 19 Nm
Exhaust headers to catalytic converter clamp 10 Nm
Exhaust balance pipe clamp 9 Nm
Exhaust silencer to frame 24 Nm
Exhaust headers to cylinder head 19 Nm
Exhaust catalytic converter heat shield to crankcase 19 Nm
Catalytic converter to heat shield 15 Nm
Catalytic converter front shield 5 Nm
Exhaust silencer to intermediate pipe 15 Nm
Exhaust cover 9 Nm
Oxygen sensor 25 Nm
Airbox to frame 6 Nm
Air intake hose clips 1.5 Nm
Evaporative canister 1.4 Nm Fit new fixing(s) if loosened or
removed
Crankshaft position sensor 6 Nm Fit new fixing(s) if loosened or
removed
Ambient air pressure sensor 2 Nm
Air temperature sensor 1.5 Nm
Gear position sensor 5 Nm Fit new fixing(s) if loosened or
removed
Immobiliser module 2 Nm
Immobiliser module bracket 4 Nm
Throttle position sensor cover 3 Nm
Fuel rail to cylinder head 6 Nm
Ignition coil assembly fixings 3 Nm Fit new fixing(s) if loosened or
removed
Air intake duct 1.5 Nm
Air intake finisher 3 Nm
Air intake finisher mounting 3 Nm
Purge valve bracket 1.5 Nm
Air filter cover to airbox 1.5 Nm

Thruxton R 65
Torque Wrench Settings

Application Torque (Nm) Notes

MAP sensor 1.5 Nm Fit new fixing(s) if loosened or
removed
Harness guide to crankcase (GPS) 4 Nm Fit new fixing(s) if loosened or
removed
Relay bracket 1.5 Nm
Engine breather pipe clip 3 Nm
Engine breather pipe mounting bracket 1.5 Nm
Throttle body transition piece to cylinder head 9 Nm
Multiplug mounting bracket 3 Nm Fit new fixing(s) if loosened or
removed

66 Thruxton R
 Torque Wrench Settings

Front Suspension
Application Torque (Nm) Notes
Upper yoke centre nut 90 Nm
Upper yoke pinch bolt 20 Nm
Lower yoke pinch bolt 25 Nm
Instrument bracket to upper yoke 8 Nm
Damping cylinder 90 Nm
Handlebar to riser clamp bolt 8.5 Nm
Handlebar end weights 5 Nm Fit new fixing(s) if loosened or
removed
Headstock bearing adjuster and lock nut * See Steering Head Bearing -
Adjustment, page 479
Right hand switch housing fixings 2.5 Nm
Left hand switch housing fixings 2.5 Nm
Handlebar riser to front fork clamp bolt 20 Nm
Twist grip housing 3.5 Nm
Fork top cap 22 Nm

Thruxton R 67
Torque Wrench Settings

Rear Suspension
Application Torque (Nm) Notes
Swinging arm pivot nut 110 Nm See
Swinging arm pivot bolt adjuster 6 Nm See Swinging Arm - Installation,
page 498
Drive chain slack adjuster lock nut 20 Nm
Drive chain guard fixings 9 Nm
Drive chain rubbing strip 9 Nm
Rear suspension unit upper mounting bolt 28 Nm
Rear suspension unit lower mounting bolt 48 Nm

68 Thruxton R
 Torque Wrench Settings

Wheels
Application Torque (Nm) Notes
Front wheel spindle/axle bolt 65 Nm
Fork to wheel spindle pinch bolts 23 Nm
Rear wheel spindle lock nut 110 Nm
Rear sprocket to sprocket carrier 55 Nm Fit new fixing(s) if loosened or
removed
Sprocket carrier stud 30 Nm See Rear Sprocket - Installation,
page 621

Thruxton R 69
Torque Wrench Settings

Front Brakes
Application Torque (Nm) Notes
Brake caliper to front fork 55 Nm Apply and hold front brake lever
when tightening the fixings
Front brake master cylinder to handlebar 8.5 Nm
Brake hose to master cylinder 25 Nm Fit new sealing washer(s)
Brake hose to front caliper 25 Nm Fit new sealing washer(s)
Brake disc to wheel 22 Nm Fit new fixing(s) if loosened or
removed
Brake lever pivot bolt 1 Nm
Brake lever pivot bolt lock nut 6 Nm
Front brake fluid reservoir cap 1 Nm
Caliper bleed screw 8 Nm

70 Thruxton R
 Torque Wrench Settings

Rear Brakes
Application Torque (Nm) Notes
Brake hose to rear caliper 25 Nm Fit new sealing washer(s)
Brake master cylinder right hand control plate 18 Nm
Master cylinder reservoir cap screws 1 Nm
Brake master cylinder reservoir to relay bracket 3 Nm Fit new sealing washer(s)
Brake hose to master cylinder 25 Nm Fit new sealing washer(s)
Brake light switch bracket to control plate 5 Nm Fit new sealing washer(s)
Brake hose P-clip to right hand control plate 5 Nm
Brake disc to wheel 22 Nm Fit new fixing(s) if loosened or
removed
Brake pad retaining pin 18 Nm

Thruxton R 71
Torque Wrench Settings

ABS System
Application Torque (Nm) Notes
ABS modulator bracket to frame 9 Nm Fit new fixing(s) if loosened or
removed
ABS pulser ring to front brake disc 5 Nm Fit new fixing(s) if loosened or
removed
ABS modulator to bracket 9 Nm Fit new fixing(s) if loosened or
removed
Brake line union block to headstock 8 Nm Fit new fixing(s) if loosened or
removed
Anti-rotation moulding to ABS modulator 5 Nm Fit new fixing(s) if loosened or
removed
Rear brake line to modulator P-clip 5 Nm
Rear ABS pulser ring to wheel 5 Nm Fit new fixing(s) if loosened or
removed
Hose routing moulding to crankcase 3 Nm Fit new fixing(s) if loosened or
removed
Brake line union to modulator 25 Nm Fit new sealing washer(s)
Front brake hose to hard line union 25 Nm Fit new sealing washer(s)
Hose guide to swinging arm 3 Nm Fit new fixing(s) if loosened or
removed

72 Thruxton R
 Torque Wrench Settings

Frame, Footrests, Control Plates and Engine Mountings

Application Torque (Nm) Notes
Footrest rubber inserts 6 Nm
Bank angle indicator 9 Nm
Front control plate 25 Nm
Pillion hanger finisher 24 Nm
Side stand switch 3 Nm Fit new fixing(s) if loosened or
removed
Side stand spring peg 7 Nm
Front right hand cylinder head bolt to frame (stage one) 24 Nm See Engine - Installation, page
265
Front right hand cylinder head bolt to frame (stage 2) 105 Nm See Engine - Installation, page
265
Frame adjuster 5 Nm See Engine - Installation, page
265
Front left hand cylinder head bolt to frame 105 Nm See Engine - Installation, page
265
Lower rear crankcase mounting 80 Nm See Engine - Installation, page
265
Upper rear crankcase mounting 80 Nm See Engine - Installation, page
265
Cradle to crankcase mounting bolts 105 Nm See Engine - Installation, page
265
Cradle to frame mounting bolts 40 Nm
Front mudguard bracket to forks 6 Nm
Front mudguard to bracket 3 Nm Fit new fixing(s) if loosened or
removed
Rear mudguard to frame 6 Nm
Rear mudguard support 6 Nm
Mirror 3 Nm
Seat lock to frame 9 Nm Fit new fixing(s) if loosened or
removed
Rear light harness cover 4 Nm
Sump guard bracket 19 Nm Fit new fixing(s) if loosened or
removed
Heel Guard 7 Nm Fit new fixing(s) if loosened or
removed - right hand side only
Seat cowl 1.5 Nm

Thruxton R 73
Torque Wrench Settings

Electrical
Application Torque (Nm) Notes
Alternator rotor to crankshaft * see Alternator Rotor -
Installation, page 693
Alternator stator to cover 12 Nm
Alternator regulator to bracket 4 Nm
Starter motor to crankcase 10 Nm
Starter motor power lead connection 5 Nm
Starter motor solenoid bracket 1.5 Nm
Starter motor solenoid lead connection 4 Nm
Spark plug 12 Nm
Alternator regulator/rectifier 4 Nm
Immobiliser ECU 2 Nm
Ignition switch 12 Nm
Headstock tidy 1.5 Nm
Headlight vertical adjuster 10 Nm
Rear light 2 Nm
Rear light assembly 5 Nm Fit new fixing(s) if loosened or
removed
Front and rear direction indicator 5 Nm
Fuse box bracket 3 Nm
Wire guide to headstock 3 Nm
Main harness to frame 3 Nm
Instrument bracket to upper yoke 8 Nm
Instruments 3 Nm
Instruments cover 3 Nm
Horn 24 Nm
Rear light harness cover 4 Nm
Alternator stator to alternator cover 12 Nm
Ignition switch 12 Nm
Tool 3880606 lock nut 10 Nm
Fall detection switch 3 Nm Fit new fixing(s) if loosened or
removed
Relay bracket 1.5 Nm
Headlight connector bracket to headlight bowl 1.5 Nm

74 Thruxton R
 6 Routings
Table of Contents
Main Wiring Harness Routing.................................................................................................................................................................. 77
Clutch Cable Routing .................................................................................................................................................................................... 78
ABS Brake Hose routing ............................................................................................................................................................................. 79
Evaporative Hose Routing ........................................................................................................................................................................ 80

Thruxton R 75
Routings

76 Thruxton R
 Routings

Main Wiring Harness Routing

Thruxton R 77
Routings

Clutch Cable Routing

cjpk

78 Thruxton R
 Routings

ABS Brake Hose routing

cjph

Thruxton R 79
Routings

Evaporative Hose Routing

cjpl

80 Thruxton R
 7 Routine Maintenance
Table of Contents
Scheduled Maintenance.............................................................................................................................................................................. 83
Scheduled Maintenance Table................................................................................................................................................................. 84

Thruxton R 81
Routine Maintenance

82 Thruxton R
 Routine Maintenance

Scheduled Maintenance 2. Motorcycles travelling approximately 10,000 miles

(16,000 km) per year must have the annual
maintenance and the specified mileage based items
Warning carried out together.
3. Motorcycles travelling more than 10,000 miles
Triumph Motorcycles cannot accept any
(16,000 km) per year must have the mileage based
responsibility for damage or injury resulting from
items maintained as the motorcycle reaches the
incorrect maintenance or improper adjustment
specified mileage. In addition to this, annual based
carried out by the owner.
items will require maintenance at their specified
Since incorrect or neglected maintenance can lead annual intervals.
to a dangerous riding condition, always have an In all cases maintenance must be carried out at or
authorised Triumph dealer carry out the scheduled before the specified maintenance intervals shown.
maintenance of this motorcycle. Consult an authorised Triumph dealer for advice on
which maintenance schedule is most suitable for
your motorcycle.
Warning Triumph Motorcycles cannot accept any
All maintenance is vitally important and must not responsibility for damage or injury resulting from
be neglected. Incorrect maintenance or incorrect maintenance or improper adjustment.
adjustment may cause one or more parts of the
motorcycle to malfunction. A malfunctioning
motorcycle may lead to loss of control and an
accident.
Weather, terrain and geographical location affect
maintenance. The maintenance schedule should
be adjusted to match the particular environment
in which the vehicle is used and the demands of
the individual owner.
Special tools, knowledge and training are required
in order to correctly carry out the maintenance
items listed in the scheduled maintenance chart.
Only an authorised Triumph dealer will have this
knowledge and equipment.
Since incorrect or neglected maintenance can lead
to a dangerous riding condition, always have an
authorised Triumph dealer carry out the scheduled
maintenance of this motorcycle.

To maintain the motorcycle in a safe and reliable

condition, the maintenance and adjustments
outlined in this section must be carried out as
specified in the schedule of daily checks, and also in
line with the scheduled maintenance chart. The
information that follows describes the procedures
to follow when carrying out the daily checks and
some simple maintenance and adjustment items.
Scheduled maintenance may be carried out by your
authorised Triumph dealer in three ways; annual
maintenance, mileage based maintenance or a
combination of both, depending on the mileage the
motorcycle travels each year.
1. Motorcycles travelling less than 10,000 miles
(16,000 km) per year must be maintained annually. In
addition to this, mileage based items require
maintenance at their specified intervals, as the
motorcycle reaches this mileage.

Thruxton R 83
Routine Maintenance

Scheduled Maintenance Table

Operation Description Odometer Reading in Miles (Km) or Time Period, whichever comes
first
First Annual Mileage Based Service
Service Service
Every 500 (800) Year 10,000 and 20,000 40,000
1 month 30,000 (32,000) (64,000)
(16,000 and
48,000)
Lubrication
Engine - check for leaks Day • • • • •
Engine oil - renew - • • • • •
Engine oil filter - renew - • • • • •
Fuel System and Engine Management
Fuel system - check for leaks, chafing etc. Day • • • • •
Throttle body plate (butterfly) - check/clean - • • •
Autoscan - Carry out a full Autoscan using - • • • • •
the Triumph Diagnostic Tool (print a customer
copy)

Exhaust clamp bolts - check/adjust - • • • • •

Air cleaner - renew - • • •
Fuel filter‡ - renew - • •
Throttle bodies - balance - • • •
Fuel hoses - renew Every 4 years regardless of mileage

Evaporative loss hoses* - renew Every 4 years regardless of mileage

Ignition System
Spark plugs - check - •
Spark plugs - renew - • •
Cooling System
Cooling system - check for leaks - • • • • •
Coolant level - check/adjust Day • • • • •
Coolant - renew Every 3 years regardless of mileage

Engine
Clutch cable - check/adjust Day • • • • •
Valve clearances - check - • •
Wheels and Tyres
Tyre wear/tyre damage - check Day • • • • •
Tyre pressures - check/adjust Day • • • • •
Wheels - inspect for damage Day • • • • •
Wheels - check wheels for broken or damaged Day • • • • •
spokes and check spoke tightness (models
with spoked wheels only)

84 Thruxton R
 Routine Maintenance

Operation Description Odometer Reading in Miles (Km) or Time Period, whichever comes
first
First Annual Mileage Based Service
Service Service
Every 500 (800) Year 10,000 and 20,000 40,000
1 month 30,000 (32,000) (64,000)
(16,000 and
48,000)
Wheel bearings - check for wear/smooth - • • • • •
operation

Electrical
All lights, instruments and electrical systems - Day • • • • •
check

Steering and Suspension

Steering - check for free operation Day • • • • •
Forks - check for leaks/smooth operation Day • • • • •
Fork oil - renew - •
Headstock bearings - check/adjust - • • • • •
Headstock bearings - lubricate - • •
Brakes
ABS and immobiliser ECMs - check for stored - • • • • •
DTCs

Brake pads - check wear levels Day • • • • •

Brake master cylinders - check for fluid leaks - • • • • •
Brake calipers - check for fluid leaks and - • • • • •
seized pistons

Brake fluid levels - check Day • • • • •

Brake fluid - renew Every 2 years regardless of mileage

Drive Chain
Drive chain slack - check/adjust Day • • • • •
Drive chain - wear check Every 500 miles (800 km)

Drive chain - lubricate Every 200 miles (300 km)

Drive chain rubbing strip - check - • • • • •

Drive chain rubbing strip - renew - • •
General
Fasteners - inspect visually for security Day • • • • •
Bank angle indicators - inspect visually for Day • • • • •
wear

Side stand/Centre stand - check operation Day • • • • •

* Evaporative system fitted to models for certain markets only.
‡ Models with twin throttle bodies only.

Thruxton R 85
Routine Maintenance

This page intentionally left blank

86 Thruxton R
 8 Engine Covers
Table of Contents
Exploded View – Sump ............................................................................................................................................................................... 89
Exploded View – Clutch Cover................................................................................................................................................................. 90
Exploded View – Alternator Cover.......................................................................................................................................................... 91
Exploded View – Camshaft Cover........................................................................................................................................................... 92
Exploded View – Sprocket Cover ............................................................................................................................................................ 93
Sump - Removal.............................................................................................................................................................................................. 94
Sump - Inspection.......................................................................................................................................................................................... 95
Sump - Installation ........................................................................................................................................................................................ 95
Clutch Cover - Removal ............................................................................................................................................................................... 97
Clutch Cover - Installation ........................................................................................................................................................................ 98
Alternator Cover - Removal ...................................................................................................................................................................... 99
Alternator Cover - Installation................................................................................................................................................................ 101
Camshaft Cover - Removal ...................................................................................................................................................................... 102
Camshaft Cover - Installation................................................................................................................................................................. 103
Front Sprocket Cover - Removal........................................................................................................................................................... 104
Front Sprocket Cover - Inspection....................................................................................................................................................... 104
Front Sprocket Cover - Installation ..................................................................................................................................................... 105

Thruxton R 87
Engine Covers

88 Thruxton R
 Engine Covers

Exploded View – Sump

6 Nm

25 Nm
10 Nm

Thruxton R 89
Engine Covers

Exploded View – Clutch Cover

10 Nm

3 Nm

4 Nm

6 Nm

10 Nm

90 Thruxton R
 Engine Covers

Exploded View – Alternator Cover

6 Nm

10 Nm

10 Nm

4 Nm

Thruxton R 91
Engine Covers

Exploded View – Camshaft Cover

See Text

92 Thruxton R
 Engine Covers

Exploded View – Sprocket Cover

9 Nm

9 Nm

Thruxton R 93
Engine Covers

Sump - Removal 2. Remove the sump to lower crankcase fixings.

2

Warning
Before starting work, ensure the motorcycle is
2
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 2 2
operator or damage to the motorcycle.

• Remove the exhaust system (see Exhaust

Silencer - Removal, page 430 and Exhaust
Intermediate and Header Pipes - Removal, page
431). 2
1
• Remove the engine cradles (see Cradle
Assemblies - Removal, page 640).
ciux 2
• Remove the catalytic converter (see Exhaust
Catalytic Converter - Removal, page 436). 1. Sump
2. Fixings
Warning 3. Release the sump from the lower crankcase.
The oil may be hot to the touch. Contact with hot Note:
oil may cause the skin to be scalded or burned. • The water pump drain tube may remain
attached to the water pump or become
detached with the sump.
Warning 4. Collect the water pump drain tube.
Prolonged or repeated contact with engine oil can 5. Remove and discard the four O- rings from the
lead to skin dryness, irritation and dermatitis. In drain tube.
addition used engine oil contains potentially
harmful contaminants which can cause cancer.
Wear suitable clothing and avoid skin contact.

1. Drain the engine oil and remove the oil filter

(see Oil and Oil Filter Change, page 244).

Warning
The exhaust system will be hot if the engine has
recently been running. Always allow sufficient time
for the exhaust to cool before working on or near
the exhaust system.
Contact with a hot exhaust could result in burn
injuries.

94 Thruxton R
 Engine Covers

Sump - Inspection Sump - Installation

1. Incorporating new O-rings (two each end of
Warning the tube), position the water pump drain tube
to the oil pump.
Ensure the oil pick-up is clean and free of
blockages or restrictions. If the oil flow is
restricted, oil pressure will be reduced and may
cause severe engine damage.

1. Check the oil pick-up for blockages or

restrictions. Remove and clean if found to be 1
blocked or restricted.

cjaq_1

1. Water pump drain tube

2. O-rings

2. Incorporating a new sump gasket/baffle,

position the sump to the lower crankcase.
3. Tighten the sump fixings to 10 Nm in the
sequence shown below.
4. Re-tighten the fixings one and two to 10 Nm.

13 9 5
3
1

15
7
12
16
11
8

4
2 14
civi 6 10
Tightening Sequence

Thruxton R 95
Engine Covers

5. Using a new washer, refit the oil drain plug

and tighten to 25 Nm. Caution
6. Apply a thin smear of clean engine oil to the If the engine oil pressure is too low, the low oil
sealing ring of the new oil filter. Fit the oil filter pressure warning light will illuminate. If this light
using service tool T3880313 and tighten to 10 stays on when the engine is running, stop the
Nm. engine immediately and investigate the cause.
Running the engine with low oil pressure will
cause engine damage.
1
• Start the engine and ensure that the low oil
pressure warning light goes out shortly after
starting.
2
• Stop the engine and check the engine oil level.
Adjust if necessary (see Engine Oil - Level
Inspection, page 243).
• Refit the seat (see Seat - Installation, page 636).

ciuy

1. Oil filter
2. Sump plug
• Refit the catalytic converter (see Exhaust
Catalytic Converter - Installation, page 437).
• Refit the exhaust system (see Exhaust
Intermediate and Header Pipes - Installation,
page 434 and Exhaust Silencer - Installation,
page 431).
• Refit the engine cradles (see Cradle Assemblies
- Installation, page 642).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Fill the engine with the correct grade of engine
oil (see Engine Oil - Specification, page 242).
• Reconnect the battery, positive (red) lead first
and tighten the battery terminals to 4.5 Nm.

Caution
Raising the engine speed above idle, before the oil
reaches all parts of the engine can cause engine
damage or seizure. Only raise engine speed after
running the engine for 30 seconds to allow the oil
to circulate fully.

96 Thruxton R
 Engine Covers

Clutch Cover - Removal 3. Release the fixings securing the clutch cover
to the crankcases. Note the position of the
encapsulated fixings and discard.
Warning
2 2
Before starting work, ensure the motorcycle is 2
2
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 1 2
operator or damage to the motorcycle.

• Remove the seat (see Seat - Removal, page

636). 2
1
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
2
1. Disconnect the clutch cable at the clutch cover
(see Clutch Cable - Removal, page 155). 1 3
2. Release the fixing and disconnect the gear 1 2 2 3
change actuator arm at the clutch cover. ciup

1. Bolt M6 x 50 mm
2. Bolt M6 x 40 mm
3. Encapsulated fixings M6 x 35 mm
4 4. Place an oil catch tray beneath the clutch
3 cover to collect any oil that may spill out on
removal.
5. Carefully withdraw the cover.
1
6. Remove the gasket and clean the surfaces of
the crankcase and the clutch cover using a lint
2 free cloth.
7. Note the position of the washer on the gear
change shaft.
ciuz

1. Gear change actuator arm

2. Fixing
3. Actuator arm alignment mark
4. Gear change shaft split line

Note:
• Note the position of the clutch cable brackets
prior to removal.

ciur
2

1. Gear change shaft

2. Flat washer

Thruxton R 97
Engine Covers

Clutch Cover - Installation • Re-tighten fixings one, two and six to 10

Nm.

Warning 13 9
5
3
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help 7 1
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Ensure the flat washer is correctly positioned 12

11
on the gear change shaft.

2 4
14 15 6 10
ciup

Tightening Sequence

7. Align the split line on the gear change

actuator arm with the alignment mark on the
gear change shaft and fit the actuator arm to
the spline. Fit the fixing and tighten to 8 Nm.

ciur
2

1. Gear change shaft 4

3
2. Flat washer

2. Thoroughly clean the cover and crankcase

mating faces. 1
3. Position a new gasket to the crankcase.
4. Refit the cover ensuring that the gasket does 2
not become dislodged.
Note:
• Ensure that the lifter piece claw engages ciuz

correctly with the pull rod during assembly. It 1. Gear change actuator arm
may be necessary to rotate the lifter piece
2. Fixing
rack to allow assembly to take place.
• Fixings 4 and 10 are encapsulated and must 3. Actuator arm alignment mark
be replaced during fitment. 4. Gear change shaft split line
5. Refit the two brackets for the clutch cable and 8. Refit and adjust the clutch cable (see Clutch
fixings as noted during removal, tighten the Cable - Installation, page 157).
fixings as described below:
• Reconnect the battery, positive (red) lead first
• Tighten fixings 1 to 13 in the sequence (see Battery - Installation, page 658) and
shown below to 10 Nm. tighten the terminals to 4.5 Nm.
6. Fit the clutch cable bracket and tighten fixings • Refit the seat (see Seat - Installation, page 636).
14 and 15 to 10 Nm.

98 Thruxton R
 Engine Covers

Alternator Cover - Removal 2. Remove the fixings, detach the alternator

harness and remove the coolant expansion
• Remove the seat (see Seat - Removal, page
tank mounting.
636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
1
Warning
The rotor magnets are very strong. When
handling the alternator cover the magnets may
'grab' the stator, causing injury to the hands or
fingers. When handling the alternator cover wear
suitable gloves and only grip the alternator cover 2
by the outside surfaces; always keep hands and
fingers clear when handling the alternator cover.
3
1
• Remove the right hand side panel (see Side cjqg
Panels, page 637).
• Remove the front sprocket cover (see Front Fixings
Sprocket Cover - Removal, page 104). Harness clip
• Remove the alternator regulator/rectifier (see Alternator harness
Alternator Regulator/Rectifier - Removal, page
694).
1. Remove the lock nuts and detach the coolant
Caution
expansion tank from its mounting. Discard the To prevent paint damage, do not spill brake fluid
lock nuts. onto any area of the bodywork. Spilled brake fluid
will damage paintwork.
1
3. Remove and discard the fixing and detach the
rear brake fluid reservoir from the relay
bracket.

2
1
2
cjpt
1
Lock nuts
Coolant expansion tank

citi_1

Fixing
Brake fluid reservoir

4. Secure the rear brake fluid reservoir in an

upright position.

Thruxton R 99
Engine Covers

5. Disconnect the crankshaft position sensor 10. Place an oil catch tray beneath the alternator
from the main harness. cover to collect any oil that may spill out on
removal.
11. Release the fixings securing the alternator
cover to the crankcases.
10 3 7

1
5 2

1 6

ciwh_1

Crankshaft position sensor electrical connector 8 9

Note: ciuo 4
• Note the routing of the crankshaft position Removal Sequence
sensor harness and for installation.
12. Carefully withdraw the alternator cover from
6. Route the crankshaft position sensor harness the crankcase.
through the frame to the harness guide on the
crankcase. 13. Remove the gasket and clean the surfaces of
the crankcase and the alternator cover using a
7. Remove and discard the fixing and detach the lint free cloth.
harness guide from the crankcase.
14. Remove and discard the O-ring from the
balancer dead shaft.
2

1
1 2

cjqb_1

Fixing civa

Harness guide
1. O-ring
8. Carefully remove the alternator harness from 2. Balancer dead shaft
the harness guide.
Note:
• Note the routing of the alternator harness and
its clips for installation.
9. Route the alternator harness with the grey
electrical connector to the alternator cover.

100 Thruxton R
 Engine Covers

Alternator Cover - Installation 5. Route the alternator harness to the alternator

regulator rectifier securing it to its clips as
noted for removal.
Warning 6. Carefully fit the alternator harness into the
The rotor magnets are very strong. When harness guide as noted for removal.
handling the alternator cover the magnets may 7. Secure the harness guide to the crankcase
'grab' the stator, causing injury to the hands or and tighten the new fixing to 4 Nm.
fingers. When handling the alternator cover wear
suitable gloves and only grip the alternator cover
by the outside surfaces; always keep hands and 2
fingers clear when handling the alternator cover.

1. Fit a new O-ring to the balancer dead shaft. 1

1
2

cjqb_1

1. Fixing
2. Harness guide

8. Route the crankshaft position sensor harness

through the frame to the right hand side of
civa
the airbox, as noted for removal.
1. O-ring 9. Connect crankshaft position sensor electrical
2. Balancer dead shaft connector to the main harness.

2. Position a new gasket to the crankcase dowels

and refit the alternator cover.
3. Tighten the fixings to 10 Nm, in the sequence
shown below.
10 3 7 1

5 2

1 6
ciwh_1

1. Crankshaft position sensor electrical connector

8 9 10. Refit the brake fluid reservoir to the relay

bracket, and tighten the new fixing to 3 Nm.
ciuo 4
Tightening Sequence

4. Re-tighten fixings one and two to 10 Nm.

Thruxton R 101
Engine Covers

11. Attach the alternator harness to the coolant Camshaft Cover - Removal
expansion tank mounting, fit the coolant
expansion tank mounting and tighten its
fixings to 7 Nm. Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
1 prevent it from falling and causing injury to the
operator or damage to the motorcycle.

• Remove the ignition coils (see Ignition Coils -

Removal, page 687).
• Remove the immobiliser/TPMS module (see
Immobiliser/TPMS Control Module - Removal,
2 page 404).
1. Remove the upper coolant tube fixing and re-
3 position the coolant filler neck to allow
1 clearance between the camshaft cover and the
cjqg
coolant filler cap.
1. Fixings
2. Harness clip
2
3. Alternator harness

12. Refit the coolant expansion tank to its

mounting bracketand tighten the new lock
nuts to 3 Nm.

1
1

cixw

1. Fixing
2. Upper coolant tube

2. Remove the spark plugs.

1 3. Progressively release the camshaft cover
2 fixings.
cjpt
4. Raise the camshaft cover and manoeuvre it
1. Lock nuts towards the right hand side of the engine,
where it can be removed.
2. Coolant expansion tank
• Refit the alternator regulator/rectifier (see
Alternator Regulator/Rectifier - Installation,
Caution
page 695 Never use a lever to remove the camshaft cover
• Refit the front sprocket cover (see Front from the cylinder head.
Sprocket Cover - Installation, page 105).
Using a lever will cause damage to the cylinder
• Refit the right hand side panel (see Side Panels, head and camshaft cover, which could lead to an
page 637). oil leak.
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and 5. Remove the camshaft cover gasket.
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

102 Thruxton R
 Engine Covers

6. Discard the camshaft cover gasket and rubber Camshaft Cover - Installation
seals.
1. Fit a new camshaft cover seal to the camshaft
7. Remove any residual oil from the mating face cover. Ensure the groove in the gasket is
of the cylinder head using a lint free cloth. correctly seated to the camshaft cover.
2. Position the camshaft cover to the cylinder
head. Ensure that the seal remains in position.
3. Lubricate the new camshaft cover fixing seals
with clean engine oil. Fit the camshaft cover
fixings and seals and tighten until finger tight.
4. Tighten the fixings in the sequence shown to
14 Nm.
1 3

Front

4 2
cius

Tightening Sequence

5. Refit the spark plugs and tighten to 12 Nm.

6. Re-position the coolant filler neck. Refit the
upper coolant tube fixing and tighten to 3 Nm.
• Refit the immobiliser/TPMS module (see
Immobiliser/TPMS Control Module - Installation,
page 405).
• Refit the ignition coils (see Ignition Coils -
Installation, page 689).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 103
Engine Covers

Front Sprocket Cover - Removal Front Sprocket Cover - Inspection

Warning Warning
Before starting work, ensure the motorcycle is Rotating the rear wheel will cause the drive chain
stabilised and adequately supported. This will help to rotate on the sprockets. To prevent injury,
prevent it from falling and causing injury to the never place loose clothing, fingers or hands near
operator or damage to the motorcycle. the drive chain or sprockets. Loose clothing,
fingers or the hands could become trapped as the
drive chain rotates on the sprockets causing a
Warning crushing injury to the fingers, hands or other
parts of the anatomy.
Rotating the rear wheel will cause the drive chain
to rotate on the sprockets. To prevent injury, 1. Inspect the rubber grommets, flanged sleeves
never place loose clothing, fingers or hands near and rubber buffer for damage or wear.
the drive chain or sprockets. Loose clothing,
fingers or the hands could become trapped as the
drive chain rotates on the sprockets causing a
crushing injury to the fingers, hands or other
parts of the anatomy.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
1. Remove the fixings securing the sprocket
cover to the crankcase.

1. Sprocket cover
2. Fixings

104 Thruxton R
 Engine Covers

Front Sprocket Cover - Installation 3. Fit the sprocket cover, ensuring that the
rubber buffer and the flanged sleeves remain
in the correct position.
Warning 4. Fit the sprocket cover fixings and evenly and
Before starting work, ensure the motorcycle is progressively tighten to 9 Nm. fixings.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle. 2

Warning
Rotating the rear wheel will cause the drive chain 1
to rotate on the sprockets. To prevent injury,
never place loose clothing, fingers or hands near
the drive chain or sprockets. Loose clothing,
fingers or the hands could become trapped as the
drive chain rotates on the sprockets causing a
crushing injury to the fingers, hands or other
2
parts of the anatomy.

1. Sprocket cover
1. If removed, refit the grommets to the sprocket
cover. 2. Fixings
2. If removed, refit the rubber buffer to the • Reconnect the battery, positive (red) lead first
swinging arm nut. (see Battery - Installation, page 658) and
1 tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

3
2
cive

1. Sprocket cover
2. Grommet
3. Rubber buffer

Thruxton R 105
Engine Covers

This page intentionally left blank

106 Thruxton R
 9 Cylinder Head
Table of Contents
Exploded View – Camshaft and Camshaft Drive........................................................................................................................... 109
Exploded View – Cylinder Head.............................................................................................................................................................. 110
Cylinder Head - Description ...................................................................................................................................................................... 111
Camshaft Drive Chain Tensioner - Removal ...................................................................................................................................... 111
Camshaft Drive Chain Tensioner - Inspection ................................................................................................................................. 113
Camshaft Drive Tensioner - Installation............................................................................................................................................. 113
Camshaft Drive Chain and Idler Gear - Removal............................................................................................................................ 116
Camshaft Chain - Inspection .................................................................................................................................................................... 117
Camshaft Drive Chain and Idler Gear - Installation...................................................................................................................... 119
Camshaft Drive Chain Rubbing Blade - Removal .......................................................................................................................... 120
Camshaft Drive Chain Rubbing Blade - Inspection........................................................................................................................ 121
Camshaft Drive Chain Rubbing Blade - Installation ..................................................................................................................... 122
Exhaust Decompressors............................................................................................................................................................................ 122
Camshaft - Removal.................................................................................................................................................................................... 123
Camshaft - Identification........................................................................................................................................................................... 125
Camshaft - Inspection................................................................................................................................................................................. 125
Valve Clearance .............................................................................................................................................................................................. 127
Valve Clearance Adjustment.................................................................................................................................................................... 127
Camshaft - Installation.............................................................................................................................................................................. 129
Cylinder Head - Removal .......................................................................................................................................................................... 134
Cylinder Head - Inspection ....................................................................................................................................................................... 135
Cylinder Head - Installation...................................................................................................................................................................... 135
Valves and Valve Stem Seals - Removal ............................................................................................................................................ 137
Valves and Valve Stem Seals - Installation...................................................................................................................................... 138

Thruxton R 107
Cylinder Head

108 Thruxton R
 Cylinder Head

Exploded View – Camshaft and Camshaft Drive

22 Nm
10 Nm

16 Nm

10 Nm

Thruxton R 109
Cylinder Head

Exploded View – Cylinder Head

10 Nm

10 Nm
22 Nm

See Text

10 Nm

110 Thruxton R
 Cylinder Head

Cylinder Head - Description Camshaft Drive Chain Tensioner -

The engine is fitted with an aluminium alloy Removal
cylinder head, which carries the camshaft, valves
and spark plugs. The cylinder head is cast as a
single entity, to which various components are Warning
permanently added after machining.
Before starting work, ensure the motorcycle is
A silent-running camshaft drive chain drives the stabilised and adequately supported. This will help
single-overhead camshaft, which runs directly in prevent it from falling and causing injury to the
the cylinder head without additional bearings. operator or damage to the motorcycle.
The crankshaft drives an idler gear, which in turn
drives the camshaft drive chain. The idler gear, and • Remove the ignition coils (see Ignition Coils -
therefore the camshaft rotates in the opposite Removal, page 687).
direction to the crankshaft.
• Remove the immobiliser/TPMS module (see
The engine is fitted with a camshaft drive chain Immobiliser/TPMS Control Module - Removal,
hydraulic tensioner. The tensioner is fed oil via a page 404).
gallery in the crankcase. The combination of oil
• Remove the camshaft cover (see Camshaft
pressure and spring pressure pushes the plunger
Cover - Removal, page 102).
against the tensioner blade which tensions the
camshaft drive chain. The hydraulic tensioner has • Remove the alternator cover (see Alternator
an oil pressure relief valve located in the plunger Cover - Removal, page 99).
that is set to open between 12 - 16 bar. The chain is 1. Rotate the engine until the service tool
guided by two nylon tensioner blades. The rubbing T3880601 can be inserted through the hole in
blade is located in the cylinder barrel by lugs on the the alternator rotor, crankcase and into the
blade. The cylinder head must be removed to idler gear.
remove this blade. The tensioner blade is secured
to the cylinder head by two bolts at its upper end,
and its lower end rests on the tensioner plunger.
Camshaft, valve, valve shim and valve seat wear 2
affect the valve clearances. The effect of this wear
is to change the clearance between the rocker and
the adjustment shim, causing engine noise and/or 1
improper running. If the valve clearances are
incorrect, permanent damage to components in the
valve-train will take place and engine performance
will be affected.
Oil is supplied to the cylinder head by an internal
passageway inside the engine. Once it arrives at
the cylinder head, it is passed through a restrictor,
and is then delivered to the camshaft bearing civb

journals along grooves and bolt holes in the

1. T3880601 - Camshaft Timing Pin
camshaft frames. The camshaft lobes are splash
fed by oil coming from the rocker arms. 2. Timing hole in alternator rotor

Thruxton R 111
Cylinder Head

2. In addition to the alignment mark, at TDC, the 4. Unscrew the hydraulic tensioner body until the
offset slot on the camshaft will align with the plunger spring tension has been released.
upper surface of the cylinder head.

cizu
cizs
2 3
1. Tensioner
1. Camshaft slot
5. Remove the hydraulic tensioner and discard
2. Cylinder head the O-rings.
3. Camshaft ladder (cylinder two)

3. With the aid of an assistant, hold the camshaft

drive chain tensioner blade to keep the
camshaft drive chain in position during
removal of the tensioner.

cjag

1. Camshaft drive chain tensioner blade

2. Tension (hand held)

Warning
The hydraulic tensioner is under spring tension.
Always wear hand, eye, and face protection when
withdrawing the tensioner. Take great care to
minimise the risk of injury and loss of components.

112 Thruxton R
 Cylinder Head

Camshaft Drive Chain Tensioner - Camshaft Drive Tensioner -

Inspection Installation
1. Inspect the camshaft drive chain tensioner
spring for damage and deformation. Renew as Warning
necessary.
Before starting work, ensure the motorcycle is
2. Inspect the tip of the camshaft drive chain
stabilised and adequately supported. This will help
tensioner plunger for wear and damage.
prevent it from falling and causing injury to the
Renew as necessary.
operator or damage to the motorcycle.

1. Ensure that the camshaft drive chain

tensioner blade is in contact with the camshaft
drive chain.
2. Check that the camshaft alignment slot aligns
with the cylinder head.
3. To set the hydraulic tensioner onto the first
tooth of the ratchet (i.e. minimum extension)
carry out the following:
Note:
• If installing a new hydraulic tensioner, do not
release the plunger before fitting.
• If installing the original hydraulic tensioner,
the engine oil must be drained out of the
tensioner to enable the plunger to be set onto
the first tooth of the ratchet.

Warning
The plunger of the camshaft drive chain tensioner
is under spring tension. Always wear hand, eye
and facial protection when removing the tensioner
as unprotected areas of the body can be injured if
the spring tension is released in an unexpected or
uncontrolled way.

4. Hold the resister ring ends together and pull

out the plunger.

2
1

cfei_2

1. Resister ring ends

2. Plunger

Thruxton R 113
Cylinder Head

5. Remove the spring. 10. Hold the resister ends together, close the vice
allowing the plunger to be pushed through the
resister ring until the snap ring aligns with the
snap ring groove.

1
2 3
1

1. Spring 4
cfei
6. While holding the resister ring in place, drain
the engine oil into a suitable container.
1. Resister ring
7. Ensure the resister ring is correctly located as
2. Plunger
shown below.
3. Snap ring groove
4. Snap ring

11. When the snap ring aligns with the snap ring
groove, release the vice and move one end of
the snap ring into the groove. Slowly release
1 the plunger to ensure it is held in place.

cfho

1. Resister ring

8. Refit the spring.

9. Support the tensioner in a soft jawed vice.

cfej

1. Snap ring groove

2. Snap ring

12. Fit two new O-rings to the camshaft drive

chain tensioner body.
13. Fit the tensioner to the cylinder head as noted
for removal. Tighten the tensioner to 16 Nm.
14. Release pressure to the camshaft drive chain
tensioner blade, taking care not to move the
tensioner blade.
15. Remove service tool T3880601.

114 Thruxton R
 Cylinder Head

16. To release the plunger from the snap ring 21. Check that the camshaft timing marks align as
holding the hydraulic tensioner, rotate the shown below.
crankshaft anticlockwise until the plunger is
released.
17. Rotate the crankshaft clockwise until the
service tool T3880601 aligns with the hole in
the crankcase and the crankshaft.
18. Check that there is tension in the camshaft
drive chain and the slot at the camshaft end is
correctly aligned.
Note: 1
• After fitting to the engine, the hydraulic
tensioner will be empty of engine oil. After
starting the engine, the camshaft drive chain
and tensioner blade will be noisy until full
pressure is felt at the tensioner plunger. This cizs
2 3
could take up to 5 seconds. 1. Camshaft slot
19. Check that the tensioner plunger is correctly 2. Cylinder head
located in the middle of the camshaft drive
3. Camshaft ladder (cylinder two)
chain tensioner blade when viewed from
above. 22. Recheck the tensioner plunger location against
20. Rotate the engine through 4 full revolutions, the camshaft drive chain tensioner blade.
and reset number 1 cylinder to TDC. Ensure 23. Remove service tool T3880601.
that the service tool T3880601 aligns with the • Refit the alternator cover (see Alternator Cover
hole in the crankcase and the crankshaft. - Installation, page 101).
• Refit the camshaft cover (see Camshaft Cover -
Installation, page 103).
• Refit the immobiliser/TPMS module (see
2 Immobiliser/TPMS Control Module - Installation,
page 405).
1 • Refit the ignition coils (see Ignition Coils -
Installation, page 689).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
civb

1. T3880601 - Camshaft Timing Pin

2. Timing hole in alternator rotor

Thruxton R 115
Cylinder Head

Camshaft Drive Chain and Idler Gear 4. Secure the idler gear in position using the
locking plate supplied with service tool
- Removal T3880016-2 by locking the gear teeth as
shown below.
Warning
2
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.

• Remove the engine (see Engine - Removal, page

261).
• Remove the camshaft cover (see Camshaft
Cover - Removal, page 102).
• Remove the alternator cover (see Alternator
Cover - Removal, page 99). 1
3
Warning cizk

1. Idler gear
The rotor magnets are very strong. When
2. Locking plate (Part of T3880016 - Balancer Gear C-
handling the alternator cover the magnets may
Spanner)
'grab' the stator, causing injury to the hands or
fingers. When handling the alternator cover wear 3. T3880039 - Idler Gear Timing Pin
suitable gloves and only grip the alternator cover 5. Remove and discard the fixing from the idler
by the outside surfaces; always keep hands and gear shaft.
fingers clear when handling the alternator cover

• Remove the alternator rotor (see Alternator

Rotor - Removal, page 692).
1. Rotate the engine until service tool T3880039
can be inserted through the hole in the 1
crankcase and into the idler gear.
2. Remove the cylinder head (see Cylinder Head -
Removal, page 134).
3. Remove the cylinder barrels (see Barrels -
Removal, page 142).

Warning
cjac
Never use a 'dot punch' to mark the camshaft
drive chain, camshaft or camshaft driven gears. 1. Fixing
Severe engine damage will result if impact is
applied to machined parts.

Note:
• To ensure the camshaft drive chain can be
refitted in the same orientation, use a suitable
marker pen to permanently mark one of the
outer plates of the camshaft drive chain prior
to removing the camshafts.
• Note the side of which the marked outer plate
is facing for installation.

116 Thruxton R
 Cylinder Head

6. Withdraw the idler gear shaft and collect the Camshaft Chain - Inspection
idler gear and camshaft drive chain from the
Visual in-situ checks can also be made as follows:
upper crankcase.
1. Check for significant blue discolouration of the
2 drive chain plates indicating excessive heat
build-up.
2. Examine all pins for signs of rotation.
3. Check for cracking or deep scratching of the
drive chain plates.
4. Check for severe wear of the inner plates as
3 indicated in the diagram below.
1

cizl

1. Idler gear shaft

2. Idler gear
3. Camshaft drive chain

7. Remove the camshaft drive chain from the

idler gear.
ccrv

For a more thorough check, proceed as follows:

1. Remove the drive chain from the engine.
2. Suspend the drive chain from a pin or hook
with a 13 kg weight attached at the lower end.

cajs

3. Measure across 23 links as shown in the

diagram below. If the drive chain is within
limits, the measurement should be no longer

Thruxton R 117
Cylinder Head

than 147.50 mm. Measurements beyond 147.50 6. Check for severe wear of the plates in the area
mm indicate that the drive chain must be shown below.
replaced.

1 2 3 4 22 23

caju

cajt
7. If any of these symptoms are evident, the
4. Check for severe wear of the inner surface of camshaft drive chain must be replaced.
the outer plates at the side-contact points
with the sprocket teeth.

ccru

5. Check for signs of stiffness or kinking.

118 Thruxton R
 Cylinder Head

Camshaft Drive Chain and Idler Gear 4. Install service tool T3880039 through the hole
in the crankcase (alternator side) and through
- Installation the smaller hole in the idler gear, as shown
1. Pre-load the backlash gear using service tool below.
T3880041 and locking plate service tool
T3880016-2 as shown below.

1
3

2
1 cjac

2 1. Idler gear
cizm
2. Backlash gear
1. Idler gear
3. T3880039 - Idler Gear Timing Pin
2. Locking plate (part of T3880016 - Balancer Gear C-
Spanner) 5. Install the idler gear shaft and a new fixing,
Counter hold the idler shaft and tighten the
3. T3880041 - Idle Gear Timing Wrench fixing to 10 Nm.
2. Install the camshaft drive chain to the idler
gear.
3. Refit the idler gear to the upper crankcase and
install the idler gear shaft. Ensure that the
marked outer plate on the camshaft drive
chain is facing the same direction as noted for 1
removal.

cjac

1 3 1. Fixing

6. Refit the barrel assembly (see Barrels -

Installation, page 143).
7. Refit the cylinder head (see Cylinder Head -
Installation, page 135).
cizl 8. Refit the camshafts (see Camshaft -
1. Idler gear shaft Installation, page 129).
2. Idler gear 9. Recheck the tensioner plunger location against
the camshaft drive chain tensioner blade.
3. Camshaft drive chain

Thruxton R 119
Cylinder Head

10. Remove service tool T3880601 from the Camshaft Drive Chain Rubbing Blade
crankcase.
- Removal
11. Remove service tool T3880039 from the idler
gear.
• Refit the camshaft cover (see Camshaft Cover - Warning
Installation, page 103).
Before starting work, ensure the motorcycle is
• Refit the alternator cover (see Alternator Cover stabilised and adequately supported. This will help
- Installation, page 101). prevent it from falling and causing injury to the
• Refit the engine (see Engine - Installation, page operator or damage to the motorcycle.
265).
• Refit the fuel tank (see Fuel Tank - Installation, Note:
page 383).
• The camshaft drive chain rubbing blade can
• Reconnect the battery, positive (red) lead first
only be removed after the cylinder head has
(see Battery - Installation, page 658) and
been removed.
tighten the terminals to 4.5 Nm.
• The camshaft drive chain tensioner blade can
• Refit the seat (see Seat - Installation, page 636). be removed without removing the cylinder
head.
• Remove the engine (see Engine - Removal, page
261).

Warning
The rotor magnets are very strong. When
handling the alternator cover the magnets may
'grab' the stator, causing injury to the hands or
fingers. When handling the alternator cover wear
suitable gloves and only grip the alternator cover
by the outside surfaces; always keep hands and
fingers clear when handling the alternator cover

• Remove the alternator cover (see Alternator

Cover - Removal, page 99).
• Remove the camshaft cover (see Camshaft
Cover - Removal, page 102).
1. Rotate the engine until service tool T3880039
can be inserted through the hole in the
alternator rotor, crankcase and into the idler
gear.
2. Remove the cylinder head (see Cylinder Head -
Removal, page 134).

120 Thruxton R
 Cylinder Head

Note: Camshaft Drive Chain Rubbing Blade

• Note the position of the camshaft drive chain - Inspection
rubbing blade upper mounting for installation.
1. Inspect the camshaft drive chain blades for
3. Lift the camshaft drive chain tensioner wear or damage. Renew as necessary.
rubbing blade out of the crankcase.

cftg

1. Camshaft drive chain tensioner rubbing blade

2. Mounting lugs

Thruxton R 121
Cylinder Head

Camshaft Drive Chain Rubbing Blade Exhaust Decompressors

- Installation Note:
1. Refit the camshaft drive chain rubbing blade. • The de-compressor is an integral part of the
Ensure the lower mounting tip is correctly camshaft. Any internal parts are not
located in the upper crankcase and the lugs serviceable and can only be replaced as part
are located in the barrel as noted during of the camshaft. Always refer to the EPC for
removal. parts availability.
2. Refit the cylinder head (see Cylinder Head -
Installation, page 135).
3. Refit the camshafts (see Camshaft -
Installation, page 129).
4. Refit the camshaft cover (see Camshaft Cover
- Installation, page 103).
• Refit the engine (see Engine - Installation, page
265).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

122 Thruxton R
 Cylinder Head

Camshaft - Removal 3. Insert the service tool T3880650 into the

camshaft slot. Ensure that the tool is centrally
located on the cylinder head and secure as
Warning shown below.
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help 2
prevent it from falling and causing injury to the
operator or damage to the motorcycle. 3

Note: 3
• The camshaft can be removed from the
cylinder head without complete removal of the
camshaft drive chain. However, the camshaft
drive chain must first be detached from the
camshaft.
• Remove the ignition coils (see Ignition Coils - 1
Removal, page 687).
• Remove the immobiliser/TPMS module (see cizt

Immobiliser/TPMS Control Module - Removal, 1. Camshaft slot

page 404). 2. T3880650 - Camshaft Timing Plate
• Remove the camshaft cover (see Camshaft
3. Fixings (6 x 12 mm)
Cover - Removal, page 102).
• Remove the alternator cover (see Alternator 4. Remove the camshaft drive chain tensioner
Cover - Removal, page 99). (see Camshaft Drive Chain Tensioner -
Removal, page 111).
1. Rotate the engine until service tool T3880601
can be inserted through the hole in the
alternator rotor, crankcase and into the idler Caution
gear.
To avoid damage to the camshaft frames, always
ensure as many camshaft lobes as possible are
facing downwards. This will reduce stress on the
camshaft frames during removal. Damage to the
2
camshaft frames will result in replacement of the
complete cylinder head.
1
Note:
• The camshaft frames can be removed either
sequentially or simultaneously.

civb

1. T3880601 - Camshaft Timing Pin

2. Timing hole in alternator rotor

2. In addition to the alignment mark, at TDC, the

offset slot on the camshaft will align with the
upper surface of the cylinder head.
Note:
• The service tool T3880650 has two different
thickness edges marked A and B. If side A will
not slide smoothly into the camshaft slot side
use side B.

Thruxton R 123
Cylinder Head

5. Evenly and progressively release the camshaft 9. Raise the camshaft slightly from the bearing
frame fixings in the sequence shown below. journals, and remove the camshaft drive chain
1 3 tensioner blade.
3 1

4
4 2 2
3
cjah

cizr
2
Camshaft Frame Release Sequence
1. Tensioner guide

Caution 2. Bearing journal

3. Camshaft
Failure to release the camshaft frame fixings
progressively and evenly may result in damage to 10. Detach the camshaft drive chain from the
the camshaft frame, the camshaft or the cylinder camshaft.
head itself. A damaged camshaft frame cannot be 11. Slide the camshaft to the right and remove it
replaced as an individual item. It can only be from the cylinder head.
obtained as part of a new cylinder head.

6. Once all of the upward force on the camshaft 2 3

frames has been released, collect the bolts.

Caution
The camshaft frames are located to the cylinder
head with dowels. When removing the camshaft
frames collect the dowels at the same time. Failure
to collect the dowels could cause them to fall into
the crankcase and may cause serious damage to
the engine.
1
7. Remove the camshaft frames. cjak

8. Release the front camshaft timing chain 1. Inlet camshaft

tensioner blade and discard the fixings.
2. Camshaft drive chain

12. Secure the camshaft drive chain to prevent it

from falling into the crankcase.

124 Thruxton R
 Cylinder Head

Camshaft - Identification Camshaft - Inspection

The single camshaft has four lobes two inlet and 1. Inspect the camshaft sprocket for damage and
two exhaust. The exhaust lobes contain worn or broken teeth.
decompressors, operated by the drive gear.
2. Inspect the bearing surfaces in the cylinder
head and camshaft frame. If wear or damage is
found, the cylinder head and the camshaft
frames must be replaced.
3. Inspect the camshaft drive chain (see
Camshaft Chain - Inspection, page 117).
Note:
• Inspect the decompressor for damaged or
missing flyweights, worn or broken springs.
Carefully inspect the pins on the
decompressor for damage or wear.
1. Check camshaft journal to camshaft frame
clearance using Plastigauge (Triumph part
cizp
number 3880150-T0301) as follows:
• Position the camshaft to the cylinder head
Camshaft
in its correct location. Ensure that the
camshaft sprocket is positioned as for
removal.
• Wipe the exposed areas of one of the
camshaft journals and the corresponding
position on the camshaft frame.
• Apply a thin smear of grease to the
camshaft journal and a small quantity of
silicone release agent to the corresponding
position on the camshaft frame.
• Size a piece of Plastigauge to fit across the
camshaft journal.
• Fit the Plastigauge to the camshaft journal
using the grease to hold it in place.
• Position the camshaft frames.
• Fit the rocker shafts to the camshaft
frames, at this stage, it is not necessary to
fit the rocker arms.
• Finger-tighten the camshaft frame bolts
until the under head areas are in contact
with the camshaft frame.

Thruxton R 125
Cylinder Head

• In the sequence shown below, progressively 4. Check the diameter of the camshaft journals,
tighten the camshaft frame bolts, until the (for specifications refer to Camshafts, page 38).
camshaft frames are in full contact with the 5. If any of the journal to camshaft frame
cylinder head. Tighten the bolts to 10 Nm. clearances are outside the specified
1 3 tolerances, but the camshaft journals are
3 1 within their specified tolerances, the cylinder
head must be replaced.

4
4 2 2
cjah

Camshaft Frame Tightening Sequence

• Release and remove the camshaft frame as
previously described.
• Utilising the gauge provided with the
Plastigauge kit, measure the width of the
now compressed Plastigauge.

cbqg_1

Plastigauge Measurement

2. Calculate the camshaft journal clearance using

the chart provided with the Plastigauge kit.
3. If the journal to camshaft frame clearance is
within the specified tolerances (for
specifications refer to Camshafts, page 38),
remove the camshaft frame and clean off all
traces of Plastigauge, silicone release agent
and grease.

126 Thruxton R
 Cylinder Head

Valve Clearance Valve Clearance Adjustment

Camshaft, valve, valve shim and valve seat wear
affect the valve clearances. The effect of this wear
is to change the clearance between the rocker and
Warning
the adjustment shim, causing engine noise and/or Before starting work, ensure the motorcycle is
improper running. If the valve clearances are stabilised and adequately supported. This will help
incorrect, permanent damage to components in the prevent it from falling and causing injury to the
valve-train will take place and engine performance operator or damage to the motorcycle.
will be affected.
Note: Note:
• Valve clearance adjustment must be carried • Valve clearance checking and adjustment
out with the engine cold. must be carried out with the engine cold.
• When replacing a valve shim, always refer to
1. Remove the camshaft cover (see Camshaft
the EPC.
Cover - Removal, page 102).
• For valve clearance specifications (see Cylinder
Note:
Head and Valves, page 37).
• Removing the spark plugs reduces
compression therefore allowing the engine to
be rotated freely.
2. Remove the spark plugs.
3. Select a high gear and, using the rear wheel,
rotate the engine until a camshaft lobe is
positioned pointing directly away from the
roller on the rocker shaft.
4. Using feeler gauges, measure and record the
clearances for this pair of valves only.

1. Feeler gauges

5. Measure and record all valve clearances as

described previously.

Thruxton R 127
Cylinder Head

6. Remove the rocker shaft and rocker arm of a Note:

valve that requires adjustment.
• Shims are available ranging from 2.00 mm to
3.20 mm in increments of 0.025 mm.
3 10. Fit the selected shim to the valve.
11. Refit the rocker arm and shaft, tighten the
bolts in the sequence shown to 10Nm.

3
1
2

2
ciaa
1
1. Rocker shaft
2. Rocker arm
3. Shims (cylinder 1 inlet shown)
4. Camshaft ciaa

Note: Rocker Shaft Tightening Sequence

• The underside of the shim displays the shim 12. Repeat the procedure until all valves requiring
size. adjustment have been correctly set.
• Always place the shim with the shim size 13. Rotate the engine several times to fully seat
facing towards the valve. the shims.
7. Remove the shim from the valve(s) that 14. Repeat the clearance checks on all valves,
requires adjustment. adjust as necessary.
15. Refit the camshaft cover (see Camshaft Cover
- Installation, page 103).
2.40
• Refit the fuel tank (see Fuel Tank - Installation,
1 page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
2
• Refit the seat (see Seat - Installation, page 636).

1
cizw_1

1. Shim
2. Valve

8. Measure the original shim, using a micrometer.

9. Calculate the shim thickness required to give
the correct clearance, for specifications refer
to Cylinder Head and Valves, page 37.
• Clearance too small - Fit a thinner shim.
• Clearance too large - Fit a thicker shim.

128 Thruxton R
 Cylinder Head

Camshaft - Installation 6. Lift the camshaft slightly from the bearing

journals, refit the camshaft drive chain
tensioner blade. Tighten the new fixings to 10
Warning Nm.
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.

Accurate camshaft timing can only be obtained

using the correct timing method and service tools
as described below. 1

Caution
The camshaft sprockets are attached to the
camshafts using slotted fixing holes. This allows 3
for very accurate valve timing and therefore 2
cizr
improved performance and fuel economy.
1. Tensioner blade
Never fit the camshaft sprockets without correctly
setting the camshaft timing using the service 2. Bearing journal
tools and timing procedure described below. 3. Camshaft
Severe engine damage will result from incorrect
valve timing adjustment. Note:
• It is not necessary to fit the rocker arms at
1. If not already installed, install the service tool this stage.
T3880601.
7. Temporarily secure number two cylinder
2. Thoroughly clean the camshaft and journals. camshaft ladder to the cylinder head with a
Lubricate the camshaft with clean engine oil rocker shaft and one fixing,
before fitting to the cylinder head.
Note:
• Ensure the sprocket fixings are centrally
located within the slotted holes of the
sprocket.
• DO NOT tighten the fixings at this stage; the
sprocket must be free to rotate.
3. If removed, refit the camshaft sprocket noting
its orientation, and secure using the original 1
fixings.
4. Locate the camshaft to the cylinder head from
the right hand side, hooking the camshaft
drive chain over the sprocket.
2 3
5. Align the slot in the camshaft end to the upper cizs

surface of the cylinder head. 1. Camshaft slot

2. Cylinder head
3. Camshaft ladder (cylinder two)

8. Adjust the camshaft sprocket, so that the

camshaft chain is taut on the inlet side (rear)
of the engine.

Thruxton R 129
Cylinder Head

9. Ensure there is no slack in the chain between 12. Fit the service tool T3880651 and tighten to 16
the crankshaft and the sprocket and the Nm.
sprocket fixings are centrally located within
the slotted holes.
1
2

cizu

1. T3880651 - Timing Chain Tensioner

cizv

1. Camshaft slot
2. Fixing (one of two on camshaft sprocket)
Caution
The torque value stated is very important to
Note: accurate timing. Always use the correct value of
• The service tool T3880650 has two different 0.6 Nm, as set using T3880609 - Timing Torque
thickness edges marked A and B. If side A will Limiter. Using an incorrect torque value will result
not slide smoothly into the camshaft slot side in incorrect valve timing being set, or damage to
use side B. the tensioner blade or other valve train
components. Either condition may result in serious
10. Insert the service tool T3880650 into the
damage to the engine, reduced engine
camshaft slot. Ensure that the tool is centrally
performance, or reduced fuel economy.
located on the cylinder head and secure as
shown below.
Note:
• The T3880609 - Timing Torque Limiter is pre-
2
set to 0.6 Nm.
3 13. Using the service tool T3880609, tighten the
internal screw thread to 0.6 Nm
3
1

3
1
2
cizt

1. T3880650 - Camshaft Timing Plate

2. Camshaft
3. Fixings (6 x 12 mm)

11. Check that the camshaft drive chain is cizu

engaged around the idler gear and the

camshaft sprocket is positioned against the 1. T3880651 - Timing Chain Tensioner
tensioner blade. 2. Adaptor
3. T3880609 - Timing Torque Limiter

130 Thruxton R
 Cylinder Head

14. Remove and discard the accessible camshaft 23. Insert the service tool T3880601 into the
sprocket fixing. Install a new encapsulated timing holes in the crankcase and crankshaft.
fixing and tighten to 22 Nm.
15. Remove the service tool T3880601.

Caution 2

Always check that the service tool T3880650 has 1

been removed before rotating the engine. Severe
damage will result to the camshafts or service tool
T3880650 if engine rotation is attempted with the
tool installed.

16. Rotate the engine until the remaining sprocket

fixing is accessible.
17. Refit the service tool T3880601.
civb

18. Remove and discard the remaining camshaft

1. T3880601 - Camshaft Timing Pin
sprocket fixing. Install a new encapsulated
fixing and tighten to 22 Nm. 2. Timing hole in alternator rotor

19. Remove service tool T3880601. Note:

Note: • The service tool T3880650 has two different
• With the aid of an assistant, hold the thickness edges marked A and B. If side A will
camshaft drive chain taut during removal of not slide smoothly into the camshaft slot side
the service tool T3880651. use side B.

20. Release the tension on the service tool 24. Check that the service tool T3880650 fits into
T3880651. the camshaft slot (to check that the camshaft
timing has not moved during the removal of
21. Refit the timing chain tensioner, incorporating the service tool T3880651.
two new O-rings (see Camshaft Drive
Tensioner - Installation, page 113). 25. Lubricate the camshaft bearing areas of the
camshaft frame with a 50/50 solution of
22. To activate the tensioner, rotate the engine oil and molybdenum disulphide grease.
crankshaft anti-clockwise two complete turns,
using the fixing fitted to the end of the 26. Fit the shims to the valves as noted during
crankshaft. Stop rotation when number 1 removal.
cylinder is at top dead centre (TDC).
Note:
• Before inserting the timing pin, ensure the
slot on the camshaft is aligned with the upper
surface of the cylinder head.

Thruxton R 131
Cylinder Head

27. Position cylinder one camshaft frame to the 33. Finger-tighten the fixings until the under head
cylinder head. areas are in contact with the camshaft frame.
1
5 3

1
2 3

6
2
cizw cjab

1. Camshaft ladder (cylinder 2) 1. Fixings (inlet rocker shaft)

2. Camshaft ladder (cylinder 1 2. Fixings (exhaust rocker shaft)
3. Shims (cylinder 2 inlet) 3. Dot mark
4. Shims (cylinder1 inlet) 34. Remove the fixing and rocker shaft from
5. Shims (cylinder 2 exhaust) cylinder number two camshaft frame.
6. Shims (cylinder 1 exhaust) 35. Lubricate the threads of the camshaft frame
fixings with clean engine oil.
28. Remove the service tool T3880650.
Note:
29. Remove the service tool T3880601.
• The rocker shaft must be fitted with the dot
30. Lubricate the threads of the camshaft frame
marks facing upwards and toward the
fixings with clean engine oil.
camshaft drive gear.
31. Fit the rocker shafts with the dot marks facing
upwards and toward the camshaft drive gear. 36. Fit the inlet and exhaust rockers and shafts to
cylinder number two. Do not fully tighten at
32. Fit the inlet and exhaust rocker shafts to this stage.
cylinder number one as shown below. Do not
fully tighten at this stage.

1
2 2

cizz

1. Dot mark
2. Rocker shaft

37. Finger tighten the fixings until the rocker

shafts are in contact with the camshaft frame.

132 Thruxton R
 Cylinder Head

Caution Caution
To avoid damage to the camshaft frame, always If any components have been renewed, the valve
ensure as many camshaft lobes as possible are clearances must be checked and adjusted.
facing away from the rocker shaft. This will reduce Running with incorrectly adjusted valve
stress on the camshaft frame during assembly. clearances may cause excess engine noise, rough
Damage to the camshaft frame will result in running and engine damage.
replacement of the cylinder head.
39. Check all of the valve clearances and adjust as
38. In the sequence shown below, necessary until the correct clearances are
• Tighten cylinder one camshaft frame achieved (see Valve Clearance Adjustment,
fixings, until the camshaft frames are in full page 127).
contact with the cylinder head. Tighten the • Refit the alternator cover (see Alternator Cover
fixings to 10 Nm. - Installation, page 101).
3 • Refit the camshaft cover (see Camshaft Cover -
1 Installation, page 103).
• Refit the immobiliser/TPMS module (see
Immobiliser/TPMS Control Module - Installation,
page 405).
• Refit the ignition coils (see Ignition Coils -
Installation, page 689).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
4 • Refit the seat (see Seat - Installation, page 636).
2
cjah

Cylinder One Camshaft Frame Tightening Sequence

• Tighten cylinder two camshaft frame
fixings, until the camshaft frames are in full
contact with the cylinder head. Tighten the
fixings to 10 Nm.
1
3

4 2
cjah

Cylinder Two Camshaft Frame Tightening Sequence

Thruxton R 133
Cylinder Head

Cylinder Head - Removal 5. Remove and discard the cylinder head gasket.
6. Using service tool T3880308 and two of the
Warning cylinder head bolts, hold the cylinder barrel in
position.
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 1
operator or damage to the motorcycle.
1
• Remove the engine (see Engine - Removal, page
261).
• Remove the camshaft cover (see Camshaft
Cover - Removal, page 102).
• Remove the camshaft (see Camshaft - Removal,
page 123).
1. Noting their position and the thickness of the
shims, remove all eight shims from the cylinder
head.
cizn

2. Progressively release the cylinder head bolts in

1. Cylinder head bolts
the order shown below.
2. T3880308 - Cylinder Barrel Clamps

3 1
5 7

6 8
2 4

cjam

Cylinder Head Bolt Release Sequence

3. Remove the cylinder head bolts, retain the

washers.
Note:
• If necessary, lightly tap the cylinder head with
a soft-faced mallet to break the gasket seal.
4. Remove the cylinder head from the crankcase.

134 Thruxton R
 Cylinder Head

Cylinder Head - Inspection Cylinder Head - Installation

1. Thoroughly clean the surface of the cylinder 1. Thoroughly clean the upper faces of the
head and check for damage and/or pitting of cylinder barrel.
the combustion chambers. 2. Refit the camshaft drive chain rubbing blade
2. Using a straight edge and feeler gauges, check (see Camshaft Drive Chain Rubbing Blade -
the cylinder head gasket face for warp, which Installation, page 122).
could lead to gasket failure. Replace the 3. Ensure that both cylinder head dowels are
cylinder head if warped beyond the flatness correctly located in the cylinder barrel.
limit.
4. Position a new cylinder head gasket to the
cylinder barrel, ensuring the gasket is fitted
1 with the lettering uppermost and to the rear
2
of the engine.

3
cizq

1. Cylinder head
2. Straight edge
cjan
3. Feeler gauges
1. Head gasket markings
3. For specifications refer to Cylinder Head and
Valves, page 37. 5. Position the cylinder head over the camshaft
4. Inspect the valve guides for damage or wear. drive chain rubbing blade and locate it onto
the dowels.
5. If a valve guide is found to be worn beyond the
service limit, the complete cylinder head must
be renewed. Caution
6. For specifications refer to Cylinder Head and Cylinder head bolts are re-usable.
Valves, page 37.
If for any reason a cylinder head bolt is lost or
7. Check the camshaft drive chain rubbing blades. deemed unusable the cylinder head bolts must be
Renew if worn or damaged. replaced as a set.
Failure to follow the correct tightening procedure
Caution or reuse of a single replacement cylinder head bolt
may lead to engine damage and premature failure
Ensure all traces of fluid (coolant, oil etc.) are of the cylinder head gasket.
removed from the threaded holes in the
crankcase. Should any fluid remain in any of the
6. Position the washers onto the new cylinder
threaded holes, severe crankcase damage could
head bolts and lubricate the bolt threads with
result from hydraulic locking of head bolts on
clean engine oil.
assembly of the engine.

Thruxton R 135
Cylinder Head

Start the engine and allow it to idle while checking

Caution for air, oil, coolant and exhaust leaks.
Rectify as necessary.
Use the correct procedure to tighten the cylinder
head bolts carefully following the four-stage
procedure below. This will ensure the long-term
reliability of the cylinder head gasket.
Failure to follow the correct tightening procedure
may lead to engine damage and premature failure
of the cylinder head gasket.

7. In the following sequence, tighten the cylinder

head bolts in four stages as follows:
• Tighten the bolts to 20 Nm.
• Tighten the bolts to 30 Nm.
• Tighten the bolts through a further 150°
using service tool 3880160-T0301 or similar
to measure the torque-angle.
• Tighten the bolts a further 60 Nm.

3 1
5 7

6 8
2 4

cjam

Tightening Sequence

8. Lubricate the valve shims with a 50/50

solution of molybdenum disulphide grease and
engine oil, then refit them to their original
locations in the cylinder head.
• Refit the camshaft (see Camshaft - Installation,
page 129).
• Check and adjust the valve clearances (see
Valve Clearance Adjustment, page 127).
• Refit the camshaft cover (see Camshaft Cover -
Installation, page 103).
• Refit the engine (see Engine - Installation, page
265).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

136 Thruxton R
 Cylinder Head

Valves and Valve Stem Seals - Note:

Removal • Ensure the inlet and exhaust valve
components do not become mixed.
1. Remove each valve from the head using a
valve spring compressor. The compressor must
act on the valve spring retainer to allow
removal of the valve collets.
1
2

4
5

ccrx 6
1. Collets
2. Valve spring retainer
3. Valve spring
Valve removal
4. Valve spring base
2. Once the collets are released, remove the 5. Valve stem oil seal
following items:
6. Valve
• Valve spring retainer
• Valve spring
• Valve spring base
• Valve stem oil seal
• Valve (deburr before removal).

carr

1. Valve stem seal

Thruxton R 137
Cylinder Head

Valves and Valve Stem Seals -

Caution
Installation
the engine is running allowing the valves to
1. Lubricate the valve stems with a 50/50
contact the pistons. Any such valve to piston
solution of engine oil and molybdenum
contact will cause severe engine damage.
disulphide grease.
2. Install the valve into the valve guide and refit
Valve Face Inspection
the spring base to the valve spring recess in
the head. Remove any carbon build-up from the valve head
area. Examine the valve seat face, checking in
3. Fit the valve stem seal over the valve stem particular for signs of cracking or pitting.
and, using a suitable tool, press down fully
until the seal is correctly seated over the valve Valve Stems
guide.
If a valve stem is found to be worn beyond the
Note: service limit, the valve must be renewed.
• During fitment of the valve stem seal, two Refer to Cylinder Head and Valves, page 37.
distinctly different degrees of resistance will
be noted when the seal is correctly fitted.
• Firstly, press the seal down the valve stem
until the lower side of the seal comes into
contact with the valve guide. Greater
resistance is felt at this contact point and
further gentle pressure is then required to
locate the seal over the top end of the valve
guide.
• On application of this pressure, the seal can be
felt to positively locate over the top face of
the valve guide. Once correctly positioned, the
seal cannot be pushed down any further.

Caution
Incorrect fitment of the valve stem oil seals could
lead to high oil consumption and blue smoke
emissions from the exhaust system. Do not use
excessive force in fitting the seal as this may
break the seal ring.

1. Install the valve spring over the valve stem.

Ensure the close wound, colour coded ends of
the springs are fitted downwards (towards the
piston).
2. Fit the valve spring retainer.
3. Compress the valve spring ensuring that the
spring is compressed squarely to prevent
damage to the valve stem and cylinder head.
4. Fit the valve collets ensuring correct collet
location in the spring retainer and valve as the
spring compressor is released.

Caution
Always check for correct location of the valve
collets during and after assembly. If not fitted
correctly, the collets may become dislodged when

138 Thruxton R
 10 Barrels And Pistons
Table of Contents
Exploded View - Barrels and Pistons.................................................................................................................................................. 141
Barrels - Removal......................................................................................................................................................................................... 142
Barrels - Inspection..................................................................................................................................................................................... 143
Barrels - Installation................................................................................................................................................................................... 143
Piston Rings - Removal............................................................................................................................................................................. 145
Piston Ring to Groove - Clearance ...................................................................................................................................................... 145
Piston Ring - End Gap ............................................................................................................................................................................... 146
Piston Rings - Assembly........................................................................................................................................................................... 146
Piston - Removal .......................................................................................................................................................................................... 147
Piston - Wear Check ................................................................................................................................................................................... 148
Piston - Installation..................................................................................................................................................................................... 149

Thruxton R 139
Barrels And Pistons

140 Thruxton R
 Barrels And Pistons

Exploded View - Barrels and Pistons

Thruxton R 141
Barrels And Pistons

Barrels - Removal 3. Lift off the barrels and recover the locating
dowels.

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.

• Remove the engine (see Engine - Removal, page

261).
• Remove the alternator cover (see Alternator
Cover - Removal, page 99).
• Remove the camshaft cover (see page Camshaft
Cover - Removal, page 102).
• Remove the cylinder head (see Cylinder Head - ciyg 1
Removal, page 134).
1. Locating dowels
1. Clean the area around the barrel base gasket
joint to prevent dirt falling into the crankcase 4. Remove and discard the base gasket.
when the barrels are removed.
2. Ensure the pistons are level with each other
then break the seal of the base gasket joint.

Caution
Do not strike or lever against the barrel cooling
fins to break the seal as the fins are easily
damaged.

Note:
• Secure the cam chain to ensure that it does
not fall into the crankcase during removal of
the barrels.

Caution
Support the pistons as the barrels are removed to
prevent piston damage.

142 Thruxton R
 Barrels And Pistons

Barrels - Inspection Barrels - Installation

1. The cylinder barrels are not measurable in 1. Thoroughly clean the mating surfaces of the
service, (see Piston, page 41). crankcase and barrels taking care not to
damage the mating surfaces.
2. Fit a new base gasket and refit the locating
dowels as noted during removal.
3. Using suitable spacers to support the pistons
whilst preventing contact with the crankcase,
rotate the crankshaft to position the pistons
level with each other.

1200 cc 10mm 900 cc 12.5mm

2
150mm 150mm
25mm 25mm
ciyu

1. Pistons
2. Spacer
3. Crankcase

Caution
Do not allow the pistons to fall against the
crankcase when turning the engine. Piston and/or
crankcase damage could occur if the pistons are
not supported while turning the engine.

4. Ensure the piston ring end gaps are correctly

positioned (see Piston Rings - Assembly, page
146).
Note:
• Ensure the barrels and pistons are clean prior
to installation.
5. Lubricate the piston rings and the cylinder
bores with clean engine oil.

Caution
Do not allow the full weight of the barrels to rest
unsupported on the pistons. Failure to support the
barrels is likely to result in piston ring breakage.

Thruxton R 143
Barrels And Pistons

10. Recheck the tensioner plunger location against

Caution the camshaft drive chain tensioner blade.

Do not force the pistons into their bores. The base 11. Remove service tool T3880039 from the
of each bore is chamfered to ease installation and crankcase.
excess force should not be needed. If either piston • Refit the alternator stator (see Alternator Rotor
jams, lift the barrels slightly and check the rings - Installation, page 693).
are correctly located into their grooves before • Refit the alternator cover to the engine (see
continuing. The use of force is likely to result in Alternator Cover - Installation, page 101).
piston ring breakage. • Refit the camshaft cover (see Camshaft Cover -
Installation, page 103).
6. With the aid of an assistant, ease the barrels • Refit the engine (see Engine - Installation, page
carefully over the pistons whilst guiding the 265).
piston rings into the base of the cylinder • Refit the fuel tank (see Fuel Tank - Installation,
bores. page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

3
1
ciyv

1. Piston
2. Barrel
3. Spacer

7. Slide the barrels fully down, remove the

spacers and locate on the dowels.
8. Refit the cylinder head (see Cylinder Head -
Installation, page 135).
9. Refit the camshafts (see page Camshaft -
Installation, page 129).

144 Thruxton R
 Barrels And Pistons

Piston Rings - Removal Piston Ring to Groove - Clearance

1. Ease the top compression ring out of its Note:
groove and remove it from the top of the
• Prior to removing the rings, check the ring-to-
piston.
groove clearance of each compression ring.

Caution 1. With the piston rings correctly installed on the

piston, check the ring-to-groove clearance of
Do not expand the piston rings any more than is each compression ring, using a feeler gauge.
necessary to allow them to be removed from the
piston. The rings are brittle and will break if
expanded too much.

2. Remove the second compression ring in the

same way.
Note:
• The top and second compression rings are
different and are not interchangeable (see
Piston Rings - Assembly, page 146).
• Piston rings must be removed from the piston
using hand pressure only. Do not overextend
the piston rings during removal.
• If the piston rings are to be reused, note the capg

orientation of the oil control rings prior to

removal. Piston Ring-to-Groove Clearance Check

3. Remove the oil control rings and expanders. 2. When checking the piston ring to groove
clearance, always refer to the specifications
Note: table (see Piston, page 41).
• If the piston rings are to be re-used, keep Note:
them with their respective piston to ensure
they are refitted in their original locations. • If the ring-to-groove clearance is too large,
replace the piston rings with a new set.
• If the gap remains too large with new piston
rings, the piston must also be replaced.
• If the gap is too small, check the piston ring
grooves closely for distortion, replacing the
piston as necessary. Do not file the ring
grooves.

Thruxton R 145
Barrels And Pistons

Piston Ring - End Gap Piston Rings - Assembly

1. Check each piston ring end gap as follows. 1. Ensure the piston ring grooves are clean.
Note: Note:
• The piston ring end gap must be measured in • Ensure all piston rings are fitted in their
the cylinder bore to which the piston ring will original locations (if original rings are being
be fitted to on installation. reused) or to the piston/bore which the end
• Ensure all piston rings are fitted in their gaps were checked (if new rings are being
original locations (if original rings are being fitted).
reused) or to the piston/bore which the end
gaps were checked (if new rings are being
installed).
Caution
• Position the piston ring into the top of the Do not expand the piston rings any more than is
cylinder bore. necessary to allow them to be installed on the
• Using the piston crown, push the piston piston. The rings are brittle and will break if
ring down into the bore (the piston will keep expanded too much.
the piston ring square) until the third
groove of the piston is level with the top of 2. Fit the oil control ring expander to the piston
the bore. then install the upper and lower control rings
• Remove the piston and measure the gap (the oil control rings are both the same and
between the ends of the piston ring, using a can be fitted either way up).
feeler gauge. 3. Fit the second compression ring carefully to
the piston, ensuring its 2T mark is facing
upwards.
4. Fit the top compression ring to the piston
ensuring its 1T mark is facing upwards.
Note:
1 • Ensure the second and top compression rings
are correctly installed.
• The second and top compression rings are
different and are not interchangeable.
• The top ring can be identified by the chamfer
on its upper inside edge.
• The second ring has no chamfer.

T908.04.03

1. Checking piston ring end gap

2. When checking the piston ring end gap, always

refer to the specifications table (see Piston,
page 41).
Note:
• If the end gap is too large, replace the piston
rings with a new set.
• If the gap remains too large with new piston
rings, both the pistons and barrels must be
replaced.
• If the gap is too small, check the cylinder bore
for distortion, replacing as necessary.
• Do not file the piston rings. Piston Ring Identification
3. Repeat the procedure for the remaining piston
rings.

146 Thruxton R
 Barrels And Pistons

5. Ensure all piston rings move freely in their Piston - Removal

grooves.
6. Position the piston ring end gaps as follows
(piston viewed from above, triangular mark
Warning
facing forwards). Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
1 operator or damage to the motorcycle.
2
• Remove the cylinder barrel (see Barrels -
1 3
3 3 Removal, page 142).
4 Note:
5
• If both pistons are being removed, mark each
piston to ensure it is refitted in its original
location.
4 1. Remove and discard the gudgeon pin circlip
from one side of the piston.
caqj
2 5
Caution
Piston Ring End Gap Locations
1. Top ring If a circlip is dropped into the crankcase, it must
be recovered before the crankshaft is rotated.
2. Second ring Failure to do so will result in serious engine
3. First steel oil control ring damage.
4. Oil control ring expander
5. Second steel oil control ring

Note:
• The top compression ring gap should be in the
12 o'clock position.
• The second compression ring gap should be in
the 6 o'clock position.
• The first oil control ring gap should be in the
12 o'clock position. 1
• The second oil control ring gap should be in
the 6 o'clock position.
• The oil control ring expander gap should be in
the 7 o'clock position.

T908_6

1. Circlip

2. Remove the gudgeon pin by pushing the pin

through the piston and connecting rod toward
the side from which the circlip was removed.

Caution
Never force the gudgeon pin through the piston.
This may cause damage to the piston which may
also damage the cylinder barrel when assembled.

Thruxton R 147
Barrels And Pistons

Note: Piston - Wear Check

• If the gudgeon pin is found to be tight in the 1. Remove any carbon build-up from the piston
piston, check the piston for a witness mark crown. Inspect the piston crown for signs of
caused by the circlip. Carefully remove the pitting and check the piston skirt and ring
mark to allow the pin to be removed. grooves for signs of wear or scuffing. If any
3. Remove the remaining circlip from the piston sign of damage is found, renew the piston.
and discard it. 2. Measure the piston outside diameter 10 mm
4. Remove the piston rings. +/- 3 mm from the bottom of the piston and at
90° to the direction of the gudgeon pin.
Note:
• The rings may be removed using a proprietary
piston ring expander tool or, if a tool is not
available, carefully spread the ring opening
using thumb pressure then push up on the
opposite side of the ring to remove it from the
piston.

1
1. Piston outside diameter
2. Measurement point

3. Always refer to the specifications table (see

Piston, page 41).
4. Replace the piston and rings if outside the
specified limit.

148 Thruxton R
 Barrels And Pistons

Piston - Installation 4. Insert the gudgeon pin into the piston and
push it fully into position.
1. Fit a new circlip to the inside of the piston.
Ensure the circlip is correctly located in the
1
piston groove.

Warning
Failure to use new gudgeon pin circlips could allow
the pin to detach from the piston. This could seize
the engine resulting in loss of motorcycle control
and an accident.

1
T908_7

Gudgeon Pin

5. Secure the gudgeon pin in position with the

remaining new circlip. Ensure the circlip is
correctly located in the piston groove.

Caution
If a circlip is dropped into the crankcase, it must
caxu be recovered before the crankshaft is rotated.
Failure to do so will result in serious engine
1. Circlip Fitment damage.
2. Lubricate the connecting rod small-end and
gudgeon pin with clean engine oil.
3. Align the piston with the connecting rod,
ensuring the triangular mark on the piston
crown is facing towards the front of the
engine.
Note:
• If the original pistons are being refitted,
ensure they are fitted in their original 1
locations.

T908_6

1. Circlip

Thruxton R 149
Barrels And Pistons

Caution
Do not allow the pistons to fall against the
crankcase when turning the engine. Piston and/or
crankcase damage could occur if the pistons are
not supported while turning the engine.

6. Install the remaining piston.

• Refit the barrels (see Barrels - Installation, page
143).
• Refit the cylinder head (see Cylinder Head -
Installation, page 135).
• Refit the alternator stator (see Alternator Rotor
- Installation, page 693).
• Refit the alternator cover to the engine (see
Alternator Cover - Installation, page 101).
• Refit the camshaft cover (see Camshaft Cover -
Installation, page 103).
• Refit the engine (see Engine - Installation, page
265).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

150 Thruxton R
 11 Clutch
Table of Contents
Exploded View – Clutch Controls........................................................................................................................................................... 153
Exploded View – Clutch............................................................................................................................................................................. 154
Clutch Cable - Removal............................................................................................................................................................................... 155
Clutch Cable - Inspection.......................................................................................................................................................................... 156
Clutch Cable - Installation ......................................................................................................................................................................... 157
Clutch - Removal .......................................................................................................................................................................................... 158
Friction Plate Inspection........................................................................................................................................................................... 159
Steel Plate Inspection ................................................................................................................................................................................ 160
Clutch Pack - Height................................................................................................................................................................................... 160
Clutch - Installation..................................................................................................................................................................................... 162

Thruxton R 151
Clutch

152 Thruxton R
 Clutch

Exploded View – Clutch Controls

See Text
12 Nm

3.5 Nm

2.5 Nm

Thruxton R 153
Clutch

Exploded View – Clutch

10 Nm

98 Nm

154 Thruxton R
 Clutch

Clutch Cable - Removal 3. Detach the inner clutch cable from the boss on
the clutch actuating arm.

Warning
Before starting work, ensure the motorcycle is
1
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. From the left hand side of the headstock,

remove the cable retaining bracket and discard 2
it’s fixings.

cixi

2 1. Clutch cable
2. Boss

4. Disconnect the cable retaining guides from the

frame down tube.
5. Align the slots in the lever adjuster and lock
nut.

1
2
ciwq

1. Clutch cable
2. Fixings

2. Loosen the cable lock nut, release the adjuster

nut adjacent to the clutch cover to allow
maximum play in the cable.

1
3 1
2
cinn

1. Lock nut
2. Lever adjuster

ciwp

1. Clutch cable
2. Adjuster nut
3. Lock nut

Thruxton R 155
Clutch

6. Pull in the clutch lever and turn the inner Clutch Cable - Inspection
cable adjuster anti-clockwise through the lock
nut, until the cable can be detached from the 1. Check the inner cable for free movement
lever. through the outer cable.
2. Examine the inner cable for frayed strands.
1 3. Examine the two inner cable nipples for signs
of looseness and damage. Replace the cable if
necessary.

gaau_1

1. Cable adjuster/lever bracket slots

2. Cable release point

Note:
• To ensure the same route can be followed on
installation, tie a length of string to one end
while pulling the cable through from the other.
When installing the new cable, tie the string
to one end of the cable and use it to guide the
new cable into position.
7. Noting the cable routing, remove the cable
from the motorcycle

156 Thruxton R
 Clutch

Clutch Cable - Installation 9. Tighten the clutch adjuster bracket lock nut at
the clutch cover end to 3 Nm.

Warning 10. Set the final adjustment of the cable to give 1 -

2 mm of free play at the lever by turning the
Before starting work, ensure the motorcycle is adjuster nut and lock nut at the lever end.
stabilised and adequately supported. This will help Secure the setting with the knurled lock nut.
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Position the cable to the motorcycle following

the same routing as noted during removal.
2. Attach the inner cable to the boss on the
clutch actuating arm using a reversal of the
removal process.
2
3. Refit the outer cable to the adjuster bracket at
the clutch cover end.

1
3 1 cinn
2
1. Clutch lever
2. Correct setting, 1 - 2 mm

ciwp

1. Clutch cable
2. Adjuster nut
3. Lock nut

4. Refit the cable retaining guides to the frame

down tube.
5. Refit the cable retaining bracket to the frame
and using new fixings tighten to 1.5 Nm.
6. Set the lever adjuster to a point where an
equal adjustment is possible in both directions.
7. Set the adjuster bracket at the clutch cover
end to give a preliminary setting of 2 - 3 mm of
free play as measured at the lever.
8. Operate the clutch lever several times and
recheck the amount of free play present.

Thruxton R 157
Clutch

Clutch - Removal 2. Remove the pull rod and bearing from the
clutch pressure plate.

Warning
3
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 2
operator or damage to the motorcycle. 1

• Remove the clutch cover (see Clutch Cover -

Removal, page 97).
Note:
• The spring seats will remain seated in the
pressure plate during removal.
1. Release the 3 fixings, remove the stopper
plate, springs and pressure plate.
1. Pull rod

5 2. Bearing
3. Clutch pressure plate
4
3. Remove the clutch plates, anti-judder seat
washers and springs, noting the orientation of
the each component as they are removed.
Note:
OU
• The two outermost and the inner friction plate
are different to the remainder and must not
T

3 be fitted in any other position.

2
• Refer to Friction Plate Inspection, page 159
for details of clutch friction plate inspection.
1 4. Engage second gear and lock the inner and
outer clutch drums together using service tool
1. Fixings
T3880307 as shown below.
2. Stopper plate
3. Springs 1
4. Spring seats
5. Pressure Plate

ciwx

1. T3880307 - Clutch Anti-rotation Jig

5. Release the clutch centre nut.

6. Remove the centre nut, Belleville washer, plain
washer, clutch inner drum and thrust washer.

158 Thruxton R
 Clutch

7. Discard both the Belleville washer and plain Friction Plate Inspection
washer.
Thickness
Caution Note:
Do not remove the bearing sleeve from the shaft. • If any friction plate thickness is outside the
Removing the bearing sleeve will allow the oil service limit, replace the friction plates as a
pump drive chain to become dislodged. set.
If the oil pump drive chain becomes dislodged the 1. Measure the thickness of the friction plate.
oil pump will not operate causing severe engine
damage.

8. Slide the bearing sleeve forward and

backwards a maximum of 10 mm to allow the
needle roller bearing to become dislodged.
9. Remove the needle roller bearing from the
clutch outer drum. 1

cbvy

1. Clutch friction plate

2 2. For the clutch friction plate thickness, refer to

Clutch and Primary Drive, page 39.

3
cixd

1. Bearing sleeve
2. Needle roller bearing
3. Shaft

10. Slide the clutch outer drum away from the

gearbox input shaft.

Thruxton R 159
Clutch

Steel Plate Inspection Clutch Pack - Height

Note:
Bend/warp
• The clutch pack height is critical for a smooth
Check all plates for bend and warp as follows:
operation of the transmission and must be
1. Place the plate being checked on a clean measured prior to installation of new clutch
surface plate and attempt to pass a feeler plates.
gauge of the maximum service limit thickness
When building a new clutch pack, its height must
between the steel plate and surface plate. If
be correct. To achieve this, build the new clutch
the feeler gauge can be passed beneath the
pack using the following:
steel plate at any point, renew the plates as a
set. • 2 x new outer friction plates
• 5 x new friction plates
2 1 • 1 x new inner friction plate
• 6 x steel plates, 2.0 mm thick
• 1 x outer steel plate, 2.0 mm thick.
1. Arrange the new friction and new steel plates
3 in a stack as shown below.

3 2 1

cbvz

1. Steel plate
2. Feeler gauge
3. Surface plate 5
4
2. For specifications refer to Clutch and Primary
Drive, page 39. Engine Side

1. Outer friction plates

2. Friction plates
3. Inner friction plate
4. Steel plate, 2.0 mm thickness
5. Outer steel plate, 2.0 mm thickness

160 Thruxton R
 Clutch

2. Place the assembled clutch pack on a flat 6. If the clutch pack height is too low, replace the
surface and measure its height as shown 2.0 mm steel plate indicated below with a new
below. 2.3 mm steel plate.

1
Engine Side
T0943_1

1. Clutch pack height 1. 2.0 mm steel plate to be replaced

3. The clutch pack height for this clutch 7. Re-check the clutch pack height as described
assembly is shown in the specification table previously.
see Clutch and Primary Drive, page 39.
4. If the clutch pack is too high, continue from
step 5, omit step 6 then continue from step 7.
If the clutch pack is too low, continue from
step 6.
Note:
• 1.6 mm and 2.3 mm steel plates are available,
refer to the Parts Catalogue for part numbers.
• No more than one 1.6 mm thick steel plate is
to be used in the clutch pack.
5. If the clutch pack height is too high, replace
the 2.0 mm steel plate indicated below with a
new 1.6 mm steel plate.

1
Engine Side

1. 2.0 mm steel plate to be replaced

Note:
• No more than one 2.3 mm thick steel plate is
to be used in the clutch pack.

Thruxton R 161
Clutch

Clutch - Installation 2. Position the clutch outer drum assembly to

the input shaft and align the oil pump sprocket
drive pegs with the corresponding holes in the
Warning rear of the clutch outer drum.
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 3 2
operator or damage to the motorcycle.

Caution
Ensure the oil pump drive chain is engaged with
the oil pump drive gears. Running the engine
without drive to the oil pump will stop oil supply to
the engine. Running the engine without oil
pressure will cause severe engine damage.
1
1. Visually check the oil pump drive chain is cixf

engaged with the drive gears. 1. Clutch outer drum (rear view)
2. Oil pump sprocket drive pegs
3. Clutch outer drum sprocket drive holes

3. While holding the clutch outer drum in position

and ensuring correct engagement with the oil
pump drive, refit the bearing.

3
1

1
cixe

1. Oil pump drive sprocket

2
2. Oil pump drive chain
3. Pump sprocket
3
ciwy

1. Outer drum
2. Bearing sleeve
3. Needle roller bearing

Note:
• When the bearing and sleeve are correctly
fitted, it will be a flush fit with the clutch
drum face.
4. Fit the thrust washer to the shaft.
5. Fit the clutch inner drum.

162 Thruxton R
 Clutch

6. Fit the flat washer, a new Belleville washer Note:

(OUT mark facing outwards), and a new centre
nut. • Always refer to the Clutch Pack - Height, page
160 prior to fitting new clutch plates to the
motorcycle.
11. Coat all clutch friction plates in clean engine oil
before fitting the friction plates, steel plates,
anti-judder spring and anti-judder seat
washer to the clutch basket in the same order
and orientation as noted during removal.
Note:
• The inner and the two outermost friction
plates are different to the other friction
plates. They must be fitted in their noted
positions.
• The outer steel plate is different to the other
6 5 4 1
3 2 plates. It must be fitted in its noted position.
cixc

1. Shaft
2. Thrust washer 1
3
3. Clutch inner drum 4 5
4. Flat washer 6
5
5. Belleville Washer OUT Mark 8
5
6. Centre nut

7. Using service tool T3880307, lock the inner

and outer drums together. Depress the rear 2
brake pedal to prevent the engine turning, and
tighten the centre nut to 98 Nm. 7
8. Remove service tool T3880307.
9
ciww

1 1. Clutch outer drum

2. Clutch inner drum
3. Anti-judder seat washer
4. Anti-judder spring
5. Inner/outer friction plate
6. Friction plates
7. Steel plates
8. Steel plate (outer)
9. Pressure plate

12. Refit the clutch pull rod.

ciwx
13. Fit the pressure plate. Ensure that the spring
1. T3880307 - Clutch Anti-rotation Jig seats are fitted into the pressure plate as
noted for removal.
9. Disengage second gear and check for free
rotation of the clutch inner drum.
10. Using a suitable pin punch, stake the nut to
the shaft.

Thruxton R 163
Clutch

Note:
• Note that the stopper plate has an OUT mark.
This must face outwards when fitted.
• There are spring seats located in the pressure
plate. Ensure the seats are in the pressure
plate prior to fitting the springs.
14. Fit the springs and stopper plate, ensure that
the OUT mark on the stopper plate is facing
outwards. Secure with the fixings and tighten
to 10 Nm.

OU
T

3
2

1. Fixings
2. Stopper plate
3. Springs
4. Spring seats
5. Pressure plate
• Refit the clutch cover (see Clutch Cover -
Installation, page 98).
• Refit the clutch cable (see Clutch Cable -
Installation, page 157).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

164 Thruxton R
 12 Crankshaft
Table of Contents
Exploded View – Crankshaft and Connecting Rod ...................................................................................................................... 167
Exploded View – Crankcase .................................................................................................................................................................... 168
Crankcase......................................................................................................................................................................................................... 169
Crankcase - Removal.................................................................................................................................................................................. 169
Crankcase - Assembly.................................................................................................................................................................................. 171
Crankshaft - Removal ................................................................................................................................................................................ 176
Crankshaft - Installation........................................................................................................................................................................... 176
Connecting Rods - Removal..................................................................................................................................................................... 177
Connecting Rod - Installation................................................................................................................................................................. 178
Connecting Rod Big End Journal Checking, Measuring and Bearing Selection.............................................................. 179
Crankshaft Main Bearing/Journal Checking, Measuring and Bearing Selection............................................................ 180
Coolant Manifold - Removal .................................................................................................................................................................... 182
Coolant Manifold - Installation............................................................................................................................................................... 182
Breather Plate - Removal......................................................................................................................................................................... 183
Breather Plate - Installation................................................................................................................................................................... 184

Thruxton R 165
Crankshaft

166 Thruxton R
 Crankshaft

Exploded View – Crankshaft and Connecting Rod

See Text

See Text

Thruxton R 167
Crankshaft

Exploded View – Crankcase

3 Nm

23 Nm

See Text
10 Nm
12 Nm

9 Nm

12 Nm

9 Nm
25 Nm

168 Thruxton R
 Crankshaft

Crankcase Crankcase - Removal

Warning Warning
The following procedures often require lifting of Before starting work, ensure the motorcycle is
heavy components. To avoid injury, always lift stabilised and adequately supported. This will help
heavy components with a hoist or block and tackle prevent it from falling and causing injury to the
and never attempt to manually lift items that are operator or damage to the motorcycle.
too heavy. Injury may result from failure to use
the correct lifting equipment. • Remove the engine (see Engine - Removal, page
261).
• Remove the camshaft cover (see Camshaft
Caution Cover - Removal, page 102).
The upper and lower crankcases are machined as • Remove the sump (see Sump - Removal, page
a matched set and must never be assembled to 94).
non-matching halves. Doing so will cause seizure • Remove the clutch (see Clutch - Removal, page
of the engine. 158).
• Remove the alternator rotor (see Alternator
Rotor - Removal, page 692).
Note:
• The crankcase halves may be separated Note:
without removing the cylinder head. • To allow correct fitment of T3880039 - Idler
If the big end fixings have been loosened or Gear Timing Pin the engine may require
removed, new fixings must be installed. rotating up to seven times.
1. Align the timing holes in the crankcase and
Caution camshaft idler gear. Lock in position using
service tool T3880039.
During crankcase assembly, ensure the two piston ciyy

cooling jets are re-installed. If the piston cooling

jets are omitted, oil pressure will be reduced.
Running the engine with low oil pressure will
cause severe engine damage. 2

1. Crankcase
2. T3880039 - Idler Gear Timing Pin

2. Remove the oil and water pump (see Oil and

Water Pump - Removal, page 247).

Thruxton R 169
Crankshaft

3. Release the fixing and remove the coolant

drain tube, discard the fixing and the O-ring. Caution
Do not use levers to separate the upper and lower
sections of the crankcase as damage to the
crankcases could result.
2
1
Note:
• Always check that all fixings have been
released before attempting to separate the
crankcases.
5. Separate the lower crankcase from the upper
crankcases noting the position of the three
location dowels.

1
ciyk

1. Coolant drain tube

2. Fixing

4. Release the lower crankcase fixings noting 1

their positions in the sequence shown below. 2

16 15
17
18
20 19
1

1 3
ciyi

5 7
1. Dowels
2. Upper crankcase

6. For removal of the:

• Front balancer shaft, (see Front Balancer
Shaft - Removal, page 189),
6 8
• Rear balancer shaft, (see Rear Balancer
Shaft - Removal, page 188),
2 4
• Crankshaft, (see Crankshaft - Removal, page
176).
10 • Selector forks and drum (see Selector Forks
24
and Drum - Removal, page 209).
12 14 • Coolant manifold, (see Coolant Manifold -
Removal, page 182).
9 • Breather plate, (see Breather Plate -
11 Removal, page 183).

13 23
22 21
ciyl

Crankcase Fixing Release Sequence

170 Thruxton R
 Crankshaft

Crankcase - Assembly 8. Apply a Apply a 2 mm (+/-0.5 mm) bead of

silicone sealant to the lower crankcase mating
1. Use high flashpoint solvent to clean the faces, (during manufacture, ThreeBond 1216E is
crankcase mating faces. Wipe the surfaces used).
clean with a lint-free cloth.
2. Position the transmission shafts and the
selector drum in the neutral position.
3. Ensure that the three dowels are located in
position in the upper crankcase.

1
2

Sealer Areas
1
Caution
ciyi
Do not use excessive amounts of sealer. The extra
1. Dowels sealer may become dislodged and could block the
oil passages in the crankcases, causing severe
2. Upper crankcase
engine damage.
4. Install and lubricate the crankshaft main
bearing shells with clean engine oil (see page 9. Position the lower crankcase to the upper. An
Crankshaft Main Bearing/Journal Checking, assistant may be required to support the
Measuring and Bearing Selection, page 180 crankcase during alignment.
before proceeding).
Note:
5. Install and lubricate the front balancer shaft
with clean engine oil. (see Front Balancer Shaft • The rear balancer shaft will rotate one tooth
- Installation, page 191). when the upper and lower crankcase are
joined.
6. Install and lubricate the rear balancer shaft
with clean engine oil (see Rear Balancer Shaft - 10. To check that the balancer shaft is correctly
Installation, page 194). timed to the crankshaft proceed as follows:
7. Lubricate the crankshaft journals with clean
engine oil.

Thruxton R 171
Crankshaft

11. Check that the dot mark on the rear balancer • Tighten all of the crankcase fixings to 10
shaft is aligned with the tab on the crankcase, Nm.
as shown below.
16 15
17
18
20 19

2 3
1

5 7

6 8
1
cjcm
2 4
1. Lower crankcase identification mark
2. Rear balancer shaft dot mark 10
24
12. Locate the fixings into their respective
positions in the lower crankcase as noted 12 14
during removal and hand tighten.
13. Tighten the crankcase fixings as follows: 9
11
Note:
• The crankcase fixings are tightened in stages.

13
Caution 22 21
23

ciyl
Failure to follow the correct tightening sequence
may result in permanent crankcase damage. All Fixings Tightening Sequence

Stage 2
Stage 1 - All Fixings
15. In the sequence shown below:
14. In the sequence shown below:

172 Thruxton R
 Crankshaft

• Loosen fixings 1 to 8. through 140°, using • Tighten fixings 1 to 8 to 10 Nm.

service tool T3880105 or similar to measure
the torque-angle. 16 15
17
18
15 20 19
16 17
18
20 19
1 3

1 3 5 7

5 7

6 8

6 8 2 4

2 4
10
24
10 12 14
24

12 14 9
11
9
11

13 23
22 21
13 23 ciyl

22 21 Fixings 1 to 8 Tightening Sequence

ciyl

17. In the sequence shown below:

Fixings 1 to 8 Loosening Sequence

Stage 3

16. In the sequence shown below:

Thruxton R 173
Crankshaft

• Tighten fixings 1 to 8 through a further 75° • Tighten fixings 9 to 13 to 32 Nm.

using service tool T3880105 or similar to
measure the torque-angle. 16 15
17
18
15 20 19
16 17
18
20 19
1 3

1 3 5 7

5 7

6 8

6 8 2 4

2 4
10
24
10 12 14
24

12 14 9
11
9
11

13 23
22 21
13 23 ciyl

22 21 Fixings 9 to 13 Tightening Sequence

ciyl

Fixings 1 to 8 Tightening Sequence Stage 5

Stage 4

18. In the sequence shown below:

174 Thruxton R
 Crankshaft

15 Note:
16 17
18 • Prior to fitting an O-ring coat the surfaces
20 19 with a commercially available petroleum jelly.
20. Refit the breather drain tube, fit a new O-ring,
1 3 tighten the new fixing to 9 Nm.

5 7

2
1

6 8

2 4

10
24

12 14 ciyk

1. Breather drain tube

9
11 2. Fixing
• Refit the oil and water pump (see Oil and Water
Pump - Installation, page 253).
• Refit the oil and water pump (see Oil and Water
13 23 Pump - Installation, page 253).
22 21 • Refit the sump (see Sump - Installation, page
ciyl

95).
19. In the sequence shown below:
• Refit the alternator (see Alternator Rotor -
• Tighten fixings 14 to 24 to 12 Nm. Installation, page 693).
Fixings 14 to 24 Tightening Sequence • Refit the clutch (see Clutch - Installation, page
162).
• Refit the gear position sensor (see Gear
Position Sensor - Installation, page 417).
• Refit the engine (see Engine - Installation, page
265).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 175
Crankshaft

Crankshaft - Removal Crankshaft - Installation

Warning Caution
Before starting work, ensure the motorcycle is Always check the main bearing journal clearance
stabilised and adequately supported. This will help (see Crankshaft Main Bearing/Journal Checking,
prevent it from falling and causing injury to the Measuring and Bearing Selection, page 180),
operator or damage to the motorcycle. before final assembly of the crankshaft. Failure to
correctly select crankshaft bearings will result in
• Remove the engine (see Engine - Removal, page severe engine damage.
261).
• Separate the lower crankcase from the upper 1. Select and fit new main and big end bearing
crankcase (see Crankcase - Removal, page 169). shells using the selection processes detailed
• Remove the connecting rod big end caps and on Crankshaft Main Bearing/Journal Checking,
discard the bolts. (see Connecting Rods - Measuring and Bearing Selection, page 180).
Removal, page 177). 2. Lubricate all of the bearings with clean engine
oil.
Note:
3. Ensure that the crankshaft is clean, and that
• Support the connecting rods during
the oil ways within the crankshaft are clean,
crankshaft removal to prevent damage to the
free from blockages and debris.
rods, liners and upper crankcase.
1. Remove the crankshaft from the upper
crankcase.
Caution
The crankshaft to idler gear timing will be lost
when the crankshaft is removed. Do not refit the
crankshaft without first setting the crankshaft to
idler gear timing. Incorrect idler gear timing will
result in incorrect camshaft timing. Rotating or
attempting to start an engine with incorrectly
adjusted camshaft timing will result in severe
engine damage.

4. Install the crankshaft to the upper crankcase,

ensuring the crankshaft drive gear is correctly
timed to the balancer shafts and idler gear
(see Front Balancer Shaft - Installation, page
191 ).
5. Align the connecting rod big ends to the
crankshaft pins.

176 Thruxton R
 Crankshaft

6. Fit and In the correct sequence, tighten the Connecting Rods - Removal
big end caps. (see Connecting Rod -
Installation, page 178). Note:
7. Assemble the crankcases (see page Crankcase • The connecting rods and caps are etch-
- Assembly, page 171). marked on one side to identify their correct
• Refit the cylinder barrels (see Barrels - orientation. However, the cylinder from which
Installation, page 143). they are individually removed should also be
identified, using a paint marker or similar.
• Refit the cylinder head (see Cylinder Head -
Installation, page 135). • Remove the engine (see Engine - Removal, page
• Refit the engine (see Engine - Installation, page 261).
265). • Remove the clutch (see Clutch - Removal, page
• Refit the fuel tank (see Fuel Tank - Installation, 158).
page 383). • Remove the cylinder barrel (see Barrels -
• Reconnect the battery positive, (red) lead first Removal, page 142).
see (Battery - Installation, page 658) and • Separate the lower crankcase from the upper
tighten the terminals to 4.5 Nm. crankcase (see Crankcase - Removal, page 169).
• Refit the seat (see Seat - Installation, page 636). • Remove and discard the connecting rod bolts.
• Start the engine and ensure that the low oil
pressure warning light goes out shortly after
starting.
2
• Stop the engine and check the engine oil level.
Adjust if necessary (see Engine Oil - Level 1
3
Inspection, page 243).

ciyh

1. Connecting rod bolts

2. Connecting rod cap
3. Connecting rod

1. Collect the connecting rod caps.

2. Collect the piston and connecting rod.
3. Label the assembly to identify the cylinder
from which it was removed.

Thruxton R 177
Crankshaft

Connecting Rod - Installation • Tighten through 210° using service tool

T3880105 or similar.
Note:
• The big end bolts are treated with an anti-rust
solution, which must not be removed.
1. Clean the connecting rod with high flashpoint
solvent.
2. Fit the piston and connecting rod assemblies
to the crankshaft.
3. Select and fit the selected big end bearing
shells to the connecting rods and big end caps
(see Connecting Rod Big End Journal Checking,
Measuring and Bearing Selection, page 179).

Warning cbxt

Always renew the big end bolts. The bolts are T3880105 - Torque Angle Gauge
torqued near to their yield point when first
installed and are severely weakened if reused. • Assemble the crankcases (see Crankcase -
Reusing the original bolts may cause bolt Assembly, page 171).
breakage resulting in engine damage, loss of • Refit the cylinder barrel (see Barrels -
motorcycle control and an accident. Installation, page 143).
• Refit the engine (see Engine - Installation, page
265).
Warning • Refit the fuel tank (see Fuel Tank - Installation,
page 383).
The torque characteristics of the connecting rod
• Reconnect the battery, positive (red) lead first
bolts are sensitive to the rate at which they are
(see Battery - Installation, page 658) and
tightened. If all the torque is applied in one action,
tighten the terminals to 4.5 Nm.
the bolts will be stretched beyond their yield point.
This may cause bolt breakage resulting in engine • Refit the seat (see Seat - Installation, page 636).
damage, loss of motorcycle control and an
accident.

Note:
• Prior to fitting the big end bolts lubricate the
under head and thread areas of the bolts with
undiluted molybdenum disulphide grease.
4. Fit new bolts to the connecting rods.
5. Tighten the bolts, in two stages as follows:
• Tighten to 14 Nm.

178 Thruxton R
 Crankshaft

Connecting Rod Big End Journal 9. Using the Plastigauge kit, measure the width
of the compressed Plastigauge.
Checking, Measuring and Bearing
Selection
Using selective bearings compensates for minor
differences in crankshaft main bearing journal and
crankcase dimensions. For further information on
bearing part number to colour cross-references,
refer to the electronic parts catalogue EPC.
1. Measure the bearing and crankshaft journal
clearance as follows.
Note:
• Do not turn the connecting rod and
crankshaft during the clearance measurement
as this will damage the Plastigauge. The cfwa
crankshaft journal clearances are measured
using Plastigauge (Triumph part number Checking the Big End Bearing/Crankshaft Journal
3880150-T0301). Clearance
2. Remove the bearing cap from the journal to be 10. For specifications refer to Crankshaft, page 42.
checked.
11. If the clearance exceeds the service limit,
3. Wipe the exposed areas of the crankshaft measure the diameter of the crankshaft
journal, and the bearing face inside the cap. bearing journal.
4. Apply a thin smear of grease to the journal
Note:
and a small quantity of silicone release agent
to the bearing. • If any journal has worn beyond the service
limit, the crankshaft must be replaced. Due to
5. Trim a length of the Plastigauge to fit across
the advanced techniques used during
the journal. Fit the strip to the journal using
manufacture, the crankshaft cannot be
the grease to hold the Plastigauge in place.
reground and no oversize bearings are
6. Release the fixings and remove the cap being available.
measured. Using the gauge provided with the
Plastigauge kit, measure the width of the Connecting Rod Bearing Selection
compressed Plastigauge.
Note:
Note:
• Minor differences in dimensions are
• The original fixings may be reused for bearing compensated for by using selective bearings.
selection. Do not use new fixings as they may For further information on bearing part
only be used once, even if the single use is number to colour cross-references, see the
related to bearing selection. latest parts information.
7. Lubricate the threads of the fixing and the 1. Select the correct bearing shell as follows:
face of the fixing with molybdenum disulphide
grease. Refit the lower crankcase and tighten 2. Measure and record the diameter of each
the original fixings (see Crankshaft - crankshaft bearing journal.
Installation, page 176). 3. Measure and record each bearing bore
8. Release the fixings and remove the cap being diameter (bearings removed, journal caps fitted
measured. and all fixings fully torqued) (see Connecting
Rod - Installation, page 178).
4. Select the correct bearings by matching the
information found in the bearing selection
chart.
5. Install the new bearings.

Thruxton R 179
Crankshaft

Big End Bearing Selection Chart Crankshaft Main Bearing/Journal

Shell Colour Connecting rod Big end bearing Checking, Measuring and Bearing
bore diameter journal diameter Selection
WHITE 41.000 to 37.993 to Using selective bearings compensates for minor
41.009 mm 38.000 mm differences in crankshaft main bearing journal and
RED 41.000 to 37.984 to crankcase dimensions. For further information on
41.009 mm 37.992 mm bearing part number to colour cross-references,
refer to the EPC.
For instance: • Separate the lower crankcase from the upper
Connecting rod Big 37.966 crankcase (see Crankcase - Removal, page 169).
End Diameter 1. Measure the bearing to crankshaft journal
clearance as follows.
Crankshaft Journal 41.004
Diameter Note:
Required Bearing White • Do not turn the connecting rods and
crankshaft during the clearance measurement
Note: as this will damage the Plastigauge. The
• Repeat the measurements for all respective crankshaft journal clearances are measured
journals. using Plastigauge (Triumph part number
• It is normal for the bearings selected to differ 3880150-T0301).
from one journal to another. 2. Wipe the exposed areas of the crankshaft
• It is also normal for there to be two options of journals, and the bearing face inside the cap.
bearing shell colour. In such cases, pick the
3. Apply a thin smear of grease to the journals
shell size that gives the greater running
and a small quantity of silicone release agent
clearance.
to the bearings.
4. Trim a length of the Plastigauge to fit across
Warning each journal. Fit the strip to the journal using
Always confirm, using the Plastigauge method, the grease to hold the Plastigauge in position.
that the running clearance is correct before final Note:
assembly. Severe engine damage could result from
• The original fixings may be reused for bearing
incorrect clearance resulting in loss of motorcycle
selection. Do not use new fixings as they may
control and an accident.
only be used once, even if the single use is
related to bearing selection.
5. Lubricate the threads and the face of the
fixings with molybdenum disulphide grease.
Refit the crankcase and tighten the original
fixings (see Crankcase - Assembly, page 171).
6. Release the fixings and remove the crankcase.

180 Thruxton R
 Crankshaft

7. Using the Plastigauge kit, measure the width Main Bearing Selection Chart
of the compressed Plastigauge.
Shell Colour Crankcase Crankshaft Running
Bore Journal Clearance
Diameter
Red 46.105 to 43.099 to 0.040 to
46.097 43.092 0.019
Red 46.114 to 43.108 to 0.041 to
46.106 43.100 0.019
Blue 46.114 to 43.099 to 0.041 to
46.106 43.092 0.020
Blue 46.123 to 43.108 to 0.042 to
46.115 43.100 0.020
Green 46.123 to 43.099 to 0.042 to
cdga
46.115 43.092 0.021

Checking the Crankshaft Journal Clearance For instance:

8. For specifications refer to Crankshaft, page 42. Crankcase Bore 46.099 mm
9. If the clearance exceeds the service limit, Crankshaft Journal 43.095 mm
measure the diameter of the crankshaft Diameter
bearing journal.
Required Bearing RED
Note:
• If any journal has worn beyond the service
limit, the crankshaft must be replaced. Due to
Warning
the techniques used during manufacture, the Always confirm, using the Plastigauge method,
crankshaft cannot be reground and oversize that the running clearance is correct before final
bearings are not available. assembly. Severe engine damage could result from
incorrect clearance resulting in loss of motorcycle
Main Bearing Selection control and an accident.
Note:
• Minor differences in dimensions are Note:
compensated for by using selective bearings. • Repeat the measurements for all respective
For further information on bearing part journals.
number to colour cross-references, see the • It is normal for the bearings selected to differ
latest parts information. from one journal to another.
• It is also normal for there to be two options of
1. Select the correct bearings as follows:
bearing shell colour. In such cases, pick the
2. Measure and record the diameter of each shell size that gives the greater running
crankshaft bearing journal. clearance.
3. Measure and record each bearing bore
diameter in the crankcase (bearings removed,
journal caps fitted and all fixings fully torqued).
4. Select and install the correct bearings by
matching the information found in the main
bearing selection chart.
5. Install the new bearings.

Thruxton R 181
Crankshaft

Coolant Manifold - Removal Coolant Manifold - Installation

1. Fit a new sealing ring to the coolant manifold.
Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help 2
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

Note:
• The oil pump and water pump are supplied as 3
an assembly and cannot be separated. This
procedure covers the removal of the oil and
water pump assembly.
• Remove the engine (see Engine - Removal, page
261). 1 3
cizf

Warning 1. Coolant manifold

2. Sealing ring
The oil may be hot to the touch. Contact with hot
3. Dowel locating holes
oil may cause the skin to be scalded or burned.

Warning
Prolonged or repeated contact with engine oil can
lead to skin dryness, irritation and dermatitis. In
addition used engine oil contains potentially
harmful contaminants which can cause cancer.
Wear suitable clothing and avoid skin contact.

• Separate the lower crankcase from the upper

crankcase (see Crankcase - Removal, page 169).
1. Remove the input and output shafts.
2. Release the fixings and remove the coolant
manifold, discard the fixings and the sealing
ring.

2 1

ciyo

1. Coolant manifold
2. Fixings

182 Thruxton R
 Crankshaft

2. Position the coolant manifold to the crankcase, Breather Plate - Removal

ensuring the locating dowels are correctly
positioned.
3. Install new fixings and tighten to 9 Nm.
Warning
Before starting work, ensure the motorcycle is
2 stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

Warning
Prolonged or repeated contact with engine oil can
lead to skin dryness, irritation and dermatitis.
2 Furthermore, used engine oil contains potentially
harmful contaminants which can cause cancer.
2 1 When handling used engine oil, always wear
protective clothing and avoid any skin contact
ciyo with the oil.
Tightening sequence
• Assemble the crankcases (see Crankcase -
Assembly, page 171).
Caution
• Refit the engine (see Engine - Installation, page Do not pour engine oil on the ground, down
265). sewers or drains, or into watercourses. To prevent
• Refit the engine cradles (see Cradle Assemblies pollution of watercourses etc., dispose of used oil
- Installation, page 642). sensibly. If in doubt contact your local authority.
• Refit the fuel tank (see Fuel Tank - Installation,
page 383). Note:
• Reconnect the battery, positive (red) lead first • The oil pump and water pump are supplied as
and tighten the battery terminals to 4.5 Nm. an assembly and cannot be separated. This
• Start the engine and ensure that the low oil procedure covers the removal of the oil and
pressure warning light goes out shortly after water pump assembly.
starting. • Remove the engine (see Engine - Removal, page
• Stop the engine and check the engine oil level. 261).
Adjust if necessary (see Engine Oil - Level
Inspection, page 243).
• Refit the seat (see Seat - Installation, page 636).
Warning
The oil may be hot to the touch. Contact with hot
oil may cause the skin to be scalded or burned.

• Separate the lower crankcase from the upper

crankcase (see Crankcase - Removal, page 169).
1. Remove the breather drain tube from the
crankcase, discard the fixing and the o-ring.

Thruxton R 183
Crankshaft

2. Remove the input and output shafts. Breather Plate - Installation

3. Remove the engine oil breather plate and
Note:
baffle, discard the fixings.
• Prior to fitting the O-ring coat the surfaces
3 with petroleum jelly.
1. Using new fixings, fit the engine oil breather
4
baffle and tighten to 12 Nm.
5 1
2. Fit a new O-ring and install the breather drain
tube to the crankcase. Ensure the tube is
correctly installed in the breather housing.
3. Install a new fixing and tighten to 9 Nm.

2 3

4
5 1
ciyz

1. Oil breather plate

2. Fixings
3. Breather drain tube
2
4. Fixings
5. O-ring

ciyz

1. Oil breather plate

2. Fixings
3. Breather drain tube
4. Fixing
5. O-ring
• Assemble the crankcases (see Crankcase -
Assembly, page 171).
• Refit the engine (see Engine - Installation, page
265).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
and tighten the battery terminals to 4.5 Nm.
• Start the engine and ensure that the low oil
pressure warning light goes out shortly after
starting.
• Stop the engine and check the engine oil level.
Adjust if necessary (see Engine Oil - Level
Inspection, page 243).
• Refit the seat (see Seat - Installation, page 636).

184 Thruxton R
 13 Balancer
Table of Contents
Exploded View – Balancers ..................................................................................................................................................................... 187
Introduction .................................................................................................................................................................................................... 188
Rear Balancer Shaft - Removal............................................................................................................................................................. 188
Front Balancer Shaft - Removal ........................................................................................................................................................... 189
Balancer shafts - Inspection ................................................................................................................................................................... 191
Front Balancer Shaft - Installation....................................................................................................................................................... 191
Rear Balancer Shaft - Installation ....................................................................................................................................................... 194
Balancer Shafts Dynamic Adjustment............................................................................................................................................... 195

Thruxton R 185
Balancer

186 Thruxton R
 Balancer

Exploded View – Balancers

12 Nm

10 Nm

10 Nm

10 Nm

10 Nm

Thruxton R 187
Balancer

Introduction Rear Balancer Shaft - Removal

Two balancer shafts are fitted to the engine, one in
front of the crankshaft in the upper crankcase and
one behind it in the lower crankcase. Each balancer
Warning
has the effect of a pair of counterbalance weights, Before starting work, ensure the motorcycle is
which create an equal amount of energy in the stabilised and adequately supported. This will help
opposite direction, and at the same time as that prevent it from falling and causing injury to the
produced by the crankshaft, pistons and operator or damage to the motorcycle.
connecting rods. Because the opposing pulses
occur at the same point of crankshaft rotation, and • Remove the engine (see Engine - Removal, page
are of an equal magnitude, a state of equilibrium or 261).
balance is reached. • Separate the lower crankcase from the upper
crankcase (see Crankcase - Removal, page 169).
1. Remove the input and output shafts.
Note:
• The rear dead shaft clamp is marked with the
R facing away from the crankcase.
2. Loosen but do not fully remove the dead shaft
clamp locking screw,
3. Remove the dead shaft clamp securing screw
and washer.

2
5

ciyx

1. Dead shaft clamp

2. Locking screw
3. Securing screw
4. Washer
5. Dead shaft

188 Thruxton R
 Balancer

4. Release the dead shaft screw and washer. Front Balancer Shaft - Removal
Discard the dead shaft screw and retain the
washer.
Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
3 prevent it from falling and causing injury to the
operator or damage to the motorcycle.

• Remove the engine (see Engine - Removal, page

261).
• Separate the lower crankcase from the upper
crankcase (see Crankcase - Removal, page 169).
1 Note:
2 • The connecting rods and caps should be
identified, using a paint mark or similar.
ciyw

1. Remove and discard the connecting rod bolts.

1. Screw
2. Washer
3. Dead shaft
2
5. Support the balancer shaft and noting its 1
orientation slide the dead shaft from the 3
crankcase.
6. Remove the balancer shaft.
7. Remove and discard the O-rings from the
deadshaft.

1
ciyh

1. Connecting rod bolts

2
2. Connecting rod cap
3. Connecting rod

2. Remove the crankshaft.

1. Deadshaft
2. O-rings

Thruxton R 189
Balancer

3. Remove the front balancer shaft blanking 6. Support the balancer shaft and noting its
screw and washer, discard the washer. orientation slide the dead shaft from the
cizb
crankcase.

1
3 2 2

1 2

cizd
1. Blanking screw
2. Washer 1. Balancer

3. Upper crankcase 2. Dead shaft

3. Dead shaft clamp
Note:
7. Remove the balancer shaft.
• The front dead shaft clamp is marked with the
F facing away from the crankcase. 8. Remove and discard the O-rings from the
deadshaft.
4. Loosen but do not fully remove the dead shaft
clamp locking screw.
5. Remove the dead shaft clamp securing screw
and washer.
1

4 2

2
1. Deadshaft
2. O-rings
5
ciza

1. Dead shaft clamp

2. Locking screw
3. Securing screw
4. Washer
5. Dead shaft

190 Thruxton R
 Balancer

Balancer shafts - Inspection Front Balancer Shaft - Installation

1. Inspect all gears for chipped or missing teeth.
2. Inspect all bearings for signs of seizure and Warning
any other damage. Check that all bearings
Before starting work, ensure the motorcycle is
rotate smoothly and without tight spots.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

Note:
• To ensure a correct relationship, the balancer
shaft must be installed in a specific
orientation relative to the crankshaft.
1. Check service tool T3880039 is fully inserted
into the idler gear, and that the camshaft to
idler gear timing is correct.
2. Fit a new O-ring to the grooves at each end of
the deadshaft.

1. Deadshaft
2. O-rings

Caution
The balancer shaft gear is designed to mesh with
the crankshaft gear.
Correct adjustment of the balancer shafts is
critical to the performance of the engine and
comfort of the rider.
Failure to correctly adjust the balancer shafts may
cause serous engine damage and a poor rider
experience.

3. Lubricate the balancer shaft, needle roller

bearings and O-rings with clean engine oil.
4. Fit the balancer shaft into the crankcase as
noted during removal.

Thruxton R 191
Balancer

5. Support the balancer shaft and noting its 9. Allow the balancer shaft to rotate anti-
orientation, slide the dead shaft through the clockwise until the flat surface rests against
balancer shaft and into the upper crankcase. the machined surface of the crankcase, as
shown.
1
2 4
3 2

5 2
cizd

cize 1
1. Balancer
2. Dead shaft 1. Balancer shaft

3. Dead shaft clamp 2. Balancer shaft 'F' (front) mark

3. Balancer shaft alignment mark
6. Position the alignment mark on the dead shaft
with the alignment mark on the crankcase. 4. T3880811 - Front Balancer Timing Tool

Note: 5. Crankcase

• The static alignment of the balancer shaft will 10. Clean the crankshaft, crankshaft bearings and
allow for initial starting of the engine. big end bearings with a high flashpoint
• Final adjustment must be carried out with the solvent.
engine running and at operating temperature, 11. Lubricate the crank shaft and bearings with
see Balancer Shafts Dynamic Adjustment, clean engine oil.
page 195
12. Position the connecting rods as noted during
removal.
Note:
• As the crankshaft is lowered into position the
balancer shaft will rotate and the T3880811 -
Front Balancer Timing Tool will no longer rest
against the crankcase.

1. Alignment mark (Crankcase)

2. Alignment mark (Dead shaft)

7. Rotate the balancer shaft until the F and dot

mark are visible.
8. Position the peg on service tool T3880811 to
the dot mark on the balancer shaft gear.

192 Thruxton R
 Balancer

13. Position the crankshaft to the crankshaft Note:

bearings, aligning the timing mark on the
crankshaft with the machined surface of the • If the balancer shafts timing is incorrect, the
crankcase. procedure must be restarted from the
beginning.
3
15. Refit the dead shaft clamp and tighten the
securing screw to 10 Nm and then tighten the
2
1 dead shaft clamp locking screw to 10 Nm.

cizc
2
1. Crankshaft timing mark
2. Balancer gear timing marks
5
3. T3880811 - Front Balancer Timing Tool ciza

4. T3880601 - Camshaft Timing Pin 1. Dead shaft clamp

14. To check that the balancer shaft is correctly 2. Locking screw
timed to the crankshaft proceed as follows: 3. Securing screw
• The alignment hole in the crank shaft is 4. Washer
visible through the hole in the crankcase.
5. Dead shaft
• The alignment mark on the balancer shaft is
visible through the screw hole in the dead • Refit the big end caps to the connecting rods
shaft clamp. (see Connecting Rod - Installation, page 178).
• The service tool T3880601 can be inserted • Refit the crankcase halves (see Rear Balancer
fully, locking the crankshaft in position. Shaft - Installation, page 194 and Crankcase -
Assembly, page 171).
• Refit the alternator cover to the engine (see
Alternator Cover - Installation, page 101).
• Refit the clutch cover (see Clutch Cover -
Installation, page 98).
• Refit the camshaft cover (see Camshaft Cover -
Installation, page 103).
3 2 • Refit the engine (see Engine - Installation, page
1
265).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
4 • Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
cizh
• Refit the seat (see Seat - Installation, page 636).
1. Crankshaft
2. Crankshaft dot mark
3. Front balancer shaft dot mark
4. Dead shaft clamp

Thruxton R 193
Balancer

Rear Balancer Shaft - Installation 5. Align the dot mark on the dead shaft with the
dot mark on the crankcase.
1. Fit a new O-ring to the grooves at each end of
the deadshaft.

3
2
1

2 ciyw

1. Crankcase dot mark

2. Dead shaft dot mark
1. Deadshaft
3. Dead shaft
2. O-rings
6. Fit a new screw to the washer, install the
2. Lubricate the balancer shaft, needle roller
screw and washer to the dead shaft, ensuring
bearings and O-rings with clean engine oil.
the dot marks are aligned. Tighten to 12 Nm.
3. Position the balancer shaft as noted during
7. Position the balancer shaft so that the preload
removal.
mark aligns with the crankcase identification
4. Fit the dead shaft into the crankcase as noted mark.
during removal and insert the balancer shaft.
8. Refit the dead shaft clamp and tighten the
securing screw to 10 Nm and then tighten the
Caution dead shaft clamp locking screw to 10 Nm.
The balancer shaft gear is designed to mesh with
the crankshaft gear.
Correct adjustment of the balancer shafts is
critical to the performance of the engine and 2
5
comfort of the rider.
Failure to correctly adjust the balancer shafts may
cause serous engine damage and a poor rider
experience.
4

Note: 3
• The static alignment of the balancer shaft will
allow for initial starting of the engine. 1
• Final adjustment must be carried out with the
ciyx
engine running and at operating temperature,
see Balancer Shafts Dynamic Adjustment, 1. Dead shaft clamp
page 195 2. Dead shaft clamp locking screw
3. Securing screw
4. Washer
5. Balancer shaft

194 Thruxton R
 Balancer

9. Lock the balancer shaft into position using Balancer Shafts Dynamic
service tool T3880809.
Adjustment
10. Lubricate the crank shaft and bearings with
clean engine oil.
Warning
Before starting work, ensure the motorcycle is
5 stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

Warning
4 1
If the engine has recently been running, the
engine oil will be hot to the touch. Contact with
3 the hot oils may cause damage to exposed skin. To
avoid skin damage, do not touch hot oil.
2
ciyn

1. Crankcase identification mark Warning

2. Rear alignment mark If the engine has recently been running, the
3. Preload mark exhaust components may be hot to the touch.
Contact with the hot components may cause
4. Dot mark
damage to exposed skin. To avoid skin damage,
5. T3880809 - Rear Balancer Timing Tool always allow the hot parts to cool before working
• Refit the crankcase halves (see Crankcase - on the exhaust system.
Assembly, page 171).
• Refit the alternator cover to the engine (see
Alternator Cover - Installation, page 101). Warning
• Refit the clutch cover (see Clutch Cover - The cooling fan is switched on and off by the
Installation, page 98). Engine Control Module in response to a signal
• Refit the camshaft cover (see Camshaft Cover - received from the coolant temperature sensor. To
Installation, page 103). prevent injury, never place loose clothing, fingers
• Refit the engine (see Engine - Installation, page or hands near the cooling fan, until the engine is
265). stopped. Loose clothing, fingers or the hands
• Refit the fuel tank (see Fuel Tank - Installation, could become trapped during cooling fan
page 383). operation and cause crushing injury to the fingers,
• Reconnect the battery, positive (red) lead first hands or other parts of the anatomy.
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636). Warning
Never start the engine or run the engine in a
confined area. Exhaust fumes are poisonous and
can cause loss of consciousness and death within
a short period of time. Always operate your
motorcycle in the open-air or in an area with
adequate ventilation.

Note:
• Before dynamically adjusting the front and
rear balancer shafts the engine coolant fan
must have cycled once and the coolant
temperature must be at least 103°C.

Thruxton R 195
Balancer

Front Balancer Shaft Dynamic Adjustment

1. Start the motorcycles engine and allow to run
Caution
to operating temperature. The dead shaft is an eccentric shaft which runs
inside the balancer shaft. When rotated the dead
shaft therefore closes or opens the gap between
the teeth of the balancer gear and the teeth of
the crankshaft gear.
If the gap between the balancer gear and
crankshaft gear is too small a whine is audible due
to the increased load on the gear teeth and
bearings.
If the gap between the balancer gear and
crankshaft gear is too large a a rattle is audible
due to the increased gap between the gear teeth.
The balancer shafts must always be adjusted in
the same operation.
Adjusting the front or rear balancer shafts
individually may cause the engine to whine or
rattle.
Unsatisfactory adjustment of the balancer shafts
may cause severe engine damage.

Gap too small Audible whine

Correct gap No audible noise

Gap too big Audible rattle

2. Stop the engine.

196 Thruxton R
 Balancer

3. Remove the embellisher from the alternator 6. Start the engine and allow to idle.
cover and discard the fixings. 7. Gently rotate the dead shaft clockwise until a
4. Remove the dead shaft clamp blanking plug whining noise can just be heard.
and discard the washer.

4 1
3
F

1
1

ciyc

cizg
1. Dead shaft
1. Embellisher
8. Rotate the dead shaft anti-clockwise until the
2. Fixings whining noise can no longer be heard.
3. Dead shaft clamp blanking plug
4. Oil filler cap
1
5. Loosen the dead shaft clamp locking screw a
maximum of two complete turns to allow
smooth rotation of the balancer dead shaft in F

the clamp.
1

2 1
1 ciyc

1. Dead shaft
2 F 9. Tighten the dead shaft clamp locking screw to
10 Nm.

cizg

1. Dead shaft clamp locking screw

2. Blanking plug orifice

Caution
When adjusting the balancer shafts do not allow
the gears to whine or rattle for a prolonged
period.
Allowing the gears to mesh incorrectly for
extended periods may cause damage to the gears
and or bearings.

Thruxton R 197
Balancer

10. Stop the engine. Rear Balancer shaft Dynamic Adjustment

1. Remove the clutch cover plug.

2
1

2 1
1

2 F

cizg

1. Dead shaft clamp locking screw ciwp_1

2. Blanking plug orifice 1. Clutch cover plug

11. Wipe away any spilt oil from the crankcase. 2. Clutch cover
12. Fit a new washer and tighten the dead shaft 2. Remove the oil filler cap and discard the o-ring.
clamp blanking plug to 23 Nm.
13. Refit the embellisher cover to the alternator
cover, tighten the new screws to 4 Nm.

1
3

4
1

2
cizg

1. Oil filler cap

cizg

1. Oil filler cap

2. Embellisher
3. Dead shaft clamp blanking plug
4. Oil filler cap

198 Thruxton R
 Balancer

3. Using service tool T3880652, loosen the dead 5. Rotate the dead shaft anti-clockwise until the
shaft clamp locking screw two full turns. whining noise can no longer be heard.

1 1

cizg

1. T3880652 - Dead Shaft Key Tool 1. Dead shaft

2. Dead shaft clamp locking screw 6. Using service tool T3880652 tighten the dead
3. Oil filter orifice shaft clamp locking screw to 10 Nm.

4. Rotate the rear dead shaft clockwise until a 7. Wipe away any spilt oil from the upper
whining noise can be heard. crankcase.
8. Using a new O-ring refit the oil filler cap and
tighten to 3 Nm.

1. Dead shaft
cizg

1. Oil filler cap

Thruxton R 199
Balancer

9. Refit the clutch cover plug and tighten to 3

Nm.

ciwp_1

1. Clutch cover plug

2. Clutch cover

10. Inspect the engine oil level (see Engine Oil -

Level Inspection, page 243).

200 Thruxton R
 14 Transmission
Table of Contents
Exploded View – Gear Selector............................................................................................................................................................. 203
Exploded View – Gear Change Lever................................................................................................................................................. 204
Gear Change Shaft - Removal............................................................................................................................................................... 205
Gear Change Shaft - Inspection........................................................................................................................................................... 206
Gear Change Shaft - Installation ......................................................................................................................................................... 206
Gear Change Detent Wheel - Removal ............................................................................................................................................. 207
Gear Change Detent Wheel - Installation ....................................................................................................................................... 208
Selector Forks and Drum - Removal .................................................................................................................................................. 209
Selector Forks and Drum Inspection .................................................................................................................................................. 210
Selector Forks and Drum - Installation ............................................................................................................................................... 211
Exploded View - Output Shaft ............................................................................................................................................................... 213
Output Shaft - Disassembly 6 speed................................................................................................................................................... 215
Output Shaft - Assembly 6 speed........................................................................................................................................................ 218
Output Shaft - Inspection ........................................................................................................................................................................ 222
Input Shaft ...................................................................................................................................................................................................... 223
Input Shaft - Disassembly ....................................................................................................................................................................... 225
Input Shaft - Inspection........................................................................................................................................................................... 226
Input Shaft - Assembly ............................................................................................................................................................................ 226

Thruxton R 201
Transmission

202 Thruxton R
 Transmission

Exploded View – Gear Selector

12 Nm

12 Nm

12 Nm

12 Nm

12 Nm

22 Nm

Thruxton R 203
Transmission

Exploded View – Gear Change Lever

6 Nm

6 Nm

8 Nm

22 Nm

204 Thruxton R
 Transmission

Gear Change Shaft - Removal 2. Withdraw the abutment dowel from the
crankcase.

Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help 1
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the clutch (see Clutch - Removal, page
158). 2
1. Remove and discard the fixings and remove cjca

the oil pump drive chain guide from the

1. Abutment dowel
crankcase.
2. Abutment spring

3. Collect the washer from the gear change shaft.

4. Withdraw the gear change shaft as an
assembly.
cjcc

1. Oil pump drive chain guide

2. Fixings
2

1. Gear change shaft assembly

2. Washer

Thruxton R 205
Transmission

Gear Change Shaft - Inspection Gear Change Shaft - Installation

1. Inspect the gear change shaft assembly and
spring for damage or wear, the springs for Warning
over-extension (i.e. abnormal gaps between
coils). Renew the components as necessary. Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
6 prevent it from falling and causing injury to the
operator or damage to the motorcycle.
3
2
1. Position the selector mechanism into the
1 crankcase, locate the pivot plate to the detent
wheel.
5

5
7
2
4
6

1. Gear change shaft assembly 1

2. Pivot plate
3. Spring (pivot plate)
4. Gear change return spring
5. Washer, 20 mm
6. Circlips 1. Pivot plate
7. Washer, 25mm 2. Detent wheel

206 Thruxton R
 Transmission

2. Insert the abutment dowel with the spring Gear Change Detent Wheel -
tangs positioned to either side.
Removal

Warning
1 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.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
2
• Remove the gear change shaft (see Gear
cjca Change Shaft - Removal, page 205).
1. Abutment dowel 1. Release the detent arm spring.
2. Abutment spring 2. Release the detent arm fixing and remove the
detent arm.
3. Refit the pump drive chain guide to the cjcd

crankcase. Tighten the new fixings to 9 Nm.

1. Detent arm spring

1. Pump drive chain guide 2. Detent arm

2. Fixings 3. Fixing

• Refit the clutch (see Clutch - Installation, page 3. Remove the fixing and the detent wheel from
162). the selector drum.
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 207
Transmission

Gear Change Detent Wheel - 4. Tighten the fixing to 12 Nm.

Installation 5. Refit the detent arm spring.

cjcd

1. Lubricate the selector drum bearings with

clean engine oil.
2. Refit the detent wheel to the selector drum, 2
ensuring the pin on the drum locates in the
slot in the detent wheel. Prevent the drum 1
from turning and tighten the fixing to 12 Nm.

1
2

1. Detent arm spring

2. Detent arm
3 4 3. Fixing
• Refit the gear change shaft (see Gear Change
cfwy
Shaft - Installation, page 206).
1. Selector drum • Reconnect the battery, positive (red) lead first
2. Detent wheel (see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
3. Pin
• Refit the seat (see Seat - Installation, page 636).
4. Slot

3. Refit the spacer, detent arm, washer and fixing

as noted during removal.

208 Thruxton R
 Transmission

Selector Forks and Drum - Removal 2. Remove and discard the fixing securing the
input selector shaft.

Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 1
operator or damage to the motorcycle.

• Remove the engine (see Engine - Removal, page

261).
• Separate the lower crankcase from the upper
crankcase (see Crankcase - Removal, page 169).
• Remove the transmission shafts.
• Remove the gear change selector shaft (see
Gear Change Shaft - Removal, page 205). cjck

• Remove the gear position sensor (see Gear

1. Fixing
Position Sensor - Removal, page 415).
1. Remove and discard the fixing securing the Note:
output selector shaft retainer. • Prior to removal, mark, or make a note of the
relative positions of each selector fork in the
selector drum.
2 3. Withdraw the input selector shaft and noting
1 its orientation remove the fork.
4. Withdraw the output selector shafts and
noting their orientation, collect the two
selector forks.

3
5
cjci

1. Fixing 3

2. Output selector shaft retainer.

3. Output selector shaft
1

cjcj
4

1. Output selector shaft

2. Input selector shaft
3. Selector fork (input shaft)
4. Selector fork (output shaft)
5. Selector fork (output shaft)

5. Remove the selector drum bearing keeper

plate and discard the fixing.

Thruxton R 209
Transmission

6. Remove the selector drum. Selector Forks and Drum Inspection

Inspect all bearings for damage or wear. Renew as
necessary.
Inspect the selector forks and selector grooves for
wear beyond the service limits. Renew the
components as necessary.
• Refer to the specifications table (see
3
Transmission, page 43).
2

1
cjch

1. Selector drum
2. Fixing
3. Bearing keeper plate

7. If required, remove the fixing and remove the

detent wheel from the selector drum.

210 Thruxton R
 Transmission

Selector Forks and Drum - 5. Position the output selector fork shaft and
selector forks to the crankcase as noted
Installation during removal,
1. If removed, refit the detent wheel to the 6. Position the input selector fork shaft and
selector drum, ensuring the pin on the drum selector fork to the crankcase as noted during
locates in the slot in the detent wheel. Prevent removal.
the drum from turning and tighten the fixing
to 12 Nm.
2

1
2
5

1
3 4
cjcj
4
cfwy
1. Output selector shaft
1. Selector drum
2. Input selector shaft
2. Detent wheel
3. Selector fork (input shaft)
3. Pin
4. Selector fork (output shaft)
4. Slot
5. Selector fork (output shaft)
2. Refit the selector drum, ensuring it is pushed
fully into the crankcase.
3. Fit the bearing keeper plate and retain the
plate in position using a new fixing. Tighten
the fixing to 12 Nm.

1
cjch

1. Selector drum
2. Bearing keeper plate
3. Fixing

4. Lubricate the forks and shafts with clean

engine oil.

Thruxton R 211
Transmission

7. Using a new fixing secure the output selector

shaft retainer, tighten the fixing to 12 Nm.

2
1

cjci

1. Fixing
2. Retainer
3. Selector shaft

8. Using a new fixing secure the input selector

shaft, tighten the fixing to 22 Nm.

cjck

1. Fixing
• Refit the gear position sensor (see Gear
Position Sensor - Installation, page 417).
• Refit the gear change shaft (see Gear Change
Shaft - Installation, page 206).
• Assemble the crankcases (see Crankcase -
Assembly, page 171).
• Refit the engine (see Engine - Installation, page
265).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

212 Thruxton R
 Transmission

Exploded View - Output Shaft

1
17
2

3 18
4 19

5 20

6
21

7
22

12
23
8

24
9
13
10 25
14
11 26

15
27
16

28

1. Bearing outer carrier

2. Circlip
3. Needle roller bearing
4. Thrust washer
5. First gear
6. Needle roller bearing
7. Fifth gear
8. Circlip
9. Splined thrust washer
10. Fourth gear
11. Plain bush

Thruxton R 213
Transmission

12. Output shaft

13. Plain bush
14. Third gear
15. Splined thrust washer
16. Circlip
17. Sixth gear
18. Thrust washer
19. Plain bush
20. Second gear
21. Second gear spacer
22. Outer bearing
23. Snap ring
24. Distance sleeve
25. Output shaft seal
26. Sprocket
27. Tab washer
28. Sprocket nut

214 Thruxton R
 Transmission

Output Shaft - Disassembly 6 speed 4. Remove the thrust washer.

Warning
When using a press, always wear overalls, eye,
face and hand protection. Objects such as
bearings frequently break-up under load and the
debris caused during break-up may cause damage
and injury to unprotected parts of the body. 1
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to
the hand, arms or other parts of the anatomy. 2

3
Note:
T908.07.27
• Make a note or mark the orientation of all
transmission parts prior to removal. 1. Circlip
1. Mark one side of the needle roller bearing 2. Needle roller bearing
outer carrier to denote its correct orientation 3. Thrust washer
and slide it away from the needle roller
bearing. 5. Collect the output shaft seal.

2 1

2 3
1
cjbz cjgk

1. Bearing outer carrier 1. Output shaft seal

2. Needle roller bearing 2. Roller bearing

2. Remove and discard the circlip. 3. Distance sleeve

3. Noting its orientation, remove the bearing from 6. Mark one side of first gear to denote its
the output shaft. correct orientation and remove it from the
shaft.

Thruxton R 215
Transmission

7. Remove the needle roller bearing from the 10. Discard the circlip.
shaft.
2
3
2 1

1
3

cjgh_2
1. Circlip
1. Thrust washer 2. Splined thrust washer
2. First gear 3. Output shaft
3. Needle roller bearing
11. Mark one side of fourth gear to denote its
4. Output shaft correct orientation and remove it from the
8. Mark one side of fifth gear to denote its shaft.
correct orientation and remove it from the 12. Noting its orientation, remove the plain bush
shaft. which runs inside the gear.

3
2
4
1

2 5
1

cjgg_1 cjgf

1. Fifth gear 1. Circlip

2. Output shaft 2. Splined thrust washer
9. Remove the circlip and splined thrust washer. 3. Fourth gear
4. Plain bush
5. Output shaft

216 Thruxton R
 Transmission

13. Working on the opposite end of the shaft, 19. Noting its orientation, remove the sixth gear.
attach a proprietary bearing separator
between the outer bearing and second gear as
shown below. Using a press, remove the outer
bearing and the distance sleeve.

4 2
1
2
1

cjgd_1

1. Sixth gear
2. Output shaft
cjgm
20. Remove the circlip and the splined thrust
1. Bearing washer, discard the circlip.
2. Distance sleeve
3. Output shaft
4. Bearing separator

14. Discard the bearing.

15. Remove the second gear spacer.
16. Mark one side of second gear to denote its
correct orientation and remove it from the
shaft.
17. Noting its orientation, remove the plain bush
4
from the shaft.
2
18. Remove the thrust washer from the shaft.
1 3
cjgi

2 1. Circlip
1 3 2. Splined thrust washer
4 3. Third gear
4. Output shaft

cjge_1

1. Second gear spacer

2. Second gear
3. Bush
4. Thrust washer
5. Output shaft

Thruxton R 217
Transmission

21. Mark one side of third gear to denote its Output Shaft - Assembly 6 speed
correct orientation and remove it from the
shaft.
22. Noting it’s orientation, remove the plain bush
Warning
from the shaft. When using a press, always wear overalls, eye,
face and hand protection. Objects such as
3 bearings frequently break-up under load and the
debris caused during break-up may cause damage
2 and injury to unprotected parts of the body.
4
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to
the hand, arms or other parts of the anatomy.

Caution
5
1 Bushes with oil holes must always be MISALIGNED
with the corresponding oil holes in the output
shaft. Reduced oil pressure and gear lubrication
cjgc may result from alignment of the oil holes, which
would cause premature wear of engine and
1. Circlip
transmission components.
2. Splined thrust washer
3. Third gear
4. Third gear bush Caution
5. Output shaft Removing the output shaft bearing from the shaft
will damage the bearing and snap ring. Never
reuse removed bearings or snap rings as use of
damaged or weakened components could lead to
engine and transmission damage.

Caution
Press only on the bearing inner race to prevent
bearing damage.

Note:
• Lubricate each gear, thrust washer and bush
with clean engine oil during assembly.
1. Locate third gear and the plain bush to the
shaft as noted during disassembly.

218 Thruxton R
 Transmission

2. Fit the splined thrust washer and retain with a 6. Fit the second gear spacer.
new circlip as shown below.
2

1 3
4

4 5
2

3
1 cjge_1

cjcl
1. Second gear spacer
1. Circlip 2. Second gear
2. Splined washer 3. Bush
3. Third gear 4. Thrust washer
4. Output shaft 5. Output shaft
3. Fit the sixth gear as noted during disassembly. 7. Place the output shaft on a press bar, align
the inner race of the ball bearing to the output
shaft.
8. Press the output shaft through the bearing
until the bearing face contacts the thrust
washer.

2 2
1

cjgd_1

1. Sixth gear
2. Output shaft

4. Fit the thrust washer.

5. Locate second gear and the plain bush to the cjgl

shaft as noted during disassembly.

1. Output shaft
2. Ball Bearing

Note:
• Ensure the chamfered edge is facing away
from the roller bearing.
9. Locate the distance sleeve to the bearing,

Thruxton R 219
Transmission

10. Press the output shaft through the distance 16. Fit the splined thrust washer and retain using
sleeve until it comes into contact with the a new circlip new circlip, as shown below.
bearing face.
3
4 2
4
1 1
2
3

cjgf

cjgb_1
1. Circlip
1. Distance sleeve 2. Splined thrust washer
2. Ball bearing 3. Fourth gear
3. Spacer 4. Plain bush
4. Output shaft 5. Output shaft
11. Lubricate and fit a new output shaft seal. 17. Fit fourth gear as noted during disassembly.
Ensure that the smaller dogs face towards
2 1 fourth gear.

3
2
cjgk 1
1. Output shaft seal
cjgg_1
2. Roller bearing
1. Fifth gear
12. Distance sleeve
2. Output shaft
13. Fit the output sprocket, new tab washer and
nut. Do not fully tighten the nut at this stage. 18. Fit the plain bush as noted during disassembly.
14. Working from the opposite end of the shaft, fit 19. Fit first gear as noted during disassembly.
the plain bush as noted during disassembly.
15. Fit fourth gear as noted during disassembly.

220 Thruxton R
 Transmission

20. Fit the thrust washer. 22. Retain the roller bearing using a new circlip.

1
3

2
4
3
T908.07.27
cjgh_2

1. Thrust washer 1. Circlip

2. First gear 2. Needle roller bearing
3. Needle roller bearing 3. Thrust washer
4. Output shaft 23. Lubricate the bearing with oil and then slide
21. Fit the roller bearing to the output shaft as the bearing outer roller carrier over the needle
noted during disassembly. roller bearing in the orientation noted during
disassembly.

2
1
cjbz

1. Bearing outer carrier

2. Needle roller bearing

Thruxton R 221
Transmission

Output Shaft - Inspection

1. Examine all gears, bearings, bushes and thrust
washers for damage, distortion, chipped teeth
and wear beyond the service limits. Replace all
defective components and always use new
circlips, a new output shaft seal and a new
sprocket tab washer to assemble the shaft.

222 Thruxton R
 Transmission

Input Shaft

1
2
3

7
8
9

10
11
12

13

14

15
16
17

Thruxton R 223
Transmission

1. Bearing retainer bolts

2. Bearing retainer plate
3. Ball bearing
4. Input shaft
5. Plain bush
6. Fifth gear
7. Splined thrust washer
8. Circlip
9. Third/fourth gear
10. Circlip
11. Splined thrust washer
12. Splined bush
13. Sixth gear
14. Second gear
15. Circlip
16. Roller bearing
17. Restrictor washer

224 Thruxton R
 Transmission

Input Shaft - Disassembly 1. Attach service tool T3880109 to the bearing,

ensuring the flat side of the tool’s jaws are in
contact with the bearing.
Warning
When using a press, always wear overalls, eye,
face and hand protection. Objects such as
bearings frequently break-up under load and the
debris caused during break-up may cause damage
and injury to unprotected parts of the body.
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to
the hand, arms or other parts of the anatomy.

Note:
• The gears on the input shaft can not be fully
disassembled or assembled in service. If for
any reason a gear requires replacing, the
complete input shaft assembly must be Service Tool Installation
replaced.
2. Support the service tool T3880109 on press
1. Remove the restrictor washer, and roller bars, then press the shaft through the
bearing. bearing. Discard the bearing.

4
1
2
4 3

3 1
2

cjbx
cfwh

1. Restrictor washer 1. Input shaft

2. Roller bearing 2. Bearing
3. Input shaft 3. T3880109 - Bearing Separator
4. Press bars
Warning
When using a press, always wear overalls, eye,
face and hand protection. Objects such as
bearings frequently break-up under load and the
debris caused during break-up may cause damage
and injury to unprotected parts of the body.
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to
the hand, arms or other parts of the anatomy.

Thruxton R 225
Transmission

Input Shaft - Inspection Input Shaft - Assembly

Examine all gears, bearings, bushes and thrust
washers for damage, distortion, chipped teeth and
wear beyond the service limits. Replace all defective
Warning
components. When using a press, always wear overalls, eye,
face and hand protection. Objects such as
bearings frequently break-up under load and the
debris caused during break-up may cause damage
and injury to unprotected parts of the body.
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to
the hand, arms or other parts of the anatomy.

Caution
Removing the input shaft bearing from the shaft
will damage the bearing. Never reuse removed
bearings as use of damaged or weakened
components could lead to engine and transmission
damage.

Note:
• Lubricate the bearings with clean engine oil
during assembly.
1. Position a new bearing to the input shaft.
2. Support the bearing on press bars as shown
below, ensuring that the press bars support
the inner race of the bearing.

226 Thruxton R
 Transmission

3. Press the bearing fully on to the shaft.

3 1

cjcg

1. Input shaft
2. Bearing
3. Press plates

4. Fit the roller bearing and restrictor washer to

the input shaft.

3 1
2

cjbx

1. Restrictor washer
2. Roller bearing
3. Input shaft

Thruxton R 227
Transmission

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228 Thruxton R
 15 Starter Drive And Sprag Clutch
Table of Contents
Exploded View - Starter and Sprag .................................................................................................................................................... 231
Starter Drive/Sprag Clutch - Removal ............................................................................................................................................... 232
Starter Drive/Sprag Clutch - Inspection .......................................................................................................................................... 234
Starter Drive/Sprag Clutch - Installation......................................................................................................................................... 234

Thruxton R 229
Starter Drive And Sprag Clutch

230 Thruxton R
 Starter Drive And Sprag Clutch

Exploded View - Starter and Sprag

12 Nm
16 Nm
16 Nm

16 Nm

Thruxton R 231
Starter Drive And Sprag Clutch

Starter Drive/Sprag Clutch - 2. Using service tool T3880375 to retain the

flywheel, remove and discard the fixings
Removal securing the starter gear thrust washer to the
sprag clutch housing, as shown below.
Warning
4
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 2
operator or damage to the motorcycle.

• Remove the clutch cover (see Clutch Cover -

Removal, page 97). 3
1. Whilst holding the first idler gear in position,
withdraw the second starter idler shaft and
gear, noting the fitted position of the
components.
1
ciwv

1 1. Fixings
2 2. T3880375 - Alternator Rotor Holder
3. Sprag clutch housing
3
4. Thrust washer

3. Remove and discard the fixings securing the

sprag clutch housing to the flywheel.

1
ciwu

1. Starter idler gear (first)

2. Starter idler gear (second)
3. Starter sprag gear
1

ciwt

1. Fixings

232 Thruxton R
 Starter Drive And Sprag Clutch

4. Withdraw the starter sprag gear and sprag 5. Remove the starter sprag gear from the sprag
clutch assembly. clutch housing and assembly.

1
2

3
ciws cixh

Starter Sprag Gear 1. Starter sprag gear

2. Sprag clutch housing
3. Sprag clutch

6. Remove the sprag clutch from the sprag

clutch housing.

1 2

1. Sprag clutch housing

2. Sprag clutch

Thruxton R 233
Starter Drive And Sprag Clutch

Starter Drive/Sprag Clutch - Starter Drive/Sprag Clutch -

Inspection Installation
1. Check the sprag clutch bearings for 1. Locate the sprag clutch to the sprag clutch
overheating, wear and/or non-smooth housing as shown below. Push firmly until the
operation. Replace the sprag clutch if lip seats in the recess provided in the housing.
overheating, wear and/or non-smooth
operation is found. 2
1
2. Examine all gears for chipped teeth and for
any other damage.
3. With the sprag clutch mounted in the housing,
check the sprag clutch for smooth, free
movement in one direction only (as indicated
by the arrow marked on the sprag clutch
body).

1. Sprag clutch housing

2. Sprag clutch

2. Fit the starter sprag gear to the sprag clutch.

3. Lubricate the crankshaft bearing with engine
oil.
4. Fit the sprag clutch housing to the flywheel.
5. Ensure that the housing is squarely seated
and is not jammed on the rotor.

1
2

3
cixh

1. Starter sprag gear

2. Sprag clutch housing
3. Sprag clutch

Note:
• Ensure the sprag is seated and flush fitting to
the housing before tightening the fixings fully.

234 Thruxton R
 Starter Drive And Sprag Clutch

6. Align the drilled holes in the sprag clutch 8. Using tool T3880375 - Alternator Rotor Holder
housing with the holes in the flywheel. Tool to retain the flywheel and using new
fixings secure the starter gear thrust washer
to the flywheel. Tighten the fixings to 12 Nm.

ciws

Sprag clutch housing assembly 1

ciwv

7. Using service tool T3880375 to retain the

1. Fixings
flywheel and working in the sequence shown,
fit the new fixings and tighten to 16 Nm. 2. T3880375 - Alternator Rotor Holder
Repeatedly check the fixings in sequence until 3. Sprag clutch housing
all are correctly torqued and do not move
4. Thrust washer
when checked, this will ensure the sprag
clutch housing is correctly seated on the rotor. 9. Refit the starter idler gear and shaft, as noted
during removal.

1 3
2

3 1
6 5

4 2

ciwr
Tightening Sequence
1. Starter idler gear (second)
2. Starter idler gear (first)
3. Starter sprag gear
• Refit the clutch cover (see Clutch Cover -
Installation, page 98).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 235
Starter Drive And Sprag Clutch

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236 Thruxton R
 16 Lubrication
Table of Contents
Exploded View – Oil Filter and Pump................................................................................................................................................. 239
Oil Circuit Diagram ...................................................................................................................................................................................... 240
Oil Circuit .......................................................................................................................................................................................................... 241
Engine Oil - Specification......................................................................................................................................................................... 242
Disposal of Used Engine Oil and Oil Filters ..................................................................................................................................... 242
Engine Oil - Level Inspection ................................................................................................................................................................. 243
Oil and Oil Filter Change........................................................................................................................................................................... 244
Low Oil Pressure Warning Light Switch - Removal .................................................................................................................... 245
Low Oil Pressure Warning Light Switch - Installation .............................................................................................................. 246
Oil and Water Pump - Removal ............................................................................................................................................................ 247
Oil Pump Disassembly ............................................................................................................................................................................... 250
Oil Pump Inspection ................................................................................................................................................................................... 250
Oil Pump Rotor Tip Clearance ................................................................................................................................................................. 251
Oil Pump Body Clearance .......................................................................................................................................................................... 251
Oil Pump End Clearance ............................................................................................................................................................................ 252
Oil Pump - Assembly................................................................................................................................................................................... 253
Oil and Water Pump - Installation........................................................................................................................................................ 253
Oil Pressure Relief Valve - Removal ................................................................................................................................................... 256
Oil Pressure Relief Valve - Installation............................................................................................................................................... 257

Thruxton R 237
Lubrication

238 Thruxton R
 Lubrication

Exploded View – Oil Filter and Pump

9 Nm

15 Nm

10 Nm 9 Nm

10 Nm 10 Nm

10 Nm

10 Nm

Thruxton R 239
Lubrication

Oil Circuit Diagram

240 Thruxton R
 Lubrication

Oil Circuit
Oil is collected from the sump and is drawn through a mesh strainer into the oil pump rotor. The oil pump is
fitted with a single pumping rotor assembly which supplies pressurised oil to the lubrication circuit. The oil
circuit is split into two parts - the Main circuit and the Transmission circuit.

Main Circuit
Pressurised oil flows past the oil pressure relief valve, which controls the maximum pressure in the oil
circuit. The relief valve is set to open at 5.1 bar (74 lb/in²) and when open, returns high pressure oil directly
to the oil pump inlet port.
The oil then flows through the oil filter. Filtered oil is then fed into the lower crankcase gallery. The low oil
pressure switch is located in this gallery.
From here oil is distributed around the engine:
• A branch supplies oil to the main gallery below the main bearings. Here it is delivered to the crankshaft
main bearings and, via drillings in the crankshaft, to the big end bearings.
• Oil is also fed to the alternator to aid cooling of the alternator. The oil is taken from the crankshaft oil
feed and directed to the alternator stator and rotor.
• Spray jets located in the upper crankcase, above the front balance shaft, lubricate the pistons and
connecting rod small ends. These jets are fed oil from the cylinder head oil feed.
• Another branch from the cylinder head oil feed supplies oil to the hydraulic camshaft drive chain
tensioner.
• Oil is sent to the cylinder head via a drilling in the upper crankcase. From the crankcase he oil divides
into the two front cylinder head bolt drilling’s, up through the cylinder barrels and into the cylinder
head. one of the bolt drilling’s feeds the left hand cam shaft frame and the other feeds the right hand
camshaft frame. Drillings and grooves in the camshaft frames allow oil to flow to the camshaft journals
and rocker shafts. Oil from the cylinder head area lubricates the camshaft drive chain before draining
back to the sump.

Transmission Circuit
• Pressurised oil is directed via drillings to the input and output shafts and the clutch. Oil is circulated
along the gearbox shafts to exit holes that feed directly to the bearings and gears before draining back
to the sump.
• The selector drum is splash fed by oil returning to the sump from the transmission gears.

Thruxton R 241
Lubrication

Engine Oil - Specification Disposal of Used Engine Oil and Oil

Use semi or fully synthetic 10W/40 or 10W/50 Filters
motorcycle engine oil which meets specification API To protect the environment, do not pour oil on the
SH (or higher) and JASO MA, such as Castrol Power ground, down sewers or drains, or into
1 Racing 4T, sold as Castrol Power RS Racing 4T in watercourses. Do not place used oil filters in with
some countries. general waste. If in doubt contact your local
Triumph recommends the fully synthetic 10W/40 authority.
motorcycle engine oil for most conditions. The oil
viscosity may need to be changed to accommodate
the ambient temperatures in your riding area.
Refer to the chart below for the correct oil viscosity
(10W/40 or 10W/50) to be used in your riding area.

Ambient Temperature (°C)

-20 -10 0 10 20 30 40 (°C)

SAE 10W/50
SAE 10W/40

-4 14 32 50 68 86 104 (°F)
Ambient Temperature (°F)
Oil Viscosity Temperature Range

Caution
Triumph high performance fuel injected engines
are designed to use semi or fully synthetic
motorcycle engine oil which meets specification
API SH (or higher) and JASO MA.
Do not add any chemical additives to the engine
oil. The engine oil also lubricates the clutch and
any additives could cause the clutch to slip.
Do not use mineral, vegetable, non-detergent oil,
castor based oils or any oil not conforming to the
required specification. The use of these oils may
cause instant, severe engine damage.
Ensure no foreign matter enters the crankcase
during an oil change or top up.

242 Thruxton R
 Lubrication

Engine Oil - Level Inspection 4. When correct, oil should be visible at a point
between the upper level and the lower level on
In order for the engine, transmission, and clutch to
the sight-glass.
function correctly, maintain the engine oil at the
correct level, and change the oil and oil filter in
accordance with scheduled maintenance
requirements.

Warning 3
1
Never start the engine or run the engine in a 4
confined area. Exhaust fumes are poisonous and
can cause loss of consciousness and death within
a short period of time. Always operate your 2
motorcycle in the open-air or in an area with
adequate ventilation.

Warning citl

1. Filler
Motorcycle operation with insufficient,
2. Sight-glass
deteriorated, or contaminated engine oil will cause
accelerated engine wear and may result in engine 3. Upper level (maximum)
or transmission seizure. Seizure of the engine or 4. Lower level (minimum)
transmission may lead to loss of motorcycle
control and an accident. Note:
• An accurate indication of the level of oil in the
engine is only shown when the engine is at
Caution normal operating temperature and the
motorcycle is upright (not on the side stand).
Running the engine with insufficient oil will cause
engine damage. If the low oil pressure indicator 5. If it is necessary to top up the oil level, remove
remains on, stop the engine immediately and the filler plug and add oil, a little at a time, until
investigate the cause. the level registered in the sight glass is
correct.
1. Start the engine and run at idle for 6. Once the correct level is reached, fit and
approximately five minutes. tighten the filler plug.
2. Stop the engine, then wait for at least three
minutes to allow the oil to settle.
3. Note the oil level visible in the sight-glass.

Thruxton R 243
Lubrication

Oil and Oil Filter Change 5. Unscrew and remove the oil filter using service
tool T3880313.

Warning 6. Dispose of the old filter in an environmentally

friendly way.
Prolonged or repeated contact with engine oil can 7. Apply a smear of clean engine oil to the sealing
lead to skin dryness, irritation and dermatitis. In ring of the new oil filter.
addition, used engine oil contains potentially
8. Using service tool T3880313, fit the new oil
harmful contamination which can cause cancer.
filter and tighten to 10 Nm.
Wear suitable clothing and avoid skin contact.
9. Fit a new sealing washer to the drain plug.
The engine oil and filter must be replaced in
accordance with scheduled maintenance 10. Fit and tighten the drain plug to 25 Nm.
requirements. 11. Fill the engine with new oil of the type and
grade (see Engine Oil - Specification, page 242).
12. Start the engine and allow it to idle for a
Caution minimum of 30 seconds.
Do not pour engine oil on the ground, down
sewers or drains, or into watercourses. To prevent Caution
pollution of watercourses etc., dispose of used oil
sensibly. If in doubt contact your local authority. Raising the engine speed above idle before the oil
reaches all parts of the engine can cause engine
1. Warm up the engine thoroughly, and then stop damage or seizure. Only raise engine speed after
the engine. running the engine for 30 seconds to allow the oil
to circulate fully.
2. Place a waste oil catch tray beneath the
engine.
Caution
Warning
If the engine oil pressure is too low, the low oil
The oil may be hot to the touch. Contact with hot pressure warning light will illuminate. If this light
oil may cause the skin to be scalded or burned. stays on when the engine is running, stop the
engine immediately and investigate the cause.
3. Remove the oil drain plug and discard the Running the engine with low oil pressure will
washer. cause engine damage.

13. Ensure that the oil pressure warning light

extinguishes shortly after starting.
14. Stop the engine and check the oil level. Adjust
if necessary.

cjkf 1 2
1. Oil drain plug
2. Oil filter

4. With the motorcycle on level ground, and on

its side stand, allow the oil to completely drain.

244 Thruxton R
 Lubrication

Low Oil Pressure Warning Light 1. Remove the lock nuts and detach the coolant
expansion tank from its mounting. Discard the
Switch - Removal lock nuts.

Warning 1

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.

Warning
Prolonged or repeated contact with engine oil can
lead to skin dryness, irritation and dermatitis. In 1
addition, used engine oil contains potentially 2
harmful contamination which can cause cancer.
Wear suitable clothing and avoid skin contact. cjpt

The engine oil and filter must be replaced in 1. Fixings

accordance with scheduled maintenance 2. Coolant expansion tank
requirements.
2. Remove the fixings, detach the alternator
harness and remove the coolant expansion
tank mounting.
Caution
Do not pour engine oil on the ground, down
sewers or drains, or into watercourses. To prevent
pollution of watercourses etc., dispose of used oil 1
sensibly. If in doubt contact your local authority.

The low oil pressure warning light switch is located

in the lower crankcase, behind the sprocket cover.
• Remove the seat (see Seat - Removal, page
636). 2
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the sprocket cover (see Front Sprocket 3
1
Cover - Removal, page 104).
cjqg

1. Fixings
2. Harness clip
3. Alternator harness

3. Disconnect the electrical connector.

Note:
• A small amount of oil will drain from the oil
gallery when the switch is removed.

Thruxton R 245
Lubrication

4. Position a suitable receptacle to collect any Low Oil Pressure Warning Light
displaced oil from the oil gallery.
Switch - Installation
5. Remove the switch and discard the sealing
washer. 1. Incorporating a new sealing washer, fit the low
oil pressure light switch
1 2. Tighten the switch to 15 Nm.

ciua

1. Low oil pressure warning light switch

ciua

1. Low oil pressure warning light switch

3. Reconnect the electrical connector.

4. Attach the alternator harness to the coolant
expansion tank mounting, fit the inner cover
and tighten its fixings to 7 Nm.

3
1
cjqg

1. Fixings
2. Harness clip
3. Alternator harness

246 Thruxton R
 Lubrication

5. Refit the coolant expansion tank to its Oil and Water Pump - Removal
mountings and tighten the new lock nuts to 3
Nm.
Warning
1
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.

Warning
Prolonged or repeated contact with engine oil can
lead to skin dryness, irritation and dermatitis. In
addition, used engine oil contains potentially
1 harmful contamination which can cause cancer.
2 Wear suitable clothing and avoid skin contact.
cjpt
The engine oil and filter must be replaced in
1. Fixings accordance with scheduled maintenance
requirements.
2. Coolant expansion tank

6. Refit the sprocket cover (see Front Sprocket

Cover - Installation, page 105). Caution
7. Reconnect the battery positive, (red) lead first
Do not pour engine oil on the ground, down
(see Battery - Installation, page 658) and
sewers or drains, or into watercourses. To prevent
tighten the terminals to 4.5 Nm.
pollution of watercourses etc., dispose of used oil
8. Start the engine and ensure that the oil sensibly. If in doubt contact your local authority.
pressure warning light extinguishes shortly
after starting. • Remove the seat (see Seat - Removal, page
9. Allow the engine to idle for a minimum of 30 636).
seconds. • Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
Caution Note:
If the engine oil pressure is too low, the low oil • The oil pump and water pump are supplied as
pressure warning light will illuminate. If this light an assembly and cannot be separated. This
stays on when the engine is running, stop the procedure covers the removal of the oil and
engine immediately and investigate the cause. water pump assembly.
Running the engine with low oil pressure will • Drain the coolant (see Coolant Replacement -
cause engine damage. Drainage, page 453).
• Drain the engine oil (see Oil and Oil Filter
10. Stop the engine and check the oil level as Change, page 244).
described (see Engine Oil - Level Inspection, • Remove the sump (see Sump - Removal, page
page 243). Adjust if necessary. 94).
11. Refit the seat (see Seat - Installation, page • Remove the clutch (see Clutch - Removal, page
636). 158).
1. Release the oil pick-up from the oil seal.

Thruxton R 247
Lubrication

2. Remove and discard the oil seal. 4. Support the oil pump drive sprocket and
carefully remove the bush, spacer and needle
roller bearing while noting it’s orientation.
1

3
2

2
4
cjaq

1. Oil pick-up
ciue

2. Oil seal
1. Oil pump drive sprocket
3. Slide the oil pump drive sprocket gently
2. Needle roller bearing
backwards and forwards and remove the
needle roller bearing. 3. Spacer
4. Bush
1
5. Release and discard the fixings securing the oil
and water pump.

1
2

ciuc

1. Oil pump drive sprocket

2. Needle roller bearing
ciud 2
1. Oil and water pump
2. Fixings

248 Thruxton R
 Lubrication

6. Detach the drive chain from the oil pump drive 9. Remove and discard the four O-rings from the
sprocket. coolant outlet sleeve and then remove and
discard the two O-rings from the oil outlet
1 sleeve.

2 3

ciuf

1. Oil pump drive sprocket

ciuh

2. Drive chain
1. Coolant outlet sleeve
7. Carefully withdraw the oil and water pump
2. O-ring (coolant)
from the crankcase.
3. Oil outlet sleeve
Note:
4. O-ring (oil)
• The water pump inlet sleeve/O-rings can
become dislodged during removal of the oil 10. Remove and discard the coolant inlet O-ring
pump. from the crankcase.
8. Remove the coolant outlet sleeve and the oil
pump outlet sleeve from the crankcase.

ciug

1. O-ring (coolant inlet)

3
ciuj

1. Coolant outlet sleeve

2. Oil outlet sleeve
3. Coolant inlet seal

Thruxton R 249
Lubrication

Oil Pump Disassembly Oil Pump Inspection

1. Inspect the sprocket and chain for wear and/
Inspection or damage. Replace the pump and chain if
1. Using service tool T3880603 release the fixing wear is found.
and remove the drive sprocket and spacer 2. Check the shaft and shaft bearings for side
washer. and end float. Replace the pump if wear is
found.
3. Carry out a visual inspection for corrosion and
scale build-up around the coolant pump
impeller and in the coolant pump body. Replace
the pump assembly if necessary.

chhn

1. T3880603 - Oil Pump Restraint

2. Release the three fixings and withdraw the oil

pump end plate.

ciuk 1
1. Oil pump end plate
2. Fixings

Caution
If any part of the oil pump is found to be outside
the service limit, the complete pump must be
replaced. Severe engine damage may result from
the continued use of a faulty oil pump.

250 Thruxton R
 Lubrication

Oil Pump Rotor Tip Clearance Oil Pump Body Clearance

1. Measure the rotor tip clearance using feeler 1. Measure the pump body clearance using feeler
gauges. gauges.
2. For specifications refer to Lubrication, page 45. 2. For specifications refer to Lubrication, page 45.

chho_1 chhp

Rotor Tip Clearance Pump Body Clearance

Thruxton R 251
Lubrication

Oil Pump End Clearance 8. For specifications refer to Lubrication, page 45.

1. Remove the end plate from the pump.

2
2. Wipe the exposed areas of the rotors and the 3 0.025

machined face of the end plate. 0.038

Note: 0.050 1
• The oil pump end clearance is measured using 0.063

Plastigauge (Triumph part number 3880150- 0.076

T0301). Do not turn the oil pump during the 0.100

clearance measurement as this will damage 0.125

0.150
the 'Plastigauge'. 0.175

3. Apply a thin smear of grease to the rotor and

a small quantity of silicone release agent to
the face of the end plate.
4. Cut a length of the Plastigauge to fit across cdqi_2

the rotor. Fit the strip to the rotor using the 1. Rotor (outer)
grease to hold the Plastigauge in place.
2. Plastigauge
3. Gauge, in millimetres
2 9. If the clearance measured is within the
1 specified tolerance, clean off all traces of
Plastigauge from the outer rotor and oil pump
cover.
10. If any clearance measured is outside the
service limits, renew the complete pump.

cdqi_1

1. Outer rotor
2. Plastigauge

5. Without any twisting action, refit the oil pump

cover and tighten its fixings to 10 Nm.
6. Release the bolts and carefully remove the end
plate.
7. Using the gauge provided with the Plastigauge
kit, measure the width of the compressed
Plastigauge.

252 Thruxton R
 Lubrication

Oil Pump - Assembly Oil and Water Pump - Installation

1. If all clearances are within service limits,
liberally apply clean engine oil to all internal Caution
components and refit the rotor to the oil pump
body. Before fitting the pump to the crankcase ensure
the pump internal surfaces have been wetted with
2. Refit the end plate. Apply ThreeBond 1374 to
clean engine oil. The pump may fail to pick up oil
the fixings, refit and tighten to 10 Nm.
from the sump if the surfaces have not been
wetted. This will cause the engine to run without
engine oil pressure and will lead to severe engine
damage.

1. Install four new O-rings to the water pump

outlet sleeve.
2. Install two new O-rings to the oil pump outlet
2
sleeve.

ciuk 1
1
1. Oil pump end plate
2 3
2. Fixings

3. Refit the spacer washer and drive sprocket.

Apply ThreeBond 1374 to the fixing and tighten 4
to 12 Nm.

1
ciuh

2 1. Coolant outlet sleeve

2. O-ring (coolant)
3 3. Oil outlet sleeve
4. O-ring (oil)
4

chhm_1

1. Oil pump
2. Spacer washer
3. Drive sprocket
4. Fixing

Thruxton R 253
Lubrication

3. Fit the coolant outlet sleeve, the oil outlet 8. Refit the oil and water pump. Install new
sleeve and the coolant inlet O-ring to the fixings and tighten to 10 Nm.
crankcase.
1

ciud 2
3
ciuj
1. Pump
1. Coolant outlet sleeve 2. Fixings
2. Oil outlet sleeve
3. O-ring (coolant inlet)

4. Fill the oil pump with new engine oil, turning

the pump rotor as the oil is poured in to
ensure all surfaces are coated with oil.
5. Position the oil and water pump to the
crankcase inserting the oil pump outlet sleeve
and the water pump outlet sleeve into the
openings.

Caution
Do not use excessive force to insert the outlet
sleeves into the oil pump. Severe oil pump or
outlet sleeve damage may result from the use of
excessive force.

6. Feed the drive chain over the transmission

input shaft and fit to the sprocket.
7. Fit the drive chain on to the oil pump sprocket.

254 Thruxton R
 Lubrication

9. Support the oil and water pump drive sprocket • Reconnect the battery, positive (red) lead first
and carefully refit the bush spacer and needle (see Battery - Installation, page 658) and
roller bearing as noted during removal. tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
1

3
2

ciue

1. Drive sprocket
2. Needle roller bearing
3. Spacer
4. Bush

10. Install a new oil seal and refit the oil pick-up.

cjaq

1. Oil pick-up
2. Oil seal
• Refit the clutch (see Clutch - Installation, page
162).
• Refit the sump, ensuring the water pump drain
tube is correctly installed (see Sump -
Installation, page 95).
• Refill the engine with oil (see Oil and Oil Filter
Change, page 244).
• Refill the cooling system (see Coolant
Replacement - Filling, page 454).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).

Thruxton R 255
Lubrication

Oil Pressure Relief Valve - Removal 2. Carefully withdraw the oil pressure relief valve
from the oil pump housing.

Warning 3. Remove and discard the O-ring from the oil

pressure relief valve.
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.

Warning
Prolonged or repeated contact with engine oil can
lead to skin dryness, irritation and dermatitis. In
addition, used engine oil contains potentially
harmful contamination which can cause cancer.
Wear suitable clothing and avoid skin contact.
The engine oil and filter must be replaced in
accordance with scheduled maintenance
requirements.

The oil pressure relief valve is located in the oil

pump housing. It is positioned behind a threaded
blanking plug in the oil pump body.
• Remove the seat (see Seat - Removal, page
636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the sump (see Sump - Removal, page
94).

Warning
The oil may be hot to the touch. Contact with hot
oil may cause the skin to be scalded or burned.

1. Remove the blanking plug.

citz

1. Blanking plug

256 Thruxton R
 Lubrication

Oil Pressure Relief Valve -

Installation
1. Lubricate the new O-ring with clean engine oil
and fit to the oil pressure relief valve.

city

1. Oil pressure relief valve

2. O-ring

2. Refit the oil pressure relief valve as noted

during removal.
3. Refit the blanking plug and tighten to 10 Nm.
4. Refit the sump, ensuring the water pump drain
tube is correctly installed (see Sump -
Installation, page 95).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 257
Lubrication

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258 Thruxton R
 17 Engine Removal And Installation
Table of Contents
Engine - Removal ......................................................................................................................................................................................... 261
Engine - Installation................................................................................................................................................................................... 265

Thruxton R 259
Engine Removal And Installation

260 Thruxton R
 Engine Removal And Installation

Engine - Removal 4. Remove the fixings securing the front

sprocket cover to the crankcase.

Warning
Before starting work, ensure the motorcycle is 2
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 side panels (see Side Panels, page
637).
• Remove the left and right hand frame cradles
(see Cradle Assemblies - Removal, page 640).
• Remove the exhaust system (see Exhaust
Intermediate and Header Pipes - Removal, page
2
431).
• Remove the throttle body (see Throttle Body -
Removal, page 421). 1. Front sprocket cover

• Remove the radiator (see page Radiator - 2. Fixings

Removal, page 462). 5. Remove the lock nuts and detach the coolant
• Drain the engine oil (see Oil and Oil Filter expansion tank from its mounting. Discard the
Change, page 244). lock nuts.
1. From the top of the frame, disconnect the
1
following electrical connectors:
• Spark plug leads.
• Fuel injectors
• Coolant temperature sensor.
2. Disconnect the clutch cable from the
crankcase (see Clutch Cable - Removal, page
155).
3. Remove and discard the fixing and detach the
rear brake fluid reservoir from the relay
bracket.
1
2
cjpt

1. Fixings
2 2. Coolant expansion tank

citi_1

1. Fixing
2. Brake fluid reservoir

Thruxton R 261
Engine Removal And Installation

6. Remove the fixings, detach the alternator 8. Disconnect the oil pressure switch electrical
harness and remove the coolant expansion connector.
tank mounting.

3
1
ciua_1

cjqg
1. Electrical connector
1. Fixings
9. Noting their orientation route the cables away
2. Harness clip from the frame.
3. Alternator harness 10. Loosen the drive chain and remove it from the
7. From the right hand side, disconnect the front sprocket (see Final Drive Chain
following electrical connectors: Adjustment, page 613).
• Gear position sensor. 11. Remove the two fixings and remove the left
• Crankshaft position sensor. heal guard.
• Starter motor cable from the starter motor
solenoid. 2

1
1

3
2
cjsb

1. fixings
ciwh
2. Heal guard
1. Gear position sensor connector
12. Remove the two fixings and detach the left
2. Crankshaft position sensor connector hand control plate from the frame.
3. Starter motor cable
4. Starter motor solenoid

262 Thruxton R
 Engine Removal And Installation

13. Carefully remove the swinging arm pivot cover 17. Engage service tool T3880104 in the slots of
on the left hand side of the frame. the frame adjuster sleeve and rotate
anticlockwise to loosen the sleeve fully.

2
3

1
2

cjsa

cjbc
1. Fixings
2. Control plate 1. Frame adjuster

3. Cover 2. T3880104 - Swinging Arm Adjuster Wrench

14. Remove the swinging arm pivot nut and collect Note:
the washer on the right hand side of the • Note the routing of the brake switch harness
frame. for installation.
18. Remove the alternator regulator/rectifier (see
Alternator Regulator/Rectifier - Removal, page
2 694).
1 Note:
• Note the routing of the alternator harness and
its clips for installation.
19. Route the alternator harness with the grey
electrical connector to the alternator cover.
20. From the left hand side, disconnect the engine
earth strap.
21. Disconnect the crankcase breather hose.

cjrw
1
1. Nut
2. Washer

15. Support the swinging arm and remove the

swinging arm spindle and washer from the left 2
hand side.
16. Partially fit the swinging arm spindle on the
right hand side to support the swinging arm.

civr

1. Hose clips
2. Engine breather pipe

Thruxton R 263
Engine Removal And Installation

22. Release the engine mounting nuts. Collect the 28. Lower the engine away from the frame, taking
nuts and washers, leaving the bolts in position. care to avoid damage to the brake pipes.
23. Remove the left hand cylinder head mounting 29. When the engine has been removed, check to
bolt. ensure that the brake line is attached to the
24. Using service tool T3880377 release the: ABS modulator bracket as shown in the
following illustration. Rectify if necessary.
• Rear cylinder head mounting adjuster on
the left side of the frame,
• Upper rear crankcase mounting adjuster,
• Lower rear crankcase mounting adjuster,
• Left hand cylinder head mounting adjuster.
25. Remove the right hand cylinder head
mounting bolt.
2
26. Remove the remaining mounting bolts,
collecting the spacer from the lower crankcase
mounting bolt.

Caution 3
1
Two brake lines are attached to the brake line tidy
cjsr
on the rear of the crankcase.
Failure to detach the brake lines from the brake 1. ABS brake line
line tidy will cause damage to the braking system. 2. Retaining clips
3. ABS modulator bracket
27. Detach the brake lines from the brake line tidy
and position away from the crankcase.

1. Brake line from ABS modulator to front master

cylinder
2. Brake line from ABS modulator to front brake caliper
3. Brake line tidy

264 Thruxton R
 Engine Removal And Installation

Engine - Installation 3. Attach the brake lines to the brake line tidy.

Warning 2

Before starting work, ensure the motorcycle is 1

stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Prior to fitting the engine, check to ensure 3

that the brake line is attached to the ABS
modulator bracket as shown in the following
illustration. Rectify if necessary.

1. Brake line from ABS modulator to front master

cylinder.
2. Brake line from ABS modulator to front brake caliper

2 3. Brake line tidy

4. Install the engine mounting bolts and the

spacer to the lower crankcase mounting as
noted during removal, do not fit the nuts or
washers at this stage.
3
1
cjsr

1. ABS brake line 4

2. Retaining clips
2
3. ABS modulator bracket
3
2. Locate the engine to the frame aligning the
engine mounting points with the
corresponding positions on the frame. 1

1. Lower rear crankcase adjuster

2. Upper rear crankcase adjuster
3. Left hand cylinder head frame adjuster
4. Rear cylinder head frame adjuster
5. Swinging arm adjuster

5. Tighten the engine mounting bolts, nuts and

adjusters in the following sequence:
• Partially withdraw the lower rear crankcase
mounting bolt and tighten the frame
adjuster to 5 Nm using service tool
T3880377. Refit the bolt and washer.

Thruxton R 265
Engine Removal And Installation

• Partially withdraw the upper rear crankcase 21. Refit the starter motor cable to the solenoid,
mounting bolt and tighten the frame tighten the fixing to 4 Nm.
adjuster to 5 Nm using service tool
T3880377. Refit the bolt and washer.
• Counter hold the front right hand cylinder
head mounting nut and tighten the bolt to 1
24 Nm.
• Withdraw the left hand cylinder head
mounting bolt and tighten the frame
adjuster to 5 Nm using service tool 4
T3880377.
• Withdraw the rear cylinder head mounting
3
bolt and tighten the frame adjuster to 5 Nm
using service tool T3880377. 2
6. Counter hold the lower rear crankcase
mounting bolt and tighten the nut to 80 Nm.
ciwh

7. Counter hold the upper rear crankcase

mounting bolt and tighten the nut to 80 Nm. 1. Gear position sensor connector

8. Counter hold the front right hand cylinder 2. Crankshaft position sensor connector
head mounting nut and tighten the bolt to 105 3. Starter motor cable
Nm. 4. Starter motor solenoid
9. Counter hold the front left hand cylinder head
22. Refit the brake fluid reservoir, tighten the new
mounting nut and tighten the bolt to 105 Nm.
fixing to 3 Nm.
10. Counter hold the nut and tighten the rear
23. Refit the drive chain to the front sprocket and
cylinder head mounting bolt to 105 Nm.
adjust (see Final Drive Chain Adjustment, page
11. Using service tool T3880104, tighten the 613).
swinging arm pivot bolt adjuster sleeve to 6
24. Attach the alternator harness to the coolant
Nm.
expansion tank mounting, fit the inner cover
12. While supporting the swinging arm, remove and tighten its fixings to 7 Nm.
the swinging arm spindle and fully insert it
from the left hand side.
13. Fit the washer and a new swinging arm spindle
nut, tighten the nut to 110 Nm. 1
14. Refit the coolant hose to the thermostat
housing and secure using service tool
T3880207 .
15. Refit the throttle body (see Throttle Body -
Installation, page 423).
2
16. Refit the clutch cable (see Clutch Cable -
Installation, page 157).
17. Refit the crankcase breather hose. 3
1
18. Reconnect the engine earth strap, tightening
cjqg
the fixing to 6 Nm.
1. Fixings
19. Route the starter motor cable, crankshaft
position sensor and gear position sensor 2. Harness clip
cables as noted during removal. Tighten the 3. Alternator harness
cable guide fixings to 4 Nm.
20. Connect the electrical connectors as follows:
• Gear position sensor,
• Crankshaft position sensor,
• Oil pressure switch.

266 Thruxton R
 Engine Removal And Installation

25. Refit the coolant expansion tank to its 30. Refit the left and right hand heal guards and
mountings and tighten the new lock nuts to 3 tighten their fixings to 7 Nm.
Nm.
2
1

1
2 cjsb

cjpt
1. fixings
1. Fixings 2. Heal guard (left hand side)
2. Coolant expansion tank
31. Refit the radiator (see Radiator - Installation,
26. Carefully refit the swinging arm pivot cover on page 463).
the left hand side of the frame. 32. Refit the exhaust system (see Exhaust
27. Fit the sprocket cover and evenly and Intermediate and Header Pipes - Installation,
progressively tighten the fixings to 9 Nm. page 434).
28. Refit the swinging arm pivot cover to the left 33. Refit the left and right hand frame cradles (see
hand side of the frame. Cradle Assemblies - Installation, page 642).
29. Refit the left hand control plate and tighten its 34. Connect the following electrical connectors:
fixings to 25 Nm. • Coolant temperature sensor;
• Fuel injectors;
• Spark plug leads.
• Refill the engine with oil (see Oil and Oil Filter
Change, page 244).
2
3 • Refill the engine with coolant (see Coolant
Replacement - Filling, page 454).
• Refit the side panels (see Side Panels, page
637).
• Refit the fuel tank (see Fuel Tank - Installation,
1 page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
cjsa • Refit the seat (see Seat - Installation, page 636).
1. Fixings
2. Control plate
3. Cover

Thruxton R 267
Engine Removal And Installation

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268 Thruxton R
 18 Fuel System And Engine Management
Table of Contents
Exploded View – Fuel Tank ..................................................................................................................................................................... 274
Exploded View – Fuel Pump.................................................................................................................................................................... 275
Exploded View – Fuel Rail, Throttles and Injectors .................................................................................................................... 276
Exploded View – Airbox............................................................................................................................................................................. 277
Exploded View – Exhaust System....................................................................................................................................................... 278
Exploded View – Evaporative System (if fitted)............................................................................................................................ 279
Exploded View – Immobiliser Control Module................................................................................................................................ 280
Fuel Requirements....................................................................................................................................................................................... 281
Glossary of Terms ....................................................................................................................................................................................... 282
Engine Management System................................................................................................................................................................. 284
Sensor Locations......................................................................................................................................................................................... 285
Actuators ........................................................................................................................................................................................................ 286
Actuator Locations..................................................................................................................................................................................... 287
Immobiliser System..................................................................................................................................................................................... 288
Components Location ............................................................................................................................................................................... 289
Engine Management Circuit Tables .................................................................................................................................................... 290
Engine Management Circuit Diagram................................................................................................................................................. 291
ECM Connector Pin Numbering ............................................................................................................................................................ 292
System Diagnostics.................................................................................................................................................................................... 292
Triumph Diagnostic Software ................................................................................................................................................................ 294
Instrument Panel Function Test .......................................................................................................................................................... 299
Diagnostic Trouble Codes ........................................................................................................................................................................ 300
Immobiliser Control Module Diagnostic Trouble Codes.............................................................................................................. 306
Electrical Connectors................................................................................................................................................................................. 307
Further Diagnosis ....................................................................................................................................................................................... 308
Crankshaft Sensor ....................................................................................................................................................................................... 310
Fuel Injectors.................................................................................................................................................................................................. 312
Throttle Position Sensor........................................................................................................................................................................... 314
Purge Valve ..................................................................................................................................................................................................... 316

Thruxton R 269
Fuel System And Engine Management

Ignition Coils.................................................................................................................................................................................................... 318

Coolant Temperature Sensor................................................................................................................................................................. 320
Inlet Air Temperature Sensor ................................................................................................................................................................. 322
Fuel Pump Relay.......................................................................................................................................................................................... 324
System Voltage............................................................................................................................................................................................. 326
Cooling Fan Relay ........................................................................................................................................................................................ 328
Oxygen Sensor ............................................................................................................................................................................................. 330
Oxygen Sensor Heater ............................................................................................................................................................................. 332
Starter Motor Relay ................................................................................................................................................................................... 334
Fall Detection Switch ................................................................................................................................................................................. 336
CAN Communication................................................................................................................................................................................... 338
Instrument Communication (CAN) ....................................................................................................................................................... 340
Ambient Air Pressure Sensor................................................................................................................................................................ 342
Manifold Absolute Pressure (MAP) Sensor ..................................................................................................................................... 344
Gear Position Sensor ................................................................................................................................................................................. 346
Fuel Level Sensor Circuit ......................................................................................................................................................................... 348
EMS Main Relay Circuit............................................................................................................................................................................. 350
EMS Ignition Voltage Input Circuit ....................................................................................................................................................... 352
5 Volt Sensor Supply Circuit................................................................................................................................................................... 354
Twist Grip Position 1 ................................................................................................................................................................................... 356
Twist Grip Position Sensor 1 Correlation Error with Twist Grip Position 2....................................................................... 358
Twist Grip Position 2 .................................................................................................................................................................................. 360
Throttle Actuator Motor .......................................................................................................................................................................... 362
Immobiliser Control Module Communication .................................................................................................................................. 364
ABS Modulator Communication............................................................................................................................................................ 366
Brake Switches ............................................................................................................................................................................................. 368
Headlight Relay ............................................................................................................................................................................................ 370
Oxygen Sensor Reverse Connection................................................................................................................................................... 372
EEPROM Error................................................................................................................................................................................................ 372
Engine ECM Internal Error ....................................................................................................................................................................... 372
Traction Control Prevented Due to ABS Malfunction ................................................................................................................. 372
Throttle Valve Drive Error........................................................................................................................................................................ 372
Tune Lock ......................................................................................................................................................................................................... 372
Instrument ID Incompatible..................................................................................................................................................................... 373
Immobiliser and TPMS Control Module ID Incompatable........................................................................................................... 373
ABS Modulator ID Incompatible............................................................................................................................................................. 373
Engine ECM Tamper Detected............................................................................................................................................................... 374
Fault Finding – Non Electrical ............................................................................................................................................................... 374
Invalid Key: Key Authentication Unsuccessful .............................................................................................................................. 376

270 Thruxton R
 Fuel System And Engine Management

Vehicle Speed Sensor ................................................................................................................................................................................ 378

Fuel Tank - Removal................................................................................................................................................................................... 379
Fuel Tank - Removal.................................................................................................................................................................................... 381
Fuel Tank - Installation............................................................................................................................................................................. 383
Fuel Pressure Checking............................................................................................................................................................................ 384
Fuel Pump Assembly - Removal........................................................................................................................................................... 385
Fuel Pump Assembly - Inspection....................................................................................................................................................... 386
Fuel Pump Assembly - Installation ..................................................................................................................................................... 387
Fuel Filter - Removal.................................................................................................................................................................................. 387
Fuel filter - Inspection............................................................................................................................................................................... 388
Fuel Filter - Installation ............................................................................................................................................................................ 389
Fuel Pressure Regulator - Removal ................................................................................................................................................... 389
Pressure Regulator - Inspection ......................................................................................................................................................... 390
Fuel Pressure Regulator - Installation ............................................................................................................................................. 390
Fuel Pump - Removal ................................................................................................................................................................................. 391
Fuel Pump - Inspection ............................................................................................................................................................................ 392
Fuel Pump - Installation........................................................................................................................................................................... 392
Fuel Level Sensor - Removal.................................................................................................................................................................. 393
Fuel Level Sensor Installation ............................................................................................................................................................... 394
Air Filter Element - Removal.................................................................................................................................................................. 394
Air Filter Element - Installation ............................................................................................................................................................ 396
Airbox - Removal ......................................................................................................................................................................................... 397
Airbox - Installation ................................................................................................................................................................................... 400
Engine Electronic Control Module (ECM) - Removal ................................................................................................................... 403
Engine Electronic Control Module (ECM) - Installation.............................................................................................................. 404
Immobiliser/TPMS Control Module - Removal ............................................................................................................................... 404
Immobiliser/TPMS Control Module - Installation.......................................................................................................................... 405
Twist Grip - Removal.................................................................................................................................................................................. 406
Twist Grip - Installation ............................................................................................................................................................................ 408
Intake Air Temperature Sensor - Removal....................................................................................................................................... 410
Intake Air Temperature Sensor - Installation ................................................................................................................................. 410
Coolant Temperature Sensor - Removal ............................................................................................................................................ 411
Coolant Temperature Sensor - Installation....................................................................................................................................... 411
Manifold Absolute Pressure (MAP) Sensor - Removal................................................................................................................ 412
Manifold Absolute Pressure (MAP) Sensor - Installation.......................................................................................................... 412
Ambient Air Pressure Sensor - Removal .......................................................................................................................................... 413
Ambient Air Pressure Sensor - Installation..................................................................................................................................... 413
Fall Detection Switch - Removal ........................................................................................................................................................... 414
Fall Detection Switch - Installation...................................................................................................................................................... 414

Thruxton R 271
Fuel System And Engine Management

Gear Position Sensor - Removal ........................................................................................................................................................... 415

Gear Position Sensor - Installation...................................................................................................................................................... 417
Crankshaft Position Sensor - Removal.............................................................................................................................................. 418
Crankshaft Position Sensor - Installation ........................................................................................................................................ 419
Throttle Actuator Motor .......................................................................................................................................................................... 420
Throttle Position Sensor.......................................................................................................................................................................... 420
Throttle Body - Removal .......................................................................................................................................................................... 421
Throttle Body - Installation.................................................................................................................................................................... 423
Throttle Body Balancing .......................................................................................................................................................................... 425
Fuel Injectors and Fuel Rail - Removal ............................................................................................................................................. 426
Fuel Injectors and Fuel Rail - Installation........................................................................................................................................ 427
Engine Management Adaption ............................................................................................................................................................. 428
Exhaust Silencer - Removal ................................................................................................................................................................... 430
Exhaust Silencer - Installation .............................................................................................................................................................. 431
Exhaust Intermediate and Header Pipes - Removal................................................................................................................... 431
Exhaust Intermediate and Header Pipes - Installation............................................................................................................ 434
Exhaust Catalytic Converter - Removal........................................................................................................................................... 436
Exhaust Catalytic Converter - Installation ..................................................................................................................................... 437
Evaporative Canister (if fitted) - Removal ....................................................................................................................................... 438
Evaporative Canister (if fitted) - Installation.................................................................................................................................. 439
Purge Control Valve (if fitted) - Removal ......................................................................................................................................... 439
Purge Control Valve (if fitted) - Installation.................................................................................................................................... 440
Evaporative Loss Control System – Certain Markets Only ..................................................................................................... 442
Evaporative Control System – Engine Off ....................................................................................................................................... 443
Evaporative Control System – Engine Running............................................................................................................................ 444

272 Thruxton R
 Fuel System And Engine Management

Thruxton R 273
Fuel System And Engine Management

Exploded View – Fuel Tank

8 Nm
1.5 Nm
5 Nm

274 Thruxton R
 Fuel System And Engine Management

Exploded View – Fuel Pump

4 Nm

7 Nm

4 Nm

7 Nm

15 Nm

5 Nm

Thruxton R 275
Fuel System And Engine Management

Exploded View – Fuel Rail, Throttles and Injectors

3.5 Nm

3 Nm

6 Nm

3 Nm 9 Nm

3.5 Nm

1.5 Nm

9 Nm

276 Thruxton R
 Fuel System And Engine Management

Exploded View – Airbox

1.5 Nm

6 Nm
6 Nm

3 Nm

1.5 Nm

3 Nm

6 Nm

3 Nm
3 Nm

1.5 Nm

1.5 Nm

1.5 Nm

Thruxton R 277
Fuel System And Engine Management

Exploded View – Exhaust System

15 Nm
25 Nm
24 Nm

9 Nm

19 Nm 19 Nm

15 Nm
9 Nm 19 Nm

25 Nm
19 Nm
10 Nm
8 Nm

8 Nm

5 Nm

19 Nm 10 Nm

9 Nm

278 Thruxton R
 Fuel System And Engine Management

Exploded View – Evaporative System (if fitted)

1.4 Nm

Thruxton R 279
Fuel System And Engine Management

Exploded View – Immobiliser Control Module

2 Nm

4 Nm

280 Thruxton R
 Fuel System And Engine Management

Fuel Requirements Methanol

Fuel Requirements - all countries except USA Caution

This model must be run on 91 RON or higher
unleaded fuel. Fuels containing methanol should not be used in
Triumph motorcycles as damage to components in
the fuel system can be caused by contact with
Fuel Requirements - USA
methanol.
In the United States of America where the octane
rating of fuel is measured in a different way, the
following information may be applied: MTBE (Methyl Tertiary Butyl Ether)
This model is designed to run on unleaded gasoline The use of gasolines containing up to 15% MTBE
with a CLC or AKI octane rating (R+M)/2 of 87 or (Methyl Tertiary Butyl Ether) is permitted in
higher. Triumph motorcycles.

Note:
• If 'Knocking' or 'Pinking' occurs at a steady
engine speed under normal load, use a
different brand of gasoline or a higher octane
rating.

Caution
The use of leaded gasoline is illegal in some
countries, states or territories and will invalidate
the vehicle and emissions control warranties.
Additionally, leaded gasoline will cause damage to
emissions control components.

Oxygenated Gasoline
To help in meeting clean air standards, some areas
of the U.S. use oxygenated gasoline to help reduce
harmful emissions. This model will give best
performance when using unleaded gasoline.
However, the following should be used as a guide to
the use of oxygenated fuels.

Caution
Because of the generally higher volatility of
oxygenated fuels, starting, engine response and
fuel consumption may be adversely affected by
their use. Should any of these difficulties be
experienced, run the motorcycle on normal
unleaded gasoline.

Ethanol
Ethanol fuel is a mixture of 10% ethanol and 90%
gasoline and is often described under the names
'gasohol', 'ethanol enhanced', or 'contains ethanol'.
This fuel may be used in Triumph motorcycles.

Thruxton R 281
Fuel System And Engine Management

Glossary of Terms Fall detection

The following terms and abbreviations will be found The fall detection switch will detect if the
in this section. Below is given a brief explanation of motorcycle is on its side and will cut power to the
what some of the more common terms and engine ECM immediately.
abbreviations mean.
Freeze-frame
Air temperature A data set captured at the time a Diagnostic
The air temperature in the airbox and intake hose. Trouble Code (DTC) is set.

Air temperature sensor Idle fuel trim

Sensor located in the airbox to detect the The percentage above or below the nominal fuel
temperature of the incoming air. requirement for the volume of air entering at idle.

ATDC Idle fueling

After Top Dead Centre (TDC). Adjustment of fueling at idle to suit the actual air
inducted.
Ambient air pressure
Idle reference speed
Pressure of the air in the airbox.
The target idle speed as determined by the engine
Battery Voltage Electronic Control Module (ECM). (It should be the
same as the actual idle speed if the motorcycle is
The voltage at the input to the Engine Electronic
operating correctly.)
Control Module (ECM).
Ignition advance
BTDC
The timing of ignition at the spark plug relative to
Before Top Dead Centre (TDC).
Top Dead Centre.
Catalytic converter Ignition switch position
Device placed in the exhaust system which reduces
The ON or OFF position of either or both the
exhaust emissions by stimulating secondary
ignition switch and the engine stop switch.
combustion of the exhaust gases.
Ignition timing
Closed throttle position
Same as ignition advance.
Throttle position at idle (i.e. against end stop),
measured as a voltage and expressed as
IImmobiliser and Tyre Pressure Monitoring
percentage.
System (TPMS) Control Module
Coolant temperature The control module for the immobiliser and TPMS
system.
The coolant temperature in the cylinder head.
Injector pulse time
Coolant temperature sensor
The time during which an injector remains open (i.e.
Sensor which detects coolant temperature.
delivering fuel).
Cooling fan status
Long term fuel trim
The ON or OFF condition of the cooling fan.
Fueling after adapting to the engine's long term
fueling requirements (closed loop only). See also
DTC short term fuel trim.
Diagnostic Trouble Code.
MAP sensor
Engine ECM Manifold Absolute Pressure (the air pressure in the
Engine Electronic Control Module. intake system).

Engine speed MIL

The crankshaft revolutions per minute. Malfunction Indicator Lamp.

282 Thruxton R
 Fuel System And Engine Management

Illuminates when most Diagnostic Trouble Codes Throttle position

(DTCs) are set. The position of the throttle butterfly given as a
percentage of the movement range. When the data
Neutral switch status is displayed on the diagnostic software, fully open
The NEUTRAL or IN GEAR status of the need not be 100% nor fully closed 0%.
transmission.
Throttle actuator motor
Off idle fuel trim Motor used to open/close the throttle.
The percentage above or below the nominal fuel
requirement for the volume of air entering at Twist grip position sensor
engine speeds other than idle. This function is not The twist grip position sensor is used to relay twist
currently used in the Triumph system. grip position information to the engine ECM. The
engine ECM uses this information to drive the
Open circuit throttle actuation motor to the correct position.
A break in an electrical circuit - current cannot
flow. Throttle voltage
Voltage at the throttle potentiometer.
Over temp
High temperature within the engine Electronic Transponder
Control Module (ECM) caused by an internal or A transponder-responder chip located in the
external failure. ignition key. The transponder is activated by a
radio signal sent out by the immobiliser control
Oxygen sensor module, via an antenna located around the ignition
The oxygen sensor measures the oxygen levels in switch. If the immobiliser control module does not
the exhaust gases and feeds this information to receive the correct code signal from the
the engine ECM. Based on this information, transponder, the immobiliser will remain active and
adjustments to air/fuel ratio are made. the engine will not start.

Purge valve duty cycle

The time the purge valve is open in an open/close
cycle, expressed as a percentage of the cycle time.

Sensor reference voltage

Supply voltage to the system sensors (nominally 5
volts).

Short circuit
A 'short cut' in an electrical circuit - current
bypasses the intended circuit (usually to ground).

Short term fuel trim

A correction applied to the fuel mixture during
closed loop catalyst operation. This, in turn, has an
effect on the long term fuel trim in that if an
engine constantly requires mixture correction, the
long term fuel trim will adapt to this requirement
thus reducing the need for constant short term
adjustment.

Side stand status

The 'up' or 'down' position of the side stand.

Target dwell time

The actual time from coil ON to coil OFF.

Thruxton R 283
Fuel System And Engine Management

Engine Management System used to optimise fueling at all engine

temperatures and to calculate hot and cold
start fueling requirements.
System Description
• Oxygen sensors - situated in the exhaust
This model is fitted with an electronic engine
header pipe system close to the cylinder head.
management system which encompasses control of
The oxygen sensors constantly feed
both ignition and fuel delivery. The engine
information to the engine ECM on the content
electronic control module (ECM) draws information
of the exhaust gases. Based on this
from sensors positioned around the engine, cooling
information, adjustments to air/fuel ratio are
and air intake systems and precisely calculates
made.
ignition advance and fueling requirements for all
engine speeds and loads. • Side stand switch - situated at the top of the
side stand leg. If the side stand is in the down
System Sensors position, the engine will not run unless the
transmission is in neutral.
• Intake air temperature sensor - situated on top
• Fall detection switch - situated on top of the
of the airbox. As the density of the air changes
airbox. The fall detection switch will detect if
with temperature (therefore the amount of
the motorcycle is on its side and will cut power
oxygen available to ignite the fuel), an intake air
to the engine ECM immediately. This prevents
temperature sensor is fitted. Changes in air
the engine from running and the fuel pump
temperature are compensated for by adjusting
from delivering fuel. In the event of a fall, the
the amount of fuel injected to a level consistent
switch is reset by returning the bike to an
with clean combustion and low emissions.
upright position and switching the ignition off
• Ambient air pressure sensor - situated on top then back on again.
of the airbox. The ambient air pressure sensor
• Gear position sensor - situated in the lower
measures atmospheric air pressure. With this
crankcase, below the drive chain front sprocket.
information, the amount of fuel per injection is
The gear position sensor provides the engine
adjusted to suit the prevailing conditions.
ECM with selected gear information. This is
• Manifold Absolute Pressure (MAP) sensor - used to prevent the engine from starting if the
situated below the fuel tank, connected to the transmission is in gear. The sensor also
manifold by a length tube. The MAP sensor provides information to the neutral lamp in the
provides information to the engine ECM which instruments.
is used at shallow throttle angles (very small
throttle openings) to provide accurate engine
load indications to the ECM. This degree of
engine load accuracy allows the ECM to make
very small adjustments to fuel and ignition
which would otherwise not be possible from
throttle angle data alone.
• Clutch switch - situated on the clutch lever. The
clutch must be pulled in for the starter motor
to operate.
• Crankshaft position sensor - situated in the
alternator cover. The crankshaft position
sensor detects movement of teeth attached to
the alternator [Link] teeth give a reference
point from which the actual crankshaft position
is calculated. The crankshaft position sensor
information is used by the engine ECM to
determine engine speed and crankshaft
position in relation to the point where fuel is
injected and ignition of the fuel occurs.
• Engine coolant temperature sensor - situated
at the front of the cylinder head near the
thermostat housing. Coolant temperature
information, received by the engine ECM, is

284 Thruxton R
 Fuel System And Engine Management

Sensor Locations

Gear Coolant
Position Crankshaft Manifold Absolute Temerature
Sensor Position Sensor Pressure Sensor Sensor

Fall Intake Air Ambient Air

Oxygen Clutch Detection Temperature Pressure Side Stand
Sensor Switch Switch Sensor Sensor Switch

Thruxton R 285
Fuel System And Engine Management

Actuators system as soon as the engine is cranked. Fuel

pressure is controlled by a regulator also
situated inside the fuel tank.
System Actuators
• Cooling fan - situated behind the radiator. The
In response to signals received from the sensors,
engine ECM controls switching on and off of the
the engine ECM controls and directs messages to a
cooling fan in response to a signal received
series of electronic and electromechanical
from the coolant temperature sensor. When the
actuators. The function and location of the
coolant temperature rises to a level where the
actuators is given below.
cooling effect of natural airflow is insufficient,
• Throttle actuator motor - situated at the rear the cooling fan is turned on by the engine ECM.
of the throttle body. The throttle actuator When the coolant temperature falls sufficiently,
motor opens and closes the throttle plate in the the engine ECM turns the cooling fan off. The
throttle body, in response to commands from fan only becomes operational when the engine
the engine ECM. The throttle actuator motor is is running. It will not operate at any other time.
an integral part of the throttle bodies.
• Canister purge valve (certain markets only) - Note:
situated behind the left hand side cover. The • In this system, the starter lockout system
purge valve controls the return of vapour which (clutch switch, neutral switch, side stand
has been stored in the carbon canister during switch) all operate through the engine
the period when the engine is switched off. The management ECM.
valve is 'pulsed' by the engine ECM to give
control over the rate at which the canister is
purged.
• Injectors - located in the cylinder head. The
engine is fitted with two injectors. The spray
pattern of the injectors is fixed but the length
of time each injector can remain open is
variable according to operating conditions. The
duration of each injection is calculated by the
engine ECM using data received from the
various sensors in the system.
• Ignition coils - situated above the camshaft
cover, attached to the frame. There are two
coils fitted, one for each of the spark plugs. The
engine ECM controls the point at which the
coils are switched on and off. In calculating the
switch-on time, the engine ECM allows
sufficient time for the coils to charge to a level
where a spark can be produced. The coils are
switched off at the point of ignition, the timing
of which is optimised for good engine
performance.
• Main power relay - situated behind the right
hand side panel. When the ignition is switched
on, the main power relay is powered up to
provide a stable voltage supply for the engine
ECM.
• Fuel pump - situated inside the fuel tank. The
electric pump delivers fuel into the fuel system,
via a pressure regulator, at a constant 3.5 bar
pressure. The pump is run continuously when
the engine is operating and is also run briefly
when the ignition is first switched on to ensure
that fuel at 3.5 bar pressure is available to the

286 Thruxton R
 Fuel System And Engine Management

Actuator Locations

Throttle
Main Power Body Ignition Cooling
Relay Motor Coils Fan

Fuel Fuel Evaporative

Injectors Pump Canister
Purge Valve

Thruxton R 287
Fuel System And Engine Management

Immobiliser System Keys

When the motorcycle is delivered from the factory
System Description it is supplied with two keys. Keys can be deleted or
The Thruxton R is fitted with an electronic added to the immobiliser system using the Triumph
immobiliser system to help protect it against theft. Diagnostic Tool. A maximum of four keys can be
This system has to be paired with the engine ECM added to the system.
and the ignition keys which contains a transponder To ensure the immobiliser system functions
chip. If all the components are correctly paired, the correctly note the following:
immobiliser will allow the engine to start. The • Do not put any magnetic materials on the same
Triumph Diagnostic Tool is the only way these key ring as the motorcycle key.
components can be paired. • Do not have two of the motorcycle ignition keys
In addition, the system has an on-board diagnostic on the same key ring, keep the spare key in a
function. This ensures that, should a malfunction safe place.
occur in the immobiliser system, a malfunction code • Do not put any other ignition key with a
is stored in the immobiliser control module's transponder chip fitted near the motorcycle key
memory. This stored data can be recovered using when in use.
the Triumph Diagnostic Tool (see Immobiliser • Do not modify the immobiliser system.
Control Module Diagnostic Trouble Codes, page
• Do not submerge the key in water or any other
306).
fluid.
• Do not drop or strike the key against hard
System Components and Operation
material.
• Transponder chip - situated inside the ignition
key. The chip is activated by the antenna coil Diagnostics
when the ignition switch is turned to the ON
position. To fully diagnose the immobiliser system it is
necessary to check for fault codes in the
• Antenna coil - situated around the ignition
immobiliser control module using the Triumph
switch. When the ignition switch is turned to
Diagnostic Tool (see System Diagnostics, page 292).
the ON position, and the transponder chip is
activated, the signal from the chip is sent to the
Further Diagnosis
immobiliser control module.
The tables that start on page Immobiliser Control
• Immobiliser control module - situated behind
Module Diagnostic Trouble Codes, page 306, if used
the headstock next to the coolant filler neck.
correctly, help to pinpoint a fault in the system
This control module communicates with the
once a diagnostic trouble code has been stored.
transponder chip in the key and the ECM and
will only allow the engine to start if a matching
signal is received.
• Alarm/immobiliser warning indicator light -
situated in the instrument pack. The light will
flash for 24 hours to show that the engine
immobiliser is on. When the ignition switch is
turned to the ON position the immobiliser and
indicator light will be off. If the indicator light
remains on it indicates that the immobiliser has
a malfunction that requires investigation.
• If an accessory alarm is fitted, the immobiliser
indicator light will only illuminate when the
conditions described in the accessory alarm
instructions are met.

288 Thruxton R
 Fuel System And Engine Management

Components Location

Immobiliser/TPMS Transponder
Control Module Chip

H
PUS

Engine Electronic
Control Module
Antenna Coil

Thruxton R 289
Fuel System And Engine Management

Engine Management Circuit Tables Key Item Description

35 Ignition Coil - Cylinder 2
Key to Circuit Diagram
36 Crankshaft Position Sensor
Key Item Description
37 EMS Relay
1 Engine Electronic Control Module
38 Fuse Box
2 Instrument Assembly Connector
3 Diagnostic Connector Key To Wiring Colour Codes
4 ABS Module Connector Code Wiring Colour
5 Bluetooth® Module B Black
6 Immobiliser U Blue
7 Ignition Switch N Brown
8 Gear Position Sensor G Green
9 Fall Detection Switch S Slate/Grey
10 Ambient Air Pressure Sensor O Orange
11 MAP Sensor K Pink
12 Fuel Level Sender R Red
13 Side Stand Switch P Purple
14 Intake Air Temperature Sensor W White
15 Coolant Temperature Sensor Y Yellow
16 Left Hand Switch Housing - 8 Way LG Light Green
Connector LU Light Blue
17 Clutch Switch
18 Main Beam Switch
19 Cruise Control Switch (if fitted)
20 Alarm Connector
21 Quickshifter
22 Twist Grip Position Sensor
23 Throttle Position sensor
24 Throttle Drive Motor
25 Fuel Pump Relay
26 Fuel Pump
27 Cooling Fan
28 Cooling Fan Relay
29 Oxygen Sensor - Cylinder 1
30 Oxygen Sensor - Cylinder 2
31 Fuel Injector - Cylinder 1
32 Fuel Injector - Cylinder 2
33 Purge Valve
34 Ignition Coil - Cylinder 1

290 Thruxton R
 Fuel System And Engine Management

Engine Management Circuit Diagram

1
38 37
7 4 2
36
1 UB UB A35

2 UP
UP UP A36
7B 8B 2B 3 1 2 5
2
G NK NK NK NK R 9

U 10
NK NK A01

NK NK A13 3
35 A33

A34
R

U
R

U
6

14
NK 1 1 GK GK B15
B 4

34 5 4
NK 1 1 GP GP B14 4 U 11

33 3 R 2

NK 2 1 B B B06 6
U 1
32 7 R 6
NK 2 1 YP YP A11
2 BG 5

31 7 B 10
2 1 YK
NK YK A10
8
30 B44 BW BW 1

NK 3 4 W W B03 B23 BK BK 2

1 2 BU A22 B34 K K 4
BU
B18 KB KB 3
B
29 9
NK 3 4 W W B02
KB 6
1 2 BY BY A21
K 4

B38 KU KU 5

28 10
27 KB

K
1

M B41 KP KP 2
3 1 2 5 B
P NK BY NK 11
KB 1

BY A27 K 3

B36 KS KS 2

26 12
25
M KB 1
3 1 2 5
B K 2
G GR BP PW B27 BY BY 4

24
BP A26 13
GR B01 K 1
1 UO UO A02 3
B43 BR BR
2 UG UG A03
B 2

14
1 UY UY B20 KO KO 1
B42
4 UG UG B26 B 2
23 2 B B B19

3 R R B33 15
B40 KG KG 1

B 2
7 R

5 B 16
6 W W B28 B 4
22 2 W W B21 B45 BO BO 3

1
B

R
B

R
B35

B17
17
A04 WU WU 7

18
A29 WR WR 5
21
1 RB B22 GR 8
19
2 B

A20 B
B
A23 B
1
A25

B08
B

B
20
B13 B

B48 B

Thruxton R 291
Fuel System And Engine Management

ECM Connector Pin Numbering System Diagnostics

Connector B Connector A The engine management system has an on-board
diagnostics feature which allows service
B16 B01 B17 A12 A01 A13 technicians to retrieve stored data from the ECM
using Triumph diagnostic software. Full details of
the Triumph diagnostic software operation and how
to interpret the results are given in the Triumph
Diagnostic Tool User Guide.
The software is connected, via an interface cable,
to the motorcycle using a dedicated diagnostic plug
situated beneath the seat. By using a dedicated
plug, no electrical connectors associated with the
system are disturbed, reducing potential connector
B48 B33 A36 A25 damage.
The software allows the user to retrieve data
associated with the system sensors and actuators,
The above illustration shows the pin numbering test various component functions, read build data
system used in the engine management circuit and make minor adjustments to the set-up of the
diagram. system. The data and tests available are described
The smaller connector's pins are prefixed A and the on the following pages.
larger connector pins B. As viewed on the mating
face with the ECM (as per the illustration), pins are On-board Fault Detection System
numbered from right to left with number one in the The on-board diagnostic system has two stages to
top right corner. fault detection. When a fault is detected, the DSM
(Diagnostic Status Manager) raises a flag to
indicate that a fault is present and increments a
counter. The counter checks the number of
instances that the fault is noted. For example, if
there is a fault in the crankshaft position sensor,
the counter will increment its count each time the
crankshaft turns through 360°, provided the fault
is still present.
When the count begins, the fault is detected but
not confirmed. If the fault continues to be detected
and the count reaches a predetermined threshold,
the fault becomes confirmed. If the fault is an
emissions related fault or a serious malfunction
affecting engine performance, a DTC (Diagnostic
Trouble Code) and freeze-frame data will be logged
in the ECM's memory and the MIL (Malfunction
Indicator Lamp) on the motorcycle instrument
panel is illuminated. Once a fault is confirmed, the
number of warm-up cycles made by the engine is
counted. If the fault clears, the warm-up cycle
counter will extinguish the MIL (Malfunction

292 Thruxton R
 Fuel System And Engine Management

Indicator Lamp) at a predetermined count, and

erase the DTC and freeze-frame data from the ECM
memory at another (higher) count.
A single warm-up cycle is deemed to have taken
place when the following criteria have been met:
• The coolant temperature must be raised to 72°C
or more.
• The coolant temperature must have risen by
23°C or more from its start temperature, when
72°C is reached.
• A controlled power down sequence must take
place.
Note:
• When a fault has been rectified, the MIL will
remain illuminated until sufficient non-fault
warm-up cycles have taken place to turn it
off. The MIL will be immediately extinguished
if, after first rectifying the fault, the DTC
(diagnostic trouble code) that caused the MIL
illumination is erased from the ECM memory
using the Triumph diagnostic software.
Note:
• In some cases, when a fault is detected, the
engine management system will revert to a
limp-home mode. In this mode, the engine will
still function though the performance and fuel
economy may be marginally affected. In some
cases, the rider may not notice any
appreciable difference from normal operation.

Thruxton R 293
Fuel System And Engine Management

Triumph Diagnostic Software

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 on-board system and what information can be
retrieved by the Triumph diagnostic software.
Note:
• Full details of how to operate the software and how to interpret the data can be found in the Triumph
Diagnostic Tool User Guide, which can be downloaded by authorised Triumph dealers from
[Link].

Build Data
The Build Data screen will display the following information:
• Motorcycle model
• Vehicle Identification Number (VIN)
• ECM type
• ECM ID
• ECM serial number
• Tune number
• Date of last tune download
• Total tune downloads since manufacture
• The lock status of the ECM (ECM Locked, Unlocked or Not Applicable).

Current Data
The data available under Current Data is:
Function Examined Result Reported (Scale)
Fuel system status 1 open or closed loop operation
Fuel system status 2 open or closed loop operation/engine not running
Calculated load value %
Engine coolant temperature °C
Short term fuel trim - bank 1 %
Short term fuel trim - bank 2 %
Intake manifold absolute pressure mmHg
Engine speed rpm
Vehicle speed km/h
Ignition timing advance - cylinder 1 degrees
Intake air temperature °C
Absolute throttle position %
Bank 1 - oxygen sensor 1 Volts
Bank 1 - oxygen sensor 1 - short term fuel trim %
Bank 2 - oxygen sensor 2 Volts
Bank 2 - oxygen sensor 2 - short term fuel trim %

Sensor Data
When using this function it is possible to check the status of various sensors and actuators.
The data sets are divided into eight groups - Sensor Voltages, Sensor Readings, Injector Data, Ignition Data,
Idle Speed and Throttle Data, Inputs, Outputs and Adaption Status. Each of these screens is described on
the following pages.

294 Thruxton R
 Fuel System And Engine Management

Sensor Voltages
The data available under Sensor Voltages is:
Item Checked Result Unit
Battery voltage Volts
Voltage from ignition switch to ECM Volts
Air temperature sensor voltage Volts
Coolant temperature sensor voltage Volts
Atmospheric pressure sensor voltage Volts
Manifold absolute pressure sensor 1 voltage Volts
Manifold absolute pressure sensor 2 voltage Volts
Throttle position sensor voltage Volts
Fuel level sensor voltage Volts
Oxygen sensor output 1 voltage Volts
Oxygen sensor output 2 voltage Volts
Exhaust butterfly valve sensor voltage‡ Volts
‡ Applies to models fitted with an exhaust butterfly valve only. All other models will show Not Applicable in
this field.

Sensor Readings
The data available under Sensor Readings is:
Item Checked Result Unit
Air temperature °C
Coolant temperature °C
Ambient air pressure mmHg
Manifold absolute pressure (one reading per cylinder) mmHg
Low fuel light on/off
Oxygen sensor 1 heater status on/off
Oxygen sensor 2 heater status on/off
Exhaust butterfly valve sensor voltage‡ %
‡ Applies to models fitted with an exhaust butterfly valve only. All other models will show Not Applicable in
this field.

Injector Data
The data available under Injector Data is:
Item Checked Result Unit
Injector 1 pulse time milliseconds
Injector 2 pulse time milliseconds

Ignition Data
The data available under Ignition Data is:
Item Checked Result Unit
Ignition timing cyl 1 degrees BTDC
Ignition timing cyl 2 degrees BTDC
Coil 1 dwell time milliseconds
Coil 2 dwell time milliseconds

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Fuel System And Engine Management

Idle Speed and Throttle Data

The data available under Idle Speed and Throttle Data is:
Item Checked Result Unit
Engine speed rpm
Idle reference speed rpm
Idle speed control current steps numeric
Idle speed control target steps numeric
Throttle position % open
Secondary air injection status ‡ SAI on/off
‡ Applies to models fitted with secondary air injection only. All other models will show Not Applicable in this
field.

Inputs
The data available under Inputs is:
Item Checked Result Unit
Starter switch status switch on/off
Side stand status up/down
Fall detection switch status normal/over
Clutch switch status release/grip
Neutral switch status gear/neutral
Gear position status numeric value or neutral
Vehicle speed km/h
Calculated load %

Outputs
The data available under Outputs is:
Item Checked Result Unit
EMS main relay status relay on/off
Fuel pump relay status on/off
Starter relay status starter on/off
Malfunction indicator light status MIL on/off
Cooling fan status fan on/off
Purge valve duty cycle %
Accessory control relay status relay on/off
Headlight relay status headlight on/off

Adaption Status
Because the fuel system is adaptive, the engine management system is able to automatically adjust to new
working conditions, such as changes in altitude, component wear, air leaks etc. This screen displays
information on the adaption status of the vehicle which will show if it has adapted or not.
Function Examined Report Method
Closed Throttle Position Adapted adapted/not adapted
Idle speed control adaption status %
Oxygen sensor 1 adaption range (off idle) %
Oxygen sensor 1 adaption range (idle) %

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 Fuel System And Engine Management

Function Examined Report Method

Oxygen sensor 1 adaption status (off idle) %
Oxygen sensor 1 adaption status (idle) %
Oxygen sensor 2 adaption range (off idle) %
Oxygen sensor 2 adaption range (idle) %
Oxygen sensor 2 adaption status (off idle) %
Oxygen sensor 2 adaption status (idle) %

Function Tests
The system allows the diagnostic software to perform a series of function tests on various actuators in the
engine management system. In some cases it is necessary to make a visual observation of a component and
in others, if faults are present, DTCs will be logged.
The Function Tests available are:
Function Examined Report Method
Instrument Panel Observe instrument panel, refer to Service Manual
Idle Air Control Stepper Motor † Observe throttle position/Stored fault code*
Purge Valve Listen for valve operation/Stored fault code*
Fuel Pump - Priming Listen for fuel pump operation/Stored fault code*
Fuel Pump - Continuous Fuel pressure test/Listen for fuel pump operation/Stored fault code*
Operation
Cooling Fan Control Observe the cooling fan/Stored fault code*
Secondary Air Injection† Listen for valve operation/Stored fault code*
Exhaust Butterfly Valve Actuator Listen or observe for exhaust butterfly valve actuator operation/Stored
† fault code*
* If a fault is detected.
†Test will only be displayed if the component is fitted.

Adjust Tune
Using the Triumph diagnostic software, it is possible to:
• reset the adaptions
• balance the throttle bodies.

Freeze-Frame Data
Freeze-frame data is stored at the time a DTC is recorded (confirmed) by the ECM. If multiple DTCs are
recorded, the freeze-frame data which is stored will relate to the first recorded DTC only.
By calling up freeze-frame data associated with the first recorded DTC, the technician can check the engine
condition at the time the fault occurred. The data available is:
Function Examined Result Reported (Scale)
DTC Diagnostic Trouble Code (DTC) number
Fuel system status 1 open or closed loop operation
Fuel system status 2 open or closed loop operation
Calculated load %
Coolant temperature °C
Short term fuel trim - bank 1 %
Short term fuel trim - bank 2 %
Intake manifold absolute pressure mmHg
Engine speed rpm
Vehicle speed km/h

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Fuel System And Engine Management

Function Examined Result Reported (Scale)

Ignition advance degrees
Intake air temperature °C
Throttle position %
Oxygen sensor 1 output voltage Volts
Oxygen sensor 1 short term fuel trim %
Oxygen sensor 2 output voltage Volts
Oxygen sensor 2 short term fuel trim %

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Instrument Panel Function Test

On the diagnostic software navigate to and select
the ‘FUNCTIONS TESTS’ option.
Click the start button and observe the instruments
for the following:
• Tachometer needle moves to 5,000 rpm
• Speedometer needle moves to 60 mph
• The neutral indicator, fuel warning light and
malfunction indicator light (MIL) lights alternate
on and off
• Fuel gauge goes to full then increments down
to zero
• The gear position display will sequentially
display the following, -, 1, N, 4, 5, N, 1 then 2
• End of test. Instruments return to normal
operation.

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Fuel System And Engine Management

Diagnostic Trouble Codes

Diagnostic trouble codes (DTCs) are logged in the ECM memory when there is a confirmed fault in the
system.
The codes are reported to the Triumph diagnostic software as a four digit code.
As mentioned earlier, when the system detects a fault, it begins to count the number of times the fault
occurs before illuminating the MIL and storing a fault code.
Similarly, if a fault clears, the ECM also records this fact and will turn off the MIL when sufficient no fault
warm-up cycles have taken place. Any fault codes will remain in the ECM memory until the required number
of no fault warm-up cycles have taken place. The number of warm-up cycles required to extinguish the MIL
will always be less than the number required to remove a DTC from the ECM memory. DTCs can be removed
at any time using the Triumph diagnostic software.
The system will log the diagnostic trouble codes listed below/over:
Diagnostic Fault Description Number of Number of MIL Pinpoint test page number
Trouble no-fault no-fault illuminated
Code (DTC) cycles cycles when fault is
before before DTC logged
turning off is erased
MIL
P0030 Oxygen sensor 1 3 40 Yes Oxygen Sensor Heater, page 332
heater open circuit
or short to ground
P0032 Oxygen sensor 1 3 40 Yes Oxygen Sensor Heater, page 332
heater short
circuit to battery
Voltage
P0050 Oxygen sensor 2 3 40 Yes Oxygen Sensor Heater, page 332
heater open circuit
or short to ground
P0052 Oxygen sensor 2 3 40 Yes Oxygen Sensor Heater, page 332
heater short
circuit to battery
Voltage
P0105 Manifold absolute 3 40 Yes Manifold Absolute Pressure (MAP)
pressure sensor 1 Sensor, page 344
open circuit or
short circuit to 5
Volt sensor supply
P0107 Manifold absolute 3 40 Yes Manifold Absolute Pressure (MAP)
pressure sensor 1 Sensor, page 344
short circuit to
ground
P0110 Intake air 3 40 Yes Inlet Air Temperature Sensor, page
temperature 322
sensor open
circuit or short
circuit to 5 Volt
sensor supply
P0112 Intake air 3 40 Yes Inlet Air Temperature Sensor, page
temperature 322
sensor short
circuit to ground

300 Thruxton R
 Fuel System And Engine Management

Diagnostic Fault Description Number of Number of MIL Pinpoint test page number
Trouble no-fault no-fault illuminated
Code (DTC) cycles cycles when fault is
before before DTC logged
turning off is erased
MIL
P0115 Engine coolant 3 40 Yes Coolant Temperature Sensor, page
temperature 320
sensor open
circuit or short
circuit to 5 Volt
sensor supply
P0117 Engine coolant 3 40 Yes Coolant Temperature Sensor, page
temperature 320
sensor short
circuit to ground
P0120 Throttle position 3 40 Yes Throttle Position Sensor, page 314
sensor 1 short
circuit to battery
Voltage or open
circuit
P0122 Throttle position 3 40 Yes Throttle Position Sensor, page 314
sensor 1 short
circuit to ground
P0130 Oxygen sensor 1 3 40 Yes Oxygen Sensor, page 330
open circuit or
short circuit to
battery Voltage
P0131 Oxygen sensor 1 3 40 Yes Oxygen Sensor, page 330
short circuit to
ground
P0150 Oxygen sensor 2 3 40 Yes Oxygen Sensor, page 330
circuit open circuit
or short circuit to
battery Voltage
P0151 Oxygen sensor 2 3 40 Yes Oxygen Sensor, page 330
short circuit to
ground
P0201 Injector 1 circuit 3 40 Yes Fuel Injectors, page 312
malfunction
P0202 Injector 2 circuit 3 40 Yes Fuel Injectors, page 312
malfunction
P0220 Throttle position 3 40 Yes Throttle Position Sensor, page 314
sensor 2 short
circuit to battery
Voltage or open
circuit
P0222 Throttle position 3 40 Yes Throttle Position Sensor, page 314
sensor 2 short
circuit to ground
P0335 Crankshaft sensor 3 40 Yes Crankshaft Sensor, page 310
circuit malfunction
P0351 Ignition coil 1 3 40 Yes Ignition Coils, page 318
malfunction

Thruxton R 301
Fuel System And Engine Management

Diagnostic Fault Description Number of Number of MIL Pinpoint test page number
Trouble no-fault no-fault illuminated
Code (DTC) cycles cycles when fault is
before before DTC logged
turning off is erased
MIL
P0352 Ignition coil 2 3 40 Yes Ignition Coils, page 318
malfunction
P0443 Purge valve short 3 40 Yes Purge Valve, page 316
circuit to ground
or open circuit
P0459 Purge valve short 3 40 Yes Purge Valve, page 316
circuit to battery
Voltage
P0460 Fuel level sensor 3 40 No Fuel Level Sensor Circuit, page 348
circuit malfunction
P0500 Vehicle speed 3 40 Yes Vehicle Speed Sensor, page 378
sensor
malfunction
P0560 System voltage - 3 40 Yes System Voltage, page 326
battery circuit
malfunction
P0571 Brake 1 switch 3 40 Yes Brake Switches, page 368
malfunction
P0603 EEPROM Error 0 40 No EEPROM Error, page 372
P0606 ECM internal error 0 0 Yes Engine ECM Internal Error, page 372
P0616 Starter relay short 3 40 Yes Starter Motor Relay, page 334
circuit to ground
or open circuit
P0617 Starter relay short 3 40 Yes Starter Motor Relay, page 334
circuit to battery
Voltage
P0914 Gear position 3 40 Yes Gear Position Sensor, page 346
sensor short
circuit to ground
or open circuit
P0917 Gear position 3 40 Yes Gear Position Sensor, page 346
sensor short
circuit to 5 Volt
sensor supply
P1105 Manifold absolute 3 40 Yes Manifold Absolute Pressure (MAP)
pressure sensor 1 Sensor, page 344
pipe malfunction
P1131 Oxygen sensor 3 40 Yes Oxygen Sensor Reverse Connection,
circuits reversed page 372
P1135 Traction Control 3 40 Yes Traction Control Prevented Due to
prevented due to ABS Malfunction, page 372
ABS malfunction

302 Thruxton R
 Fuel System And Engine Management

Diagnostic Fault Description Number of Number of MIL Pinpoint test page number
Trouble no-fault no-fault illuminated
Code (DTC) cycles cycles when fault is
before before DTC logged
turning off is erased
MIL
P1231 Fuel pump relay 3 40 Yes Fuel Pump Relay, page 324
short circuit to
ground or open
circuit
P1232 Fuel pump relay 3 40 Yes Fuel Pump Relay, page 324
short circuit to
battery Voltage
P1508 Unmatched 3 40 Flashing Immobiliser and TPMS Control
immobiliser ECM Module ID Incompatable, page 373
P1520 Unmatched ABS 3 40 Flashing ABS Modulator ID Incompatible,
module page 373
P1521 CAN fault - lost 3 40 Yes ABS Modulator Communication,
communication page 366
with ABS module
or ABS system
status error
P1552 Cooling fan relay 3 40 Yes Cooling Fan Relay, page 328
short circuit to
ground or open
circuit
P1553 Cooling fan relay 3 40 Yes Cooling Fan Relay, page 328
short circuit to
battery Voltage or
over temp
P1571 Brake 2 switch 3 40 Yes Brake Switches, page 368
malfunction
P1576 Brake 1 switch 3 40 Yes Brake Switches, page 368
correlation error
with brake switch
2
P1577 Brake 2 switch 3 40 Yes Brake Switches, page 368
correlation error
with brake switch 1
P1604 ECM tamper 0 0 Yes Engine ECM Tamper Detected, page
detected - return 374
to Triumph
P1605 ECM locked by the Only if tune Flashing Tune Lock, page 372
tune lock function lock is
unlocked
P1607 ECM ride by wire 3 40 Yes Engine ECM Internal Error, page 372
internal error
P1608 ECM ride by wire 3 40 Yes Engine ECM Internal Error, page 372
internal error

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Fuel System And Engine Management

Diagnostic Fault Description Number of Number of MIL Pinpoint test page number
Trouble no-fault no-fault illuminated
Code (DTC) cycles cycles when fault is
before before DTC logged
turning off is erased
MIL
P1614 Instrument ID Only if Flashing Instrument ID Incompatible, page
incompatible Instrument 373
ID
Matching
P1619 Headlamp relay 0 40 No Headlight Relay, page 370
short circuit to
ground or open
circuit
P1620 Headlamp relay 0 40 No Headlight Relay, page 370
short circuit to
battery Voltage
P1631 Fall detection 3 40 Yes Fall Detection Switch, page 336
circuit short circuit
to ground
P1632 Fall detection 3 40 Yes Fall Detection Switch, page 336
circuit short circuit
to battery Voltage
P1650 CAN fault - lost 3 40 Yes Immobiliser Control Module
communication Communication, page 364
with Immobiliser
ECM
P1659 Ignition power 3 40 Yes EMS Ignition Voltage Input Circuit,
supply malfunction page 352
P1685 Main relay circuit 3 40 Yes EMS Main Relay Circuit, page 350
malfunction
P1690 CAN Fault 3 40 Yes CAN Communication, page 338
P1695 CAN fault - lost 0 40 No Instrument Communication (CAN),
communication page 340
with Instrument
panel
P1698 5 Volt sensor 3 40 Yes 5 Volt Sensor Supply Circuit, page
supply malfunction 354
P2100 Throttle actuator 3 40 Yes Throttle Actuator Motor, page 362
control motor
open circuit
P2102 Throttle actuator 3 40 Yes Throttle Valve Drive Error, page 372
control internal
motor relay does
not operate
P2103 Throttle actuator 3 40 Yes Throttle Valve Drive Error, page 372
control internal
motor relay
operates
continually

304 Thruxton R
 Fuel System And Engine Management

Diagnostic Fault Description Number of Number of MIL Pinpoint test page number
Trouble no-fault no-fault illuminated
Code (DTC) cycles cycles when fault is
before before DTC logged
turning off is erased
MIL
P2111 Throttle valve 3 40 Yes Throttle Valve Drive Error, page 372
drive error (stuck
open)
P2119 Throttle valve 3 40 Yes Throttle Valve Drive Error, page 372
drive error
2120 Twist grip position 3 40 Yes Twist Grip Position 1, page 356
sensor 1 short
circuit to ground
or open circuit
P2123 Twist grip position 3 40 Yes Twist Grip Position 1, page 356
sensor 1 short
circuit to battery
Voltage
P2125 Twist grip position 3 40 Yes Twist Grip Position 2, page 360
sensor 2 short
circuit to ground
or open circuit
P2128 Twist grip position 3 40 Yes Twist Grip Position 2, page 360
sensor 2 short
circuit to battery
Voltage
P2135 Throttle position 3 40 Yes Throttle Position Sensor, page 314
sensor 1
correlation error
with throttle
position sensor 2
P2138 Twist grip position 3 40 Yes Twist Grip Position Sensor 1
sensor 1 Correlation Error with Twist Grip
correlation error Position 2, page 358
with twist grip
position sensor 2
P2226 Ambient air 3 40 Yes Ambient Air Pressure Sensor, page
pressure sensor 342
circuit open circuit
or short circuit to
5 Volt sensor
supply
P2228 Ambient air 3 40 Yes Ambient Air Pressure Sensor, page
pressure sensor 342
circuit short circuit
to ground

Thruxton R 305
Fuel System And Engine Management

Immobiliser Control Module Diagnostic Trouble Codes

Diagnostic trouble codes (DTCs) are logged in the immobiliser/TPMS control module memory when there is a
confirmed fault in the system.
The codes are reported to the Triumph Diagnostic Tool as a four digit code.
The system will log the Diagnostic Trouble Codes listed below:
Diagnostic Trouble Fault Description Warning Light/Information
Code (DTC)
L0008 Invalid key: Key authentication unsuccessful Alarm/Immobiliser light ON

306 Thruxton R
 Fuel System And Engine Management

Electrical Connectors
Before beginning any diagnosis, the following
Caution
connector related information should be noted: Never disconnect an ECM when the ignition switch
Note: is in the ON position as this may cause multiple
fault codes to be logged in the ECM memory.
• A major cause of hidden electrical faults can
be traced to faulty electrical connectors. For Always disconnect an ECM after disconnecting the
example: battery negative (black) lead first.
• Dirty/corroded terminals
• Damp terminals
For example, the engine electronic control module
(engine ECM) relies on the supply of accurate
information to enable it to plan the correct fuelling
and ignition timing. One dirty terminal will cause an
excessive voltage drop resulting in an incorrect
signal to the engine ECM.
If, when carrying out fault diagnosis, a fault
appears to clear by simply disconnecting and
reconnecting an electrical plug, examine each
disconnected plug for the following.

When Disconnecting a Connector:

• Check for a security device that must be
released before the connector can be
separated, e.g. barb, hook and eye etc.

When Inspecting a Connector:

• Check that the individual pins have not been
bent
• Check for dampness/dirt/corrosion
• Check cables for security
• Check cable pin joints for damage.

When Connecting a Connector:

• Ensure there is no dirt around the connector/
seal
• Push together squarely to ensure terminals are
not bent or incorrectly located
• Push the two halves together positively.

Disconnection of the Engine ECM Connectors

Caution
When disconnecting a connector, never pull
directly on the wires as this may result in cable
and connector damage.

Thruxton R 307
Fuel System And Engine Management

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.

308 Thruxton R
 Fuel System And Engine Management

This page intentionally left blank

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Fuel System And Engine Management

Crankshaft Sensor
Fault Code Possible cause Action
P0335 Crankshaft sensor circuit View and note diagnostic software 'freeze-
malfunction frame' data if available.
Ensure sensor is fitted correctly and
connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check terminal and cable integrity: OK Disconnect sensor and proceed to test
- ECM pin A35 2

- ECM pin A36 Faulty Rectify fault, proceed to test 6

2 Check cable for short circuit: OK Proceed to test 3

- ECM pin A35 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin A36 to ground to test 6

3 Check cable continuity: OK Proceed to test 4

- ECM pin A35 to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed
- ECM pin A36 to sensor pin 2 to test 6

4 Check cable for short circuit: OK Proceed to test 5

- ECM pin A35 to ECM pin A36 Short circuit Locate and rectify wiring fault, proceed
to test 6
5 Check crankshaft toothed wheel: OK Renew crankshaft sensor, proceed to
- Damage to teeth - magnetic debris test 6
contamination Faulty Clean/renew toothed wheel, proceed to
test 6
6 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared.
Fault still Contact Triumph service
present

310 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronical
Control Module -
Connector A

12 1
24 13
36 35 25

2 UP A36 Engine Electronic

Crankshaft Sensor
1 UB A35 Control Module

2 1

Thruxton R 311
Fuel System And Engine Management

Fuel Injectors
Fault Code Possible cause Action
P0201 Injector 1 circuit malfunction View and note diagnostic software 'freeze-
frame' data if available.
P0202 Injector 2 circuit malfunction
Ensure relevant injector connector is
secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ECM pin A10 Faulty Rectify fault, proceed to test 7
- ECM pin A11
2 Check resistance value: 11.4 to 13 Proceed to test 3
- ECM pin A01 to ECM pin A10 (injector 1) Ohms

- ECM pin A01 to ECM pin A11 (injector 2) Open circuit Disconnect relevant injector and
proceed to test 4
Short circuit Disconnect relevant injector and
proceed to test 5
3 Check cable for short circuit to ground: OK Proceed to test 7
- ECM pin A10 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin A11 to ground to test 7

4 Check cable continuity: OK Proceed to test 6

- EMS relay pin 5 to relevant injector pin 2 Open circuit Locate and rectify wiring fault, proceed
- ECM pin A10 to injector 1 pin 1 to test 7
- ECM pin A11 to injector 2 pin 1
5 Check cable for short circuit to supply box: OK Proceed to test 6
- ECM pin A01 to ECM pin A10 (injector 1) Short circuit Locate and rectify wiring fault, proceed
- ECM pin A01 to ECM pin A11 (injector 2) to test 7

6 Check relevant injector resistance: 11.4 to 12.6 Proceed to test 7

- Injector pin 1 to injector pin 2 Ohms
Faulty Renew relevant injector, proceed to
test 7
7 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared.
Fault still Contact Triumph service
present

312 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

3B 2A 4A 1A Module - Connector A

5B 5A

1B 4B 2B 3A 12 11 10 6 1
24 13
36 25

EMS Relay
3 1 2 5
NK

NK A01

NK
2 1
YK A10
Engine Electronic
1
2 1
Control Module
NK 2 YP A11

1 2

Thruxton R 313
Fuel System And Engine Management

Throttle Position Sensor

Fault Code Possible cause Action
P0120 Throttle position sensor 1 short View and note diagnostic software 'freeze-
circuit to battery Voltage or frame' data if available.
open circuit View and note diagnostic software 'sensor'
P0122 Throttle position sensor 1 short data.
circuit to ground Ensure throttle position sensor connector
P0220 Throttle position sensor 2 short is secure. Disconnect the engine ECM and
circuit to battery Voltage or proceed to pinpoint test 1:
open circuit
P0222 Throttle position sensor 2 short
circuit to ground
P2135 Throttle position sensor 1
correlation error with throttle
position sensor 2

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect sensor and proceed to test
- ECM pin B19 2

- ECM pin B33 Faulty Rectify fault, proceed to test 5

- ECM pin B20
- ECM pin B26
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B20 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin B26 to ground to test 5

3 Check cable continuity: OK Proceed to test 4

- ECM pin B20 to throttle body connector Open circuit Locate and rectify wiring fault, proceed
pin 6 to test 5
- ECM pin B20 to throttle position sensor
connector pin 1
- ECM pin B26 throttle position sensor
connector pin 4
- ECM pin B19 to throttle position sensor
connector pin 2
- ECM pin B33 to throttle position sensor
connector pin 3
4 Check cable for short circuit: OK Renew the throttle body, proceed to
- ECM pin B33 to ECM pin B20 test 5

- ECM pin B33 to ECM pin B26 Short circuit Locate and rectify wiring fault, proceed
to test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared.
Fault still Contact Triumph service
present

314 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector B

1 2
16 1
32 26 20 19 17
3 4 48 33

2 B B19

Throttle Body 4 UG B26 Engine Electronic

3 R B33
Position Sensor Control Module
1 UY B20

Thruxton R 315
Fuel System And Engine Management

Purge Valve
Fault Code Possible cause Action
P0443 Purge valve short circuit to View and note diagnostic software 'sensor'
ground or open circuit data.
Ensure purge valve connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:
P0459 Purge valve short circuit to Disconnect the purge valve and proceed to
battery Voltage pinpoint test 5:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ECM pin B06 Faulty Rectify fault, proceed to test 7
- EMS relay pin 5
2 Check resistance value: 22 to 30 Proceed to test 3
- ECM pin A01 to ECM pin B06 Ohms
Open circuit Disconnect purge valve and proceed to
test 4
Short circuit Disconnect purge valve and proceed to
test 5
3 Check cable for short circuit: OK Proceed to test 7
- ECM pin B06 to ground Short circuit Locate and rectify wiring fault, proceed
to test 7
4 Check cable continuity: OK Proceed to test 6
- EMS relay pin 5 to valve pin 2 Open circuit Locate and rectify wiring fault, proceed
- ECM pin B06 to valve pin 1 to test 7

5 Check cable for short circuit: OK Proceed to test 6

- ECM pin A01 to ECM pin B06 Short circuit Locate and rectify wiring fault, proceed
to test 7
6 Check purge valve resistance: 22 to 30 Proceed to test 7
- Valve pin 1 to valve pin 2 Ohms
Faulty Renew purge valve, proceed to test 7
7 Reconnect harness, clear fault code and OK Action complete - quit test
run diagnostic software function test to
Fault still Contact Triumph service
visually verify operation of purge valve.
present

316 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

3B 2A 4A 1A
Module - Connector A
5B 5A

1B 4B 2B 3A

12 1
24 13
36 25

EMS Relay
3 1 2 5
NK

NK A01

2 1
NK B B06

Purge Valve

1 2 16 6 1
32 17
48 33

Engine Electronic Control

Module - Connector B

Thruxton R 317
Fuel System And Engine Management

Ignition Coils
Fault Code Possible cause Action
P0351 Ignition coil 1 malfunction View and note diagnostic software 'freeze-
frame' data if available.
P0352 Ignition coil 2 malfunction
Ensure relevant ignition coil connector is
secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ECM pin B14 Faulty Rectify fault, proceed to test 7
- ECM pin B15
- EMS relay pin 5
2 Check resistance value: 3.0 to 4.2 Proceed to test 3
ECM pin A01 to Ohms

- ECM pin B14 (ignition coil 1) Open circuit Disconnect relevant ignition coil and
proceed to test 4
- ECM pin B15 (ignition coil 2)
Short circuit Disconnect relevant ignition coil and
proceed to test 5
3 Check cable for short circuit: OK Proceed to test 6
- ECM pin B14 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin B15 to ground to test 6

4 Check cable continuity: OK Proceed to test 5

- EMS relay pin 5 to relevant ignition coil Open circuit Locate and rectify wiring fault, proceed
pin to test 6
- ECM pin B14 to ignition coil 1 pin 1
- ECM pin B15 to ignition coil 2 pin 1
5 Check relevant ignition coil resistance: 3.0 to 4.2 Proceed to test 6
- Ignition coil pin 1 to ignition coil pin 2 Ohms
Faulty Renew relevant ignition coil, proceed to
test 6
6 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared.
Fault still Contact Triumph service
present

318 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector A

3B 2A 4A 1A

12 1
5B 5A
24 13
36 25
1B 4B 2B 3A

EMS Relay
3 1 2 5
NK

NK A01
2 1
NK 1 GP B14
2 1
NK 2 GK B15

Ignition Coils

16 15 14 1
32 17
48 33

Engine Electronic Control

Module - Connector B

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Fuel System And Engine Management

Coolant Temperature Sensor

Fault Code Possible cause Action
P0115 Engine coolant temperature View and note diagnostic software 'freeze-
sensor open circuit or short frame' data if available.
circuit to 5 Volt sensor supply View and note diagnostic software 'sensor'
data.
Ensure sensor connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:
P0117 Engine coolant temperature Disconnect temperature sensor and
sensor short circuit to ground proceed to pinpoint test 6:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ECM pin B40 Faulty Rectify fault, proceed to test 7
2 Check resistance value: OK Proceed to test 6
- ECM pin B40 to ground (Temperature Open circuit Disconnect temperature sensor and
dependent - see overleaf) proceed to test 3
Short circuit Disconnect temperature sensor and
proceed to test 4
3 Check cable continuity: OK Proceed to test 5
- ECM pin B40 to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed
- Ground to sensor pin 2 to test 7

4 Check cable for short circuit: OK Proceed to test 5

- ECM pin B40 to ECM pin A01 Short circuit Locate and rectify wiring fault, proceed
to test 7
5 Check sensor resistance: OK Proceed to test 7
- Sensor pin 1 to sensor pin 2 (Temperature Faulty Renew temperature sensor, proceed to
dependent - see overleaf) test 7
6 Check cable for short circuit: OK Proceed to test 7
- ECM pin B40 to ground Short circuit Locate and rectify wiring fault, proceed
to test 7
7 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared.
Fault still Contact Triumph service
present

320 Thruxton R
 Fuel System And Engine Management

Resistance data under typical conditions:

Cold engine: Resistance Value
20ºC ambient 2.22 to 2.71 K Ohms
-10ºC ambient 8.50 to 10.25 K
Ohms
Warm engine: Resistance Value
- 100 to 400 Ohms

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 17
48 40 33

Coolant Temperature
Sensor
1 KG B40
Engine Electronic
2
A01
Control Module
B

1 2 12 1
24 13
36 25

Engine Electronic Control

Module - Connector A

Thruxton R 321
Fuel System And Engine Management

Inlet Air Temperature Sensor

Fault Code Possible cause Action
P0110 Intake air temperature sensor View and note diagnostic software 'freeze-
open circuit or short circuit to 5 frame' data if available.
Volt sensor supply View and note diagnostic software 'sensor'
data.
Ensure sensor connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:
P0112 Intake air temperature sensor Disconnect the engine ECM and inlet air
short circuit to ground temperature sensor and proceed to
pinpoint test 6:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ECM pin B42 Faulty Rectify fault, proceed to test 7
2 Check resistance value: OK Proceed to test 6
- ECM pin B42 to ground (Temperature Open circuit Disconnect temp sensor and proceed
dependent - see below) to test 3
Short circuit Disconnect temp sensor and proceed
to test 4
3 Check cable continuity: OK Proceed to test 5
- ECM pin B42 to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed
- Ground to sensor pin 2 to test 7

4 Check cable for short circuit: OK Proceed to test 5

- ECM pin B42 to ECM pin A01 Short circuit Locate and rectify wiring fault, proceed
to test 7
5 Check sensor resistance: OK Proceed to test 7
- Sensor pin 1 to sensor pin 2 (Temperature Faulty Renew air temperature sensor,
dependent - see below) proceed to test 7
6 Check cable for short circuit: OK Proceed to test 7
- ECM pin B42 to ground Short circuit Locate and rectify wiring fault, proceed
to test 7
7 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared.
Fault still Contact Triumph service
present

Resistance data:
If engine is warm, remove the sensor and allow time to cool to ambient temperature prior to test.

322 Thruxton R
 Fuel System And Engine Management

Ambient Temperature Resistance Value

80ºC 200 to 400 Ohms
20ºC 2.35 to 2.65 K
Ohms
-10ºC 8.50 to 10.25 K
Ohms

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 17
48 42 33

Intake Air Temperature

Sensor Engine Electronic
1 KO B42
2
A01
Control Module
B

12 1
1 2 24 13
36 25

Engine Electronic Control

Module - Connector A

Thruxton R 323
Fuel System And Engine Management

Fuel Pump Relay

Fault Code Possible cause Action
P1231 Fuel pump relay short circuit to Check if pump runs briefly when ignition is
ground or open circuit switched on.
Ensure fuel pump relay connector is
secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:
P1232 Fuel pump relay short circuit to Disconnect the engine ECM and fuel pump
battery Voltage relay and proceed to pinpoint test 4:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect fuel pump relay and
- ECM pin A26 proceed to test 2

- Alarm pin 1 Faulty Rectify fault, proceed to test 5

- Alarm pin 2
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin A26 to ground Short circuit Locate and rectify wiring fault, proceed
to test 5
3 Check cable continuity: OK Proceed to test 4
- ECM pin A26 to fuel pump relay pin 2 Open circuit Locate and rectify wiring fault, proceed
- Alarm pin 1 to fuel pump relay pin 1 to test 5

4 Check cable for short circuit: OK Proceed to test 5

- ECM pin A26 to ECM pin A01 Short circuit Locate and rectify wiring fault, proceed
to test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run diagnostic software function test to
Fault still Contact Triumph service
verify fault cleared.
present

324 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

3B 2A 4A 1A
Engine Electronic Control
5B 5A
Module - Connector A
1B 4B 2B 3A

12 1
24 13
36 26 25

Fuel Pump
Relay
3 1 2 5

GR BP A26
Alarm Engine Electronic
Control Module
1 B GR B01

1 2 5

6 16 1
12
32 17
48 33

Engine Electronic Control

Module - Connector B

Thruxton R 325
Fuel System And Engine Management

System Voltage
Fault Code Possible cause Action
P0560 System voltage - battery circuit View and note diagnostic software 'sensor'
malfunction data.
Ensure voltage across battery is
acceptable, note voltage.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ECM pin A01 Faulty Rectify fault, proceed to test 3
- ECM pin A13
- EMS relay pin 5
2 With Ignition on check voltage at: Same as Proceed to test 3
- ECM pin A01 across
battery
voltage
Less than Locate and rectify wiring fault, proceed
across to test 3
battery
voltage
3 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared.
Fault still Contact Triumph service
present

326 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector A
3B 2A 4A 1A

5B 5A
12 1
24 23 20 13
1B 4B 2B 3A
36 25

EMS Relay
3 1 2 5

NK
NK A01

NK A13

B A20

B A25 Engine Electronic

B A23 Control Module

B B08

B B13

B B48

16 13 08 1
32 17
48 33

Engine Electronic Control

Module - Connector B

Thruxton R 327
Fuel System And Engine Management

Cooling Fan Relay

Fault Code Possible cause Action
P1552 Cooling fan relay short circuit to View and note diagnostic software 'sensor'
ground or open circuit data.
Ensure fan relay connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:
P1553 Cooling fan relay short circuit to Disconnect the engine ECM and fan relay
battery Voltage or over temp and proceed to pinpoint test 4:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect fan relay and proceed to
- ECM pin A27 test 2

- EMS relay pin 5 Faulty Rectify fault, proceed to test 5

2 Check cable for short circuit: OK Proceed to test 3

- ECM pin A27 to ground Short circuit Locate and rectify wiring fault, proceed
to test 5
3 Check cable continuity: OK Proceed to test 4
- ECM pin A27 to fan relay pin 2 Open circuit Locate and rectify wiring fault, proceed
- EMS relay pin 5 to fan relay pin 1 to test 5

4 Check cable for short circuit: OK Proceed to test 5

- ECM pin A27 to ECM pin A01 Short circuit Locate and rectify wiring fault, proceed
to test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run diagnostic software function test to
Fault still Contact Triumph service
visually verify operation of cooling fan.
present

328 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

3B 2A 4A 3B 2A 4A 1A
1A

5B 5A 5B 5A

1B 4B 2B 1B 4B 2B 3A
3A

EMS Relay Cooling Fan Relay

3 1 2 5 3 1 2 5

BY A27
NK

Engine Electronic
Control Module
NK NK A01

12 1
24 13
36 27 25

Engine Electronic Control

Module - Connector A

Thruxton R 329
Fuel System And Engine Management

Oxygen Sensor
Fault Code Possible cause Action
P0130 Oxygen sensor 1 open circuit or View and note 'freeze-frame' data if
short circuit to battery Voltage available.
P0131 Oxygen sensor 1 short circuit to View and note 'sensor' data.
ground Ensure sensor connector is secure.
P0150 Oxygen sensor 2 circuit open Disconnect the engine ECM and proceed to
circuit or short circuit to battery pinpoint test 1:
Voltage
P0151 Oxygen sensor 2 short circuit to
ground

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect oxygen sensors and
- ECM pin B02 proceed to test 2

- ECM pin B03 Faulty Rectify fault, proceed to test 5

- EMS relay pin 5
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B02 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin B03 to ground to test 4

3 Check cable continuity: OK Proceed to test 4

- ECM pin B02 to left hand oxygen sensor Open circuit Locate and rectify wiring fault, proceed
pin 4 to test 4
- ECM pin B03 to right hand oxygen sensor
pin 4
- ECM pin A01 to relevant oxygen sensor
pin 3
4 Check cable for short circuit: OK Renew relevant oxygen sensor,
- ECM pin A01 to ECM pin B02 (left hand proceed to test 5
oxygen sensor) Short circuit Locate and rectify wiring fault, proceed
- ECM pin A01 to ECM pin B03 (right hand to test 5
oxygen sensor)
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
Check adaption status. present

330 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

3B 2A 4A 1A Engine Electronic Control

Module - Connector B
5B 5A

1B 4B 2B 3A
16 3 2 1
32 17

1 2 48 33

3 4

Left Hand
EMS Relay Oxygen Sensor
3 1 2 5 3 1 2 4

W B02
NK B
BY A21
Engine Electronic
NK NK A01 Control Module
B BU A22

W B03
NK B

Right Hand 3 1 2 4

Oxygen Sensor

12 1
24 22 21 13
1 2 36 25

3 4
Engine Electronic Control
Module - Connector A

Thruxton R 331
Fuel System And Engine Management

Oxygen Sensor Heater

Fault Code Possible cause Action
P0030 Oxygen sensor 1 heater open View and note 'freeze-frame' data if
circuit or short to ground available.
P0050 Oxygen sensor 2 heater open View and note 'sensor' data.
circuit or short to ground Ensure sensor connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:
P0032 Oxygen sensor 1 heater short Disconnect oxygen sensor and proceed to
circuit to battery Voltage pinpoint test 4:
P0052 Oxygen sensor 2 heater short
circuit to battery Voltage

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect oxygen sensors and
- ECM pin A21 proceed to test 2

- ECM pin A22 Faulty Rectify fault, proceed to test 5

2 Check cable for short circuit: OK Proceed to test 3

- ECM pin A21 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin A22 to ground to test 5

3 Check cable continuity: OK Proceed to test 5

- ECM pin A21 to left hand oxygen sensor Open circuit Locate and rectify wiring fault, proceed
pin 2 to test 5
- ECM pin A22 to right hand oxygen sensor
pin 2
4 Check cable for short circuit: OK Renew relevant oxygen sensor and
- ECM pin A01 to ECM pin A21 (left hand proceed to test 5
oxygen sensor) Short circuit Locate and rectify wiring fault, proceed
- ECM pin A01 to ECM pin A22 (right hand to test 5
oxygen sensor)
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
Check adaption status. present

332 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

3B 2A 4A 1A Engine Electronic Control

Module - Connector B
5B 5A

1B 4B 2B 3A
16 3 2 1
32 17

1 2 48 33

3 4

Left Hand
EMS Relay Oxygen Sensor
3 1 2 5 3 1 2 4

W B02
NK B
BY A21
Engine Electronic
NK NK A01 Control Module
B BU A22

W B03
NK B

Right Hand 3 1 2 4

Oxygen Sensor

12 1
24 22 21 13
1 2 36 25

3 4
Engine Electronic Control
Module - Connector A

Thruxton R 333
Fuel System And Engine Management

Starter Motor Relay

Fault Code Possible cause Action
P0616 Starter relay short circuit to Ensure starter motor relay connector is
ground or open circuit secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:
P0617 Starter relay short circuit to Disconnect the engine ECM and starter
battery Voltage motor relay proceed to pinpoint test 4:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect starter relay and proceed
- ECM pin B25 to test 2

- ECM pin A19 Faulty Rectify fault, proceed to test 5

- Starter Relay pin 1
- Starter Relay pin 2
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B25 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin A19 to ground to test 5

3 Check cable continuity: OK Proceed to test 4

- ECM pin B25 to starter relay pin 2 Open circuit Locate and rectify wiring fault, proceed
- ECM pin A19 to starter relay pin 1 to test 5

4 Check cable for short circuit: OK Proceed to test 5

- ECM pin B25 to ECM pin A01 Short circuit Locate and rectify wiring fault, proceed
to test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared
Fault still Contact Triumph service
present

334 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Starter Motor
Relay

3B 2A 4A 1A

5B 5A Engine Electronic Control

Module - Connector B
1B 4B 2B 3A

16 1
32 25 17
48 33

3 3 1 2 5

B B WR YN

YN B25
Engine Electronic
WR A19 Control Module

1 3 5

6 12

Alarm 12 1
24 19 13
36 25

Engine Electronic Control

Module - Connector A

Thruxton R 335
Fuel System And Engine Management

Fall Detection Switch

Fault Code Possible cause Action
P1631 Fall detection circuit short circuit View and note 'freeze-frame' data if
to ground available.
P1632 Fall detection circuit short circuit View and note 'sensor' data.
to battery Voltage Ensure switch connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect sensor and proceed to test
- ECM pin B18 2

- ECM pin B34 Faulty Rectify fault, proceed to test 4

- ECM pin B38
- Sensor pin 4, 5, 6
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B38 to ECM pin B18 Short circuit Locate and rectify wiring fault, proceed
- ECM pin B38 to ECM pin B34 to test 4

3 Check cable continuity: OK Proceed to test 4

- ECM pin B34 to sensor pin 4 Open circuit Locate and rectify wiring fault, proceed
- ECM pin B18 to sensor pin 6 to test 4

4 Reconnect harness, clear fault code. OK Action complete - quit test

Fault still Contact Triumph service
present

336 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 18 17
48 38 34 33

5 KU B38
Engine Electronic
Fall Detection Switch 4 K B34 Control Module
6 KB B18

1 2 3

4 5 6

Thruxton R 337
Fuel System And Engine Management

CAN Communication
Fault Code Possible cause Action
P1690 CAN Fault View and note 'freeze-frame' data if
available.
View and note 'sensor' data.
Ensure Instrument connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect instruments and proceed
- ECM pin A34 to test 2

- ECM pin A33 Faulty Rectify fault, proceed to test 5

- Instrument pin 9
- Instrument pin 10
- ABS module pin 2
- ABS module pin 11
- Immobiliser module pin 1
- Immobiliser module pin 6
- Bluetooth® module pin 3 ‡
- Bluetooth® module pin 4 ‡
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin A34 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin A33 to ground to test 5

3 Check cable continuity: OK Proceed to test 4

- ECM pin A34 to Instrument pin 10 Open circuit Locate and rectify wiring fault, proceed
- ECM pin A33 to Instrument pin 9 to test 5
- ECM pin A34 to ABS control module pin 11
- ECM pin A33 to ABS control module pin 2
- ECM pin A34 to Immobiliser module pin 1
- ECM pin A33 to Immobiliser module pin 6
- ECM pin A34 to Bluetooth® module pin 4 ‡
- ECM pin A33 to Bluetooth® module pin 3 ‡
4 Check cable for short circuit: OK Proceed to test 5
- ECM pin A34 to ECM pin A33 Short circuit Locate and rectify wiring fault, proceed
to test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present
‡ Bluetooth® is an optional accessory.

338 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

9 8 2 1
9 10
1 12
17 11 13 24
18 10

Instruments
9 R

10 U

ABS Control
Module
2 R Engine Electronic
Control Module
11 U

R A33
1 6 8 Diagnostic connector U A34

6 R
9 14 16
14 U

Immobiliser Control
Module
6 R

1 U

5 1 12 1
24 13
10 6 Bluetooth® Module Connector 36 34 33 25

3 R
Engine Electronic
4 U Control Module -
Connector A

3 1

6 4

Thruxton R 339
Fuel System And Engine Management

Instrument Communication (CAN)

Fault Code Possible cause Action
P1695 CAN fault - lost communication View and note 'freeze-frame' data if
with Instrument panel available.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect instruments and proceed
- ECM pin A33 to test 2

- ECM pin A34 Faulty Rectify fault, proceed to test 5

- Instrument pin 9
- Instrument pin 10
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin A33 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin A34 to ground to test 5

3 Check cable continuity: OK Proceed to test 4

- ECM pin A33 to Instrument pin 9 Open circuit Locate and rectify wiring fault, proceed
- ECM pin A34 to Instrument pin 10 to test 5

4 Check cable for short circuit: OK Proceed to test 5

- ECM pin A33 to ECM pin A34 Short circuit Locate and rectify wiring fault, proceed
to test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

340 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

9 10
1 12
13 24

Engine Electronic
Control Module

Instruments 9 R A33

Assembly 10 U A34

12 1
24 13
36 34 33 25

Engine Electronic Control

Module - Connector A

Thruxton R 341
Fuel System And Engine Management

Ambient Air Pressure Sensor

Fault Code Possible cause Action
P2228 Ambient air pressure sensor View and note 'freeze-frame' data if
circuit short circuit to ground available.
P2226 Ambient air pressure sensor View and note 'sensor' data.
circuit open circuit or short Ensure sensor connector is secure.
circuit to 5 Volt sensor supply
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect barometric pressure sensor
- ECM pin B18 and proceed to test 2

- ECM pin B34 Faulty Rectify fault, proceed to test 4

- ECM pin B41
- Sensor pin 1, 2, 3
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B41 to ECM pin B18 Short circuit Locate and rectify wiring fault, proceed
- ECM pin B41 to ECM pin B34 to test 4

3 Check cable for continuity: OK Renew barometric pressure sensor and

- ECM pin B34 to sensor pin 3 proceed to test 4

- ECM pin B18 to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed
to test 4
- ECM pin B41 to sensor pin 2
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

342 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 18 17
48 41 34 33

1 KB B18
Engine Electronic
Ambient Pressure Sensor 2 KP B41
3 K B34 Control Module

1 2 3

Thruxton R 343
Fuel System And Engine Management

Manifold Absolute Pressure (MAP) Sensor

Fault Code Possible cause Action
P0107 Manifold absolute pressure View and note 'freeze-frame' data if
sensor 1 short circuit to ground available.
P0105 Manifold absolute pressure View and note 'sensor' data.
sensor 1 open circuit or short Ensure sensor connector is secure.
circuit to 5 Volt sensor supply
Disconnect the engine ECM and proceed to
pinpoint test 1:
P1105 Manifold absolute pressure Check connection/condition of pipes from
sensor 1 pipe malfunction MAP sensors to throttle body.

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect MAP sensors and proceed
- ECM pin B18 to test 2

- ECM pin B34 Faulty Rectify fault, proceed to test 4

- ECM pin B36
- Sensor pin 1, 2, 3
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B36 to ECM pin B18 Short circuit Locate and rectify wiring fault, proceed
- ECM pin B36 to ECM pin B34 to test 4

3 Check cable for continuity: OK Renew relevant MAP pressure sensor,

- ECM pin B34 to MAP sensor pin 3 proceed to test 4

- ECM pin B18 to MAP sensor pin 1 Open circuit Locate and rectify wiring fault, proceed
to test 4
- ECM pin B36 to MAP sensor pin 2
4 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

344 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 18 17
48 36 34 33

1 KB B18
Engine Electronic
MAP Sensor 2 KS B36
Control Module
3 K B34

1 2 3

Thruxton R 345
Fuel System And Engine Management

Gear Position Sensor

Fault Code Possible cause Action
P0914 Gear position sensor short View and note 'freeze-frame' data if
circuit to ground or open circuit available.
P0917 Gear position sensor short View and note 'sensor' data.
circuit to 5 Volt sensor supply Ensure sensor connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect sensor and proceed to test
- ECM pin B23 2

- ECM pin B44 Faulty Rectify fault, proceed to test 5

2 Check cable for short circuit: OK Proceed to test 3

- ECM pin B23 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin B34 to ground to test 5
- ECM pin B44 to ground
3 Check cable continuity: OK Proceed to test 4
- ECM pin B23 to sensor pin 2 Open circuit Locate and rectify wiring fault, proceed
- ECM pin B18 to sensor pin 3 to test 5
- ECM pin B34 to sensor pin 4
- ECM pin B44 to sensor pin 1
4 Check cable for short circuit: OK Renew gear position sensor and
- ECM pin B23 to ECM pin B44 contact pin and proceed to test 5

- ECM pin B23 to ECM pin B34 Short circuit Locate and rectify wiring fault, proceed
to test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

346 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 23 18 17
48 44 34 33

Gear Position Sensor

1 BW B44
2 BK B23 Engine Electronic
3 KB B18
Control Module
4 K B34

1 2

3 4

Thruxton R 347
Fuel System And Engine Management

Fuel Level Sensor Circuit

Fault Code Possible cause Action
P0460 Fuel level sensor circuit View and note 'freeze-frame' data if
malfunction available.
View and note 'sensor' data.
Ensure sensor connector is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect sensor and proceed to test
- ECM pin B27 2
Faulty Rectify fault, proceed to test 4
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B27 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin B34 to ground to test 4

3 Check cable continuity: OK Proceed to test 4

- ECM pin B27 to sensor pin 4 Open circuit Locate and rectify wiring fault, proceed
- ECM pin B34 to sensor pin 2 to test 4
- ECM pin B18 to sensor pin 1
5 Reconnect harness, clear fault code. OK Action complete - quit test
Fault still Contact Triumph service
present

348 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 27 18 17
48 34 33

Fuel Level Sensor

1 KB B18 Engine Electronic

2 K B34
Control Module
4 BY B27

1 2

3 4

Thruxton R 349
Fuel System And Engine Management

EMS Main Relay Circuit

Fault Code Possible cause Action
P1685 Main relay circuit malfunction Note that the starter motor cannot be
powered if a main relay fault exists. Ensure
the EMS main relay connector is secure.
Proceed to pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Ensure ignition has been switched off for OK Proceed to test 4
greater than 90 seconds. Identify EMS main
Faulty Disconnect EMS main relay and engine
relay on the harness.
ECM. Proceed to test 4
Check that relay operates when the ignition
is switched ON and the stop and run switch
is in the RUN position.
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B31 to ground Short circuit Locate and rectify wiring fault, replace
- ECM pin A01 to ground Fuse 5 and proceed to test 6

3 Check cable and terminal integrity: OK Disconnect main relay and proceed to
- ECM pin B31 test 4

- EMS main relay pin 1 Faulty Rectify fault, proceed to test 5

- EMS main relay pin 2
- EMS main relay pin 3
- EMS main relay pin 5
4 Check fuse box fuse 2 integrity OK Proceed to test 5
Short circuit Replace fuse and proceed to test 5
5 Check cable continuity: OK Replace EMS main relay and proceed to
- ECM pin A01 to EMS main relay pin 5 test 6

- ECM pin B31 to EMS relay pin 1 Open circuit Locate and rectify wiring fault, proceed
to test 6
- EMS main relay pin 2 to ground
- EMS main relay pin 3 to fuse box fuse 2
6 Reconnect harness, clear fault code. Switch OK Action complete - quit test
ignition off for longer than 90 seconds.
Fault still Contact Triumph service
Switch ignition on and check that the EMS
present
main relay operates. Start engine as final
check.

350 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

3B 2A 4A 1A

5B 5A

1B 4B 2B 3A
Engine Electronic Control
Module - Connector A

12 1
24 13
36 25

Fuse Box

2
EMS Relay
3 1 2 5
B

NK A01
Engine Electronic
Control Module
NK YS B31

1 2 3 4 5 6

8
7 9 16 1
32 31 17
48 33

Engine Electronic Control

Module - Connector B

Thruxton R 351
Fuel System And Engine Management

EMS Ignition Voltage Input Circuit

Fault Code Possible cause Action
P1659 Ignition power supply Disconnect the engine ECM and proceed to
malfunction pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check fuse box Fuse 7 integrity. OK Proceed to test 3
Faulty Proceed to test 2
2 Check cable for short circuit: OK Replace Fuse 10 and proceed to test 3
- ECM pin B01 to ground Short circuit Locate and rectify wiring fault, replace
Fuse 10 and proceed to test 5
3 Check cable and terminal integrity: OK Proceed to test 4
- ECM pin B01 Faulty Rectify fault, proceed to test 5
- Alarm connector pin 1
- Alarm connector pin 2
- Right hand switch housing pin 1 (8 pin
connector)
- Right hand switch housing pin 2 (8 pin
connector)
4 Check cable continuity: OK Proceed to test 5
- ECM pin B01 to fuse box Fuse 7 Open circuit Locate and rectify wiring, immobiliser
Note that the engine stop switch must be or engine stop switch fault, proceed to
in the RUN position and any alarm fitted test 5
must be disarmed.
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared.
Fault still Contact Triumph service
present

352 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

4 2 1

1 4

5 8 8 5
1 2 5

6 12

Engine Stop
Switch Alarm

5 1 2 2 1

Ignition Switch G G GN B B

GR B01
7

Engine Electronic
Fuse Box Control Module

16 1
32 17
48 33

Engine Electronic Control

Module - Connector B

Thruxton R 353
Fuel System And Engine Management

5 Volt Sensor Supply Circuit

Fault Code Possible cause Action
P1698 5 Volt sensor supply malfunction View and note 'sensor' data. Note ECM
sensors requiring a power supply will not
be active.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ECM pin B18 Faulty Rectify fault, proceed to test 5
- ECM pin B34
2 Check cable for short circuit OK Proceed to test 4
- ECM pin B18 to ECM pin B34 Faulty Proceed to test 3
3 Disconnect the following sensors in turn: OK Replace sensor last removed and
- MAP sensor proceed to test 5

- Ambient pressure sensor Faulty Proceed to test 4

- Fall detection sensor
- Fuel level sensor
- Side stand switch
- Gear position sensor
and retest for short circuit
- ECM pin B18 to ECM pin B34
4 Check cable for short circuit: OK Proceed to test 5
- ECM pin B18 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin B34 to ground to test 5
- ECM pin B18 to A01
- ECM pin B34 to A01
- ECM pin B18 to battery positive
- ECM pin B34 to battery positive
5 Reconnect harness, clear fault code and OK Action complete - quit test
use diagnostic software to check for
Fault still Contact Triumph service
correct sensor outputs and 5 volt sensor
present
supply voltage level.

354 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

1 2 1 2

1 2 3 3 4
3 4

1 2 3 2 1
1 2 3
4 5 6 3

Ambient Air Fall Fuel Side Gear

Pressure MAP Detection Level Stand Position
Sensor Sensor Switch Sender Switch Sensor

3 1 3 1 4 6 2 1 1 2 4 3

Engine K KB K KB K KB K KB K B K KB
Electronic
Control Module
B34 K

B18 KB

A01

1 12 1
16
24 13
32 18 17
36 25
48 34 33

Engine Electronic Engine Electronic

Control Module - Control Module -
Connector B Connector A

Thruxton R 355
Fuel System And Engine Management

Twist Grip Position 1

Fault Code Possible cause Action
P2120 Twist grip position sensor 1 short View and note 'sensor' data. Note ECM
circuit to ground or open circuit sensors requiring a power supply will not
be active.
P2123 Twist grip position sensor 1 short
circuit to battery Voltage Ensure twist grip position sensor is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect twist grip position sensor
- ECM pin B17 and proceed to test 2

- ECM pin B21 Faulty Rectify fault, proceed to test 5

- ECM pin B35
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B21 to ground Short circuit Locate and rectify wiring fault, proceed
to test 5
3 Check cable continuity: OK Proceed to test 4
- ECM pin B17 to sensor pin 1 Open circuit Locate and rectify wiring fault, proceed
- ECM pin B21 to sensor pin 2 to test 5
- ECM pin B35 to sensor pin 3
4 Check cable for short circuit: OK Renew twist grip position sensor,
- ECM pin B21 to ECM pin B17 proceed to test 5

- ECM pin B21 to ECM pin B35 Short circuit Locate and rectify wiring fault, proceed
to test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared
Fault still Contact Triumph service
present

356 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 28 21 19 17
48 35 33

2 W W B21

3 B B B35

Twist Grip 1 R R B17 Engine Electronic

Position Sensor Control Module
6 W W B28

5 B B B19

7 R R B33

1 2 3 4

5 6 7 8

Thruxton R 357
Fuel System And Engine Management

Twist Grip Position Sensor 1 Correlation Error with Twist Grip Position 2
Fault Code Possible cause Action
P2138 Twist grip position sensor 1 View and note diagnostic tool freeze frame
correlation error with twist grip data if available.
position sensor 2 View and note diagnostic tool sensor data.
Disconnect twist grip position sensor and
proceed to pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Turn the ignition on and measure the 5V DC Proceed to test 2
Voltage between: Faulty Rectify fault, proceed to test 2
- ECM pin B33 and ECM pin B19
- ECM pin B17 and ECM pin B35
2 Check cable continuity: OK Renew the twist grip and proceed to
- ECM pin B21 to sensor pin 2 test 3

- ECM pin B28 to sensor pin 6 Open circuit Rectify fault, proceed to test 3

3 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared
Fault still Contact Triumph service
present

358 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 28 21 19 17
48 35 33

2 W W B21

3 B B B35

Twist Grip 1 R R B17 Engine Electronic

Position Sensor Control Module
6 W W B28

5 B B B19

7 R R B33

1 2 3 4

5 6 7 8

Thruxton R 359
Fuel System And Engine Management

Twist Grip Position 2

Fault Code Possible cause Action
P2125 Twist grip position sensor 2 short View and note 'sensor' data. Note ECM
circuit to ground or open circuit sensors requiring a power supply will not
be active.
P2128 Twist grip position sensor 2 short
circuit to battery Voltage Ensure twist grip position sensor is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect twist grip position sensor
- ECM pin B19 and proceed to test 2

- ECM pin B28 Faulty Rectify fault, proceed to test 5

- ECM pin B33
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin B28 to ground Short circuit Locate and rectify wiring fault, proceed
to test 5
3 Check cable continuity: OK Proceed to test 4
- ECM pin B19 to sensor pin 5 Open circuit Locate and rectify wiring fault, proceed
- ECM pin B28 to sensor pin 6 to test 5
- ECM pin B33 to sensor pin 7
4 Check cable for short circuit: OK Renew twist grip position sensor,
- ECM pin B28 to ECM pin B19 proceed to test 5

- ECM pin B28 to ECM pin B33 Short circuit Locate and rectify wiring fault, proceed
to test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine to verify fault cleared
Fault still Contact Triumph service
present

360 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

Module - Connector B

16 1
32 28 21 19 17
48 35 33

2 W W B21

3 B B B35

Twist Grip 1 R R B17 Engine Electronic

Position Sensor Control Module
6 W W B28

5 B B B19

7 R R B33

1 2 3 4

5 6 7 8

Thruxton R 361
Fuel System And Engine Management

Throttle Actuator Motor

Fault Code Possible cause Action
P2100 Throttle actuator short circuit to View and note diagnostic tool freeze frame
ground or short circuit to data if available.
battery Voltage View and note diagnostic tool sensor data.
Throttle actuator with default Ensure throttle actuator motor connector
spring open circuit is secure.
Disconnect the engine ECM and proceed to
pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect throttle actuator connector
- ECM pin A02 and proceed to test 2

- ECM pin A03 Faulty Rectify fault, proceed to test 5

- Throttle actuator motor connector pin 1
- Throttle actuator motor connector pin 2
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin A02 to ground Short circuit Locate and rectify wiring fault, proceed
- ECM pin A03 to ground to test 4

3 Check cable for short circuit: OK Proceed to test 4

- ECM pin A02 to ECM pin A01 Short circuit Locate and rectify wiring fault, proceed
- ECM pin A03 to ECM pin A01 to test 4

4 Check cable for short circuit: OK Renew twist grip position sensor,
-Throttle actuator motor connector pin 1 proceed to test 5

- Throttle actuator motor connector pin 2 Short circuit Renew throttle body and proceed to
test 5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

362 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Throttle Actuator Motor 1 UO A02 Engine Electronic

2 UG A03 Control Module
Connector

1 2

12 6 3 2 1
24 13
36 25

Engine Electronic Control

Module - Connector A

Thruxton R 363
Fuel System And Engine Management

Immobiliser Control Module Communication

Fault Code Possible cause Action
P1650 CAN fault - lost communication View and note 'freeze-frame' data if
with Immobiliser ECM available.
Ensure immobiliser control module
connector is secure.
Ensure the ignition switch is turned to the
OFF position.
Proceed to pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect the engine ECM and
- ECM pin A33 proceed to test 2

- ECM pin A34 Faulty Rectify fault, proceed to test 6

- Immobiliser pin 1
- Immobiliser pin 2
- Immobiliser pin 6
- Immobiliser pin 7
- Immobiliser pin 8
2 Check cable for short circuit: OK Disconnect immobiliser, ignition switch
- ECM pin A33 to ground and proceed to test 3

- ECM pin A34 to ground Faulty Locate and rectify wiring fault, proceed
to test 6
3 Check fuse box Fuse 7 integrity. OK Proceed to test 5
Faulty Proceed to test 4
4 Check cable for short circuit: OK Proceed to test 5
- Immobiliser pin 2 to ground Faulty Locate and rectify wiring fault, replace
- Immobiliser pin 8 to ground relevant fuse, proceed to test 6

5 Check cable continuity: OK Proceed to test 6

- ECM pin A33 to immobiliser pin 6 Fault still Locate and rectify wiring fault, proceed
- ECM pin A34 to Immobiliser pin 1 present to test 6
- Immobiliser pin 7 to ground
- Fuse box Fuse 7 to immobiliser pin 2
- Fuse box Fuse 7 to immobiliser pin 8
6 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

364 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

12 1
Module - Connector A
24 13
36 34 33 25

Immobiliser

A33 R 6
Engine Electronic
Control Module
A34 U 1

G 8

1
G 2

7 G
2
BG 5

3
B 10
8
Fuse Box 7
4 B 7

6 G BG B

5 2 7

5 2 1

Ignition Switch 10 8 7 6

2
1 4

5 8
7

Thruxton R 365
Fuel System And Engine Management

ABS Modulator Communication

Fault Code Possible cause Action
P1521 CAN fault - lost communication View and note 'freeze-frame' data if
with ABS module or ABS system available.
status error Ensure ABS modulator connector is secure.
Proceed to pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect the engine ECM and
- ECM pin A33 proceed to test 2

- ECM pin A34 Faulty Rectify fault, proceed to test 6

- ABS modulator pin 2
- ABS modulator pin 4
- ABS modulator pin 10
- ABS modulator pin 11
- ABS modulator pin 18
2 Check cable for short circuit: OK Disconnect ABS modulator and
- ECM pin A33 to ground proceed to test 3

- ECM pin A34 to ground Faulty Locate and rectify wiring fault, proceed
to test 6
3 Check fuse box Fuse 5 and 7 integrity. OK Proceed to test 5
Faulty Proceed to test 4
4 Check cable for short circuit: OK Proceed to test 5
- ABS pin 2 to ground Faulty Locate and rectify wiring fault, replace
- ABS pin 11 to ground relevant fuse, proceed to test 6

5 Check cable continuity: OK Proceed to test 6

- ECM pin A33 to ABS pin 2 Fault still Locate and rectify wiring fault, proceed
- ECM pin A34 to ABS pin 11 present to test 6
- ABS pin 4 to ground
- Fuse box Fuse 5 to ABS pin 18
- Fuse box Fuse 7 to ABS pin 4
6 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

366 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

1 2 3 4 5 6

8
7 9

Fuse Box

5 7

R G

18 R

4 G

ABS Modulator R R A33

2 Engine Electronic

11 U U A34 Control Module

10 B

12 1
9 8 2 1
4 24 13
36 34 33 25
17 11
18 10

Engine Electronic Control

Module - Connector A

Thruxton R 367
Fuel System And Engine Management

Brake Switches
Fault Code Possible cause Action
P0571 Brake 1 switch malfunction View and note freeze frame data if
available.
P1576 Brake 1 switch correlation error
with brake switch 2 Ensure brake switches connectors are
secure.
P1571 Brake 2 switch malfunction
Disconnect engine ECM and proceed to
P1577 Brake 2 switch correlation error pinpoint test 1:
with brake switch 1

Pinpoint Tests
Test Result Action
1 Turn ignition on, operate rear brake switch OK Proceed to test 2
and check brake light operation
Faulty Rectify fault, proceed to test 6
2 Check cable and terminal integrity: OK Disconnect front and rear brake
- ECM pin A06 switches connector, proceed to test 3

- ECM pin A07 Faulty Rectify fault, proceed to test 6

- Ignition switch pin 8
3 With brakes released, check front and rear OK Proceed to test 4
brake switch operation:
Faulty Replace relevant brake switch, proceed
The following should be short circuit to test 6
- Front brake switch pin 2 to pin 3
- Rear brake light switch pin 2 to pin 3
The following should be open circuit
- Front brake switch pin 1 to pin 3
- Rear brake light switch pin 1 to pin 3
4 Check cable continuity: <10V Proceed to test 5
- ECM pin A07 to front brake switch pin 1 >5V Locate and rectify wiring fault, proceed
- ECM pin A07 to rear brake switch pin 1 to test 6
- ECM pin A06 to rear brake switch pin 1
5 With the ignition switch on, measure the OK Proceed to test 6
following Voltages:
Faulty Locate and rectify wiring fault, proceed
- ECM pin A06 to ground to test 6
- Rear brake switch pin 2
- Rear brake switch pin 3
- Front brake switch pin 2
- Front brake switch pin 3
- Ignition switch pin 8
6 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

368 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Control Module

1 2 3 1 2 3

Ignition Front Brake Switch Rear Brake Switch

Switch

8 3 2 1 3 2 1

OG Y GU GP GU B GP

B A06

BY A07

1 4

5 8

Engine Electronic Control 12 7 6 1

Module - Connector A 24 13
36 25

Thruxton R 369
Fuel System And Engine Management

Headlight Relay
Fault Code Possible cause Action
P1619 Headlamp relay short circuit to View and note 'freeze-frame' data if
ground or open circuit available.
Disconnect the engine ECM and proceed to
pinpoint test 1:
P1620 Headlamp relay short circuit to Disconnect the engine ECM and headlight
battery Voltage relay and proceed to pinpoint test 4:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect headlight relay and
- ECM pin A18 proceed to test 2

- Headlamp relay pin 1 Faulty Rectify fault, proceed to test 5

- Headlamp relay pin 2
- Check fuse box fuse 7 integrity
2 Check cable for short circuit: OK Proceed to test 3
- ECM pin A18 to ground Faulty Locate and rectify wiring fault, replace
relevant fuse, proceed to test 5
3 Check cable continuity: OK Renew headlight relay, proceed to test
- ECM pin A18 to headlight relay pin 1 5

- Fuse box Fuse 7 to headlight relay pin 2 Faulty Locate and rectify wiring fault, proceed
to test 5
4 Check cable for short circuit: OK Renew headlight relay, proceed to test
- ECM pin A18 to fuse box fuse 7 5
Short circuit Renew headlight relay, proceed to test
5
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

370 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

9 7
8

3B 2A 4A 1A

6 5 4 3 2 1 5B 5A

1B 4B 2B 3A

7
Fuse Box
Headlight
1 2 Relay

G BN G

Engine Electronic
Control Module

BN A18

12 1
24 18 13
36 25

Engine Electronic Control

Module - Connector A

Thruxton R 371
Fuel System And Engine Management

Oxygen Sensor Reverse Connection

Fault Code Possible cause Action
P1131 Oxygen sensor circuits reversed Check oxygen sensor connections and
swap cylinder number 1 and cylinder
number 2 connections if incorrect.

EEPROM Error
Fault Code Possible cause Action
P0603 EEPROM error View and note 'freeze frame'
data if available.
No tests available - contact
Triumph service.

Engine ECM Internal Error

Fault Code Possible cause Action
P0606 Engine ECM internal error Contact Triumph service.
P1607 Engine ECM ride by wire internal
P1608 error

Traction Control Prevented Due to ABS Malfunction

Fault Code Possible cause Action
P1135 Traction Control prevented due Check that there is no other DTC linked to
to ABS malfunction the ABS system or CAN communication
stored.
Contact Triumph service.

Throttle Valve Drive Error

Fault Code Possible cause Action
P2111 Throttle valve drive error (stuck View and note 'freeze-frame' data if
open) available.
P2119 Throttle valve drive error View and note 'sensor' data.

P2102 Throttle actuator control internal Check throttle body for mechanical
motor relay does not operate malfunctions. Clear fault code and contact
Triumph service if fault is still present.
P2103 Throttle actuator control internal
motor relay operates continually

Tune Lock
Fault Code Possible cause Action
P1605 Engine ECM locked by the tune This is also identified by a fast flashing MIL
lock function indication, and a disabled engine
management system.
Unlock the engine ECM using the diagnostic
software and supplied unlock code from
Triumph service.

372 Thruxton R
 Fuel System And Engine Management

Instrument ID Incompatible
Fault Code Possible cause Action
P1614 Instrument ID incompatible This is also identified by a fast flashing MIL
indication, and a disabled engine
management system.

Pinpoint Tests
Test Result Action
1 Check engine ECM part number is correct OK Proceed to test 2
for the motorcycle.
Incorrect Replace engine ECM with correct part
and proceed to test 3
2 Check that the tune is correct for the OK Proceed to test 3
motorcycle, using the diagnostic software.
Incorrect Update tune using diagnostic software,
proceed to test 3
3 Clear fault code, check for normal OK Action complete - quit test
operation.
Fault still Contact Triumph service
present

Immobiliser and TPMS Control Module ID Incompatable

Fault Code Possible cause Action
P1508 Unmatched Immobiliser/chassis This is also identified by a fast
ECM, causing the engine ECM to flashing MIL indication and a
be disabled to prevent the disabled engine management
motorcycle from being operated system.

Pinpoint Tests
Test Result Action
1 Follow the Pair ECM and Immobiliser OK Action complete - quit test
procedure as described in the
Fault still present Contact Triumph service
Triumph Diagnostic Tool user guide

ABS Modulator ID Incompatible

Fault Code Possible cause Action
P1520 Unmatched ABS module This is also identified by ABS
warning light indication.
Proceed to pinpoint test 1:

Thruxton R 373
Fuel System And Engine Management

Pinpoint Tests
Test Result Action
1 Check ABS modulator part number is OK Proceed to test 2
correct for the motorcycle.
Incorrect Replace ABS modulator with correct
part and proceed to test 3
2 Check that the tune is correct for the OK Proceed to test 3
motorcycle, using the diagnostic tool.
Incorrect Update tune using service tool,
proceed to test 3
3 Clear fault code, check for normal OK Action complete - quit test
operation.
Fault still Contact Triumph service
present

Engine ECM Tamper Detected

Fault Code Possible cause Action
P1604 Engine ECM tamper detected - Contact Triumph service
return to Triumph

Fault Finding – Non Electrical

Symptom Possible cause(s)
Poor throttle response at low rpm Low fuel pressure caused by filter blockage/leaks
Low fuel pressure caused by loose fuel pipes to the
fuel pump and filter
Cutting out at idle Throttle bodies out of balance
Low fuel pressure caused by loose fuel pipes to the
fuel pump and filter
Low fuel pressure
Weak mixture caused by air leak at the throttle
body/transition piece to cylinder head face
Idle speed too low/high Incorrect closed throttle position setting
Diagnostic software malfunctions during tune Low battery voltage
download procedure
Throttle hang-up Incorrect closed throttle position setting
Bike will start but cuts out immediately Low fuel pressure caused by loose fuel pipes to the
fuel pump and filter
Low fuel pressure due to split fuel filter
Abnormally high fuel pressure Fuel pressure regulator inoperative
Temperature gauge reads cooler than normal Cooling system air–locked resulting in coolant
temperature sensor operating in air instead of
coolant
Thermostat fault

374 Thruxton R
 Fuel System And Engine Management

This page intentionally left blank

Thruxton R 375
Fuel System And Engine Management

Invalid Key: Key Authentication Unsuccessful

Fault Code Possible cause Action
L0008 Invalid key: Key authentication Check that the key has been registered
or unsuccessful with the immobiliser control module, if it is
a new key or an additional key.
Alarm/immobiliser
warning indicator light Check that there are no additional keys
is on when the ignition with a transponder chip fitted close to the
switch is at the ON ignition key and proceed to pinpoint test 1:
position (only visible on
motorcycles without
the accessory alarm
fitted)

Pinpoint Tests
Test Result Action
1 If available, try to start the motorcycle with OK Transponder chip in the key not
the second registered key: functioning correctly. Register a new
key using the Triumph Diagnostic Tool
then proceed to test 5
Faulty Proceed to test 2
2 Check the condition of cable, connector OK Disconnect the ignition switch, proceed
housing and terminals for the following: to test 3
- Ignition switch Faulty Rectify fault, proceed to test 5
- Immobiliser control module
3 Check antenna coil resistance: 7 to 13 Ohms Proceed to test 4
- Ignition switch pin 2 to ignition switch pin Faulty Replace the ignition switch, register
7 new keys and proceed to test 5
4 Check cable continuity: OK Proceed to test 4
- Ignition switch pin 2 to Immobiliser control Faulty Rectify fault, proceed to test 5
module pin 5
- Ignition switch pin 7 to Immobiliser control
module pin 10
5 Reconnect harness, clear fault code and OK Action complete - quit test
run engine.
Fault still Contact Triumph service
present

376 Thruxton R
 Fuel System And Engine Management

Circuit Diagram

Engine Electronic Control

12 1
Module - Connector A
24 13
36 34 33 25

Immobiliser

A33 R 6
Engine Electronic
Control Module
A34 U 1

G 8

1
G 2

7 G
2
BG 5

3
B 10
8
Fuse Box 7
4 B 7

6 G BG B

5 2 7

5 2 1

Ignition Switch 10 8 7 6

2
1 4

5 8
7

Thruxton R 377
Fuel System And Engine Management

Vehicle Speed Sensor

Fault Code Possible cause Action
P0500 Wheel speed sensor fault Refer to the following ABS DTCs.
Front Wheel Sensor Open
Circuit/Short Circuit, page 568
Front Wheel Sensor Abnormal
Input/Losing Contact, page 575
Rear Wheel Sensor Open Circuit/
Short Circuit, page 572
Rear Wheel Sensor Abnormal
Input/Losing Contact, page 575

378 Thruxton R
 Fuel System And Engine Management

Fuel Tank - Removal 3. Detach the breather hose from its retaining
clips on the fuel tank then disconnect it from
the fuel tank.
Warning
Observe the warning advice given in the General
Information section on the safe handling of fuel
and fuel containers.
A fire, causing personal injury and damage to
property could result from spilled fuel or fuel not
handled or stored correctly.

Warning 1

Before starting work, ensure the motorcycle is

stabilised and adequately supported. This will help 2
prevent it from falling and causing injury to the 3
operator or damage to the motorcycle. cjpz

1. Breather hose
• Remove the seat (see Seat - Removal, page 2. Retaining clips
636).
3. Fuel tank spigot
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658). 4. Disconnect the electrical connectors for the
1. Remove the fixing securing the rear of the fuel fuel pump and the fuel level sensor from the
tank to the frame. main harness.

2
1
1

ciwf
cjqk

1. Fuel level sensor electrical connector

1. Fixings
2. Fuel pump electrical connector
2. Pivot the fuel tank upwards at the rear.

Warning
If the fuel rail is dismantled without first reducing
pressure, fuel may escape causing clothing and
components to be coated with fuel.
This would represent a serious fire hazard which
could lead to burn injuries and damage to
property.

5. Temporarily reconnect the battery, positive

(red) lead first and tighten the terminals to 4.5
Nm.

Thruxton R 379
Fuel System And Engine Management

Note: 9. Disconnect the fuel hose by squeezing the

sides of the connector and pulling the hose
• Because fuel stored in the fuel rail will be at free from its spigot on the fuel pump rail.
3.5 bar pressure, it is essential that the fuel Collect any fuel remaining in the hose in a
pressure is reduced before any dismantling of suitable container.
the fuel rail takes place. To reduce pressure,
briefly crank the engine with the fuel pump
disconnected.
• When disconnected, the fuel tank is self-
sealing but a small amount of fuel may dribble
from the hose.
• To protect the components under the fuel
tank, place suitable material over the 1
components to absorb the small amount of
fuel that may come from the fuel tank and its
fuel lines.
6. Briefly crank the engine to reduce the fuel
pressure in the fuel rail.
7. Disconnect the battery, negative (black) lead
first. ciwd

8. To release the double check clip, ease the latch 1. Fuel hose
away from the connector until the release
buttons are exposed. 10. Detach the fuel pump and fuel level sensor
electrical connectors from the ignition coil
bracket.
1 2
11. Slide the tank rearwards to detach it from the
frame.
12. Take care not to lose the front mounting and
rear mounting rubbers. Renew any mounting
rubber which shows signs of damage.

cekp

1. Locked Position
2. Unlocked Position

380 Thruxton R
 Fuel System And Engine Management

Fuel Tank - Removal 3. Detach the breather hose from its retaining
clips on the fuel tank then disconnect it from
the fuel tank.
Warning
Observe the warning advice given in the General
Information section on the safe handling of fuel
and fuel containers.
A fire, causing personal injury and damage to
property could result from spilled fuel or fuel not
handled or stored correctly.

Warning 1

Before starting work, ensure the motorcycle is

stabilised and adequately supported. This will help 2
prevent it from falling and causing injury to the 3
operator or damage to the motorcycle. cjpz

1. Breather hose
• Remove the seat (see Seat - Removal, page 2. Retaining clips
636).
3. Fuel tank spigot
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658). 4. Disconnect the electrical connectors for the
1. Remove the fixing securing the rear of the fuel fuel pump and the fuel level sensor from the
tank to the frame. main harness.

2
1
1

ciwf
cjqk

1. Fuel level sensor electrical connector

1. Fixings
2. Fuel pump electrical connector
2. Pivot the fuel tank upwards at the rear.

Warning
If the fuel rail is dismantled without first reducing
pressure, fuel may escape causing clothing and
components to be coated with fuel.
This would represent a serious fire hazard which
could lead to burn injuries and damage to
property.

5. Temporarily reconnect the battery, positive

(red) lead first and tighten the terminals to 4.5
Nm.

Thruxton R 381
Fuel System And Engine Management

Note: 9. Disconnect the fuel hose by squeezing the

sides of the connector and pulling the hose
• Because fuel stored in the fuel rail will be at free from its spigot on the fuel pump rail.
3.5 bar pressure, it is essential that the fuel Collect any fuel remaining in the hose in a
pressure is reduced before any dismantling of suitable container.
the fuel rail takes place. To reduce pressure,
briefly crank the engine with the fuel pump
disconnected.
• When disconnected, the fuel tank is self-
sealing but a small amount of fuel may dribble
from the hose.
• To protect the components under the fuel
tank, place suitable material over the 1
components to absorb the small amount of
fuel that may come from the fuel tank and its
fuel lines.
6. Briefly crank the engine to reduce the fuel
pressure in the fuel rail.
7. Disconnect the battery, negative (black) lead
first. ciwd

8. To release the double check clip, ease the latch 1. Fuel hose
away from the connector until the release
buttons are exposed. 10. Detach the fuel pump and fuel level sensor
electrical connectors from the ignition coil
bracket.
1 2
11. Slide the tank rearwards to detach it from the
frame.
12. Take care not to lose the front mounting and
rear mounting rubbers. Renew any mounting
rubber which shows signs of damage.

cekp

1. Locked Position
2. Unlocked Position

382 Thruxton R
 Fuel System And Engine Management

Fuel Tank - Installation 7. Lower the tank into position ensuring the
breather pipe is not trapped, kinked or twisted.

Warning 8. Tighten the rear fuel tank mounting bolt to 8

Nm.
Observe the warning advice given in the General • Reconnect the battery, positive (red) lead first
Information section on the safe handling of fuel (see Battery - Installation, page 658) and
and fuel containers. tighten the terminals to 4.5 Nm.
A fire, causing personal injury and damage to • Refit the seat (see Seat - Installation, page 636).
property could result from spilled fuel or fuel not
handled or stored correctly.

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. Ensure the front and rear mounting rubbers

are correctly fitted.
2. Manoeuvre the tank into position, engaging it
with the front mounting rubbers.
3. Reconnect the fuel feed hose by gently
pushing inwards until the hose engages with a
click.
4. Slide the double check latch to the locked
position until the release buttons are covered.
If the latch will not slide into position, then the
fuel hose is not fully home on its spigot and
must therefore be refitted correctly.

1 2

cekp

1. Locked Position
2. Unlocked Position

5. Attach and connect the breather pipe to the

fuel tank.
6. Connect the electrical connectors for the fuel
pump and the fuel level sensor to the main
harness and attach them to the ignition coil
bracket.

Thruxton R 383
Fuel System And Engine Management

Fuel Pressure Checking 4. Connect the adapter hose to the fuel pump
plate outlet and fuel hose as shown in the
illustration below.
Warning
Observe the fuel handling precautions given in the
General Information section.

Fuel pressure is checked using service tool

T3880001.

2
1

1. Adaptor hose 'A'

2. T3880391 - Fuel Pump Extension Cable

5. Connect the fuel pressure gauge to the

cdgh
adapter hose as shown below by pushing the
gauge spigot into the adapter until a click can
T3880001 - Fuel Pressure Gauge be heard.
1. Remove the fuel tank (see Fuel Tank - Removal,
page 379) and place on a suitable support,
close to the motorcycle.
2. Using the service tool T3880391, carefully
connect the fuel pump connection on the main
harness to the fuel tank.
3. Select the fuel pressure gauge adapter marked 2
1
'A' from service tool T3880001.

Warning
Always use the correct fuel pressure gauge
adapter. Use of an incorrect adapter will result in
a fuel leak. A fuel leak can result in a fire causing cdvr_2

damage to property and injury to persons.

1. Adapter hose
2. Fuel pressure gauge

Note:
• To release the fuel pressure gauge from the
adapter, slide the outer ferrule downwards.
This will allow the gauge to spring upwards
from the adapter.
6. Ensure the gauge is visible to the side of the
motorcycle.
7. Start the engine and observe the fuel pressure
reading on the gauge.
Note:
• The fuel pressure should be 3.5 bar nominally.

384 Thruxton R
 Fuel System And Engine Management

8. When fuel pressure checking is complete, Fuel Pump Assembly - Removal

disconnect the fuel pressure gauge adapter
and wiring extension. Collect any fuel in the
hose in a suitable container. Warning
9. Refit the fuel tank (see Fuel Tank - Installation, Observe the warning advice given in the General
page 383). Information section on the safe handling of fuel
and fuel containers.
A fire, causing personal injury and damage to
property could result from spilled fuel or fuel not
handled or stored correctly.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).

Warning
Never drain fuel from the tank using non-
approved, non-professional standard fuel handling
equipment. A fire causing destruction of property
and injury to persons may result from use of non-
approved fuel handling equipment.

1. Using proprietary professional automotive

workshop equipment approved for fuel
handling, drain all fuel from the fuel tank.
2. Remove the fuel tank (see Fuel Tank - Removal,
page 379).
3. Invert the fuel tank and place on a protective
surface to prevent paint damage.
4. Remove the ring of fixings securing the fuel
pump mounting plate to the tank.

ciwg

1. Fuel pump mounting plate

2. Fixing

5. Detach the pump assembly from the fuel tank.

6. Disconnect the fuel level sensor from the
electrical connector on the fuel pump plate.

Thruxton R 385
Fuel System And Engine Management

7. Detach the P-clip for the fuel level sensor Fuel Pump Assembly - Inspection
harness from the fuel pump bracket.
1. Inspect all hoses for cracks, splits, fraying and
other damage. Replace as necessary.
1
2. Check all hose clamps for cracks and signs of
distortion. Replace as necessary.

civy

1. Electrical connector
2. P-clip

8. Remove the fuel pump assembly and discard

the fuel pump plate seal.

386 Thruxton R
 Fuel System And Engine Management

Fuel Pump Assembly - Installation Fuel Filter - Removal

Warning Warning
Observe the warning advice given in the General Observe the warning advice given in the General
Information section on the safe handling of fuel Information section on the safe handling of fuel
and fuel containers. and fuel containers.
A fire, causing personal injury and damage to A fire, causing personal injury and damage to
property could result from spilled fuel or fuel not property could result from spilled fuel or fuel not
handled or stored correctly. handled or stored correctly.

1. Position a new fuel pump plate seal to the fuel • Remove the fuel pump assembly (see Fuel Pump
pump plate as noted for removal. Assembly - Removal, page 385).
2. Route the fuel level sensor as noted for 1. Release the two fuel hose clips from either
removal and connect it to the electrical side of the fuel filter.
connector on the fuel pump plate. 2. Remove the hose bracket from the fuel pump
3. Attach the P-clip for the fuel level sensor bracket.
harness to the fuel pump bracket. 1
4. Refit the fuel pump assembly to the fuel tank.
Fit and tighten the fixings to 5 Nm working on
diagonally opposite fixings to spread the
clamping load evenly.
5. Refit the fuel tank (see Fuel Tank - Installation,
page 383).
6. Refill the fuel tank with the fuel drained during
removal, and check carefully for fuel leaks.
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
2
• Refit the seat (see Seat - Installation, page 636).
civv

1. Hose clips
2. Hose bracket

3. Carefully detach the baffle housing from the

fuel pump.

1
civw

1. Baffle housing
2. Hose clip

Thruxton R 387
Fuel System And Engine Management

4. Remove the fuel pump securing bolt and strap. Fuel filter - Inspection
1. Inspect all hoses for cracks, splits, fraying and
1 other damage. Replace as necessary.
2. Check all hose clamps for cracks and signs of
distortion. Replace as necessary.

civx

1. Strap
2. Bolt

5. Disconnect the fuel pump hose from the fuel

filter inlet.
6. Remove and discard the two fuel filter cable
ties.

civv_1

1. Cable ties

Note:
• Prior to removing the filter, note the direction
of the arrow on the side of the filter. The
arrow should point away from the fuel pump,
towards the pressure regulator.
7. Remove the fuel filter from the outlet hose.

388 Thruxton R
 Fuel System And Engine Management

Fuel Filter - Installation Fuel Pressure Regulator - Removal

• Remove the fuel pump assembly (see Fuel Pump
Warning Assembly - Removal, page 385).
1. Remove and discard the circlip securing the
Observe the warning advice given in the General fuel pressure regulator in its housing.
Information section on the safe handling of fuel
and fuel containers.
A fire, causing personal injury and damage to
property could result from spilled fuel or fuel not 1
handled or stored correctly.

1. Install the fuel filter to the outlet hose,

ensuring the arrow on the filter points away
from the pump. Secure the hose with the hose
clip.
2
2. Check and ensure that the feet of the rubber
isolator engage correctly in the fork.

cixu

1. Circlip
1 2. Fuel pressure regulator
2
2. Remove the fuel pressure regulator from the
fuel pump plate. Discard the large O-ring from
the fuel pressure regulator and the small O-
ring in the pressure regulator housing.

cevu

1. Fork
2. Isolator feet

3. Secure the fuel filter to the fuel pump bracket

with two new cable ties.
4. Connect the fuel pump hose to the fuel filter
and secure with the hose clip.
1 3
5. Refit the fuel pump securing bolt and strap
and tighten the bolt to 4 Nm. cixv

6. Refit the hose bracket to the fuel pump 1. Large O-ring

bracket and tighten its fixing to 7 Nm.
2. Fuel pressure regulator
7. Carefully refit the baffle material into the front
3. Small O-ring
of the baffle housing.
8. Refit the baffle housing to the fuel pump as
noted for removal.
• Refit the fuel pump assembly (see Fuel Pump
Assembly - Installation, page 387).

Thruxton R 389
Fuel System And Engine Management

Pressure Regulator - Inspection Fuel Pressure Regulator -

1. Inspect all hoses for cracks, splits, fraying and Installation
other damage. Replace as necessary. 1. Install new O-rings to the fuel pressure
2. Check all hose clamps for cracks and signs of regulator.
distortion. Replace as necessary.

cixv_1

1. O-rings

2. Apply a small amount of grease, conforming to

NLGI 2 specification, to the two O-rings.
3. Position the fuel pressure regulator squarley
to the fuel pump plate and press it evenly into
its housing.
4. Secure the fuel pressure regulator with a new
circlip.
5. Refit the hose and secure with the hose clip.
Check for any fuel leaks and rectify if
necessary.
• Refit the fuel pump assembly (see Fuel Pump
Assembly - Installation, page 387).

390 Thruxton R
 Fuel System And Engine Management

Fuel Pump - Removal 5. Remove the baffle housing hose clip over the
inlet filter.
• Remove the fuel pump assembly (see Fuel Pump
Assembly - Removal, page 385). 6. Disconnect the fuel pump electrical connector.
1. Release the fuel hose clip from the fuel pump 7. Remove the fuel pump securing bolt and strap.
side of the fuel filter.
2. Remove the hose bracket from the fuel pump 1
bracket.
1

civx

1. Strap
2
2. Bolt
civv

8. Detach the fuel pump and connector hose

1. Hose clips from the fuel pump bracket as an assembly.
2. Hose bracket 9. If necessary, release the hose clip and remove
3. Release the hose clip securing the baffle the connector hose from the pump.
housing to the fuel pump.
4. Reposition the hose clip and carefully slide the
baffle housing off the fuel pump body.
Note:
• Note the orientation of the baffle housing for
installation.
• It is not necessary to disconnect the baffle
housing hose from the fuel pressure regulator
unless it is to be removed at the same time as
the fuel pump.

1
civw

1. Baffle housing
2. Hose clip

Thruxton R 391
Fuel System And Engine Management

Fuel Pump - Inspection Fuel Pump - Installation

1. Inspect all hoses for cracks, splits, fraying and 1. If removed, refit the connector hose to the fuel
other damage. Replace as necessary. pump. Secure with the hose clip.
2. Check all hose clamps for cracks and signs of 2. Position the fuel pump to the bracket,
distortion. Replace as necessary. ensuring the feet of the rubber isolator
engage correctly in the fork.

1
2

cevu

1. Fork
2. Isolator feet

3. Align the fuel pump to the fuel pump bracket

and fit the connector hose on to the fuel filter.
4. Fit the fuel pump strap, secure with a new bolt
and tighten to 4 Nm.

civx

1. Strap
2. Bolt

5. Reconnect the fuel pump electrical connector.

6. Position the baffle housing hose clip loosely
over the fuel pump body.

392 Thruxton R
 Fuel System And Engine Management

7. Check that the baffle material within the baffle Fuel Level Sensor - Removal
housing is positioned as noted for removal.
8. Refit the baffle housing over the fuel pump, as
noted for removal. Refit the hose clip and
Warning
tighten to 3 Nm. Observe the warning advice given in the General
• Refit the fuel pump assembly (see Fuel Pump Information section on the safe handling of fuel
Assembly - Installation, page 387). and fuel containers.
A fire, causing personal injury and damage to
property could result from spilled fuel or fuel not
handled or stored correctly.

Note:
• The fuel level sensor is located inside the fuel
tank on the right hand side.
• Access to the fuel level sensor is through the
aperture for the fuel pump.
• Remove the fuel pump assembly (see Fuel Pump
Assembly - Removal, page 385).
Note:
• The mounting for the fuel level sensor is
located inside the fuel tank. The illustration
shows the bracket outside the fuel tank for
clarity.
1. Release the locking device and slide the fuel
level sensor up the bracket and release the
two locating lugs from the bracket.

1
2

cixt

1. Locking device
2. Locating lugs
3. Bracket

2. Remove the fuel level sensor.

Thruxton R 393
Fuel System And Engine Management

Fuel Level Sensor Installation Air Filter Element - Removal

Warning Warning
Observe the warning advice given in the General Before starting work, ensure the motorcycle is
Information section on the safe handling of fuel stabilised and adequately supported. This will help
and fuel containers. prevent it from falling and causing injury to the
A fire, causing personal injury and damage to operator or damage to the motorcycle.
property could result from spilled fuel or fuel not
handled or stored correctly. • Remove the left and right hand side panels (see
Side Panels, page 637).
1. Align the two locating lugs into the holes in 1. Remove the fixing and remove the air intake
the bracket. finishers.
2. Slide the fuel level sensor down the bracket for
the locking device to engage and secure the
sensor.

1
1
2

cjpo

1. Fixing

2. Remove the two fixings and remove the

cixt
mountings for the air intake finisher.
1. Locking device
2. Locating lugs
3. Bracket
• Refit the fuel pump assembly (see Fuel Pump
Assembly - Installation, page 387). 3
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
1 2

cjpp

1. Fixings
2. Mounting (right hand side shown)

394 Thruxton R
 Fuel System And Engine Management

3. Remove the fixing securing the engine 5. Release the four fixings securing the air filter
breather hose bracket to the airbox. cover to the airbox.

2 1
2

1
cjom cjln

1. Fixing 1. Fixings
2. Engine breather hose bracket 2. Air filter cover

4. Release the two hose clips and remove the 6. Remove the air filter cover and remove the air
engine breather hose. filter element from the housing.
7. Inspect the cover seal for damage, replace if
necessary.
Note:
• Note the orientation of the air filter moulding
for installation.
8. Remove the air filter cassette from the air
1 filter.

cjlo

1. Hose clips
2. Engine breather hose

1
civq_1

1. Cassette
2. Air filter element

Thruxton R 395
Fuel System And Engine Management

Air Filter Element - Installation 7. Fit the mountings for the air intake finisher
and tighten its fixings to 3 Nm.

Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
3
operator or damage to the motorcycle.

1. Clean the air filter cover and interior of the 2

1
airbox.
2. Locate the new filter element into the air filter
cassette, as noted for removal.
3. Fit the air filter and cassette assembly into the
airbox.
4. Refit the air filter cover and tighten its fixings cjpp

to 1.5 Nm. 1. Fixings

5. Refit the engine breather hose and secure 2. Mounting (right hand side shown)
with the hose clips.
8. Fit the air intake finishers and tighten to 3 Nm.
6. Secure the engine breather hose bracket to
the airbox and tighten the fixing to 1.5 Nm.

cjpo

1. Fixing
• Refit the left and right hand side panels (see
Side Panels, page 637).

396 Thruxton R
 Fuel System And Engine Management

Airbox - Removal 2. Remove the two fixings and remove the

mountings for the air intake finisher.

Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
3
operator or damage to the motorcycle.

• Remove the left and right hand side panels (see 2

1
Side Panels, page 637).
• Remove the rear wheel (see Rear Wheel -
Removal, page 602).
• Remove the rear mudguard (see Rear
Mudguard - Removal, page 638).
• If fitted, remove the evaporative canister (see cjpp

Evaporative Canister (if fitted) - Removal, page

438). 1. Fixings
2. Mounting (right hand side shown)
1. Remove the fixing and remove the air intake
finishers. 3. Remove the fixing securing the engine
breather hose bracket to the airbox.

2 1

cjpo

1. Fixing cjom

1. Fixing
2. Engine breather hose bracket

Thruxton R 397
Fuel System And Engine Management

4. Release the two hose clips and remove the Note:

engine breather hose.
• Note the position of the battery strap to the
fusebox bracket for installation.
9. Remove the three fixings and detach the
fusebox bracket from the airbox.

2
1
1

cjlo

1. Hose clips 3
2
2. Engine breather hose

Note: cjpr

• Before the disconnection of any wiring, note 1. Diagnostic connector

the routing of all wiring and wiring connectors 2. Fixings
on both sides of the airbox. 3. Fusebox bracket
5. Remove the fixing and detach the air intake
Note:
temperature sensor from the airbox.
• The seal for the air intake may come off with
6. Remove the fixing and detach the ambient air
the air intake duct.
pressure sensor from the airbox.
7. Remove and discard the fixings securing the 10. Remove the fixing and remove the air intake
fall detection switch to the airbox. Discard the duct on the left hand side of the airbox.
fixings.

2
1

2
cjpn

cjpy 1. Fixing
1. Fixing, Air temperature sensor 2. Air intake duct
2. Fixing, Ambient air pressure sensor Note:
3. Fixings, Fall detection switch • Note the routing of the rear wheel ABS sensor
8. Detach the diagnostic connector from the harness for installation.
fusebox bracket.

398 Thruxton R
 Fuel System And Engine Management

11. Disconnect the rear wheel ABS sensor from 14. Remove the three fixings and detach the relay
the main harness and detach from the airbox. bracket from the airbox.

1
2

cjqd cixq

1. ABS sensor harness connector 1. Starter motor solenoid (detached)

2. ABS sensor connector 2. Fixings

Note: Note:
• If fitted, note the position and orientation of • Note the position of the clamp for the throttle
the purge control valve and its bracket for body intake hose for installation.
installation.
15. Loosen the clamps for the throttle body intake
12. Remove the fixing and detach the roll over hoses.
valve and, if fitted, the purge control vale
bracket from the airbox. 2

2
1

4
cjkv_1

1. Clamp (right hand side shown)

cjrb

2. Throttle body
1. Fixing
3. Airbox
2. Roll over valve
3. Purge control valve
4. Bracket

13. Detach the starter motor solenoid from the

relay bracket on the right hand side of the
airbox.

Thruxton R 399
Fuel System And Engine Management

16. Remove the two fixings and their shouldered Airbox - Installation
washers from under the rear of the airbox.

2
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.

Note:
• When installing the airbox, ensure that the
brake lines on the right hand side of the frame
1
do not get damaged.
1. Position the airbox to the frame ensuring the
throttle body air ducts are correctly aligned to
cjqy
the throttle bodies.
1. Fixings 2. Check that the harnesses and hoses are
2. Shouldered washers routed as noted on removal.
3. Airbox 3. Secure the airbox with the four shouldered
washers and fixings, tighten the fixings to 6
17. Remove the fixing and shouldered washer
Nm.
from both sides of the airbox.
4. Tighten the intake hose clamps to 1.5 Nm.
1
5. Refit the relay bracket to the right hand side
2 of the airbox, ensuring the harness is not
3 trapped, and tighten the three fixings to 1.5
Nm.

cjps

1. Fixing
2. Shouldered washer 1

3. Airbox
cixq_1
Note:
1. Fixings
• When removing the airbox, ensure that the
brake lines on the right hand side of the frame 6. Refit the starter motor solenoid to the relay
do not get damaged. bracket.
18. Manoeuvre the airbox rearward to remove it
from the motorcycle.

400 Thruxton R
 Fuel System And Engine Management

7. Refit the roll over valve bracket and, if fitted, 10. Refit the air intake duct to the airbox and
the purge control valve and tighten the fixing tighten its fixing to 1.5 Nm.
to 1.5 Nm.

3
1
1

2
cjpn

cjrb
1. Fixings
1. Fixing 2. Air intake duct
2. Roll over valve
11. Attach the fuse box bracket to the airbox and
3. Purge control valve tighten the three fixings to 3 Nm.
4. Bracket 12. Attach the diagnostic connector to the fuse
8. Connect the the rear wheel ABS sensor to the box bracket.
main harness and attach to the airbox as
noted for removal.
2
1

2
3
2

cjpr

1. Diagnostic connector
cjqd
2. Fixings
1. ABS sensor harness connector 3. Fusebox bracket
2. ABS sensor connector
13. Attach the air intake temperature sensor to
9. If necessary, refit the air intake duct seal to the airbox and tighten its fixing to 1.5 Nm.
the airbox. 14. Attach the ambient air pressure sensor to the
airbox and tighten its fixing to 2 Nm.

Thruxton R 401
Fuel System And Engine Management

15. Attach the fall detection switch to the airbox 18. Fit the mountings for the air intake finisher
and tighten the new fixings to 3 Nm. and tighten its fixings to 3 Nm.

1 2

2
1

cjpy cjpp

1. Fixing, Air temperature sensor 1. Fixings

2. Fixing, Ambient air pressure sensor 2. Mounting (right hand side shown)
3. Fixings, Fall detection switch 19. Fit the air intake finishers and tighten to 3 Nm.
16. Refit the engine breather hose and secure
with the hose clips.
17. Secure the engine breather hose bracket to
the airbox and tighten the fixing to 1.5 Nm.
1

cjpo

1. Fixing
• If removed, refit the evaporative canister (see
Evaporative Canister (if fitted) - Installation,
page 439).
• Refit the rear mudguard (see Rear Mudguard -
Installation, page 639).
• Refit the rear wheel (see Rear Wheel -
Installation, page 604).
• Refit the left and right hand side panels (see
Side Panels, page 637).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

402 Thruxton R
 Fuel System And Engine Management

Engine Electronic Control Module 2. Detach the engine ECM harnesses and the
rear light harness form the engine ECM
(ECM) - Removal bracket.
1
Warning 2

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. 3

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
1. From the underside of the rear mudguard,
release the two locking tangs securing the
engine ECM bracket to the mudguard. cjpw

1 1. Engine ECM harnesses

2. Rear light harness
3. Engine ECM bracket

Note:
• Note the orientation of the engine ECM
bracket for installation.
3. Raise the rear of the engine ECM and bracket
assembly to release the locating lugs on the
2 front of the bracket from the rear mudguard.
Remove the engine ECM bracket.

cjpv

1. Locking tangs
2. Rear mudguard
3
Note:
• Note the routing of the engine ECM harnesses
and the rear light harness for installation.

2 1 2
cjqz

1. Locating lugs
2. Holes for locating lugs
3. Engine ECM bracket

4. Disconnect the two electrical connectors (see

Electrical Connectors, page 307) and remove
the engine ECM and bracket assembly.

Thruxton R 403
Fuel System And Engine Management

Engine Electronic Control Module Immobiliser/TPMS Control Module -

(ECM) - Installation Removal

Warning Warning
Before starting work, ensure the motorcycle is Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help stabilised and adequately supported. This will help
prevent it from falling and causing injury to the prevent it from falling and causing injury to the
operator or damage to the motorcycle. operator or damage to the motorcycle.

1. Reconnect the engine ECM connectors (see 1. Remove the fixing and detach the coolant filler
Electrical Connectors, page 307). neck from the immobiliser/TPMS control
2. Position the engine ECM bracket onto the module bracket.
engine ECM as noted for removal.
3. Locate the locating lugs on the of the bracket
into its locating holes in the rear mudguard. 2 3

3 1

cixw

1. Fixing

2 2 2. Coolant filer neck

cjqz
1
3. Immobilser/TPMS control module bracket
1. Locating lugs
2. Remove the two fixings (one either side) and
2. Holes for locating lugs detach the immobilser/TPMS control module
3. Engine ECM bracket and bracket assembly from the frame.

4. Route and attach the engine ECM harnesses 2

and the rear light harness to the engine ECM
bracket as noted for removal.
5. Secure the engine ECM bracket two locating
tangs into the two holes in the rear mudguard.
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
1

cixx

1. Fixing (right hand side shown)

2. Immobilser/TPMS control module bracket

404 Thruxton R
 Fuel System And Engine Management

3. Carefully manoeuvre the immobilser/TPMS Immobiliser/TPMS Control Module -

control module and bracket assembly through
to the left hand side of the frame. Installation
4. Disconnect the immobiliser/TPMS electrical
connector from the main harness. Warning
5. Release the locking device, detach the main Before starting work, ensure the motorcycle is
harness electrical connector from the bracket stabilised and adequately supported. This will help
and remove the immobilser/TPMS control prevent it from falling and causing injury to the
module and bracket assembly. operator or damage to the motorcycle.

1
1. Fit the immobilser/TPMS control module to its
bracket and tighten the fixings to 2 Nm.
2. Securely attach the main harness electrical
connector to the bracket.

3
2
cixz

1. Immobiliser/TPMS electrical connector

2. Main harness electrical connector
3. Bracket 2
6. Remove the fixings and remove the cjdx

immobilser/TPMS control module from its

bracket. 1. Harness electrical connector
2. Locking device
1
3. Connect the immobiliser/TPMS electrical
connector to the main harness.

1
2

cjdy

1. Fixings
2. Immobilser/TPMS control module

Thruxton R 405
Fuel System And Engine Management

4. Carefully manoeuvre the immobilser/TPMS Twist Grip - Removal

control module and bracket assembly to the
frame and tighten the fixings to 4 Nm.
Warning
2
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.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
1 first (see Battery - Removal, page 658).
• Remove the headlight from the headlight bowl
(see Headlight - Removal, page 669).
• Remove the right hand mirror (see Mirrors -
cixx
Removal, page 644).
1. Fixing (right hand side shown) 1. Release the fixings and detach the harness
bracket from the headlight bowl.
2. Immobilser/TPMS control module bracket

5. Attach the coolant filler neck to the

immobiliser/TPMS control module bracket and 2
tighten the fixing to 3 Nm.

2 3

3 1
1
cjdt

1. Fixings
2. Harness bracket
cixw 3. Headlight bowl
1. Fixing Note:
2. Coolant filer neck • Note the routing of the twist grip harness for
3. Immobilser/TPMS control module bracket installation.
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

406 Thruxton R
 Fuel System And Engine Management

2. On the back of the harness bracket, locate and Note:

disconnect the twist grip electrical connector
from the main harness. • Note the position and orientation of the twist
grip to its housing for installation.
1 5. To remove the twist grip, pivot it downwards
noting that the cut out in the guide aligns with
the locating lug on the twit grip housing.
2

cjcz

1. Twist grip electrical connector

2. Harness bracket

Note: cjir

• Note the routing of the twist grip harness for 1. Cut out in the guide
installation. 2. Locating lug on the twist grip housing
3. Route the twist grip harness out of the
headlight bowl.
Note:
• The anti-tamper fixings on the twist grip
housing must not be loosened or removed.
• If the anti-tamper screws have been loosened
or removed any warranty claims for the twist
grip housing will not be honoured.
4. Release the fixings and remove the clamp for
the twist grip housing from the handlebar.

2
1
3

cjhh

1. Twist grip housing fixings

2. Twist grip housing
3. Anti-tamper fixings

Thruxton R 407
Fuel System And Engine Management

Twist Grip - Installation 1. If removed, refit the twist grip to the twist grip
housing as noted for removal. Ensure the twist
grip guide with the cut out aligns with the lug
Warning on the twist grip housing.
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 2
operator or damage to the motorcycle.
1
Note:
• The twist grip has two guides. One guide has a
cut out in it and this guide fits over the lug on
the twist grip housing (7).

2
cjir

3
1. Cut out in the guide
5 2. Locating lug on the twist grip housing

2. Check and ensure that the twist grip is

correctly fitted as shown in the following
illustration.

7 5
1 6 4

cjhg

1. Twist grip housing

2. Twist grip
3. Twist grip housing clamp
1
4. Lug
1
5. Twist grip guides
6. Cut out in one guide
7. Lug
2

1. Cut out in twist grip guide

2. Twist grip lug

3. Position the twist grip onto the handlebar.

408 Thruxton R
 Fuel System And Engine Management

4. Fit the clamp for the twist grip, ensure that 7. On the back of the harness bracket, connect
the locating lug on the clamp locates into the the twist grip electrical connector to the main
hole on the handlebar. harness.

1 1
2
2

cjhk cjcz

1. Twist grip housing 1. Twist grip electrical connector

2. Locating lug (shown removed for clarity) 2. Harness bracket

5. Fit the fixings and tighten, upper one first, to 8. Fit the harness bracket to the headlight bowl
3.5 Nm. and tighten the fixings to 1.5 Nm.

2 2
1
3

3 1

cjhh cjdt

1. Twist grip housing fixings 1. Fixings

2. Twist grip housing 2. Harness bracket
3. Anti-tamper fxings 3. Headlight bowl

6. Route the twist grip harness to the headlight • Refit the right hand mirror (see Mirrors -
bowl as noted for removal. Installation, page 645).
• Refit the headlight to the headlight bowl (see
Headlight - Installation, page 670).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 409
Fuel System And Engine Management

Intake Air Temperature Sensor - Intake Air Temperature Sensor -

Removal Installation
1. Fit the sensor to the airbox and secure with
Warning the fixing. Tighten to 1.5 Nm.
2. Reconnect the electrical connector to the
Before starting work, ensure the motorcycle is
sensor.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the • Reconnect the battery, positive (red) lead first
operator or damage to the motorcycle. (see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Remove the seat (see Seat - Removal, page • Refit the seat (see Seat - Installation, page 636).
636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
1. Disconnect the electrical connector from the
sensor.
2. Remove the fixing and remove the sensor from
the airbox.

1
2

cjpy_1

1. Fixing
2. Electrical connector

410 Thruxton R
 Fuel System And Engine Management

Coolant Temperature Sensor - Coolant Temperature Sensor -

Removal Installation
1. Drain the cooling system (see Coolant 1. Fit the coolant temperature sensor into the
Replacement - Drainage, page 453). cylinder head and tighten to 18 Nm.
2. Detach the coolant temperature connector 2. Route the wiring as noted prior to removal and
from the ignition coils bracket. reconnect the sensor to the main harness.
3. Refit the coolant temperature sensor electrical
connector to the ignition coils bracket.
4. Refill the cooling system (see Coolant
2
Replacement - Filling, page 454).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

cjdw
1

1. Coolant temperature sensor connector

2. Ignition coils bracket

3. Press the wire locking device fully in and

detach the coolant temperature sensor from
the main harness.
Note:
• Note the routing of the coolant temperature
harness for installation.
4. Remove the rubber cover and using a suitable
19 mm slotted socket, remove the coolant
temperature sensor from the cylinder head.

cjdh

1. Coolant temperature sensor

Thruxton R 411
Fuel System And Engine Management

Manifold Absolute Pressure (MAP) Manifold Absolute Pressure (MAP)

Sensor - Removal Sensor - Installation
1. Fit the sensor to the ignition coils bracket and
Warning tighten the fixing to 1.5 Nm.
• Refit the ignition coils and bracket assembly
Before starting work, ensure the motorcycle is (see Ignition Coils - Installation, page 689).
stabilised and adequately supported. This will help
• Refit the fuel tank (see Fuel Tank - Installation,
prevent it from falling and causing injury to the
page 383).
operator or damage to the motorcycle.
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
• Remove the ignition coils and bracket assembly
tighten the terminals to 4.5 Nm.
(see Ignition Coils - Removal, page 687).
• Refit the seat (see Seat - Installation, page 636).
1. Remove the fixing and remove the MAP
sensor.

1
cjdv

1. MAP sensor
2. Fixing

412 Thruxton R
 Fuel System And Engine Management

Ambient Air Pressure Sensor - Ambient Air Pressure Sensor -

Removal Installation
1. Fit the sensor to the airbox and secure with
Warning the fixing. Tighten to 2 Nm.
2. Reconnect the electrical connector to the
Before starting work, ensure the motorcycle is
sensor.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the • Reconnect the battery, positive (red) lead first
operator or damage to the motorcycle. (see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Remove the seat (see Seat - Removal, page • Refit the seat (see Seat - Installation, page 636).
636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
1. Disconnect the electrical connector from the
sensor.
2. Remove the fixing and remove the sensor from
the airbox.

1
2

cjpy_2

1. Fixing
2. Electrical connector

Thruxton R 413
Fuel System And Engine Management

Fall Detection Switch - Removal Fall Detection Switch - Installation

1. Connect the electrical connector to the fall
Warning detection switch.
2. Fit the fall detection switch to the airbox and
Before starting work, ensure the motorcycle is
tighten the new fixings to 3 Nm.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the • Reconnect the battery, positive (red) lead first
operator or damage to the motorcycle. (see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Remove the seat (see Seat - Removal, page • Refit the seat (see Seat - Installation, page 636).
636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
1. Remove and discard the fixings securing the
fall detection switch to the airbox.
2. Disconnect the electrical connector and
remove the fall detection switch.

cjpy_3

1. Fixings
2. Fall detection switch
3. Electrical connector

414 Thruxton R
 Fuel System And Engine Management

Gear Position Sensor - Removal 2. Remove the fixings, detach the alternator
harness and remove the coolant expansion
tank mounting.
Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help 1
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658). 2
• Remove the right hand side panel (see Side
Panels, page 637).
3
• Remove the front sprocket cover (see Front 1
Sprocket Cover - Removal, page 104). cjqg

1. Remove the lock nuts and detach the coolant 1. Fixings

expansion tank from its mounting. Discard the
2. Harness clip
lock nuts.
3. Alternator harness
1

Caution
To prevent paint damage, do not spill brake fluid
onto any area of the bodywork. Spilled brake fluid
will damage paintwork.

3. Remove and discard the fixing and detach the

rear brake fluid reservoir from the relay
bracket.
1
2
cjpt

1. Fixings
2
2. Coolant expansion tank

citi_1

1. Fixing
2. Brake fluid reservoir

4. Detach the gear position sensor electrical

connector from the relay bracket.

Thruxton R 415
Fuel System And Engine Management

5. Disconnect the gear position sensor electrical 8. Carefully remove the gear position sensor
connector from the main harness. harness from the harness guide.

1
2

ciwh cjqa

1. Gear position sensor electrical connector 1. Harness guide

Note: 2. Harness

• Note the routing of the gear position sensor 9. Remove and discard the two fixings and
harness for installation. remove the gear position sensor.
6. Route the gear position sensor harness
through the frame to the harness guide on the 1
crankcase.
Note:
• Note that the white tape on the harnesses
within the harness guide aligns with the upper
gap for installation.
7. Remove and discard the fixings and detach
the harness guide from the crankcase. 2

2
cjra

1 1. Fixings
2. Gear position sensor

3
4

cjqb

1. Fixing
2. Harness guide
3. Upper gap
4. White tape

416 Thruxton R
 Fuel System And Engine Management

Gear Position Sensor - Installation gear position sensor electrical connector to

the main harness and attach it to the relay
bracket.
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
1. Fit a new O-ring to the sensor. Lubricate the
O-ring with a smear of petroleum jelly.
2. Position the sensor to the engine, ensuring
that the sensor engages with the slot in the
selector drum shaft. Secure with the two new
fixings and tighten to 5 Nm.
3. Carefully fit the gear position sensor harness
into the harness guide as noted for removal ciwh

with the white tape shown in the upper gap.

1. Gear position sensor electrical connector
4. Secure the harness guide to the crankcase
and tighten the new fixings to 4 Nm. 6. Refit the brake fluid reservoir to the relay
bracket, and tighten the new fixing to 3 Nm.

1 2

3
1
4

cjqb
citi_1

1. Fixing
1. Fixing
2. Harness guide
2. Brake fluid reservoir
3. Upper gap
4. White tape

5. Route the gear position sensor harness

through the frame to the right hand side of
the airbox, as noted for removal. Connect the

Thruxton R 417
Fuel System And Engine Management

7. Attach the alternator harness to the coolant Crankshaft Position Sensor -

expansion tank mounting, fit the inner cover
and tighten its fixings to 7 Nm. Removal

Warning
1 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.

Note:
2 • If the crankshaft position sensor needs to be
replaced, the alternator stator will also be
replaced as they are one assembly.
3
1 • Remove the seat (see Seat - Removal, page
cjqg
636).
• Disconnect the battery, negative (black) lead
1. Fixings first (see Battery - Removal, page 658).
2. Harness clip • Remove the right hand side panel (see Side
3. Alternator harness Panels, page 637).
• Remove the alternator cover (see Alternator
8. Refit the coolant expansion tank to its
Cover - Removal, page 99).
mountings and tighten the new lock nuts to 3
Nm. 1. Remove and discard the fixings securing the
crankshaft position sensor to the alternator
1 cover.

1
2
cjpt

1
1. Lock nuts
civn

2. Coolant expansion tank

1. Crankshaft position sensor
• Refit the front sprocket cover (see Front
2. Fixings
Sprocket Cover - Installation, page 105).
• Refit the right hand side panel (see Side Panels, Note:
page 637). • Note the routing of the alternator harness for
• Reconnect the battery, positive (red) lead first installation.
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

418 Thruxton R
 Fuel System And Engine Management

2. Remove and discard the fixing and remove the Crankshaft Position Sensor -
harness cover from the alternator cover.
Installation
3. Remove and discard the fixings securing the
stator to the alternator cover and remove the
stator. Warning
Before starting work, ensure the motorcycle is
3 stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Position the stator to the alternator cover and

4 route the harness as noted for removal.
Secure the stator with new fixings and tighten
to 12 Nm.
2. Fit the harness cover and tighten the new
fixing to 6 Nm.
1 Note:
2 • The air gap for the crankshaft position sensor
cjcs
is not adjustable.
1. Fixing
3. Fit the crankshaft position sensor with two
2. Harness cover new fixings and tighten to 9 Nm.
3. Fixings • Refit the alternator cover to the engine (see
4. Stator Alternator Cover - Installation, page 101).
• Refit the right hand side panel (see Side Panels,
page 637).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 419
Fuel System And Engine Management

Throttle Actuator Motor Throttle Position Sensor

Note:
Caution • The fixings for the throttle position sensor are
The fixings for the throttle actuator motor and marked with yellow paint and must not be
the butterfly hard stop adjustment screws are loosened or removed. If the fixings have been
marked with yellow paint and must not be loosened or removed any warranty claims for
loosened or removed. the throttle bodies will be rejected.

If the fixings or adjustment screws have been

loosened or removed the throttle body assembly Caution
must be replaced as there are no means to reset
the throttle actuator motor to its correct position. The fixings for the throttle position sensor are
marked with yellow paint and must not be
loosened or removed.
The throttle actuator motor is an integral part of
the throttle body and cannot be adjusted or If the fixings have been loosened or removed the
replaced separately. throttle body assembly must be replaced as there
are no means to reset the throttle position sensor
1 to its correct position.

The throttle position sensor can not be removed,

replaced or adjusted in service. If necessary, the
throttle bodies and throttle position sensor must
be replaced as an assembly.

cjkw

1. Throttle actuator motor fixings (two shown)

2. Butterfly hard stop adjustment screws
The only adjustment permitted on the throttle
body is throttle balance adjustment (see Throttle 1
Body Balancing, page 425).
cjky

1. Fixings
2. Throttle position sensor

420 Thruxton R
 Fuel System And Engine Management

Throttle Body - Removal 4. Remove the fixing and remove the air intake
finishers.

Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
1
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

• Remove the left and right hand side panels (see

Side Panels, page 637). 2
1. Protect the crankcase, crankcase covers and
starter motor painted surfaces from damage,
using suitable self adhesive tape such as
masking tape.
2. Remove the fixing securing the engine cjpo

breather hose bracket to the airbox.

1. Fixing

5. Remove the two fixings and remove the

mountings for the air intake finisher.

2 1

1 2

cjom

1. Fixing
2. Engine breather hose bracket cjpp

3. Release the two hose clips and remove the 1. Fixings

engine breather hose.
2. Mounting (right hand side shown)

Note:
• Note the routing for the throttle actuator and
throttle position harnesses for installation.

cjlo

1. Hose clips
2. Engine breather hose

Thruxton R 421
Fuel System And Engine Management

6. Disconnect the throttle actuator motor Note:

multiplug.
• The clamps securing the throttle bodies to the
transition pieces have a spacer fitted between
the clamp ends.
• The threaded lug is not secure and may fall
out when the fixing has been released.
10. Remove the throttle body four hose clamps.
1

2
1

cjkx

1. Multiplug

7. Release the locking device and detach the

throttle position sensor from the mounting
bracket.
3
8. Disconnect the throttle position sensor cjkv

multiplug from the main harness. 1. Evaporative hose (if fitted)

2. MAP sensor hose

2 3. Hose clamps

11. Carefully detach the throttle bodies from the

transition piece hoses and the airbox hoses
and remove the throttle bodies.
12. To remove the transition pieces from the
cylinder head, remove the fixings and remove
the transition piece(s).

3 2
1
1
cjoz

1. Locking device
2. Throttle position sensor multiplug
3. Mounting bracket

Note:
• Note which spigots on the throttle bodies the
MAP sensor hose is fitted to and, if fitted,
which spigot the evaporative emissions hose is
fitted to for installation. cjor

1. Fixings
9. Disconnect the MAP hoses and the
evaporative emissions hoses (if fitted) from the 2. Transition pieces
throttle bodies.

422 Thruxton R
 Fuel System And Engine Management

Throttle Body - Installation 5. Connect the MAP hose and the evaporative
emissions hose (if fitted) to the throttle bodies,
as noted for 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. 2
1

1. Thoroughly clean the transition piece to

cylinder head mating faces.
2. Refit the transition piece to the cylinder head
and tighten the fixings to 9 Nm.

2
3
1 cjkv

1. Evaporative hose (if fitted)

2. MAP sensor hose
3. Hose clamps

6. Connect the throttle position sensor to the

main harness and secure the multiplug to the
bracket.

2
cjor

1. Fixings
2. Transition pieces

Note:
• While installing the throttle bodies, route the
throttle position sensor and throttle actuator
motor harnesses as noted for removal.
3. Carefully fit the throttle bodies to transition 3
piece hoses and the airbox hoses.
Note: 1
cjoz

• Ensure that the clamps securing the throttle 1. Locking device

bodies have the threaded lug fitted and the
spacer on the fixing between the two ends of 2. Throttle position sensor multiplug
the clamp. 3. Mounting bracket
4. Fit the throttle body four hose clamps and
tighten to 1.5 Nm.

Thruxton R 423
Fuel System And Engine Management

7. Connect the throttle actuator motor multiplug. 10. Fit the engine breather hose and secure with
the two hose clips.

2
cjkx

cjlo
1. Multiplug
1. Hose clips
8. Fit the mountings for the air intake finisher
and tighten its fixings to 3 Nm. 2. Engine breather hose

11. Secure the engine breather hose bracket to

the airbox and tighten the fixing to 1.5 Nm.

1 2
2 1

cjpp

1. Fixings
cjom
2. Mounting (right hand side shown)
1. Fixing
9. Fit the air intake finishers and tighten to 3 Nm.
2. Engine breather hose bracket
• Refit the left and right hand side panels (see
Side Panels, page 637).
• Refit the fuel tank (see Fuel Tank - Installation,
1 page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
2

cjpo

1. Fixing

424 Thruxton R
 Fuel System And Engine Management

Throttle Body Balancing 7. When the engine temperature is at operating

temperature navigate to ADJUST TUNE (see
Note: System Diagnostics, page 292).
• The throttles cannot be balanced using 8. Select BALANCE THROTTLES.
equipment to measure vacuum in each
throttle. Instead, the Triumph diagnostic tool
Adjust Tune Procedure
must be used.
Adjust the throttle balance as described in the Service Manual until
• Remove the airbox (see Airbox - Removal, page balanced
397). Press cancel to cancel the adjustment process
Press OK to finish

Warning Throttle Status: Throttles Balanced

Cylinder 1 MAP Pressure: 480 mmHg

If the engine has recently been running, the
Cylinder 2 MAP Pressure: 481 mmHg
components beneath the fuel tank may be hot to
the touch.

1. Remove the anti-tamper Torx T30 blanking Adjusting parameter - Balance Throttles
screw from the throttle control motor housing,
located between cylinders one and two.
Balance Throttles Screen

Note:
1 • The balance throttles screen shows the
2
vacuum value of each throttle in mmHg. In
addition, when the throttles are balanced to
3 an acceptable range of each other the words
'THROTTLES BALANCED' in green text will
appear on the right of the screen. At this
point, no further adjustment is necessary or
productive.
• If the throttles are not balanced to each other
the words 'THROTTLES UNBALANCED' in red
text will appear on the right of the screen. At
cjoq this point adjustment will be necessary.
1. Throttle balance blanking screw
2. Throttle body
Warning
3. Bracket Total cleanliness must be observed at all times
whilst the throttle balance blanking screw is
2. Temporarily refit the fuel tank and reconnect
removed, and adjustment must take place in a
the fuel supply and fuel pump connection
dirt/dust-free environment. Dirt or dust ingress to
using service tool T3880001 (minus the fuel
the throttle motor housing will cause the throttles
pressure gauge) and service tool T3880391
to stick, leading to loss of motorcycle control and
(see Fuel Pressure Checking, page 384).
an accident.
3. Using proprietary professional automotive
workshop equipment approved for fuel
handling, partially refill the fuel tank with the
fuel removed earlier.
4. Temporarily reconnect the battery, positive
(red) lead first.
5. Attach exhaust extraction hoses to the
silencers.
6. Attach the Triumph diagnostic tool, start the
engine.

Thruxton R 425
Fuel System And Engine Management

9. Using a suitable Torx T20 screwdriver, adjust Fuel Injectors and Fuel Rail -
the throttle adjuster until the words
'THROTTLES BALANCED' appear on the Removal
diagnostic tool.
Warning
Before starting work, ensure the motorcycle is
1 stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

• Remove the throttle bodies (see Throttle Body -

Removal, page 421).
Note:
• The fuel rail and injectors are removed from
the cylinder head together.
1. Disconnect the electrical connector from the
cjoq_1 fuel injectors.
1. Adjuster 2. Remove the two fixings securing the fuel rail
and fuel rail covers to the cylinder head.
10. When balanced, stop the engine and Collect the spacers between the fuel rail and
disconnect the diagnostic tool. cylinder head and the two covers.
11. Refit the anti-tamper Torx T30 blanking screw
to the throttle control motor housing and
tighten to 5 Nm.
12. Disconnect the battery, negative (black) lead
first. 2

13. Using proprietary professional automotive 5

workshop equipment approved for fuel 1
handling, drain any remaining fuel from the
fuel tank.
• Refit the airbox (see Airbox - Installation, page
400). 3
• Refit the fuel tank (see Fuel Tank - Installation,
page 383). 4
• Reconnect the battery, positive (red) lead first cjdk
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm. 1. Electrical connector (right hand side shown)
• Refit the seat (see Seat - Installation, page 636). 2. Fuel rail cover (right hand side shown)
3. Fixing (right hand side shown)
4. Spacer
5. Fuel rail

3. Gently ease the fuel rail and injectors upwards

to release them from the cylinder head.
Note:
• The fuel injectors are not to be removed from
the fuel rail unless they are to be replaced.
• If the injectors require replacing continue from
step 4.
• Note the position of the retaining clip for
installation.

426 Thruxton R
 Fuel System And Engine Management

4. Carefully remove the retaining clips securing Fuel Injectors and Fuel Rail -
the fuel injectors to the fuel rail.
Installation
5. Ease each injector from the fuel rail.
Note:
• If the fuel injectors have been removed from
the fuel rail, continue from step 1 and omit
3 steps 3 and 4.
• If the fuel injectors have not been removed,
continue from step 3.
1. Lightly lubricate the O-rings with clean engine
2 oil and fit the new fuel injectors to the fuel rail.
2. Fit the retaining clip for each fuel injector as
noted for removal.

1 3

1
1. Retaining clip
2. Injector
3. Fuel rail

2
cjdj

1. Retaining clip
2. Fuel injector
3. Fuel rail

3. Remove and discard the O-ring on the fuel

injector.
4. Fit a new O-ring using finger pressure only.
5. Lightly lubricate the O-ring on the injectors
and fit the injector/fuel rail assembly to the
cylinder head, orientating each injector such
that the electrical connection is facing
upwards.

Thruxton R 427
Fuel System And Engine Management

6. Fit the spacers between the fuel rail and Engine Management Adaption
cylinder head, fit the fuel rail covers, fit and
tighten the fixings to 6 Nm.
General Information
The engine management system fitted to this
model is adaptive. This means that the system is
able to learn about new or changing operating
2 conditions and continuously adapt itself without
needing to constantly make major adjustments
5 from a fixed baseline setting.
1 Adaptive changes can become necessary because
of changing rider behaviour, changes in the region
in which the bike is operated (i.e. operation at high
altitude where it was previously used at sea level)
3 or because a new part may have been fitted which
has slightly different characteristics to the old part.
4 All adaptive changes are automatic and require no
intervention by rider or dealer.
cjdk

1. Electrical connector (right hand side shown) Adaption Status

2. Fuel rail cover (right hand side shown) To see if a motorcycle has fully adapted, a facility
named 'ADAPTION STATUS' is provided on the
3. Fixing (right hand side shown)
diagnostic tool. The following adaption details can
4. Spacer be examined:
5. Fuel rail
Function Examined Report Method
7. Connect the electrical connectors to the fuel
Closed throttle position Adapted/not
injectors.
reference status adapted
• Refit the throttle bodies (see Throttle Body -
Installation, page 423). Idle speed control adaption %
• Refit the fuel tank (see Fuel Tank - Installation, status
page 383). Oxygen sensor adaption status %
• Reconnect the battery, positive (red) lead first (off idle)
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm. Oxygen sensor adaption range %
(off idle)
• Refit the seat (see Seat - Installation, page 636).
Oxygen sensor adaption status %
(idle)
Oxygen sensor adaption range %
(idle)

Terminology
Where the term 'status' is used, this indicates how
far the present operating parameter is from the
stored (baseline) value. The nearer these figures
are to zero the better as it indicates the motorcycle
has adapted to its current operating conditions.
The term 'range' indicates how much (in
percentage terms) of the adjustment range has
been used to reach the current operating status.

428 Thruxton R
 Fuel System And Engine Management

Status Range Warning

+100%
100% Not adapted and death within a short time. Always operate the
motorcycle in the open-air or in an area with
+75%
adequate ventilation.

Note:
+30% • Resetting adaptions with the motorcycle
connected to an exhaust extraction system
may cause incorrect values to be set, causing
0% Adapted poor engine running. Always reset the
0%
adaptions with the engine disconnected from
any exhaust extraction system whilst
-30% ensuring the motorcycle is positioned in a well
ventilated area.
1. Ensure the engine is cold.
-75% 2. WITHOUT TOUCHING THE THROTTLE, start the
engine and allow it to warm up until the
cooling fan comes on.
-100%
3. Leave the engine to idle for a further 12
minutes.

Typical Values Note:

In a correctly adapted motorcycle, the following will • As an alternative to the above process,
be typical: connect the diagnostic tool, select ADJUST
TUNE (see the Triumph Diagnostic Tool User
Function Examined Read Out Guide) and select RESET ADAPTIONS. This will
Closed throttle position Adapted force a fast adaption routine to take place in
reference status around five seconds. For this to happen, the
engine MUST be running, it must be at normal
Idle speed control adaption Between +100 operating temperature and in closed loop
status and -100% control mode. Under any other conditions fast
Oxygen sensor adaption status 0% +/- 10% adaption will not take place and may cause
(off idle) default values to be loaded, which may then
require a normal 12 minute adaption routine to
Oxygen sensor adaption range Between +100 be run.
(off idle) and -100%
Oxygen sensor adaption status 0% +/- 10% Fault Indications
(idle) If 'range' figures at 100% are seen, then the
adjustment has reached maximum indicating a
Oxygen sensor adaption range Between +100
mechanical fault exists on the motorcycle. This can
(idle) and -100%
be due to a number of faults but the most likely
causes will be low/high fuel pressure, faulty
Forcing Adaption to Take Place injectors or air leaks at the throttle bodies or
If the read out indicates that the motorcycle is not airbox.
adapted, the following will force the system to In these circumstances, locate and rectify the fault,
make adaptions: and reset the adaptions as described above.

Warning
Never start the engine or let it run for any length
of time in a closed area. The exhaust fumes are
poisonous and may cause loss of consciousness

Thruxton R 429
Fuel System And Engine Management

Exhaust Silencer - Removal 2. Support the silencer, remove the rear

mounting fixing and remove the silencer.
Discard the lock nut.
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.
2
1
Warning
If the engine has recently been running, the
exhaust components may be hot to the touch.
Contact with the hot components may cause
damage to exposed skin. To avoid skin damage,
always allow the hot parts to cool before working
on the exhaust system. cjqf

1. Fixing
Note: 2. Lock nut
• Always note the position and orientation of
3. Remove and discard the exhaust gasket.
the exhaust clamps prior to releasing them,
and return them to the noted position and
orientation on assembly.
1. Release the clamps securing the silencers to
the intermediate pipe.
Note:
• Note the position of the washers and rubber
bushes in the footrest hanger for installation.

cjqe

1. Silencer clamp fixing (left hand side)

2. Silencer

Note:
• Note the position of the washers and rubber
bushes in the silencer mounting for
installation.

430 Thruxton R
 Fuel System And Engine Management

Exhaust Silencer - Installation Exhaust Intermediate and Header

1. Check rubber mountings for cracks and wear, Pipes - Removal
replace if necessary.
2. Fit a new exhaust silencer gasket and position Warning
the clamp over the joint.
Before starting work, ensure the motorcycle is
3. Position the silencer onto the intermediate
stabilised and adequately supported. This will help
pipe.
prevent it from falling and causing injury to the
4. Align the silencer rear mounting to the frame operator or damage to the motorcycle.
and fit the bolt and a new lock nut. Tighten
the fixing to 19 Nm.
Warning
If the engine has recently been running, the
exhaust components may be hot to the touch.
Contact with the hot components may cause
damage to exposed skin. To avoid skin damage,
2 always allow the hot parts to cool before working
1 on the exhaust system.

Note:
• Always note the position and orientation of
exhaust clamps prior to releasing them, and
return them to the noted position and
orientation on assembly.
cjqf

• Remove the seat (see Seat - Removal, page

1. Fixing 636).
2. Lock nut • Disconnect the battery, negative (black) lead
5. Position the silencer clamps as noted for first (see Battery - Removal, page 658).
removal and tighten to 15 Nm. • Remove the exhaust silencers (see Exhaust
Silencer - Removal, page 430).
• Remove the engine cradle assemblies (see
Cradle Assemblies - Removal, page 640).
1. Remove the fixing for the exhaust cover.
Detach the rear of the cover from the exhaust
and move it rearwards for removal.

cjqe

1. Silencer clamp fixing (left hand side)

2. Silencer

6. Start the engine and check for exhaust gas

leaks. Rectify if necessary. 1
cjqn

1. Fixings
2. Exhaust cover (left hand side shown)

Thruxton R 431
Fuel System And Engine Management

2. Left hand intermediate exhaust pipe only: 6. Loosen the clamp securing the exhaust header
Remove the fixing securing the intermediate pipe to the catalytic converter.
exhaust pipe to the frame.
2

1
2

3
1
cjcr

cjqv
1. Clamp
1. Fixing 2. Exhaust header pipe
2. Intermediate exhaust pipe 3. Catalytic converter
3. Loosen the clamp securing the intermediate
Note:
pipe to the catalytic converter. Remove the
exhaust intermediate pipe. • Note the routing of the oxygen sensor
harness for installation.
• The oxygen sensor electrical connections
2 must not be swapped between cylinders. If the
1
connections are swapped over, engine
malfunctions will occur.
• The right hand (Cylinder 2) oxygen sensor
connector on the main harness has a red
connector (main harness side).
• The oxygen sensors are NOT marked. Always
ensure the right hand oxygen sensor harness
is connected to the main harness connector
with the red connector.

3
cjct

1. Exhaust clamp
2. Exhaust intermediate pipe
3. Catalytic converter

4. Remove and discard the exhaust intermediate

pipe to catalytic converter gasket.
5. Remove the fuel tank (see Fuel Tank - Removal,
page 379).

432 Thruxton R
 Fuel System And Engine Management

7. Disconnect the oxygen sensors from the main 12. Remove and discard the exhaust header pipe
harness. gasket from the catalytic converter, cylinder
head ports and the exhaust balance pipe.
3 13. If necessary, remove finned clamps and the
the oxygen sensor.

2
cjql

1. Right hand oxygen sensor connector

2. Left hand oxygen sensor connector
3. Red tape

8. Loosen the exhaust balance pipe two clamps.

9. Remove the fixings securing the exhaust
header pipe to the cylinder head.
1

2
3

cjqu
4

1. Fixings
2. Finned clamps
3. Exhaust balance pipe clamp (one shown)
4. Exhaust header pipe

10. Detach the one of the exhaust header pipe

from the catalytic converter, cylinder head and
the exhaust balance pipe. Remove the exhaust
header pipe.
11. Detach the other header pipe from the
catalytic converter and the cylinder head.
Remove the header pipe and exhaust balance
pipe assembly.

Thruxton R 433
Fuel System And Engine Management

Exhaust Intermediate and Header 6. Fit new gaskets to the cylinder head ports.

Pipes - 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 1
operator or damage to the motorcycle.

1. If removed, apply a thin smear of anti-seize

compound to the threads of the oxygen 2
sensor, install the oxygen sensor and tighten
to 25 Nm.
2. If removed refit the finned clamps to the cjcu

exhaust header pipes, 1. Cylinder head port

3. Fit new gaskets to the exhaust balance pipe 2. Gasket
an fit it to one of the exhaust header pipes.
7. Apply a proprietary high temperature grease
4. Fit a new exhaust gasket and the flanged
to the exhaust header pipe studs on the
sleeve to the exhaust intermediate pipe port
cylinder head.
on the catalytic converter.
8. Locate the exhaust header pipe, with the
5. If removed, apply a thin smear of anti-seize
exhaust balance pipe, to the cylinder head,
compound to the threads of the clamp and fit
ensure the gasket does not become displaced
to the exhaust intermediate pipe port on the
during assembly. Fit the fixings to the cylinder
catalytic converter. Do not tighten the clamp.
head studs but do not fully tighten at this
stage.
9. Attach the exhaust header pipe to the
catalytic converter, do not tighten the clamp
at this stage.
10. Locate the other exhaust header pipe to the
1 cylinder head while also aligning it to the
3 exhaust balance pipe. Fit the fixings to the
cylinder head studs but do not fully tighten at
this stage.
11. Attach the exhaust header pipe to the
catalytic converter, do not tighten the clamp
4 at this stage.
2
12. Tighten the exhaust header to cylinder head
cjdb
fixings to 19 Nm.
1. Gasket 13. Tighten the exhaust header to catalytic
2. Flanged sleeve converter clamp to 10 Nm.
3. Clamp 14. Tighten the exhaust balance pipe clamps to 9
4. Exhaust intermediate pipe ports Nm.
15. Route the oxygen sensor harness as noted for
Note:
removal and connect to the main harness as
• To retain the gaskets during assembly, apply a noted for removal.
smear of grease or petroleum jelly to the
gasket faces in the head.

434 Thruxton R
 Fuel System And Engine Management

16. Attach the exhaust intermediate pipe to the 19. Tighten the exhaust intermediate pipe to
catalytic converter, ensure the anti-rotation catalytic converter clamp to 8 Nm.
rod is placed between the two halves of the 20. Fit the exhaust cover and tighten its fixing 9
clamp. Do not tighten the clamp at this stage. Nm.

1
2

2 1
cjcy
cjqn

1. Anti-rotation rod 1. Fixings

2. Clamp 2. Exhaust cover (left hand side shown)
3. Exhaust intermediate pipe • Refit the engine cradle assemblies (see Cradle
17. Fit the exhaust silencer (see Exhaust Silencer - Assemblies - Installation, page 642).
Installation, page 431). • Refit the fuel tank (see Fuel Tank - Installation,
18. Left hand intermediate exhaust pipe only: page 383).
Secure the intermediate exhaust pipe to the • Reconnect the battery, positive (red) lead first
frame and tighten the fixing to 19 Nm. (see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
• Start the engine and check for exhaust gas
leaks. Rectify if necessary.

1
2

cjqv

1. Fixing
2. Intermediate exhaust pipe

Thruxton R 435
Fuel System And Engine Management

Exhaust Catalytic Converter - 3. Remove the catalytic converter from the

motorcycle.
Removal
2
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.

Warning
If the engine has recently been running, the
exhaust components may be hot to the touch. 3
Contact with the hot components may cause 1
cjgp
damage to exposed skin. To avoid skin damage,
always allow the hot parts to cool before working 1. Fixings (left hand side)
on the exhaust system. 2. Locating lug (right hand side)
3. Catalytic converter
Note:
4. If required, remove the three fixings and
• Always note the position and orientation of
remove the heat shield.
exhaust clamps prior to releasing them, and
return them to the noted position and
orientation on assembly.
• Remove the seat (see Seat - Removal, page 2
636).
• Disconnect the battery, negative (black) lead 1
first (see Battery - Removal, page 658).
• Remove the exhaust intermediate and header
pipes (see Exhaust Intermediate and Header
Pipes - Removal, page 431).
1. Remove the two fixings and rubber mountings
securing the catalytic converter to its heat
shield.
2. Manoeuvre the catalytic converter down and
cjda
to the left hand side to disengage its locating
lug from the right hand side of the heat shield. 1. Fixings
2. Heat shield

436 Thruxton R
 Fuel System And Engine Management

Exhaust Catalytic Converter - 5. Position the catalytic converter into its heat
shield, ensure the locating lug and its rubber
Installation mounting fully engages into the heat shield.

Warning
Before starting work, ensure the motorcycle is 3
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. If removed, refit the catalytic converter heat

shield and tighten the fixings to 19 Nm.
2. Fit the gasket and flanged sleeve to the
exhaust intermediate pipe ports on the 4
catalytic converter. 1
2
3. Fit the clamp, as noted for removal. Do not
cjdi
tighten the clamp.
1. Locating lug
2. Rubber mounting
3. Heat shield
4. Catalytic converter

6. Fit the fixings and rubber mountings. Tighten

1 the fixings to 15 Nm.
3
• Refit the exhaust intermediate and header
pipes (see Exhaust Intermediate and Header
Pipes - Installation, page 434).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
4
tighten the terminals to 4.5 Nm.
2
• Refit the seat (see Seat - Installation, page 636).
cjdb

• Start the engine and check for exhaust gas

1. Gasket leaks. Rectify if necessary.
2. Flanged sleeve
3. Clamp
4. Exhaust intermediate pipe ports

4. Check the mounting rubber for cracks, replace

if necessary.

Thruxton R 437
Fuel System And Engine Management

Evaporative Canister (if fitted) - Note:

Removal • Note the position of the two hoses attached to
the left hand side of the evaporative canister
for installation.
Warning
3. Detach the two hoses on the left hand side of
Before starting work, ensure the motorcycle is the evaporative canister and remove.
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 fixings and washers securing the 3

evaporative canister to the right hand side of
the airbox.

2 1

1 2
3

cjqm

1. Hoses
2. Evaporative canister
3. Airbox

cjcv

1. Fixings
2. Evaporative canister
3. Airbox

2. Slide the evaporative canister to the right

hand side to release its locating lug from the
airbox grommet.

438 Thruxton R
 Fuel System And Engine Management

Evaporative Canister (if fitted) - Purge Control Valve (if fitted) -

Installation Removal

Warning Warning
Before starting work, ensure the motorcycle is Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help stabilised and adequately supported. This will help
prevent it from falling and causing injury to the prevent it from falling and causing injury to the
operator or damage to the motorcycle. operator or damage to the motorcycle.

1. Position the evaporative canister to the • Remove the seat (see Seat - Removal, page
motorcycle and connect the two hoses to the 636).
left hand side of the evaporative canister as • Disconnect the battery, negative (black) lead
noted for removal. first (see Battery - Removal, page 658).
• Remove the left hand side panel (see Side
Panels, page 637).
1. Remove the fixing and remove the air intake
duct on the left hand side of the airbox.
3

1 1
2

cjqm

1. Hoses
2. Evaporative canister
3. Airbox 2
cjpn

2. Fit the evaporative canister to the motorcycle,

1. Fixing
ensure the locating lug on the left hand side
locates into its hole in the airbox grommet. 2. Air intake duct

3. Align the right hand side to the air box, fit the Note:
fixings and tighten to 1.4 Nm.
• Note the position and orientation of the purge
• Refit the rear wheel (see Rear Wheel - control valve and its bracket for installation.
Installation, page 604).
2. Remove the fixing and detach the roll over
valve and the purge control vale bracket from
the airbox.
3. Detach the purge control valve from the
bracket.

Thruxton R 439
Fuel System And Engine Management

4. Detach the upper and lower hoses and remove Purge Control Valve (if fitted) -
the purge control valve.
Installation

Warning
3
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
1 prevent it from falling and causing injury to the
operator or damage to the motorcycle.
2

1. Connect the electrical connector and the

upper hose to the purge control valve.
4
2. Connect the upper and lower hoses to the
purge control valve.
3. Position the purge control valve to the airbox
cjrb
as noted for removal. Secure in position with
1. Fixing its bracket and tighten the fixing to 1.5 Nm.
2. Roll over valve
3. Purge control valve
4. Bracket
3
5. Press the wire locking device fully in and
disconnect the electrical connector from the 1
purge control valve.
2

cjrb

1. Fixing
2. Roll over valve
3. Purge control valve
4. Bracket

440 Thruxton R
 Fuel System And Engine Management

4. If necessary, refit the air intake duct seal to

the airbox. Ensure that the larger rubber
flange of the seal faces outwards.
5. Refit the air intake duct to the airbox and
tighten its fixing to 1.5 Nm.

2
cjpn

1. Fixing
2. Air intake duct
• Refit the left hand side panel (see Side Panels,
page 637).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 441
Fuel System And Engine Management

Evaporative Loss Control System – Certain Markets Only

Some models in certain markets are fitted with a system to control the evaporation of fuel vapour to the
atmosphere.
A carbon filled evaporative canister absorbs vapour while the engine is not running. When the engine is
started, the vapour is returned to the engine and burnt.
There are two distinct phases to the system's operation; engine off and engine running. These two
conditions are explained overleaf.

Component Locations
Evaporative Canister - under the airbox.
Purge Control Valve - (electronically controlled by the ECM) left hand side of the airbox behind the side
panel.

1. Evaporative canister
2. Purge control valve

442 Thruxton R
 Fuel System And Engine Management

Evaporative Control System – Engine Off

When the engine is stationary, any pressure increase in the fuel tank due to a rise in ambient temperature
will cause the fuel vapour to pass down the breather pipe A to a carbon filled evaporative canister which
stores the vapour.
Once in the canister, vapour cannot return to the fuel tank because the purge valve is closed.

1. Breather pipe A
2. Evaporative canister
3. Purge valve

Thruxton R 443
Fuel System And Engine Management

Evaporative Control System – Engine Running

When the engine is started, a vacuum is applied to the purge hose from the throttle bodies.
At certain times, the ECM opens the purge valve. The vacuum applied to the purge valve now begins to
draw stored vapour from the carbon filled evaporative canister and returns it to the throttle bodies for
burning in the engine.
In order to control the speed at which vapour is purged from the canister, the engine management system
regularly shuttles the purge control valve between open and closed positions.

2
1

1. Throttle bodies
2. Purge valve
3. Evaporative canister

444 Thruxton R
 19 Cooling
Table of Contents
Exploded View – Radiator and Hoses ............................................................................................................................................... 447
Exploded View - Coolant Expansion Tank ....................................................................................................................................... 448
Radiator Hoses ............................................................................................................................................................................................. 449
Radiator and Cooling Fan Inspection................................................................................................................................................. 449
Coolant.............................................................................................................................................................................................................. 450
Coolant Level Inspection........................................................................................................................................................................... 451
Coolant Level Adjustment....................................................................................................................................................................... 452
Coolant Replacement - Drainage......................................................................................................................................................... 453
Coolant Replacement - Filling................................................................................................................................................................ 454
Water Pump................................................................................................................................................................................................... 455
Water Pump - Inspection ........................................................................................................................................................................ 456
Coolant System Pressure Test.............................................................................................................................................................. 456
Coolant Pressure Cap Test ..................................................................................................................................................................... 458
Thermostat - Removal.............................................................................................................................................................................. 459
Thermostat - Inspection.......................................................................................................................................................................... 460
Thermostat - Installation ......................................................................................................................................................................... 461
Radiator - Removal..................................................................................................................................................................................... 462
Radiator - Installation............................................................................................................................................................................... 463

Thruxton R 445
Cooling

446 Thruxton R
 Cooling

Exploded View – Radiator and Hoses

3 Nm

9 Nm

6 Nm

9 Nm

5 Nm

5 Nm

Thruxton R 447
Cooling

Exploded View - Coolant Expansion Tank

3 Nm

7 Nm

448 Thruxton R
 Cooling

Radiator Hoses Radiator and Cooling Fan Inspection

Check the radiator hoses for cracks or
deterioration, and hose clamps for tightness in Radiator
accordance with scheduled maintenance
requirements. Caution
Using high pressure water, such as from a
pressure-washer, can damage the radiator fins
and impair the radiator's efficiency.
Do not obstruct or deflect airflow through the
radiator by installing unauthorised accessories in
front of the radiator or behind the cooling fan.
Interference with the radiator airflow can lead to
overheating and consequent engine damage.

1. Check the radiator for stone damage.

2. Check the radiator core for damage to fins or
obstructions to air flow.
3. Clean off any obstructions with a stream of
low-pressure water.

Caution
To avoid overheating and consequent engine
damage, replace the radiator if the cores are
blocked or if the fins are badly deformed or
broken.

4. Rectify any damage.

Cooling Fan

Warning
The cooling fan is turned on or off by the chassis
ECM, in response to a request sent by the engine
ECM. The request from the engine ECM to turn the
cooling fan on or off, is sent to the chassis ECM in
response to a signal received from the coolant
temperature sensor.
To prevent injury, never place loose clothing,
fingers or hands near the cooling fan, until the
engine is stopped. Loose clothing, fingers or the
hands could become trapped during cooling fan
operation and cause crushing injury to the fingers,
hands or other parts of the anatomy.

The motorcycle is fitted with a thermostatically

controlled electric fan situated behind the radiator.
When the fan operates with the motorcycle
stationary or at slow speed, cool air is drawn
through the radiator from the front of the
motorcycle.

Thruxton R 449
Cooling

1. Check that the cooling fan spins freely and Coolant

without tight spots.
A year-round, Hybrid Organic Acid Technology
2. Check the cooling fan blades for signs of heat (known as Hybrid OAT or HOAT) coolant is installed
distortion. in the cooling system when the motorcycle leaves
3. Rectify as necessary. the factory. It is coloured green, contains a 50%
solution of ethylene glycol based antifreeze, and
has a freezing point of -35°C (-31°F).
Always change the coolant at the intervals
specified in the Scheduled Maintenance chart.

Warning
The standard coolant mixture contains toxic
chemicals that are harmful to the human body.
Never swallow neat antifreeze or any of the
coolant mixture.

Caution
The antifreeze incorporated in the coolant mixture
contains a corrosion inhibitor that helps prevent
damage to the cooling system and engine.
Without this inhibitor, the coolant would 'attack'
the metals and the resulting corrosion would
cause blockages in the cooling system leading to
engine overheating and damage.
Always use the antifreeze listed in the
Specification section and never use a methanol
based antifreeze as this does not contain the
required corrosion inhibition properties.

Note:
• HD4X Hybrid OAT coolant, as supplied by
Triumph, is premixed and does not need to be
diluted prior to filling or topping up the cooling
system.

Caution
If hard water is used in the cooling system, it will
cause scale accumulation in the engine and
radiator and considerably reduce the efficiency of
the cooling system. Reduced cooling system
efficiency may cause the engine to overheat and
suffer severe damage.

450 Thruxton R
 Cooling

Coolant Level Inspection 2. The coolant level must be between the MAX
(upper line) and MIN (lower line) marks in the
expansion tank.
Warning
Before starting work, ensure the motorcycle is 1
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle. 2

Caution
If the coolant level is found to be low, or if coolant
has to be added regularly, inspect the cooling
system for coolant leaks. If necessary, pressure
test the system to locate the source of the leak
and rectify as necessary. Loss of coolant may
cause the engine to overheat and suffer severe
damage. 1. Expansion tank cap
2. MAX and MIN marks
1. Position the motorcycle on level ground and in
an upright position. 3. If the level of coolant is low, remove the cap
Note: from the expansion tank and add coolant
mixture as necessary to bring the level up to
• Only inspect the coolant level when the engine the MAX mark. Refit the cap (see Coolant Level
is cold. Adjustment, page 452).
• The coolant level within the expansion tank
can be inspected without removing any
covers. The expansion tank can be viewed
from the left hand side of the motorcycle,
towards the rear of the engine. Always
inspect the coolant level with the engine cold.

Thruxton R 451
Cooling

Coolant Level Adjustment Note:

• In an emergency, distilled water can be added
Warning to the cooling system. However, the coolant
must then be drained and replenished with
Before starting work, ensure the motorcycle is HD4X Hybrid OAT coolant as soon as possible.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

Warning
Do not remove the expansion tank or coolant
pressure cap when the engine is hot. When the
engine is hot, the coolant inside the cooling
system will be hot and may also be under
pressure. Contact with hot coolant will cause
scalds and skin damage.

1. Allow the engine to cool for a minimum of 30

minutes.
2. Remove the front sprocket cover (see Front
Sprocket Cover - Removal, page 104).
3. Remove the cap from the expansion tank, and
add coolant mixture through the filler opening
until the level reaches the MAX mark. Refit the
cap.

cjpt_1

1. Maximum level
2. Minimum level
3. Filler opening

4. Refit the front sprocket cover (see Front

Sprocket Cover - Installation, page 105).
Note:
• If the coolant level is being checked because
the coolant has overheated, also check the
level in the radiator and top up if necessary.

452 Thruxton R
 Cooling

Coolant Replacement - Drainage 3. Using service tool T3880207 , release the hose
clamps then release the bottom hose from the
radiator and allow the coolant to drain.
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.
2
3

Warning
4
Do not remove the coolant pressure cap when the
engine is hot. When the engine is hot, the coolant
inside the radiator is hot and also under pressure.
Contact with hot coolant will cause scalds and skin 1
damage.
cjfz

Note: 1. Hose clamps

• Prior to disassembly of the coolant hoses, 2. Bottom hose
note the orientation and position of the hose 3. Coolant hose alignment mark
clamps to help ensure that they are returned
to the same positions and orientation on 4. Hose alignment mark
assembly. 4. Disconnect the bottom hose.
• Use service tool T3880207 for removal and
installation of the hose clamps.
1. Remove the coolant pressure cap.

cixw

1. Radiator cap

2. Position a container below the engine and

radiator to collect the displaced coolant.

Thruxton R 453
Cooling

Coolant Replacement - Filling 2. With the aid of an assistant, raise the rear
wheel until the filler opening is above the
radiators upper coolant tank.
Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help 1
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

Warning 2
Do not remove the coolant pressure cap when the
engine is hot. When the engine is hot, the coolant
inside the radiator is hot and also under pressure.
Contact with hot coolant will cause scalds and skin
damage.
cjfu

1. Refit the bottom hose. Ensure the hose clamp 1. Filler opening
is positioned to the alignment mark as noted
2. Radiators upper coolant tank
for removal.
3. Slowly add coolant mixture to the system,
through the filler opening, until coolant
escapes from the filler opening.
Note:

2 • If the system has filled correctly and fully,

3 there should be coolant visible through the
filler opening.

4 Note:
• During filling, squeezing the bottom hose with
both hands will help to pump coolant around
1 the system and remove trapped air.
4. Refit the coolant pressure cap.
cjfz
5. Lower the motorcycle’s rear wheel to the
1. Hose clamps ground.
2. Bottom hose 6. Refit the fuel tank (see Fuel Tank - Installation,
page 383).
3. Coolant hose alignment mark
7. Reconnect the battery, positive (red) lead first
4. Hose alignment mark
and tighten the battery terminals to 4.5 Nm.
8. Start the motorcycle and allow the engine to
idle. Briefly raise the engine speed several
times to allow any air to be expelled from the
system.
9. Stop the engine and allow it to cool.
10. With the aid of an assistant, raise the fuel tank
to allow access to the coolant pressure cap.
11. Remove the coolant pressure cap.

454 Thruxton R
 Cooling

12. If necessary, top up the system through the Water Pump

filler.
13. Refit the coolant pressure cap.
• Refit the fuel tank (see Fuel Tank - Installation,
Warning
page 383). Before starting work, ensure the motorcycle is
• Check the expansion tank level and top up if stabilised and adequately supported. This will help
necessary (see Coolant Level Inspection, page prevent it from falling and causing injury to the
451). operator or damage to the motorcycle.
• Refit the seat (see Seat - Installation, page 636).
Note:
• The oil pump and water pump are supplied as
an assembly and cannot be separated. For
additional information, refer to Oil Pump (see
Oil and Water Pump - Removal, page 247 for
removal and Oil and Water Pump - Installation,
page 253 for installation).

Thruxton R 455
Cooling

Water Pump - Inspection Coolant System Pressure Test

1. Remove the pump outer cover to check for
corrosion and scale build-up around the Warning
impeller and in the pump body. Renew the
pump if leakage is evident. Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
2. Check the water pump shaft and shaft
prevent it from falling and causing injury to the
bearings for side and end float. Renew the
operator or damage to the motorcycle.
pump if wear is evident.
3. Check the water pump face and shaft seals for
signs of leakage. Renew the pump if leakage is
evident.
Warning
Do not remove the coolant pressure cap when the
engine is hot. When the engine is hot, the coolant
inside the radiator is hot and also under pressure.
Contact with hot coolant will cause scalds and skin
damage.

1. Remove the fixing and position the coolant

filler neck away from the immobiliser bracket.

2 3

cixw

1. Fixing
2. Coolant filler cap
3. Immobiliser bracket

2. Remove the coolant filler cap.

3. Select the service tool T3880176 bayonet type
adapter and securely fasten to the coolant
filler neck.

456 Thruxton R
 Cooling

4. Carefully connect the hand pump (part of 8. De-pressurise the coolant test kit using the
T3880147 - Radiator and Cap Tester Kit) to the pressure release valve.
service tool T3880176 ensuring an air tight seal
is maintained. 3
4

cjhr_1
1

1 2. Coolant filler neck

cjhr

3. Bayonet type connector

1. Coolant filler neck
4. Hand held pump
2. T3880176 - Radiator Pressure Test (use with
3880147) 5. Pressure release valve

3. Hand held pump (part of T3880147 - Radiator and 9. Detach the service tool T3880176 bayonet type
Cap Tester Kit) adapter from the coolant filler neck.
10. Refit the coolant filler neck and tighten the
Note:
fixing to 3 Nm.
• Do not exceed 1.2 bar when carrying out a • Fill the coolant expansion tank to the maximum
coolant pressure test. mark (see Coolant Level Adjustment, page 452).
5. Pressurise the cooling system to the operating • Refit the coolant pressure cap.
pressure, using the hand pump taking care not • Refit the fuel tank (see Fuel Tank - Installation,
to exceed 1.2 bar. page 383).
6. Hold the pressure for a minimum of 10 • Reconnect the battery, positive (red) lead first
minutes, whilst visually inspecting the external (see Battery - Installation, page 658) and
components of the coolant system for leaks. tighten the terminals to 4.5 Nm.
Note: • Refit the seat (see Seat - Installation, page 636).
• If the engine oil is contaminated further
exploratory investigation will be required.
• Engine oil with a hazy or milky appearance
may indicate water emulsion.
• If the engine oil is contaminated rectify the
cause of the problem and then renew the oil
and filter.
7. Remove the engine oil filler cap and check for
contamination of the engine oil caused by
coolant escaping into the engine sump.

Thruxton R 457
Cooling

Coolant Pressure Cap Test Note:

• It is recommended to carry out coolant
Warning pressure cap and cooling system pressure
tests consecutively.
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
Warning 3
Do not remove the coolant pressure cap when the 2
engine is hot. When the engine is hot, the coolant
inside the radiator is hot and also under pressure.
Contact with hot coolant will cause scalds and skin
damage.
4
1. Allow the engine temperature to cool for at 5
least 30 minutes.
1. Hand held pump
2. Remove the coolant pressure cap.
2. Bayonet type connector
3. Check the condition of the upper and lower
seals of the coolant pressure cap. 3. Pressure cap test adapter 44 mm
4. Pressure cap test adapter 46 mm

1 5. Coolant cap type connector

5. Select the correct test adapter and securely

fasten to the pressure cap.

3
2

ccer

1. Lower Seal
2. Upper Seal
3. Spring

Note:
• If there is any sign of damage or deterioration
replace the cap.
4. Pressure test the cap and cooling system to
the blow off pressure of 1.2 bar as described
using service tool T3880147.

458 Thruxton R
 Cooling

6. Carefully connect the hand pump to the Thermostat - Removal

adapter ensuring an air tight seal is
maintained.
Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
3 operator or damage to the motorcycle.

Warning
Do not remove the coolant pressure cap when the
engine is hot. When the engine is hot, the coolant
inside the radiator is hot and also under pressure.
1 Contact with hot coolant will cause scalds and skin
2
damage.
cgwq

1. Pressure cap Note:

2. Test adapter • Prior to disassembly of the coolant hoses,
3. Hand held pump note the orientation and position of the hose
clamps to help ensure that they are returned
7. Pressure test the cap to it’s 1.2 bar blow off to the same positions and orientation on
pressure. If the coolant cap opens at a lower assembly.
pressure, fails to open at the correct pressure
• Drain the coolant (see Coolant Replacement -
or the seal leaks, replace the cap.
Drainage, page 453).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383). 1. Release the hose clamp from the thermostat
housing.
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

1
cjfu

1. Thermostat housing
2. Hose clamp
3. Top hose

Thruxton R 459
Cooling

2. Release the fixings securing the thermostat Thermostat - Inspection

housing to the cylinder head, and withdraw
the housing downwards, detaching it from the 1. Inspect the thermostat at room temperature.
top hose. If the thermostat is open, it must be replaced.
3. Remove the housing, collect the thermostat 2. To check the thermostat is opening at the
and discard the seal. correct temperature, suspend the thermostat
in a container of water and raise the
temperature of the water until the thermostat
opens.
3
• Refer to the General Information section for
the correct thermostat opening
temperature.
3. If the temperature at which thermostat
opening takes place is incorrect, replace the
1 thermostat.

2
cjga

1. Thermostat
2. Thermostat seal
3. Bypass hole

460 Thruxton R
 Cooling

Thermostat - Installation 4. Reconnect the top hose to the thermostat

housing. Ensure the hose clamp is positioned
as noted during removal.
Warning 5. Locate the thermostat housing to the cylinder
Before starting work, ensure the motorcycle is head, ensuring that the top hose is fully
stabilised and adequately supported. This will help seated on to the thermostat outlet. Tighten
prevent it from falling and causing injury to the the fixings to 9 Nm.
operator or damage to the motorcycle. • Refill the cooling system (see Coolant
Replacement - Filling, page 454).
• Check the expansion tank level and top up if
Warning necessary (see Coolant Level Inspection, page
451).
Do not remove the coolant pressure cap when the • Refit the fuel tank (see Fuel Tank - Installation,
engine is hot. When the engine is hot, the coolant page 383).
inside the radiator is hot and also under pressure.
• Reconnect the battery, positive (red) lead first
Contact with hot coolant will cause scalds and skin
(see Battery - Installation, page 658) and
damage.
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
1. Clean the mating surfaces of the cylinder head
and thermostat housing.
2. Position a new seal to the thermostat, seating
the thermostat into the groove in the seal.
3. Locate the thermostat into the cylinder head
with the centre bars of the thermostat in a
horizontal position, and the bypass hole
positioned uppermost.

2
cjga

1. Thermostat
2. Thermostat seal
3. Bypass hole

Thruxton R 461
Cooling

Radiator - Removal 2. Disconnect the bottom hose from the radiator.

Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 2
3
operator or damage to the motorcycle.

4
Warning
Do not remove the coolant pressure cap when the
engine is hot. When the engine is hot, the coolant 1
inside the radiator is hot and also under pressure.
Contact with hot coolant will cause scalds and skin cjfz

damage.
1. Hose clamps
2. Bottom hose
Note:
3. Coolant hose alignment mark
• Prior to disassembly of the coolant hoses,
note the orientation and position of the hose 4. Outlet pipe alignment mark
clamps to help ensure that they are returned 3. Disconnect the top hose clamp from the
to the same positions and orientation on radiator.
assembly.
4. Release the fixing securing the radiator to the
• Use T3880207 - Hose Clip Pliers for their
frame,
removal and installation.
• Refit the engine cradles (see Cradle Assemblies
- Installation, page 642).
• Drain the coolant (see Coolant Replacement -
Drainage, page 453).
1. Disconnect the cooling fan electrical
connector.

2 4
3
1
1
cjfw

1. Top hose
2. Hose clamp
3. Radiator
4. Fixing

cjcp_1

1. Cooling fan electrical connector

462 Thruxton R
 Cooling

5. Release the top hose. Radiator - 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. Align the radiator’s lower rubber mounting to

its mounting on the left hand cradle assembly.
2
1
3
cjfy

1. Radiator
2. Top hose

6. Raise the radiator and rubber mounting from 2

its lower mounting on the left hand cradle
assembly.

3 1
cjfx

1. Radiator
2. Radiator lower mounting

2 3. Rubber mounting

2. Refit the radiator to the top hose, ensure the

top hose clamp is positioned as noted during
removal.
3. Align the radiator upper mounting and tighten
1 the fixing to 6 Nm.
cjfx

1. Radiator
2. Radiator lower mounting
3. Rubber mounting

7. Remove the radiator from the motorcycle,

taking care not to damage the radiator, left
hand frame cradle or front mudguard.
2 4
3

1
cjfw

1. Top hose
2. Clamp
3. Radiator
4. Fixing

Thruxton R 463
Cooling

4. Refit the right hand frame cradle assembly

(see Cradle Assemblies - Installation, page 642).
5. Refit the bottom hose, positioning the clamps
as noted during removal.

2
3

cjfz

1. Clamps
2. Bottom hose
3. Coolant hose alignment mark
4. Outlet pipe alignment mark

6. Re-connect the cooling fan electrical

connector.

cjcp_1

1. Cooling fan electrical connector

7. Refill the cooling system (see Coolant

Replacement - Filling, page 454).
8. Check the expansion tank level and top up if
necessary (see Coolant Level Inspection, page
451).
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

464 Thruxton R
 20 Front Suspension
Table of Contents
Exploded View – Front Fork, Bottom Yoke and Steering Head Bearings ........................................................................ 467
Exploded View – Handlebars and Top Yoke ................................................................................................................................... 468
Fork Inspection............................................................................................................................................................................................. 469
Front Fork - Removal ................................................................................................................................................................................ 469
Front Fork - Installation............................................................................................................................................................................ 471
Fork Oil Change - Oil Draining ............................................................................................................................................................... 472
Fork Oil Change - Oil Refilling ................................................................................................................................................................ 473
Front Fork - Disassembly ........................................................................................................................................................................ 475
Front Fork - Inspection ............................................................................................................................................................................ 476
Front Fork - Assembly ............................................................................................................................................................................... 477
Steering Head Bearing - Check ............................................................................................................................................................ 478
Steering Head Bearing - Adjustment................................................................................................................................................ 479
Handlebars - Removal............................................................................................................................................................................... 480
Handlebars - Installation......................................................................................................................................................................... 482
Upper Yoke - Removal .............................................................................................................................................................................. 484
Upper Yoke - Installation......................................................................................................................................................................... 485
Lower Yoke and Headstock Bearings - Removal......................................................................................................................... 486
Lower Yoke and Headstock Bearings - Bearing Removal ....................................................................................................... 486
Lower Yoke and Headstock Bearings - Installation ................................................................................................................... 487

Thruxton R 465
Front Suspension

466 Thruxton R
 Front Suspension

Exploded View – Front Fork, Bottom Yoke and Steering Head Bearings

See Text

20 Nm

22 Nm

20 Nm
65 Nm

Thruxton R 467
Front Suspension

Exploded View – Handlebars and Top Yoke

25 Nm
8 Nm

3.5 Nm 90 Nm

2.5 Nm

8.5 Nm

25 Nm
8.5 Nm

8 Nm

2.5 Nm
20 Nm

8.5 Nm

20 Nm
3.5 Nm

8 Nm

468 Thruxton R
 Front Suspension

Fork Inspection Front Fork - Removal

Examine each fork for any sign of damage or
scratching of the slider surface or for oil leaks. Warning
If any damage or oil leakage is found, strip and
repair as described in this section or consult an Before starting work, ensure the motorcycle is
authorised Triumph dealer. stabilised and adequately supported. This will help
Check for smooth operation of the forks as follows: prevent it from falling and causing injury to the
operator or damage to the motorcycle.
• Place the motorcycle on level ground
• While holding the handlebars and applying the
• Raise and support the front of the motorcycle.
front brake, pump the forks up and down
several times. • Remove the front wheel (see Front Wheel -
Removal, page 599).
If roughness or excessive stiffness is detected,
repair as described in this section or consult an
authorised Triumph dealer. Warning
Never allow the brake calipers to hang on the
Warning brake hoses as this may damage the hoses. A
damaged brake hose can cause a reduction in
Riding the motorcycle with defective or damaged
braking efficiency leading to loss of motorcycle
suspension can cause loss of motorcycle control
control and an accident.
and an accident. Never ride with damaged or
defective suspension.
• Remove the front mudguard (see Front
Mudguard - Removal, page 637).
Note:
• Note the routing of the ABS wheel speed
sensor harness for installation.
• There is a shim between the ABS wheel speed
sensor and the front fork leg.
1. Release the fixing and detach the ABS wheel
speed sensor from the left hand fork leg, and
collect the shim.

2
cjsl

1. Fixing
2. Front ABS wheel speed sensor
3. ABS wheel speed sensor harness
4. Shim

Thruxton R 469
Front Suspension

Note: Note:
• If the forks are to be dismantled, loosen the • The right hand handlebar has the front brake
fork top caps. master cylinder attached to it. Ensue the
master cylinder remains upright when the
2. Loosen the upper yoke pinch bolt.
handlebar riser is removed from the front fork.
3. Note the orientation and position of the
handlebar riser on the forks, loosen the 5. As the fork is released, slide the handlebar
handlebar riser pinch bolt. riser off the fork and tie aside. Do not allow
the handlebar to hang on the wiring harnesses
1 or cables.
2
6. Remove the forks from the lower yoke.

cjrj
3
1. Pinch bolts
2. Upper yoke
3. Handlebar riser

4. Loosen the lower yoke pinch bolts and slide

the fork down through the yokes.

1
cjrq

1. Pinch bolts
2. Lower yoke

Caution
Care must be taken when removing the forks, to
ensure that the outer surfaces do not become
scratched.

470 Thruxton R
 Front Suspension

Front Fork - Installation 12. The air gap between the ABS pulser ring and
the sensor must be between 0.40 mm and 1.20
1. Position the handlebar risers between the mm. Check, and if necessary, adjust the air gap
upper and lower yokes. (see Air Gap Measurement, page 545).
2. Install each fork through the lower yoke and 13. Lower the motorcycle to the ground and park
slide handlebar risers on to the forks. it on the side stand.
3. Position the fork through the lower yoke so
that the upper surface of the fork top cap
flange 23.5 mm from lower edge of top yoke to
the top of the outer tube (not the top cap).

23.5 mm

cjqq_1

1. Upper yoke

4. Tighten the lower yoke pinch bolts to 25 Nm.

5. If the fork top caps have been loosened,
tighten them to 22 Nm.
6. Tighten the upper yoke clamp bolts to 20 Nm.
7. Position the handlebar risers as noted for
removal and tighten the fixings to 20 Nm.

Warning
Move the handlebars to the left and right full lock
while checking that cables and harnesses do not
bind or that the steering feels tight or difficult to
turn. A cable or harness that binds, or steering
that is tight/difficult to turn will restrict the
steering and may cause loss of control and an
accident.

8. 9
9. Refit the front mudguard (see Front Mudguard
- Installation, page 638).
10. Route secure the ABS wheel speed sensor
harness as noted for removal and fit the wheel
speed sensor and shim to the fork leg. Tighten
the fixing to 9 Nm.
11. Install the front wheel (see Front Wheel -
Installation, page 601).

Thruxton R 471
Front Suspension

Fork Oil Change - Oil Draining 4. Hold the fork inner tube fully into the fork
outer tube. Using service tool T3880634
• Remove the fork assembly (see Front Fork -
unscrew and remove the top cap and fork
Removal, page 469).
damping assembly from the fork inner tube.

Caution 2

When securing the fork in service tool T3880171,

take care not to over tighten the clamp as this will
cause the fork tube to distort beyond repair.

1. Using a soft jawed vice, clamp the service tool 3

T3880171 such that the fork can be mounted
vertically.
2. With the top cap facing upwards, very gently
1
clamp the fork inner tube into service tool
T3880171. 4
3. Using service tool T3880186 carefully unscrew
the top cap from the fork outer tube. cjqi

1. T3880634 - Wrench Damper Cylinder

2. Top cap
1 3. Damping rod
4. Fork outer tube

cjqh

1. T3880184 - 45 mm Octagonal Socket

2. Fork outer tube

Warning
The fork damping assembly is under pressure
from the fork spring. As the last few threads of
the damping assembly are unscrewed, keep the
damping assembly pushed firmly into the tube to
prevent it being forcibly expelled as the threads
release. To prevent injury, always wear eye, face
and hand protection when removing the top cap.

472 Thruxton R
 Front Suspension

5. Lift out the upper spring collar and the spring. Fork Oil Change - Oil Refilling
The oil level is measured from the upper surface of
the fork outer tube, with the fork fully compressed.
3 2 1

For the measurement,

refer to the fork oil
level chart

cjrk

1. Upper spring collar

cbyf_1
2. Spring
3. Fork outer tube Fork Oil Level (fork fully compressed)

6. Invert the fork and pour out the fork oil into a
suitable container. Collect the lower spring Fork Oil Level Chart
collar. Pump the fork assembly to remove all
oil. Warning
Any variation from the figures quoted in the fork
1 oil level chart could result in an unsafe riding
condition leading to loss of motorcycle control and
an accident.

Oil Oil Oil Grade Fork Pull Through

Level* Volume
68 582 cc Showa The upper
mm SS47 surface of the
fork top cap
flange 23.5 mm
from lower edge
of top yoke to
cjrl the top of the
1. Lower spring collar outer tube (not
the top cap)

Thruxton R 473
Front Suspension

1. Fill the fork with the specified fork oil until the M2 is the required torque to be 90 Nm
oil level passes the side holes in the fork inner applied
tube.
L1 is the normal length of the 300 mm
torque wrench
2 L2 is the extended length of the 325 mm
torque wrench (including the crows
foot spanner)
1
M1 is the calculated torque value = 83 Nm

5. Fill the fork with the specified fork oil until the
oil level passes over the damping rod guide
case.

cjrp
1
1. Hole (one of four shown)
2. Fork inner tube

2. Pump the fork outer tube several times to

expel any trapped air then fully compress the
fork and support it in an upright position.
Leave the fork for a few minutes to allow the
oil level to stabilise.
Note:
cjro

• When fitting the fork top cap and fork

damping assembly, care must be taken not to 1. Fork damping rod
damage the top ring of the damping assembly. 2. Damping rod
3. With the fork fully compressed use service tool 6. Pump the fork several times to expel any
T3880634 to fit the fork damping assembly to trapped air then fully compress the fork and
the inner tube. Hand tighten only. support it in an upright position. Leave the
4. With the lower end of the fork inner tube fork for a few minutes to allow the oil level to
secure in service tool T3880171, tighten the stabilise.
damping assembly to 90 Nm using the formula
described below.
Note:
• The torque is calculated using a crow’s foot
spanner measured at 25 mm across the centre
of the spanner head and the centre of the
drive square.
• If for any reason a different length crow’s foot
spanner is used, re-calculate the torque figure
using the table below.

L2

L1

ciyj

M1 = M2 x L1 / L2 Example

474 Thruxton R
 Front Suspension

7. Refer to the oil level chart and set the scale on Front Fork - Disassembly
service tool 3880160-T0301 to the specified
• Remove the fork assembly (see Front Fork -
level.
Removal, page 469).
1. Drain the fork oil (see Fork Oil Change - Oil
Draining, page 472).
1
Caution
When securing the fork in service tool T3880171,
4 take great care not to over tighten the clamp as
this will cause the fork tube to distort beyond
3
repair.

2
2. Ease the dust seal out of the outer tube.

cbyg_1

1. 3880160 -T0301 - Fork Oil Filler/Evacuator 2

2. Adjuster plate
1
3. Scale area
4. Hole (zero position)

Note:
• Zero level on the tool is set at the small exit
hole in the side of the scale tube, NOT AT THE
END TIP. Do not attempt to block this side hole
as this will cause the final fluid level to be
incorrect. ceto_1

8. Insert the scale end of the tool into the fork 1. Dust seal
inner tube. 2. Inner tube
9. Hold the tool adjuster plate level with the 3. Carefully ease the circlip out from the top of
upper surface of the fork outer tube and draw the outer tube.
fluid into the syringe until fluid flow ceases
(empty the syringe if the body becomes full
before fluid flow stops).
10. The fluid level in the fork is now set to the
height set on the tool scale. Check the tool 1
scale setting and repeat the process if
incorrectly set.

cetn

1. Circlip

Thruxton R 475
Front Suspension

4. Compress the fork then pull the inner tube Front Fork - Inspection
sharply out of the outer tube. Repeat this
procedure until the upper bush and seal are 1. Thoroughly clean and examine all components
forced out of position and the inner and outer for damage, wear, scoring, corrosion etc.,
tube can be separated. paying particular attention to the bushes and
damper rod piston ring. Renew as necessary.
5. Carefully slide the upper bush off the fork
inner tube. Discard the upper bush. 2. Always renew the oil seal, dust seal and the
damper rod bolt sealing washer every time the
Note: fork is dismantled.
• Note the orientation of the oil seal and dust
seal for installation.
6. Slide the lower bush, washer, oil seal, circlip
and dust seal off the fork inner tube. Discard
the lower bush, oil seal, circlip and dust seal.

6
5
4 3
2
1

ccup_5

1. Upper bush
2. Lower bush
3. Washer
4. Oil seal
5. Circlip
6. Dust seal
7. Fork inner tube

476 Thruxton R
 Front Suspension

Front Fork - Assembly 7. Using the narrow end of service tool

T3880003, guide the lower bush, washer and
oil seal into place.
Warning
1
The front forks comprise many precision machined 2 3
parts. Total cleanliness must be observed at all 4
times and assembly must take place in a dirt/
dust-free environment.
Dirt ingress may cause damage to the fork parts,
leading to incorrect operation, instability, loss of
motorcycle control or an accident.

1. Lubricate the oil seal, upper and lower bushes

for the inner tube with clean fork oil.
2. Slide a new dust seal on to the fork inner tube
as noted for removal.
cjrm
3. Slide the circlip and a new oil seal on to the
fork inner tube as noted for removal. 1. T3880003 - Front fork Seal Installer
4. Slide the washer and a new lower bush onto 2. Oil seal
the inner tube. 3. Fork inner tube
5. Fit a new upper bush to the fork inner tube. 4. Fork outer tube

8. Secure the oil seal in position with the circlip,

6 ensuring it is correctly located in its groove.
5 9. Position the dust seal to the outer tube.
4 3 10. Invert service tool T3880003 and, using hand
pressure only, push the dust seal squarely into
2 the outer tube.
1
1
2

ccup_5

1. Upper bush
2. Lower bush
3. Washer
4. Oil seal
5. Circlip
cjrm
6. Dust seal
1. T3880003 - Front fork Seal Installer
7. Fork inner tube
2. Dust seal
6. Insert the fork inner tube assembly into the
fork outer tube.

Thruxton R 477
Front Suspension

11. Fit the lower spring collar into the fork inner Steering Head Bearing - Check
tube as noted for removal.

Warning
1
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. Raise and support the motorcycle so that the

front wheel is clear of the ground.
2. Move the handlebars from lock-to-lock whilst
checking for signs of tight spots or notchiness
(bearings overtightened).
3. Hold the lower end of the front forks and try
cjrl to move them forward and backward to check
for signs of free play in the bearings (bearings
1. Lower spring collar
insufficiently tightened or worn).
12. Fit the spring and the upper spring collar into
the fork inner tube as noted for removal.

3 2 1

jaau_4

Checking for Free Play in Steering Head Bearings

cjrk

4. Adjust as described in Steering Head Bearing -

1. Upper spring collar
Adjustment, page 479 then lower the
2. Spring motorcycle to the ground.
3. Fork outer tube

13. Return the fork to an upright position, with

the lower end of the fork inner tube secure in
service tool T3880171.
14. Refill the fork with new oil (see Fork Oil Change
- Oil Refilling, page 473).

478 Thruxton R
 Front Suspension

Steering Head Bearing - Adjustment • Loosen the adjuster nut, then re-tighten to
15 Nm.
• Fit the tab washer and lock nut.
Warning
Before starting work, ensure the motorcycle is Warning
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the It is essential that the adjuster nut is not over-
operator or damage to the motorcycle. 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
• Remove the seat (see Seat - Removal, page
loss of motorcycle control and an accident.
636).
• Disconnect the battery, negative (black) lead
first. Note:
• Ensure the adjuster nut does not move as the
Warning lock nut is tightened.
• With the bearing free play correctly set,
If the lower yoke fixings are also loosened, the hold the adjuster nut stationary then
forks will no longer support the weight of the tighten the lock nut to 40 Nm.
motorcycle.
Do not loosen the lower yoke fixings as, in this 1
condition, the motorcycle could topple over
2
causing damage and/or risk of injury.

• Remove the upper yoke (see Upper Yoke - 3

Removal, page 484).
1. Using service tool T3880023 loosen the lock 5
nut and adjuster nut.

1
4
2

3 cjbu

1. T3880023 - 50 mm Socket
5 2. Lock nut
3. Tab washer
4. Adjuster nut
4
• Refit the upper yoke (see Upper Yoke -
Installation, page 485).
• Check that the free play has been eliminated
cjbu
and that the steering can be turned freely from
1. T3880023 - 50 mm Socket lock-to-lock without any sign of tightness.
2. Lock nut Readjust if necessary.

3. Tab washer
4. Adjuster nut
5. Dust seal

2. Adjust the bearing free play as follows:

• Remove the lock nut, tab washer and
adjuster nut.
• Thoroughly clean the threads on the
steering stem.
• Refit the adjuster nut and tighten to 40 Nm.

Thruxton R 479
Front Suspension

Handlebars - Removal
Warning
Operation of the motorcycle with incorrectly Warning
adjusted steering head bearings, either too loose
or too tight, may cause a dangerous riding Before starting work, ensure the motorcycle is
condition leading to loss of motorcycle control and stabilised and adequately supported. This will help
an accident. prevent it from falling and causing injury to the
operator or damage to the motorcycle.
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and • Remove the seat (see Seat - Removal, page
tighten the terminals to 4.5 Nm. 636).
• Refit the seat (see Seat - Installation, page 636). • Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the mirrors (see Mirrors - Removal,
page 644).
Note:
• The left hand handlebar can be identified by
the two dot alignment marks on it for the
alignment to the riser.
• The right hand handlebar can be identified by
the single dot alignment mark on it for the
alignment to the riser.

Left Hand Handlebar

1. Release the fixings and remove the clamp from
the clutch lever assembly. Position the clutch
lever to one side.

1
cjrd_1

1. Fixings
2. Clutch lever clamp

480 Thruxton R
 Front Suspension

2. Release the fixings and detach the left hand

switch housing from the handlebar. Caution
To prevent paint damage, do not spill brake fluid
2 1
onto any area of the bodywork or frame. Spilled
brake fluid will damage paintwork.

1. Release the fixings and remove the clamp from

the master cylinder. Detach the master
cylinder from the handlebars and support it in
an upright position.

1
cjbn

1. Fixings
2. Left hand switch housing

3. Remove the left hand grip.

4. Release the handlebar to riser pinch bolts and
slide the handlebar in towards the centre of
the motorcycle to expose the circlip on the 2
handlebar. cjrc_1

5. Remove and discard the circlip then remove 1. Fixings

the handlebar.
2. Clamp

1 2. Release the fixings securing the right hand

switch housing to the handlebar.
3. Release the handlebar to riser pinch bolts and
slide the handlebar in towards the centre of
the motorcycle to expose the circlip on the
handlebar.
4. Remove and discard the circlip then remove
the handlebar.

3
2 1

cjre_4

1. Fixings
2. Handlebar
3. Circlip

Right Hand Handlebar 3 2

• Remove the twist grip (see Twist Grip - Removal,
page 406).
cjrf_2

1. Fixings
2. Handlebar
3. Circlip

Thruxton R 481
Front Suspension

Handlebars - Installation 5. Align the left hand switch housing to the

handlebar, ensure the locating lug aligns with
the hole in the handlebar. Fit the two screws
Warning and tighten to 2.5 Nm.
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help 2 1
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

Note:
• The left hand handlebar can be identified by
the two dot alignment marks on it for the
alignment to the riser.
• The right hand handlebar can be identified by
the single dot alignment mark on it for the
alignment to the riser.
1
Left Hand Handlebar cjbn

1. Fit a new circlip to the handlebar. 1. Fixings

2. Locate the left hand handlebar in to the left 2. Left hand switch housing
hand riser. Do not fully tighten at this stage.
6. Locate the clutch lever assembly to the
3. Rotate the handlebar so that the two handlebar and fit the clamp.
alignment marks on the handlebar aligns with
7. Align the clutch lever split line with the
the split line of the left hand riser. Tighten the
alignment mark on the handlebar. Tighten the
fixings to 8.5 Nm.
clamp fixings, upper one first, to 12 Nm.

3 1
2

2 3

4
cjre_3
cjrd

1. Alignment mark
1. Clutch lever split line
2. Split line (left hand riser)
2. Handlebar alignment mark
3. Fixings
3. Clamp
4. Fit the left hand grip. 4. Fixings

Right Hand Handlebar

1. Fit a new circlip to the handlebar.
2. Locate the right hand handlebar in to the right
hand riser. Do not fully tighten at this stage.

482 Thruxton R
 Front Suspension

3. Rotate the handlebar so that the alignment 6. Locate the master cylinder to the handlebars
mark on the handlebar aligns with the split line and position the clamp with the UP arrow
of the right hand riser. Tighten the fixings to pointing upwards. Do not tighten the clamp
8.5 Nm. fixings at this stage.
7. Align the split line of the master cylinder clamp
to the alignment mark on the upper surface of
3 the handlebar. Tighten the clamp fixings,
upper one first, to 8.5 Nm.

1 1 3

cjrf_3

1. Alignment mark
2. Split line (left hand riser) 2
3. Fixings cjrc

4. Align the right hand switch housing to the 1. Alignment mark

handlebar, ensure the locating lug aligns with
2. UP arrow
the hole in the handlebar. Fit the two fixings
and tighten to 2.5 Nm. 3. Fixings

5. Fit the twist grip (see Twist Grip - Installation,

page 408). Warning
Move the handlebars to the left and right full lock
Caution while checking that cables and harnesses do not
To prevent paint damage, do not spill brake fluid bind or that the steering feels tight or difficult to
onto any area of the bodywork or frame. Spilled turn. A cable or harness that binds, or steering
brake fluid will damage paintwork. that is tight/difficult to turn will restrict the
steering and may cause loss of motorcycle control
and an accident.

• Refit the mirrors (see Mirrors - Installation,

page 645).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 483
Front Suspension

Upper Yoke - Removal 3. Remove the fixing and washer securing the
handlebar riser to the upper yoke.

Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
4
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

• Remove the seat (see Seat - Removal, page 3

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
2
• Remove the headlight and its subframe (see
Headlight Bracket - Removal, page 673).
1
Note: cjrh_1

• Note the position and the routing of the 1. Fixing

ignition switch harness for installation. 2. Washer
1. Follow the routing of the ignition switch 3. Handlebar riser
harness and disconnect it from the main
4. Upper yoke
harness.
4. Loosen the upper yoke pinch bolts.
Caution 5. Loosen the handlebar riser pinch bolts.
1
To prevent paint damage, do not spill brake fluid 2
onto any area of the bodywork or frame. Spilled
brake fluid will damage paintwork.

2. Remove the two fixings and detach the

instruments and mounting bracket assembly
from the upper yoke.

cjrj
3
1. Pinch bolts
2 2. Upper yoke
3. Handlebar riser

1 6. Remove the upper yoke centre nut from the

steering stem and remove the upper yoke.
cjri

484 Thruxton R
 Front Suspension

Upper Yoke - Installation

Warning
1. Refit the upper yoke and tighten the upper
yoke centre nut to 90 Nm. Move the handlebars to the left and right full lock
while checking that cables and harnesses do not
2. Tighten the upper yoke pinch bolts to 20 Nm.
bind or that the steering feels tight or difficult to
3. Position the handlebar riser to the underside turn. A cable or harness that binds, or steering
of the upper yoke. Fit the washer and fixing that is tight/difficult to turn will restrict the
for the handlebar riser to upper yoke, do not steering and may cause loss of motorcycle control
fully tighten at this stage. and an accident.
Note:
• Up to half of the clamp slot overlap is • Reconnect the battery, positive (red) lead first
acceptable. (see Battery - Installation, page 658) and
• If over half of the clamp slot is overlaped, the tighten the terminals to 4.5 Nm.
handlebar riser will require adjustment. • Refit the seat (see Seat - Installation, page 636).
• Check the headlight operation and the beam
4. Push the handlebar fully forward and tighten
setting, rectify as necessary.
the handlebar riser to upper yoke fixing to 8
Nm.
5. Visually check the alignment of the upper yoke
clamp slot to the handlebar clamp line.

2
3
cjta

1. Upper yoke clamp slot

2. Handlebar riser clamp slot
3. Clamp slot overlap (shown as acceptable)

Note:
• If the handlebar riser requires adjustment,
loosen the handlebar riser to upper yoke
fixing and repeat step 4.
6. Tighten the handlebar riser pinch bolt to 20
Nm.
7. Refit the instruments and bracket assembly to
the upper yoke. Tighten the new fixings to 8
Nm.
8. Route the ignition switch harness and connect
it to the main harness as noted for removal.
• Refit the headlight subframe and headlight (see
Headlight Bracket - Installation, page 674).

Thruxton R 485
Front Suspension

Lower Yoke and Headstock Bearings Lower Yoke and Headstock Bearings
- Removal - Bearing Removal
• Remove the seat (see Seat - Removal, page 1. Using a suitable drift, evenly and progressively
636). drive the bearing outer races from the frame
• Disconnect the battery, negative (black) lead headstock.
first (see Battery - Removal, page 658).
• Remove both front forks (see Front Fork -
Removal, page 469).
Caution
• Remove the upper yoke (see Upper Yoke - Protect the threads of the lower yoke when using
Removal, page 484). a press or puller as damaged threads may mean
replacing the lower yoke completely.
1. Using service tool T3880023 remove the lock
nut, tab washer, adjuster nut and the dust
seal. 2. Remove the bearing inner race from the lower
yoke using a press or puller.
1
Note:
2 • Note the orientation of the dust seal for
installation.
3 3. Remove the dust seal from the lower yoke.

cjbu

1. T3880023 - 50 mm Socket
2. Lock nut
3. Tab washer
4. Adjuster nut
5. Dust seal

2. Remove the lower yoke from below the frame

headstock.

486 Thruxton R
 Front Suspension

Lower Yoke and Headstock Bearings 6. Insert the lower yoke to the frame headstock,
fit the upper bearing, inner race, dust seal and
- Installation retain with the adjuster nut.
1. Fit a new dust seal to the steering stem on the 7. Adjust the bearing free play as follows:
lower yoke as noted for removal. • Remove the adjuster nut.
• Thoroughly clean the threads on the
Caution steering stem.
• Refit the adjuster nut and tighten to 40 Nm.
Protect the threads of the lower yoke when using
a press or a puller as damaged threads may mean • Loosen the adjuster nut, then re-tighten to
replacing the lower yoke completely. 15 Nm.
• Fit the tab washer and lock nut.
2. Press a new lower bearing inner race onto the
steering stem of the lower yoke. 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.
2
1 Note:
• Ensure the adjuster nut does not move as the
lock nut is tightened.

cjst

1. Dust seal
2. Bearing inner race

3. Evenly and progressively drive the new upper

and lower bearing outer races into the frame
headstock.

cjbm

1. Headstock

4. Lubricate the headstock bearings using grease

conforming to NLGI 2 specification.
5. Fit the bearing to the bearing inner race on
the steering stem.

Thruxton R 487
Front Suspension

• With the bearing free play correctly set,

hold the adjuster nut stationary then
tighten the lock nut to 40 Nm.

cjbu

1. T3880023 - 50 mm Socket
2. Lock nut
3. Tab washer
4. Adjuster nut
5. Dust seal
• Refit the upper yoke (see Upper Yoke -
Installation, page 485).
• Refit both front forks (see Front Fork -
Installation, page 471).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

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.

• Check and if necessary correct the headlight

adjustment (see Headlight Vertical Adjustment,
page 668).
• 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

488 Thruxton R
 21 Rear Suspension
Table of Contents
Exploded View – Swinging Arm............................................................................................................................................................. 491
Exploded View – Rear Suspension Units......................................................................................................................................... 492
Rear Suspension Units - Removal ...................................................................................................................................................... 493
Rear Suspension Unit - Inspection..................................................................................................................................................... 493
Rear Suspension Units - Installation................................................................................................................................................. 494
Swinging Arm - Removal ......................................................................................................................................................................... 494
Swinging Arm - Disassembly ................................................................................................................................................................. 496
Swinging Arm - Inspection ..................................................................................................................................................................... 497
Swinging Arm - Assembly ....................................................................................................................................................................... 497
Swinging Arm - Installation.................................................................................................................................................................... 498

Thruxton R 489
Rear Suspension

490 Thruxton R
 Rear Suspension

Exploded View – Swinging Arm

9 Nm

20 Nm

9 Nm

9 Nm

110 Nm

Thruxton R 491
Rear Suspension

Exploded View – Rear Suspension Units

28 Nm

28 Nm

48 Nm

48 Nm

492 Thruxton R
 Rear Suspension

Rear Suspension Units - Removal Rear Suspension Unit - Inspection

1. Remove all traces of dirt and inspect for
Warning damage/wear to the mountings and springs.
2. Inspect the unit closely for fluid leaks from all
Before starting work, ensure the motorcycle is
parts of the unit and for cracks and damage to
stabilised and adequately supported. This will help
the springs. If there is any damage, or any
prevent it from falling and causing injury to the
leaks are evident, both rear suspension units
operator or damage to the motorcycle.
must be renewed as a matched pair.

1. Raise and support the motorcycle so that the 3. Check the mounting rubbers for cracks and
rear wheel is clear of the ground. signs of elongation. Replace as necessary.

2. Remove the exhaust silencers (see Exhaust

Silencer - Removal, page 430). Warning
Note: Always renew both rear suspension units as a
• If both suspension units are to be removed, pair, even if only one appears to be faulty. If only
place a block beneath the rear wheel to one suspension unit is replaced, the handling of
prevent it dropping when the second unit is the motorcycle could be adversely affected. This
removed. could result in an unsafe riding condition leading
to a loss of motorcycle control and an accident.
3. Loosen and remove the upper and lower
mounting bolts and washers then remove the
suspension unit from its mounting spigots.
Discard the bolts.
2

cjrx

1. Rear suspension unit

2. Upper mounting bolt
3. Lower mounting bolt

4. Repeat step 3 for the other rear suspension

unit (if required).

Thruxton R 493
Rear Suspension

Rear Suspension Units - Installation Swinging Arm - Removal

• Support the motorcycle so that the rear wheel
Warning is clear of the ground, with no weight on the
swinging arm and suspension units.
Before starting work, ensure the motorcycle is • Remove the rear wheel (see Rear Wheel -
stabilised and adequately supported. This will help Removal, page 602).
prevent it from falling and causing injury to the • Remove the rear suspension units (see Rear
operator or damage to the motorcycle. Suspension Units - Removal, page 493).
• If fitted, remove the evaporative canister (see
1. Locate the suspension units to the mounting Evaporative Canister (if fitted) - Removal, page
spigots, articulating the swinging arm until the 438).
distance between the upper and lower spigots
allows the units to fit. 1. Remove and discard the two fixings and
detach the hose guide from the left hand side
2. Fit the washer and new mounting bolt to the of the swinging arm.
upper mounting and tighten to 28 Nm.
3. Fit a new mounting bolt to the lower mounting
and tighten to 48 Nm.
4. Repeat steps 2 and 3 for the other rear
suspension unit (if removed). 1
5. Refit the exhaust silencers (see Exhaust
Silencer - Installation, page 431).
6. Remove the wheel support (if fitted), lower the
motorcycle to the ground and park it on the
side stand.

2
cjrv

1. Fixings
2. Harness guide

2. Remove the two fixings and remove the left

heal guard.

cjsb

1. fixings
2. Heal guard

3. Remove the two fixings and detach the left

hand control plate from the frame.

494 Thruxton R
 Rear Suspension

4. Carefully remove the swinging arm pivot cover 7. Remove the swinging arm pivot nut and collect
on the left hand side of the frame. the washer on the right hand side of the
frame.

2
2 1
3

cjsa

cjrw
1. Fixings
2. Control plate 1. Nut

3. Cover 2. Washer

5. Remove the fixings securing the front 8. Support the swinging arm and remove the
sprocket cover to the crankcase and remove swinging arm spindle and washer from the left
the sprocket cover. hand side.
9. Partially fit the swinging arm spindle on the
right hand side to support the swinging arm.
2 10. Engage service tool T3880104 in the slots of
the frame adjuster sleeve and rotate
anticlockwise to loosen the sleeve fully.

1
1

2
2
1. Front sprocket cover
2. Fixings

6. Carefully remove the swinging arm pivot cover

on the right hand side of the frame. cjbc

1. Frame adjuster
2. T3880104 - Swinging Arm Adjuster Wrench

11. Support the swinging arm and withdraw the

swinging arm spindle from the right hand side.

Thruxton R 495
Rear Suspension

Note: Swinging Arm - Disassembly

• When removing the swinging arm, ensure that
the harness and hoses on the left hand side of Warning
the frame do not get damaged.
Before starting work, ensure the motorcycle is
12. Lower the left hand side and raise the right
stabilised and adequately supported. This will help
hand side of the swinging arm and carefully
prevent it from falling and causing injury to the
manoeuvre the swinging arm rearwards and
operator or damage to the motorcycle.
remove from the frame.

• Support the motorcycle so that the rear wheel

is clear of the ground, with no weight on the
swinging arm and suspension units.
• Remove the swinging arm (see Swinging Arm -
Removal, page 494).
1 1. Remove the left hand ball bearings by drifting
through from the right.
2. Collect the spacer tube.
Note:
• The needle roller bearing in the right hand side
of the arm cannot be removed undamaged.
3. Remove the right hand needle roller bearing by
cjru
drifting through from the left.
1. Swinging arm

8
7

6
5

2
1 4
3
1. Sleeve
2. Seal
3. Needle roller bearing
4. Spacer tube
5. Ball bearings
6. Circlip
7. Seal
8. Spacer

496 Thruxton R
 Rear Suspension

Swinging Arm - Inspection Swinging Arm - Assembly

1. Check all swinging arm bearings for damage,
pitting, and cracks. Replace as necessary. Warning
2. Check the swinging arm for damage. Replace
Before starting work, ensure the motorcycle is
as necessary.
stabilised and adequately supported. This will help
3. Check the wheel bearings for damage, pitting, prevent it from falling and causing injury to the
and cracks. Replace as necessary. operator or damage to the motorcycle.
4. Check all bearing seals for damage, splits etc.
Replace as necessary. 1. Install the bearings (marked faces outwards),
5. Check the drive chain for wear, damage etc. sleeves and seals etc. into the swinging arm in
Replace as necessary. the order shown in the following illustration.
Use new seals throughout.
6. Check both drive chain sprockets for wear,
damage etc. Replace as necessary.

8
7

6
5

2
1 4
3
1. Sleeve
2. Seal
3. Needle roller bearing
4. Spacer tube
5. Ball bearings
6. Circlip
7. Seal
8. Spacer
• Refit the swinging arm (see Swinging Arm -
Installation, page 498).

Thruxton R 497
Rear Suspension

Swinging Arm - Installation 2. With the swinging arm at the same angle for
removal, position the swinging arm to the
frame.
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:
• When installing the swinging arm, ensure that
the harness and hoses on the left hand side of
the frame do not get damaged.
1. Prior to installing the swinging arm, check that
the harnesses and breather pipe are secure as
shown in the following illustration.
cjru

1. Swinging arm

3. Refit the swinging arm spindle from the right

6
1 hand side such that it will support the
swinging arm, but not pass all the way
through the frame adjuster sleeve. This will
allow service tool T3880104 to engage in the
slot in the frame adjuster sleeve.
4
4. Using service tool T3880104, tighten the
3 2 swinging arm pivot bolt adjuster sleeve to 6
Nm.

5 1

cjrt

1. Side stand harness

2. Coolant overflow pipe
3. Rear wheel ABS sensor harness
4. Quick shifter electrical connector
5. Harness guides 2
6. Main harness

cjbc

1. Frame adjuster
2. T3880104 - Swinging Arm Adjuster Wrench

5. While supporting the swinging arm, remove

the swinging arm spindle and fully insert it
from the left hand side.
6. Fit the washer and a new swinging arm spindle
nut, tighten the nut to 110 Nm.
7. Refit the front sprocket cover and tighten to 9
Nm.

498 Thruxton R
 Rear Suspension

8. Refit the swinging arm pivot cover to the left 10. Refit the left and right hand heal guards and
hand side of the frame. tighten their fixings to 7 Nm.
9. Refit the left hand control plate and tighten its
fixings to 25 Nm. 2

2
3

cjsb

1. fixings
cjsa
2. Heal guard (left hand side)
1. Fixings
11. Refit the hose guide to the left hand side of
2. Control plate the swinging arm and tighten the new fixings
3. Cover to 3 Nm.

2
cjrv

1. Fixings
2. Harness guide
• If removed, refit the evaporative canister (see
Evaporative Canister (if fitted) - Installation,
page 439).
• Refit the rear suspension units (see Rear
Suspension Units - Installation, page 494).
• Refit the rear wheel (see Rear Wheel -
Installation, page 604).
• Lower the motorcycle to the ground and park it
on the side stand.
• Pump the rear brake pedal to position the rear
brake pads.

Thruxton R 499
Rear Suspension

This page intentionally left blank

500 Thruxton R
 22 Brakes
Table of Contents
Exploded View – Front Brake Master Cylinder, Caliper and Brake Disc ........................................................................... 505
Exploded View – Rear Brake Master Cylinder, Caliper and Brake Disc............................................................................. 506
Exploded View – ABS System................................................................................................................................................................ 507
Braking System Maintenance Safety Precautions ..................................................................................................................... 508
Brake Fluid Level Inspection .................................................................................................................................................................. 509
Changing Brake Fluid ................................................................................................................................................................................... 511
Brake Pads Wear............................................................................................................................................................................................ 511
Brake Wear Inspection ............................................................................................................................................................................... 512
Breaking-in New Brake Pads and Discs............................................................................................................................................. 512
Bleeding the Front Brakes, Renewing Brake Fluid........................................................................................................................ 513
Front Brake Pads - Removal................................................................................................................................................................... 516
Front Brake Pads - Inspection ............................................................................................................................................................... 517
Front Brake Pads - Installation.............................................................................................................................................................. 517
Front Brake Caliper - Removal............................................................................................................................................................... 519
Front Brake Caliper - Disassembly...................................................................................................................................................... 520
Front Brake Caliper - Inspection............................................................................................................................................................ 521
Front Brake Caliper - Assembly ............................................................................................................................................................. 521
Front Brake Caliper - Installation ......................................................................................................................................................... 522
Front Brake Disc - Wear ........................................................................................................................................................................... 522
Front Brake Disc - Removal .................................................................................................................................................................... 523
Front Brake Disc - Installation............................................................................................................................................................... 523
Front Brake Master Cylinder - Removal........................................................................................................................................... 524
Front Brake Master Cylinder - Disassembly ................................................................................................................................... 525
Front Brake Master Cylinder - Assembly ........................................................................................................................................ 526
Front Brake Master Cylinder - Installation...................................................................................................................................... 527
Bleeding the Rear Brakes, Renewing Brake Fluid ....................................................................................................................... 529
Rear Brake Pads - Removal ..................................................................................................................................................................... 531
Rear Brake Pads - Inspection ................................................................................................................................................................ 532
Rear Brake Pads - Installation............................................................................................................................................................... 532

Thruxton R 501
Brakes

Rear Brake Caliper - Removal ............................................................................................................................................................... 533

Rear Brake Caliper - Disassembly ....................................................................................................................................................... 534
Rear Brake Caliper - Inspection ........................................................................................................................................................... 534
Rear Brake Caliper - Assembly .............................................................................................................................................................. 535
Rear Brake Caliper - Installation.......................................................................................................................................................... 536
Rear Brake Disc - Wear............................................................................................................................................................................. 537
Rear Brake Disc - Removal...................................................................................................................................................................... 537
Rear Brake Disc - Installation ............................................................................................................................................................... 538
Rear Brake Master Cylinder - Removal ............................................................................................................................................ 538
Rear Brake Master Cylinder - Disassembly .................................................................................................................................... 540
Rear Brake Master Cylinder - Inspection ........................................................................................................................................ 540
Rear Brake Master Cylinder - Assembly ........................................................................................................................................... 541
Rear Brake Master Cylinder - Installation....................................................................................................................................... 542
Front ABS Wheel Speed Sensor - Removal .................................................................................................................................... 544
Front ABS Wheel Speed Sensor - Installation............................................................................................................................... 545
Air Gap Measurement ............................................................................................................................................................................... 545
Front ABS Pulser Ring - Removal ....................................................................................................................................................... 546
Front ABS Pulser Ring - Inspection ................................................................................................................................................... 546
Front ABS Pulser Ring - Installation.................................................................................................................................................. 547
Rear ABS Wheel Speed Sensor - Removal ...................................................................................................................................... 547
Rear ABS Wheel Speed Sensor - Installation ................................................................................................................................ 548
Rear ABS Pulser Ring - Removal......................................................................................................................................................... 549
Rear ABS Pulser Ring - Inspection..................................................................................................................................................... 549
Rear ABS Pulser Ring - Installation ................................................................................................................................................... 550
ABS Hydraulic Modulator/ECM - Removal ...................................................................................................................................... 550
ABS Hydraulic Modulator/ECM - Installation................................................................................................................................... 551
Anti-lock Brake System (ABS) ................................................................................................................................................................ 553
ABS System Circuit Tables ...................................................................................................................................................................... 556
ABS System Circuit Diagram................................................................................................................................................................... 557
System Diagnostics..................................................................................................................................................................................... 557
Triumph Diagnostic Software - ABS................................................................................................................................................... 558
Diagnostic Trouble Codes ........................................................................................................................................................................ 559
ABS Electrical Connectors....................................................................................................................................................................... 562
Further Diagnosis ....................................................................................................................................................................................... 563
ABS Warning Light ON (No DTCs Stored)......................................................................................................................................... 564
ABS Warning Light Does not Illuminate (No DTCs Stored) ...................................................................................................... 566
Front Wheel Sensor Open Circuit/Short Circuit ........................................................................................................................... 568
Rear Wheel Sensor Open Circuit/Short Circuit.............................................................................................................................. 572
Front Wheel Sensor Abnormal Input/Losing Contact................................................................................................................ 575

502 Thruxton R
 Brakes

Rear Wheel Sensor Abnormal Input/Losing Contact.................................................................................................................. 575

Front Wheel Pulser Ring Missing Teeth........................................................................................................................................... 576
Rear Wheel Pulser Ring Missing Teeth.............................................................................................................................................. 577
Front or Rear Input/Output solenoid Open/Short Circuit ....................................................................................................... 578
Incorrect Tyre Size Detected ................................................................................................................................................................. 580
Front or Rear Wheel Actuator (Hydraulic Control) Wheel Lock............................................................................................ 580
Motor – Lock; Motor Stuck OFF; Motor stuck ON......................................................................................................................... 582
Power Source Voltage Drop/Voltage Rise....................................................................................................................................... 584
CAN Fault......................................................................................................................................................................................................... 586
ABS ECM Internal Error............................................................................................................................................................................ 588
ABS Hydraulic Circuit Layout ................................................................................................................................................................ 589

Thruxton R 503
Brakes

504 Thruxton R
 Brakes

Exploded View – Front Brake Master Cylinder, Caliper and Brake Disc

6 Nm
6 Nm

1 Nm

8.5 Nm
5 Nm

8 Nm

1 Nm 55 Nm

6 Nm

22 Nm

Thruxton R 505
Brakes

Exploded View – Rear Brake Master Cylinder, Caliper and Brake Disc

5 Nm

5 Nm

18 Nm 5 Nm

22 Nm

5 Nm

22 Nm
18 Nm

506 Thruxton R
 Brakes

Exploded View – ABS System

25 Nm

25 Nm 25 Nm

9 Nm
25 Nm
5 Nm

8 Nm

25 Nm

3 Nm

25 Nm

25 Nm

25 Nm
25 Nm 25 Nm

9 Nm 9 Nm

9 Nm
9 Nm

Thruxton R 507
Brakes

Braking System Maintenance Safety

Warning
Precautions
may reduce the efficiency of the braking system
leading to loss of motorcycle control and an
Warning accident.
Brake fluid is hygroscopic which means it will Failure to change the brake fluid at the interval
absorb moisture from the air. The absorbed specified in the Scheduled Maintenance chart may
moisture will greatly reduce the boiling point of reduce braking efficiency resulting in loss of
the brake fluid causing a reduction in braking motorcycle control and an accident.
efficiency.
Replace brake fluid in line with the Scheduled
Maintenance chart. A dangerous riding condition Warning
could result if this important maintenance item is
Never use mineral-based grease in any part of the
neglected.
braking system or in any area where contact with
Do not spill brake fluid onto any area of the the braking system is possible. Mineral-based
bodywork as this will damage any painted or grease will damage the hydraulic seals in the
plastic surface. calipers and master cylinders. Damage caused by
Always use new brake fluid from a sealed contact with mineral-based grease may reduce
container and never use fluid from an unsealed braking efficiency resulting in loss of motorcycle
container or from one that has been previously control and an accident.
opened.
Do not mix different brands of fluid. Check for fluid
leakage around brake fittings, seals and joints. Warning
Check regularly for brake hose damage. Before installation, all internal brake components
FAILURE TO OBSERVE ANY OF THE ABOVE should be cleaned and lubricated with clean new
WARNINGS MAY REDUCE BRAKING EFFICIENCY DOT 4 brake fluid.
LEADING TO LOSS OF MOTORCYCLE CONTROL AND Never use solvents, petrol (gasoline), engine oil or
AN ACCIDENT. any other petroleum distillate on internal brake
components as this will cause deterioration of the
hydraulic seals in the calipers and master
Warning cylinders.
A dangerous riding condition leading to loss of
If there has been an appreciable drop in the level
motorcycle control and an accident could result if
of the fluid in either brake fluid reservoir, consult
this warning is ignored.
your authorised Triumph dealer 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 you must have your
authorised Triumph dealer take remedial action
before you attempt to ride the motorcycle again.
Failure to take remedial action may reduce braking
efficiency leading to loss of motorcycle control and
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

508 Thruxton R
 Brakes

Brake Fluid Level Inspection

Warning
A magnetised brake disc and/or a magnetised ABS Warning
pulser ring may cause problems with the ABS
sensor which will illuminate the ABS warning light Before starting work, ensure the motorcycle is
and disable the ABS. stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
To prevent these parts becoming magnetised, we
operator or damage to the motorcycle.
strongly recommend that magnets, and items that
contain magnets, must not be stored near or
placed on brake discs or ABS pulser rings. In accordance with the Scheduled Maintenance
chart, inspect the brake fluid level in the front and
This includes parts fitted to motorcycles, parts
rear master cylinder reservoirs.
removed during motorcycle service and new parts
in dealer stores.
Front Brake Fluid Reservoir
Examples of items that may contain magnets, are
1. The brake fluid level must be kept between the
listed below:
upper and lower level lines with the motorcycle
∙Alternator rotor on its side stand and the steering on full left
∙Magnetic fuel tank bags lock.
∙Audio speakers
∙Magnetic dial test indicator stand
1
∙Magnetic parts tray.
3
If the ABS is not functioning, the brake system will
continue to function as a non-ABS braking
system. Do not continue to ride for longer than is 2
necessary with the indicator light illuminated. Ride
with extreme caution when performing diagnostic
troubleshooting on a non-functioning ABS system.
In this situation braking too hard will cause the
wheels to lock resulting in loss of motorcycle
4
control and an accident.

jajc_2

1. Fixings
2. Reservoir cap
3. Upper level line
4. Lower level line

Front Brake Fluid Level Adjustment

1. Remove the two fixings.
2. Remove the reservoir cap and the diaphragm
seal.
3. Fill the reservoir to the upper level line using
new DOT 4 fluid from a sealed container.
4. Refit the reservoir cap and diaphragm seal
ensuring that the diaphragm seal is correctly
positioned between the cap and the reservoir
body.
5. Refit the two fixings and tighten to 1 Nm.

Thruxton R 509
Brakes

Rear Brake Fluid Reservoir 4. Refit the reservoir cap ensuring that the
diaphragm seal is correctly positioned between
1. Remove the right hand side panel (see Side
the cap and the reservoir body. Tighten the
Panels, page 637).
cap retaining screws to 1 Nm.
2. The brake fluid level must be kept between the
5. Refit the brake fluid reservoir to the relay
upper and lower level lines (reservoir held
bracket, and tighten the new fixing to 3 Nm.
horizontal).

1 2

2
1

citi_1
citi_1

1. Fixing
1. Upper level line
2. Brake fluid reservoir
2. Lower level line
6. Refit the right hand side panel (see Side
Rear Brake Fluid Level Adjustment Panels, page 637).
1. Remove and discard the fixing and detach the
rear brake fluid reservoir from the relay
bracket.

citi_1

1. Fixing
2. Brake fluid reservoir

2. Release the cap screws and remove the

reservoir cover noting the position of the
sealing diaphragm.
3. Fill the reservoir to the upper level line using
new DOT 4 fluid from a sealed container.

510 Thruxton R
 Brakes

Changing Brake Fluid Brake Pads Wear

Brake fluid must be changed every two calendar Front and rear brake pad wear is automatically
years, irrespective of the mileage the motorcycle compensated for and has no effect on brake lever
has covered in that time. or pedal action.

Thruxton R 511
Brakes

Brake Wear Inspection Breaking-in New Brake Pads and

In accordance with the Scheduled Maintenance Discs
chart, inspect the brake pads for wear. The After replacement brake discs and/or pads have
minimum thickness of lining material for any front been fitted to the motorcycle, we recommend a
or rear brake pad is 1.5 mm. If any pad has worn to period of careful breaking-in that will optimise the
the bottom of the groove in the pad centre, replace performance and longevity of the discs and pads.
all the brake pads on that wheel. The recommended distance for breaking in new
pads and discs is 200 miles (300 km).
After fitting new brake discs and/or pads avoid
1 extreme braking, ride with caution and allow for
greater braking distances during the breaking-in
period.
2

cbmz_1

1. Brake pads
2. Minimum thickness line

Warning
Do not replace individual brake pads; replace both
pads in the brake caliper. On the front where two
calipers are mounted on the same wheel, all the
pads in both calipers must be replaced
simultaneously. Replacing individual pads will
reduce braking efficiency and may cause loss of
motorcycle control and an accident.

512 Thruxton R
 Brakes

Bleeding the Front Brakes, Renewing 3. Attach a transparent tube to the bleed nipple.

Brake Fluid
1
Warning
Before starting work, ensure the motorcycle is 3
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 2
operator or damage to the motorcycle. 4

Note:
• The master cylinder should always be bled
last. Bleed each caliper in turn before bleeding
the master cylinder.
ceze_1

1. Note the original setting of the brake lever

adjuster in order that it can be returned to the 1. Bleed nipple
same position when the bleeding operation is 2. Spanner
complete. Turn the brake lever adjuster fully in. 3. Bleed tube
4. Container

1 4. Place the other end of the tube in a suitable

2 receptacle containing new brake fluid.
5. Turn the handlebars to bring the fluid reservoir
to a level position.

1
cggq_1

1. Brake lever
2. Adjusting screw

2. Remove the rubber cap from the bleed nipple

on the right hand caliper. 2
abdj_2

1. Front reservoir upper level

2. Front reservoir lower level
3. Screws

6. Remove the screws from the brake reservoir

cover.

Warning
Ensure absolute cleanliness when adding brake
fluid to the brake 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

Thruxton R 513
Brakes

16. Repeat the bleed procedure for the bleed

Warning nipple on the master cylinder. Tighten the
bleed nipple to 5 Nm.
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. 3 1
A dangerous riding condition leading to an 2
accident could result if this warning is ignored.

Caution 4

To prevent body damage, do not spill brake fluid

onto any area of the bodywork.

7. Carefully remove the reservoir cover taking

care not to spill any fluid.
8. Check the condition of the sealing diaphragm cexz_1

for the reservoir. Replace if necessary.

1. Bleed nipple
9. Release the bleed nipple.
2. Spanner
3. Bleed tube
Warning 4. Container
Use only DOT 4 specification brake fluid as listed in
17. When both calipers and the master cylinder
the general information section of this manual.
have been bled, ensure the brake lever
The use of brake fluids other than those DOT 4
operation has a firm resistive feel to it, does
fluids listed in the general information section may
not feel spongy and that the lever cannot be
reduce the efficiency of the braking system
pulled directly back to the handlebar. Take
leading to an accident.
remedial action as necessary.
Observe the brake fluid handling warnings given
18. Fill the reservoir to the upper level with new
earlier in this section of the manual.
DOT 4 fluid.
19. Refit the reservoir diaphragm and cover.
Note: Secure the cap with its screws. Tighten the
• During bleeding, do not allow the fluid level to screws to 1 Nm.
fall below the lower level mark in the
reservoir. If the level is allowed to fall below
this mark, air may enter the system and the
Warning
sequence of bleeding must be repeated. Always return the lever adjuster to the original
10. Slowly pull the brake lever to the handlebar setting. Operating the motorcycle with lever
and, holding the lever fully in, close the bleed settings which are unfamiliar may lead to loss of
nipple. control or an accident.
11. Repeat steps 9 and 10 until no more air
appears in the bleed tube. 20. Reset the brake lever adjuster to the original
setting.
12. When all air has been expelled from the
system, hold the lever in and close the bleed 21. Check that the brake operates correctly.
nipple. Tighten the nipple to 8 Nm. Rectify as necessary.

13. Fill the reservoir to the upper level with new

DOT 4 fluid. Warning
14. Remove the transparent bleed tube. It is dangerous to operate the motorcycle with
15. Repeat the bleeding procedure for the left defective brakes; you must have your authorised
hand caliper. Triumph dealer take remedial action before you
ride the motorcycle again. Failure to take remedial

514 Thruxton R
 Brakes

Warning Caution
action may result in reduced braking efficiency The ABS modulator must be allowed to cool
leading to loss of motorcycle control and an between bleeding operations. Always allow the
accident. ABS modulator to cool for 5 minutes before
starting the bleed procedure again. Failure to
22. Connect the Triumph diagnostic tool (see follow this instruction may result in damage to the
Triumph Diagnostic Software - ABS, page 558). ABS modulator.
23. Follow the on screen menu to ABS Diagnostics.
From the menu, select 'BLEED SYSTEM' (see
Triumph Diagnostic Software - ABS, page 558).
Note:
• On pressing the Start button, the diagnostic
software will send a command to the ABS ECM
to open the 2nd circuit solenoid.
• The front brake lever travel will increase as
ABS modulator solenoids are opened and will
then decrease as the solenoids are
automatically closed.
• Pressure must be applied to the front brake
lever before operating the bleed sequence on
the diagnostic tool. An assistant will be
required to open the bleed nipple while
pressure is applied to the brake lever.
24. Apply pressure to the front brake lever, press
the Start button to activate the bleed
sequence on the diagnostic tool, and with
assistance, release one of the bleed nipples.
25. Get an assistant to slowly pull the brake lever
to the handlebar.
26. With the lever held fully against the handlebar,
close the bleed nipple. Once the bleed nipple is
closed, release the brake lever.
27. Repeat steps 5 and 6 until no more air appears
in the bleed tube, maintaining the brake fluid
level between the upper and lower reservoir
levels whilst bleeding is being carried out.
28. The bleed sequence will run for a maximum of
90 seconds. Press the Stop button to end the
bleed sequence at any time. Once the bleed
sequence has completed the diagnostic tool
will display a message ABS system bleed
complete.
29. Repeat the above procedure as necessary
until all air is expelled from the system.
30. When all air has been expelled from the
system, apply pressure to the brake lever and
close the bleed nipple. Tighten the nipple to 8
Nm.
31. Repeat the brake bleed procedure as detailed
in steps 1 to 21.

Thruxton R 515
Brakes

Front Brake Pads - Removal 2. Release the brake pad retaining lug from its
mounting in the caliper and remove the brake
pad.
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

Warning
Do not allow a brake component to hang
unsupported on the brake hose or line.
Brake hoses or lines that are not supported may
become damaged or bent.
Bent or damaged brake hoses or lines lead to chay
reduced braking efficiency causing loss of
motorcycle control and an accident. 1. Brake pad retaining lug

3. Repeat for the other brake pad.

1. Remove the caliper mounting bolts and slide
Note:
the caliper off the disc.
• Note the position and orientation of the anti-
rattle spring for installation.
• Note that the arrow on the anti-rattle spring
is pointing in the same direction as the arrow
on the caliper.
2

1 2
1

chbg

1. Caliper mounting bolts

2. Caliper

chba

1. Arrow, anti-rattle spring

2. Arrow, front caliper

516 Thruxton R
 Brakes

Front Brake Pads - Inspection Front Brake Pads - Installation

1. Check the brake pad retainer, anti-rattle
spring and retaining pin. Renew any Warning
component which shows signs of damage or
corrosion. Never use mineral-based grease (such as lithium
or copper based grease) in any area where
2. Check the brake caliper body slides easily on
contact with the braking system hydraulic seals
the mounting bracket pins and check there is
and dust seals is possible. Mineral-based grease
no sign of leakage from the piston seals.
will damage the hydraulic seals and dust seals in
Rectify any problems before installing the
the calipers and master cylinders.
brake pads.
Damage caused by contact with mineral-based
3. Inspect the brake pads for wear (see Brake
grease may reduce braking efficiency resulting in
Wear Inspection, page 512).
loss of motorcycle control and an accident.

Warning
If fitting new proprietary brakes pads, check that
the carrier plate of the brake pad is at least 4.5
mm thick.
Fitting brake pads with the carrier plate less than
4.5 mm thick may result in brake failure due to the
possible loss of the brake pad as it wears.

Brake pads for this model supplied by Triumph will

have the carrier plate at least 4.5 mm thick. Always
have replacement brake pads supplied and fitted by
your Triumph dealer.

4.5 mm

1
2

cezg_1

1. Carrier plate
2. Brake pad

Thruxton R 517
Brakes

9. Secure the brake caliper with the fixings, do

Caution not fully tighten at this stage.

Never lever directly against the disc, caliper or the

pad lining material as this will damage these
components. Always use a levering tool made from
a soft material which will not cause damage to the
load bearing surfaces.
2
Brake fluid will be displaced as the caliper pistons
are compressed. To prevent body damage, ensure
that the displaced fluid does not come into
contact with any part of the bodywork.

1. If new pads are being installed, push the

pistons fully back into the caliper body. Keep 1
an eye on the fluid level in the reservoir whilst
retracting the pistons to prevent fluid spillage. chbg

2. Ensure that the anti-rattle plate position and 1. Caliper mounting fixings
orientation is as noted for removal.
2. Caliper
3. Fit one of the brake pad's retaining lugs into
its mounting in the caliper with its friction 10. Pump the brake lever to correctly position the
material surfaces facing the other side of the caliper pistons.
caliper. 11. Have an assistant apply the front brake, then
tighten the front brake caliper mounting
fixings to 55 Nm.
3 Note:
• When the brake caliper is fitted, there must be
a minimum gap of 0.3 mm between the caliper
and brake disc.
2
12. Using feeler gauges, measure the gap between
the front brake caliper and the brake disc, as
shown in the following illustration. Minimum
gap to be 0.3 mm.
1 Minimum Gap
0.3 mm Minimum Gap
chaz
0.3 mm
1. Anti-rattle spring
2. Retaining lug
1
3. Retaining lug mounting

4. Using finger pressure only, fit the pad's other

retaining lug into its mounting of the caliper.
2
Ensure that both retaining lugs are fully fitted
into their mountings.
5. Repeat steps 2 to 4 for the other brake pad.
6. Thoroughly clean the threaded fixing holes for cjtk

the front fork brake caliper fixings.

1. Front brake caliper
7. Position the caliper over the disc.
2. Front brake disc
8. Thoroughly clean the threaded part of the
fixing and smear the first four threads with a 13. If necessary, loosen the caliper fixings, apply
proprietary copper based grease. the front brake and tighten the front brake
caliper mounting fixings to 55 Nm.

518 Thruxton R
 Brakes

14. Repeat the removal, inspection and installation Front Brake Caliper - Removal
process for the other caliper.

Warning Warning
Before starting work, ensure the motorcycle is
Use only DOT 4 specification brake fluid as listed in stabilised and adequately supported. This will help
the general information section of this manual. prevent it from falling and causing injury to the
The use of brake fluids other than those DOT 4 operator or damage to the motorcycle.
fluids listed in the general information section may
reduce the efficiency of the braking system
leading to loss of motorcycle control and an
accident.
Caution
Observe the brake fluid handling warnings given To prevent paint damage, do not spill brake fluid
earlier in this section of the manual. onto any area of the bodywork. Spilled brake fluid
will damage paintwork.
15. Check the front brake fluid level and top up as
required with new DOT 4 fluid. Note:
16. Check for correct brake operation. Rectify as • Note the orientation of the brake hose on the
necessary. caliper for installation.
1. Disconnect the brake hose at the caliper and
Warning place the free end of the hose in a suitable
container to collect the brake fluid.
It is dangerous to operate the motorcycle with
defective brakes; you must have your authorised 2. Remove the front brake pads (see Front Brake
Triumph dealer take remedial action before you Pads - Removal, page 516).
ride the motorcycle again. Failure to take remedial
action may result in reduced braking efficiency
leading to loss of motorcycle control and an
accident.

Thruxton R 519
Brakes

Front Brake Caliper - Disassembly Note:

• The piston seals are slightly thicker than the
Warning dust seals.

To prevent injury, never place fingers or hands

inside the caliper opening when removing the
pistons. Always wear eye, hand and face
protection when using compressed air. Eye, face 1
and skin damage will result from direct contact
with compressed air.

2
Warning
Ensure the seal grooves in the caliper bores are
not damaged during the removal of the seals.
Damage to the seal grooves may allow brake fluid
to leak past the seals resulting in a dangerous 2
riding condition leading to loss of motorcycle chbc

control and an accident. 1. Piston seals

2. Dust seals
1. Cover the caliper opening with a clean heavy
cloth and using either compressed air or by 3. Check the pistons, caliper and mounting
reconnecting the master cylinder and pumping bracket for signs of damage, paying particular
the brake lever, remove the pistons one at a attention to the caliper bores and pistons. If
time. damage is present, renew the worn component
or the complete caliper assembly.
4
1 2
3

3 2
1

3
chbd

1. Dust seal
2. Piston seal
3. Pistons
4. Caliper

2. Extract the dust seals and piston seals, taking

care not to damage the caliper bores. Discard
the old seals, these must not be re-used.

520 Thruxton R
 Brakes

Front Brake Caliper - Inspection Front Brake Caliper - Assembly

Warning Warning
Always renew caliper seals and pistons after Never use mineral-based grease (such as lithium
removal from the caliper. An effective hydraulic or copper based grease) in any area where
seal can only be made if new components are contact with the braking system hydraulic seals
used. and dust seals is possible. Mineral-based grease
A dangerous riding condition leading to loss of will damage the hydraulic seals and dust seals in
control of the motorcycle or an accident could the calipers and master cylinders.
result if this warning is ignored. Damage caused by contact with mineral-based
grease may reduce braking efficiency resulting in
1. Check the pistons and caliper bores for loss of motorcycle control and an accident.
corrosion, scoring and damage. Renew as
necessary.
2. Inspect the brake pads for damage and wear Warning
beyond the service limit. Renew as necessary. 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 cause 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 result if
this warning is ignored.

If all components are serviceable, obtain a piston

seal kit and reassemble the caliper as follows:
1. Ensure all components are clean, then fit the
new seals to their grooves in the caliper bores.
2. Lubricate the fluid seals, caliper bore and the
outside of the pistons with clean DOT 4 brake
fluid.
3. Ease the pistons squarely back into the bores,
taking care not to displace the seals.

Thruxton R 521
Brakes

Front Brake Caliper - Installation Front Brake Disc - Wear

1. Remove the front wheel (see Front Wheel -
Removal, page 599). Warning
2. Temporarily fit the calipers to the forks.
Before starting work, ensure the motorcycle is
3. Connect the brake hoses to the calipers stabilised and adequately supported. This will help
incorporating new sealing washers on each prevent it from falling and causing injury to the
side of the hose connections. operator or damage to the motorcycle.
4. Ensure the orientation of the brake hose is as
noted for removal and tighten the union bolt Front Brake Disc Wear
to 25 Nm.
Front Brake Disc Thickness

Warning Standard 4.5 mm

Service limit 4.0 mm
Do not allow the calipers to hang on the brake
hoses as this may damage the hoses and could Brake Disc Run-out
lead to loss of motorcycle control and an accident.
Service limit 0.25 mm
5. Detach the calipers from the front forks and 1. Measure disc run out using an accurate dial
refit the wheel (see Front Wheel - Installation, gauge mounted on a surface plate.
page 601).
6. Fit the brake pads (see Front Brake Pads - 2
Installation, page 517). 1

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 system
leading to loss of motorcycle control and an
accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual. cjmo

1. Disc
7. Fill the master cylinder with new, DOT 4 brake 2. Dial gauge
fluid from a sealed container.
2. Replace any brake disc worn beyond the
8. Bleed the front brake line (see Bleeding the
service limit or exceeding the disc run-out
Front Brakes, Renewing Brake Fluid, page 513).
limit.
9. Check for correct brake operation.

Warning
It is dangerous to operate the motorcycle with
defective brakes; you must have your authorised
Triumph dealer take remedial action before you
ride the motorcycle again. Failure to take remedial
action may result in reduced braking efficiency
leading to loss of motorcycle control and an
accident.

522 Thruxton R
 Brakes

Front Brake Disc - Removal Front Brake Disc - Installation

Warning Warning
Before starting work, ensure the motorcycle is Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help stabilised and adequately supported. This will help
prevent it from falling and causing injury to the prevent it from falling and causing injury to the
operator or damage to the motorcycle. operator or damage to the motorcycle.

• Remove the front wheel (see Front Wheel - 1. Check the front brake damper for deterioration
Removal, page 599). and cracks, replace if necessary.
Note:
Warning • The ABS pulser ring is to be fitted to the left
To avoid wheel damage, always support the wheel hand brake disc.
as instructed below. A dangerous riding condition 2. Locate the brake discs and ABS pulser ring
leading to loss of motorcycle control and an (left hand side) to the wheel as noted during
accident could result if this warning is ignored. removal.
3. Fit new disc fixings and tighten to 22 Nm.
Caution 4. Refit the wheel (see Front Wheel - Installation,
page 601).
The fixings securing the left hand brake disc to 5. Check and, if necessary, adjust the air gap
the wheel also secures the ABS pulser ring. between the wheel speed sensor and the ABS
Note the orientation of the brake discs and the pulser ring (see Air Gap Measurement, page
ABS pulser ring fitted for installation. 545).
6. Check the operation of the front brake. Rectify
1. Support the wheel on blocks to avoid damage as necessary.
to the wheel centre and brake disc.
2. Remove and discard the brake disc fixings and Warning
remove the brake disc and the ABS pulser ring,
if fitted. It is dangerous to operate the motorcycle with
defective brakes; you must have your authorised
Triumph dealer take remedial action before you
attempt to ride the motorcycle again. Failure to
take remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
accident.

cjmn_1

1. Fixings
2. Brake disc (right hand side shown)

3. Repeat the steps for the other side.

Thruxton R 523
Brakes

Front Brake Master Cylinder - 2. On the back of the harness bracket, locate and
disconnect the front brake switch electrical
Removal connector from the main harness.

Warning
Before starting work, ensure the motorcycle is
2
stabilised and adequately supported. This will help
1
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

Caution
To prevent paint damage, do not spill brake fluid
onto any area of the bodywork. Spilled brake fluid
will damage paintwork.
cjcz_4
• Remove the headlight from the headlight bowl
(see Headlight and Daytime Running Light Bulb 1. Front brake switch electrical connector
Replacement, page 671). 2. Harness bracket
1. Release the fixings and detach the harness 3. Route the front brake switch harness out of
bracket from the headlight bowl. the headlight bowl to the front brake master
cylinder.
2 4. To drain the fluid from the master cylinder,
attach a tube to the front brake caliper bleed
nipple, loosen the nipple and operate the brake
lever until all fluid has been expelled into a
suitable container.
5. Release the fixing and detach brake fluid
reservoir bracket from the master cylinder.
6. Disconnect the brake fluid reservoir hose from
the master cylinder and remove the brake fluid
reservoir.
3 1
4
1
cjdt 2
1. Fixings
2. Harness bracket
3. Headlight bowl

Note:
• Note the routing of the front brake switch
harness for installation.

cjrz

1. Fixing
2. Bracket
3. Brake fluid reservoir hose
4. Brake fluid reservoir

524 Thruxton R
 Brakes

7. Disconnect the brake hose from the master Front Brake Master Cylinder -
cylinder and discard the two sealing washers.
Disassembly
8. Remove the pivot bolt and lock nut securing
the brake lever to the master cylinder. Remove The following items can be replaced on the front
the brake lever. brake master cylinder:
• Brake lever;
• Bleed screw;
2 • Brake light switch.

Brake Lever
1. Remove the lock nut from the brake lever pivot
bolt.
2. Remove the brake lever pivot bolt.
3. Release the brake lever from the master
cylinder assembly.

4 Bleed Screw
3 1. Remove the cover from the bleed screw.
1
cjry
Release the bleed screw and remove from the
1. Brake hose union master cylinder assembly.
2. Pivot bolt
3. Lock nut 1
4. Brake lever

9. Release the fixings, remove the clamp and the

master cylinder.
2

1. Bleed screw
2. Front brake master cylinder

2
cjrc_1

1. Fixings
2. Clamp

Thruxton R 525
Brakes

Brake Switch Front Brake Master Cylinder -

1. Pulling carefully on the brake switch housing, Assembly
remove the brake switch from the master
cylinder assembly.
Brake Lever
1. Locate the pin of the brake lever assembly into
the hole in the master cylinder dust seal,
ensuring the rubber seal correctly locates into
position.
2

2
1. Brake switch
3
2. Location holes
4

1. Front brake master cylinder

2. Dust seal
3. Brake lever pin
4. Brake lever

2. Line up the holes of the brake lever and

master cylinder, and insert the pivot bolt.
Tighten the pivot bolt to 1 Nm.
3. Fit the pivot bolt lock nut and tighten to 6 Nm.
4. Check lever operation and ensure the rubber
seal is still correctly seated.

526 Thruxton R
 Brakes

Bleed Screw Front Brake Master Cylinder -

1. Fit the bleed screw to the master cylinder and Installation
tighten to 5 Nm

Warning
1
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
2 operator or damage to the motorcycle.

Caution
To prevent paint damage, do not spill brake fluid
onto any area of the bodywork. Spilled brake fluid
will damage paintwork.

1. Locate the master cylinder to the handlebars

1. Bleed screw and position the clamp with the UP arrow
pointing upwards. Do not tighten the clamp
2. Front brake master cylinder fixings at this stage.
2. Fit the rubber cover to the bleed screw. 2. Align the split line of the master cylinder clamp
to the alignment mark on the upper surface of
Brake Switch the handlebar. Tighten the clamp fixings,
1. Position the brake switch to the master upper one first, to 8.5 Nm.
cylinder. Locate the brake switch in the
location holes and push firmly home.

1 3

1 2
cjrc

1. Alignment mark
2. UP arrow
1. Brake switch
3. Fixings
2. Location holes
3. Position the brake lever ensuring that the
pivot boss is correctly aligned to the master
cylinder push rod.
4. Fit and tighten the pivot bolt to 1 Nm, and the
lock nut to 6 Nm.

Thruxton R 527
Brakes

5. Connect the brake hose to the master cylinder 9. On the back of the harness bracket, locate and
incorporating new sealing washers to each connect the front brake switch electrical
side of the union. Tighten the union bolt to 25 connector to the main harness as noted for
Nm. removal.

2
2
1

4
3
cjry
1 cjcz_4

1. Brake hose union bolt 1. Front brake switch electrical connector

2. Pivot bolt 2. Harness bracket
3. Lock nut 10. Fit the harness bracket to the headlight bowl
4. Brake lever and tighten the fixings to 1.5 Nm.

6. Connect the brake fluid reservoir hose to the

master cylinder. 2
7. Fit the brake fluid reservoir bracket to the
master cylinder and tighten its fixing to 6 Nm.
4
1
2

3 1

cjdt

1. Fixings
3 2. Harness bracket
3. Headlight bowl
cjrz

1. Fixing Warning
2. Bracket
Use only DOT 4 specification brake fluid as listed in
3. Brake fluid reservoir hose the General Information section of this manual.
4. Brake fluid reservoir The use of brake fluids other than those DOT 4
fluids listed in the General Information section
8. Route the front brake switch harness to the
may reduce the efficiency of the braking system
headlight bowl as noted for removal.
leading to loss of motorcycle control and an
accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.

528 Thruxton R
 Brakes

Bleeding the Rear Brakes, Renewing

Caution
Brake Fluid
To prevent body damage, do not spill brake fluid
onto any area of the bodywork. Spilled brake fluid
will damage paintwork.
Warning
Before starting work, ensure the motorcycle is
11. Fill and bleed the front brakes (see Bleeding stabilised and adequately supported. This will help
the Front Brakes, Renewing Brake Fluid, page prevent it from falling and causing injury to the
513). operator or damage to the motorcycle.
12. Examine the system for correct operation and
fluid leaks. Rectify as necessary.
13. Check the operation of the front brake. Rectify
Caution
as necessary. To prevent paint damage, do not spill brake fluid
onto any area of the bodywork. Spilled brake fluid
Warning will damage paintwork.

It is dangerous to operate the motorcycle with 1. Remove the cap from the rear bleed nipple.
defective brakes; you must have your authorised
Triumph dealer take remedial action before you 2. Attach a transparent tube to the bleed nipple.
attempt to ride the motorcycle again. Failure to 3. Place the other end of the tube in a suitable
take remedial action may reduce braking efficiency receptacle containing new brake fluid.
leading to loss of motorcycle control and an
accident. 1

• Fit the headlight to the headlight bowl (see

Headlight and Daytime Running Light Bulb
Replacement, page 671).

cjff_1

1. Bleed nipple
2. Bleed tube

Warning
Ensure absolute cleanliness when adding brake
fluid to the brake 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 that 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.

Thruxton R 529
Brakes

12. Apply pressure to the rear brake pedal, press

Caution the Start button to activate the bleed
sequence on the diagnostic tool and release
To prevent paint damage, do not spill brake fluid the bleed nipple.
onto any area of the bodywork. Spilled brake fluid
will damage paintwork. 13. Slowly depress the brake pedal and, holding
the pedal fully down, close the bleed nipple.
Repeat until no more air appears in the bleed
4. Release the cap screws and remove the
tube, maintaining the brake fluid level between
reservoir cover noting the position of the
the upper and lower reservoir levels whilst
sealing diaphragm.
bleeding is being carried out.
5. Check the condition of the reservoir sealing
14. Repeat steps 12 and 13 until no more air
diaphragm. Replace if necessary.
appears in the bleed tube, maintaining the
6. Release the bleed nipple. brake fluid level between the upper and lower
reservoir levels whilst bleeding is being carried
Caution out.
15. The bleed sequence will run for a maximum of
During bleeding, do not allow the fluid level to fall 20 seconds. Press the Stop button to end the
below the lower level mark in the reservoir. If the bleed sequence at any time. Once the bleed
fluid level is allowed to fall below this mark, air may sequence has completed, the diagnostic tool
enter the system and the sequence of bleeding will display the message ABS system bleed
must be repeated. complete.

7. Get an assistant to slowly depress the brake

pedal and, holding the pedal fully down, close
Caution
the bleed nipple. The ABS module must be allowed to cool between
8. Repeat steps 6 and 7 until no more air appears bleeding operations. Always allow the ABS
in the bleed tube. modulator to cool for 5 minutes before starting
the bleed procedure again. Failure to follow this
9. When all air has been expelled from the
instruction may result in damage to the ABS
system, hold the pedal fully down and close
modulator.
the bleed nipple.
10. Connect the Triumph Diagnostic Interface (see 16. Repeat the above procedure a minimum of
System Diagnostics, page 557). twice or as necessary until all air is expelled
11. Follow the on screen menu to ABS Diagnostics. from the system.
From the menu, select BLEED SYSTEM (see 17. When all air has been expelled from the
System Diagnostics, page 557). system, apply pressure to the brake lever and
close the bleed nipple.
Caution 18. Disconnect the Triumph diagnostic Interface.
On pressing the Start button, the diagnostic 19. Repeat steps 6 and 7 until no more air appears
software will send a command to the ABS ECM to in the bleed tube.
open the 2nd circuit solenoid. 20. When all air has been expelled from the
When the ABS modulator 2nd circuit is activated system, apply pressure to the brake pedal and
by the bleed command, the rear brake pedal travel close the bleed nipple and tighten it to 8 Nm.
will increase as the ABS modulator solenoids are 21. Remove the bleed tube.
opened and will then decrease as the solenoids
are automatically closed. 22. Replace the bleed nipple cap.

Pressure must be applied to the rear brake pedal 23. Fill the reservoir to the upper level with new
before operating the bleed sequence on the DOT 4 fluid.
diagnostic tool. An assistant will be required to
open the bleed nipple while pressure is applied to Warning
the rear brake pedal.
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

530 Thruxton R
 Brakes

Rear Brake Pads - Removal

Warning
may reduce the efficiency of the braking system Warning
leading to loss of motorcycle control and an
accident. Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
Observe the brake fluid handling warnings given
prevent it from falling and causing injury to the
earlier in this section of the manual.
operator or damage to the motorcycle.

Caution 1. Remove the right hand side panel to gain

access to the rear brake fluid reservoir (see
To prevent paint damage, do not spill brake fluid Side Panels, page 637).
onto any area of the bodywork. Spilled brake fluid 2. Loosen the brake pad retaining pins.
will damage paintwork.
3. Remove the rear wheel (see Rear Wheel -
Removal, page 602).
24. When the caliper has been bled, ensure the
brake pedal operation has a firm resistive feel 4. Detach the brake caliper and anchor plate
to it, does not feel spongy and that the brake assembly from the swinging arm.
pedal does not have excessive movement. Take 5. Remove the brake pad retaining pins.
remedial action as necessary.
25. Refit the reservoir cap ensuring that the
diaphragm seal is correctly positioned between
the cap and the reservoir body. Tighten the
cap retaining screws to 1 Nm.
26. Check the operation of the rear brake. Rectify
as necessary.

Warning
It is dangerous to operate the motorcycle with
defective brakes; you must have your authorised
Triumph dealer take remedial action before you
attempt to ride the motorcycle again. Failure to
1
take remedial action may reduce braking efficiency cjsc

leading to loss of motorcycle control and an 1. Brake pad retaining pins

accident.
6. Remove the brake pads and the anti-rattle
spring.

cjsd

1. Brake pads
2. Anti-rattle spring

Thruxton R 531
Brakes

Rear Brake Pads - Inspection Rear Brake Pads - Installation

1. Check the friction material of each brake pad
for signs of contamination and measure its Warning
thickness. If the friction material of either pad
is contaminated or has worn beyond the Before starting work, ensure the motorcycle is
service limit, renew both pads as a set. stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
2
Warning
Never use mineral-based grease (such as lithium
or copper based grease) in any area where
contact with the braking system hydraulic seals
and dust seals is possible. Mineral-based grease
will damage the hydraulic seals and dust seals in
the calipers and master cylinders.
Damage caused by contact with mineral-based
1 grease may reduce braking efficiency resulting in
jafz_1 loss of motorcycle control and an accident.

1. Friction material thickness (service limit 1.5 mm)

2. Brake pads Caution
2. Check the anti-rattle spring and retaining pins. Brake fluid will be displaced as the caliper pistons
Renew any component which shows signs of are compressed. To prevent body damage, ensure
damage or corrosion. that the displaced fluid does not come into
3. Check the caliper body slides easily on the contact with any part of the bodywork or the rear
mounting bracket pins and check there is no wheel.
sign of leakage from the piston seals. Rectify
any problems before installing the brake pads. 1. If new pads are being installed, push the
pistons fully back into the caliper body. Keep
an eye on the fluid level in the reservoir whilst
retracting the pistons to prevent fluid spillage.
2. Install the anti-rattle spring into the caliper.

1. Anti-rattle spring

532 Thruxton R
 Brakes

Rear Brake Caliper - Removal

Warning
Do not apply more than a minimum coating of Warning
grease to the pad retaining pins. Excess grease
may contaminate the brake pads, hydraulic seals Before starting work, ensure the motorcycle is
and discs causing reduced braking efficiency and stabilised and adequately supported. This will help
an accident. prevent it from falling and causing injury to the
operator or damage to the motorcycle.
3. Lubricate the brake pad retaining pins with a
thin smear of proprietary high temperature 1. Release the fixing and detach the rear wheel
copper based grease. ABS sensor from the rear brake anchor plate.
Collect the shim.
4. Fit the brake pads into the caliper with their
friction material facing each other. Ensure 2. Disconnect the rear brake hose at the caliper
both pads are correctly located then align and place the free end of the hose into a
them with the caliper body and fit the suitable container to collect the brake fluid.
retaining pins. Discard the two sealing washers.
5. Fit the brake caliper and anchor assembly to 3. If the brake caliper is to be disassembled,
the swinging arm. loosen the two brake pad retaining pins.
6. Refit the rear wheel (see Rear Wheel -
Installation, page 604).
1
7. Pump the brake pedal to correctly position the
caliper pistons.
8. Check the brake fluid level and top up as
required with new DOT 4 fluid.
9. Check the operation of the rear brake. Rectify
as necessary. 2

Warning
4
Use only DOT 4 specification brake fluid as listed in
the General Information section of this manual.
3
The use of brake fluids other than those DOT 4 cjsc_1

fluids listed in the General Information section 1. ABS sensor

may reduce the efficiency of the braking system
2. Fixing
leading to loss of motorcycle control and an
accident. 3. Brake hose union
Observe the brake fluid handling warnings given 4. Brake pad retaining pins
earlier in this section of the manual. 4. Remove the rear wheel (see Rear Wheel -
Removal, page 602).

Warning 5. If the brake caliper is to be disassembled,

remove the brake pads and the anti-rattle
It is dangerous to operate the motorcycle with spring.
defective brakes; you must have your authorised
Triumph dealer take remedial action before you
attempt to ride the motorcycle again. Failure to
take remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
accident.

Thruxton R 533
Brakes

Rear Brake Caliper - Disassembly Rear Brake Caliper - Inspection

Warning Warning
To prevent injury, never place fingers or hands Always renew caliper seals and pistons after
inside the caliper opening when removing the removal from the caliper. An effective hydraulic
pistons. Always wear eye, hand and face seal can only be made if new components are
protection when using compressed air. Eye, face used.
and skin damage will result from direct contact A dangerous riding condition leading to loss of
with compressed air. control of the motorcycle or an accident could
result if this warning is ignored.
1. Separate the brake caliper and the mounting
bracket. 1. Check the pistons, caliper, mounting bracket
and mounting bracket sliding pin gaiters for
signs of damage, paying particular attention to
the caliper bores and pistons. If damage is
present, renew the worn component or the
1 complete caliper assembly.

cjsy

1. Mounting bracket

2. Cover the caliper opening with a clean, heavy

cloth and, using either compressed air or by
reconnecting the master cylinder and pumping
the rear brake pedal, eject both pistons from
the caliper at the same time.

Warning
Ensure the seal grooves in the caliper bores are
not damaged during the removal of the seals.
Damage to the seal grooves may allow brake fluid
to leak past the seals resulting in a dangerous
riding condition leading to loss of motorcycle
control and an accident.

3. Extract the dust seals and piston seals, taking

care not to damage the caliper bores.

534 Thruxton R
 Brakes

Rear Brake Caliper - Assembly bracket and caliper. Ensure the pin gaiters are
correctly located on both the bracket and
1. If all components are serviceable, obtain a caliper.
piston seal kit and reassemble the caliper as
follows:

Warning 2
1

Always renew caliper seals after removal of the

pistons. An effective hydraulic seal can only be
made if new seals are fitted.
A dangerous riding condition leading to an
accident could result if this warning is ignored.

Warning
Before installation, all internal brake components cjsy_1

should be cleaned and lubricated with clean new

DOT 4 brake fluid. 1. Sliding pins

Never use solvents, petrol (gasoline), engine oil, or 2. Sliding pin gaiters
any other petroleum distillate on internal brake
components as this will cause 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 result if
this warning is ignored

2. Ensure all components are clean, then fit the

new seals to their grooves in the caliper bores.
3. Lubricate the fluid seals, caliper bore and the
outside of the pistons with clean DOT 4 brake
fluid.
4. Ease the pistons squarely back into the bores,
taking care not to displace the seals.

Warning
Never use mineral based grease (such as lithium
or copper based grease) in any area where
contact with the braking system hydraulic seals
and dust seals is possible. Mineral based grease
will damage the hydraulic seals and dust seals in
the calipers and master cylinders. Damage caused
by contact with mineral based grease may reduce
braking efficiency resulting in an accident.

5. Lubricate the mounting bracket pins with

silicone based grease (such as T2022021
supplied by Triumph) then reassemble the

Thruxton R 535
Brakes

Rear Brake Caliper - Installation

Warning
Warning It is dangerous to operate the motorcycle with
defective brakes; you must have your authorised
Before starting work, ensure the motorcycle is Triumph dealer take remedial action before you
stabilised and adequately supported. This will help attempt to ride the motorcycle again. Failure to
prevent it from falling and causing injury to the take remedial action may reduce braking efficiency
operator or damage to the motorcycle. leading to loss of motorcycle control and an
accident.
1. If the caliper has been overhauled, install the
brake pads.
2. Position the rear brake anchor plate onto the
swinging arm.
3. Fit the rear wheel (see Rear Wheel -
Installation, page 604).
4. If loosened or removed, tighten the brake pad
retaining pins to 18 Nm.
5. Refit the rear wheel ABS sensor and its spacer
to the rear brake anchor plate. Check and, if
necessary, adjust the ABS sensor to pulser
ring air gap (see Air Gap Measurement, page
545). Then tighten the new fixing to 9 Nm.
6. Connect the brake hose to the caliper
incorporating new sealing washers on each
side of the brake hose union.
7. Tighten the brake hose union to 25 Nm.

cjsc_1
3

1. ABS sensor
2. Fixing
3. Brake hose union
4. Brake pad retaining pins

8. Bleed the rear brake (see Bleeding the Rear

Brakes, Renewing Brake Fluid, page 529).
9. Check the operation of the brake and carry out
a thorough leak check before riding the
motorcycle.

536 Thruxton R
 Brakes

Rear Brake Disc - Wear Rear Brake Disc - Removal

Wear Warning
Warning Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
Before starting work, ensure the motorcycle is prevent it from falling and causing injury to the
stabilised and adequately supported. This will help operator or damage to the motorcycle.
prevent it from falling and causing injury to the
operator or damage to the motorcycle. • Remove the rear wheel (see Rear Wheel -
Removal, page 602).
1. Replace any brake disc worn beyond the 1. Support the wheel on blocks to avoid damage
service limit or exceeding the disc run-out to the wheel centre.
limit.
2. Remove and discard the fixings and remove
Rear Disc Thickness the ABS pulser ring.
Standard 5.0 mm (standard) 3. Remove and discard the fixings and remove
the brake disc.
Service limit 4.5 mm (service limit)

Disc Run-out
Service limit 0.5 mm
4 1
Measure disc run-out using an accurate dial gauge
mounted on a surface plate.

2 cjfe_2

1. Fixings (ABS pulser ring)

2. ABS pulser ring
3. Fixing (rear brake disc)
1
4. Rear brake disc
cjfe_5

1. Brake disc (front wheel shown)

2. Dial gauge

Thruxton R 537
Brakes

Rear Brake Disc - Installation Rear Brake Master Cylinder -

1. Locate the brake disc to the wheel. Removal
2. Fit new fixings and tighten to 22 Nm.
3. Locate the ABS pulser ring to the rear brake Warning
disc.
Before starting work, ensure the motorcycle is
4. Fit new fixings and tighten to 5 Nm. stabilised and adequately supported. This will help
• Refit the rear wheel (see Rear Wheel - prevent it from falling and causing injury to the
Installation, page 604). operator or damage to the motorcycle.
• Check and, if necessary, adjust the air gap
between the wheel speed sensor and the ABS
ring (see Air Gap Measurement, page 545). Caution
• Check the operation of the rear brake. Rectify
To prevent paint damage, do not spill brake fluid
as necessary.
onto any area of the bodywork. Spilled brake fluid
will damage paintwork.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the front sprocket cover (see Front
Sprocket Cover - Removal, page 104).
1. Drain the fluid from the master cylinder by
bleeding the system at the rear brake caliper
until all fluid has been expelled.
2. Remove and discard the fixing and detach the
rear brake fluid reservoir from the relay
bracket.

citi_1

1. Fixing
2. Brake fluid reservoir

3. Disconnect the brake line from the rear master

cylinder. Discard the sealing washers.

Caution
Note the routing of the brake switch harness for
installation.

538 Thruxton R
 Brakes

4. Remove the fixing and detach the brake line P- 8. Slide the brake light switch forwards and
clip from the right hand control plate. detach it from its locating pin on the right
5. Remove the fixings and detach the right hand hand control plate.
control plate from the frame.

4 2 2
3

3
1

cjsh_1

cjsk 1. Fixing
1. Brake line union 2. Locating pin
2. Fixing (P-clip) 3. Brake light switch and bracket assembly
3. Fixings (right hand control plate) 9. Release the clip, and noting its orientation,
4. Brake line remove the brake fluid reservoir and hose from
the master cylinder.
6. Disconnect the rear brake switch from the
main harness and remove the brake master 10. Remove the clip and clevis pin at the lower end
cylinder and control plate assembly. of the brake pushrod.
Note:
• Note that the front fixing for the rear brake
master cylinder has a lock nut.
1 11. Remove the two fixings and detach the rear
brake master cylinder from the right hand
control plate. Discard the lock nut.

1 5

cjsf

1. Electrical connector

7. Remove the fixing securing the brake light

switch and bracket assembly to the right hand 4
control plate.
3
2
cjsi

1. Hose clip
2. Hose

Thruxton R 539
Brakes

Rear Brake Master Cylinder - Rear Brake Master Cylinder -

Disassembly Inspection
1. Remove the rubber boot from the cylinder and 1. Check the following for wear, damage, cracks
pushrod. or deterioration:
2. Remove the circlip retaining the pushrod to
the cylinder.

2 1 3
4
2

ccad

1. Cylinder bore
ccan_1
2. Dust cover
1. Rubber boot 3. Spring
2. Circlip 4. Piston
3. Remove the pushrod and piston set from the 2. Examine the pushrod for distortion and other
master cylinder bore noting the relative damage. Replace as necessary.
position of the seals and piston components.

2 1 2

ccao

1. Piston
2. Seals

540 Thruxton R
 Brakes

Rear Brake Master Cylinder - 4. Install the pushrod in the master cylinder,
compress the spring and retain the assembly
Assembly with a new circlip.

Warning
2
Never use mineral-based grease in any part of the
braking system or in any area where contact with
the braking system is possible. Mineral-based
grease will damage the hydraulic seals in the
calipers and master cylinders. A dangerous riding
condition leading to loss of motorcycle control and
an accident could result from use of mineral
grease. 1

1. Lubricate the piston and cylinder with new,

clean brake fluid.
ccan

Warning 1. Pushrod
Ensure that the piston and piston seal are fitted 2. Circlip
facing the same way as noted during removal. A 5. Refit the master cylinder boot.
dangerous riding condition leading to loss of
motorcycle control and an accident could result
from incorrect assembly of the master cylinder.

2. Fit the new piston and seal set into the master
cylinder.

2 1 2

ccao

1. Piston
2. Seals (in correct orientation)

3. Apply a small amount of brake grease to the

pushrod.

Thruxton R 541
Brakes

Rear Brake Master Cylinder - 6. Slide the brake switch assembly rearward until
it stops against the switch actuation plate.
Installation Tighten the fixing to 5 Nm.

Warning 2

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 spill brake fluid
onto any area of the bodywork. Spilled brake fluid
1
will damage paintwork.

cjsh_2
1. Fit the rear brake master cylinder to the right
hand control plate. Fit a new lock nut to the 1. Switch actuation plate
front fixing and tighten the fixings to 18 Nm. 2. Brake light switch (control plate removed for clarity)
2. Position the brake pedal to the pushrod, 7. Connect the rear brake switch to the main
engage the clevis and retain it with the clip. harness.
Ensure the clip is fitted as shown below:
3. Refit the brake fluid reservoir and its hose to
the master cylinder as noted on for removal.
Secure with the clip.
1

2 4

cjsf

1. Electrical connector
1
8. Attach the right hand control plate to the
3
cjsh frame and tighten the fixings to 25 Nm.
1. Brake switch bracket 9. With the brake switch harness routed as
noted for removal, attach the brake line P-clip
2. Lock nut
to the right hand control plate and tighten the
3. Cli[p fixing to 5 Nm.
4. Clip

4. Position the brake light switch and bracket

assembly to its locating pin on the right hand
control plate.
5. Fit a new fixing but do not fully tighten at this
stage.

542 Thruxton R
 Brakes

10. Incorporating new washers to either side of

the union, fit the brake line. Tighten the union Warning
bolt to 25 Nm.
take remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
4 2 accident.
3

1 • Check the operation of the rear brake and

brake light. Rectify as necessary.

cjsk

1. Brake line union

2. Fixing (P-clip)
3. Fixings (right hand control plate)
4. Brake line

11. Refit the front sprocket cover (see Front

Sprocket Cover - Installation, page 105).
12. Refit the rear brake fluid reservoir to the relay
bracket and tighten the new fixing to 3 Nm.

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 system
leading to loss of motorcycle control and an
accident. Observe the brake fluid handling
warnings given earlier in this section of the
manual.

• Reconnect the battery, positive (red) lead first

and tighten the battery terminals to 4.5 Nm.
• Fill and bleed the rear brake system (see
Bleeding the Rear Brakes, Renewing Brake
Fluid, page 529).
• Refit the seat (see Seat - Installation, page 636).

Warning
It is dangerous to operate the motorcycle with
defective brakes; you must have your authorised
Triumph dealer take remedial action before you
attempt to ride the motorcycle again. Failure to

Thruxton R 543
Brakes

Front ABS Wheel Speed Sensor - 4. Release the fixing securing the wheel speed
sensor to the fork leg.
Removal
5. Remove the wheel speed sensor and collect
the shim.
Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 3
operator or damage to the motorcycle.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
1
• Remove the headlight from the headlight bowl
(see Headlight - Removal, page 669).
1. Disconnect the wheel speed sensor electrical
3
connector from the main harness, located cjsl

inside the headlight. 1. Fixing

2. Clip (to brake line, one shown)
Caution 3. Front ABS wheel speed sensor
Note the routing of the wheel speed sensor
harness and it clips for installation.

2. Detach the front ABS wheel speed sensor

harness from the clips on the front brake line.
3. Route the front ABS wheel speed sensor
harness down to the front brake caliper.
Note:
• There is a shim between the wheel speed
sensor and the front fork leg.

544 Thruxton R
 Brakes

Front ABS Wheel Speed Sensor - Air Gap Measurement

Installation 1. Using feeler gauges, measure the air gap
between the wheel speed sensor and the
Warning pulser ring.

Before starting work, ensure the motorcycle is 3

stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle. 2
1
1. Position the wheel speed sensor and shim to
the fork leg, as noted for removal. Fit the fixing
and tighten to 9 Nm.
2. Secure the wheel speed sensor harness to the 4
brake hose clips.
3. Route the harness as noted for removal and
connect the wheel speed sensor electrical cdhj_1

0.40 mm to 1.20 mm
connector to the main harness.
4. Fit the regulator/rectifier to the lower yoke
1. ABS sensor (front sensor shown)
and tighten the fixings to 4 Nm.
2. Shim
5. Refit the headlight to the headlight bowl (see
Headlight - Installation, page 670). 3. Pulser ring

6. The air gap between the wheel speed sensor 4. Fixing

and the pulser ring must be between 0.4 mm 2. Rotate the wheel and repeat the measurement
and 1.2 mm. Check, and if necessary, adjust the in several places to ensure the pulser ring is
air gap (see Air Gap Measurement, page 545). not distorted or bent. Renew a damaged
• Reconnect the battery, positive (red) lead first pulser ring.
(see Battery - Installation, page 658) and
3. Adjust the air gap using the correct shim to
tighten the terminals to 4.5 Nm.
achieve an air gap between 0.40 mm and 1.20
• Refit the seat (see Seat - Installation, page 636). mm.
4. Shims are available in the following sizes:
• shims - 0.5 mm, 1.0 mm, 1.5 mm and 2.0 mm.
5. If necessary, remove the wheel speed sensor,
fit the correct thickness shim and refit the
wheel speed sensor and tighten the fixing to 9
Nm.
6. Repeat the air gap measurement. Readjust as
necessary.

Thruxton R 545
Brakes

Front ABS Pulser Ring - Removal Front ABS Pulser Ring - Inspection
Note: 1. Check the pulser ring for damaged, missing or
cracked teeth or distortion. Renew the pulser
• The front ABS pulser ring is mounted on the
ring as necessary.
left hand brake disc.
1. Remove front brake disc and pulser ring (see
Front Brake Disc - Removal, page 523).

546 Thruxton R
 Brakes

Front ABS Pulser Ring - Installation Rear ABS Wheel Speed Sensor -
1. Fit the front brake disc and ABS pulser ring Removal
(see Front Brake Disc - Installation, page 523).
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.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the left hand side panel (see Side
Panels, page 637).
Note:
• Note the location of the shim for the ABS
wheel speed sensor for installation.
1. Release the fixing and detach the wheel speed
sensor from the rear brake caliper carrier.
Collect the shim.

cjsc_2

1. Fixing
2. Rear ABS wheel speed sensor

2. Remove the rear wheel (see Rear Wheel -

Removal, page 602).
3. If fitted, remove the evaporative canister (see
Evaporative Canister (if fitted) - Removal, page
438).

Thruxton R 547
Brakes

4. Detach the ABS sensor cable and brake hose Rear ABS Wheel Speed Sensor -
from their cable guide on the left hand side of
the swinging arm. Installation
1. Connect the wheel speed sensor electrical
connector to the main harness.
2. Route and secure the ABS wheel speed sensor
harness to its retaining clips as noted for
2 removal.
3. Refit the left hand side panel (see Side Panels,
page 637).
4. Attach the ABS sensor cable and brake hose to
their cable guide on the left hand side of the
swinging arm.

1
cjrv_1

2
1. Brake hose
2. Harness guide

Caution
Note the routing of the wheel speed sensor
harness and it clips for installation.

5. Disconnect the rear wheel ABS sensor from 1

the main harness and detach from the airbox. cjrv_1

1. Brake hose
2. Harness guide

5. If removed, refit the evaporative canister (see

1 Evaporative Canister (if fitted) - Installation,
page 439).
6. Refit the rear wheel (see Rear Wheel -
Installation, page 604
7. Position the wheel speed sensor and shim to
2
the brake caliper carrier, as noted for removal.
Fit the fixing and tighten to 9 Nm.
8. The air gap between the wheel speed sensor
ring and the sensor must be between 0.40 mm
cjqd
and 1.20 mm. Check, and if necessary, adjust
the air gap (see Air Gap Measurement, page
1. ABS sensor harness connector 545).
2. ABS sensor connector • Reconnect the battery, positive (red) lead first
6. Route the sensor harness to the rear caliper (see Battery - Installation, page 658) and
and remove rear ABS wheel speed sensor. tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

548 Thruxton R
 Brakes

Rear ABS Pulser Ring - Removal Rear ABS Pulser Ring - Inspection
• Remove the rear wheel (see Rear Wheel - 1. Check the pulser ring for damaged, missing or
Removal, page 602). cracked teeth or distortion. Renew the pulser
1. Remove and discard the five fixings and ring as necessary.
remove the pulser ring.

cjfe_3

1. Fixings (ABS pulser ring)

2. ABS pulser ring

Thruxton R 549
Brakes

Rear ABS Pulser Ring - Installation ABS Hydraulic Modulator/ECM -

1. Locate the pulser ring on the brake disc, fit Removal
new fixings and tighten to 5 Nm.
2. Refit the rear wheel (see Rear Wheel - Warning
Installation, page 604).
Before starting work, ensure the motorcycle is
3. Check and, if necessary, adjust the air gap
stabilised and adequately supported. This will help
between the wheel speed sensor and the ABS
prevent it from falling and causing injury to the
pulser ring (see Air Gap Measurement, page
operator or damage to the motorcycle.
545).

Caution
To prevent paint damage, do not spill brake fluid
onto any area of the bodywork. Spilled brake fluid
will damage paintwork.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Drain the brake fluid from the front master
cylinder by bleeding the system at the front
caliper until all fluid has been expelled (see
Bleeding the Front Brakes, Renewing Brake
Fluid, page 513).
• Drain the fluid from the rear master cylinder by
bleeding the system at the rear caliper until all
fluid has been expelled (see Bleeding the Rear
Brakes, Renewing Brake Fluid, page 529).
1. Remove the swinging arm (see Swinging Arm -
Removal, page 494).
2. Remove the alternator regulator/rectifier (see
Alternator Regulator/Rectifier - Removal, page
694).

Caution
When loosening the ABS modulator brake line
unions, hold the ABS modulator.
Note the position of the four brake lines on the
ABS modulator for installation.

3. Disconnect the ABS modulator multiplug (see

ABS Electrical Connectors, page 562).
4. Remove the four brake line unions and discard
the sealing washers.

550 Thruxton R
 Brakes

5. Remove the two fixings shown in the following ABS Hydraulic Modulator/ECM -
illustration and remove the ABS modulator.
Discard the fixings. Installation
2
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
1 3
To prevent paint damage, do not spill brake fluid
onto any area of the bodywork. Spilled brake fluid
will damage paintwork.
cjsg
4
1. If removed, fit the anti-rotation moulding and
1. ABS modulator harness tighten the new fixing to 5 Nm.
2. Brake line unions
2
3. Fixing (ABS modulator to bracket)
4. Fixing (ABS modulator bracket to frame)

6. If necessary, release the fixing and remove the

anti-rotation moulding from the ABS
modulator. Discard the fixing.
2

cjeh

1. Fixing
2. Anti-rotation moulding
1
2. Position the ABS modulator onto its bracket.
Fit new fixings and tighten to 9 Nm.
3. Connect the ABS modulator multiplug (see ABS
cjeh
Electrical Connectors, page 562).
1. Fixing
2. Anti-rotation moulding

Thruxton R 551
Brakes

4. Incorporating new washers to either side of

the unions, fit the brake lines to the ABS
modulator as noted for removal. Tighten the
brake line unions to 25 Nm.

1 3

cjsg
4
1. ABS modulator harness
2. Brake line unions
3. Fixing (ABS modulator to bracket)
4. Fixing (ABS modulator bracket to frame)

5. Refit the alternator regulator/rectifier (see

Alternator Regulator/Rectifier - Installation,
page 695).
6. Fit the swinging arm (see Swinging Arm -
Installation, page 498).
7. Reconnect the battery, positive (red) lead first
and tighten the battery terminals to 4.5 Nm.
8. Refit the seat (see Seat - Installation, page
636).

Warning
It is dangerous to operate the motorcycle with
defective brakes; you must have your authorised
Triumph Dealer take remedial action. Failure to
take remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
accident.

• Bleed the front brakes (see Bleeding the Front

Brakes, Renewing Brake Fluid, page 513).
• Bleed the rear brakes (see Bleeding the Rear
Brakes, Renewing Brake Fluid, page 529).
• Check the operation of the front and rear
brakes. Rectify as necessary.

552 Thruxton R
 Brakes

Anti-lock Brake System (ABS)

System Description
The Thruxton R is fitted with an electronic anti-lock brake system which is designed to prevent the wheels
from locking or skidding by reducing braking effort to the front or rear brake caliper as required.
The system consists of a hydraulic modulator and ECM assembly mounted to a bracket beneath the
swinging arm, a front wheel speed sensor mounted to the front fork, and a rear wheel speed sensor
mounted to the rear brake caliper carrier.
Both front and rear wheels have a pulser ring mounted on to the wheel hub.
The front and rear master cylinders are connected via lines to the modulator and from the modulator the
lines connect to the brake calipers.
The front and rear brake circuits operate as separate systems. The front and rear brakes are not connected
in any way inside the modulator.
The modulator ECM continuously calculates the front and rear wheel speeds, and from these inputs the
ECM calculates the estimated motorcycle speed, wheel deceleration/acceleration, the wheel speed difference
and the wheel slip (skid) rate. This is calculated by comparing the calculated wheel speeds with the
calculated vehicle speed, so that if one wheel speed deviates significantly from the other two readings, this
wheel is calculated to be slipping (skidding).
Under braking, if the modulator detects that either wheel is slipping, due to the brake force exceeding the
available traction between the tyre and road surface (the wheel will begin to slip or 'skid'), the ECM very
rapidly releases and reapplies the brake pressure to prevent the wheel from slipping.
This is felt through the brake pedal or lever as a rapid 'pulsing'.
If the rider reduces braking effort, or traction increases (so that traction exceeds braking force, the wheel
will rotate once more) the wheel will no longer lock up. The ABS system will detect this and stop controlling
brake pressure, and return to its monitoring state.
The system has a self diagnostic function built-in which monitors the fail safe relay, solenoid valves, motor
relay, wheel speed sensors, power supply and ground, as well as internal ECM functions. In the event of a
malfunction being detected, the ECM will illuminate the ABS warning light, and store a diagnostic trouble
code in the system memory. This stored data can then be recovered using the Triumph Diagnostic Tool
which is mandatory for all Triumph dealers. In this way, precise diagnosis of a fault can be made and the
fault quickly rectified.
Under normal operation, the ABS warning light will flash on and off after the ignition is switched on and
until the vehicle speed exceeds 6 mph (10 km/h). The ABS performs a self check and if no faults are found
the light is extinguished. If a trouble code is stored the ABS warning light will stay illuminated and the ABS
will not function, however the brakes will operate normally. If the ABS warning light does not extinguish, or
illuminates whilst the motorcycle is being ridden, refer to the ABS system diagnostics (see System
Diagnostics, page 557).

Thruxton R 553
Brakes

Component Locations

Front Brake
Switch Rear Brake Rear Pulser
ABS
Switch Modulator Ring

Front Wheel
Front Rear Wheel
Speed Sensor
Pulser Ring Speed Sensor

554 Thruxton R
 Brakes

This page intentionally left blank

Thruxton R 555
Brakes

ABS System Circuit Tables ABS ECM Connector Pin Numbering

Key To Wiring Circuit Diagram 9 8 2 1

Key Item Description
1 ABS Modulator
2 Fuse Box
3 Front Brake Switch
4 Rear Brake Switch
5 Engine Electronic Control Module -
Connector A
6 Rear Light Sub-harness Connector
18 17 11 10
7 Front Wheel Speed Sensor chzl

8 Rear Wheel Speed Sensor The above illustration shows the pin numbering
system used in the ABS circuit diagram.
9 Instruments Connector As viewed on the mating face with the ABS ECM (as
10 Diagnostic Connector per the illustration), pins are numbered from right
to left with number one in the top right hand
corner.
Key To Wiring Colour Codes
Code Wiring Colour
B Black
U Blue
N Brown
G Green
S Slate/Grey
O Orange
K Pink
R Red
P Purple
W White
Y Yellow
LG Light Green
LU Light Blue

556 Thruxton R
 Brakes

ABS System Circuit Diagram

2
7 5
1
10A 25A

R 18

G 4

3 1 GP GP 7

4 1 GP

5 A07 BY

6 3 GP

1 UW 17
7 2 BG 8

1 UR 15
8 2 BG 6

9 21 BU 3

1 OG 13

7 BG 5
10
6 R 2

14 U 11

B 10

System Diagnostics The software is connected, via an interface cable,

to the motorcycle using a dedicated diagnostic plug
The ABS system has an on-board diagnostics
situated beneath the seat. By using a dedicated
feature which allows service technicians to retrieve
plug, no electrical connectors associated with the
stored data from the ECM using Triumph diagnostic
system are disturbed, reducing potential connector
software. Full details of the Triumph diagnostic
damage.
software operation and how to interpret the
results are given in the Triumph Diagnostic Tool
User Guide.

Thruxton R 557
Brakes

The software allows the user to retrieve data Triumph Diagnostic Software - ABS
associated with the system sensors and actuators,
Described on the following pages is the range of
test various component functions, read build data
information which can be retrieved from the ECM’s
and make minor adjustments to the set-up of the
memory and the adjustments which can be
system. The data and tests available are described
performed using the Triumph diagnostic software.
on the following pages.
The tables indicate which tests are performed by
Diagnostic Tool Connection the on-board system and what information can be
retrieved by the Triumph diagnostic software.
Diagnostic Trouble Codes Note:
Diagnostic trouble codes (DTCs) are logged in the • Full details of how to operate the software
ABS ECM memory when there is a confirmed fault can be found in the Triumph Diagnostic Tool
in the system. User Guide, which can be downloaded by
The codes are reported to the Triumph Diagnostic authorised Triumph dealers from
Tool as a four digit code. [Link].

Build Data
The Build Data screen will display the following
information:
Function Examined
ECM type
ECM ID number
Software version number

Current Data
The Current Data screen will display the following
information:
Function Examined Result Reported (Scale)
Front wheel speed km/h
Rear wheel speed km/h
Brake switch status On/Off
ABS warning light On/Off
status

Bleed System
Using the Triumph diagnostic tool, it is possible to
bleed the ABS modulator of trapped air. This is
necessary when the hydraulic brake system has
been dismantled, or the ABS modulator renewed.

558 Thruxton R
 Brakes

Diagnostic Trouble Codes

Diagnostic Trouble Codes (DTCs) 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 tool.
The system will log the diagnostic trouble codes listed below:

Diagnostic Trouble Codes

Dependant on the DTC stored, the ABS ECM will act in one of two ways:
1. Inhibit ABS operation immediately, irrespective of the ABS operating mode;
or
2. Allow the ABS operation to complete before inhibiting the ABS.
Once the ABS ECM has inhibited ABS function, the ECM will act in one of three ways:
1. Allow the ABS to resume operation if the fault clears;
or
2. Allow ABS operation after an ignition cycle if the fault clears;
or
3. Inhibit the ABS function until the fault is rectified and the DTC erased.
The ABS system will act on the DTC stored according to the table:
Note:
• ABS is Active means that the ABS system is completing an ABS manoeuvre.

Thruxton R 559
Brakes

Fault Description ABS warning ABS operation ABS continues to ABS will resume operation if
light is inhibited operate when fault clears (DTC still stored
illuminated when fault is fault is logged for 40 cycles)
when fault is logged (Only when ABS
logged is Active. When
ABS is no longer
active, operation
is inhibited)
Front Wheel Sensor Open Yes Yes No
Circuit/Short Circuit DTC stored for 40 cycles
Front Wheel Sensor Yes Yes Yes Yes, if after ignition cycle,
Abnormal Input/Losing no fault is detected. DTC
Contact remains stored - for 40
cycles
Rear Wheel Sensor Open Yes Yes No
Circuit/Short Circuit
Rear Wheel Sensor Yes Yes Yes Yes, if after ignition cycle,
Abnormal Input/Losing no fault is detected. DTC
Contact remains stored - for 40
cycles
Front Wheel Pulser Gear Yes Yes Yes Yes, if after ignition cycle,
Missing Teeth no fault is detected for 1
second and speed
exceeds 30 km/h. DTC
remains stored - for 40
cycles
Rear Wheel Pulser Gear Yes Yes Yes Yes, if after ignition cycle,
Missing Teeth no fault is detected for 1
second and speed
exceeds 30 km/h. DTC
remains stored - for 40
cycles
Front Wheel Input Solenoid Yes Yes No
Open/Short Circuit
Front Wheel Output Yes Yes No
Solenoid Open/Short
Circuit
Rear Wheel Input Solenoid Yes Yes No
Open/Short Circuit
Rear Wheel Output Yes Yes No
Solenoid Open/Short
Circuit
Front Wheel Actuator Yes Yes Yes Yes, if after ignition cycle,
(Hydraulic Control) Wheel no fault is detected. DTC
Lock remains stored
Rear Wheel Actuator Yes Yes Yes Yes, if after ignition cycle,
(Hydraulic Control) Wheel no fault is detected. DTC
Lock remains stored
Motor - Lock Yes Yes No
Motor - Stuck OFF Yes Yes No

560 Thruxton R
 Brakes

Fault Description ABS warning ABS operation ABS continues to ABS will resume operation if
light is inhibited operate when fault clears (DTC still stored
illuminated when fault is fault is logged for 40 cycles)
when fault is logged (Only when ABS
logged is Active. When
ABS is no longer
active, operation
is inhibited)
Motor - Stuck ON Yes Yes No
Solenoid Relay - Stuck Yes Yes No
OFF/ON
Power Source Voltage Yes, Light will Yes Yes, if voltage rises above
Drop extinguish if a preset threshold for
fault clears more than 10 seconds
Power Source Voltage Rise Yes, Light will Yes Yes, if voltage drops below
extinguish if a preset threshold for
fault clears more than 10 seconds
Different Tyre Diameter Yes Yes No
Abnormal ECU Yes Yes No

Thruxton R 561
Brakes

ABS Electrical Connectors Disconnection of ABS ECM Connector

Before beginning any diagnosis, the following
connector related information should be noted: Caution
Note: When disconnecting a connector, never pull
• A major cause of hidden electrical faults can directly on the wires as this may result in cable
be traced to faulty electrical connectors. and connector damage.
For example:
• Dirty/corroded terminals
• Damp terminals
Caution
• Broken or bent cable pins within multiplugs. Never disconnect the ABS ECM when the ignition
For example, the ABS electronic control module switch is in the ON position as this may cause
(ABS ECM) relies on the supply of accurate multiple fault codes to be logged in the ECM
information to enable it to monitor and control the memory.
brake system. One dirty terminal will cause an Always disconnect an ECM after disconnecting the
excessive voltage drop resulting in an incorrect battery negative (black) lead first.
signal to the ECM.
If, when carrying out fault diagnosis, a fault Reconnection of the ABS ECM Connector
appears to clear by simply disconnecting and
reconnecting an electrical plug, examine each
disconnected plug for the following. Caution
Damage to the connector pins may result if an
Before Disconnection: attempt to fit the connectors incorrectly is made.
• If testing with a voltmeter, the voltage across a
connector should be virtually battery Volts
(unless a resistor is fitted in the circuit). If there
is a noticeable change, suspect faulty/dirty
connections.

When Disconnecting a Connector:

• Check for a security device that must be
released before the connector can be separated
e.g. barb, hook and eye etc.

When Inspecting a Connector:

• Check that the individual pins have not been
bent.
• Check for dampness/dirt/corrosion.
• Check cables for security.
• Check cable pin joints for damage.

When Connecting a Connector:

• Ensure there is no dirt around the connector/
seal.
• Push together squarely to ensure terminals are
not bent or incorrectly located.
• Push the two halves together positively.

562 Thruxton R
 Brakes

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.

Warning
If the ABS is not functioning, the brake system will
continue to function as a non-ABS braking
system. Do not continue to ride for longer than is
necessary with the indicator light illuminated. Ride
with extreme caution when performing diagnostic
troubleshooting on a non-functioning ABS system.
In this situation braking too hard will cause the
wheels to lock resulting in loss of motorcycle
control and an accident.

3. Ride the motorcycle at a road speed in excess

of 30 km/h. If the DTC is repeated, proceed to
the relevant pinpoint test.
4. If the DTC is not repeated, this indicates the
DTC may have been stored due to external
influences such as bad road surfaces or
electrical interference.

After Completion of Pinpoint Tests:

1. Delete the stored DTCs.
2. Switch the ignition OFF and ON.
3. Ride the motorcycle at a road speed in excess
of 30 km/h. If the DTC is repeated, proceed to
the relevant pinpoint test.
4. If a DTC is stored, there is a further fault. Read
the stored DTC and refer to the relevant
pinpoint test.

Thruxton R 563
Brakes

ABS Warning Light ON (No DTCs Stored)

Fault Code Possible cause Action
ABS Warning Light ON (No DTCs ABS Ignition supply fuse/circuit Ensure ABS ECM connector is
Stored) fault secure.
ABS Warning light circuit fault Disconnect ABS ECM connector
and proceed to pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ABS ECM connector pin 4 and Faulty Rectify fault, proceed to test 5
ground pin 10
2 Check cable continuity of the ABS Voltage greater Proceed to test 3
ignition supply circuit: With the than 10 V
ignition 'ON', check voltage between:
Voltage less than Locate and rectify wiring fault, proceed
- ABS ECM connector pin 4 and 10 V to test 5
ground pin 10
3 Check cable continuity of the ABS Voltage greater Proceed to test 4
warning light circuit: than 1.5 V
Check voltage between: Voltage less than Locate and rectify fault, proceed to test
- ABS ECM connector pin 3 and 1.5 V 5
ground pin 10
4 Check cable continuity of the ABS ABS warning light Proceed to test 5
warning light circuit: - Short ABS ECM 'OFF'
connector pin 3 and ground pin 10
ABS warning light Locate and rectify fault, proceed to test
together:
'ON' 5
Turn ignition 'ON'
5 Reconnect ABS ECM harness, clear OK Action complete - quit test
fault code and test ABS to verify fault
Fault still present Contact Triumph service
cleared.

564 Thruxton R
 Brakes

Circuit Diagram

1 4 9 4 3 2 1
8

5 8 18 17 11 10

G
7 5
Fuse Box

Ignition Switch

R 18

G 4

21 BU 3
Instruments

10

ABS Control Module

1 12

13 24

21

Thruxton R 565
Brakes

ABS Warning Light Does not Illuminate (No DTCs Stored)

Fault Code Possible cause Action
ABS Warning Light OFF (No DTCs Warning light circuit fault Ensure ABS ECM connector is
Stored) ABS ECM ground circuit fault secure.
Ensure ABS ECM ground
connection is secure.
Disconnect ABS ECM connector
and proceed to pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check the ABS warning light circuit OK Proceed to test 2
and ignition fuses in the fuse box
Faulty Rectify fault, proceed to test 6
(fuse 7 and 5:
2 Check cable and terminal integrity: OK Proceed to test 3
- ABS ECM connector pin 4 and Faulty Replace fuse, proceed to test 6
ground pin 10
3 Check cable for short to voltage: With 0V Proceed to test 4
ignition 'OFF', check voltage between:
Above 3 V Locate and rectify wiring fault, proceed
- ABS ECM connector pin 4 and to test 6
ground
4 Check cable for short to ground: With Voltage greater Proceed to test 5
ignition 'ON', check the ABS warning than 1.5 V
light circuit voltage between:
Voltage less than Locate and rectify fault, proceed to test
- ABS ECM connector pin 3 and 1.5 V 6
ground
5 Check cable for continuity: ABS ECM OK Proceed to test 6
connector pin 10 and ground:
Faulty Locate and rectify fault, proceed to test
6
6 Reconnect ABS ECM harness, clear OK Action complete - quit test
fault code and test ABS to verify fault
Fault still present Contact Triumph service
cleared.

566 Thruxton R
 Brakes

Circuit Diagram

1 4 9 4 3 2 1
8

5 8 18 17 11 10

G
7 5
Fuse Box

Ignition Switch

R 18

G 4

21 BU 3
Instruments

10

ABS Control Module

1 12

13 24

21

Thruxton R 567
Brakes

Front Wheel Sensor Open Circuit/Short Circuit

Fault Code Possible cause Action
C1611 Front wheel sensor short circuit Ensure ABS ECM connector is
to ground or open circuit secure.
Ensure wheel speed sensor
connector is secure.
Disconnect ABS ECM connector
and proceed to pinpoint test 1:

568 Thruxton R
 Brakes

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ABS ECM connector pin 17 and ABS Faulty Rectify fault, proceed to test 9
ECM connector pin 8
2 Check cable for short circuit: OK Proceed to test 4
- ABS ECM connector pin 8 and Short circuit Proceed to test 3
ground
3 Disconnect the front wheel speed OK Replace the wheel speed sensor,
sensor connector. Check cable for proceed to test 9
short circuit:
Short circuit Locate and rectify wiring harness fault,
- Wheel speed sensor connector pin 2 proceed to test 9
(motorcycle harness side) and ground
4 Check cable for short circuit: OK Proceed to test 6
- ABS ECM connector pin 17 and Short circuit Proceed to test 5
ground
5 Check cable for short circuit: OK Replace the wheel speed sensor,
- Wheel speed sensor connector pin 1 proceed to test 9
(motorcycle harness side) and ground Short circuit Locate and rectify wiring harness fault,
proceed to test 9
6 Check cable continuity: OK Proceed to test 7
- ABS ECM connector pin 8 and wheel Open circuit Locate and rectify wiring harness fault,
speed sensor connector pin 2 proceed to test 9
(motorcycle harness side)
7 Check cable continuity: OK Proceed to test 8
- ABS ECM connector pin 17 and wheel Open circuit Locate and rectify wiring harness fault,
speed sensor connector pin 1 proceed to test 9
(motorcycle harness side)
8 Reconnect the front wheel speed 1.8 mA to 16.8 mA Proceed to test 9
sensor connector. Check the wheel
Faulty Replace the wheel speed sensor,
speed sensor operation:
proceed to test 9
- Connect a suitable voltage supply
between 10 V and 16 V between ABS
ECM connector pin 8 (positive) and pin
17 (negative), and measure the
current consumption of the wheel
speed sensor
9 Reconnect ABS ECM harness, clear OK Action complete - quit test
fault code and test ABS to verify fault
Fault still present Contact Triumph service
cleared.

Circuit Diagram
Wheel speed sensor current consumption data under typical conditions:
Supply Voltage Min Typical Max
10 - 16 V 5.9 mA 7.5 mA 16.8 mA

Thruxton R 569
Brakes

9 8 2 1

18 17 11 10

1 UW 17
Front Wheel ABS Control
Speed Sensor 2 BG 8 Module

1 2

570 Thruxton R
 Brakes

This page intentionally left blank

Thruxton R 571
Brakes

Rear Wheel Sensor Open Circuit/Short Circuit

Fault Code Possible cause Action
C1613 Rear wheel sensor short circuit Ensure ABS ECM connector is
to ground or open circuit secure.
Ensure wheel speed sensor
connector is secure.
Disconnect ABS ECM connector
and proceed to pinpoint test 1:

572 Thruxton R
 Brakes

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ABS ECM connector pin 6 and ABS Faulty Rectify fault, proceed to test 9
ECM connector pin 15
2 Check cable for short circuit: OK Proceed to test 4
- ABS ECM connector pin 6 and Short circuit Proceed to test 3
ground
3 Disconnect the rear wheel speed OK Replace the wheel speed sensor,
sensor connector. Check cable for proceed to test 9
short circuit:
Short circuit Locate and rectify wiring harness fault,
- Wheel speed sensor connector pin 6 proceed to test 9
(motorcycle harness side) and ground
4 Check cable for short circuit: OK Proceed to test 6
- ABS ECM connector pin 15 and Short circuit Proceed to test 5
ground
5 Check cable for short circuit: OK Replace the wheel speed sensor,
- Wheel speed sensor connector pin 1 proceed to test 9
(motorcycle harness side) and ground Short circuit Locate and rectify wiring harness fault,
proceed to test 9
6 Check cable continuity: OK Proceed to test 7
- ABS ECM connector pin 6 and wheel Open circuit Locate and rectify wiring harness fault,
speed sensor connector pin 2 proceed to test 9
(motorcycle harness side)
7 Check cable continuity: OK Proceed to test 8
- ABS ECM connector pin 15 and wheel Open circuit Locate and rectify wiring harness fault,
speed sensor connector pin 1 proceed to test 9
(motorcycle harness side)
8 Reconnect the rear wheel speed 1.8 mA to 16.8 mA Proceed to test 9
sensor connector. Check the wheel
Faulty Replace the wheel speed sensor,
speed sensor operation:
proceed to test 9
- Connect a suitable voltage supply
between 10 V and 16 V between ABS
ECM connector pin 6 (positive) and pin
15 (negative), and measure the
current consumption of the wheel
speed sensor
9 Reconnect ABS ECM harness, clear OK Action complete - quit test
fault code and test ABS to verify fault
Fault still present Contact Triumph service
cleared.

Circuit Diagram
Wheel speed sensor current consumption data under typical conditions:
Supply Voltage Min Typical Max
10 - 16 V 5.9 mA 7.5 mA 16.8 mA

Thruxton R 573
Brakes

9 2 1
8 6

18 17 15 11 10

1 UR 15
Rear Wheel ABS Control
Speed Sensor 2 BG 6 Module

1 2

574 Thruxton R
 Brakes

Front Wheel Sensor Abnormal Input/Losing Contact

Fault Code Possible cause Action
C1612 Front wheel sensor incorrect or Ensure ABS ECM connector is
missing signal secure.
Incorrect wheel speed sensor air Ensure wheel speed sensor
gap connector is secure.
Damaged or dirty pulser ring Proceed to pinpoint test 1:
Loose or incorrectly installed
wheel speed sensor

Pinpoint Tests
Test Result Action
1 Measure the air gap of the front OK Proceed to test 2
wheel speed sensor between the
Faulty Rectify the fault and proceed to test 5
sensor and the pulser ring:
- Air gap between 0.40 mm and 1.20
mm
2 Check the pulser ring for damage or OK Proceed to test 3
contamination by road grime or
Faulty Clean or replace the ABS pulser ring,
ferrous metal filings
proceed to test 5
3 Check the wheel speed sensors for OK Proceed to test 4
correct installation, and the fixings
Faulty Rectify the fault and proceed to test 5
for correct torque
4 Check the wheel speed sensor circuit OK Proceed to test 5
(see Front Wheel Sensor Open Circuit/
Faulty Rectify the fault and proceed to test 5
Short Circuit, page 568)
5 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

Rear Wheel Sensor Abnormal Input/Losing Contact

Fault Code Possible cause Action
C1614 Rear wheel sensor incorrect or Ensure ABS ECM connector is
missing signal secure.
Incorrect wheel speed sensor air Proceed to pinpoint test 1:
gap
Damaged or dirty pulser ring
Loose or incorrectly installed
wheel speed sensor

Thruxton R 575
Brakes

Pinpoint Tests
Test Result Action
1 Measure the air gap of the rear wheel OK Proceed to test 2
speed sensor between the sensor and
Faulty Rectify the fault and proceed to test 5
the pulser ring:
- Air gap between 0.40 mm and 1.20
mm
2 Check the pulser ring for damage or OK Proceed to test 3
contamination by road grime or
Faulty Clean or replace the ABS pulser ring,
ferrous metal filings
proceed to test 5
3 Check the wheel speed sensors for OK Proceed to test 4
correct installation, and the fixings
Faulty Rectify the fault and proceed to test 5
for correct torque
4 Check the wheel speed sensor circuit OK Proceed to test 5
(see Rear Wheel Sensor Open Circuit/
Faulty Rectify the fault and proceed to test 5
Short Circuit, page 572)
5 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

Front Wheel Pulser Ring Missing Teeth

Fault Code Possible cause Action
C1621 Front wheel pulser ring missing Ensure ABS ECM connector is
teeth secure.
Damaged or dirty pulser ring Proceed to pinpoint test 1:
Loose or incorrectly installed
wheel speed sensor
Damaged/incorrect wheels

Pinpoint Tests
Test Result Action
1 Measure the air gap of the front OK Proceed to test 2
wheel speed sensor between the
Faulty Rectify the fault and proceed to test 5
sensor and the pulser ring:
- Air gap between 0.40 mm and 1.20
mm
2 Check the pulser ring for damage or OK Proceed to test 3
contamination by road grime or
Faulty Clean or replace the ABS pulser ring,
ferrous metal filings
proceed to test 5
3 Check the wheel speed sensors for OK Proceed to test 4
correct installation, and the fixings
Faulty Rectify the fault and proceed to test 5
for correct torque
4 Check the motorcycle wheel for OK Proceed to test 5
damage/incorrect size
Faulty Rectify the fault and proceed to test 5
5 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

576 Thruxton R
 Brakes

Rear Wheel Pulser Ring Missing Teeth

Fault Code Possible cause Action
C1623 Rear wheel pulser ring missing Ensure ABS ECM connector is
teeth secure.
Damaged or dirty pulser ring Proceed to pinpoint test 1:
Loose or incorrectly installed
wheel speed sensor
Damaged/incorrect wheels

Pinpoint Tests
Test Result Action
1 Measure the air gap of the rear wheel OK Proceed to test 2
speed sensor between the sensor and
Faulty Rectify the fault and proceed to test 5
the pulser ring:
- Air gap between 0.40 mm and 1.20
mm
2 Check the pulser ring for damage or OK Proceed to test 3
contamination by road grime or
Faulty Clean or replace the ABS pulser ring,
ferrous metal filings
proceed to test 5
3 Check the wheel speed sensors for OK Proceed to test 4
correct installation, and the fixings
Faulty Rectify the fault and proceed to test 5
for correct torque
4 Check the motorcycle wheel for OK Proceed to test 5
damage/incorrect size
Faulty Rectify the fault and proceed to test 5
5 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

Thruxton R 577
Brakes

Front or Rear Input/Output solenoid Open/Short Circuit

Fault Code Possible cause Action
C1631 Front wheel input solenoid short Ensure ABS ECM connector is
circuit to ground or open circuit secure.
C1632 Front wheel output solenoid Disconnect ABS ECM connector
short circuit to ground or open and proceed to pinpoint test 1:
circuit
C1633 Rear wheel input solenoid short
circuit to ground or open circuit
C1634 Rear wheel output solenoid short
circuit to ground or open circuit
C1635 Master cylinder isolation valve
short circuit to ground or open
circuit
C1636 Low pressure feed valve short
circuit to ground or open circuit
C1654 Solenoid relay does not operate
or operates continually

Pinpoint Tests
Test Result Action
1 Check the ABS main fuse in the fuse OK Proceed to test 3
box (fuse 5):
Faulty Proceed to test 2
2 Check cable and terminal integrity: OK Replace fuse, proceed to test 5
- ABS ECM connector pin 18 and Faulty Rectify fault, replace fuse, proceed to
ground pin 10 test 5
3 Check cable continuity: With ignition Voltage greater Proceed to test 4
'ON', check voltage between: than 11 V
- ABS ECM connector pin 18 and Voltage less than Locate and rectify fault, proceed to test
ground pin 10 11 V 5
4 Check cable for continuity: OK Proceed to test 5
- ABS ECM connector pin 10 and Faulty Locate and rectify fault, proceed to test
ground 5
5 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

578 Thruxton R
 Brakes

Circuit Diagram

1 4 9 4 2 1
8

5 8 18 17 11 10

G
7 5 Fuse Box

Ignition
Switch
R 18

G 4

10

ABS
Control
Module

Thruxton R 579
Brakes

Incorrect Tyre Size Detected

Fault Code Possible cause Action
C1671 Incorrect tyre size detected Ensure ABS ECM connector is
Incorrect tyre pressures secure.

Incorrect wheel speed sensor air Proceed to pinpoint test 1:

gap
Damaged or dirty pulser ring

Pinpoint Tests
Test Result Action
1 Check for installation of wheels and OK Proceed to test 2
tyres of the correct size
Faulty Rectify fault, proceed to test 5
2 Check the tyre pressures OK Proceed to test 3
Faulty Rectify fault, proceed to test 5
3 Check the pulser rings for damage or OK Proceed to test 4
contamination by road grime or
Faulty Clean or replace the ABS pulser ring,
ferrous metal filings
proceed to test 5
4 Measure the air gap of the wheel OK Proceed to test 5
speed sensors between the sensor
Faulty Rectify the fault and proceed to test 5
and the pulser ring:
- Air gap between 0.40 mm to 1.20
mm
5 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

Front or Rear Wheel Actuator (Hydraulic Control) Wheel Lock

Fault Code Possible cause Action
C1641; Front Wheel Actuator (Hydraulic Ensure ABS ECM connector is
Control) Wheel Lock secure.
Binding brake Proceed to pinpoint test 1:
Incorrect Wheel speed sensor air
gap
Loose or incorrectly installed
wheel speed sensor
C1643 Rear Wheel Actuator (Hydraulic
Control) Wheel Lock
Binding brake
Incorrect Wheel speed sensor air
gap
Loose or incorrectly installed
wheel speed sensor

580 Thruxton R
 Brakes

Pinpoint Tests
Test Result Action
1 Check the relevant wheel for brake OK Proceed to test 2
bind caused by caliper or master
Faulty Rectify the fault and proceed to test 4
cylinder faults, or other mechanical
causes
2 Measure the air gap of the wheel OK Proceed to test 3
speed sensor between the sensor and
Faulty Rectify the fault and proceed to test 4
the pulser ring:
- Air gap between 0.40 mm to 1.20
mm
3 Check the wheel speed sensors for OK Proceed to test 4
correct installation, and the fixings
Faulty Rectify the fault and proceed to test 4
for correct torque
4 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

Thruxton R 581
Brakes

Motor – Lock; Motor Stuck OFF; Motor stuck ON

Fault Code Possible cause Action
C1651 Motor - Circuit fault Ensure ABS ECM connector is
secure.
C1652 Motor - Does not run
Turn the ignition 'ON'.
C1653 Motor - Runs continually
Proceed to pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check the ABS main fuse in the fuse OK Proceed to test 2
box (fuse 5)
Faulty Replace fuse and proceed to test 5
2 Check the motor function: OK Proceed to test 3
Check that with the motorcycle Motor runs Contact Triumph service
stationary and the ABS ECM continually
modulator connected, the motor does
not operate
3 Check cable continuity: With ignition Voltage greater Proceed to test 4
'ON', check voltage between: than 11 V
- ABS ECM connector pin 18 and Voltage less than Locate and rectify wiring fault, proceed
ground pin 10 11 V to test 5
4 Check cable for continuity: OK Proceed to test 5
- ABS ECM connector pin 10 and Faulty Locate and rectify fault, proceed to test
ground 5
5 Reconnect ABS ECM harness, clear OK Action complete - quit test
fault code and test ABS to verify fault
Fault still present Contact Triumph service
cleared.

582 Thruxton R
 Brakes

Circuit Diagram

1 4 9 4 2 1
8

5 8 18 17 11 10

G
7 5 Fuse Box

Ignition
Switch
R 18

G 4

10

ABS
Control
Module

Thruxton R 583
Brakes

Power Source Voltage Drop/Voltage Rise

Fault Code Possible cause Action
C1661; Power source voltage too low Ensure ABS ECM connector is
secure.
C1662 Power source voltage too high
Disconnect ABS ECM connector
and proceed to pinpoint test 1:

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Proceed to test 2
- ABS ECM connector pin 4 and Faulty Rectify fault, proceed to test 5
ground pin 10
2 Check the cable for continuity: OK Proceed to test 3
- ABS ECM connector pin 10 and Faulty Rectify wiring harness fault, proceed to
ground test 5
3 Check battery voltage: With ignition Voltage greater Proceed to test 4
'ON', check the voltage between: than 11 V
- ABS ECM connector pin 4 and Voltage less than Locate and rectify fault, proceed to test
ground pin 10 11 V 5
4 Check battery voltage: Reconnect ABS Voltage between 11 Proceed to test 5
ECM connector and start the engine, V and 16 V
check the voltage between:
Voltage greater Check the battery charging circuit.
- Battery positive (red) terminal and than 16 V Locate and rectify fault, proceed to test
negative (black) terminal 5
5 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

584 Thruxton R
 Brakes

Circuit Diagram

1 4 9 4 3 2 1
8

5 8 18 17 11 10

G
7 5
Fuse Box

Ignition Switch

R 18

G 4

21 BU 3
Instruments

10

ABS Control Module

1 12

13 24

21

Thruxton R 585
Brakes

CAN Fault
Fault Code Possible cause Action
C1682 CAN fault - lost communication Ensure ABS ECM connector is
with engine ECM secure.
C1683 CAN fault - lost communication Proceed to pinpoint test 1:
with instrument panel
C1684 CAN fault - all communication
lost

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect instruments and proceed to
- ABS ECM connector pin 2 test 2

- ABS ECM connector pin 11 Faulty Rectify fault, proceed to test 5

2 Check the cable for continuity: OK Proceed to test 3

- ABS ECM pin 2 to ground Short circuit Rectify wiring harness fault, proceed to
- ABS ECM pin 11 to ground test 5

3 Check cable continuity: OK Proceed to test 4

- ABS ECM pin 2 to ECM pin A33 Open circuit Rectify wiring harness fault, proceed to
- ABS ECM pin 11 to ECM pin A34 test 5
- ABS ECM pin 2 to Instruments pin 9
- ABS ECM pin 11 to Instruments pin 10
- ABS ECM pin 2 to Diagnostic
connector pin 6
- ABS ECM pin 11 to Diagnostic
connector pin 14
- ABS ECM pin 2 to Immobiliser
module pin 6
- ABS ECM pin 11 to Immobiliser
module pin 1
4 Check cable for short circuit: OK Proceed to test 5
- ABS ECM pin 2 to ABS ECM pin 11 Short circuit Rectify wiring harness fault, proceed to
test 5
5 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

586 Thruxton R
 Brakes

Circuit Diagram
Engine Electronic
Controll Module -
Connector A

12 1
24 13
36 34 33 25

Engine Electronic 3 1

Control Module
A33 A34 6 4

9 10
1 12
R U
13 24

R U R U R U R U R U

9 10 2 11 6 14 6 1 3 4

Instruments ABS Control Diagnostic Immobiliser Bluetooth® Module

Module Connector Connector

9 2 1 1 6 8
8
5 1
18 17 11 10
9 11 16 10 6

Thruxton R 587
Brakes

ABS ECM Internal Error

Fault Code Possible cause Action
C1681 ABS ECM internal error Ensure ABS ECM connector is
Incorrect wheel speed sensor air secure.
gap Proceed to pinpoint test 1:
Damaged or dirty pulser ring
Loose or incorrectly installed
wheel speed sensor

Pinpoint Tests
Test Result Action
1 Measure the air gap of the wheel OK Proceed to test 1
speed sensors between the sensor
Faulty Rectify the fault and proceed to test 4
and the pulser ring:
- Air gap between 0.40 mm to 1.20
mm
2 Check the pulser rings for damage or OK Proceed to test 2
contamination by road grime or
Faulty Clean or replace the ABS pulser ring,
ferrous metal filings
proceed to test 4
3 Check the wheel speed sensors for OK Proceed to test 4
correct installation, and the fixings
Faulty Rectify the fault and proceed to test 4
for correct torque
4 Clear fault code and test ABS to OK Action complete - quit test
verify fault cleared.
Fault still present Contact Triumph service

588 Thruxton R
 Brakes

ABS Hydraulic Circuit Layout

D
B

E 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 ABS Modulator

D. Rear Brake Circuit from ABS

Modulator to Rear Caliper

E. ABS Modulator

Thruxton R 589
Brakes

This page intentionally left blank

590 Thruxton R
 23 Wheels And Tyres
Table of Contents
Exploded View – Front Wheel ............................................................................................................................................................... 593
Exploded View – Rear Wheel and Cush Drive ............................................................................................................................... 594
Tyres .................................................................................................................................................................................................................. 595
Tyre Inflation Pressures........................................................................................................................................................................... 595
Minimum Recommended Tread Depth .............................................................................................................................................. 596
Important Tyre Information.................................................................................................................................................................... 597
Tyre Wear/Wheel Inspection ................................................................................................................................................................. 598
Front Wheel - Removal............................................................................................................................................................................. 599
Front Wheel - Inspection......................................................................................................................................................................... 600
Front Wheel - Installation ........................................................................................................................................................................ 601
Rear Wheel - Removal .............................................................................................................................................................................. 602
Rear Wheel - Inspection .......................................................................................................................................................................... 603
Rear Wheel - Installation......................................................................................................................................................................... 604
Front and Rear Wheel Bearings - Removal.................................................................................................................................... 605
Inspection - Bearings................................................................................................................................................................................ 606
Front and Rear Wheel Bearings - Installation.............................................................................................................................. 606

Thruxton R 591
Wheels And Tyres

592 Thruxton R
 Wheels And Tyres

Exploded View – Front Wheel

65 Nm

Thruxton R 593
Wheels And Tyres

Exploded View – Rear Wheel and Cush Drive

30 Nm

55 Nm

110 Nm

594 Thruxton R
 Wheels And Tyres

Tyres Tyre Inflation Pressures

Warning
Warning Incorrect tyre inflation will cause abnormal tread
Inner tubes must only be used on motorcycles wear and instability problems that may lead to
fitted with spoked wheels. loss of control and an accident.
Some brands of approved tyres marked Underinflation may result in the tyre slipping on,
'TUBELESS' may be suitable for use with an inner or coming off the rim. Overinflation will cause
tube. Where this is the case, the tyre wall may be instability and accelerated tread wear.
marked with text permitting the fitment of an Both conditions are dangerous as they may cause
inner tube (see illustration below). loss of control leading to an accident.
All tyres approved for this model by Triumph are
suitable for use with an inner tube. Correct inflation pressure will provide maximum
For the correct inner tube and tyre, a list of stability, rider comfort and tyre life. Always check
approved tyres specific to this model is available tyre pressures before riding when the tyres are
from your authorised Triumph dealer, or on the cold. Check tyre pressures daily and adjust if
internet at [Link]. necessary. See the Specification section for details
of the correct inflation pressures.
Use of a tyre not approved for use with an inner
tube may result in loss of tyre pressure leading to
loss of motorcycle control and an accident.

ON
TUB
FIT E TY
A T PE
UB RIM
E

Typical Tyre Marking - Tubeless Tyre Suitable For Use

With An Inner Tube

Thruxton R 595
Wheels And Tyres

Minimum Recommended Tread Depth

In accordance with the periodic maintenance chart,
Warning
measure the depth of the tread with a depth Operation with excessively worn tyres is
gauge, and replace any tyre that has worn to, or hazardous and will adversely affect traction,
beyond the minimum allowable tread depth stability and handling which may lead to loss of
specified in the table below: control and an accident.
Under 0.08 in (2 mm) When tubeless tyres become punctured, leakage is
80 mph often very slow. Always inspect tyres very closely
(130 km/h) for punctures. Check the tyres for cuts, embedded
nails or other sharp objects. Operation with
Over Rear 0.12 in punctured or damaged tyres will adversely affect
80 mph (3 mm) motorcycle stability and handling which may lead
(130 km/h) Front 0.08 in to loss of control or an accident.
(2 mm) Check the rims for dents or deformation.
Operation with damaged or defective wheels or
Warning tyres is dangerous and loss of motorcycle control
or an accident could result.
This Triumph motorcycle must not be operated Always consult your authorised Triumph dealer for
above the legal road speed limit except in tyre replacement, or for a safety inspection of the
authorised closed course conditions. tyres.

Warning
Only operate this Triumph motorcycle at high
speed in closed course, on-road competition or on
closed course racetracks. High-speed operation
should only then be attempted by riders who have
been instructed in the techniques necessary for
high-speed riding and are familiar with the
motorcycle’s characteristics in all conditions. High
speed operation in any other circumstances is
dangerous and will lead to loss of motorcycle
control and an accident.

596 Thruxton R
 Wheels And Tyres

Important Tyre Information

All Triumph motorcycles are carefully and
Warning
extensively tested in a range of riding conditions to If a tyre or inner tube sustains a puncture, the
ensure that the most effective tyre combinations tyre and inner tube must be replaced together.
are approved for use on each model. It is essential Failure to replace a punctured tyre and inner tube
that approved tyre combinations are used when together, or operation with a repaired tyre or
purchasing replacement tyres as the use of non- inner tube can lead to instability, loss of
approved tyres or approved tyres in non-approved motorcycle control or an accident.
combinations may lead to motorcycle instability. A
If tyre or inner tube damage is suspected, such as
list of approved tyres specific to this model is
after striking the kerb, ask your authorised
available from your authorised Triumph dealer, or
Triumph dealer to inspect the tyre both internally
on the internet at [Link].
and externally and to also inspect the inner tube.
Remember, tyre damage may not always be visible
Warning from the outside. Operation of the motorcycle with
damaged tyres could lead to loss of motorcycle
The ABS computer operates by comparing the control and an accident.
relative speed of the front and rear wheels. Use of
non-recommended tyres can affect wheel speed When replacing a 'TUBE-TYPE' tyre on a spoked
and cause the ABS function not to operate, wheel, always inspect the rim tape (rim protection
potentially leading to loss of motorcycle control band) to ensure that it is correctly protecting the
and an accident in conditions where the ABS tube from the spoke threads. A damaged rim tape
would normally function. may lead to rapid tyre deflation causing loss of
control and an accident.

Warning Warning
Always check tyre pressures before riding when
the tyres are cold. Operation with incorrectly Do not install tube-type tyres on tubeless rims.
inflated tyres may affect handling leading to loss The bead will not seat and the tyres could slip on
of control and an accident. the rims, causing tyre deflation that may result in
a loss of motorcycle control and an accident.
Do not install an inner tube inside a tubeless tyre.
Warning This may cause instability and excessive heat
build-up may cause the tube to burst resulting in
Operation with excessively worn or damaged tyres rapid tyre deflation, loss of vehicle control and an
will adversely affect handling and control leading accident.
to loss of control or an accident.

Warning
Warning
The use of tyres other than those listed at your
Inner tubes must only be used on motorcycles authorised Triumph dealer, or on the internet, at
fitted with spoked wheels. [Link], may adversely affect handling
All Triumph motorcycles are carefully and leading to loss of motorcycle control or an
extensively tested in a range of riding conditions accident. Use the recommended tyre options only
to ensure that the most effective tyre in the combinations listed at your authorised
combinations are approved for use on each model. Triumph dealer, or on the internet at
It is essential that approved tyre combinations are [Link]. Do not mix tyres from
used when purchasing replacement tyres as the different manufacturers or tyres from the same
use of non-approved tyres or approved tyres in manufacturer but from another option.
non-approved combinations may lead to
motorcycle instability. A list of approved tyres
specific to this model is available from your
authorised Triumph dealer, or on the internet at
[Link].

Thruxton R 597
Wheels And Tyres

Tyre Wear/Wheel Inspection

Warning As the tyre tread wears down, the tyre becomes
Accurate wheel balance is important for safe, more susceptible to puncture and failure. It is
stable handling of the motorcycle. Do not remove estimated that 90% of all tyre failures occur during
or change any wheel balance weights. Incorrect the last 10% of tread life (90% worn). It is false
wheel balance may cause instability leading to loss economy and unsafe to use tyres until they are
of motorcycle control and an accident. worn to their minimum.
When wheel balancing is required, such as after All tyres are fitted with tread wear indicators.
tyre replacement, see your authorised Triumph When the tyre becomes worn down as far as the
dealer. top of a tread wear indicator, the tyre is worn
beyond its service life and must be replaced.
Only use self-adhesive weights. Clip-on weights
will damage the wheel and tyre potentially
resulting in tyre deflation, loss of motorcycle
control and an accident.

Warning
When replacement tyres are required, consult
your authorised Triumph dealer who will arrange
for the tyres to be fitted according to the tyre
manufacturer’s instructions.
When tyres are replaced, allow time for the tyre to
seat itself to the rim (approximately 24 hours).
During this seating period, ride cautiously as an
incorrectly seated tyre could cause loss of
motorcycle control or an accident. Initially, the 1. Tread wear indicator
new tyre will not produce the same handling In accordance with the scheduled maintenance
characteristics as the worn tyre and the rider chart, measure the depth of the tread with a depth
must allow adequate riding distance gauge, and replace any tyre that has worn to, or
(approximately 100 miles/160 km) to become beyond the minimum allowable tread depth.
accustomed to the new handling characteristics.
Inspect wheels for cracks, splits and kerb damage.
After both 24 hours and 100 miles (160 km), the Always replace wheels that are suspected of
tyre pressures should be checked and adjusted having become damaged.
and the tyre examined for correct seating and
rectified as necessary.
Use of a motorcycle when not accustomed to its
handling characteristics, with incorrect tyre
pressures or an incorrectly seated tyre is
dangerous and may lead to loss of motorcycle
control and an accident.

598 Thruxton R
 Wheels And Tyres

Front Wheel - Removal

Warning
Operation with excessively worn tyres is Warning
hazardous and will adversely affect traction,
stability and handling which may lead to loss of Before starting work, ensure the motorcycle is
control and an accident. stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
When tubeless tyres become punctured, leakage is
operator or damage to the motorcycle.
often very slow. Always inspect tyres very closely
for punctures. Check the tyres for cuts, embedded
nails or other sharp objects. Operation with
punctured or damaged tyres will adversely affect Warning
motorcycle stability and handling which may lead
Do not allow the brake caliper to hang on the
to loss of control or an accident.
brake hose as this may damage the hose.
Check the rims for dents or deformation.
Damaged hoses could cause brake failure leading
Operation with damaged or defective wheels or
to loss of motorcycle control and an accident.
tyres is dangerous and loss of motorcycle control
or an accident could result.
1. Raise and support the front of the motorcycle.
Always consult your authorised Triumph dealer for
tyre replacement, or for a safety inspection of the Note:
tyres. • It is not necessary to disconnect the brake
hoses.
2. Detach and support the front brake calipers
(see Front Brake Pads - Removal, page 516).
3. Loosen the pinch bolt at the lower end of the
right hand fork.
4. Working from the right hand side, release and
remove the wheel spindle which is threaded
into the left hand fork.

1
cjsv

1. Pinch bolt
2. Wheel spindle

Thruxton R 599
Wheels And Tyres

5. Remove the wheel, recovering the spacers Front Wheel - Inspection

from both sides.
1. Check the wheel bearings spin smoothly with
no signs of play. If not, renew the bearings
(see Front and Rear Wheel Bearings - Removal,
page 605).

cjeu_2

1. Spacer (right hand shown)

6. Place the wheel on wooden blocks to prevent

damage to the brake discs.

Warning
Do not allow the wheel to rest on the brake disc as
this may damage the disc leading to loss of
motorcycle control and an accident.

Caution
To prevent wheel and wheel bearing damage,
ensure dirt and debris are not allowed to enter
the wheel bearings.

7. Thoroughly clean all components and inspect

for wear or damage.

600 Thruxton R
 Wheels And Tyres

Front Wheel - Installation

Warning
Warning take remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
Before starting work, ensure the motorcycle is accident.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Lightly smear the spacers with grease and

locate into the left hand and right hand sides
of the hub.

cjeu_2

1. Spacer (right hand shown)

2. Position the wheel between the forks.

3. Raise the wheel until it is in alignment with the
spindle holes in both forks. Take care to not
dislodge the spacers.
4. Refit the wheel spindle from the right hand
side and tighten to 65 Nm.
5. Thoroughly clean and degrease the brake
discs.
6. Fit the brake caliper (see Front Brake Pads -
Installation, page 517).
7. Check that the brake disc is centrally located
to the caliper. If not, apply gentle pressure to
the fork to ensure the disc is centred with the
caliper.
8. Maintaining the above position, tighten the
fork pinch bolt to 23 Nm.
9. Check the operation of the front brake. Rectify
as necessary.

Warning
It is dangerous to operate the motorcycle with
defective brakes; you must have your authorised
Triumph dealer take remedial action before you
attempt to ride the motorcycle again. Failure to

Thruxton R 601
Wheels And Tyres

Rear Wheel - Removal 5. Remove the spindle nut and washer then
support the wheel and withdraw the spindle.
Discard the nut.
Warning
Before starting work, ensure the motorcycle is 1
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Support the motorcycle so the rear wheel is

raised clear of the ground.
2. Release the fixings and remove the drive chain
guard.
3. Loosen the wheel spindle nut. 2
4. Release the lock nuts on both the left hand
and right hand chain adjuster bolts. 3
citw_3

1. Nut
2. Washer
3. Spindle

6. Lower the wheel to the ground, and noting its

position, release the brake caliper and carrier
from the slot on the swinging arm.

Warning
Do not allow the caliper to hang on the brake hose
2 as this may damage the hose.
3 1 Damaged hoses could cause brake failure leading
citw_2
to loss of motorcycle control and an accident.
1. Adjuster bolt
2. Adjuster bolt lock nut 7. Roll the wheel forward until the drive chain
can be detached from the rear sprocket.
3. Rear wheel spindle nut
8. Manoeuvre the wheel out of position and
recover the spacers from the hub and drive
flange.

Warning
Do not allow the wheel to rest on the brake disc as
this may damage the disc leading to loss of
motorcycle control and an accident.

602 Thruxton R
 Wheels And Tyres

Rear Wheel - Inspection

Caution
1. Check the wheel bearings spin smoothly with
To prevent wheel and wheel bearing damage, no signs of play. If not, renew the bearings
ensure dirt and debris are not allowed to enter (see Front and Rear Wheel Bearings - Removal,
the wheel bearings. page 605).

cjfe_1

1. Spacer (left hand shown)

Thruxton R 603
Wheels And Tyres

Rear Wheel - Installation 6. Fit the washer and a new nut to the spindle
and hand tighten.

Warning
1
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. Lubricate the lips of the wheel bearing seals

with a smear of multipurpose grease.
2. Fit the spacer to the hub and drive flange.
2
3
citw_3
1
1. Nut
2. Washer
3. Spindle

7. Lower the motorcycle to the ground and

adjust the drive chain free movement (see
Final Drive Chain Adjustment, page 613), then
tighten the spindle nut to 110 Nm.
8. Operate the brake pedal a few times to ensure
cjfe_1
the brake pads are in firm contact with the
disc.
1. Spacer (left hand shown)
9. Check the operation of the rear brake. Rectify
3. Position the wheel in between the swinging as necessary.
arm and engage the drive chain with the
sprocket.
4. Fit the brake caliper mounting plate, locating
Warning
its slot on the swinging arm lug. It is dangerous to operate the motorcycle with
5. Lift the wheel into position, ensuring the defective brakes; you must have your authorised
spacers and caliper mounting plate remain Triumph dealer take remedial action before you
correctly positioned, and insert the spindle attempt to ride the motorcycle again. Failure to
from the left hand side. take remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
accident.

604 Thruxton R
 Wheels And Tyres

Front and Rear Wheel Bearings - 2. Remove and discard the seal (two on the front
wheel, one on the rear) and the bearing circlip.
Removal
3. Using a suitable pin punch through the centre
• Remove the front wheel (see Front Wheel - of the wheel, drift out the wheel bearings.
Removal, page 599). Collect the centre sleeve.
• Remove the rear wheel (see Rear Wheel -
Removal, page 602).

Warning
To avoid wheel damage, always support the wheel
as instructed below. A dangerous riding condition
leading to loss of motorcycle control and an
accident could result if this warning is ignored.

1. Support the wheel on blocks to prevent

damage to the sprcket and wheel rim.

Warning
cdio

Always wear eye, hand and face protection when

Wheel Bearing Removal
using a drift as use of a hammer and drift can
cause bearings to fragment. Pieces of fragmented
bearing could cause eye and hand injuries if
suitable protective apparel is not worn.

Caution
To prevent wheel damage and to aid bearing
removal, always apply force evenly on both sides
of the bearing to prevent it from 'tipping' and
becoming stuck. Application of uneven force will
lead to difficulty in removing the bearing and to a
damaged wheel.

Thruxton R 605
Wheels And Tyres

Inspection - Bearings Front and Rear Wheel Bearings -

1. Check the wheel bearings spin smoothly with Installation
no signs of play. If not, renew the bearings.
Note:
• Refer to the chart below for the correct tool
and tool face when inserting bearings.
Bearings are inserted by means of a draw bolt
acting on the insertion tool. A support tool is
located on the opposite side of the wheel to
the insertion tool and as the bolt is tightened,
the bearing is drawn into the wheel.
• Insert bearings with the marked or shielded
side facing outwards and always fit a new
bearing circlip and seals.

Front Wheel Bearing Tool Selection Chart

Bearing insertion Support tool
tool
Left bearing service tool service tool
T3880053 T3880075
Small face to Large face to
bearing wheel
Right service tool service tool
bearing T3880053 T3880075
Small face to Large face to
bearing wheel

Rear Wheel Bearing Tool Selection Chart

Bearing insertion Support tool
tool
Left bearing service tool service tool
T3880053 T3880075
Large face to Large face to
bearing wheel
Right service tool service tool
bearing T3880053 T3880075
Large face to Large face to
bearing wheel

606 Thruxton R
 Wheels And Tyres

1. Fit the wheel bearings and centre sleeve using

the method described above.

cjfe_1

1. T3880075 - Bearing Installer in position on rear

wheel

2. Fit a new circlip.

3. Lubricate and fit new seal(s) to the wheel.
Lubricate the seal’s knife-edge with grease to
NLGI 2 specification.
• Fit the front wheel (see Front Wheel -
Installation, page 601).
• Refit the rear wheel (see Rear Wheel -
Installation, page 604).

Thruxton R 607
Wheels And Tyres

This page intentionally left blank

608 Thruxton R
 24 Final Drive
Table of Contents
Exploded View – Final Drive ..................................................................................................................................................................... 611
Final Drive Chain ........................................................................................................................................................................................... 612
Final Drive Chain Lubrication.................................................................................................................................................................. 612
Final Drive Chain Adjustment................................................................................................................................................................. 613
Drive Chain and Sprocket Wear Inspection..................................................................................................................................... 614
Drive Chain Replacement ......................................................................................................................................................................... 615
Front Sprocket - Removal ........................................................................................................................................................................ 618
Front Sprocket - Installation ................................................................................................................................................................. 620
Rear Sprocket - Removal.......................................................................................................................................................................... 621
Rear Sprocket - Installation .................................................................................................................................................................... 621
Rear Sprocket Carrier and Cush Drive - Removal ....................................................................................................................... 622
Rear Sprocket Carrier and Cush Drive - Inspection ................................................................................................................... 623
Rear Sprocket Carrier and Cush Drive - Installation.................................................................................................................. 623
Rear Sprocket Carrier Bearings - Disassembly ............................................................................................................................ 624
Rear Sprocket Carrier Bearings - Assembly .................................................................................................................................. 625

Thruxton R 609
Final Drive

610 Thruxton R
 Final Drive

Exploded View – Final Drive

30 Nm

55 Nm

30 Nm

110 Nm
55 Nm

180 Nm

9 Nm

9 Nm

Thruxton R 611
Final Drive

Final Drive Chain Final Drive Chain Lubrication

For safety and to prevent excessive wear, the drive Lubrication is necessary every 200 miles (300 km)
chain must be checked, adjusted and lubricated in and also after riding in wet weather, on wet roads,
accordance with scheduled maintenance or any time that the chain appears dry.
requirements. Checking, adjustment and lubrication Use the special drive chain lubricant as
must be carried out more frequently for extreme recommended in the specification section.
conditions such as salty or heavily gritted roads. Correct application is critical for drive chain
If the drive chain is badly worn or incorrectly lubrication. Apply the lubricant for one full drive
adjusted (either too loose or too tight) the drive chain revolution only, then leave for eight hours
chain could jump off the sprockets or break. before riding. This allows the lubricant’s solvent
(used to thin the oil) to evaporate and the oil to
Warning 'soak' into all parts of the drive chain. If the
lubricant is applied and the motorcycle is ridden
A drive chain that breaks or jumps off the shortly afterwards, the lubricant is unlikely to
sprockets could snag on the engine sprocket or reach all parts and the majority will be flung off
lock the rear wheel, severely damaging the and wasted. Applying excessive amounts is not
motorcycle and causing an accident. Never neglect helpful under any circumstances.
chain maintenance. It should be noted that the lubricant is applied to
the drive chain to lubricate its action across the
Note: sprockets. In an O-ring chain, external lubrication
does not penetrate to the bushes and rollers as the
• Lubrication of the drive chain should ideally be O-ring seals prevents this from happening.
carried out with the motorcycle set up so that
the rear suspension hangs free.
• The drive chain must be adjusted with the Caution
motorcycle in an upright position, resting on
Do not use a power jet washer to clean the chain
its wheels, and with no additional weight on it.
as this may cause damage to the chain
components.

612 Thruxton R
 Final Drive

Final Drive Chain Adjustment 2. Release the lock nuts on both the left hand
and right hand chain adjuster bolts.

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.

Drive Chain Free movement Inspection

2
3 1
citw_2

1. Adjuster bolt
2. Adjuster bolt lock nut
3. Rear wheel spindle nut

3. Moving both adjusters by an equal amount,

turn the adjuster bolts clockwise to increase
1
chain free-movement and counter clockwise to
reduce chain free-movement.

1. Maximum movement position 4. When the correct amount of chain free

movement has been set, push the wheel into
1. Place the motorcycle on a level surface and firm contact with the adjusters.
hold it in an upright position with no weight on
it.
Caution
2. Rotate the rear wheel by pushing the
motorcycle to find the position where the drive Check for equal adjustment on both sides using
chain has least slack. Measure the drive the graduation marks on the swinging arm.
chain’s vertical movement, mid-way between
sprockets. 5. Tighten both adjuster lock nuts to 20 Nm and
3. If correct, the vertical movement of the drive the rear wheel spindle nut to 110 Nm.
chain midway between the sprockets should 6. Repeat the chain adjustment check. Re-adjust
be 20 - 30 mm. if necessary.

Drive Chain Free movement Adjustment

Warning
1. Loosen the wheel spindle nut.
Operation of the motorcycle with insecure
adjuster lock nuts or a loose wheel spindle may
result in impaired stability and handling of the
motorcycle. This impaired stability and handling
may lead to loss of motorcycle control and an
accident.

Thruxton R 613
Final Drive

Drive Chain and Sprocket Wear 4. Examine the whole length of the drive chain. If
there are any excessively tight or loose
Inspection sections, loose pins or damaged rollers, the
drive chain should be replaced.
Warning 5. Inspect sprockets for unevenly or excessively
worn teeth. Also examine the sprockets for
Before starting work, ensure the motorcycle is damaged teeth.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
WORN TOOTH WORN TOOTH
(ENGINE SPROCKET) (REAR SPROCKET)

ccol

10-20
KG

2
1. Measurement across 20 links
2. 10 - 20 kg Weight

1. Stretch the chain taut by hanging a 10 - 20 kg

(20 - 40 lb) weight on the drive chain.
2. Measure a length of 20 links on the straight
part of the drive chain from pin centre of the
1st pin to pin centre of the 21st pin. Repeat the
test at various sections of the drive chain to
establish an average reading. This is because
the drive chain may wear unevenly.
3. If the length exceeds the service limit of 319
mm (12.56 in), the chain must be replaced.

Warning
A drive chain that breaks or jumps off the
sprockets could snag on the engine sprocket or
lock the rear wheel, severely damaging the
motorcycle and causing loss of motorcycle control
and an accident.

614 Thruxton R
 Final Drive

Drive Chain Replacement 2. Insert the cut/rivet pin into the pin holder so
its smaller diameter end (cutting point) is
facing away from the holder as shown.
Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 2
operator or damage to the motorcycle.

Rivet Link Type 1

The following instructions for the replacement of
rivet link type drive chains requires the use of
service tool T3880635.

1
3

2 1. Pin holder
4 2. Cut/rivet pin

3. If required, file the domed heads of the chain

5 link pins flat.
4. Position service tool T3880635 so that the
drive chain is between the cut/rivet pin and
6
the service tool body with the pin to be remove
aligned with the hole service tool body.
5. Turn the pin holder clockwise until its pin
contacts the link pin. Ensure that the pin is
T3880635 - Final Drive Chain Cut and Rivet
centralised on the link pin to be removed.
1. Service tool body
2. Pin holder 2
3. Cut/rivet pin 1
4. Plate holder A
5. Plate holder B
6. Gauge

1. Support the motorcycle on a stand so the rear

wheel is clear of the ground.
3

1. Guide plate holder

2. Service tool body
3. Drive chain

6. Retain the tool body and rotate the pin holder

clockwise until the link pin is pressed out from
the chain.
7. Remove the tool and separate the two ends of
the chain.

Thruxton R 615
Final Drive

Note: 11. Fit the guide plate A to the service tool as

shown below.
• The replacement chain is supplied in a split
condition, complete with a link kit to join the 4
two ends.
3

Caution 2

The component parts of the new link kit are

coated with a special grease which must not be 1
removed. Removal of this special grease will
severely reduce the service life of the chain.

8. Use the old drive chain to pull the new chain

into position as follows: Temporarily attach the
end of the new chain to a free end of the old
chain using the old connector link. Carefully
pull the other end of the old chain to pull the
new chain around the sprockets. 1. Cut/rivet pin

Note: 2. Guide plate B

• Do not use the new connector link as the 3. Guide plate A

special grease on it may be removed. 4. Service tool body
9. Using the new link supplied with the chain kit, 12. Fit the new connecting link plate to the new
join the two ends of the chain. Ensure that the link by hand or with a suitable pair of pliers.
O-rings are positioned as shown below and the 13. Position service tool T3880635 so that the new
link plate is fitted with its markings facing connecting link plate of the drive chain is in
outwards. contact with guide plate A.
14. Rotate the pin holder clockwise until the drive
1 chain link makes contact with guide plate B.
2
15. Ensure the connecting link is correctly
positioned and then continue to rotate the pin
holder to press the connecting link fully on.

2
1

1 3
camw

1. O-rings 3
2. Link
3. Link plate

10. Insert the cut/rivet pin into the pin holder so

its larger diameter end (riveting point) is facing
away from holder as shown. 1. Guide plate A
2. Guide plate B
3. Drive chain

616 Thruxton R
 Final Drive

16. Rotate the pin holder counter clockwise and 20. Remove the tool from the chain and using the
remove the Guide plate A and insert the cut/ gauge from service tool T3880635 check that
rivet pin into the pin holder so its larger both the split link pins are correctly riveted.
diameter end (riveting point) is facing away The rivet should not pass through the slot on
from the holder. the gauge.
17. Align one of the split link pins to the cut/rivet
pin then turn the pin holder clockwise until the
pin contacts the split link pin. Ensure the split 1
link pin is centrally located on the cut/rivet pin.
Note:
• The riveting end of the cut/rivet pin is shaped
to prevent over tightening. Over tightening
may cause damage to the connecting link pin
and the cut/rivet pin. 2
18. Retain the tool body then tighten the pin
holder until the split link end is riveted-over. 3

2
1
1. Gauge
2. Slot
3. Rivet

21. Also check that both the split link pins are
correctly riveted as shown below.
3

1. Cut rivet pin

2. Guide plate B
3. Drive chain

19. Back off the pin holder and rivet the remaining
split link pin as described above. 1 2 3 4

cana

1. Correct riveting
2. Insufficient riveting
3. Excessive riveting
4. Riveting off-centre

Warning
If either split link pin is not correctly riveted, the
split link must be removed and replaced with a
new link. Never operate the motorcycle with an
incorrectly riveted split link as the link could fail
resulting in an unsafe riding condition leading to
loss of motorcycle control and an accident.

Thruxton R 617
Final Drive

Endless Type Front Sprocket - Removal

Warning Warning
Before starting work, ensure the motorcycle is Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help stabilised and adequately supported. This will help
prevent it from falling and causing injury to the prevent it from falling and causing injury to the
operator or damage to the motorcycle. operator or damage to the motorcycle.

• Remove the swinging arm (see Swinging Arm -

Removal, page 494 Caution
1. Free the chain from the front sprocket and
remove it from the motorcycle. To prevent paint damage, do not spill brake fluid
onto any area of the bodywork. Spilled brake fluid
2. Locate the new chain on the front sprocket. will damage paintwork.
• Refit the swinging arm (see Swinging Arm -
Installation, page 498). • Position the motorcycle on the side stand.
• Remove the front sprocket cover (see Front
Sprocket Cover - Removal, page 104).
• Remove the right hand side panel (see Side
Panels, page 637).
1. Remove the lock nuts and detach the coolant
expansion tank from its mounting. Discard the
lock nuts.

1
2
cjpt

1. Fixings
2. Coolant expansion tank

618 Thruxton R
 Final Drive

2. Remove the fixings, detach the alternator 5. Have an assistant sit on the motorcycle, select
harness and remove the coolant expansion sixth gear and apply the front brake hard.
tank mounting. 6. Loosen the front sprocket nut.

3
1
2

3
1
cjqg

1. Fixings 1. Nut
2. Harness clip 2. Lock washer
3. Alternator harness 3. Front sprocket

7. Remove the front sprocket nut and discard the

Caution lock washer.
To prevent paint damage, do not spill brake fluid 8. Set the drive chain adjustment to allow
onto any area of the bodywork. Spilled brake fluid maximum free play in the drive chain.
will damage paintwork. Note:
• Note the orientation of the front sprocket for
3. Remove and discard the fixing and detach the
installation.
rear brake fluid reservoir from the relay
bracket. 9. Disengage the front sprocket from the drive
chain and slide it off the output shaft.

citi_1

1. Fixing
2. Brake fluid reservoir

Note:
• Note the routing of the brake switch harness
for installation.
4. Bend back the front sprocket lock washer.

Thruxton R 619
Final Drive

Front Sprocket - Installation 7. Attach the alternator harness to the coolant

expansion tank mounting, fit the inner cover
and tighten its fixings to 7 Nm.
Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help 1
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Fit the front sprocket, as noted for removal,

and engage it with the drive chain.
2. Fit a new lock washer engaging it with the
2
output shaft splines, and fit the sprocket nut
hand tight.
3
1
3 cjqg

2 1. Fixings
2. Harness clip
1 3. Alternator harness

8. Refit the coolant expansion tank to its

mountings and tighten the new lock nuts to 3
Nm.

1. Nut
2. Lock washer
3. Front sprocket

3. Have an assistant sit on the motorcycle, select

sixth gear and apply the front brake hard.
4. Tighten the front sprocket nut to 180 Nm.
1
5. Secure the front sprocket nut in position by 2
bending the lock washer down to contact one
of the nut flats. cjpt

6. Adjust the final drive chain free movement 1. Lock nuts

(see Final Drive Chain Adjustment, page 613). 2. Coolant expansion tank

9. Attach the rear brake fluid reservoir to the

relay bracket and tighten the new fixing to 3
Nm.
• Refit the right hand side panel (see Side Panels,
page 637).
• Refit the front sprocket cover (see Front
Sprocket Cover - Installation, page 105).

620 Thruxton R
 Final Drive

Rear Sprocket - Removal Rear Sprocket - Installation

Caution Caution
Do not allow the wheel to rest on the brake disc, Do not allow the wheel to rest on the brake disc,
as this may damage the disc. Support the wheel as this may damage the disc. Support the wheel
on wooden blocks, equally spaced around the rim, on wooden blocks, equally spaced around the rim,
such that the brake disc is raised above the such that the brake disc is raised above the
ground. ground.

• Remove the rear wheel (see Rear Wheel - 1. If necessary, replace any rear sprocket studs
Removal, page 602). that have been loosened or removed as
1. Place the wheel on wooden blocks with the follows:
drive chain sprocket uppermost. • Remove and discard any of the studs that
have become loose.
Note:
• Fit new studs and tighten to 30 Nm.
• If the studs for the rear sprocket become • Check the height of the studs when fitted
loose or removed, they must be replaced. to the sprocket carrier. The top of the stud
2. Evenly and progressively, remove and discard must be between 16.5 to 18.5 mm above the
the rear sprocket lock nuts. sprocket carrier face.
Note:
• Note the orientation of the rear sprocket for
installation.
3. Remove the rear sprocket.
16.5 to 18.5 mm
1

2
1. Height of stud (16.5 to 18.5 mm)

2. Fit the rear sprocket to the sprocket carrier as

noted for removal.
cjej_1 3. Fit new lock nuts, evenly and progressively
tighten to 55 Nm.
1. Lock nut
• Refit the rear wheel (see Rear Wheel -
2. Sprocket Installation, page 604).

Thruxton R 621
Final Drive

Rear Sprocket Carrier and Cush 2. Gently lever the drive chain sprocket and
flange from the wheel hub. Collect the spacer.
Drive - Removal

Warning 1

Before starting work, ensure the motorcycle is

stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 2
operator or damage to the motorcycle.

Caution
Do not allow the wheel to rest on the brake disc, 3
as this may damage the disc. Support the wheel
on wooden blocks, equally spaced around the rim,
cjeo
such that the brake disc is raised above the
ground. 1. Rear sprocket carrier
2. Spacer
• Remove the rear wheel (see Rear Wheel -
3. Cush drive rubber
Removal, page 602).
1. Place the wheel on wooden blocks with the 3. Remove the cush drive rubber.
drive chain sprocket uppermost.
Note:
1
• Note the position and orientation of the
spacer for installation.

1. Cush drive rubber

622 Thruxton R
 Final Drive

Rear Sprocket Carrier and Cush Rear Sprocket Carrier and Cush
Drive - Inspection Drive - Installation
1. Check the cush drive rubbers for deterioration
and cracks. Warning
2. Inspect the sprocket teeth for wear, damage
Before starting work, ensure the motorcycle is
and chips.
stabilised and adequately supported. This will help
3. Check the wheel and drive flange for wear, prevent it from falling and causing injury to the
cracks and damage. operator or damage to the motorcycle.

Caution
Do not allow the wheel to rest on the brake disc,
as this may damage the disc. Support the wheel
on wooden blocks, equally spaced around the rim,
such that the brake disc is raised above the
ground.

1. Install the cush drive rubbers to the wheel

hub.
2. Fit the spacer to the wheel hub as noted for
removal.
3. Refit the sprocket carrier to the wheel.
• Refit the rear wheel (see Rear Wheel -
Installation, page 604).

Thruxton R 623
Final Drive

Rear Sprocket Carrier Bearings -

Caution
Disassembly
To prevent sprocket carrier damage and to aid
1. Remove the rear sprocket carrier and cush
bearing removal, always apply force evenly on
drive (see Rear Sprocket Carrier and Cush
both sides of the bearing to prevent it from
Drive - Removal, page 622).
'tipping' and becoming stuck. Application of
2. Remove and discard the seal. uneven force will lead to difficulty in removing the
bearing and to a damaged drive flange.
1
4. Turn the sprocket carrier over, and use a pin
punch to drift out the ball bearing.

cjej_1

1. Sprocket carrier
2. Seal 2
3. Remove and discard the bearing circlip. cjek

1. Sprocket carrier
1
2. Ball bearing

cjej

1. Sprocket carrier
2. Circlip

Warning
Always wear eye, hand and face protection when
using a hammer and drift. Use of a hammer and
drift can cause bearings to fragment. Pieces of
fragmented bearing could cause eye and soft
tissue injuries if suitable protective apparel is not
worn.

624 Thruxton R
 Final Drive

Rear Sprocket Carrier Bearings -

Assembly

Warning
When using a press, always wear overalls, eye,
face and hand protection. Objects such as
bearings frequently break-up under load and the
debris caused during break-up may cause damage
and injury to unprotected parts of the body.
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to
the hand, arms or other parts of the anatomy.

1. Position the ball bearing, marked side facing

outwards, to the drive flange.
2. Using a suitable press, fully insert the ball
bearing into the sprocket carrier.
3. Fit a new circlip.
4. Install a new seal, marked side facing
outwards, to the sprocket carrier.
5. Lubricate the seal’s knife-edge with grease to
NLGI 2 specification.
6. Install the cush drive rubbers to the wheel
hub.
7. Fit the spacer to the wheel hub as noted for
removal.
8. Refit the sprocket carrier to the wheel.

Thruxton R 625
Final Drive

This page intentionally left blank

626 Thruxton R
 25 Frame And Bodywork
Table of Contents
Exploded View – Frame and Fixings .................................................................................................................................................. 629
Exploded View – Front and Rear Mudguards ............................................................................................................................... 630
Exploded View – Front and Rear Footrests .................................................................................................................................... 631
Exploded View – Seat................................................................................................................................................................................ 632
Exploded View – Side Panels ................................................................................................................................................................. 633
Exploded View – Side Stand................................................................................................................................................................... 634
General Frame Inspection ....................................................................................................................................................................... 635
Bank Angle Indicators............................................................................................................................................................................... 635
Seat - Removal ............................................................................................................................................................................................. 636
Seat - Installation........................................................................................................................................................................................ 636
Side Panels ..................................................................................................................................................................................................... 637
Front Mudguard - Removal.................................................................................................................................................................... 637
Front Mudguard - Installation .............................................................................................................................................................. 638
Rear Mudguard - Removal ..................................................................................................................................................................... 638
Rear Mudguard - Installation................................................................................................................................................................ 639
Cradle Assemblies - Removal................................................................................................................................................................. 640
Cradle Assemblies - Installation ........................................................................................................................................................... 642
Mirrors - Removal ....................................................................................................................................................................................... 644
Mirrors - Installation.................................................................................................................................................................................. 645
Side Stand - Removal ................................................................................................................................................................................ 645
Side Stand - Installation........................................................................................................................................................................... 646

Thruxton R 627
Frame And Bodywork

628 Thruxton R
 Frame And Bodywork

Exploded View – Frame and Fixings

See text

See text

See text

See text
25 Nm

See text

See text

See text

See text

Thruxton R 629
Frame And Bodywork

Exploded View – Front and Rear Mudguards

6 Nm

3 Nm
3 Nm

6 Nm

6 Nm

3 Nm

6 Nm

630 Thruxton R
 Frame And Bodywork

Exploded View – Front and Rear Footrests

24 Nm

7 Nm

24 Nm

25 Nm

7 Nm

25 Nm

9 Nm

6 Nm

25 Nm

6 Nm

9 Nm

Thruxton R 631
Frame And Bodywork

Exploded View – Seat

632 Thruxton R
 Frame And Bodywork

Exploded View – Side Panels

Thruxton R 633
Frame And Bodywork

Exploded View – Side Stand

3 Nm
1.5 Nm

7 Nm

634 Thruxton R
 Frame And Bodywork

General Frame Inspection Bank Angle Indicators

1. Inspect the frame, bodywork and footrests for
accident and other damage, cracks, splits and Bank Angle Indicators
general dilapidation. Check all fixings for 1. Inspect the bank angle indicators on the
security. If any faults are found, rectify as rider's footrests for wear. The bank angle
necessary. If any faults with the frame are indicators are worn out when 5 mm of the
found, the frame must be replaced; repairs to bank angle peg remains.
the frame are not permitted.

Warning
If the motorcycle is involved in an accident or
collision it must be taken to an authorised Triumph
dealer for inspection and repair before it is ridden
again.

Warning 1

The frame must not be modified in any way. Any

modification to the frame, such as welding or
drilling, may weaken the structure causing an
citc_1
unsafe riding condition leading to loss of
motorcycle control and an accident. 1. Bank Angle Indicators

2. Check the operation of the side stand to make

sure it is securely held in the retracted
Warning
position by the spring. Rectify any faults. Use of a motorcycle with bank angle indicators
worn beyond the maximum limit (when the bank
Warning angle indicator is worn to a minimum 5 mm in
length) will allow the motorcycle to be banked to
If the return spring is faulty, the side stand could an unsafe angle. Therefore, always replace the
extend whilst the motorcycle is being ridden. This bank angle indicator pegs when they are worn to
will cause an unsafe riding condition, which could 5 mm in length.
lead to loss of motorcycle control and an accident. Banking to an unsafe angle may cause instability,
loss of motorcycle control and an accident.

Warning
The bank angle pegs must not be used as a guide
to how far the motorcycle may be safely banked.
This depends on many various conditions
including, but not limited to, road surface, tyre
condition and weather. Banking to an unsafe
angle will lead to loss of motorcycle control and an
accident.

Thruxton R 635
Frame And Bodywork

Seat - Removal Seat - Installation

1. Engage the seat’s tongue under the fuel tank.
Warning Note:
Before starting work, ensure the motorcycle is • An audible click can be heard when the seat is
stabilised and adequately supported. This will help correctly engaged in the lock.
prevent it from falling and causing injury to the
2. Press firmly down in the centre of the seat to
operator or damage to the motorcycle.
engage the seat lock.

Caution Warning
To prevent damage to the seats or seat covers, To prevent detachment of the seat during riding,
care must be taken not to drop the seats. Do not after fitting always grasp the seat and pull firmly
lean the seats against the motorcycle or any upwards. If the seat is not correctly secured it will
surface which may damage the seats or seat detach from the lock. A loose or detached seat
covers. Instead, place the seats, with the seat could cause loss of motorcycle control and an
cover facing upwards, on a clean, flat surface accident.
which is covered with a soft cloth.
Do not place any item on the seats which may 3. Grasp the seat and ensure that it is securely
cause damage or staining to the seat covers. retained.

1. Insert the ignition key into the seat lock and

turn it anticlockwise while pressing down on
the rear of the seat.
2. Lift the seat up from the back and slide
rearwards for complete removal from the
motorcycle.

cith_1

1. Seat lock

636 Thruxton R
 Frame And Bodywork

Side Panels Front Mudguard - Removal

1 2 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 and discard the four fixings securing

the front mudguard to the front forks and
carefully remove the mudguard.

citf
2
1. Side panel (right hand shown)
2. Grommets 1
To remove either side panel, grasp the panel firmly
in both hands and pull the panel away from the
motorcycle until it clears the three retaining
grommets (leaving the grommets in place).
To refit, position the three locating dowels to the
grommets, then press firmly to secure the panel.
Finally, grasp the panel and make sure that it is
fully retained. cjsl

1. Fixings
2. Front mudguard

Thruxton R 637
Frame And Bodywork

Front Mudguard - Installation Rear Mudguard - Removal

Warning Warning
Before starting work, ensure the motorcycle is Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help stabilised and adequately supported. This will help
prevent it from falling and causing injury to the prevent it from falling and causing injury to the
operator or damage to the motorcycle. operator or damage to the motorcycle.

1. Carefully manoeuvre the mudguard into • Remove the seat (see Seat - Removal, page
position between the front forks. 636).
2. Fit four new fixings and tighten to 6 Nm. • Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
2 1. Disconnect the rear light harness from the
main harness.
2. Remove the engine ECU (see Engine Electronic
Control Module (ECM) - Removal, page 403).
1 3. Remove the two front fixings and flanged
sleeves from the underside of the rear
mudguard.

cjsl

1. Fixings
2. Front mudguard

cjqw

1. Fixings
2. Shouldered washers

638 Thruxton R
 Frame And Bodywork

Note: Rear Mudguard - Installation

• Note the routing of the harnesses for
installation. Warning
4. Remove the four rear fixings and flanged
Before starting work, ensure the motorcycle is
sleeves from the rear mudguard and carefully
stabilised and adequately supported. This will help
remove the mudguard.
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1
1. Carefully locate the mudguard to the frame,
positioning the locating holes to the holes in
2
the frame.
2. Fit the four flanged sleeves and the new
fixings. Tighten the fixings to 6 Nm.

1
2

2
1
cjqx

1. Fixings
2. Shouldered washers
2

1
cjqx

1. Fixings
2. Shouldered washers

3. Fit the two flanged sleeves and the new

fixings. Tighten the fixings to 6 Nm.

cjqw

1. Fixings
2. Shouldered washers

Thruxton R 639
Frame And Bodywork

4. Refit the engine ECU (see Engine Electronic Cradle Assemblies - Removal
Control Module (ECM) - Installation, page 404).
5. Connect the rear light harness to the main
harness.
Warning
• Reconnect the battery, positive (red) lead first Before starting work, ensure the motorcycle is
(see Battery - Installation, page 658) and stabilised and adequately supported. This will help
tighten the terminals to 4.5 Nm. prevent it from falling and causing injury to the
• Refit the seat (see Seat - Installation, page 636). operator or damage to the motorcycle.

Left Hand Cradle Assembly

1. Remove the left hand side panel (see Side
Panels, page 637).

Caution
Note the routing and the retaining clips of the side
stand switch harness for installation.

2. Disconnect the side stand switch electrical

connector from the main harness and feed it
down to the side stand switch.

cjss

1. Side stand switch electrical connector

3. Detach the two clutch cable clips from the

cradle assembly.
4. Detach the two harness clips from the cradle
assembly.

640 Thruxton R
 Frame And Bodywork

5. Disconnect the two wires, release the fixing Right Hand Cradle Assembly
and remove the horn.
1. Remove the fixing and detach the electrical
connector bracket from the frame. Discard the
2 fixing.

3 1

cjen

1. Clips (clutch cable)

2. Clips (harness, exhaust header removed for clarity) cjqj

3. Horn connectors 1. Fixing

2. Electrical connector bracket
6. Remove the cradle assembly two rear
mounting bolts and collect the nuts. 2. Remove the cradle’s rear mounting bolt and
nut.
3. Remove the nut and bolt securing the exhaust
intermediate pipe to the cradle assembly.

1
cjep

1. Mounting bolts
3 1
4
cjeg

1. Bolt
2. Intermediate exhaust pipe
3. Bolt
4. Cradle assembly

Both Cradle Assemblies

1. Remove the crankcase front mounting nut and
bolt.

Thruxton R 641
Frame And Bodywork

2. Remove the nut and bolt securing the cradle Cradle Assemblies - Installation
assemblies to the headstock.

Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
2 operator or damage to the motorcycle.

1. Position the cradle assembly to the frame,

ensure the lower mounting of the radiator is
1 attached to the cradle assembly.
2. Fit the crankcase front mounting nut and bolt,
do not fully tighten at this stage.
3. Fit the nut and bolt securing the cradle
cjem assembly to the headstock, do not fully tighten
at this stage.
1. Bolt (to crankcase front mounting)
2. Bolt (to headstock)

3. Detach the cradle assembly from the lower

mounting of the radiator and remove the
cradle assembly.
2

cjem

1. Bolt (to crankcase front mounting)

2. Bolt (to headstock)
2
cjeq
Right Hand Cradle Assembly
1. Radiator lower mounting 1. Fit the cradle assembly rear mounting bolt and
nut, do not fully tighten at this stage.
2. Cradle assembly (left hand side shown)

642 Thruxton R
 Frame And Bodywork

2. Fit the nut and bolt to secure the exhaust 6. Tighten the exhaust intermediate pipe to
intermediate pipe to the cradle assembly. Do cradle assembly to 19 Nm.
not fully tighten at this stage. 7. Attach the electrical connector bracket to the
frame and tighten its new fixing to 3 Nm

3 1
4
cjeg

1. Bolt cjqj

2. Intermediate exhaust pipe 1. Fixing

3. Bolt 2. Electrical connector bracket
4. Cradle assembly
Left Hand Cradle Assembly
Note:
1. Fit the cradle assembly two rear mounting
• When tightening the cradle assembly bolts and captivated nuts, do not fully tighten
mounting bolts and nuts, hold the nut and at this stage.
torque the bolt.
3. Tighten the cradle assembly to headstock bolt
to 40 Nm.
4. Tighten the cradle assembly rear mounting
bolt to 40 Nm
5. Tighten cradle assembly to crankcase bolt to
105 Nm.

1
cjep

1. Mounting bolts

Note:
• When tightening the cradle assembly
mounting bolts and nuts, hold the nut and
torque the bolt.
2. Tighten the cradle assembly to headstock bolt
to 40 Nm.
3. Tighten the cradle assembly rear mounting
bolts to 40 Nm.
4. Tighten cradle assembly to crankcase bolt to
105 Nm.

Thruxton R 643
Frame And Bodywork

5. Fit the horn to the cradle arm and tighten its Mirrors - Removal
fixing to 24 Nm. Connect the two wires to the
horn. 1. Remove the handlebar end weight. Discard the
fixing.
6. Refit the clips for the clutch cable and horn
harness to the cradle assembly Note:
• Note the orientation of the mirror for
installation.
2
2. Loosen the mirror pinch bolt and remove the
mirror.

3
1
1

cjen

1. Clips (clutch cable)

2. Clips (harness, exhaust header removed for clarity)
2

3. Horn connectors
cjqs

7. Route the side stand switch harness to the

1. Fixing (bar end weight)
left hand side of the airbox as noted for
removal. Connect the electrical connector to 2. Bar end weight
the main harness. 3. Pinch bolt

cjss

1. Side stand switch electrical connector

8. Fit the left hand side panel (see Side Panels,

page 637).

Both Cradle Assemblies

• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

644 Thruxton R
 Frame And Bodywork

Mirrors - Installation Side Stand - Removal

Warning Warning
If the mirror fixing is too loose, the mirror may Before starting work, ensure the motorcycle is
blow back at speed. This will result in a loss of stabilised and adequately supported. This will help
vision to the rear of the motorcycle. It is prevent it from falling and causing injury to the
dangerous to ride a motorcycle without sufficient operator or damage to the motorcycle.
rearward vision.
1. Raise and support the motorcycle.
1. Refit the mirror as noted for removal and
tighten the pinch bolt to 3.5 Nm.
Warning
2. Refit the right hand handlebar end weight and
tighten its new fixing to 8 Nm. Wear hand, eye and face protection when
unhooking the stand spring. Take great care to
minimise the risk of personal injury and loss of
components.
3
1 2. Remove the left hand exhaust intermediate
pipe (see Exhaust Intermediate and Header
Pipes - Removal, page 431).
3. With the side stand in the up position, unhook
the spring from the side stand and remove it
from the motorcycle.
4. Remove and discard the E-clip securing the
2
clevis pin.
5. Remove the clevis pin and remove the side
stand.
cjqs

1. Fixing (bar end weight)

3
2. Bar end weight
3. Pinch bolt

2 1
cjfq

1. Spring
2. E-clip
3. Clevis pin

Thruxton R 645
Frame And Bodywork

Side Stand - 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. Lubricate the clevis pin shoulder and side

stand pivot with multipurpose grease.
2. Fit the side stand to the motorcycle and insert
the clevis pin.
3. Fit a new E-clip to secure the clevis pin.

Warning
Wear hand, eye and face protection when fitting
the stand spring. Take great care to minimise the
risk of personal injury and loss of components.

4. Hook the spring onto its frame lug then

carefully hook it onto the side stand lug.
5. Refit the left hand exhaust intermediate pipe
(see Exhaust Intermediate and Header Pipes -
Installation, page 434).
6. Check the operation of the side stand before
riding the motorcycle. Ensure the spring holds
the stand securely in the retracted position.

646 Thruxton R
 26 Electrical
Table of Contents
Exploded View – Instruments ............................................................................................................................................................... 650
Exploded View – Alternator and Starter Motor ............................................................................................................................ 651
Exploded View – Headlight..................................................................................................................................................................... 652
Exploded View – Rear Lights................................................................................................................................................................. 654
Exploded View – Indicators .................................................................................................................................................................... 655
Exploded View – Battery, Horn and Wiring.................................................................................................................................... 656
Battery ............................................................................................................................................................................................................. 657
Battery Disposal .......................................................................................................................................................................................... 657
Battery - Removal....................................................................................................................................................................................... 658
Battery - Installation................................................................................................................................................................................. 658
Battery Commissioning and Charging............................................................................................................................................... 659
Battery Maintenance ................................................................................................................................................................................ 660
Battery Already in Service...................................................................................................................................................................... 660
Fuse Box........................................................................................................................................................................................................... 661
Starting Circuit ............................................................................................................................................................................................. 662
Diagnosis – Starter Circuit...................................................................................................................................................................... 664
Alternator/Charging System ................................................................................................................................................................. 666
Headlight ......................................................................................................................................................................................................... 668
Headlight Vertical Adjustment.............................................................................................................................................................. 668
Headlight - Removal .................................................................................................................................................................................. 669
Headlight - Installation............................................................................................................................................................................. 670
Headlight and Daytime Running Light Bulb Replacement....................................................................................................... 671
Headlight and Position Light Bulb Replacement ......................................................................................................................... 672
Headlight Bracket - Removal................................................................................................................................................................. 673
Headlight Bracket - Installation ........................................................................................................................................................... 674
Rear Light - Removal ................................................................................................................................................................................ 675
Rear Light - Installation........................................................................................................................................................................... 676
Bulb Replacement LED ............................................................................................................................................................................. 678
Direction Indicator Lights - Bulb Replacement ............................................................................................................................ 678

Thruxton R 647
Electrical

Front Direction Indicators - Removal ................................................................................................................................................ 679

Front Directional Indicators - Installation....................................................................................................................................... 680
Rear Direction Indicators - Removal.................................................................................................................................................. 680
Rear Direction Indicators - Installation ............................................................................................................................................. 681
Instruments - Removal............................................................................................................................................................................. 682
Instruments - Installation....................................................................................................................................................................... 683
Ignition Switch - Removal ....................................................................................................................................................................... 684
Ignition Switch - Installation.................................................................................................................................................................. 685
Side Stand Switch - Removal................................................................................................................................................................. 685
Side Stand Switch - Installation ........................................................................................................................................................... 686
Ignition Coils - Removal............................................................................................................................................................................ 687
Ignition Coils - Installation ...................................................................................................................................................................... 689
Alternator Stator - Removal .................................................................................................................................................................. 690
Alternator Stator - Installation ............................................................................................................................................................. 691
Alternator Rotor - Removal ................................................................................................................................................................... 692
Alternator Rotor - Installation.............................................................................................................................................................. 693
Alternator Regulator/Rectifier - Removal....................................................................................................................................... 694
Alternator Regulator/Rectifier - Installation ................................................................................................................................. 695
Starter Motor - Removal.......................................................................................................................................................................... 695
Starter Motor - Installation.................................................................................................................................................................... 696
Alternator Stator......................................................................................................................................................................................... 698
Regulator/Rectifier..................................................................................................................................................................................... 702
Lighting Circuit tables............................................................................................................................................................................... 706
Lighting Circuit Diagram .......................................................................................................................................................................... 707
Starting and Charging Circuit Tables................................................................................................................................................. 708
Starting and Charging Circuit Diagram ............................................................................................................................................ 709
Auxiliary and Accessory Circuit Tables.............................................................................................................................................. 710
Auxiliary and Accessory Circuit Diagram ........................................................................................................................................... 711
Engine Management Circuit Tables ...................................................................................................................................................... 712
Engine Management Circuit Diagram.................................................................................................................................................. 713
ABS System Circuit Tables ....................................................................................................................................................................... 714
ABS System Circuit Diagram.................................................................................................................................................................... 715
Complete Main Harness Table ................................................................................................................................................................ 716
Complete Main Harness Diagram .......................................................................................................................................................... 717

648 Thruxton R
 Electrical

Thruxton R 649
Electrical

Exploded View – Instruments

3 Nm

3 Nm

3 Nm

650 Thruxton R
 Electrical

Exploded View – Alternator and Starter Motor

4 Nm

4 Nm

4 Nm

See Text

12 Nm
9 Nm

12 Nm

10 Nm

5 Nm

Thruxton R 651
Electrical

Exploded View – Headlight

All Markets Except India and Indonesia

24 Nm

24 Nm
24 Nm

10 Nm

9 Nm

24 Nm

10 Nm
4 Nm
1.5 Nm

652 Thruxton R
 Electrical

India and Indonesia Markets Only

24 Nm

24 Nm
24 Nm

10 Nm

9 Nm

10 Nm
4 Nm
1.5 Nm

Thruxton R 653
Electrical

Exploded View – Rear Lights

5 Nm

2 Nm

4 Nm 5 Nm

654 Thruxton R
 Electrical

Exploded View – Indicators

5 Nm

5 Nm

Thruxton R 655
Electrical

Exploded View – Battery, Horn and Wiring

3 Nm
6 Nm
3 Nm 1.5 Nm

1.5 Nm
3 Nm

3 Nm

3 Nm

24 Nm
4 Nm

1.5 Nm 3 Nm

4 Nm

656 Thruxton R
 Electrical

Battery Battery Disposal

Should the battery ever require replacement, the
Warning original battery must be handed to a recycling
agent who will ensure that the dangerous
Under some circumstances, the battery can give substances from which the battery is
off explosive gases; keep sparks, flames and manufactured do not pollute the environment.
cigarettes away. Provide adequate ventilation
when charging or using the battery in an enclosed
space.
The battery contains sulphuric acid (electrolyte).
Contact with skin or eyes may cause severe burns.
Wear protective clothing and a face shield.
If electrolyte gets on your skin, flush with water
immediately.
If electrolyte gets in your eyes, flush with water
for at least 15 minutes and SEEK MEDICAL
ATTENTION IMMEDIATELY.
If electrolyte is swallowed, drink large quantities of
water and SEEK MEDICAL ATTENTION
IMMEDIATELY.
KEEP ELECTROLYTE OUT OF THE REACH OF
CHILDREN.

Warning
The battery contains harmful materials. Always
keep children away from the battery whether or
not it is fitted in the motorcycle.
Do not attach jump leads to 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 gases causing a
risk of personal injury.

Thruxton R 657
Electrical

Battery - Removal Battery - Installation

Warning Warning
Before starting work, ensure the motorcycle is Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help stabilised and adequately supported. This will help
prevent it from falling and causing injury to the prevent it from falling and causing injury to the
operator or damage to the motorcycle. operator or damage to the motorcycle.

1. Remove the seat (see Seat - Removal, page

636). Warning
2. Disconnect the battery leads, negative (black) Ensure that the battery terminals do not touch
lead first. the motorcycle frame as this may cause a short
1 2 circuit or spark, which would ignite battery gases
causing a risk of personal injury.

1. Place the battery in the battery case and

secure with the battery strap.
2. Secure with the battery strap and make sure
the USB port socket is refitted.
3. Reconnect the battery, positive (red) lead first
and tighten the battery terminals to 4.5 Nm.
4. Apply a light coat of grease to the terminals to
prevent corrosion.
4 5. Cover the positive terminal with the protective
cjaj
3 cap.
6. Refit the seat (see Seat - Installation, page
1. Battery
636).
2. Positive (+) terminal
3. Negative (-) terminal
4. Battery strap

Warning
Ensure that the battery terminals do not touch
the motorcycle frame as this may cause a short
circuit or spark, which would ignite battery gases
causing a risk of personal injury.

3. Remove the battery strap and the USB port

socket.
4. Take the battery out of the case.

658 Thruxton R
 Electrical

Battery Commissioning and Charging 5. Remove the battery sealing strip from the
electrolyte container and save for later in this
procedure. Place the sealing strip on a clean
New Battery
surface, with the upper side facing downwards
In order to correctly and safely commission a new to avoid contamination of the sealing strip. Do
battery, the battery commissioning procedure not break the seal on the electrolyte container.
listed below must be carefully followed. This is the
only battery commissioning procedure that 6. Place the electrolyte container on the battery
Triumph recommends. The procedure is designed to and fill the battery according to the
ensure that the battery is at its best when fitted to manufacturers instructions.
the motorcycle, and will provide the best possible 7. After starting to fill the battery with
performance and reliability. electrolyte, allow the battery to stand for 30
Failure to comply with this procedure may lead to minutes with the filling container in place.
reduced battery performance and/or shorten the 8. Check that all of the electrolyte has drained
life of the battery. from the container. Do not remove the
container at this point. If the container has not
Warning completely drained, tap the sides of the
container to start the electrolyte flowing
The battery gives off explosive gases; keep sparks, again.
flames and cigarettes away. Provide adequate 9. After the electrolyte has drained into the
ventilation when charging or using the battery in battery, allow the battery to stand with the
an enclosed space. electrolyte container in place for a further 2
The battery contains sulphuric acid (electrolyte). hours.
Contact with skin or eyes may cause severe burns. 10. Remove the electrolyte container carefully,
Wear protective clothing and a face shield. and dispose of immediately.
If electrolyte gets on your skin, flush with water
11. Place the sealing cap strip LOOSELY over the
immediately.
filling holes of the battery.
If electrolyte gets in your eyes, flush with water
12. Charge the battery using the BatteryMate
for at least 15 minutes and SEEK MEDICAL
Battery Charger. Refer to the instructions
ATTENTION IMMEDIATELY.
supplied with the BatteryMate Battery
If electrolyte is swallowed, drink large quantities of Charger.
water and SEEK MEDICAL ATTENTION
IMMEDIATELY.
Caution
KEEP ELECTROLYTE OUT OF THE REACH OF
CHILDREN. The caps must be fitted (after charging) within
two hours of filling the battery with acid. Leaving
1. Ensure the VIN number printed on the anti- the battery open to the atmosphere for longer
tamper label attached to the battery matches than is necessary will start to reverse the
the motorcycle VIN. chemical reaction which takes place within the
battery, greatly reducing the battery’s service life.
2. Check the battery carefully for damage.
13. After charging is complete, press down firmly
Caution with both hands to seat the caps (do not use
tools or force the caps into position).
Ensure the electrolyte container part number
matches the battery part number to be filled. 14. Disconnect the charger and allow the battery
Battery life will be greatly reduced if the incorrect to stand for 1 hour before fitting to the
volume (either too little or too much) of acid is motorcycle.
added to the battery. 15. Fit the battery to the motorcycle, positive (red)
lead first.
3. Read the instructions and warnings delivered
with the battery.
4. Place the battery on a flat level surface and
remove the sealing foil.

Thruxton R 659
Electrical

Battery Maintenance Battery Already in Service

The battery is a sealed type and does not require Note:
any maintenance other than checking the voltage
and routine recharging such as during storage. • Before carrying out the following procedure
the battery must be disconnected and
It is not possible to adjust the electrolyte level in
removed from the motorcycle.
the battery.
Use the guidelines in the table below for charging.
Note: Always verify the battery condition before
• The charge level in the battery must be charging, and 30 minutes after charging.
maintained to maximise the battery life.
Note:
With normal use of the motorcycle, the charging
• A fully charged battery should read 12.8 volts
system will keep the battery charged. If the
or higher after the battery has been off the
motorcycle is unused, the battery will gradually
charger for 30 minutes or more.
discharge due to battery self discharge and the
continuous current drain for the clock and the
engine control module memory. Table of Battery Charging Times
The rate of battery discharge can be greatly State of Voltage Action Charge time
increased by the addition of electrical security charge (using
systems or other accessories. BatteryMate
Allowing a battery to discharge, or leaving it 150-9)
discharged over a period of time, causes sulphation 100% 12.8 V - None. Check None
of the lead plates within the battery. 13.0 V at 6 months required
Sulphation is a normal chemical reaction inside the from date of
battery and over a period of time sulphate will manufactur
crystallise on to the lead plates making charging e
difficult or impossible. The result is a permanently
damaged battery, which would not be covered by 75% - 12.5 V - May need 3 - 6 hours
the motorcycle warranty. 100% 12.8 V slight
charge. If no
Keeping a battery at full charge reduces the
charge
chance of it freezing in cold conditions. Allowing a
given, check
battery to freeze can cause serious internal
in 3 - 4
damage to the battery.
months
When leaving the motorcycle standing for more
than a few days, regularly check the battery 50% - 12.0 V - Needs 5 - 11 hours
voltage using a digital multimeter. Should the 75% 12.5 V charge
battery voltage fall below 12.8 V, charge the battery
25% - 11.5 V - Needs At least 13
using the BatteryMate Battery Charger - see latest
50% 12.0 V charge hours
Parts Catalogue for part number information. Refer
to the instructions supplied with the BatteryMate 0% - 11.5 V or Needs 20 hours
Battery charger. 25% less recovery
For extended periods of storage (beyond two using
weeks) the battery should be removed and the BatteryMate
battery voltage checked regularly and charged 150-9.
when below 12.8 V. Retest after
recovery

660 Thruxton R
 Electrical

Fuse Box Position Circuit Protected Rating

(Amps)

Warning 8 Instruments and alarm 15

9 USB port socket 5
Always replace blown fuses with new ones of the
correct rating (as specified on the fuse box cover)
and never use a fuse of higher rating.
Use of an incorrect fuse could lead to an electrical
problem, resulting in motorcycle damage, loss of
motorcycle control and an accident.

A blown fuse is indicated when all of the systems

protected by that fuse become inoperative. When
checking for a blown fuse, refer to the fuse
identification table to establish which fuse has
blown.
The fuse box is located underneath the seat.
To allow access to the fuse box, the seat must be
removed (see Seat - Removal, page 636).
Note:
• Numbers shown in the following illustration
correspond to the position numbers in the
fuse identification table.

1 2
9

3
8

7
6 5 4
citn

1. Fuse box

Fuse Identification Table

Position Circuit Protected Rating
(Amps)
1 Dip and high headlight beams 15
2 Ignition switch, starter circuit 10
3 Auxiliary lights 10
4 Engine management system 15
5 Accessory socket 5
6 Cooling fan 15
7 ABS 25

Thruxton R 661
Electrical

Starting Circuit
All Triumph models are equipped with an electric start system. This system consists of a starter relay,
starter motor, starter switch, side stand switch, engine stop switch, clutch switch and the sprag clutch. The
starter motor is connected to the starter relay and the battery by heavy duty cables in order to supply the
large currents required by the motor to start the engine. When the starter button is pressed, the relay is
energised, which then allows current to the starter motor. The starter motor will not operate unless the
clutch lever is pulled in. Also, the starter will not operate if the side stand is down, unless the transmission
is in neutral. If the starter motor does not operate, the following basic checks must be carried out before
further diagnosis is performed:
• Check the engine stop switch is in the 'RUN' position.
• Check the battery terminals are clean and tight.
• Check the frame and engine earth connections are clean, tight and free from corrosion.
• Ensure the battery is fully charged and in good condition.
• Check that any fuse in the circuit is not blown and is of the correct rating.
• Using the Triumph Diagnostic Tool, check the operation of the neutral switch or gear position sensor (if
fitted), side stand and clutch switches.
Note:
• On all new models from Daytona 675 onwards which use a CAN communication, the engine will not
crank if the instruments, ABS ECM, or immobiliser/chassis ECM (if fitted) are disconnected.
Rectify any defects as necessary.

General Fault Finding – Starter Motor and Relay

Symptom Possible cause(s)
Starter relay does not click, starter motor does not Battery discharged or defective
turn
Blown main or starter relay fuse
Defective starter relay wiring or starter switch
Check that the side stand, transmission and clutch
lever are positioned for engine starting i.e.
transmission in neutral, clutch lever pulled in and
the side stand down
Defective alarm system - ensure any alarm fitted is
working correctly
Starter motor turns slowly Battery discharged or defective
Loose, corroded or dirty battery connections
Loose, corroded or dirty starter motor or starter
relay connections
Defective starter motor
Loose, corroded or dirty battery ground
connections
Starter relay clicks but engine does not turn over Battery discharged or defective
Crankshaft does not turn due to engine defect
Defective starter motor
Starter cable open circuit
Defective starter relay
Starter motor turns but engine does not turn over Starter motor or starter ring gear

662 Thruxton R
 Electrical

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Thruxton R 663
Electrical

Diagnosis – Starter Circuit

Note:
• Prior to carrying out the diagnosis, ensure the battery voltage is 12 - 13.5 V, the immobiliser system (if
fitted) is functioning correctly, the transmission is in neutral and the clutch lever is pulled fully to the
handlebar.

WITH THE IGNITION SWITCH ON AND USING A SUITABLE HEAVY DUTY

THE ENGINE STOP SWITCH AT ‘RUN’, JUMPER CABLE, CONNECT THE
CLICKS
CHECK FOR A CLICK AT THE STARTER STARTER POSITIVE TERMINAL TO
RELAY WHEN THE STARTER SWITCH THE BATTERY POSITIVE TERMINAL
IS PRESSED

STARTER STARTER
MOTOR MOTOR
TURNS DOES NOT
TURN

LOOSE OR FAULTY STARTER

NO DISCONNECTED WIRE MOTOR
CLICK OR CABLE. FAULTY
STARTER RELAY/
SOLENOID

FAULTY NEUTRAL SWITCH

NO CONTINUITY FAULTY CLUTCH SWITCH
DISCONNECT THE STARTER RELAY
FAULTY SIDESTAND SWITCH
SWITCH CONNECTOR. CHECK THE
BAD CONTACT AT CONNECTOR
RELAY COIL EARTH (GROUND) WIRE
OPEN CIRCUIT IN WIRING LOOM
FAULTY ALARM OR ENGINE ECM (IF FITTED)

CONTINUITY

FAULTY IGNITION SWITCH/ENGINE

CONNECT THE STARTER RELAY
STOP SWITCH
SWITCH CONNECTOR. MEASURE NO VOLTAGE BROKEN STARTER SWITCH CABLE
THE STARTER RELAY VOLTAGE
BAD CONTACT AT CONNECTOR
AT THE STARTER RELAY
OPEN CIRCUIT IN WIRING LOOM
SWITCH CONNECTOR
FAULTY ALARM

VOLTAGE
MEASURED

CHECK THE STARTER NORMAL

LOOSE OR POOR CONTACT
RELAY OPERATION AT STARTER RELAY

ABNORMAL FAULTY STARTER RELAY

664 Thruxton R
 Electrical

This page intentionally left blank

Thruxton R 665
Electrical

Alternator/Charging System
The charging system consists of an alternator, a rectifier/regulator assembly and the battery. The
alternator is made up of two parts, the stator, which is mounted to the crankcase or the engine cover, and
the rotor, mounted to the end of the crankshaft. The stator is an assembly of 18 coils, arranged into 3
phases. The rotor is a series of magnets mounted in the engine flywheel, which are arranged so as to be
positioned around the outside of the stator coils. As the engine rotates the alternator produces an AC
(alternating current) voltage in each of the three phases of the alternator, typically of around 35 to 40 volts
AC at 4,000 - 5,000 rpm, although this figure varies between models. As the battery requires DC (direct
current) voltage for correct charging, this AC voltage must be first rectified to DC current, and then
regulated to the correct voltage for the battery of 14.5 +/- 0.5 volts. This is done by the rectifier/regulator,
which uses diodes to convert the alternator output to DC Volts and limits the resulting output to the
correct figure required for optimal battery charging.
If the charging circuit does not operate correctly, the following basic checks must be carried out before
further diagnosis is performed:
• Check the battery terminals are clean and tight.
• Check the frame and engine earth connections are clean, tight and free from corrosion.
• Ensure the battery is fully charged and in good condition.
• Check that any fuse in the circuit is not blown and is of the correct rating.
Rectify any defects as necessary.

666 Thruxton R
 Electrical

Diagnosis – Charging Circuit

Thruxton R 667
Electrical

Headlight Headlight Vertical Adjustment

1. Switch the headlight dipped beam on.
Warning 2. Loosen the headlight assembly mounting
fixings sufficiently to allow restricted
Adjust road speed to suit the visibility and
movement of the headlight.
weather conditions in which the motorcycle is
being operated. 3. Adjust the position of the headlight to give the
required beam setting.
Make sure that the beam is adjusted to illuminate
the road surface sufficiently far ahead without 4. Tighten the mounting fixings to 10 Nm.
dazzling oncoming traffic. An incorrectly adjusted 5. Recheck the headlight beam setting.
headlight may impair visibility causing an accident.
6. Switch the headlight off when the beam
setting is satisfactorily set.
Warning
Never attempt to adjust a headlamp beam when
the motorcycle is in motion.
Any attempt to adjust a headlamp beam when the
motorcycle is in motion may result in loss of
control and an accident.

Caution
Do not cover the headlight or lens with any item 1
likely to obstruct air flow to, or prevent heat
escaping from, the headlight lens.
Covering the headlight lens during operation with
items of clothing, luggage, adhesive tape, devices 1. Headlight mounting fixings
intended to alter or adjust the headlight beam or
non genuine headlight lens covers will cause the
headlight lens to overheat and distort, causing
irreparable damage to the headlight assembly.
Damage caused by overheating is not considered
a manufacturing defect and will not be covered
under warranty.
If the headlight must be covered during use - such
as taping of the headlight lens required during
closed‑course conditions - the headlight must be
disconnected.

668 Thruxton R
 Electrical

Headlight - Removal 3. Release the fixings and detach the harness

bracket from the headlight bowl.

Warning
2
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.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
1. Release the two fixings and detach the 3 1
headlight from the headlight bowl.
cjdt

1. Fixings
2. Harness bracket
3. Headlight bowl

Note:
• Note the position of the electrical connectors
on the back of the harness bracket for
installation.

1. Headlight fixing (one of two)

2. Disconnect the electrical connector from the

headlight bulb, detach the position light and
remove the headlight.

Thruxton R 669
Electrical

4. On the back of the harness bracket, detach all Headlight - Installation

the electrical connectors and remove the
harness bracket.
Warning
1
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
2 prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Refit the headlight bowl while feeding the

harnesses into the headlight bowl. Do not fully
tighten the fixings at this stage.

cjcz

1. Electrical connectors
2. Harness bracket

5. Remove the headlight mounting fixings and

remove the headlight bowl while feeding the
harnesses out of the headlight bowl.
1

1. Headlight mounting fixings

2. Fit the wiring harness electrical connectors to

the back of the harness bracket as noted
during removal.

1 2

1. Headlight mounting fixings

cjcz

1. Electrical connectors
2. Harness bracket

670 Thruxton R
 Electrical

3. Fit the harness bracket to the headlight bowl Headlight and Daytime Running
and tighten the fixings to 1.5 Nm.
Light Bulb Replacement
2 Warning
The bulbs become hot during use. Always allow
sufficient time for the bulbs to cool before
handling. Avoid touching the glass part of the
bulb. If the glass is touched or gets dirty, clean
with alcohol before reuse.

Caution
3 1
The use of non-approved headlight bulbs may
result in damage to the headlight lens.
cjdt

Use a genuine Triumph supplied headlight bulb as

1. Fixings specified in the Triumph Parts Catalogue.
2. Harness bracket Always have replacement headlight bulbs installed
3. Headlight bowl by an authorised Triumph dealer.
4. Reconnect the headlight electrical connector
and refit the position light. • Remove the seat (see Seat - Removal, page
636).
5. Refit the headlight, tightening the fixings to 4
• Disconnect the battery, negative (black) lead
Nm.
first (see Battery - Removal, page 658).

Daytime Running Lights

The daytime running lights (DRL) are situated
within the headlight assembly and are sealed,
maintenance free LED units.

Headlight Bulb
1. Release the two fixings and detach the
headlight from the headlight bowl.

1. Headlight fixing (one of two)

• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
• Check the headlight operation and the beam
setting, rectify as necessary.
1

1. Headlight fixing (one of two)

Thruxton R 671
Electrical

2. While supporting the light unit, disconnect the Headlight and Position Light Bulb
multipin electrical connector from the
headlight bulb and the electrical connector for Replacement
the daytime running light from the main
harness. Warning
3. Remove the rubber dust cover.
The bulbs become hot during use. Always allow
4. Unhook the headlight bulb's wire retainer. sufficient time for the bulbs to cool before
5. The headlight bulb can now be removed. handling. Avoid touching the glass part of the
bulb. If the glass is touched or gets dirty, clean
with alcohol before reuse.
1 2

Caution
The use of non-approved headlight bulbs may
result in damage to the headlight lens.
Use a genuine Triumph supplied headlight bulb as
specified in the Triumph Parts Catalogue.
Always have replacement headlight bulbs installed
3 by an authorised Triumph dealer.

• Remove the seat (see Seat - Removal, page

cizx_2
636).
1. Wire retainer • Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
2. Headlight bulb
3. DRL harness Position Lights
6. Installation is the reversal of removal. The position lights are situated within the headlight
assembly and are sealed, maintenance free LED
units.

Headlight Bulb
1. Release the two fixings and detach the
headlight from the headlight bowl.

1. Headlight fixing (one of two)

672 Thruxton R
 Electrical

2. While supporting the light unit, disconnect the Headlight Bracket - Removal
multipin electrical connector from the
headlight bulb and the electrical connector for
the daytime running light from the main Warning
harness.
Before starting work, ensure the motorcycle is
3. Remove the rubber dust cover. stabilised and adequately supported. This will help
4. Unhook the headlight bulb's wire retainer. prevent it from falling and causing injury to the
operator or damage to the motorcycle.
5. The headlight bulb can now be removed.

• Remove the seat (see Seat - Removal, page

1 2 636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the headlight (see Headlight - Removal,
page 669).
Note:
• The upper fixing for the headlight bracket has
a domed nut.
• The lower fixing has a captivated nut.
3
1. Release the fixings and remove the headlight
bracket from the headlight subframe.
cizx_2

1. Wire retainer 2

2. Headlight bulb
3. DRL harness

6. Installation is the reversal of removal.

1
3

cjsw

1. Fixings
2. Domed nut
3. Headlight bracket

Headlight Subframe
If the subframe is to be removed, carry out the
following steps
1. Remove the front direction indicators (see
Front Direction Indicators - Removal, page
679).

Thruxton R 673
Electrical

2. Remove the fixings securing the headlight Headlight Bracket - Installation

subframe to the lower yoke. Collect the washer
and discard the lock nut.
3. Move the lower end of the subframe forward,
Warning
detach it from the upper yoke and remove. Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
2 prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1
1. If removed, check the rubber grommets for the
headlight subframes for cracks and wear,
replace if necessary.
2. Position the headlight subframes to the upper
yoke.
3. Align the headlight subframes to the lower
yoke, fit the washers, a new lock nut and
3
tighten to 3 Nm.

cjsw
2
1. Fixings
2. Headlight subframe 1
3. Lower yoke

cjsw

1. Fixings
2. Headlight subframe
3. Lower yoke

4. Refit the front direction indicators (see Front

Directional Indicators - Installation, page 680).
Note:
• The upper fixing for the headlight bracket has
a domed nut.
• The lower fixing has a captivated nut.
5. Refit the headlight brackets to the headlight
subframes. Tighten the fixings to 24 Nm.
• Refit the headlight (see Headlight - Installation,
page 670).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

674 Thruxton R
 Electrical

Rear Light - Removal 3. Release the fixing and remove the harness
cover.

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 seat (see Seat - Removal, page
636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the rear mudguard (see Rear
Mudguard - Removal, page 638). 2

1. Remove the license plate from the rear light cjpb

bracket.
1. Fixings
2. Release the fixings and remove the rear light
2. Harness cover
assembly from the rear mudguard.
Note:
• Note the routing of the direction indicator
harnesses for installation.
2
• The right hand direction indicator harness can
be identified by the red tape on it.
4. Disconnect the direction indicators from the
rear light harness.
5. Release the two fixings and remove the rear
light cover.
1
1

cjsz

1. Fixings 3
2. Rear light assembly

3 2
cjpa

1. Fixings
2. Rear light cover
3. Direction indicator harnesses

6. Detach the rear light harness from the rear

light bracket.

Thruxton R 675
Electrical

Note: Rear Light - Installation

• Note the routing of the rear light harness for
installation. Warning
7. Release the three fixings and remove the rear
Before starting work, ensure the motorcycle is
light.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
2
1. Fit the rear light to the rear light bracket and
tighten the three fixings to 2 Nm.
2. Route the harness as noted for removal and
attach the rear light harness to its clip on the
rear light bracket.

1
cjpc

1. Harness clip
2. Fixings

1
cjpc

1. Harness clip
2. Fixings

3. Refit the rear light cover and tighten its two

fixings to 2 Nm.
Note:
• The harness for the right hand direction
indicator can be identified by the red tape on
it.

676 Thruxton R
 Electrical

4. Route the direction indicator harness as noted 6. Refit the rear light to the rear mudguard and
for removal and connect the electrical tighten the new fixings to 5 Nm.
connectors to the rear light harness.
1
2

1
1

3 2 cjsz

cjpa
1. Fixings
1. Fixings 2. Rear light assembly
2. Rear light cover
7. Refit the rear mudguard (see Rear Mudguard -
3. Direction indicator harnesses Installation, page 639).
5. Fit the harness cover and tighten its fixings to • Reconnect the battery, positive (red) lead first
4 Nm. (see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
• Check the rear light operation, rectify as
necessary.

cjpb

1. Fixings
2. Harness cover

Thruxton R 677
Electrical

Bulb Replacement LED Direction Indicator Lights - Bulb

The rear light unit is a sealed, maintenance free Replacement
LED unit.

3 1
1. Lens
2. Locating tangs
3. Bulb
Carefully twist the lens clockwise and remove from
the indicator to gain access to the bulb for
replacement.
To remove the bulb, gently press inwards and twist
anti-clockwise. Replace the bulb.
Installation for the bulb is the reverse of the
removal procedure.

Caution
When installing the lens, make sure that the
locating tangs are correctly aligned to the
indicator body.

678 Thruxton R
 Electrical

Front Direction Indicators - Removal 2. Remove the fixings and detach the headlight
bowl from the headlight subframe.

Warning 3. Remove the fixing and remove the front

direction indicator.
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.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the headlight (see Headlight - Removal,
page 669).
2 3
Note: 1
• Note the routing of the front direction
indicator harness for installation. cjsu

1. Disconnect the direction electrical connectors 1. Fixing

from the main harness on the back of the 2. Right hand direction indicator
harness bracket.
3. Headlight subframe

2
cjcz_1

1. Left hand direction indicator connectors

2. Right hand direction indicator connectors

Thruxton R 679
Electrical

Front Directional Indicators - Rear Direction Indicators - Removal

Installation • Remove the seat (see Seat - Removal, page
636).
1. Fit the direction indicator to the headlight
• Disconnect the battery, negative (black) lead
subframe and tighten the fixing to 5 Nm.
first (see Battery - Removal, page 658).
2. Route the direction indicator harness as noted • Remove the rear light (see Rear Light -
for removal and connect it to the main Removal, page 675).
harness on the back of the harness bracket.
The main harness for the right hand direction 1. Release the fixing and remove the harness
indicator is marked with red tape to aid correct cover.
connection.
3. Fit the headlight bowl to the headlight
brackets. Do not fully tighten the fixings at
this stage.
• Fit the headlight (see Headlight - Installation,
page 670).
1
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
• Check the headlight alignment and adjust if
necessary (see Headlight Vertical Adjustment,
2
page 668).
• Check the operation of the direction indicators, cjpb

rectify as necessary.
1. Fixings
2. Harness cover

Note:
• Note the routing of the direction indicator
harnesses for installation.
• The harness for the right hand direction
indicator can be identified by the red tape on
it.

680 Thruxton R
 Electrical

2. Disconnect the direction indicator electrical Rear Direction Indicators -

connectors from the rear light harness.
Installation
3. Release the fixing and remove the direction
indicator. 1. Fit the direction indicator to the rear light
assembly and tighten the fixing to 5 Nm.
Note:
2 • The harness for the right hand direction
indicator can be identified by the red tape on
1 it.

2
cjpc_1

1. Direction indicator connectors

2. Fixings

Thruxton R 681
Electrical

2. Route the direction indicator harness as noted Instruments - Removal

for removal and connect the electrical
connectors to the rear light harness.
Warning
Before starting work, ensure the motorcycle is
2 stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
1 operator or damage to the motorcycle.

• Remove the seat (see Seat - Removal, page

636).
1 • Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the headlight (see Headlight - Removal,
page 669).
2
1. Remove the four fixings and remove the
cjpc_1 instrument cover.
1. Direction indicator connectors
2. Fixings 2
1 1
3. Fit the harness cover and tighten its fixings to
4 Nm.

cjog

1. Fixings
2. Instruments cover
2

cjpb

1. Fixings
2. Harness cover
• Refit the rear light to the rear mudguard (see
Rear Light - Installation, page 676).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).
• Check the direction indicators operation, rectify
as necessary.

682 Thruxton R
 Electrical

2. Remove the three fixings and detach the Instruments - Installation

instruments from its bracket.

Warning
1 2 Before starting work, ensure the motorcycle is
1 stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Connect the electrical connector to the

instruments, slide the cover over the electrical
connector.

2
cjof

1. Fixings
2. Instruments bracket

3. Slide the cover off the electrical connector,

disconnect the electrical connector and
remove the instruments.

1
2
cjoh

1. Cover
2. Electrical connector

cjoh

1. Cover
2. Electrical connector

Thruxton R 683
Electrical

2. Position the instruments to the headlight Ignition Switch - Removal

bracket, secure with the three fixings and
tighten to 3 Nm.
Warning
Before starting work, ensure the motorcycle is
1 2 stabilised and adequately supported. This will help
1 prevent it from falling and causing injury to the
operator or damage to the motorcycle.

• Remove the seat (see Seat - Removal, page

636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the upper yoke (see Upper Yoke -
Removal, page 484).
1. Remove the sheared bolts then remove the
cjof ignition switch.
1. Fixings
2. Headlight bracket
2
3. Refit the instrument cover and tighten the
fixings to 3 Nm. 1
1

2
1 1

cjtb_1

1. Sheared bolts
2. Ignition switch

cjog

1. Fixings
2. Instruments cover
• Refit the headlight (see Headlight - Installation,
page 670).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

684 Thruxton R
 Electrical

Ignition Switch - Installation Side Stand Switch - Removal

Warning Warning
Before starting work, ensure the motorcycle is Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help stabilised and adequately supported. This will help
prevent it from falling and causing injury to the prevent it from falling and causing injury to the
operator or damage to the motorcycle. operator or damage to the motorcycle.

1. Fit the ignition switch to the upper yoke. • Remove the seat (see Seat - Removal, page
2. Fit new shear bolts and tighten to 12 Nm. 636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
2 1. Remove the left hand side panel (see Side
Panels, page 637).
1
1 Caution
Note the routing and the retaining clips of the side
stand switch harness for installation.

2. Disconnect the side stand switch electrical

connector from the main harness and feed it
down to the side stand switch.

cjtb

1. Shear bolts
2. Ignition switch
• Fit the upper yoke to the motorcycle (see Upper 1
Yoke - Installation, page 485).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

cjss

1. Side stand switch electrical connector

Thruxton R 685
Electrical

3. Remove and discard the fir tree clip from the Side Stand Switch - Installation
frame cradle and retain the P clip.

Warning
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
2 operator or damage to the motorcycle.

1. Refit the side stand switch, tighten the new

1 fixings to 3 Nm.

1. Fir tree clip

2. P clip

4. Remove the side stand switch and discard the

fixings.

2
1. Side stand switch
2. Fixings

2. Secure the harness using a new fir tree clip

and the original P clip.

1. Side stand switch

2

2. Fixings

1. Fir tree clip

2. P clip

686 Thruxton R
 Electrical

3. Route the side stand switch harness to the Ignition Coils - Removal
left hand side of the airbox as noted for
removal. Connect the electrical connector to
the main harness. 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
1. Disconnect the high tension cables from the
spark plugs.
Note:
• The ignition coil wires identified with the red
tape are fitted to the right hand side of the
ignition coils.
• Note the position of the four wires connected
to the ignition coils for installation.
cjss
2. Disconnect the four wires from the ignition
1. Side stand switch electrical connector coils (two either side of the ignition coils).
4. Fit the left hand side panel (see Side Panels,
page 637).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

ciwj

1. Ignition coil connections (right hand side shown)

2. Ignition coils

Thruxton R 687
Electrical

3. Detach the coolant temperature connector 6. Disconnect the MAP sensor hose and the
from the ignition coils bracket. electrical connector from the MAP sensor.

1
2

2 3
1
ciwk ciya

1. Coolant temperature sensor connector 1. Fuel pump harness

4. Remove the three fixings and detach the 2. MAP sensor electrical connector
ignition coil bracket from the motorcycle 3. MAP sensor hose
frame.
Note:
• The front ignition coil has the longer HT lead.
7. Remove and discard the four fixings and
remove the ignition coils from their bracket.

1 2

2
ciwm

1. Fixing (left hand side shown)

2. Ignition coil bracket
2 1
Note: ciwl

• Note the routing of the fuel pump harness on 1. Fixings

the ignition coil bracket for installation.
2. Ignition coils
5. Detach the fuel pump harness from the
ignition coils bracket.

688 Thruxton R
 Electrical

Ignition Coils - Installation 6. Connect the four wires from the ignition coils
as noted for removal (two either side of the
ignition coils).
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. Position the ignition coils onto their bracket,

secure with new fixings and tighten to 3 Nm.
1
2. Connect the MAP sensor hose and the
electrical connector to the MAP sensor.
3. Attach the fuel pump harness to the ignition
coil bracket, as noted for removal. 2

ciwj
1
1. Ignition coil connections (right hand side shown)
2. Ignition coils

7. Connect the high tension cables to the spark

plugs.
• Refit the fuel tank (see Fuel Tank - Installation,
page 383).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
2 3 • Refit the seat (see Seat - Installation, page 636).

ciya

1. Fuel pump harness

2. MAP sensor electrical connector
3. MAP sensor hose

4. Position the ignition coils and bracket

assembly to the motorcycle frame, secure with
the fixings and tighten to 3 Nm.
5. Attach the coolant temperature sensor
connector onto the ignition coil bracket.
Note:
• The wires for the right hand side of the
ignition coils are identified with the red tape.

Thruxton R 689
Electrical

Alternator Stator - Removal 2. Remove and discard the fixing securing the
cable bracket to the alternator cover.

Warning 3. Remove and discard the fixings securing the

stator to the alternator cover and remove the
Before starting work, ensure the motorcycle is stator.
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the 3
operator or damage to the motorcycle.

Note:
• If the alternator stator needs to be replaced,
4
the crankshaft position sensor will also be
replaced as they are one assembly.
• Remove the seat (see Seat - Removal, page
636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658). 1
• Remove the alternator cover (see Alternator
2
Cover - Removal, page 99). cjcs

Note: 1. Cable bracket fixing

• Note the routing of the stator harness for 2. Cable bracket

installation. 3. Stator fixing
1. Remove and discard the fixings securing the 4. Stator
crankshaft position sensor to the alternator
cover.

1. Fixings

690 Thruxton R
 Electrical

Alternator Stator - Installation 2. Route the harness as noted for removal, fit the
harness retainer and tighten its new fixing to
9 Nm.
Warning
Before starting work, ensure the motorcycle is 3
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.

1. Fit the stator to the alternator cover and 4

tighten its new fixings to 12 Nm.

cjcs
2
1. Cable bracket fixing
2. Cable bracket
3. Stator fixing
4. Stator

3. Fit the crankshaft position sensor to the

alternator cover and tighten its new fixings to
9 Nm.

1. Fixings
• Refit the alternator cover to the engine (see
Alternator Cover - Installation, page 101).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 691
Electrical

Alternator Rotor - Removal 2. Using the service tool T3880606 and service
tool T3880656, prevent the rotor from turning
• Remove the seat (see Seat - Removal, page
and remove the rotor fixing and washer from
636).
the end of the crankshaft.
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
• Remove the alternator cover (see Alternator 2
Cover - Removal, page 99).
1. Assemble the service tool T3880656 to the
service tool T3880606, ensuring the shorter
pin is fitted to the short arm of service tool
T3880606. Fit the nuts and tighten to 10 Nm.

2 3
2
1

civd

1. T3880606 - Flywheel Restraint Handle

2. T3880656 - Pulley Wrench Pin Set
1
3. Rotor fixing
3 3. Locate the spigot from the larger of the two
thrust pads supplied with service tool
T3880365 to the crankshaft.

1. T3880606 - Flywheel Restraint Handle

2. Pins (T3880656 - Pulley Wrench Pin Set)
3. Nuts (T3880656 - Pulley Wrench Pin Set)
1
Warning
The rotor magnets are very strong. When fitting
the service tools to the rotor the magnets may
'grab' the service tool, causing injury to the hands
or fingers. When installing the service tools, wear
suitable gloves to protect hands and fingers.

civc

1. Thrust pad

4. Assemble service tool T3880365 to the

threaded centre section of the rotor.
Note:
• Ensure that the thrust pad does not fall out
during assembly of the tool.

692 Thruxton R
 Electrical

5. Hold the outer of the tool to prevent rotation Alternator Rotor - Installation
then tighten the draw-bolt in the centre of the
tool to release the taper seating of the rotor 1. Refit the Woodruff key to the crankshaft.
from the crankshaft. 2. Assemble the rotor to the key way on the
crankshaft, ensuring the Woodruff key
remains in position.

1
Warning
The rotor magnets are very strong. When fitting
the service tools to the rotor the magnets may
2 'grab' the service tool, causing injury to the hands
or fingers. When installing the service tools, wear
suitable gloves to protect hands and fingers.

3. Refit the service tool T3880606 and service

tool T3880656to prevent the crankshaft from
rotating.
civb
4. Tighten the rotor retaining fixing in the
1. Rotor following stages:
2. T3880365 - Alternator Housing Puller • Stage 1. Tighten the rotor retaining fixing to
85 Nm.
6. Withdraw the rotor and tool as an assembly • Stage 2. Tighten the rotor retaining fixing to
and then separate the tool from the rotor. 120 Nm.
Collect the Woodruff Key and the tool thrust
pad from the crankshaft.
2

3
2
1

civd

1. T3880606 - Flywheel Restraint Handle

2. T3880656 - Pulley Wrench Pin Set
3. Rotor fixing

5. Remove the service tool T3880606 and service

tool T3880656 from the rotor.
• Refit the alternator cover to the engine (see
Alternator Cover - Installation, page 101).
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

Thruxton R 693
Electrical

Alternator Regulator/Rectifier - Note:

Removal • Note the position of the electrical connectors
for installation.
Note:
3. Disconnect both electrical connectors from the
• The alternator rectifier is located near the
alternator regulator/rectifier.
swingarm below the ABS modulator. The
rectifier does not contain any serviceable 2 3
parts and must be replaced if faulty.
• Remove the seat (see Seat - Removal, page
636).
• Disconnect the battery, negative (black) lead
first (see Battery - Removal, page 658).
1. Remove the fixings and shouldered washers
then remove the ABS modulator cover.

1
cjsq

1. Fixings
2. Electrical connectors
3. Regulator/rectifier.

cjsp

1. Fixings
2. ABS modulator cover

2. Release the two fixings securing the rectifier

to lower yoke and remove the alternator
rectifier.

694 Thruxton R
 Electrical

Alternator Regulator/Rectifier - Starter Motor - Removal

Installation
1. Reconnect the two electrical connectors to the Warning
alternator rectifier as noted for removal.
Before starting work, ensure the motorcycle is
2. Position the alternator rectifier to its mounting stabilised and adequately supported. This will help
bracket below the ABS modulator, secure with prevent it from falling and causing injury to the
the two fixings and tighten to 4 Nm. operator or damage to the motorcycle.
3. Refit the ABS modulator cover fit the
shouldered washers and tighten its fixings to • Remove the seat (see Seat - Removal, page
4 Nm. 636).
• Reconnect the battery, positive (red) lead first • Disconnect the battery, negative (black) lead
(see Battery - Installation, page 658) and first (see Battery - Removal, page 658).
tighten the terminals to 4.5 Nm. 1. Ease the rubber boot from the starter cable,
• Refit the seat (see Seat - Installation, page 636). release the nut and disconnect the cable.
2. Protect the crankcase painted surfaces from
damage, using a suitable self-adhesive tape
such as masking tape.
3. Release the two bolts securing the starter
motor to the crankcase.

3
cjfr

1. Rubber boot
2. Nut
3. Bolts

Caution
Damage to painted surfaces could result from
inadequate care during removal or installation of
the starter motor. Always protect the crankcase
from damage during removal or installation.

4. Carefully manoeuvre the starter motor out to

the right hand side of the motorcycle.

Thruxton R 695
Electrical

Starter Motor - 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. Fit a new O-ring to the starter motor.

cjfs

1. O-ring

Caution
Damage to painted surfaces could result from
inadequate care during removal or installation of
the starter motor. Always protect the crankcase
from damage during removal or installation.

2. Carefully position the starter to the crankcase

and retain with the two bolts and tighten to 10
Nm.
3. Remove any self-adhesive tape used to
protect the crankcase.
4. Locate the starter cable to its connection pole.
Fit the nut and tighten it to 5 Nm.
5. Refit the rubber boot.
• Reconnect the battery, positive (red) lead first
(see Battery - Installation, page 658) and
tighten the terminals to 4.5 Nm.
• Refit the seat (see Seat - Installation, page 636).

696 Thruxton R
 Electrical

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Thruxton R 697
Electrical

Alternator Stator
The stator is an assembly of 18 coils, arranged into three phases. It is possible to check for continuity and
short circuits through the coils and to earth.
Note:
• Only repair the stator harness between the rectifier and where the harness goes into the crankcase.
• Do not attempt to repair the stator coils.
• If the battery is not fully charged, the charging voltage may be lower than specified when checking at
2,000 rpm.
• Ensure all additional accessories (auxiliary lights, heated grips etc.) are switched off.

Fault Possible cause Action

Battery not charging Main fuse Check the condition of the main
30A fuse:
Battery Check the condition of the
battery. Test the battery using
the BatteryMate 150-9. Refer to
the instructions supplied with
the BatteryMate 150-9.
Ensure the battery is serviceable:
Alternator Proceed to pinpoint test 1:
Regulator/Rectifier Test the regulator/rectifier (see
Regulator/Rectifier, page 702)

698 Thruxton R
 Electrical

Pinpoint Tests
Test Result Action
1 Check cable and terminal integrity: OK Disconnect the battery leads, negative
- Battery positive (+) (black) lead first. Disconnect regulator/
rectifier black connector and proceed to
- Battery negative (-) test 2
- Regulator/rectifier black connector pin
Faulty Rectify fault, proceed to test 4
1
- Regulator/rectifier black connector pin
3
- Regulator/rectifier grey connector pin
1
- Regulator/rectifier grey connector pin
2
- Regulator/rectifier grey connector pin
3
2 Check cable continuity: OK Reconnect the battery leads, positive (red)
- Regulator/rectifier black connector pin lead first. Reconnect the regulator/
1 to battery lead negative connector rectifier black connector. Disconnect the
rectifier/regulator grey connector and
- Regulator/rectifier black connector pin proceed to test 3
3 to battery lead positive connector
Open circuit Locate and rectify wiring fault, proceed to
test 4
3 Check resistance through the coils: 0.14 to 0.18 Proceed to test 4
- Alternator pin 1 to pin 2 Ohms

- Alternator pin 2 to pin 3 Open circuit If the fault is between the rectifier and
or short the crankcase, repair the harness.
- Alternator pin 3 to pin 1
circuit Proceed to test 4
If the fault is after the crankcase, replace
the unit. Proceed to test 5
4 Reconnect the harness and run the 13.5 V - 15 V Action complete - quit test
engine. Check the charging voltage at
Fault still Disconnect the regulator/rectifier grey
2,000 rpm:
present connector and proceed to test 5
5 Check the alternator AC output voltage 15 V AC to 25 Test regulator/rectifier (see Regulator/
at 850 rpm by probing the 3-pin stator V AC Rectifier, page 702)
connector as follows:
Less than 15 V Replace unit. Proceed to pinpoint test 6
- Positive (+) probe to pin 1 negative (-) AC
probe to pin 2
- Positive (+) probe to pin 2 negative (-)
probe to pin 3
- Positive (+) probe to pin 3 negative (-)
probe to pin 1
6 Reconnect the harness and run the 13.5 V - 15 V Action complete - quit test
engine. Check the charging voltage at
Fault still Contact Triumph service
2,000 rpm:
present

Thruxton R 699
Electrical

Circuit Diagram

B
- +

3 1

N
2

N
1 2 3
B
B
B

BR

B
B
B
B

1 2 3 3 1 4

1. Battery
2. Starter solenoid main fuse
3. Alternator
4. Rectifier/Regulator

700 Thruxton R
 Electrical

This page intentionally left blank

Thruxton R 701
Electrical

Regulator/Rectifier
Internally the rectifier/regulator consists of three diodes, one between each input and the positive terminal,
and three Field Effect Transistors (FETs), one between each input and the ground terminal.
As the voltage of the AC signal from the alternator rises, the voltage controller switches the FETs to avoid
over voltage on the output.
The diodes and FETs can be checked using a multimeter on DIODE setting. Disconnect the two electrical
connectors from the rectifier/regulator and check the readings as indicated below.
Note:
• This test does not check for voltage regulation.

Fault Possible cause Action

Battery not charging Main Fuse Check the condition of the main
30A fuse:
Battery Check the condition of the
battery. Test the battery using
the BatteryMate 150-9. Refer to
the instructions supplied with
the BatteryMate 150-9.
Ensure the battery is
serviceable.
Regulator/Rectifier Disconnect the black and the
grey connectors from the
rectifier/regulator and proceed
to pinpoint test 1:
Alternator Test the alternator stator (see
Alternator Stator, page 698).

702 Thruxton R
 Electrical

Pinpoint Tests
Test Result Action
1 Check FET forward bias: 0.4 V to 0.7 V Proceed to test 2
Positive (+) probe to rectifier black socket pin Open circuit or Replace the unit. Proceed to test 4
1 to: short circuit
- Negative (-) probe to rectifier grey socket
pin 1
- Negative (-) probe to rectifier grey socket
pin 2
- Negative (-) probe to rectifier grey socket
pin 3
2 Check diodes function forward bias: 0.1 V to 0.3 V Proceed to test 3
Negative (-) probe to rectifier black socket pin Open circuit or Replace the unit. Proceed to test 4
3 to: short circuit
- Positive (+) probe to rectifier grey socket pin
1
- Positive (+) probe to rectifier grey socket pin
2
- Positive (+) probe to rectifier grey socket pin
3
3 Check diodes reverse bias: More than 1.4 Proceed to test 4
Negative (-) probe to rectifier black socket pin V or OL on
1 to: meter

- Positive (+) probe to rectifier grey socket pin Less than 1.4 Replace the unit. Proceed to test 4
1 V or short
circuit
- Positive (+) probe to rectifier grey socket pin
2
- Positive (+) probe to rectifier grey socket pin
3
Positive (+) probe to rectifier black socket pin
3 to:
- Negative (-) probe to rectifier grey socket
pin 1
- Negative (-) probe to rectifier grey socket
pin 2
- Negative (-) probe to rectifier grey socket
pin 3
4 Reconnect the harness and run the engine. 13 V - 15 V Action complete - quit test
Check the charging voltage at 2,000 rpm:
Fault still Test alternator stator (see
present Alternator Stator, page 698)
If alternator stator is serviceable,
contact Triumph service

Thruxton R 703
Electrical

Circuit Diagram

+
3 Black socket
2 for
1 rectifier out

Grey socket 3
for 2
Alternator 1

Voltage controller

3 2 1 3 2 1

Grey socket Black socket

for for
Alternator rectifier out

704 Thruxton R
 Electrical

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Thruxton R 705
Electrical

Lighting Circuit tables Code Wiring Colour

LU Light Blue
Key to Circuit Diagram
Key Item Description
1 Fuse Box (Fuses 1, 7and 8)
2 Front Brake Switch
3 Rear Brake Switch
4 Bluetooth Module Connector
5 Engine Control Module - Connector A
6 ABS Modulator
7 Rear Light Sub-Harness Connector
8 Instrument Assembly Connector
9 Oil Pressure Instruments Light
10 High Beam Warning Light
11 Engine Oil Pressure Switch
12 Daytime Running Light (DRL) Unit
13 Headlamp Bulb
14 Left Hand Switch Housing - 3 Way
Connector
15 Left Hand Switch Cube - DIP/DRL Switch
16 Main/DIP Beam Relay
17 Ignition Switch Connector
18 Starter Motor Solenoid Relay
19 Headlamp Relay

Key To Wiring Colour Codes

Code Wiring Colour
B Black
U Blue
N Brown
G Green
S Slate/Grey
O Orange
K Pink
R Red
P Purple
W White
Y Yellow
LG Light Green

706 Thruxton R
 Electrical

Lighting Circuit Diagram

1 2 3

8 7 1

3 2 1 3 2 1

Y GU GP GU B GP
U G Y Y

4
1

4A
U 3A 4A U
5A UG 3A
5A
G 1A 2A
1A 2A

19 B
18 B A06

BN A18

5
UY A30

BY A07

Y OG
17
6 8 GP 7
6

GP 3

Y 5
7
Y 2

B 4
B UY Y

1 2 3
16
4 U
U 3
5 UW

BN 1 2 G
12 8

14 11 9
1 BU 12
1 U

3 UR

2 UY UW 14

15 10

UW UW B UR

1 3 2

13

Thruxton R 707
Electrical

Starting and Charging Circuit Tables

Key to Circuit Diagram
Key Item Description
1 Battery
2 Starter Solenoid
3 Starter Motor
4 Starter Solenoid Relay
5 Engine Electronic Control Module -
Connector B
6 Engine Electric Control Module -
Connector A
7 EMS Relay
8 Alarm Connector
9 Right Hand Switch Housing - 8 Way
Connector
10 Instrument Assembly Connector
11 Immobiliser
12 Bluetooth® Module Connector
13 Ignition Switch
14 Regulator Rectifier - DC Connector
15 Fuse Box
16 Headlamp Relay
17 USB Socket

Key To Wiring Colour Codes

Code Wiring Colour
B Black
U Blue
N Brown
G Green
S Slate/Grey
O Orange
K Pink
R Red
P Purple
W White
Y Yellow
LG Light Green
LU Light Blue

708 Thruxton R
 Electrical

Starting and Charging Circuit

Diagram

1 2 3
M

1 2 3 4

N N WR B

4
UG 3
5 WR
16
14 3
1
BR
B
1 2 YN

U 3
5
B WR
G 1 2

B
A19
6
5
GR B01

YS B31

Y G N YN B25
N

9
15 7 8 2

Y G U NK

7
17 1
U

NK 3

YS 1 2

N Y G
9
1 4 5
3 B

G 1 2 GN

13 G 4
10 BBB B B

4 2 5 3 1
G 8

G 2 11 μP
8
G 6
12

Thruxton R 709
Electrical

Auxiliary and Accessory Circuit Code Wiring Colour

Tables O Orange
K Pink
Key to Circuit Diagram
R Red
Key Item Description
P Purple
1 Fuse Box
W White
2 Accessory Socket - Rider
Y Yellow
3 Ignition Switch
LG Light Green
4 Right Hand Switch Housing - 8 Way
Connector LU Light Blue

5 Hazard Light Switch

6 Right Hand Heated Grip (Internal
connector)
7 Diagnostic Connector
8 Rear Light Sub-Harness Connector
9 Alarm
10 Left Hand Front Direction Indicator
11 Right Hand Front Direction Indicator
12 Instrument Assembly Connector
13 Left Hand Switch Housing - 6 Way
Connector
14 Horn Switch
15 Left Hand Heated Grip (Internal
connector)
16 Direction Indicator Switch
17 Left Hand Switch Housing - 8 Way
Connector
18 Heated Grips Switch
19 Scroll Switch
20 Mode Switch
21 Blanked Electrical Connector
22 Horn
23 Heated Grip Connector

Key To Wiring Colour Codes

Code Wiring Colour
B Black
U Blue
N Brown
G Green
S Slate/Grey

710 Thruxton R
 Electrical

Auxiliary and Accessory Circuit

Diagram

1
6 3

21
1 BR P P

2 B

20
2 BR

18
6 BG

17 1 BO
P 2
4 B 2
19 B 1

14 22
4 PB PB 1 1 OG

5 B

15 BG 1
B

6 GU GU 2 23
B 3
OG
13
16 4
8

1 GR

3 GW
5
2 LGN LGN 7
GW 8
GR 6
3
GU 4

B 5 6

1 LGN
13 GU
22 BG
14 GU
19
23
BR
BO 7
15 P P 16
2 P
5 P

12
6 GR GR 6

8 GW GW 1
8
24 B
B 4
11 B

1 1 GW

11 B B B B B

B 10 11 6 8 7
1 1

W
1 1 GR
9
10 B
1 1

Thruxton R 711
Electrical

Engine Management Circuit Tables Key Item Description

35 Ignition Coil - Cylinder 2
Key to Circuit Diagram
36 Crankshaft Position Sensor
Key Item Description
37 EMS Relay
1 Engine Electronic Control Module
38 Fuse Box
2 Instrument Assembly Connector
3 Diagnostic Connector Key To Wiring Colour Codes
4 ABS Module Connector Code Wiring Colour
5 Bluetooth® Module B Black
6 Immobiliser U Blue
7 Ignition Switch N Brown
8 Gear Position Sensor G Green
9 Fall Detection Switch S Slate/Grey
10 Ambient Air Pressure Sensor O Orange
11 MAP Sensor K Pink
12 Fuel Level Sender R Red
13 Side Stand Switch P Purple
14 Intake Air Temperature Sensor W White
15 Coolant Temperature Sensor Y Yellow
16 Left Hand Switch Housing - 8 Way LG Light Green
Connector LU Light Blue
17 Clutch Switch
18 Main Beam Switch
19 Cruise Control Switch (if fitted)
20 Alarm Connector
21 Quickshifter
22 Twist Grip Position Sensor
23 Throttle Position sensor
24 Throttle Drive Motor
25 Fuel Pump Relay
26 Fuel Pump
27 Cooling Fan
28 Cooling Fan Relay
29 Oxygen Sensor - Cylinder 1
30 Oxygen Sensor - Cylinder 2
31 Fuel Injector - Cylinder 1
32 Fuel Injector - Cylinder 2
33 Purge Valve
34 Ignition Coil - Cylinder 1

712 Thruxton R
 Electrical

Engine Management Circuit Diagram

1
38 37
7 4 2
36
1 UB UB A35

2 UP
UP UP A36
7B 8B 2B 3 1 2 5
2
G NK NK NK NK R 9

U 10
NK NK A01

NK NK A13 3
35 A33

A34
R

U
R

U
6

14
NK 1 1 GK GK B15
B 4

34 5 4
NK 1 1 GP GP B14 4 U 11

33 3 R 2

NK 2 1 B B B06 6
U 1
32 7 R 6
NK 2 1 YP YP A11
2 BG 5

31 7 B 10
2 1 YK
NK YK A10
8
30 B44 BW BW 1

NK 3 4 W W B03 B23 BK BK 2

1 2 BU A22 B34 K K 4
BU
B18 KB KB 3
B
29 9
NK 3 4 W W B02
KB 6
1 2 BY BY A21
K 4

B38 KU KU 5

28 10
27 KB

K
1

M B41 KP KP 2
3 1 2 5 B
P NK BY NK 11
KB 1

BY A27 K 3

B36 KS KS 2

26 12
25
M KB 1
3 1 2 5
B K 2
G GR BP PW B27 BY BY 4

24
BP A26 13
GR B01 K 1
1 UO UO A02 3
B43 BR BR
2 UG UG A03
B 2

14
1 UY UY B20 KO KO 1
B42
4 UG UG B26 B 2
23 2 B B B19

3 R R B33 15
B40 KG KG 1

B 2
7 R

5 B 16
6 W W B28 B 4
22 2 W W B21 B45 BO BO 3

1
B

R
B

R
B35

B17
17
A04 WU WU 7

18
A29 WR WR 5
21
1 RB B22 GR 8
19
2 B

A20 B
B
A23 B
1
A25

B08
B

B
20
B13 B

B48 B

Thruxton R 713
Electrical

ABS System Circuit Tables ABS ECM Connector Pin Numbering

Key To Wiring Circuit Diagram 9 8 2 1

Key Item Description
1 ABS Modulator
2 Fuse Box
3 Front Brake Switch
4 Rear Brake Switch
5 Engine Electronic Control Module -
Connector A
6 Rear Light Sub-harness Connector
18 17 11 10
7 Front Wheel Speed Sensor chzl

8 Rear Wheel Speed Sensor The above illustration shows the pin numbering
system used in the ABS circuit diagram.
9 Instruments Connector As viewed on the mating face with the ABS ECM (as
10 Diagnostic Connector per the illustration), pins are numbered from right
to left with number one in the top right hand
corner.
Key To Wiring Colour Codes
Code Wiring Colour
B Black
U Blue
N Brown
G Green
S Slate/Grey
O Orange
K Pink
R Red
P Purple
W White
Y Yellow
LG Light Green
LU Light Blue

714 Thruxton R
 Electrical

ABS System Circuit Diagram

2
7 5
1
10A 25A

R 18

G 4

3 1 GP GP 7

4 1 GP

5 A07 BY

6 3 GP

1 UW 17
7 2 BG 8

1 UR 15
8 2 BG 6

9 21 BU 3

1 OG 13

7 BG 5
10
6 R 2

14 U 11

B 10

Thruxton R 715
Electrical

Complete Main Harness Key Item Description Key Item Description

Table 27 Immobiliser Antenna 57 MAP Sensor
28 Rider Accessory Socket 58 Ambient Air Pressure
Key to Circuit Diagram Sensor
29 Immobiliser
Key Item Description 59 Roll Over Switch
30 Front Brake Switch
1 Engine Electronic 60 Side Stand Switch
Control Module 31 Engine OFF Switch
61 Fuel Level Sender
2 Intake Air Temperature 32 Engine Start Switch
Sensor 62 Gear Position Sensor
33 Hazard Light Switch
3 Engine Coolant 63 Ignition Coil 2
34 Direction Indicator
Temperature Sensor Switch 64 Ignition Coil 1
4 Cooling Fan 35 Horn Switch 65 Oxygen Sensor 2
5 Cooling Fan Relay 36 Dip/Main Switch 66 Oxygen Sensor 1
6 Engine ECM Main Relay 37 Clutch Switch 67 Injector 2
7 Fuel Pump 38 Instrument Scroll Switch 68 Injector 1
8 Fuel Pump Relay 39 Mode Switch 69 Purge Valve
9 Rear Brake Switch 40 Heated Grips Switch (if 70 Drive By Wire Throttle
10 Brake Light fitted) Motor

11 Rear Light 41 Cruise Control 71 Throttle Position Sensor

12 Licence Plate Light 42 Bluetooth® Module 72 Twist Grip Position

Connector Sensor
13 Left Hand Rear Direction
Indicator 43 USB Charging Point 73 Crankshaft Position
Connector sensor
14 Right Hand Rear
Direction Indicator 44 Rear Wheel Speed 74 Quick shifter
Sensor
15 Rear Light Sub-Harness
45 Front Wheel Speed Key To Wiring Colour Codes
Electrical Connector
Sensor
16 Dip/Main Headlamp Code Wiring Colour
Relay 46 ABS Modulator B Black
17 Alarm Connector 47 Diagnostic Connector U Blue
18 Engine Alternator 48 Headlamp Bulb N Brown
Connector 49 Front Position Light/ G Green
19 Starter Motor Solenoid Daytime running Lights
(DRL) S Slate/Grey
Relay
50 Right Hand Front O Orange
20 Starter Motor Solenoid
Direction Indicator K Pink
21 Harness Battery
Negative Connection 51 Left Hand Front R Red
Direction Indicator
22 Battery P Purple
52 Horn
23 Starter Motor W White
53 Dip/Daytime Running
24 Fuse Box Lights (DRL) Switch Y Yellow
25 Headlamp Main Relay 54 Instruments LG Light Green
26 Ignition Switch 55 Oil Pressure Switch LU Light Blue
Connector
56 Heated Grip Switch

716 Thruxton R
Electrical

Complete Main Harness Diagram

59 60 61 62 63 64 65 66 67 68 69 70 71 72
1

K 4
KB 6
KU 5

BR 3
B 2
K 1

BY 4
K 2
KB 1

4
3
1
2

1
2
4
3

1
2
4
3

NK 2
YP 1

NK 2
YK 1

NK 2
B 1

UO 1
UG 2

4
1
2
3
2 3

UG
GP

GK

BU
NK

NK

UY
NK
KB

BK

NK

BY
BW

W
B 1

R
K

B
B
4

RB B22
B28
B35
B21
B17
B33
B19
B20
B26
A03
A02
B06
A10
A11
B02
A21
B03
A22

GK B15

GP B14

BK B23
BW B44

KB B18
B34

BY B27

BR B43

KU B38

B41
B36
B45
A36
A35
A29
A34
A33
A30
A04
B08
B48
B13
A20
A25
A23

B25
A18
A19
B31
A01
A13
A27

B01
A26
A07
A06
B40
B42
NK 2

KO 1
B 2

KG 1
B 2
5
7
1
2
3
6

WR

UW

GW
UG
UG
UO

WR
BO
UY

BU

UP
UB

NK
UY
YK
YP

KP
KS

GR
BY

GY

KG
KO
YN
BN

NK
NK
YS

BP
W

W
R
R

R
1 KB

B
B
B
B
B
B
W

B
R
R
B

B
58 2 KP
3 K NK 5
NK 1

1 KB 5
57 2 KS
3 K
BY 2
NK 3

2 GU NK
56 1 B
3 BG
NK 5
YS 1
6

UP
UB
55 1 BU
B 2

2
1
NK 3
12 BU
10
9
R
R
73
7 B
11
24
B
B
B 1
PW 2 7
14 GU
8 GW
1 LgN
54 13
23
GU
BW
PW 5
GR 1
22 BG
15 P 8
2 P BP 2
5 P G 3
20 UW
6 GR
4 G
19 BR 1 B 2
RB
21 BU 74 2 B
GU
GP
3
1
9

53 1 U GP 3 GP GP
2 UY B 10
3 UR

BU Y 5 Y
B
Y 11
52

B
PB
Y 2
B
B 12

B
1 GR GR 6 GR GR 1 1 GR

51 13
1 B 1 1
B B 4 B B

1 GW GW 1 GW GW 1 1 GW

50 15 14
1 B B 1 1 B

B 8
1 B B 7
49 3
2
Y
UY
B
B
10
11
B 1
B 5
1 UW
3 B
B 6 17
48 B 2

2 UR U 4 B 4
3 U B 3
UW 5 B 9
16 P 16 B 12
4 B G 2 1 BN
14 U 4
47 6 R U 3
7 BG 5 UG
1 OG
G 1 2 B BR 3

10 B B 1
18
3 BU
13 OG 25 4 U
5 BG UG 3
2 R 5 WR
11 U B
18 R WR 1 2 YN
46 4 G

P
7 GP
19
6
15
8
17

G
N

N
OG

BG
G
N

B
20
LgN

LgN
GW

GW
WR

WU

WR
WB
GR

GU

GR

GU

GR

GN
BG

GB

GP
BR

KB

PB
BR

U
B

B
UW

1
BG
UR
BG

N
1

7
Y
B

26
1
2

8
5
6
2

1
4

5
4
2
1

4
5

8
6
7

2
3
1

1
1 2 3 4 5 6 7 8 9
23 2
3
N
WR
45
WG
WB
W

W
N

N
Y

2
LgN

LgN
GW

GW

WR
GR

GR

GN
BG

BG
PB

M
G

G
G
R

U
R

R
U
B

4 B
21
B
P

NK

NK
24

G
R

U
Y

Y
1
44
10
7
6
1
8
2

1
2

2 B 1 1
L R 28 27
B

B
G
R
U
B

B
29 P
2
3
4
6
1

2
43 42 41 40 39 38 37 36 35 34 22
1
33 32 31 30

Thruxton R 717