Triumph Scrambler 1200 XC Bedienungsanleitung

Service Manual - Scrambler 1200

Introduction

This manual is designed primarily for use by trained technicians in a properly

equipped workshop. However, it contains enough detail and basic information to

make it useful to the owner who desires to perform his own basic maintenance and

repair work. The work can only be carried out if the owner has the necessary hand

and special service tools to complete the job.

A basic knowledge of mechanics, including the proper use of tools and workshop

procedures is necessary in order to carry out maintenance and repair work

satisfactorily. Whenever the owner has insufficient experience or doubts regarding his

ability to do the work, an authorised Triumph dealer must undertake all adjustments,

maintenance, and repair work.

In order to perform the work efficiently and to avoid costly mistakes, read the text and

thoroughly familiarise yourself with procedures before starting work.

All work should be performed with great care and in a clean working area with

adequate lighting.

Always use the correct special service tools or equipment specified. Under no

circumstances use makeshift tools or equipment since the use of substitutes may

adversely affect safe operation.

Where accurate measurements are required, they can only be made using

calibrated, precision instruments.

For the duration of the warranty period, an authorised Triumph dealer must perform

all repairs and scheduled maintenance.

To maximise the life of your motorcycle:

Accurately follow the maintenance requirements of the periodic maintenance

chart in the Service Manual.

Do not allow problems to develop. Investigate unusual noises and changes in

the riding characteristics of the motorcycle. Rectify all problems as soon as

possible (immediately if safety related).

Use only genuine Triumph parts as listed in the electronic parts catalogue (EPC).

Follow the procedures in this manual carefully and completely. Do not take short

cuts.

Keep complete records of all maintenance and repairs with dates and any new

parts installed.

Service Manual - Scrambler 1200 XC 1 of 640

Use only approved lubricants, as specified in the Owner's Handbook, in the

maintenance of the motorcycle.

How to use this manual

To assist in the use of this manual, the section title is given at the top.

Each major section starts with a contents page, listing the information contained in

the section.

The individual steps comprising repair operations are to be followed in the sequence

in which they appear.

Adjustment and repair operations include reference to service tool numbers and the

associated illustration depicts the tool.

Where usage is not obvious, the tool is shown in use.

Adjustment and repair operations also include reference to wear limits, relevant data,

torque figures, specialist information and useful assembly details.

Warnings, Cautions and Notes

Particularly important information is presented in the following form:

WARNING

This warning symbol identifies special instructions or procedures which, if not

correctly followed, could result in personal injury, or loss of life.

CAUTION

This caution symbol identifies special instructions or procedures which, if not

strictly observed, could result in damage to or destruction of equipment.

Note

This note symbol indicates points of particular interest for more efficient and

convenient operation.

Tampering with Noise Control System Prohibited

Owners are warned that the law may prohibit:

The removal or rendering inoperative by any person other than for purposes of

maintenance, repair or replacement, of any device or element of design

incorporated into any new vehicle for the purpose of noise control prior to its sale

or delivery to the ultimate purchaser or while it is in use; and

The use of the vehicle after such device or element of design has been removed

or rendered inoperative by any person.

Service Manual - Scrambler 1200 XC 2 of 640

References

References to the left hand or right hand side given in this manual are made when

viewing the motorcycle from the rear.

Operations covered in this manual do not always include reference to testing the

motorcycle after repair. It is essential that work is inspected and tested after

completion and, if necessary, a road test of the motorcycle is carried out particularly

where safety related items are concerned.

Dimensions

The dimensions quoted are to design engineering specification with service limits

where applicable.

During the period of running-in from new, certain adjustments may vary from the

specification figures given in this manual. These will be reset by the dealer at the 500

mile/800 km service, and thereafter should be maintained at the figures specified in

this manual.

Repairs and Replacements

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.

Tightening procedure

Service Manual - Scrambler 1200 XC 3 of 640

Generally, when installing a part with several bolts, nuts or screws, they should all be

started in their holes and tightened to a snug fit, evenly and in a cross pattern. This is

to avoid distortion of the part and/or gas or oil leakage. Conversely, bolts, nuts, or

screws, should all be loosened (in sequence if specified) by about a quarter of a turn

and then removed.

Where there is a tightening sequence specified in this Service Manual, the bolts,

nuts, or screws must be tightened in the order and by the method indicated.

Torque wrench setting figures given in this manual must be observed. The torque

tools used must be of accurate calibration.

Torque Tolerance

Torque

Tolerance

0 Nm to 25 Nm

+/- 10%

26 Nm to 100 Nm

+ 10% -0%

101 Nm to 200 Nm

+10% -0%

Locking devices, where specified, must be fitted. If the efficiency of a locking device is

impaired during removal it must be renewed. This applies particularly to micro-

encapsulated fixings which must always be replaced if disturbed. Where necessary,

the text in this manual will indicate where such a fixing is used.

Use of Crow Foot Spanner Adapters with Torque Wrenches

The use of a crow foot spanner adapter will effectively lengthen the lever arm of a

torque wrench. The amount of torque applied to a fastener is increased as the torque

wrench lever arm is extended, therefore the torque wrench setting must be adjusted

in order to achieve the correct tightening torque.

Before tightening a fixing using a crow foot spanner adapter, measure the normal

length of the torque wrench from the centre of the drive square to the centre of the

handle (dimension L1). Fit the crow foot spanner adapter to the torque wrench as

shown below. Measure the extended length of the torque wrench from the centre of

the crow foot spanner head to the centre of the handle (dimension L2).

Use the following formula to calculate the correct torque wrench setting to achieve the

required tightening torque.

Note

The example shown below is calculated using a crow foot spanner measuring

25 mm from the centre of the spanner head to the centre of the drive square.

Service Manual - Scrambler 1200 XC 4 of 640

ciyj

M1 = M2 x L1 / L2

Example

M2 is the required tightening torque to be applied

90 Nm

L1 is the normal length of the torque wrench,

measured from the centre of the drive square to the

centre of the handle

300 mm

L2 is the extended length of the torque wrench,

measured from the centre of the crow foot spanner

head to the centre of the handle

325 mm

M1 is the calculated torque wrench setting

83 Nm

General Information

Ignition System Safety Precautions

WARNING

The ignition system produces extremely high voltages. Do not touch any part of the

ignition system or any cables while the engine is running.

An electric shock caused by contact with the ignition system may lead to illness,

injury or death.

WARNING

Wearers of surgically implanted heart pacemaker devices should not be in close

proximity to ignition circuits and or diagnostic equipment.

The ignition system and any diagnostic equipment may interrupt the normal

operation of such devices causing illness or death.

Dangerous Substances

Service Manual - Scrambler 1200 XC 5 of 640

WARNING

Many liquids and other substances used in motor vehicles are poisonous and

should under no circumstances be consumed and should, as far as possible, be

kept from contact with the skin. These substances among others include acid,

antifreeze, asbestos, brake fluid, fuel, lubricants, and various adhesives. Always

pay close attention to the instructions printed on labels and obey the instructions

contained within. These instructions are included for your safety and well-being.

NEVER DISREGARD THESE INSTRUCTIONS!

Third Party Products

WARNING

Many proprietary products, such as chemicals, solvents and cleaning agents, will

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.

Fluoroelastomers

WARNING

Fluoroelastomer material is used in the manufacture of various seals in Triumph

motorcycles.

In fire conditions involving temperatures greater than 315°C this material will

decompose and can then be potentially hazardous. Highly toxic and corrosive

decomposition products, including hydrogen fluoride, carbonyl fluoride, fluorinated

olefins and carbon monoxide can be generated and will be present in fumes from

fires.

In the presence of any water or humidity, hydrogen fluoride may dissolve to form

extremely corrosive liquid hydrofluoric acid.

If such conditions exist, do not touch the material and avoid all skin contact. Skin

contact with liquid or decomposition residues can cause painful and penetrating

burns leading to permanent, irreversible skin and tissue damage.

Oils

Service Manual - Scrambler 1200 XC 6 of 640

WARNING

The engine oil may be hot to the touch. Contact with hot oil may 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.

Health Protection Precautions

Avoid prolonged and repeated contact with oils, particularly used engine oils.

Wear protective clothing, including impervious gloves where practicable.

Do not put oily rags in pockets.

Overalls must be cleaned regularly. Discard heavily soiled clothing and oil

impregnated footwear.

First aid treatment should be obtained immediately for open cuts and wounds.

Always be aware of who your nearest First Aider is and where the medical

facilities are kept.

Use barrier creams, applying before each work period to protect the skin from the

effects of oil and grease and to aid removal of the same after completing work.

Wash with soap and water to ensure all oil is removed (skin cleansers and nail

brushes will help). Preparations containing lanolin replace the natural skin oils

which have been removed.

Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning

skin.

If skin disorders develop, obtain medical advice without delay.

Where practicable, degrease components prior to handling.

WARNING

Any risk of eye injury must be avoided. Always wear eye protection when using a

hammer, air line, cleaning agent or where there is ANY risk of flying debris or

chemical splashing.

Environmental Protection Precautions

Service Manual - Scrambler 1200 XC 7 of 640

CAUTION

Do not pour oil on the ground, down sewers or drains, or into water courses. To

prevent pollution of water courses etc., dispose of used oil sensibly. If in doubt

contact your local authority.

Burning of used engine oil in small space heaters or boilers can be recommended

only for units of approved design. If in doubt, check with the appropriate local authority

and/or manufacturer of the approved appliance.

Dispose of used oil and used filters through authorised waste disposal contractors,

to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt,

contact your local authority for advice on disposal facilities.

Brakes

WARNING

Brake fluid is hygroscopic which means it will absorb moisture from the air. Any

absorbed moisture will greatly reduce the boiling point of the brake fluid causing a

reduction in braking efficiency.

Replace brake fluid in line with the routine maintenance schedule. A dangerous

riding condition could result if this important maintenance item is neglected!

Do not spill brake fluid onto any area of the bodywork as this will damage any

painted or plastic surface.

Always use new brake fluid from a sealed container and never use fluid from an

unsealed container or from one that has been previously opened.

Do not mix different brands of fluid. Check for fluid leakage around brake fittings,

seals and joints.

Check regularly for brake hose damage.

FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING

EFFICIENCY LEADING TO AN ACCIDENT.

WARNING

If there has been an appreciable drop in the level of the fluid in either brake fluid

reservoir, consult your authorised Triumph dealer for advice before riding.

If the brake lever or pedal feels soft when it is applied, or if the lever/pedal travel

becomes excessive, there may be air in the brake lines or the brake may be

defective.

It is dangerous to operate the motorcycle under such conditions and remedial

action must be taken by your authorised Triumph dealer before riding the

Service Manual - Scrambler 1200 XC 8 of 640

WARNING

motorcycle.

Failure to take remedial action may reduce braking efficiency leading to an

accident.

WARNING

Use only DOT 4 specification brake fluid as listed in the General Information

section of this manual. The use of brake fluids other than those DOT 4 fluids listed

in the General Information section may reduce the efficiency of the braking system

leading to an accident.

Failure to change the brake fluid at the interval specified in the routine

maintenance schedule may reduce braking efficiency resulting in an accident.

WARNING

Never use mineral-based 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.

Damage caused by contact with mineral-based grease may reduce braking

efficiency resulting in an accident.

WARNING

Before installation, all internal brake components should be cleaned and

lubricated with clean new DOT 4 brake fluid.

Never use solvents, petrol (gasoline), engine oil or any other petroleum distillate

on internal brake components as this will 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.

Safety Instructions

Jacking and Lifting

WARNING

Always ensure that any lifting apparatus has adequate load and safety capacity for

Service Manual - Scrambler 1200 XC 9 of 640

WARNING

the weight to be lifted. Ensure the motorcycle is well supported to prevent any

possibility of the machine falling prior to lifting or jacking or while repairs and

servicing are carried out.

Never rely on a single means of support when working with the motorcycle. Use

additional safety supports and straps to prevent toppling.

Do not leave tools, lifting equipment, spilled oil, etc. in a place where they could

become a hazard to health. Always work in a clean, tidy area and put all tools away

when the work is finished.

Precautions Against Damage

Avoid spilling brake fluid or battery acid on any part of the bodywork. Wash spillages

off with water immediately.

Disconnect the battery earth lead before starting 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.

WARNING

Do not remove the radiator cap when the engine is hot. When the engine is hot,

the coolant inside the radiator is hot and also under pressure. Contact with the

pressurised coolant will cause scalds and skin damage.

CAUTION

The coolant antifreeze contains a corrosion inhibitor which helps prevent damage

to the metal surfaces inside the cooling system. 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

correct antifreeze as specified in the Owner's Handbook. Never use a methanol

Service Manual - Scrambler 1200 XC 10 of 640

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