FUEL SYSTEM/ENGINE MANAGEMENT CONTENTS Page Exploded Views ........ are 83 Fuel requirements . aed a7 Glossary of terms g 87 Engine Management System 10 System Description 8.10 ‘System Sensors .... 8.10 Sensor Locations eetive o Bn 3 System Actuators .. seas 2 - B12 Pa ‘Actuator Locations 813 i Circuit Diagram - T7600 8.14 Circuit Diagram ~ Speed Four 8.16 t ‘System Diagnostics 8.18 Service Diagnostic Tool ........ 8.22 Tool Keys . 8.23 Diagnostic Test Procedure 4 8.23 Restarting Tune Download ........... 8st { Electrical Connectors . 852 Removal of ECM connectors 8.53 Refitting of ECM connectors aie 8.53 ECM Connector Pin Numbering .......2.ceseecee “ 8.53 Further Diagnosis - Electrical ..........0s00. rf feniicn 8.53 Further Diagnosis - Non-electrical empaticAiwiss + B69 Fuel Tank . be 8 ie oh 568 i 8.70 Fuel Tank Removal 3 6 * 8.70 Installation . a a7 Fuel Pump a 8.72 Removal 2... eee eee + 872 Assembly 873 Fuel Pressure Testing «00... .20ceceseeeee : - 873 Test Procedure . Bib abae bers rupees 8.73 Fusl Filter . 874 Removal pipiew sadn 8.74 Assembly... 2 enn eat 8.75 Low Fusl Level Sender “ etd B76 Removal ‘ ¥ 8.75 Assembly is 8.76 Airbox Removal InstallationCONTENTS cont'd Page Ait Filer oes i : ete 8.78 Removal ......... a7 Assembly . 878 Intake Air Temperature Sensor 8.78 Removal cats 8.78 Installation... cece eee ae 8.78 Crankshaft Positon Sensor a79 Removal 879 Installation ... 87a Throttle Cable .. 8.80 Removal 8.80 Examination 8.81 Installation 8.81 Adjustment 8.81 Throttle Bodies ase Removal 8.82 Installation 8.83 Throttle Body Balancing ..... 8.84 Injectors / Fuel Rail / Fuel Pressure Regulator ...... i 8.86 Removal . 8.86 Disassembly... 286 Assembly ... 8.87 Installation 8.87 Idle Air Control Vaive ‘i ‘ 8.88 Removal 2.2.0.2... “ 8.88 Installation... sles 8.88 Idle CO Setting see 8.89 Exhaust System... 2.02... 8.90 Installation «2.2... ¢ 8.91 Evaporative Loss Control System - California Models Only... 8.91 Component Locations .....0.6.cceceee 8.91 Evaporative Control System - Engine Off, Seyuiceotesel abe: Evaporative Control System - Engine Running 8.93 Evaporative Control System - Hose Routing. ........ 06 cecesesseeeseee 8.94 Secondary Air injection System .... " gai Aasrramanlondese cs, BBE System Operation 8.95 Reed Valve Assembly 8.95 Removal : 8.95 Disassembly 8.98 Inspection ...... a Assembly Installation scarica mechaFUEL SYSTEMIENGINE MANAGEMENT 88 FUEL SYSTEM/ENGINE MANAGEMENT Exploded View - Fuel Rail, Throttles and InjectorsFUEL SYSTEM/ENGINE MANAGEMENT 88 FUEL SYSTEM/ENGINE MANAGEMENT Exploded View - Exhaust SystemFUEL REQUIREMENTS . Fuel Requirements - all countries except USA Outside America, all motorcycles are designed to be run on 85 RON unleaded fuel, Fuel Requirements - USA In the United States of America where the octane rating of fuel is measured in a different way, the following information may be applied: Triumph motorcycles are designed torun on unleaded gasoline with a CLC or AKI “octane rating (R+M)/2 of 89 or higher. 4\ CAUTION: The use of leaded gasoline is itlegal in some countries, states or territories. Check local regulations before using leaded gasoline. Oxygenated Gasoline ‘Tohelp in meeting clean air standards, some areas ofthe U.S. use oxygenated gasoline to help reduce harmful emissions. Triumph motorcycles wil give best performance when using unleaded gasoline. However, the following should be used as a guide to the use of oxygenated fuels. [ ZA, CAUTION: | Beseuse 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 ‘gasoho'’, ‘ethanol enhanced’, or ‘contains ethanol’. This fuel may be used in Triumph motorcycles. Methanol LN CAUTION: Fuels containing methanol should not be used in Triumph motoreycles as damage to components in the fuel [system can be caused by contact with methanol. MTBE (Methyl Tertiary Butyl Ether) The use of gasolines containing up to 15% MTBE ! “thy! Tetary Butyl Ether) is permitted in Triumph wlorcycles FUEL SYSTEM/ENGINE MANAGEMENT 8 GLOSSARY OF TERMS The following terms and abbreviations will be found in this section. Below is given a brief explanation of what some of the more common terms and abbreviations mean. Adaptive Stepper Position The position of the idle air control valve stepper motor after adapting to a particular engine's operational characteristics. Air temperature The intake air temperature in the air box. Air temperature sensor . Sensor located in the airbox to detect the temperature of the incoming air. aToc After Top Dead Centre. Barometric pressure Pressure of the air in the airbox Battery voltage The voltage at the input to the Electronic Control Module (ECM), sTDc Before Top Dead Centre (TDC). Calculated load The actual volume of air per stroke flowing into the engine, expressed as a percentage of the maximum. volume that can enter. Provides an indication of the Percent engine capacity that is being used (100% = full throttle) Catalyst Device placed in the exhaust system which reduces exhaust emissions,8 FUEL SYSTEM/ENGINE MANAGEMENT Closed throttle position Throttle position at idle (.¢. against end stop), measured as a voltage and expressed as percentage. 0% = Ovolts 100% = 5 volts Coolant temperature ‘The coolant temparature in the cylinder head, Coolant temperature sensor ‘Sensor which detects coolant temperature. Cooling fan status ‘The ‘on’ or ‘off condition of the cooling fan, Corrected Throttle Position The electronic value of the throttle position corrected according to the closed value of the throttle potentiometer. The reading for corrected throttle Position will be different to the actual throttle position. ore Diagnostic Trouble Code. ECM Engine Control Module. Engine speed ‘The crankshatt revolutions por minute, Freeze frame A data set captured at the time a Diagnostic Trouble Code (DTC) is sat lacy Idle Air Control valve. Idle air contro! valve stepper position The position of the idle air control valve stepper motor; 0 = fully closed 180 = fully open TRuun Idle fuel trim i q The percentage above or below the nominal fucl requirement for the volume of air entering at idle. : Idle fueting : Adjustment of fueling at idle to suit the actual air : inducted, Idle reference speed ‘ The target idle speed as determined by the Electronic Control Module (ECM). (It should be the same as the actualidle speed ifthe motorcycleis operating correcty) — Ignition advance ‘ i The timing of ignition at the spark plug relative to top : dead centre. Ignition switch position The ‘on’ or ‘off position of either or both the ignition switch and the engine stop switch. Ignition timing Same as ‘ignition advance’, Injector pulse time The time during which an injector remains open (Le. delivering fuel). Long term fuel trim Fusling after adapting to the engine's long term fusting requirements (closed loop only). See also short term uel trim, 3 mL Malfunction Indicator Lamp. f liluminates when most Diagnostic Trouble Codes (TC's) are set 3 Neutral switch status The ‘neutral’ or ‘in gear’ status of the gearchange. &“The percentage above or below the nominal fuel ““Tequirement for the volume of air entering at engine “Speeds other than idle, This function is not currently | Qused in the Triumph system, open circuit Abreak in an electrical circuit ~ current cannot flow. “Over temp’ {High temperature within the Electronic Control Module (ECM) caused by an internal or external failure. ‘purge valve duty eyele ‘The time the purge valveis open in an open close cycle, expressed as a percentage of the cycle time. ‘Sensor reference voltage ‘Supply voltage to the throttle potentiometer (nominally 5 volts) Short circuit ‘A'short cut" in an electrical circuit — current by-passes the intended circuit (usually to earth). Short term fuel trim ‘A correction applied to the fuel mixture during closed loop catalyst operation. This, in turn has an effect on the Jong term fuel tim in that, fan engine constantly requires mixture correction, the jong term fuel trim will adapt to requirement thus reducing the need for constant snort term agjustment, Sidestand status ‘The ‘up' or ‘down’ position of the side stand, FUEL SYSTEM/ENGINE MANAGEMENT 8 Target dwell time ‘The actual time from coil ‘on’ to coil ‘off Throttle position The position of the throttle butterfly given as a percentage of the movement range. When the data is displayed on the tool, fully open need not be 100% nor fully closed 0%. Generally, fully open will be in the 7096 range. (See also corrected throttle position). Throttle voltage Voltage at the throitle potentiometer. Voatt Battery voltage, * 398 FUEL SYSTEM/ENGINE MANAGEMENT ENGINE MANAGEMENT SYSTEM ‘System Description This model is fitted with an electronic engine management system which encompasses control of both ignition and fuel delivery. The electronic control module (ECM) draws information from sensors positionied around the engine, cooling and air intake systems and precisely calculates ignition advance and fueling requirements for all engine speeds and loads. In addition, the system has hardware diagnostic functions similar to the US state of California requirements for on-board diagnostics (OBDII). This function ensures that, should a matfunction occur in the system, the malfunction type and engine data at the time the malfunction occurred are storedin the ECM memory. This stored data can then be racovered by a Triumph dealer using a special service tool which is mandatory for all Triumph dealers. In this way, precise diagnosis of a fault can be made and the fault quickly rectified. System Sensors * Intake air temperature sensor - situated at the rear ofthe airbox, between the air filler element and the air intakes. AAs the density of the air (and therefore the amount of oxygen available to ignite the fuel) changes with temperature, an intake air temperature sensor is fitted. Changes in air temperature (and therefore air density) are compensated for by adjusting the amount of fuel injected to a level consistent with clean combustion and low emissions, ° Barometric pressure sensor - situated in the Electronic Control Module (ECM), the barometric pressure sensor measures atmospheric air pressure. From this measurement the air density is calculated, and when added to other inputs to the ECM, the engine load is calculated. With this, information, the amount of fuel per injection is ‘adjusted to suit the prevailing conditions. Trumps Crankshaft position sensor ~ situated on top of the crankcase directly above the alternator cover, ‘The crankshaft position sensor detects movement of a toothed wheel attached to the alternator rotor. The toothed wheel has a number teeth which are evenly spaced, and one triple length tooth next toa triple length gap. The triple length tooth/gap givesa reference point from which the actual crankshaft position is calculated. The crankshaft position sensor informations used by the 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 on the left hand side of the cylinder head. Coolant temperature information, received by the ECM, is used to optimise fueling at all engine temperatures and to calculate hot and cold start fueling requirements. Throttle position sensor - situated at the right hand end of the throttle spindle. In relaying information to the ECM, all other throttle opening angles are calculated using the fully closed position as a base, Throttle angle Is used by the ECM to determine fueling requirements for all throttia positions. i OMe eS eNO Neutral switch - situated in the gearbox. The neutral switch indicates when the transmission is in neutral, in addition, the neutral switch provides an interlock facility preventing the rider from riding off with sidestand down. If a gear is selected with the sidestand down, the ECM will cause the engine lo cut-out. Side stand switch - situated at the top of the sidestand leg. If the sidestand is in the down | Position, the engine will not run unless the ‘transmission is in neutral. |gine Management System Sensor Locations Engine Coolant Temperature Sensor _Intake Air Temperature Sensor (in the eylinder head, left side) (in airbox, at the rear) FUEL SYSTEM/ENGINE MANAGEMENT 8 Engine Control Module Barometric Pressure Sensor (below seat, in ECM) Crankshaft Position Sensor (on crankcase, left hand side) ‘Throttle Position Sensor (right hand end of throttle bodies) Neutral Switch (in transmission case) Side Stand Switch (on side stand bracket)8 FUEL SYSTEM/ENGINE MANAGEMENT ‘System Actuators In response to signals received from the sensors, the ECM controls and directs messages to a series of electronic and electro-mechanical actuators. The function and location of the actuators is given below. * Idle Air Control System - Locate on a bracket mounted on the rear of the crankcase. The idle alr control system comprises an air control valve, (connected to the airbox by a rubber hose), and a stepper motor. The system has a controling influence over the following: + Idle speed + Induction air supply during engine overrun. + Airfluel ratio correction when operating at altitudes above sea level * Cold and hot start air/fuel ratio correction. ‘When in operation, the stepper motor opens the air control valve by a variable distance, allowing a controlled supply of air to flow along a series of pipes, into the induction systam. The air is fed to a point between the throttle plates and the inlet valves. dling - When the engine is idling, the stepper ‘motor opens the idle air control valve éllowing air to be fed to the engine even though the throttles are closed. The distance that theidle air control valve is ‘opened is controlled by the ECM using information received from the coolant temperature sensor, barometric pressure sensor eic. Idle ar fuel ratio is adjusted by feeding more or less air to mix with the fuel supplied by the injectors. Overrun ~ During overrun conditions, where air flow into the cylinder is very low, the idle air control system feeds additional arto the induction system allowing normal air/fuel ratios to be maintained. Altitude correction - ifthe motorcycle is operated at high altitude, the reduced air density will be ‘compensated for by varying tre amount of air fed to the engine via the idle ait control system. For example, at high altitudes, the idle air control systemfeeds a greater volume of airio the induction system to compensate for the airs reduced oxygen content. Cold and hot start - Except in very cold conditions where a small amount of throttle opening aids cold start performance, the engine is usually started with the throttle in the closed position. The idle air control system regulates the start-up air supply to the induction system. * Canister purge valve (California models only) ~ situated in the vapour retum line between the carbon canister and the throttle. The purge valve Controle the return of vapour which has been stored in the carbon canister during the period when the engine is switched off. The valve is ‘pulsed’ by the ECM to give control over the rate at which the canister is purged. Injectors - located in the throttle body assembly, The engine is fitted with four injectors which are targeted at the back face of the inlet valves. The spray pattern of the injectors is fixed but the length of ime each injector remains open is variable. The duration of each injection is calculated by the ECM using date received from the various sensors in the system. Plug top ignition coils - mounted directly onto the top of each spark plug. The ECM controls the point at which the coils are switched on and off. In calculating the switch-on time, the ECM allows sufficient time for the coils to charge to a level where a spark canbe produced. The coils are switched off at the point of ignition, the timing of which is ‘optimised for good engine performance. Main power relay - located beneath the motorcycle seat. When the ignition is switched on, the main power relay is powered up lo provide @ stable voltage supply for the ECM. When the ignition is switched off, the ECM holds the ‘main power ralay on so that it can carry out the power down procedure which includes; + writing data to the ECM memory, + referencing the position of the idle air control valve stepper motor, * running the cooling fan until the engine is sufficiently cool Once all the power down procedures have been carried out, the main power relay is turned off. 4 4 ;Fuel pump - located inside the fuel tank. The electric pump delivers fue! into the fuel system, viaa pressure regulator, at a constant 3 bar pressure. ‘The pump is run continuously when the engine is operating and is also run briefiy when the ignition is first switched on to ensure that 8 bar is available to the system as soon as the engine is cranked. “Actuator Locations Fuel Pump {in base of fuel tank) Canister Purge Valve (below throttle bodies) Idle Air Control System (below airbox) FUEL SYSTEM/ENGINE MANAGEMENT 8& Cooling fan - located in front of the radiator, The ECM controls switching on and off of the cooling fan in response to a signal received from the coolant temperature sensor. When the coolant temperature rises to a level where the cooling effect of natural airfow is insufficient, the cooling fan is tured on by the ECM. When the coolant temperature falls sufficiently, the ECM turns the cooling fan off. I'the engine is switched off when the fan is running, the fan will continue to run until the temperature has been reduced to a normal level. Plug Top Ignition Coils top of cam covey) Cooling Fan (behind radiator) Injectors (in cylinder head)8 FUEL SYSTEMIENGINE MANAGEMENT Tapa ENGINE MANAGEMENT CIRCUIT DIAGRAM - Key To Wiring Colour Codes ‘T7600 + Code Wiring Colour Key To Wiring Circuit Diagram 3 ee Key [Item u Blue 1 [Engine connector N Brown 2 [Engine control module G Green 3 [Fuel pump s Grey @_| Evaporative system purge valve Q Orange 3 | ignition coils us Pink @ | Fuel injectors Fi Rest 7__|[Goaling Tan F Lis Ww ‘White 8 | Diagnostic connector ¥ aie 9 | Idle air control valve stepper motor ie Light Green 10. | Low fuel level sensor i Tati bs 7_|Side stand switch 12 | Throttle position sensor 13 | Intake air temperature sensor 14 | Oil pressure switch 15 [Coolant temperature sensor 16 | Neutral switch 17 | Crankshaft position sensorFUEL SYSTEM/ENGINE MANAGEMENT 83 zosues uonisod yeysmuero[ 2b yous jenneN| 9b Josues einjeredwiey wuejooo| Si owns 1u61) Gujwiem einssaid jo mo7] pL Josues eunesedwiay se eyeiui| eb josuesuomsod emomi| Zi yowms puesepis| bb sosues jene| jeru mor] Ob a LE ARNE cet pm 4 eniqwn] at sojour 1addeys onjen jonuoo we eipi| 6 vee won] 97 Joyeuos snsoubeig| 8 moieal A ey Buyjoog|—Z eum] Mm suopefuijens] 9 aiding] syoouonubi] —¢ peu] uf enenebing| + Ul x duind jena £ abueo| Oo woa z fears] s sojeuuos eubua] uaai9| 5 yequinu ane a uonduoseg} wel ena] wresBerg ynosig Bumpy o1 Koy) oe 8 4nod Ga3adS SBS OER, ~ WVHDVIG LINDHID LNSWADVNVIl INIDNS ININTOVNVN ANIONAINALSAS TANS 8Neon FUEL SYSTEM/ENGINE MANAGEMENT 8 ircuit Diagram - Engine Management System - peed Four8 FUEL SYSTEM/ENGINE MANAGEMENT ‘System Diagnostics The engine management system has en on-board diagnostics feature which allaws service technicians to retrieve stored data from the ECM using a Triumph service tool. Full details of the tool's operation and how to interpret the results are given elsewhere in this section. The tool is connected 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 damage. The too! allows the user to retrieve data associated with the system sensors and actuators, test various component functions, read build data and make minor adjustments to the set-up of the system. The data and tests available are described on the following pages. On-board Fault Detection System The on-board diagnostic system has to stages to 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 thatthe fauit s noted. For example, if there is a fault inthe crankshaft position sensor, the counter will increment its count each time the crankshaft turns through 360°, provided the fault is stil present, When the count begins, the fault is detected but not ‘confirmed. if the foult continues to be detectad and the count reaches a pre-determined threshold, the fault becomes confirmed. If the fault is an emissions related fault or a sefious malfuncton affecting engine performance, a DTC (Diagnostic Trouble Code) and freeze-trame data willbe logged in the ECM's memory and the MIL (Matfunction indicator Lamp) on the motorcycle instrument panels iluminated. Once a faut is confirmed, the number of warm-up cycles made by the engine is Counted. If the faut clears, the warm-up cycle counter will ‘extinguish the MIL (Malfunction Indicator Lamp) at a pre determined count, and erase the DTC and freeze frame data from the ECM memory at ancther (higher) count. A single warm-up cycle is deemed to have taken place when the following criteria have bsen met: + The coolant temperature must be raised to 72°C or more, + The coolant temperature must have risen by 23°C or more from is start temperature, when 72°C is reached. + Acontrolied power-down sequence must take place. NOTE: * When a fault has been rectified, the MIL witt remain illuminated until sufficient non-feult 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 tool. NOTE: * In most 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. ‘Triumph Diagnostic Too! 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 service diagnostic tool The tables indicate which tests are performad by the ‘on-board system and what information can be retrieved by the Triumph diagnostic tool, Full details of how to operate the tool andhow tointerpret esheets“By using the Triumph diagnostic tool, live engine data '= (engine running) can be recovered from the motorcycle. © The data available is: FUEL SYSTEM/ENGINE MANAGEMENT 8 Function Tests The system allows the diagnostic tool to perform a series of function tests on various actuators in the engine management system. In some cases it is necessary to make @ visual observation of a component and in other, it Function Examined _ | Result Reported (Scale) faults are present, OTCs will be logged. onion OF100% The function tests available are:~ Coolant temperature =40- ¥2159C t Iie fuel tim 100 = + 99.2% Function Examined Result Reported °{__ Off idle fuel trim Not Used Fuel pump test None (observation only) Engine speed 0- 16,383 APM Fuel pump priming | None (observation only) ‘Air temperature a0 +215°C Cooling fan None (observation only) Ignition Advance ~649 = 463.59 Instrument panel Observation/DTCs Throttle Position 0-100% Purge vale DTGs Idle Air Control Valve Observation/DTCs Freeze-frame Data Checks/Adjustments Freeze frame datais stored at the time a DTCs recorded (confrmed) by the ECM. If multiple DTCs are recorded, Adjustments 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 Memorised | Result Reported (Scale) Using the Triumph diagnostic tool, itis possible to adjust the value of two items which affect the idle speed and idle emission settings of the system, The tool allows adjustment of these items by making small changes to certain parts of the ECM software, The values that can be adjusted are [Setting Adjusted Closed Throttle position Setting Affected Voltage vaiue of closed throttle threshold Idle emissions IAGV start point Idle fueling ‘Adaptive stepper position | NOTE: * In special circumstances, Triumph will make available a password which can be keyed into Calculated Toad 0-100% Coolant temperature ~40- +215°C_ idle uel tim =100- + 982% Off idle fuel trim Not Used Engine speed 0 - 16,383 RPM Air temperature 40 - +215°C ignition Advance | 62° +5357 | Throttle Position 0-100% Barometric pressure 0 = 983 mmiFig the tool which will allow download of a completely new engine tune. This special facility will be made available only when necessary. For example, this may be necessary a motorcycle is transferred to a country or area where legislation requires a different tune to the original version installed at the factory,8 FUEL SYSTEMIENGINE MANAGEMENT Treumpa 3 Diagnostic Trouble Codes Diagnostic trouble codes (DTCs) are logged in the ECM and willtum off the MIL when sufficient no-fault warm-up memory when there is @ confirmed fault in the system. cycles have taken place. Any fault codes will remain in | the ECM memory until the required number of no-fault ‘The codes are reported tothe Triumph diagnostictoolas warm-up cycles have taken place. The number of a four digit code, as required by California legislation. warm-up cycles required to extinguish the MIL wil always be less than the number required to remove a ‘As mentioned earlier, when the system detects a fault, it~ DTC from the ECM memory. DTCs can be removed at begins to count the number of times the fault occurs any time using the Triumph diagnostic tool before illuminating the MIL and storing a fault code. ‘The system will log the diagnostic trouble codes listed below/over:~ Diagnostic Fault Description Number of | Number of MIL Trouble no-fault | no-fault | illuminated Code cycles cycles | when fault (orc) before | beforeDTC | is logged turning off | is erased iL, Poa35__| Crankshatt sensor circuit malfunction 3 40 Yes P1935 _| Crankshaft sensor incorrect sequence pattern 3 40 Yes P0207 | Injector 1 circuit malfunction 3 40 Yes P0202 _| Injector 2 circuit malfunction 3 40 Yes P0203 _| Injector 8 circuit malfunction 3 40 Yes P0204 _| Injector 4 circuit matfunction 3 40 Yes P1201 _ | Injector 1 open circulshort to ground 3 40 Yes P1202 _| Injector 2 open circulshort to ground a 40 Yes P1203 _| Injector 8 open circuil/short to ground 3 40 Yes P1204 _ | Injector 4 open circuitfshort to ground 3 40 Yes P1205 _ Injector 1 short to battery voltagejover temperature 3 40 Yes P1206 _ | Injector 2 short to battery voltage/over temperature 3 40 Yes P1207 _ | Injector 3 short to battery voltage/over temperature 3 40 Yes, P1208 _| Injector 4 short to battery voltage/over temperature 3 40 Yes P0105 | Barometric pressure sensor circuit malfunction 3 40 Yes P0122 _ | Throttle position sensor low input 3 40 Yes P0123 _| Throttle Position sensor high input 3 40 Yes "P0444 _ | Purge valve system open circuitlshort circuit to ground 3 40 Yes P0445 | Purge valve system short circuit to battory voltage 3 40 Yes over temperature P0351 ignition coll t matfunction| 3 40 Yes P0352 [ignition coll 2 matfurciion 3 40 Yes P0353 | Ignition coil 3 malfunction 3 40 Yes 3 40 Yes P0354 Ignition coil 4 malfunctionFUEL SYSTEM/ENGINE MANAGEMENT 8 Fault Description Number of | Number of MIL no-fault | no-fault | illurninated cycles cycles | when fault before | before DTC | is logged tuning off | is erased MIL Ignition coil 1 open circul/short circuit to ground 3 40 Yes P1352 _| Ignition coil 2 open circui/short circuit to ground a 40 Yes P1353 _| Ignition coll 3 open circuilshort circuit to ground 3 40 Yes P1354 [Ignition coil 4 open circull/short circult to ground 3 40 Yes P1355 _| Ignition coll 1 short to battery voltage/over temperature 3 40 Yes P1356 | Ignition coil 2 short to battery voltage/over temperature 3 40 Yes: _[/ P1387 | Ignition coil $ short to battery votage/over temperature 3 40 Yes | 5 -{ 21358 | Ignition coil 4 short to battery voltage/over temperature: 3 40 Yes | FF Port | Engine coolant temperate too high 3440 Yes P0178 _ | Engine coolant temperature too low 3 40 Yes P0119 _| Engine coolant sensor high voltage 3 40 Yes P0110 _ | Intake air temperature sensor ciroult malfunction 3 40 Yes [P0112 | Intake air temperature too high 3 40 Yes otis [Intake air temperature too law 3 40 Yes 0230 _| Fuel pump fault 3 40 Yes P1231 _ | Fuel pump open circuit a 40 Yes P1232 | Fuel pump short circuit 3 «0 Yes P1560 | Sensor supply voliage circuit fauit 3 40 Yes P0560 _| System voltage malfunction 3 40 Yes Pos62 _| System voltage low 3 40 Yes | ..0563 | System voltage high 3 40 Yes P1601 [MIL open circuil/short to ground NA 40 No P1602 _| MIL shortto battery voltage NA 40 No P1552 | Cooling fan short circuitviopen circuit 3 40 Yes P1559 | Cooling fan short to battery vottage/over temperature 3 40 Yes P1118 _ | Coolant temperature signal short Grouitjopen circuit NA 40 No P1117 | Coolant temperature signal shart to batiery NA 40 No voltagejover temperature P1386 | Tachometer short circuiljopen circuit NA 40 No P1387 _ | Tachometer short to battery voltage/over temperature NA 40 No8 FUEL SYSTEM/ENGINE MANAGEMENT Checks ‘When using this function itis possible to check the status of various sensors and actuators and also check certain items of factory data logged during vehicle assembly. The data available is: item Checked Result Unit “ir temperature sensor Vals Air temperature Degrees Celsius Coolant temperature Volts sensor Coolant temperature Degrees Calsius Engine speed RPM Tale reference speed RPM Battery voltage Vals ‘Sensor reference vollage Volts Injector pulse time Wiliseconds Barometic pressure mmiFig Calculated Toad Percentage Target dwell ime Miliseconds Tonition timing Degrees BTOGIATOC Throttle voltage "Volts Corrected Throtile Percentage position Purge valve duty 6yele Percentage Tale air control valve Theremantal steps stepper position ranging from 0 to 255 ignition switch postion On/Off Cooling fan status On/oit Sidestand status Up/Down Nouiral switch status Neutralin gear SERVICE DIAGNOSTIC TOOL is 1 i ‘ : ? & fs ‘ 1. Memory card 3 2. Sereen i 3. Return key i 4. Up key : 5. Down key i 6. Validate key i 7. Help key ; The memory card (1) contains all the information necessary to allow the technician to follow a number of different paths to: © Diagnose faults © Obtain data Make checks / adjustments Itis removeable to allow replacement / update cards to be inserted. : ‘The screen comprises four horizontal lines and twenty vertical columns forming a series of boxes into which letters and numbers can be displayed to provide the ecessary question, message, answer etc. Atthe left of the screen, one or more symbols as detailed below may be displayed.FUEL SYSTEM/ENGINE MANAGEMENT 8 DIAGNOSTICS CURRENT DATA READ STORED DTCs FUNCTION TESTS Typical screen showing symbol examples ilable to be seen above and/or below those already in by scrolling the text up or down using the ‘Up’ or jown' keys. ‘Cursor to show which line of text is “Active’. Indicates further help/guidance information available _sthatline by pressing the help key Fuad key ‘The Up and Down keys ~ press to move the lines of ext up or down. They are also used to enter the Dealer ‘number and the date. wn keys (2 separate keys) ¥ Cursors to indicate that further lines of text are Press the Validation key (:k) to move on to the next message. Validation key * The Help key can be used when the '?" symbol shows, to get more information about that line of text. To return to the diagnostic screen from the help area, press the help °?’ button again. Help key TEST PROCEDURE The following describes the procedure to follow when Using the service diagnostic tool. It does not cover the further diagnosis that must be carried out once a fault area has been identified. For details of the procedure to follow when a fault area or fault code has been identified, refer to the diagnosis details later in this section, NOTE: * The tool does not retain any memory of faults, diagnosis etc. carried out on any particular motorcycle. Any such mdmiory is only-retained in the motorcycle’s ECM. The following five pages describe the tool operations in flow chert forin,8 FUEL SYSTEM/ENGINE MANAGEMENT TReunpa CONNECT BIKE SYSTEM ERROR J ereoxenno > Present SELECT LANGUAGE ENGLISH INSERT MEMORY FRANCAIS I CARD DEUTSCH ESPANOL, NEDERLANDS ¥ ‘TRIUMPH MOTORCYCLES DIAGNOSTIC TOOL, SOFTWARE VERSION 18.0 2003 ' SWITCH ON BIKE IGNITION False DATA LINK FAULT VALIDATE SBIRY =v. : Main Menu MAIN MENU SERVICE DATA SERVICE DATA DIAGNOSTICS DEALER 555555 DATE 15603 [—P) —CHECK/ADIUST : ourrFUEL SYSTEM/ENGINE MANAGEMENT & Main Menu MAIN MENU ee STORED ERRORS: cuca FAULT COUNT 2 Ql CAMSHAFT SENSOR ae TON COIL OSE Diagnostics Starred DTC DIAGNOSTICS CURRENT DA TAULT CODES FUNCTION TESTS Fault codes an Current a data * Freeze frame data CURRENT DATA cALCULEIED SED FREEZE PRAM WATER TEMP CALCULATED LOAD I us EL TRI WATER Tents i On ous Te DLE FusL Tan ' REV COUNT Or Tua i AIR TEM REV COUNT IGN ADTANCE AIR TEM ‘ LAGOA TELIA nance : ROTTLE POSITION confoutnsee beta voizhoe ‘korres osm FUEL SYSTEM STATUS ee eee oxypEn SENSOR OUTPUT VoLThor TUEL SYSTEM STAs ' STORED ERRORS STOP ENGINE < Return RETURN TO DTCs I Cuan one Clear <} a cas FUNCTION TEST INSTRUMENT PANEL IAC VALVE PURGE VALVE FUEL PUMP Error Count COOLING FAN Screen FUEL PUMP PRIME, 1 Cancel FUNCTION TEST Proceed FUNCTION TEST TEST NAME TESTING... OBSERVE, OTC present Zer0 DTCs, FUNCTION TEST FUNCTION TEST ‘TEST NAME ‘TEST NAME TEST FAILED PIII ‘TEST COMPLETE : ‘S/CTO VBATT CLEAR DTC FUNCTION TEST PERFORM ANOTHER TEST YES NO 8.28FUEL SYSTEM/ENGINE MANAGEMENT 8 Main menu MAIN MENU DIAGNOSTICS (CHECK/ADJUST Quit Check/Change (CHECK/ADJUST eae Quit CHANGE Quir Check Change ‘Check ment Change menu’ p ‘CHECK CHANGE Oui Quit BUILD DATA ADIUST TUNE it i READ SENSORS ‘TUNE UPDATE i Quir our v { Read sensors READ SENSORS ‘ADIUST TUNE ‘AIR SENSOR IDLEFUELADI99.9% |—— ‘AIR TEMP SET CLOSED TP WATER TEMP SENSOR SET LG TERM FUELT ‘WATER TEMP SET ADAPT STEP POS REV COUNT IDLE REF. Engine tem BATERY in range "| Engine temp| ‘SENSOR REF out Cot range: INJECTOR — ca eran uATED IDLE FUELADI99.9% en ESV COUN REIN Se AION Tea CALCULATED LOAD 99% THROTTLE POSITION 1 ) PURGE VALVE CYCLE TACV STEPS ENGINE TEMPERATURE IGNITION SWITCH OUTOFRANGE COOLING Fan ‘SIDE STAND PLEASE WaIT NEUTRAL SWITCH Build data y : v ADIUST TUNE, BUILD DATA |_| TAROTILE Posirion ee HAS BEEN SET JOOOKXIXKAKXX) TRIUMPH ECU PART NO XXXKXKAAXKAKIN ‘— si SAGEN ECU PART NO XXXXXKXAXKAKKK ADIUST TUNE ECU SERIAL NO LONG TERM FUEL TRIM XOXO RRA HAS BEEN SET SWRELEASE XXGBIOOOOOKAK TUNE NUMBER y XXXXXXXXXXXXXX ie ADJUST TUNE ADAPTIVE STEP POSITION v |___ HASBEEN SET » % S8 FUEL SYSTEM/ENGINE MANAGEMENT Tren ] Xs Main menu_y MAIN MENU DIAGNosTics CHECK/ADIUST urr CheeWAdjust ‘Check/Adjust menu ¥ CHECK/ADIUST ‘CHECK Quit CHANGE Qurr Change - ‘ADIUST ADJUST TUNE UPDATE TUNE ourr Update tune iY: TUNE 100K ‘UPDATE TUNE TUNE OOK UPDATE TUNE TUNE 1XXXX CONFIRM Pass CANCEL | ourr TEST PASSWORD Fail ¥ = UPDATE TUNE SECURITY DOWNLOADING... 10% COMPLETE ACCESS DENIED r DOWNLOAD Ok? "2 Yes UPDATE TUNE UPDATE TONE DOWNLOAD COMPLETE DOWNLOAD FAILED a >FUEL SYSTEM/ENGINE MANAGEMENT 8 2. SELECT LANGUAGE ———S SELECT LANGUAGE > ENGLISH FRANCAIS DEUTSCH ESPANOL NEDERLANDS {____=s=="eeeses _A message appears on the screen and certain checks are made automatically, e.g. Is the memory card fitted ? ‘SELECT LANGUAGE” will then be displayed. Use the ‘Up" and ‘Down’ keys to move the cursor in : column 4 and select the language required. NOTE: * Thetoot will always select English as the default language, and it is only necessary to use the cursor to select one of the other languages. The entire diagnostic session will then continue in the chosen language. Press the validation key “>k" to move on. 3.298 FUEL SYSTEM/ENGINE MANAGEMENT ‘3. TRIUMPH MOTORCYCLES Trap 4. SWITCH ON BIKE IGNITION TRIUMPH MOTORCYCLES DIAGNOSTIC TOOL SOFTWARE VSN 18.0 é 2003 IGNITION The screen will display the message ‘Triumph Motorcycles Diagnostic Too!’ and will also give the diagnostic software version and the software release year. Press the validation key ‘:k’ to move on. Ifthe Return key (.) is pressed, the tool will return to the "SELECT LANGUAGE” display. () <2 ap ‘Switch on the ignition. Do NOT start the engine. Press the validation key %k'. During a short delay period the too! will carry out certain validation checks. If it detects a problem which will invalidate the test, ‘DATA LINK FAULT RETRY?’ will be displayed. SWITCH ON BIKE | | Ifall is OK, ‘SERVICE DATA’ will appear on the screen. 8.30 ce sa —DATA LINK FAULT RETRY? DATA LINK FAULT RETRY? i the above is displayed, check that the ignition is \ed on. [isthe ignition is already on, the problem may be caused ‘by bed connections, faulty ignition switch, cable break, “faulty ECM, fat battory tc. ‘ePress the Help key ‘' for advice. “Rectify the problem and press the Validation key ‘xk' to Felurn to ‘SWITCH ON BIKE IGNITION’. Press the Validation key °K’ again. Ifthe tool accepts that {_sroblemhas been rectified, ‘SERVICE DATA’ will be ‘displayed. ‘This is the frst of 2 screens for which the operator has to input information, without which the testing cannot proceed further. FUEL SYSTEM/ENGINE MANAGEMENT 8 6. SERVICE DATA — DEALER SERVI CE vy S:S05)5 9:8 DAT DEALER L_____ >| =| <= PS oc Enter your Dealer number as follows: ‘The number “S55555" is displayed, with the cursor Pointing down at the first digit Press the ‘Up’ or ‘Down’ keys to change this digit to the first digit of your dealer code. Press the Validation key ‘>’, ‘The cursor will now re-position over the second digit ‘5 Enter the 2nd digit of your Dealer number in the same way. Continue unti all 5 digits of your dealer code have been entered, NOTE: * Many digit has been entered incorrectly, press the ‘Return’ key (J) to start again. When all § digits have been entered correctly, press the Validation key ‘> ‘You must enter a valid Dealer Number to continue. If you do not know your dealer number, contact Triumph or your importer for advice.8 FUEL SYSTEM/ENGINE MANAGEMENT 7. SERVICE DATA ~ DATE SERVICE DATA : | | | 01/01/00 DATE | | | l Enter the date using the Up’ and ‘Down’ keys in the same. way that the Dealer number was entered. NOTE: * Gdigits must always be entered, e.g, if it is the ‘7th month this must be entered as 07. The date must be entered in the order Day/Month / Year. When complete, press the Validation key ‘>’ to display — "MAIN MENU’, 8. MAIN MENU MAIN MEN DIAGNOSTICS | CHECK/ ADJUST Quit When this screen is displayed, you have to decide 3 Whether to proceed along one of two routes: ~ ‘DIAGNOSTICS’ ~ ‘CHECK/ADJUST’ ‘The ‘DIAGNOSTICS’ menu provides access to: Current data e.g. actual engine temperature, engine = speed ete. iaanostic Tr 's) i.e. access to codes stored in the motor cycle ECM which indicate a confirmed fault(s) in the system, Eunction tests e.g. of tachometer, water temperature gauge, fuel pump etc, 5 The ‘CHECK/ADJUST’ menu provides: Checks i.e. build information, system data. Adjustments e.g. adjustment of idle fueV/CO etc., and = entry of software updates. Use the ‘Up and Down’ keys to position the cursor opposite the desired choice, end press the Validation key ce Either ‘DIAGNOSTICS’ (operation 9) or *CHECK/ADJUST" (operation 27) will be displayed, dependent on the selection NOTE: * If QUIT’ is selected and the validation key ‘>' MOTORCYCLES’, 2 8FUEL SYSTEM/ENGINE MANAGEMENT & DIAGNOSTICS (If DIAGNOSTICS’ is selected) 10. CURRENT DATA DIAGNOSTICS [ CURRENT DATal | START ENGI NE CURRENT DATA [,CALCULATED Loan 29 READ STORED DTCs} |[WENGINE TEMP es. <= <= m= Df a ae | This display is the ‘DIAGNOSTICS’ menu, Start the engine. ‘CURRENT DATA’ includes the information shown in the table below which can be ‘Pe the ‘Up" and ‘Down’ keys to scroll the text untl the accessed by scaling, using the Up'and "bev or keys. At horizontal arrowhead is positioned opposite the desired the end of each line of text the actual reading at that “hoice, and press the Validation key k’. instant is provided to assist diagnosis e.g. ENGINE . ‘TEMP 95C. ‘The choices are: ‘CURRENT DATA AVAILABLE 4 ‘CURRENT DATA’ (see operation 10) Function Examined | Result Reported (Scale) ~ ‘READ STORED DTCS' (see operation 12) Faulis stored (quantity) 1-187 = 'FUNCTION TESTS' (see operation 18) Galetatod toned 210% Coolant temperature =40- 295°C > FQUIT is selected, the display wil return to ide fool tn ons “TRIUMPH MOTORCYCLES: Wide maes —— Engine speed 0 76.383 RPM ‘ir temperature ~40~ ¥815°C Ignition Advance ~64~ 465.50 Throtile Position 0-100% If further clarification of any line of displayed text is required, scroll that line opposite the '?' symbol in the left hand column and press the Help key (2). Limited information on the selected topic will then be displayed. Press any key to return to the ‘CURRENT DATA’ text. When all information has been Noted, press either the Validation 2k" or Return (.) keys.8 FUEL SYSTEM/ENGINE MANAGEMENT TRups 12. To select ‘READ STORED DTCS" (Diagnostic 11, STOP ENGINE ‘Trouble Codes) from the MAIN MENU:— STOP ENGINE MALN MEN >» DIAGNOSTICS * CHECK/ ADIUST Quir <> mi LD mD ae ‘Switch off the engine. Use the ‘Up’ and ‘Down’ keys to position the cursor As the tool is powered from the motorcycle, this will end opposite DIAGNOSTICS. the diagnostic session. To contnue, return to the power-up section and select tests as required. Press the Validation key ‘xk’ to display ‘DIAGNOSTICS’ menu. Select'READ STORED DTCS’, andpress the Validation key "'. ‘STORED DTCS' will be displayed.FUEL SYSTEM/ENGINE MANAGEMENT 8 18. STORED DTCS 14. Three options are now available:— STORED DTCS DTC COUNT 99 7P0335 2 WP1335 STORED DTCs} VY FREEZE F.RAME DaTa | CLEAR DTCS | NS The secondline — ‘DTC COUNT’, shows the number of DTC's stored in the ECM memory, Lines 3 and 4 display up to two of the DTC'S stored (if any). Hfadditional DTC'S are stored, this willbe indicated by a downward pointing arrowhead, and itthey can be accessed using the ‘Up’ and ‘Down’ keys. If there are no DTC's shown, press the Return key (!) to return to MAIN MENU. (if DTC's are present when the Return key is pressed, ¢' lay will read ‘STORED DTCS, ERASE ALL DTC L_JAYESINO’) Information about each DTC can be obtained by serol the text until the appropriate code is opposite the line 3; then press the Help key (2) DTC example: P0335 Help text CRANKSHAFT SENSOR CIRCUIT MALFUNCTION Press the Validation key ‘2k' to continue (operation 14) IMPORTANT: Ma OTChasan asterisk (*)toits right, this indicates thata snap shot of engine data at the time the DTC was stored 's available to aid your fault diagnosis. To access this, nf “nation, press the Validation key 'X’ to go to > ation 14 and open ‘FREEZE FRAME DATA’. <> ayo Align ‘FREEZE FRAME DATA’ with the cursor, and press the validation key > to display FREEZE FRAME” (see 15). Align ‘CLEAR DTCS' with the cursor, and press the validation hey “fo eplay ‘ERASE ALL DTC DATA’ see 17), Press the Return key {.)} to gé back to ‘STORED DTCS! (operation 13).