Triumph Scrambler 1200 XC - Service manual > Barrels

Exploded View - Barrels and Pistons

Barrels - 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

Perform the following operations:

• Seat - Removal
• Battery - Removal
• Fuel Tank - Removal
• Engine - Removal
• Alternator Cover - Removal
• Camshaft Cover - Removal
• Cylinder Head - Removal

1, Clean the area around the barrel base gasket joint to prevent dirt falling into the crankcase 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 camshaft drive 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.

3, Lift off the barrels and recover 3. the locating dowels.

1. Locating dowels

4, Remove and discard the base gasket.

Barrels - Inspection

1, The cylinder barrels are not measurable in service, (see Piston Specifications - 1200).

Barrels - Installation

1, Thoroughly clean the mating surfaces of the 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.

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).

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 may result in piston ring breakage.

CAUTION

Do not force the pistons into their bores. The base of each bore is chamfered to ease installation and excess force should not be needed. If either piston jams, lift the barrels slightly and check the rings are correctly located into their grooves before continuing. The use of force may result in piston ring breakage.

6, With the aid of an assistant, ease the barrels carefully over the pistons whilst guiding the piston rings into the base of the cylinder bores.

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).

9. Refit the camshafts (see page Camshaft - Installation).

10. Recheck the tensioner plunger location against the camshaft drive chain tensioner blade.

11. Remove T3880039 - Idler Gear Timing Pin from the crankcase.

12, Refit the camshaft cover (see Camshaft Cover - Installation).

Perform the following operations:

• Alternator Cover - Installation
• Engine - Installation
• Fuel Tank - Installation
• Battery - Installation
• Seat - Installation

See also: