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Triumph 2010 Tiger 800, Service Manual

The Triumph 2010 Tiger 800 Service Manual is a comprehensive guide for maintaining and repairing your motorcycle. You can download this manual for free from manualshive.com, ensuring you have the necessary information to keep your bike in top condition. Don't miss out on this essential resource for all Tiger 800 owners.

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Frame and  Bodywork 

Lower  Radiator  Panel 

Removal 

1. 

Remove the two  radiator infill fixings. 

1. 

Radiator  infill 

2. 

Fixings 

2. 

Remove  the  fixing  and  remove  the  panel  towards 

the  rear of the motorcycle. 

Installation 

1. 

Align the panel the hook on the upper radiator panel 
and secure  with  the three fixings. 

2.  Tighten the screws to 

3  Nm. 

Upper Radiator  Panel 

Removal 

1. 

Remove the rider's seat (see  page  76- 13). 

2. 

Disconnect the battery,  negative  (black>  lead  first. 

3 .  

Remove the lower radiator panel (see  page  16- 14). 

4. 

Remove and discard  the radiator infill panel fixing. 

1. 

Radiator infill  panel 

2. 

Fixing 

�-

Remove  the rear  fixing  and  unhook the  panel  from 
the  cockpit panel  and  fuel  tank. 

1. 

Upper  radiator  panel 

2. 

Fixing 

6. 

Disconnect  the  direction  indicator  connectors  and 
remove the panel. 

16.14 

Se1Vice Manual 

-

Tiger 800  and Tiger 800XC 

Summary of Contents for 2010 Tiger 800

Page 1: ...are 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...

Page 2: ...11 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 3: ...nder Head Clutch Crankshaft Connecting Rods and Pistons Balancer Transmission Lubrication Engine Removal Refit Fuel System Engine Management Cooling Rear Suspension Front Suspension Brakes Wheels Tyre...

Page 4: ...This page intentionally left blank iv SeNice Manual Tiger 800 and Tiger 800XC...

Page 5: ...is manual vi Warnings Cautions and Notes vi Tampering with Noise Control System Prohibited vii References vii Dimensions vii Repairs and Replacements vii Force vii Edges vii Tightening procedure vii I...

Page 6: ...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 genuin...

Page 7: ...w 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 ca...

Page 8: ...Introduction This page intentionally left blank viii SeiVice Manual Tiger 800 and Tiger 800XC...

Page 9: ...onents 1 7 Lubrication 1 7 Joints and Joint Faces_ 1 7 Gaskets 0 rin gs 1 7 Liquid Gasket Non permanent Locking Agent 1 7 Screw Threads 1 7 Locking Devices 1 8 Fitting a Split Pin 1 8 Circlips Retaini...

Page 10: ...cification SeiVice Tools and Garage Equipment Full Specification 1 1 2 1 1 2 1 1 3 1 1 3 1 1 3 1 1 3 1 14 1 14 1 16 1 16 1 17 1 17 1 18 1 19 1 19 1 20 1 20 1 21 1 22 1 22 1 22 1 22 1 23 1 28 Engine 1...

Page 11: ...rbox 1 42 Rear Suspension 1 43 Front Suspension 1 43 Wheels 1 43 Front Brakes 1 44 Rear Brakes 1 44 ABS System 1 45 Frame Footrests Control Plates and Engine Mountings 1 45 Electrical 1 46 Bodywork 1...

Page 12: ...uct 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 o...

Page 13: ...own 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 hea...

Page 14: ...leum 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 con...

Page 15: ...ain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulphide grease in the assembly of certain engine and chassis...

Page 16: ...Grease Seals Replace any oil or grease seals that are removed Removal will cause damage to an oil seal which if re used would cause an oil leak Ensure the surface on which the new seal is to run is f...

Page 17: ...arts 4 Any excess grease should be smeared on the outside of the rollers Lubrication and Checks While SeiVicing a Bearing 1 Disassemble parts as necessary to access the bearing Refer to the relevant s...

Page 18: ...nitable mixture The vapour is heavier than air and will always fall to the lowest level lt can readily be distributed throughout any indoor environment by air currents consequently even a small spilla...

Page 19: ...etrol gasoline has been extracted or drained from a fuel tank the precautions governing naked lights and ignition sources should be maintained Failure to observe any of the above warnings could bring...

Page 20: ...cal components and connectors Always ensure these items are dry and oil free before disconnecting and connecting test equipment Never force connectors apart either by using tools or by pulling on the...

Page 21: ...R of a circuit is measured in Ohms cm Ohms law for practical work can be described as Voltage C Resistance urrent Power is calculated by multiplying Volts x Amps Watts Volts x Amps By transposing eit...

Page 22: ...iring colour codes Circuit diagrams also depict the inner workings of a switch cube I E which wire connects to which when a switch is turned from one position to another so that a test of that switch...

Page 23: ...witch To close the relay contacts and complete the circuit an electromagnet in the relay is energised which causes the relay contacts to close making the circuit complete Relays are used when the elec...

Page 24: ...le 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 feed other circuits If these circuits...

Page 25: ...amine the splice for its integrity The most common fault is where one of the wires at the joint has come adrift usually causing the circuit it feeds or earths to become dead Switches To check a switch...

Page 26: ...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...

Page 27: ...ATTERY VOLTAGE SHOULD BE 14 5 0 5 VOLTS Below 0 1 4 Volts lr STOP THE ENGINE AND DISCONNECT THE ALTERNATOR CONNECTOR RE START THE ENGINE AND ALLOW TO IDLE MEASURE THE ALTERNATING CURRENT AC VOLTAGE FR...

Page 28: ...f the neutral switch or gear position sensor if fitted sidestand and clutch switches Note On all new models from Daytona 675 onwards which use a CAN connection between the instruments and the ECM the...

Page 29: ...LAY VOLTAGE AT TH E STARTER RELAY SWITCH CONNECTOR Voltage Measured CH ECK THE STARTER RELAY OPERATION No Continuity No Voltage Normal Abnormal Starter motor turns Starter motor does not turn LOOSE OR...

Page 30: ...hat a trained technician is used have an authorised Triumph dealer fit the parts The fitment of parts accessories and conversions by personnel other than a trained technician at an authorised Triumph...

Page 31: ...ations 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 SeiVice Tools...

Page 32: ...haft Turning T3880026 Clutch Holding Tool Universal cdpr T3880365 Puller Alternator Rotor T3880375 Alternator Rotor Holder T3880313 Oil Filter Wrench T3880057 Engine Management Diagnostics gahc 1 24 S...

Page 33: ...0166 Wrench Engine Mounting Adjuster 3880160 T0301 Fork Filler Evacuator T3880158 Collet Nylon Fork Support Tiger 800 ccha T3880154 Collet Nylon Fork Support Tiger 800XC T3880067 Fork Spring Compresso...

Page 34: ...Fork Seal and Bush Fitment Tiger 800 ccxa_1 ccxb T3880157 Fork Seal and Bush Fitment Tiger 800XC T3880053 Extraction Kit Wheel Bearing ccxb 3880070 T0301 Bearing Installer 3880065 T0301 Bearing Insta...

Page 35: ...123 Extension Cable cdbp BatteryMate Battery Charger See Latest Parts Catalogue T3880001 Fuel Pressure Gauge for Part Number Information ol dJ3 A a 9 0 I I la I D T3880147 Radiator and Cap Tester cgwp...

Page 36: ...r 12 valve DOHC Transverse in line 800 cc 74 x 61 94 mm 1 1 1 1 Left to Right no 3 adjacent to camchain Number 1 at left 1 2 3 70 kW at 9 300 rpm 95 PS 94 bhp 79 Nm at 7 850 rpm 58 lb ft Tiger SOOXC 3...

Page 37: ...Service Limit 4 043 mm 4 043 mm Valve Stem to Guide In 0 010 0 040 mm 0 010 0 040 mm Clearance Service Limit 0 078 mm 0 078 mm Valve Stem to Guide Ex 0 030 0 060 mm 0 030 0 060 mm Clearance Service Li...

Page 38: ...hafts Cam Timing Inlet Open 5 18 BTDC Open 5 18 BTDC 1 0 mm lift 1 0 mm lift Close 25 18 ABDC Close 25 18 ABDC 1 0 mm lift 1 0 mm lift Duration 210 36 210 36 Exhaust Open 3Z27 BBDC Open 3Z27o BBDC 1 0...

Page 39: ...974 73 990 mm Service Limit 73 930 mm 73 930 mm Piston Ring to Groove Clearances Top 0 02 0 06 mm 0 02 0 06 mm Service Limit 0 075 mm 0 075 mm Second 0 02 0 06 mm 0 02 0 06 mm Service Limit 0 075 mm 0...

Page 40: ...Type 6 Speed Constant Mesh 6 Speed Constant Mesh Gear Ratios 1 st 2 313 1 37 16 2 313 1 37 16 2nd 1 857 1 39 21 1 857 1 39 21 3rd 1 500 1 36 24 1 500 1 36 24 4th 1 285 1 27 21 1 285 1 27 21 5th 1 136...

Page 41: ...m 0 15 mm Service Limit 0 20 mm 0 20 mm Oil Pump Body Clearance 0 15 0 22 mm 0 15 0 22 mm Service Limit 0 35 mm 0 35 mm Oil Pump Rotor End Float 0 04 0 09 mm 0 04 0 09 mm Service Limit 0 17 mm 0 17 mm...

Page 42: ...bar Thermostat Opening Temperature 71 oc nominal 71 oc nominal Cooling Fan Switch On Temperature 103 C 103 C Temperature Gauge Sensor Resistance 2 3 2 6 KQ 20 C 2 3 2 6 KQ 20 C Suspension Front Fork...

Page 43: ...take air temperature gear position MAP temperature gear position MAP Emissions Controls Catalysts 1 in down pipe 1 in down pipe Oxygen sensor Heated in down pipe Heated in down pipe Evaporative Contro...

Page 44: ...ont Wheel Size MT 2 5 X 17 WM 2 5 X 21 Front Tyre Size 100 90 19 90 90 21 Front Tyre Pressure 2 5 bar 36 lb in2 2 5 bar 36 lb in2 Recommended Front Tyre Option 1 Pirelli Scorpion Trail Bridgestone Bat...

Page 45: ...5 mm 60 8 in Seat Height 813 mm 32 0 in 847 mm 33 3 in Rake 23 9 24 3 Trail 92 4 mm 95 3 mm Wet Weight 210 kg 463 lb 215 kg 474 lb Maximum Payload rider passenger 225 kg 496 lb 223 kg 492 lb luggage a...

Page 46: ...der head to crankcase bolts Refer to section 3 Camshaft cap and ladder to head Refer to section 3 Cylinder head dry seal plug 22 Replace fixing s if removed Apply ThreeBond 1305 to the threads Sound s...

Page 47: ...olts to crankcase 8 Alternator cover 35 mm bolts to crankcase 9 Wire retainer on alternator cover 6 Crank cover 25 mm bolts to crankcase 8 Crank cover 35 mm bolts to crankcase 9 Balancer cover to cran...

Page 48: ...emoved Oil pump drive chain retainer plate 9 Replace fixing s if removed Oil pump to crankcase 12 Replace fixing s if removed Oil pump drive sprocket to pump shaft 12 Apply ThreeBond 1374 to the threa...

Page 49: ...only 12 Fan shroud to radiator 2 5 Water temperature sensor 18 Radiator lower bracket to radiator 6 Radiator lower bracket to water outlet bracket 6 Expansion tank to frame 3 Expansion tank cover to f...

Page 50: ...19 Silencer heat shield 5 Torque every service Silencer to frame 15 Silencer rear finisher 5 Apply ThreeBond 1305 o the threads Silencer front finisher 5 Silencer clamp to intermediate pipe 10 Oxygen...

Page 51: ...tes Upper yoke pinch bolt 20 Lower yoke pinch bolt 20 Upper yoke centre nut 90 Fork top cap 35 Damping cylinder bolt 20 Replace sealing washer s if removed Damping rod to top cap 20 Handlebar clamp ri...

Page 52: ...Master cylinder brake hose clamp to fork leg 6 Brake hose wire guide 7 Rear Brakes Application Torque Nm Notes Rear brake caliper to carrier 22 Rear brake caliper sliding bolt 27 Rear brake pad retain...

Page 53: ...brake hose 17 Frame Footrests Control Plates and Engine Mountings Application Torque Nm Notes Lower crankcase to frame 48 Refer to section 9 Cylinder head to frame 48 Refer to section 9 Heel guard to...

Page 54: ...er motor to crankcase 10 Starter motor power lead connection 3 Starter motor solenoid lead connection 5 Spark plug to cylinder head 12 Horn 18 Immobiliser ECU 9 Ignition switch 12 Replace fixing s if...

Page 55: ...ast at fronO 5 Centre panel Tiger 800 or Beak support moulding 5 Tiger 800XC to subframe nut and screw Beak to beak support moulding 3 Beak support moulding to subframe 5 Cockpit infill panels to cock...

Page 56: ...General Information Clutch Cable Routing 1 48 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 57: ...General Information Throttle Cable Routing SeiVice Manual Tiger 800 and Tiger SOOXC 1 49...

Page 58: ...General Information Main Wiring Harness Routing 1 50 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 59: ...eneral Information Front and Rear Brake Hose Routing Models Without ABS Rear brake Tiger 800 and Tiger 800XC Front Brake Tiger 800 SeiVice Manual Tiger 800 and Tiger 800XC Front Brake Tiger 800XC 1 5...

Page 60: ...General Information ABS Hose Routing 1 52 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 61: ...General Information Fuel Tank Breather Hose Routing SeiVice Manual Tiger 800 and Tiger SOOXC 1 53...

Page 62: ...General Information This page intentionally left blank 1 54 Service Manual Tiger 800 and Tiger 800XC...

Page 63: ...2 Scheduled Maintenance Table of Contents Introduction 2 2 Scheduled Maintenance Chart 2 3 SeiVice Manual Tiger 800 and Tiger 800XC 2 1...

Page 64: ...ed As only an authorised Triumph dealer will have this knowledge and equipment Triumph strongly recommends that your authorised Triumph dealer carries out all scheduled maintenance A dangerous riding...

Page 65: ...ck adjust Day Coolant renew Fuel system check for leaks Day Lights instruments electrical systems check Day Steering check for free operation Day Headstock bearings check adjust Headstock bearings lub...

Page 66: ...yre damage check Day Tyre pressures check adjust Day Clutch cable check adjust Day Stand check operation Day Secondary exhaust clamp bolts check adjust Accessory rack sliding carriage check for correc...

Page 67: ...Tensioner Blade 3 1 2 Disassembly 3 1 2 Assembly 3 1 2 Camshafts 3 1 3 Removal 3 1 3 Camshaft and Bearing Cap Inspection 3 14 Installation 3 15 Stage 1 3 15 Stage 2 3 16 Valve Clearances Valve Clearan...

Page 68: ...Cylinder Head Valve to Valve Guide Clearance Valve Guides Valve Face Inspection 3 2 SeNice Manual Tiger 800 and Tiger 800XC 3 25 3 25 3 25...

Page 69: ...Cylinder Head Exploded View Cylinder Head and Valves See text 15 Nm 10 Nm 12 Nm 10 Nm 0 12 Nm SeiVice Manual Tiger 800 and Tiger 800XC 3 3...

Page 70: ...Cylinder Head Exploded View Camshaft Cover 10 Nm 3 4 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 71: ...Cylinder Head Exploded View Camshaft and Camshaft Drive 9 Nm SeiVice Manual Tiger 800 and Tiger 800XC 3 5...

Page 72: ...prings have close wound coils at one end to assist in the prevention of valve bounce at high engine speed and to give a smooth valve actuation When assembling the cylinder head it is important that th...

Page 73: ...linder Head Installation 1 Refit the three dowels to the camshaft ladder 1 Dowels 2 Fit a new camshaft cover seal to the cylinder head JQV Ensure the groove in the gasket is correctly seated to the he...

Page 74: ...all Models Removal 1 Remove the camshaft cover see page 3 6 2 Remove the right hand crank cover Discard the gasket Note the positions of the two different bolt lengths Discard the 35 mm bolts 1 Right...

Page 75: ...tensioner Evenly release the hydraulic tensioner mounting bolts until the plunger spring tension has been released Remove the hydraulic tensioner and discard the 0 ring and gasket Cylinder Head Instal...

Page 76: ...ister ring and move one end of the snap ring into the groove Slowly release the plunger to ensure that it is held in place 2 cfej J 1 Groove for snap ring 2 Snap ring 1 1 Fit a new 0 ring and gasket t...

Page 77: ...e through 4 full revolutions and reset number 1 cylinder to TDC Ensure that the dot mark on the primary gear aligns with the line at the bottom of the cover 1 Dot mark 2 Marker line 18 Check that the...

Page 78: ...and remove the pad cfee n 1 Pad 2 Clip one side shown 2 Detach the top hook from the tensioner blade cfef 1 Top hook 2 Tensioner blade 3 Release the three side locating devices cfeg 1 Locating devices...

Page 79: ...e the camshaft ladder and top pad and collect the dowels if loose and spark plug tower 0 rings 5 Lift the camshaft drive chain from the exhaust camshaft sprocket and remove the exhaust camshaft Cylind...

Page 80: ...ighten the camshaft ladder in the sequence shown overleaf see page 3 15 b Remove the camshaft ladder using the bolt release sequence given earlier Wipe the exposed areas of both the camshaft journal a...

Page 81: ...shaft sprocket Position the camshaft in the same position as for removal before attempting to fit the ladder that is with the timing marks on the camshaft sprockets level and pointing inwards and with...

Page 82: ...number 1 cylinder to TDC Ensure that the got mark on the primary gear aligns with the line on the crankcase 1 Dot mark 2 Marker line Note In addition to the dot mark alignment at TDC the alignment ma...

Page 83: ...Using feeler gauges measure and record the clearances for this pair of valves only 5 Repeat the process until the valve clearances for all valves have been checked Cylinder Head Note If the measuremen...

Page 84: ...0 mm to 3 00 mm in increments of 0 025 mm 5 Fit the new shim to the valve head 6 Lubricate the tappet bucket s with a 50 50 solution of engine oil and molybdenum disulphide grease Z Refit the tappet b...

Page 85: ...s follows 1 Remove the chain from the engine 2 Suspend the chain from a pin or hook with a 13kg weight attached at the lower end cajs Cylinder Head 3 Measure across 23 links as shown in the diagram be...

Page 86: ...possible with the engine in the frame 1 Remove the engine from the frame see page 9 3 2 Remove the camshafts see page 3 13 3 Remove the camshaft drive chain see page 3 18 4 Remove the camshaft drive c...

Page 87: ...of the combustion chambers Using a straight edge check the cylinder head gasket face for warp which could lead to gasket failure Replace the head if warped 1 Cylinder head gasket face 2 aight edge 3...

Page 88: ...o engine damage through a damaged head gasket 5 Fit new bolts and washers to the head and tighten until finger tight 6 The cylinder head bolts must be tightened in the following sequence 6 2 4 8 Cylin...

Page 89: ...ighten to 9 Nm 8 Clean and lubricate the tappet buckets with a 50150 solution of engine oil and molybdenum disulphide grease and refit the buckets and shims in the same locations from which they were...

Page 90: ...e 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 Incorrect fitment...

Page 91: ...mit 0 078 mm Exhaust 0 030 0 060 mm Service limit 0 098 mm Cylinder Head Valve Guides If a valve guide is found to be worn beyond the service limit the complete cylinder head must be renewed Valve Fac...

Page 92: ...Cylinder Head This page intentionally left blank 3 26 SeNice Manual Tiger 800 and Tiger SOOXC...

Page 93: ...4 3 Exploded View Clutch Controls 4 4 Clutch Cable 4 5 Removal 4 5 Inspection 4 5 Assembly 4 5 Clutch 4 6 Disassembly 4 6 Clutch Plate Inspection 4 7 Friction Plate Thickness 4 7 Steel Plate Bend warp...

Page 94: ...Clutch Exploded View Clutch Cover 12 Nm 9 Nm 9 Nm 4 2 SeiVice Manual Tiger 800 and Tiger SOOXC...

Page 95: ...Clutch Exploded View Clutch Assembly 98 Nm SeiVice Manual Tiger 800 and Tiger 800XC 4 3...

Page 96: ...Clutch Exploded View Clutch Controls 4 4 12 Nm 1 MJ I Q 1 Nm I V 3 5 Nm SeiVice Manual Tiger 800 and Tiger 800XC...

Page 97: ...ner cable for frayed strands 3 Examine the two inner cable nipples for signs of looseness and damage Replace the cable if necessary Assembly 1 Position the cable to the motorcycle using the same routi...

Page 98: ...er spring 4 Anti judder seat washer 5 Clutch inner drum Note The inner and outermost friction plates are different to the remainder and are also different to each other They must be fitted in their no...

Page 99: ...1 Slide the clutch outer drum assembly gently backwards and forwards to dislodge the inner bearing sleeve Carefully remove the bearing sleeve while supporting the clutch drum 1 Outer drum 2 Bearing s...

Page 100: ...ion and must be measured prior to installation of new clutch plates If used clutch plates are being re fitted the clutch pack height measurement is not necessary as the plates may not be worn to the s...

Page 101: ...used in the clutch pack 1 Replace the 2 0 mm steel plate next to the 1 6 mm steel plate indicated below with a new 1 6 mm steel plate Clutch outer 1 2 0 mm steel plate to be replaced 2 1 6 mm steel pl...

Page 102: ...1 Clutch outer drum 2 Oil pump sprocket drive pegs 3 Oil pump drive holes 3 While holding the clutch outer drum in position and ensuring correct engagement with the oil pump drive refit the bearing s...

Page 103: ...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 outermost friction plates are different t...

Page 104: ...also it should be free to turn 13 Clean and refit the clutch cover incorporating a new gasket Tighten the clutch cover bolts to 9 Nm 14 Refit the clutch cable to the actuating arm at the clutch end s...

Page 105: ...Connecting Rods 5 8 Removal 5 8 Installation 5 8 Connecting Rod Big End Bearing Selection Crankshaft Journal Wear Check 5 10 Checking the Measured Clearance 5 10 Connecting Rod Bearing Selection 5 11...

Page 106: ...Crankshaft Connecting Rods and Pistons Exploded View Crankshaft Connecting Rod Piston and Liner 27 Nm 5 2 Service Manual Tiger 800 and Tiger 800XC...

Page 107: ...Crankshaft Connecting Rods and Pistons Exploded View Crankcase 22 Nm i I 8 22 Nm SeNice Manual Tiger 800 and Tiger 800XC 5 3...

Page 108: ...kcase Do not use levers to separate the upper and lower sections of the crankcase or damage to the crankcases could result Note At this point the transmission shafts balancer crankshaft bearings etc c...

Page 109: ...und its circumference Piston cooling iets must not be installed incorrectly Z Install and lubricate the crankshaft bearing shells with clean engine oil see bearing selection on page 5 12 before procee...

Page 110: ...onnecting rods see page 5 8 4 Remove the camshaft drive chain see page 3 18 5 Release and remove the crankshaft from the upper crankcase Note Identify the location of each bearing shell Remove all bea...

Page 111: ...ee page 5 12 1 cdmx 1 Big end shells 3 Lubricate all bearings with a 50150 solution of engine oil and molybdenum disulphide grease 4 Ensure that the crankshaft is clean and that the oilways within the...

Page 112: ...the piston from the connecting rod see page 5 13 Installation Note Connecting rod bolts are treated with an anti rust solution which must not be removed Clean the connecting rod with high flash point...

Page 113: ...istics of the connecting rod bolts are sensitive to the correct lubrication being applied If the threads and under head areas are not lubricated with molydenum disuplhide grease the bolts may be stret...

Page 114: ...using the grease to hold the Plastigage in place e Lubricate the threads and under head of the bolt with molybdenum disulphide grease Refit the bearing and cap and tighten the big end bolts see page...

Page 115: ...hell Colour White Con rod Big End 36 009 Bore Dia 36 000 Crankshaft Journal 33 000 Dia 32 992 Running Clearance For instance Con rod Big End Diameter Crankshaft Journal Diameter Required Bearing Note...

Page 116: ...e page 5 10 Checking Crankshaft Journal Clearance using Plastigage Crankshaft main bearing journal clearance Standard Service limit 0 020 0 044 mm 0 07 mm If the clearance exceeds the service limit me...

Page 117: ...necting rods from the crankshaft 1 Remove the cylinder head see page 3 20 2 Remove the liner using the frame from tool T3880315 and tool T3880101 see page 5 17 3 Remove and discard the gudgeon pin cir...

Page 118: ...eck the pistons for uneven groove wear by visually inspecting the ring grooves If all the rings do not fit parallel to the groove upper and lower surfaces the piston must be replaced Clean the piston...

Page 119: ...bore for distortion replacing as necessary Do not file piston rings Piston Assembly 1 Clean the piston ring grooves and fit the piston rings to the piston Note The top ring upper surface is marked N...

Page 120: ...uld be in the 6 o clock position The oil control ring expander should be in the 7 o clock position 6 Fit the piston into the liner from below using a gentle rocking motion to engage the rings in the b...

Page 121: ...t the tool fully into the cylinder bore positioning the tool legs on the crarkcase Turn the locking nut clockwise until the rubber sleeve on the tool tightly grips the bore of the liner 6 Check that t...

Page 122: ...thout need for a piston ring compressor Fit each liner over whichever piston is at TDC When turning the engine do not allow the pistons to contact the inside of the crankcase and also do not allow fit...

Page 123: ...6 Balancer Table of Contents Exploded View Balancer Shaft 6 2 Balancer 6 3 Removal 6 3 I nspect 1 on 6 3 Assembly Installation 6 4 SeNice Manual Tiger 800 and Tiger 800XC 6 1...

Page 124: ...Balancer Exploded View Balancer Shaft 6 2 Service Manual Tiger 800 and Tiger 800XC...

Page 125: ...sher and using a press and press bars remove the bearing race from the shaft ensuring the inner bearing race is supported Note the orientation of the bearing prior to removal DO NOT remove the drive g...

Page 126: ...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 5 Refit the washe...

Page 127: ...mbling the balancer to the crank cdon 1 Tool T3880156 2 Securing fixture 3 Balancer backlash gear marking If the balancer and crankshaft are not correctly aligned severe engine vibration will occur le...

Page 128: ...the crankcase 2 cdok 1 Balancer shaft left hand bearing 2 Circlip 3 Dowel 12 Remove the securing fixture 13 Check that the balancer and crankshaft are correctly aligned before continuing to assemble...

Page 129: ...Forks and Drum 7 7 Removal Z 7 Inspection Z 8 Installation Z9 Input and Output Shafts Assemblies 7 10 Removal Z 10 Installation Z 1 1 Input Shaft Z 12 Disassembly Z 12 Inspection 7 13 Exploded View I...

Page 130: ...Transmission Exploded v 1ew In 12 Nm 7 2 put and 0utput Shafts 85 Nm SeJVic M e anual Tiger 800 and r ger 800XC...

Page 131: ...Transmission Exploded View Sprag Clutch and Starter Gears 16 Nm SeiVice Manual Tiger 800 and Tiger BOOXC 7 3...

Page 132: ...Transmission Exploded View Gear Selectors and Drum 6 12 Nm l 12 Nm 12 Nm 7 4 Service Manual Tiger 800 and Tiger 800XC...

Page 133: ...Transmission Exploded View Gear Change Mechanism 6 Nm 22 Nm j 20 m Seavice Manual Tiger 800 and Tiger 800XC 7 5...

Page 134: ...ent arm spring 6 Collect the detent spring Installation Z Rotate the selector drum to the neutral position 0 cglv 1 Detent wheel 2 Neutral position 8 Using grease to N LGI 2 specification lubricate th...

Page 135: ...age 4 10 Transmission Selector Forks and Drum Removal 1 Remove the engine from the frame see page 9 3 2 Separate the two halves of the crankcase see page 5 4 3 Remove the output shaft from the crankca...

Page 136: ...ctor fork in the gearbox 1 Input selector shaft 2 Selector fork 8 Remove the gear position sensor the selector drum from within the crankcase 1 Selector drum removal 10 Collect the input shaft selecto...

Page 137: ...m Transmission 5 Rotate the selector drum and ensure a smooth movement Rectify as necessary The selector forks can be fitted incorrectly Ensure the position and orientation of the selector forks are t...

Page 138: ...removed from the upper crankcase after first separating the lower crankcase from the upper Note The rear needle roller bearing on the input shaft remains in the crankcase on removal of the shaft 1 Rem...

Page 139: ...ube into the crankcase ensuring the tag on the tube locates in the slot in the crankcase 2 Locate the input shaft to the upper crankcase installing it through the aperture for the bearing housing 3 Fi...

Page 140: ...move sixth gear 6 complete with the splined bush 5 which runs inside the gear 5 Remove the splined thrust washer 7 from in front of the circlip between sixth and third fourth gear 6 Remove and discard...

Page 141: ...hen press the bearing through the housing Pressing out the Bearing Inspection 1 Examine all gears bearings and bushes and thrust washers for damage distortion chipped teeth and wear beyond the service...

Page 142: ...ned bush 6 Sixth gear 7 Splined thrust washer 8 Circlip 9 Third fourth gear 7 14 8 7 o 6 o 17 16 15 5 14 4 3 0 13 2 G 12 ______ 11 10 9 10 Circlip 1 1 Splined thrust washer 12 Fifth gear 13 Plain bush...

Page 143: ...mission damage Also check for damage to the housing itself 1 Position the bearing to the housing Press only on the bearing outer race to prevent bearing damage Transmission 2 Support the housing on pr...

Page 144: ...d an accident 9 Fit a new circlip 8 to the input shaft ensuring that the circlip is located in the circlip groove as shown below cdmp 1 Sixth gear 2 Thrust washer 3 Circlip 10 Fit the splined thrust w...

Page 145: ...ientation Remove sixth gear 17 from the shaft 12 Remove the circlip 18 from in front of second gear Transmission 13 Remove the splined thrust washer 19 14 Mark one side of second gear to denote its co...

Page 146: ...12 Splined washer 13 Splined bush 14 Third gear 15 Splined washer 7 18 3 4 5 9 10 11 o 12 ___ 13 14 15 8 16 o 23 24 25 26 27 ___ 28 29 16 Circlip 17 Sixth gear 18 Circlip 19 Splined thrust washer 20 P...

Page 147: ...emoved bearings or snap rings as use of damaged or weakened components could lead to engine and transmission damage Press only on the bearing inner race to prevent bearing damage Transmission 1 If rem...

Page 148: ...1 Third gear 2 Large splined lock washer 3 Small splined lock washer 1 1 Fit the splined bush 10 from fourth gear Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in...

Page 149: ...draw the starter idler gear and shaft noting the fitted position of the components 1 Idler gear 2 Idler shaft Transmission 6 Remove b_ e alternator rotor see page 17 19 Z Withdraw the starter drive ge...

Page 150: ...nd is not jammed on the rotor Install new fixings 4 Working in the sequence shown tighten the bolts to 16 Nm Once all six bolts have been tightened go around again in sequence and recheck each bolt is...

Page 151: ...gasket to the crankcase dowels then refit the left hand engine cover Transmission 1 1 Refit the bottom hose bracket to the front two bolts XX Install the cover bolts using new 35 mm bolts as noted dur...

Page 152: ...Transmission This page intentionally left blank 7 24 SeJVice Manual Tiger 800 and Tiger 800XC...

Page 153: ...ation 8 6 Triumph Engine Oil 8 6 Oil Level Inspection 8 6 Oil and Oil Filter Change 8 7 Disposal of Used Engine Oil 8 8 Oil Pump 8 8 Removal 8 8 Inspection 8 11 Assembly 8 12 Installation 8 13 Low Oil...

Page 154: ...Lubrication Exploded View Sump 12Nm 25Nm 8 2 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 155: ...Lubrication Exploded View Oil Pump Water Pump Gears and Heat Exchanger 13 Nm 10 Nm 59 Nm 12 Nm SeiVice Manual Tiger 800 and Tiger 800XC 8 3...

Page 156: ...Lubrication Engine Oil Circuit A COOLED OIL 6 U NCOOLED OIL cdah 8 4 Service Manual Tiger 800 and Tiger 800XC...

Page 157: ...irectly to the sprocket end of the camshafts Oil is then fed through the hollow camshafts to the other camshaft bearings the tappet buckets and the valves Oil is fed to the gearbox via internal oil pi...

Page 158: ...f the engine lubricants currently available to the limits of their performance Oil Level Inspection In order for the engine transmission and clutch to function correctly maintain the engine oil at the...

Page 159: ...ause cancer Wear suitable clothing and avoid skin contact The engine oil and filter must be replaced in accordance with scheduled maintenance requirements 1 Warm up the engine thoroughly and then stop...

Page 160: ...down sewers or drains or into water courses Dispose of used oil sensibly If in doubt contact your local authority Oil Pump t I j J f il t J l Prolonged or repeated contact with engine oil can lead to...

Page 161: ...and discard the two 0 ring seals j 8 1 Oil transfer pipe 2 Fixings 8 Release and discard the two fixings and remove the oil pick up Remove and discard the 0 ring seal Lubrication 9 Remove and discard...

Page 162: ...backwards and forwards to dislodge the inner needle roller bearing 1 Oil pump drive sprocket 2 Needle roller bearing 13 Carefully remove the bearing while supporting the oil pump drive sprocket 1 Need...

Page 163: ...rankcase D ve cham 1 pump from 2 n thdraw the oo h inlet sleeve Z Carefully Wl h O ring from t e 1 d discard t e 18 Remove a t n er pump body on the wa Inspection and Release the fixmg 1 and spacer wa...

Page 164: ...ody to the oil pump rotor Refit the fixings and tighten to 12 Nm 2 If any clearance measured is outside the service limits renew the complete pump 3 Inspect the sprockets and chain for wear and or dam...

Page 165: ...case Do not use excessive force to insert the dowel into the crankcase Severe dowel or crankcase damage may result from the use of excessive force 5 Using a suitable pin punch gently tap the dowel dow...

Page 166: ...ive red lead first 18 Refit the rider s seat see page 16 13 19 Refill the engine with oil see page 8 7 20 Refill the cooling system see page 1 1 5 Low Oil Pressure Warning Light Switch The low oil pre...

Page 167: ...Remove the three fixings and remove the sump guard bracket cgya 1 Sump guard bracket 2 Fixings 6 Remove the exhaust system see page 10 1 18 The exhaust system will be hot if the engine has recently be...

Page 168: ...Tighten to 15 Nm 1 Sump guard bracket 2 Fixings 6 Refit the sump guard see page 16 2T Note Use new exhaust gaskets at the downpipe connections with the cylinder head Z Fill the engine with the correc...

Page 169: ...oil may cause skin to be scalded or burnt Prolonged or repeated contact with engine oil can lead to skin dryness irritation and dermatitis In addition used engine oil contains potentially harmful con...

Page 170: ...heat exchanger in position by hand cgyq 1 Heat exchanger tab 2 Crankcase boss 2 Fit the heat exchanger to the crankcase and tighten the centre bolt to 59 Nm 3 Fit the coolant hoses to the heat exchang...

Page 171: ...9 Engine Removal Refit Table of Contents Exploded View Frame Fixings 9 2 Engine Removal Refit 9 3 Removal 9 3 Installation 9 5 SeiVice Manual Tiger 800 and Tiger 800XC 9 1...

Page 172: ...Engine Removal Refit Exploded View Frame Fixings 48 Nm 48 Nm 48 Nm 48 Nm 9 2 Service Manual Tiger 800 and Tiger 800XC...

Page 173: ...prevent chain damage do not allow the chain to come into contact with dirt road grit etc 1Z Set the drive chain adjustment to allow maximum free play in the chain see page 12 8 18 Remove the swinging...

Page 174: ...h a Frame Adjuster Sleeve 1 Using tool T3880166 loosen the frame adjuster and unscrew it fully to allow clearance between the frame and engine 1 Rear lower frame adjuster sleeve 2 Tool T3880166 All Mo...

Page 175: ...ght hand front cylinder head bolt as noted during removal 2Y 1 Left hand rear cylinder head bolt 2 Left hand front cylinder head bolt 3 Spacers Z Fit the front cylinder head bolts from the outside Fit...

Page 176: ...l electrical connections to the engine 6 Refit the gearchange linkage aligning the slot in the gear selector arm with the dot on the gear change shaft Refit the bolt and tighten to 9 Nm Z Refit the sp...

Page 177: ...ge 10 92 16 Refit the battery to the battery box and reconnect positive red lead first see page 17 8 Engine Removal Refit 1Z Refill the cooling system see page 1 1 S 18 Remove the motorcycle from the...

Page 178: ...Engine Removal Refit This page intentionally left blank 9 8 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 179: ...l 10 12 MTBE Methyl Tertiary Butyl Ether 10 12 Glossary of Terms 10 13 Air temperature 10 13 Air temperature sensor 10 13 ATDC 10 13 Barometric pressure 10 13 Battery voltage 10 13 BTDC 10 13 Catalyst...

Page 180: ...ottle voltage 1 0 15 TDC 1 0 15 TPMS 1 0 15 Transponder 1 0 15 Vbatt 1 0 15 Engine Management System 1 0 1 6 System Description 1 0 1 6 System Sensors 1 0 1 6 Sensor Locations 1 0 1 7 System Actuators...

Page 181: ...1 0 39 Disconnection of ECM connectors 1 0 39 Reconnection of ECM connectors 1 0 4 0 Further Diagnosis 1 0 4 0 Crankshaft Sensor 1 0 41 Idle Speed Control 1 0 4 2 Fuel Injectors 1 0 4 4 Throttle Posi...

Page 182: ...5 Rear Wheel Unit Sensor Fault Alert 10 8 6 Front Wheel Unit Sensor Loss of Communication 1 0 8 7 Rear Wheel Unit Sensor Loss of Communication 1 0 8 8 lmmobiliser TPMS Control Module Fault 10 89 Inval...

Page 183: ...0 4 Throttle Cable 10 10 4 Adjustment 10 10 4 Removal 10 105 Inspection 10 106 Installation 10 106 Throttle Bodies Injectors 10 107 Removal 10 107 Inspection 10 10 8 Installation 10 109 Throttle Body...

Page 184: ...ative Emissions Control System 1 0 1 21 California Models Only 1 0 1 21 Component Locations 1 0 121 Evaporative Control System Engine Off 1 0 1 2 2 Evaporative Control System Engine Running 1 0 1 2 3...

Page 185: ...Fuel System Engine Management Exploded View Fuel Tank and Fuel Pump j SeiVice Manual Tiger 800 and Tiger 800XC 1 0 7...

Page 186: ...Fuel System Engine Management Exploded View Fuel Rail T hrottles and lniectors 3 5 Nm 3 5 Nm 3 5 Nm 12 Nm r 2 Nm 1 5 Nm 10 8 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 187: ...Fuel System Engine Management Exploded View Airbox 1 5 Nm 1 5 Nm SeNice Manual Tiger 800 and Tiger 800XC 10 9...

Page 188: ...Fuel System Engine Management Exploded View Exhaust System 10 Nm e 25 Nm y 10 10 Se1Vice Manual Tiger 800 and Tiger 800XC See text See text...

Page 189: ...Fuel System Engine Management Exploded View Evaporative System SeNice Manual Tiger 800 and Tiger 800XC 10 11...

Page 190: ...ne 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...

Page 191: ...d as a voltage and expressed as percentage Fuel System Engine Management Coolant temperature The coolant temperature in the cylinder head Coolant temperature sensor Sensor which detects coolant temper...

Page 192: ...d loop only See also short term fuel trim MAP sensor Manifold Absolute Pressure the air pressure in the intake system Measured after the throttle valves This reading is compared to the ambient pressur...

Page 193: ...ement Throttle position The position of the throttle butterfly given as a percentage of the movement range When the data is displayed on the diagnostic software fully open need not be 100 nor fully cl...

Page 194: ...h the actual crankshaft position is calculated The crankshaft position sensor information is used by the ECM to determine engine speed and crankshaft position in relation to the point where fuel is in...

Page 195: ...AN I FOLD ABSOLUTE PRESSURE MAP SENSOR CRAN K POSITION SENSOR ROAD SPEED SENSOR FAll DETECTION SWITCH BAROMETRIC PRESSURE SENSOR COOLANT TEMPERATURE SENSOR SIDE STAN D SWITCH GEAR POSITION SENSOR I NT...

Page 196: ...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 EMS main relay situated behin...

Page 197: ...or Locations Fuel System Engine Management THROTILE STEPPER MOTOR FUEL PUMP FUEL INJECTORS IGNITION COILS COOLI NG FAN EMS MAIN POWER RELAY CANISTER PURGE VALVE SeNice Manual Tiger 800 and Tiger 800XC...

Page 198: ...signal is received Alarm immobiliser warning indicator light Situated in the instrument pack The light will flash on and off for 24 hours to show that the engine immobiliser is on When the ignition sw...

Page 199: ...Fuel System Engine Management Components Location ENGIN E CONTROL MODULE SeNice Manual Tiger 800 and Tiger 800XC 10 21...

Page 200: ...light lmmobiliser TPMS control module Receives the data from the tyre pressure sensors and sends the information to the instrument pack Tyre pressure sensor Situated inside the front and rear wheel Ea...

Page 201: ...Component Locations TYRE SYMBOL TYRE PRESSURE DISPLAY IMMOBI ISERITPMS CONTROL MODULE Fuel System Engine Management TYRE PRESSU RE SENSOR SeiVice Manual Tiger 800 and Tiger 800XC 10 23...

Page 202: ...ontrol Stepper Motor 23 Coil 3 24 Coil 2 25 Coil 1 26 Oxygen Lambda Sensor Heater 27 Fuel Injector 3 28 Fuel Injector 2 29 Fuel Injector 1 30 Purge Valve 31 Crankshaft Position Sensor 32 Engine Contro...

Page 203: ...A12 ow All ou AlO 22 OK All W 21 B 816 l 1 2 5 B A35 ___ 1 iol r BYY 830 L _ su s j_ 20 IJEJ19 18 I ___ _ A14 f lG Al4 f KY 828 i R 827 1 u A32 f B0 8 B 5 1 AJJ i BR g _r B 2 7 804 BG 821 KU 801 K All...

Page 204: ...eed Control Stepper Motor 23 Coil 3 24 Coil 2 25 Coil 1 26 Oxygen l ambda Sensor 27 Fuel Injector 3 28 Fuel Injector 2 29 Fuel Injector 1 30 Purge Valve 31 Crankshaft Position Sensor 32 Engine Control...

Page 205: ...GP 818 24 NK E2 3 G8 G8 817 23 22 r l l c w 1 01 All 21 B 816 l1 l S 8 AlS i IL __ L 1 _ _ _ _ e u 2 2 8 j_ 8Y 830 A24 BG 7 Bl3i BY BY BOSi BN BN 8 3 _ __ __ J _ m 4 1s A32 BO B _l_ 5 1 m m 7 IT ru6 f...

Page 206: ...detected and the count reaches a pre determined threshold the fault becomes confirmed If the fault is an emissions related fault or a serious malfunction affecting engine performance a DTC Diagnostic...

Page 207: ...e 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 informa...

Page 208: ...n Calculated load value Engine coolant temperature oc Short term fuel trim Bank 1 Intake manifold absolute pressure mm hg Engine speed RPM Vehicle speed km h Ignition timing advance cylinder 1 degrees...

Page 209: ...mperature 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...

Page 210: ...a is Item Checked Result Unit Ignition timing cyl 1 degrees BTDC Ignition timing cyl 2 degrees BTDC Ignition timing cyl 3 degrees BTDC Coil dwell time milliseconds Idle Speed and Throttle Data The dat...

Page 211: ...ty cycle t Apphes to models f1tted w1th a purge valve only All other models w1ll show Not Applicable m th1s field Adaption Status Because the fuel system is adaptive the engine management system is ab...

Page 212: ...ming Listen for fuel pump operation Stored fault code Fuel Pump Continuous Operation Fuel pressure test Listen for fuel pump operation Stored fault code Cooling Fan Controlt Observe the cooling fan St...

Page 213: ...page 10 1 10 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 fir...

Page 214: ...s P0202 Injector 2 circuit malfunction 3 40 Yes P0203 Injector 3 circuit malfunction 3 40 Yes P1201 Injector 1 open circuit short to ground 3 40 Yes P1202 Injector 2 open circuit short to ground 3 40...

Page 215: ...rcuit to ground or open circuit 3 40 Yes P0445 Purge valve system short circuit to battery 3 40 Yes P0617 Starter relay short circuit to battery 3 40 Yes P0616 Starter relay short circuit to ground or...

Page 216: ...es P1659 EMS ignition voltage input malfunction 3 40 Yes P1698 Sensor supply Nee circuit malfunction 3 40 Yes P1602 Tunelock Only if Flashing Tunelock is unlocked P1614 ECM or tune ID Incorrect Only i...

Page 217: ...at 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 c...

Page 218: ...connector pins may result if an attempt to fit the connectors incorrectly is made 1 ECM grey connector 2 ECM black connector 1 Fit the first connector into its socket and whilst holding the connector...

Page 219: ...nd run OK engine to verify fault cleared Circuit Diagram Fault still present Crankshaft Sensor llil us L j UP Engine sub harness connector Action View note diagnostic software freeze frame data if ava...

Page 220: ...test 7 ECM pin A20 to earth Short circuit Locate and rectify wiring fault proceed to ECM pin A21 to earth test 7 ECM pin A22 to earth ECM pin A23 to earth 4 Check cable continuity OK Proceed to test 6...

Page 221: ...Circuit Diagram Idle Speed Control Stepper Motor Fuel System Engine Management w I N ou OK ECM SeNice Manual Tiger 800 and Tiger 800XC 10 43...

Page 222: ...heck cable for short circuit to ground OK Proceed to test 7 ECM pin A15 to earth Short circuit Locate and rectify wiring fault proceed to ECM pin A 14 to earth test 7 ECM pin A13 to earth 4 Check cabl...

Page 223: ...Circuit Diagram EMS Main Relay Fuel System Engine Management NK 1 YK 1 YP 1 YB _ _ _J Fuel Injectors ECM SeiVice Manual Tiger 800 and Tiger 800XC 10 45...

Page 224: ...n A10 Faulty Rectify fault proceed to test 5 2 Check cable for short circuit OK Proceed to test 3 ECM pin A 10 to ground Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable c...

Page 225: ...Circuit Diagram Fuel System Engine Management Throttle Position Sensor 0 ECM SeiVice Manual Tiger 800 and Tiger SOOXC 10 47...

Page 226: ...eed to test 5 3 Check cable for short circuit OK Disconnect purge valve and proceed to test 7 ECM pin 809 to earth Short circuit Locate and rectify wiring fault proceed to test 7 4 Check cable continu...

Page 227: ...Circuit Diagram Fuel System Engine Management EMS Main Relay PurgeValve 1 2 NK YR ECM SeiVice Manual Tiger 800 and Tiger 800XC 10 49...

Page 228: ...to test 7 ECM pin B 17 to earth Short circuit Locate and rectify wiring fault proceed to ECM pin A 18 to earth test 7 ECM pin B 18 to earth 4 Check cable continuity OK Proceed to test 6 EMS main relay...

Page 229: ...Circuit Diagram Fuel System Engine Management EMS Main Relay llo NK GK K GP NK GB Ignition Coils ECM Service Manual Tiger 800 and Tiger 800XC 10 5 1...

Page 230: ...o test 3 Temperature dependent see below Short circuit Disconnect temp sensor and proceed to test 4 3 Check cable continuity OK Proceed to test 5 ECM pin A29 to sensor pin 1 Open circuit Locate and re...

Page 231: ...istance data under typical conditions Warm engine Cold engine 20 C ambient 10oC ambient 200 to 400Q 2 35 to 2 65KQ 8 50 to 10 25KQ Coolant Engine Temperature sub harness Sensor connector ECM KB l KG L...

Page 232: ...it Disconnect temp sensor and proceed to test 3 Short circuit Disconnect temp sensor and proceed to test 4 3 Check cable continuity OK Proceed to test 5 ECM pin A1 1 to sensor pin 1 Open circuit Locat...

Page 233: ...arm remove sensor and allow time to cool to ambient prior to test Resistance data Ambient temp 80 C 20 C 10 C Resistance value 200 to 400Q 2 35 to 2 6SKQ 8 50 to 10 2SKQ Inlet Air ECM Temperature Sens...

Page 234: ...nd terminal integrity OK Proceed to test 2 ECM pin A06 Faulty Rectify fault proceed to test 3 2 With Ignition ON check voltage at Same as across Proceed to test 3 battery voltage ECM pin A06 Less than...

Page 235: ...ort circuit OK Proceed to test 3 ECM pin B30 to ground Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity OK Proceed to test 4 Fan relay pin 2 to ECM pin B30 Open...

Page 236: ...d to test 4 ECM pin 820 2 Check cable for short circuit OK Proceed to test 3 ECM pin A26 to ECM pin 820 Short circuit Locate and rectify wiring fault proceed to ECM pin A26 to ECM pin A06 test 4 3 Che...

Page 237: ...aulty Rectify fault proceed to test 5 2 Check cable for short circuit OK Proceed to test 3 ECM pin B 14 to ground Short circuit Locate and rectify wiring fa ult proceed to test 5 3 Check cable continu...

Page 238: ...ngine Management EEPROM Error Fault Code Possible cause Action P0603 EEPROM error View note freeze frame data if available No tests available contact Triumph service 10 60 Se1Vice Manual Tiger 800 and...

Page 239: ...y wiring fault proceed to test 6 3 Check cable continuity OK Proceed to test 4 ECM pin B01 to sensor pin 4 Open circuit Locate and rectify wiring fault proceed to ECM pin B21 to sensor pin 5 test 6 EC...

Page 240: ...to ground Faulty ECM pin A34 to Instruments pin 9 3 Check cable for continuity OK ECM pin A34 to sensor pin 3 Open circuit Sensor pin 2 to ground Instruments pin 9 to sensor pin 1 4 Reconnect harness...

Page 241: ...Instrument pin 4 Instrument pin 5 ABS unit pin 1 Diagnostic connector pin 6 Diagnostic connector pin 14 2 Check cable for short circuit OK Proceed to test 3 ECM pin B28 to ground Faulty Locate and re...

Page 242: ...OK ECM pin B28 to Instrument pin 4 Open circuit ECM pin B27 to Instrument pin 5 4 Reconnect harness clear fault code and run OK engine Circuit Diagram Fault still present Instruments ECM IT41 R L____...

Page 243: ...ness clear fault code OK Circuit Diagram Fault still present Fuel Level ECM Sensor G sG i 1 12 Action View note freeze frame data if available View note sensor data Ensure sensor connector is secure D...

Page 244: ...test 5 ECM pin 820 ECM pin 801 2 Check cable for short circuit OK Proceed to test 3 ECM pin A27 to ECM 820 Short circuit Locate and rectify wiring fault proceed to ECM pin A27 to ground test 5 3 Check...

Page 245: ...8 Faulty Rectify fault proceed to test 5 ECM pin 820 ECM pin 801 2 Check cable for short circuit OK Proceed to test 3 ECM pin A28 to ECM 820 Short circuit Locate and rectify wiring fault proceed to EC...

Page 246: ...d to test 3 ECM pin 824 to ground Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable for continuity OK Proceed to test 4 ECM pin 824 to sensor pin 1 Open circuit Locate and...

Page 247: ...Circuit Diagram Fuel System Engine Management ECM Gear Position Sensor BW BK 1 KB 2 SeiVice Manual Tiger 800 and Tiger 800XC 10 69...

Page 248: ...tify fault proceed to test 5 2 Check cable for short circuit to ground OK Proceed to test 3 ECM pin 829 to earth Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuit...

Page 249: ...Fuel System Engine Management Circuit Diagram Fuel Pump Main Relay GR ECM Alarm BP Q GR B A19 SeiVice Manual Tiger 800 and Tiger 800XC 10 71...

Page 250: ...lace Fuse 6 EMS Main relay pin 3 to ground and proceed to test 7 4 Check cable and terminal integrity OK Disconnect Main Relay and proceed to test 5 ECM pin A06 Faulty Rectify fault proceed to test 7...

Page 251: ...Circuit Diagram Fuse box r I I I I I 6 I 20 A I I Fuel System Engine Management ECM NK vs E__j SeiVice Manual Tiger 800 and Tiger 800XC 10 73...

Page 252: ...1 Alarm Connector pin 2 Right hand switchcube pin 2 Right hand switchcube pin 5 4 Check cable continuity OK ECM pin A19 to fuse box Fuse 2 note that Open circuit and proceed to test 5 Proceed to test...

Page 253: ...ceed to test 5 MAP sensor Faulty Proceed to test 4 Ambient pressure sensor Throttle position switch Exhaust control valve actuator Fall detection sensor and retest for short circuit ECM pin B01 to ECM...

Page 254: ...ocked to prevent the This is also identified by a fast flashing motorcycle from being operated MIL indication and a disabled engine management system Unlock the ECM using the diagnostic software and s...

Page 255: ...Tests Test Result Action 1 Check ECM part number is correct for the OK Proceed to test 2 motorcycle Incorrect Replace ECM with correct part and proceed to test 3 2 Check that the tune is correct for...

Page 256: ...1 Immobiliser pin 6 2 Check cable for short circuit OK Disconnect immobiliser ignition switch and proceed to test 3 ECM pin 828 to ground Faulty Locate and rectify wiring fault proceed to test ECM pin...

Page 257: ...ser and TPMS MIL indication and a disabled engine control module causing the ECM to management system be disabled to prevent the motorcycle from being operated Pinpoint Tests Test Result Action 1 Foll...

Page 258: ...Possible cause Action P1520 There is a mismatch between the Check ABS modulator part number is ECM and the ABS modulator causing correct for the motorcycle the ECM to be disabled to prevent the motorc...

Page 259: ...ECM pin B28 to ABS modulator pin 1 Fault still present ECM pin B27 to ABS modulator pin 17 3 Reconnect harness clear fault code and run OK engine Fault still present Circuit Diagram ABS Modulator Q R...

Page 260: ...lt with the throttle linkage Diagnostic software malfunctions during tune download Low battery voltage procedure Throttle hang up Incorrect closed throttle position setting Motorcycle will start but c...

Page 261: ...software Fault Code Possible cause Action L0001 Low battery voltage Replace the front wheel pressure or sensor following the procedure The TPMS tyre symbol in the described in the Triumph diagnostic...

Page 262: ...eel pressure or sensor following the procedure The TPMS tyre symbol in the described in the Triumph diagnostic instrument pack will be on for 8 tool user guide seconds with the F symbol with lo Record...

Page 263: ...e problem persists detected a hardware error Replace the front wheel pressure Note This DTC will automatically be sensor following the procedure generated if DTC L0007 occurs described in the Triumph...

Page 264: ...problem persists detected a hardware error Replace the rear wheel pressure Note This DTC will automatically be sensor following the procedure generated if DTC L0007 occurs described in the Triumph di...

Page 265: ...umph diagnostic tool wheel sensor unit check that the correct I D number for Low battery voltage the front wheel pressure sensor is Wrong sensor ID number has been registered to the lmmobiliser TPMS r...

Page 266: ...mph diagnostic tool wheel sensor unit check that the correct I D number for Low battery voltage the rear wheel pressure sensor is Wrong sensor I D number has been registered to the lmmobiliser TPMS re...

Page 267: ...t I D numbers for and rear wheel sensor units the wheel pressure sensors are Low battery voltage registered to the lmmobiliser TPMS Wrong sensor ID numbers have been control module registered in the i...

Page 268: ...able continuity OK Ignition switch pin 7 to Immobiliser and Faulty TPMS control module pin 10 Ignition switch pin 2 to Immobiliser and TPMS control module pin 5 5 Reconnect harness clear fault code an...

Page 269: ...curing the fuel tank to the frame 1 Fuel tank 2 Fuel tank to frame bolt 8 Raise the fuel tank and disconnect the electrical connections to the fuel pump and the fuel level sensor When disconnected the...

Page 270: ...ck 4 Slide the double check latch down i e towards the spigot 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 mus...

Page 271: ...not handled or stored correctly 5 Invert the fuel tank and place on a protective surface to prevent paint damage 6 Remove the fixings securing the fuel pump mounting plate to the fuel tank 1 Mounting...

Page 272: ...der arm from moving through its full range of movement causing incorrect fuel gauge readings 4 Check that the fuel level sender wiring is not routed over the fuel level sender arm 5 Locate the fuel pu...

Page 273: ...ing that the upper tang and two side tangs are correctly attached to the bracket inside the fuel tank 1 Upper tang 2 Side tangs Routing the fuel level sender wiring over the fuel level sender arm will...

Page 274: ...Select the fuel pressure gauge adapter marked B from service tool T3880001 Always us the correct fuel pressure gauge adapter adapter B for Tiger 800 and Tiger SOOXC Use of an incorrect adapter will r...

Page 275: ...Note The fuel pressure should be 3 0 bar nominally 10 When fuel pressure checking is complete disconnect the fuel pressure gauge adapter and wiring extension 1 1 Refit the fuel tank see page 10 92 12...

Page 276: ...irbox _ 1 Air intake duct 2 Fixing 4 Remove the fuel tank see page 10 91 5 Disconnect the intake air temperature sensor multi plug 1 Intake air temperature sensor 2 Multi plug 6 Disconnect the MAP sen...

Page 277: ...0 Remove the airbox rear fixing located below the air filter Fuel System Engine Management 1 1 Raise the airbox and disconnect the engine breather hose at the airbox cooo 1 Engine breather hose 2 Spri...

Page 278: ...12 Refit the rider s seat see page 16 13 Air Filter Element Removal Note 1 2 The air filter element can be accessed after first removing the airbox upper section lt is not necessary to remove the lowe...

Page 279: ...sitive red lead first 5 Refit the rider s seat see page 16 13 Fuel System Engine Management MAP Sensor Removal 1 Remove the rider s seat see page 16 73 2 Disconnect the battery negative black lead fir...

Page 280: ...4 Refit the rider s seat see page 16 13 Fall Detection Switch Removal Note The fall detection switch is located below the rear rack forward of the rear light unit 1 Remove the rider s seat see page 1...

Page 281: ...hten to 4 Nm 3 Re route the harness as noted during disassembly and reconnect the sensor to the main wiring harness 4 Refit the alternator cover see page 17 20 5 Reconnect the battery positive identif...

Page 282: ...Remove the remainder of the shear bolt from the frame Installation 1 Installation is the reverse of removal noting the following Install new shear bolts and tighten until the heads shear off Throttle...

Page 283: ...ident Ensure that the adjuster locknuts are tightened A loose throttle cable adjuster could cause the throttle to stick leading to loss of motorcycle control and an accident Z Refit the fuel tank see...

Page 284: ...1 Locate the cables to the frame following the routing noted during removal 2 Engage the inner cable nipples to the throttle grip ensuring the opening cable is located in the upper slot in the thrott...

Page 285: ...pump disconnected 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...

Page 286: ...e fuel rail gently ease the injector from the rail cdvp 1 1njector 2 Fuel rail 15 To detach the transition pieces from the head release the screws raise the transition pieces and collect the 0 rings 1...

Page 287: ...Nm 1 Fuel rail 2 Fuel rail screws 6 Re attach the throttle cables see page 10 104 The throttle body clips must be positioned as shown below If the clips are not positioned as shown this could cause th...

Page 288: ...from service tool T3880001 r Always us the correct fuel pressure gauge adapter adapter B for Tiger 800 and Tiger SOOXC Use of an incorrect adapter will result in a fuel leak A fuel leak can result in...

Page 289: ...creen At this point adjustment will be necessary The adjusters operate on the outer cylinders only cylinders 1 and 3 The centre throttle cylinder 2 adjustment is fixed this being controlled by the idl...

Page 290: ...ck the Adjust button 9 On pressing the adjust button the diagnostic tool will send a command which drives the primary throttle to the fully closed position The tool will also display the voltage readi...

Page 291: ...ge 10 92 18 Reconnect the battery positive red lead first 19 Check and clear any stored faults using the diagnostic tool refer to the Triumph Diagnostic Tool User Guide 20 Refit the rider s seat see p...

Page 292: ...m as shown below 2 If removed loosely fit the spring and collar on the stepper motor arm cdax 1 Collar 2 Spring 3 Locate the stepper motor to its bracket and tighten the fixings to 3 5 Nm 1 Idle speed...

Page 293: ...uel System Engine Management 13 Check the voltage reading shown on the software If the reading is between the target voltage range then proceed to step 1Z If the reading is not within this range adjus...

Page 294: ...e system is able to learn about new or changing operating conditions and continuously adapt itself without needing to constantly make major adjustments from a fixed baseline setting Adaptive changes c...

Page 295: ...n an area with adequate ventilation 1 Ensure the engine is cold 2 WITHOUT TOUCH I NG THE TH ROTILE start the engine and allow it to warm up until the cooling fan comes on 3 Leave the engine to idle fo...

Page 296: ...the clamp securing the silencer to the header pipe cgph 1 Silencer 2 Clamp 3 Header pipe 4 Support the right hand silencer and release the bolt and nut securing the silencer mounting bracket to the r...

Page 297: ...n sensor and tighten to 25 Nm 2 Fit new seals to the cylinder head Ensure that the face of the seal with the tab is facing the cylinder head Note A smear of grease may be used to retain the seals in t...

Page 298: ...not tighten the clamp at this stage 1 1 Align the silencer mounting bracket to the rear frame bracket Refit the nut Tighten the fixings to 15 Nm Align the clamp for the silencer to header pipe joint...

Page 299: ...he 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 Carb...

Page 300: ...re will cause the fuel vapour to pass down the breather hose 1 to a carbon filled canister 2 which stores the vapour Once in the canister vapour cannot enter the engine because the purge valve is clos...

Page 301: ...stored vapour from the carbon filled area of the 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...

Page 302: ...Fuel System Engine Management This page intentionally left blank 10 124 SeiVice Manual Tiger800 and Tiger800XC...

Page 303: ...evel Inspection 11 4 Coolant Replacement 11 5 Drainage 11 5 Filling 11 5 Water Pump 11 7 Coolant Pressure Cap and Coolant System 11 7 Inspection andTesting 11 7 Thermostat 11 9 Removal 11 9 Inspection...

Page 304: ...Cooling Exploded View Cooling System 1 Nm 2 Nm 2 Nm Q Tiger SOOXC Only 11 2 SeNice Manual Tiger800 and Tiger800XC...

Page 305: ...body Never swallow anti freeze or any of the motorcycle coolant The coolant mixture contains a corrosion inhibitor which helps prevent damage to the metal surfaces inside the coqling system Without th...

Page 306: ...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 Note Only inspect the coolant level...

Page 307: ...y negative black lead first 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 the pressur...

Page 308: ...cycle fully over to the right hand side and then the left hand side to release air trapped in the cooling system Repeat as necessary 12 Reconnect the battery positive red lead first 13 Start the motor...

Page 309: ...nt will cause scalds and skin damage 1 Allow the engine temperature to cool for at least 30 minutes 2 Remove the coolant pressure cap 3 Check the condition of the upper and lower seals of the coolant...

Page 310: ...urely fasten to the radiator 2 Carefully connect the hand pump to the bayonet connector ensuring an air tight seal is maintained 1 Radiator filler 2 Bayonet type connector 3 Hand held pump 3 Pressuris...

Page 311: ...at see page 16 13 2 Disconnect the battery negative black lead first 3 Drain the coolant see page 11 S 4 Remove the fuel tank see page 10 9 1 5 Remove the airbox see page 10 98 6 Remove the throttle b...

Page 312: ...stat opening takes place is incorrect replace the thermostat Installation 1 Fit a new seal to the thermostat 2 Locate the thermostat into the cylinder head Ensure the bleed valve is uppermost as shown...

Page 313: ...kin damage 3 Drain the coolant see page 1 1 5 4 Disconnect the top hose and expansion tank hose at the radiator 5 Disconnect the bottom hose from the radiator cgxu 1 Top hose 2 Expansion tank hose 3 B...

Page 314: ...signs of heat distortion Installation 1 Align the radiator grommet to the frame stud Fit the upper mounting bolt and tighten the bolt to 6 Nm 2 Align the radiator lower mounting to the bracket on the...

Page 315: ...g Link 12 7 Drive Chain 12 8 Chain Lubrication 12 8 Chain Adjustment 12 8 Chain Free movement Inspection 12 8 Chain Free movement adjustment 12 9 Chain Wear Inspection 12 9 Rear Suspension Unit 12 10...

Page 316: ...Rear Suspension Exploded View Swinging Arm 9 Nm 110Nm 9 Nm 12 2 SeiVice Manual Tiger800 and Tiger800XC...

Page 317: ...Rear Suspension Exploded View Rear Hub and Wheel Tiger 800 110Nm L l 1 I I __ Service Manual Tiger800 and Tiger800XC 12 3...

Page 318: ...Rear Suspension Exploded View Rear Hub and Wheel Tiger SOOXC I L_______________________________________l I I I II __ J 12 4 SeiVice Manual Tiger800 and TigerSOOXC...

Page 319: ...Rear Suspension Exploded View Rear Suspension Unit Tiger 800 48Nm 48Nm Service Manual Tiger800 and Tiger800XC 12 5...

Page 320: ...Rear Suspension Exploded View Rear Suspension Unit Tiger SOOXC 3Nm 48Nm 12 6 SeiVice Manual Tiger800 and Tiger800XC...

Page 321: ...Exploded v lew Dr I op Drag Link 80Nm 80Nm tDCCD 0 c J 0 aoNm r 80Nm SeiVice Manual Tiger800 and T ger800XC Rear Suspension 80Nm 80Nm 80Nm 12 7...

Page 322: ...leave for eight hours before riding This allows the lubricant s solvent used to thin the oil to evaporate and the oil to soak into all parts of the chain If the lubricant is applied and the motorcycl...

Page 323: ...lt 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 remedi...

Page 324: ...m Rear Suspension Unit Removal I t r I I If the engine has recently been running the exhaust system will be hot Before working on or near the exhaust system allow sufficient time for the exhaust syste...

Page 325: ...o disassemble the rear suspension unit or remote reservoir lt contains fluid under pressure and serious injury could result if any part of the system is disturbed 5 Inspect the remote reservoir and ho...

Page 326: ...rking on or near the exhaust system allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries t Before starting work ensure the motorc...

Page 327: ...8 Fit the seats see page 16 13 Rear Suspension Swinging Arm Removal If the engine has recently been running the exhaust system will be hot Before working on or near the exhaust system allow sufficient...

Page 328: ...both sides 2 Remove the bearing sleeves from both sides 3 Remove the four seals 4 Remove the bearings by drifting through from the outside 1 Dust cover 2 Bearing sleeve 3 Seal 4 Needle roller bearing...

Page 329: ...Rectify as necessary if correct brake operation is not restored see page 14 23 lt is dangerous to operate the motorcycle with defective brakes you must have your authorised Triumph dealer take remedia...

Page 330: ...h a special grease which must not be removed Removal of this special grease will severely reduce the service life of the chain 9 Use the old drive chain to pull the new chain into position as follows...

Page 331: ...k plate 3 Chain link 4 Link plate holder groove 15 Retain the tool body and tighten the large pressure screw until the link plate is pressed fully onto the link 16 Back off the pressure screw slide th...

Page 332: ...d check that both the split link pins are correctly riveted as shown below 1 2 3 4 cana 1 Correct riveting 2 Insufficient riveting 3 Excessive riveting 4 Riveting off centre If either split link pin i...

Page 333: ...Removal 13 5 Installation 13 6 Fork Oil Change 13 7 Draining 13 7 Oil Refilling 13 7 Fork Oil Level Chart 13 8 Front Fork 13 9 Disassembly 13 9 Inspection 13 12 Assembly 13 12 Headstock Bearing Check...

Page 334: ...Front Suspension Exploded View Front Fork Tiger 800 35 Nm 0 2 0Nm See text See text t J 22Nm e 13 2 SeiVice Manual Tiger800 and Tiger800XC...

Page 335: ...Front Suspension Exploded View Front Fork Tiger SOOXC 35 Nm See text See text c f J c 22 Nm 2 0Nm e SeiVice Manual Tiger800 and Tiger800XC 2 0Nm 13 3...

Page 336: ...Front Suspension Exploded View Handlebars 5 Nm L 35 Nm 5 Nm A ov 9 0Nm 2 0Nm 2 0Nm 13 4 Service Manual Tiger800 and Tiger800XC...

Page 337: ...fective or damaged suspension can cause loss of motorcycle control and an accident Never ride with damaged or defective suspension Front Suspension Front Fork Removal Before starting work ensure the m...

Page 338: ...osition the forks within the yokes so that the lip of the outer tube not the top cap is 4 mm above the upper surface of the top yoke 1 Outer tube 2 Top cap 3 Top yoke 2 Tighten the bottom yoke clamp b...

Page 339: ...e fork spring see page 13 9 4 Holding the inner and outer tubes together invert the fork and pour out the fork oil into a suitable container Pump the damper rod to remove all the oil Oil Refilling The...

Page 340: ...syringe until fluid flow ceases empty the syringe if the body becomes full before fluid flow stops 6 The fluid level in the fork is now set to the height set on the tool scale Check the tool scale se...

Page 341: ...rew and remove the top cap If necessary remove the 0 ring seal from the top cap assembly 4 Holding the inner and outer tubes together invert the fork and pour out the fork oil into a suitable containe...

Page 342: ...r end Note the orientation of the spring before removal 10 Remove the spring spacer and spring cdno 1 Washer 2 Spring spacer Tiger 800 shown 3 Spring 4 Damper rod Note To help with identification of t...

Page 343: ...seal and bushes from the outer tube separate the inner and outer tubes leaving the seals and bushes in place on the inner tube ccuw Note the relative positions and orientation of all bushes and seals...

Page 344: ...ed at all 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 control or an accident N...

Page 345: ...not become damaged Front Suspension 10 Using the narrow end of tool T3880003 Tiger 800 models or T3880157 Tiger 800XC models guide the lower bush washer and seal into place 1 Tool T3880003 mger 800 or...

Page 346: ...or should dislodge or detach the resulting release of spring tension could cause parts to fly off resulting in injury to the user 20 Tiger 800XC only Refit tool T3880067 as previously described compre...

Page 347: ...be returned to the same position when the repair operation is complete 2 Raise and support the front of the motorcycle 3 Release the fixings securing the handlebar clamps to the risers detach the clam...

Page 348: ...ster nut then re tighten to 15 Nm Fit the tab w asher and lock nut 14 t i l lt is essential that the adjuster nut is not over tightened If the adjuster is over tightened it will cause a pre load on th...

Page 349: ...k Bearing Removal Before starting work ensure the motorcycle is stabilised and adequately supported This will help to prevent it falling and causing injury to the operator or damage to the motorcycle...

Page 350: ...t worn 8 Using a suitable drift evenly and progressively drive the bearing races from the frame headstock 9 Remove the inner race and dust seal from the bottom yoke using a press or puller Inspection...

Page 351: ...multi purpose grease 5 Drive a new lower outer bearing into the frame headstock Front Suspension 6 Lubricate the upper bearing using multi purpose grease Z Insert the lower yoke to the frame fit the...

Page 352: ...left switch gear assembly from the handlebar Without disconnecting any wiring lay the switch aside 6 Unscrew the bolts and remove the clamp from the clutch lever assembly Without disconnecting the cl...

Page 353: ...upper clamps risers 3 Tighten the 10 mm bolts to 35 Nm 1 Upper clamp 2 Clamp split line 3 Centre marking 4 Refit the 8 mm bolts and tighten to 26Nm 5 Fit the left hand handlebar grip 6 Position the cl...

Page 354: ...e with the two fixings using new fixings at the handguard to spacer position Tighten the handguard to spacer fixing to 6Nm and the handguard to bracket fixing to 9 Nm 18 19 20 21 Check the throttle ca...

Page 355: ...4 10 Rear Brake Fluid Level Inspection 14 11 Changing Brake Fluid 14 12 Brake Pads 14 12 Brake Wear Inspection 14 12 Breaking in NewBrake Pads and Discs 14 12 Bleeding the Front Brakes Renew ing Brake...

Page 356: ...4 34 Installation 14 34 Front ABS Pulser Ring 14 35 Removal 14 35 Inspection 14 35 Installation 14 35 Bleeding the Rear Brake Fluid Motorcycles w ith ABS 14 36 Rear ABS Wheel Speed Sensor 14 37 Remova...

Page 357: ...ning Light Does Not Illuminate No D TCs Stored 14 59 Front Wheel Sensor Open Circuit Short Circuit 14 61 Rear Wheel Sensor Open Circuit Short Circuit 14 63 Front Wheel Sensor Abnormal Input losing Con...

Page 358: ...Brakes Exploded View Front Brake Master Cylinder Tiger 800 12 Nm J 25 Nm 6 Nm 6 Nm J 1 Nm o 25 Nm 25 Nm 14 4 SeiVice Manual Tiger800 and Tiger800XC...

Page 359: ...Brakes Exploded View Front Brake Master Cylinder Tiger SOOXC 12 Nm J 25 Nm JIP7 Nm 6 Nm J 2 5 Nm SeNice Manual Tiger800 and Tiger800XC 14 5...

Page 360: ...Brakes Exploded View Front Brake Caliper 28Nm 22 Nm 14 6 SeiVice Manual Tiger800 and Tiger800XC...

Page 361: ...Brakes Exploded View Rear Brake Master Cylinder 15 Nm V 7 Nm 22Nm 16Nm Setvice Manual Tiger800 and Tiger800XC 14 7...

Page 362: ...Brakes Exploded View Rear Brake Caliper 18Nm 3 Nm ZZ Nm 27 Nm 14 8 SeiVice Manual Tiger800 and Tiger800XC...

Page 363: ...Brakes Exploded View ABS System 9 Nm SeiVice Manual Tiger800 and Tiger800XC 14 9...

Page 364: ...ding 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 lt is dangerous to opera...

Page 365: ...ch the cover noting the position of the sealing diaphragm Fill the reservoir to the upper level line using newDO T 4 fluid from a sealed container Refit the cover ensuring that the diaphragm seal is c...

Page 366: ...The recommended distance for breaking in new pads and discs is 200 miles 300 km Bleeding the Front Brakes Renewing Brake Fluid Before starting work ensure the motorcycle is stabilised and adequately...

Page 367: ...upper level with new DOT 4 fluid 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 t...

Page 368: ...brake hoses as this may damage the hoses and could lead to loss of motorcycle control and an accident 3 Slacken and remove the caliper mounting bolts and slide the caliper off the disc cgyz Q 1 Calip...

Page 369: ...ced 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 pis...

Page 370: ...for correct brake operation Rectify as necessary lt is dangerous to operate the motorcycle with defective brakes you must have your authorised Triumph dealer take remedial action before you ride the m...

Page 371: ...caliper as follows Brakes 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 accid...

Page 372: ...f 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...

Page 373: ...curate dial gauge mounted on a surface plate 1 Disc 2 Dial gauge Removal I t Brakes Do not renew front brake discs individually Discs must always be renewed in pairs even if one of a pair is serviceab...

Page 374: ...njury to the operator or damage to the motorcycle 1 Remove the rider s seat see page 16 13 2 Disconnect the battery negative black lead first To prevent paint damage do not spill brake fluid onto any...

Page 375: ...piston components 1 cequ 1 Master cylinder 2 Spring and piston assembly 3 Circlip 4 Rubber boot Brakes Inspection 1 Check the following for wear damage cracks or deterioration Cylinder bore Rubber boo...

Page 376: ...eading to an accident could result from incorrect assembly of the master cylinder 2 Fit the new piston set into the master cylinder and retain with a new circlip 3 Refit the master cylinder boot Insta...

Page 377: ...iumph 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 Br...

Page 378: ...e air appears in the bleed tube 9 Maintain the brake fluid level between the upper and lower reservoir levels whilst bleeding is being carried out 10 When all air has been expelled from the system hol...

Page 379: ...e Before removing the brake pads note the relationship of the pads to the caliper and ensure that on assembly they are fitted in the same way Do not allow the caliper to hang on the brake hoses as thi...

Page 380: ...proprietary high temperature Copaslip type grease 6 Install the pad retaining pin Z Lower the caliper over the brake disc ensuring that the pads remain in the correct positions 1 Plug 2 Pad retaining...

Page 381: ...e spring I 1 J f j 1 t To prevent injury never place fingers or hands inside the caliper opening when removing the piston Always wear eye hand and face protection when using compressed air Eye face an...

Page 382: ...trol and an accident could result if this warning is ignored 1 Fit new fluid seals to the caliper Apply brake fluid to the outside of the caliper piston and fluid seal 2 1 1 Piston 2 Seals Ensure that...

Page 383: ...on 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 B...

Page 384: ...ent it from falling and causing injury to the operator or damage to the motorcycle 1 Remove the rider s seat see page 16 13 2 Disconnect the battery negative black lead first To prevent paint damage d...

Page 385: ...grease may reduce braking efficiency resulting in an accident Before installation all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid Never use solvents pet...

Page 386: ...se 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...

Page 387: ...e diagnostic tool and with assistance release one of the bleed nipples 5 Get an assistant to slowly pull the brake lever to the handlebar 6 With the lever held fully against the handlebar close the bl...

Page 388: ...Front ABS wheel speed sensor 2 Bolt Installation Note Check the condition of the shim before use Do not use a shim which is bent or damaged 1 Position the wheel speed sensor to the fork leg with its...

Page 389: ...pport the wheel on blocks as illustrated below 1 Wheel 2 Support block Brakes 3 Remove and discard the five disc bolts and remove the pulser ring 1 Pulser ring 2 Disc bolt Inspection 1 Check the pulse...

Page 390: ...to the rear brake pedal press the Start button to activate the bleed sequence on the diagnostic tool and with assistance release the bleed nipple 5 Slowly depress the brake pedal and holding the pedal...

Page 391: ...ck the condition of the shim before use Do not use a shim which is bent or damaged Position the shim to the fixing such that it will be installed between the wheel speed sensor and the brake caliper c...

Page 392: ...perate correctly Air Gap Measurement Front and Rear Wheel Speed Sensors 1 Using feeler gauges measure the air gap between the wheel speed sensor and the pulser ring I I i i i i i i i i __ f 0 1 mm 1 5...

Page 393: ...ront seat bridge 1 Front seat bridge 2 ABS modulator upper fixing To prevent body damage do not spill brake fluid onto any area of the bodywork or wheels Z Drain the brake fluid from the front and rea...

Page 394: ...Detach the three front brake hard line clips from the frame 1 Front brake hard lines 2 Clips 14 Remove the left hand lower ABS modulator fixing located under the front seat bridge 2 Left hand lower f...

Page 395: ...tion disconnect the four brake hard line unions and taking care not to bend the brake lines detach the lines from the ABS modulator 19 Remove the ABS modulator and bracket from the motorcycle cgze 1 A...

Page 396: ...tage 6 Refit the brake lines in to the clip on the underside of the modulator cgze 1 ABS modulator 2 Front brake master cylinder hard line 3 Front brake caliper hard line 4 Rear brake master cylinder...

Page 397: ...1 Refit the fuel tank see page 10 92 22 Reconnect the battery positive red lead first Brakes Use only DOT 4 specification brake fluid as listed in the general information section of this manual The us...

Page 398: ...s determined to be skidding Under braking if the modulator detects that either wheel is about to slip due to the brake force exceeding the available traction between the tyre and road surface the whee...

Page 399: ...Component Location FRONT PULSER RING REARWHEEL SPEED SENSOR FRONT WHEEL SPEED SENSOR REAR PULSER RING FRONT BRAKE LIGHT SWITCH SeiVice Manual Tiger800 a ld Tiger800XC Brakes 14 45...

Page 400: ...ring colour codes Code Wiring Colour B Black u Blue N Brown G Green s Slate Grey 0 Orange K Pink R Red p Purple w White y Yellow LG Light Green LU Light Blue ABS ECM Connector PinNumbering cdhg 1 0 1...

Page 401: ...ABS System Circuit Diagram 3 r I I 2 I 2 I I I lOA lOA J m 16 1 7 2 10 UWI 8G 12 81 _________ ___ 1 1 _18 GP _j 6 go oc 121 GP 41 E I I 1 GP l 5 SeiVice Manual Tiger 800 and Tiger 800XC Brakes 1 14 47...

Page 402: ...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...

Page 403: ...nline net Build Data The Build Data screen will display the following information Function Examined ECM type ECM I D number Software version number Brakes Current Data The Current Data screen will dis...

Page 404: ...uit Short Circuit C1614 Rear Wheel Sensor Abnormal Input Losing Contact C1 621 Front Wheel Pulser Gear Missing Teeth C1623 Rear Wheel Pulser Gear Missing Teeth C1631 Front Wheel Input Solenoid Open Sh...

Page 405: ...is when fault is when fault is logged logged logged Only when ABS is Active When ABS is no longer active operation is inhibited Front Wheel Sensor Open Yes Yes No Circuit Short Circuit Front Wheel Sen...

Page 406: ...Wheel fault is detected DTC remains Lock stored Rear Wheel Actuator Yes Yes Yes if after ignition cycle no Hydraulic Control Wheel fault is detected DTC remains Lock stored Motor Lock Yes Yes No Moto...

Page 407: ...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...

Page 408: ...han 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...

Page 409: ...ht circuit Short ABS ECM connector pin 21 and Ground pin 24 together Turn Ignition ON 5 Reconnect ABS ECM harness clear fault code and test ABS to verify fault cleared Circuit Diagram proceed to pinpo...

Page 410: ...ed to test 6 3 Check cable for short to voltage With ov Proceed to test 4 Ignition OFF check voltage between ABS ECM connector pin 1 6 and Ground Above 3 V Locate and rectify wiring fault proceed to t...

Page 411: ...Circuit Diagram Headlamp Relay Rear Fuse Box r 20A 2 I I 20AI _J y R SeiVice Manual Tiger 800 and Tiger 800XC ABS Control Module 8 9 RU 16 21 B 24 8 25 Brakes 14 57...

Page 412: ...le for short circuit OK Replace the wheel speed sensor proceed to test 9 Wheel speed sensor connector pin 1 Short circuit Locate and rectify wiring harness fault motorcycle harness side and Ground pro...

Page 413: ...current consumption data under typical conditions Voltage Min Typical Max Low 4 5 V 3 1 mA 4 1 mA 5 3 mA High 1 6V 8 1 mA 10 5 mA 13 6 mA Front Wheel ABS Speed Sensor Control Module I I uw I I BG SeiV...

Page 414: ...e for short circuit OK Replace the wheel speed sensor proceed to test 9 Wheel speed sensor connector pin 1 Short circuit Locate and rectify wiring harness fault motorcycle harness side and Ground proc...

Page 415: ...or current consumption data under typical conditions Voltage Min Typical Max Low 4 5 3 1 mA 4 1 mA 5 3 mA High 1 6 8 1 mA 10 5 mA 13 6 mA Rear Wheel ABS Speed Sensor Control Module I I BG I UR SeiVice...

Page 416: ...between 0 1 mm to 1 5 mm Faulty Rectify the fault and proceed to test 5 2 Check the pulser ring for damage or OK Proceed to test 3 contamination by road grime or ferrous metal filings Faulty Clean or...

Page 417: ...m Faulty Rectify the fault and proceed to test 5 2 Check the pulser ring for damage or OK Proceed to test 3 contamination by road grime or ferrous metal filings Faulty Clean or replace the ABS pulser...

Page 418: ...Rectify the fault and proceed to test 5 2 Check the pulser ring for damage or OK Proceed to test 3 contamination by road grime or ferrous metal filings Faulty Clean or replace the ABS pulser ring pro...

Page 419: ...Rectify the fault and proceed to test 5 2 Check the pulser ring for damage or OK Proceed to test 3 contamination by road grime or ferrous metal filings Faulty Clean or replace the ABS pulser ring pro...

Page 420: ...battery voltage 4 Check cable for continuity OK ABS ECM connector pin 24 and Ground Faulty 5 Clear fault code and test ABS to verify fault OK cleared Fault still present Circuit Diagram Rear Fuse Box...

Page 421: ...r faults or other mechanical causes Faulty Rectify the fault and proceed to test 4 2 Measure the air gap of the wheel speed sensor OK Proceed to test 3 between the sensor and the pulser ring Air gap b...

Page 422: ...ont fuse box OK Proceed to test 3 fuse 2 Faulty Replace fuse and proceed to test 5 3 Check cable continuity With Ignition ON check Same as across Proceed to test 4 voltage between battery voltage ABS...

Page 423: ...ignition ON Check Voltage greater Proceed to test 4 the voltage between than 10 V ABS ECM connector pin 16 and Ground pin 24 Voltage less Locate and rectify fault proceed to test 5 than 10 V 4 Check...

Page 424: ...k the tyre pressures OK Proceed to test 3 Faulty Rectify fault proceed to test 5 3 Check the pulser ring for damage or OK Proceed to test 4 contamination by road grime or ferrous metal filings Faulty...

Page 425: ...ap between 0 1 mm to 1 5 mm Faulty Rectify the fault and proceed to test 4 2 Check the pulser rings for damage or OK Proceed to test 2 contamination by road grime or ferrous metal filings Faulty Clean...

Page 426: ...from Master Cylinder to ABS Modulator B Front Brake Circuit from ABS Modulator to Front Calipers C Rear Brake Circuit from Master Cylinder to Modulator D Rear Brake Circuit from ABS Modulator to Rear...

Page 427: ...ssures 15 7 Tyre Wear Wheel Inspection 15 8 Important Tyre Information 15 8 Front Wheel 15 10 Removal 1 5 10 Installation 15 1 1 Rear Wheel 15 1 1 Removal 15 1 1 Installation 15 12 Front Wheel Bearing...

Page 428: ...Wheels Tyres Exploded view Front Wheel Tiger 800 65 Nm 15 2 SeiVice Manual Tiger 800 and Tiger SOOXC...

Page 429: ...Wheels Tyres Exploded view Front Wheel Tiger SOOXC 65 Nm SeiVice Manual Tiger 800 and Tiger 800XC 15 3...

Page 430: ...es Exploded View Rear Wheel Final Drive Tiger 800 1 10 Nm I L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ l I II 0 c ID 1 II I I I 15 4 Seavice Manual Tiger 800 and T...

Page 431: ...ls Tyres Exploded View Rear Wheel Final Drive Tiger SOOXC 1 10 Nm I L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ l I I _ J Service Manual Tiger 800 and Tiger 800XC 1...

Page 432: ...ehicle control and an accident Never install an inner tube inside a tubeless tyre This will cause friction inside the tyre and the resulting heat build up may cause the tube to burst resulting in rapi...

Page 433: ...efore riding when the tyres are cold Check tyre pressures daily and adjust if necessary Correct on road tyre pressures are Tiger 800 and Tiger 800XC Tyre Pressure Front 2 5 bar 3 6 psi Tyre Pressure R...

Page 434: ...ed Tread Depth The following chart can be used as a guide to the minimum safe tread depth Under mph Over mph 130 km h 80 2 mm 0 08 in 130 km h 80 Rear 3 mm 0 12 in Front 2 mm 0 08 in I Triumph motorcy...

Page 435: ...amage the wheel and tyre resulting in tyre deflation loss of control and an accident Wheels Tyres When replacement tyres or inner tubes are required consult your authorised Triumph dealer who will arr...

Page 436: ...nd support the front brake calipers see page 14 16 Note lt is not necessary to disconnect the brake hoses 4 Slacken both pinch bolts at the lower end of the right hand fork 1 Fork pinch bolts 5 Releas...

Page 437: ...on the left hand side If not apply gentle pressure to the fork to ensure the disc is centred with the caliper 6 Maintaining the above position tighten the fork pinch bolts to 22 Nm 1 Fork pinch bolts...

Page 438: ...r sprocket 5 The rear caliper and caliper carrier will remain in position on the swinging arm when the wheel is removed Do not allow the caliper to hang on the brake hose as this may damage the hose D...

Page 439: ...ght hand chain adjuster block is installed on the wheel spindle 9 Fit the wheel spindle with the threaded end facing to the left Wheels Tyres 10 Fit the left hand chain adjuster block and a new rear w...

Page 440: ...lect the centre sleeve Wheel Bearing Remov il Inspection I 1 I o t l d Only remove raised witness marks from within the wheel Removal of material below any raised areas will reduce the level of interf...

Page 441: ...n blocks to prevent damage to the brake disc 3 Remove and discard the seals and the bearing circlip y A0 t j t f Always wear eye hand and face protection when using a hammer and drift Use of a hammer...

Page 442: ...he 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...

Page 443: ...isc is raised above the ground 2 Place the wheel on wooden blocks with the drive sprocket uppermost 3 Gently lever the drive flange from the wheel hub 1 Rear wheel 2 Drive flange Wheels Tyres 4 Remove...

Page 444: ...Wheels Tyres This page intentionally left blank 15 18 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 445: ...nt Mudguard Tiger 800 16 10 Exploded View Front Mudguard Tiger 800 XC 16 1 1 Exploded View Rear Mudguard all Models 16 12 Rear Seat 16 13 Removal 16 13 Rider s Seat 16 13 Removal 16 13 Lower Radiator...

Page 446: ...19 Front Mudguard Tiger 800 XC 16 20 Removal 16 20 Installation 16 20 Rear Rack 16 20 Removal 16 20 Installation 16 20 Rear Side Panel 16 21 Removal 16 21 Installation 16 21 Rear Mudguard 16 22 Remova...

Page 447: ...Frame and Bodywork Exploded View Frame all Models 48 Nm 48 Nm 48 Nm 48 Nm Service Manual Tiger 800 and Tiger 800XC 16 3...

Page 448: ...Frame and Bodywork Exploded View Cockpit and Mountings Tiger 800 5 Nm 3 Nm fJ0 if Nm v 5 Nm 7 5 Nm 3 Nm 5 Nm 3 Nm li e 5 Nm 5 Nm 16 4 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 449: ...Frame and Bodywork Exploded View Cockpit and Mountings Tiger SOOXC S Nm Jjl S Nm g 5 Nm 3 Nm g S Nm SeiVice Manual Tiger 800 and Tiger 800XC 16 5...

Page 450: ...Frame and Bodywork Exploded View Lower Panels and Sumpguard all Models 3 Nm 3 Nm 3 Nm IS Nm 3 Nm 3Nm 10 Nm 8 15 Nm 10 Nm 16 6 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 451: ...Frame and Bodywork Exploded View Rear Panels all Models 20 Nm r S Nm 20 Nm SeNice Manual Tiger 800 and Tiger 800XC 16 7...

Page 452: ...Frame and Bodywork Exploded View Footrests and Mountings all Models 16 8 Service Manual Tiger 800 and Tiger 800XC...

Page 453: ...Frame and Bodywork Exploded View Sidestand all Models 45 Nm 7 Nm 20 Nm SeiVice Manual Tiger 800 and Tiger 800XC 16 9...

Page 454: ...Frame and Bodywork Exploded View Front Mudguard Tiger 800 16 10 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 455: ...Frame and Bodywork Exploded View Front Mudguard Tiger SOOXC 6Nm 6Nm 6Nmz SeiVice Manual Tiger 800 and Tiger 800XC 16 11...

Page 456: ...Frame and Bodywork Exploded View Rear Mudguard all Models 6 Nm 6 Nm 3 Nm 16 12 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 457: ...6 13 Grasp the riders seat on either side and slide it rearwards and upwards for complete removal from the motorcycle To refit the seat engage the seat s front rail into the bracket at the rear of the...

Page 458: ...the screws to 3 Nm Upper Radiator Panel Removal 1 Remove the rider s seat see page 76 13 2 Disconnect the battery negative black lead first 3 Remove the lower radiator panel see page 16 14 4 Remove an...

Page 459: ...6 13 2 Disconnect the battery negative black lead first 3 Remove the lower radiator panel see page 16 14 4 Remove the upper radiator panel see page 16 14 5 Right hand radiator infill panel only Remove...

Page 460: ...the fog lamp wiring and secure with new cable ties Attach the relay to the tang 5 Left hand radiator infill panel only If accessory heated grips are fitted reposition the heated grip wiring and secure...

Page 461: ...odels Remove the front upper fixings located below the headlight Collect the nuts from the inside of the cockpit I o4 v c 1 I I 1 Front upper fixing left hand shown 6 Lift the rear of the cockpit asse...

Page 462: ...of the ignition switch cover 3 Refit the two inner rear fixings and tighten to 5 Nm 4 Tiger SOOXC only Fit two new front lower fixings and tighten to 5 Nm 5 All models Refit the front upper fixings lo...

Page 463: ...d 2 Remove the two right hand fixings and collect the front fork protector 1 Brake hose clip 2 Front fork protector 3 Mudguard 4 Fixings 3 Support the front mudguard and remove the two left hand fixin...

Page 464: ...fixings Installation 1 Position the front mudguard to the front forks 2 Fit four new lower fixings and tighten to 6 Nm 3 Fit two new rear fixings and tighten to 6 Nm 4 Refit the front brake hose to t...

Page 465: ...el 1 Side panel left hand shown 2 Bolts nuts nuts not shown 3 Pannier mount plates 4 Lower fixing Frame and Bodywork Installation 1 Refit the side panel and secure with the lower fixing Do not tighten...

Page 466: ...same fixings as the splash guard shown below with the addition of a third fixing behind the licence plate 1 Remove the two lower splash guard or mudguard extension fixings located under the rear mudg...

Page 467: ...the seat rails and locate the holes in the mudguard over the lugs on the frame 3 Secure the rear mudguard to the seat rails using new fir tree clips 4 Following the routing noted during disassembly r...

Page 468: ...xings Inspection 1 Inspect the frame footrests and bodywork for damage cracks chafing and other dangerous conditions Check bodywork and frame fixings for security If the motorcycle is involved in an a...

Page 469: ...17 10 Battery Already in Service 17 10 Table of Battery Charging Times 17 10 Relays 17 1 1 Relay Identification 17 1 1 Direction Indicator Unit 17 1 1 Fuses 17 1 1 Fuse Identification 17 1 1 Front fus...

Page 470: ...26 Key to wiring colours 17 26 Starting and Charging Circuit 17 28 Key to circuit diagram 17 28 Key to wiring colours 17 28 Auxiliary and Accessory Circuit 17 30 Key to circuit diagram 17 30 Key to wi...

Page 471: ...w Instruments Exploded VIe f 2 Nm 800XC r 800 and Tiger Manual T ge Se1V1ce Electrical 17 3...

Page 472: ...Electrical Exploded View Headlight 3 5 Nm 3 5 Nm 3 Nm 17 4 SeiVice Manual Tiger 800 and Tiger 800XC...

Page 473: ...Exploded View Rear Light Reflectors g c 3 Nm SeiVice Manual Tiger 800 and Tiger 800XC Electrical 3 Nm 17 5...

Page 474: ...Electrical Exploded View Direction Indicators 3 Nm 3 Nm 3 Nm 17 6 SeNice Manual Tiger 800 and Tiger 800XC...

Page 475: ...Electrical Exploded View Alternator Starter and Immobiliser 9 Nm 12 Nm 120 Nm SeiVice Manual Tiger 800 and Tiger 800XC 17 7...

Page 476: ...risk of personal injury The battery electrolyte is corrosive and poisonous Never swallow battery electrolyte or allow electrolyte to come into contact with the skin Always wear eye and skin protectio...

Page 477: ...the electrolyte container if applicable and s ve for later in this procedure Place the sealing strip on a clean surface Electrical with the upper side facing downwards to avoid contamination of the s...

Page 478: ...ver a period of time sulphate will crystallise on to the lead plates making charging difficult or impossible The result is a permanently damaged battery which would not be covered by the motorcycle wa...

Page 479: ...the correct current rating A blown fuse is indicated when all of the systems protected by that fuse become inoperative When checking for a blown fuse use the table below to establish which fuse has bl...

Page 480: ...espond with those printed on the fuse box cover Rear fuse box Fuse No 1 2 3 4 5 6 cebw Front of Motorcycle 1 Front fuse box cover 2 Front fuse box 3 Spar fuses 4 Rear fuse box 5 Rear fuse box cover Ci...

Page 481: ...he instrument pack from the bracket bayonet fixings 2 Bayonet fixings 3 Electrical connector Installation 1 Position the instrument pack to the bracket 2 Insert the bayonet fixings into the grommets 3...

Page 482: ...attempt to adjust a headlight beam when the motorcycle is in motion may result in loss of control and an accident Headlight Bulb Replacement 2 1 Bulb retainer right hand shown 2 Bulb retainer hook 3...

Page 483: ...g Note Tighten the headlight surround fixings to 3 Nm Reconnect the battery positive red lead first Electrical Headlight Assembly Removal 1 Remove the rider s seat see page 16 13 2 Disconnect the batt...

Page 484: ...ght unit 2 Rear light fixings 3 Electrical connector 6 Remove the rear light Installation 1 Installation is the reverse of the removal procedure noting the following Note Tighten the rear light fixing...

Page 485: ...n t 1e rear rack fixings to 3 Nm Reconnect the battery positive red lead first Electrical Front Direction Indicator Removal 1 Remove the rider s seat see page 76 13 2 Disconnect the battery negative b...

Page 486: ...ure the starter turns freely and without binding 2 Check the starter 0 ring for damage and deterioration Replace as necessary Installation 1 Lubricate the starter motor 0 ring with a small amount of p...

Page 487: ...card the bolts cgzm 1 Stator 2 Stator fixings 3 Cable bracket 4 Cable bracket fixing S Alternator spray bar Z Withdraw the stator Electrical Do not use tools to tighten service tool T3 880375 Tighten...

Page 488: ...o the keyway on the crankshaft ensuring the Woodruff key remains in position Do not use tools to tighten service tool Tighten the tool by hand only Over tightening of the tool will lead to damage to t...

Page 489: ...fixings to 9 Nm 2 g 1 Left hand engine cover 2 Bottom hose bracket 12 Refit the starter motor see page 17 18 13 Reconnect the battery positive red lead first 14 Refit the rider s seat see page 16 13...

Page 490: ...eed to test 2 Rectifier regulator black connector pin 1 Faulty Rectify fault proceed to test 4 Rectifier regulator black connector pin 3 Rectifier regulator grey connector pin 1 Rectifier regulator gr...

Page 491: ...tive probe to pin 1 negative probe 15V AC 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 engine 13 5V 15V...

Page 492: ...ge 17 22 Pinpoint Tests Test Result Action 1 Check diodes forward bias 0 4V to 0 7V Proceed to test 2 Positive probe to rectifier black socket pin 1 to Open circuit or Replace the unit Proceed to test...

Page 493: ...still present Test alternator stator see page 17 22 Circuit Diagram Grey Socketfor Alternator 3 2 I 1 If alternator stator is serviceable contact Triumph service i Voltage Controller l 1l I 1 Voltage...

Page 494: ...N Brown 4 Instrument Assembly G Green 5 Oil Pressure LED s Slate I Grey 6 Oil Pressure Switch 0 Orange 7 Main Beam LED K Pink 8 Headlights R Red 9 Pass Light Switch p Purple 10 Headlight Switch w Whi...

Page 495: ...it I 2 3 I j j p y 1 5 l t ___J 1 4 1 1 2 1 H 1 1 r 1 2 f u 1 0 CE 9 1 Y UR 1 I T l UW B UR Y l 1 1 i i 8 6 o 0 0 P y hl 3 B 8 6 _rs 1 B 1 J r 13 Service Manual Tiger 800 and Tiger 800XC Electrical 2...

Page 496: ...er G Green 5 Fuse Box Rear s Slate I Grey 6 Fuse Box Front 0 Orange 7 Starter Relay K Pink 8 Engine Control Module Relay R Red 9 Cooling Fan Relay p Purple 10 Fuel Pump Relay w White 1 1 ECM Connector...

Page 497: ...p 16 Electrical 2 3 m NNWR B l_ 5 rr s 1 1 1 2 3 4 5 I I I I I I I _ L _ _ _ _ _ _ _ _ 7 8 9 00 00 00 I NK JN WR 13 15 14 GR 17 1I 1a YNt_ NrYSIT NKT B P WR 10 00 3 1 1 B T 4 2 5 3 1 I Y L _ _ r 2 5...

Page 498: ...tch K Pink 6 Brake Light R Red 7 Rear Brake Light Switch p Purple 8 Rear Left Direction Indicator w White 9 Rear Right Direction Indicator y Yellow 10 Alarm LG Light Green 1 1 Front Left Direction Ind...

Page 499: ...LGN 6 1 PB 8 1 B 5 3 4 p R _ w LGN GR G N 1 2 B _j_ 1 8 J a 1 1 B _j_ r I I I I 1 I I 5 I I 5 I I I I I I I L _ _j L _ _ J a a a I I 7 ID f f f f l 6 10 1 1 8 7 1 0 SeiVice Manual Tiger 800 and Tiger...

Page 500: ...10 Fall Detection Switch p Purple 1 1 Barometric Pressure Sensor w White 12 Intake Air Temperature Sensor V Yellow 13 MAP Sensor 14 Coolant Temperature Sensor LG Light Green 15 Oxygen Lambda Sensor LU...

Page 501: ...A20 OK All 819 835 816 A35 T 1 1 BU 8 20 BY 830 0019 18 8 1 BP 829 A24 f KG A34 1 KY 828 1 R 827 f U All f eo 8 s 5 1 A33 f BR g _r 8 l 7 804 f BG 821 1 KU 801 f K A27 f KP 820 f t s All f Ko A28 f K...

Page 502: ...sor R Red 10 Fall Detection Switch p Purple 11 Barometric Pressure Sensor w White 12 Intake Air Temperature Sensor y Yellow 13 MAP Sensor 14 Coolant Temperature Sensor LG Light Green 15 Oxygen Lambda...

Page 503: ...p 818 24 821 NK E3 GB 8 817 23 801 A27 N A22 820 w All u A20 A21 22 B 819 All 8 835 8 816 8 A3S A28 A29 Y 830 m21 I ___ i A26 AlO A31 824 829 t BG f sv 8Y 1 sN__r ___BN 3DJ R 1 u r R r u u 4 f so 8 _L...

Page 504: ...26 Coil1 27 Cooling Fan Relay 28 Coil2 29 Fuel Pump 30 Cooling Fan 31 Sidestand Switch 32 Idle Speed Stepper Motor 33 Ground 34 Diagnostic Connector 35 Rear Brake Switch 36 Rear Right Direction Indica...

Page 505: ......

Page 506: ...Pass Switch 55 Headlight Switch 16 Fall Detection Switch 56 Rear Wheel Speed Sensor 17 Intake Air Temperature Sensor 18 Throttle Potentiometer 57 Front Wheel Speed Sensor 58 ABS Module 19 Ambient Pres...

Page 507: ......

Page 508: ...Electrical This page intentionally left blank 17 40 Setvice Manual Tiger 800 and Tiger 800XC...

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