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Triumph 2012 Tiger 800 Service Manual

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Table of Contents
Triumph T iger 800 and Tiger SOOXC
Part Number 3856760, issue 1, 12.2010
T his document is protected by copyright and may not, in whole or part be stored in a retrieval system, or transmitted in
any form or by any means, copied, photocopied, translated or reduced to any machine-readable form without prior
consent in writing from Triumph Motorcycles Limited.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken to make it as complete and accurate as possible.
Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior notice and without
incurring an obligation to make such changes to products manufactured previously. See your authorised Triumph dealer
for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations in this publication are intended for reference use only and may not depict actual model component parts.
©
Triumph Motorcycles Ltd.
Motorcycle Service Manual
2010
SeiVice Manual
Tiger 800 and Tiger 800XC
-
(Including ABS models)

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  Summary of Contents for Triumph 2012 Tiger 800

  • Page 1 Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your authorised Triumph dealer for the latest information on product improvements incorporated after this publication.
  • Page 2 SeiVice Manual Tiger 800 and Tiger 800XC ·...
  • Page 4 Th is page intentionally left blan k SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 5: Table Of Contents

    Introduction Table of Contents How to use this manual ..............Warni ngs, Cautions and Notes .
  • Page 6: How To Use This Manual

    Recti fy a l l problems as soon as possible • particular interest for more efficient and (immediately if safety related ). convenient operation. Use only gen u ine Triumph pa rts as listed i n the parts catalogue/parts microfiche. • Follow procedures this manual carefu lly and com pletely.
  • Page 7: Tampering With Noise Control System Prohibited

    Operations covered in this manual do not always include than genuine Triumph parts are fitted. In certain territories, reference to testing the motorcycle after repair. lt is legislation prohibits...
  • Page 8 Introduction This page intentionally left bla n k viii SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 9 1 General Information Table of Contents ............Ignition System Safety Precautions .
  • Page 10: General Information

    General Information • 1.1 2 Battery Disconnecting 1.1 2 Disciplines ............... . . 1.1 3 Electrical Wires .
  • Page 11 General Information ..............1.38 Torque Wrench Setti ngs .
  • Page 12: Ignition System Safety Precautions

    The ignition system produces extremely high voltages. Fluoroelastomer material is used in the manufacture of Do not touch any part of the ignition system or any various seals in Triumph motorcycles. cables while the engine is running. In fire conditions involving temperatures greater than An electric shock caused by contact with the ignition 315°C this material will decompose and can then be...
  • Page 13: Health Protection Precautions

    General Information Environmental Protection Health Protection Precautions Precautions Avoid prolonged and repeated contact with oils, particu la rly used engine oils. Wear protective cloth ing, i ncluding impervious gloves where practicable. Do not pour oil on the ground, down sewers or drains, Do not put oily rags in pockets.
  • Page 14: Safety Instructions

    Triumph dealer for advice before riding. If the brake lever or pedal feels soft when it is applied, or Always ensure that any lifting apparatus has adequate if the lever/pedal travel becomes excessive, there may load and safety capacity for the weight to be lifted.
  • Page 15: Cleaning Components

    Gener al Inform ation Joints and Joint Faces Assemble joints dry unless otherwise specified in this manual. The coolant anti-freeze contains a corrosion inhibitor If gaskets and/or jointing compound is recommended for which helps prevent damage to the metal surfaces inside use, remove all traces of old jointing material prior to re­...
  • Page 16: Locking Devices

    This prevents severe stress or damage to the load recommended in the Triumph Parts Catalogue. carrying components. Press a ball bearing until it touches the shoulder in the bore or on the shaft. Self Locking Nuts Press or drift seals to the depth of its housing, with the...
  • Page 17 Gener al Inform ation Check the bearing for smooth operation and visually General check for corrosion, dents and flaking in the bearing For a bearing to be serviceable for its anticipated life span race, rollers or cage. Replace if necessary. Refer to it must be checked, adjusted and lubricated at regular the relevant service manual.
  • Page 18: Metal Bushes

    General Information Fuel Handling Precautions Any excess grease should be smeared on the outside of the rollers. General The following information provides basic precautions which must be observed if petrol <gasoline> is to be handled safely. lt also outlines other areas of risk which must not be ignored.
  • Page 19: Fuel Tank Removal

    If the motorcycle is involved in an 'accident or collision it must be taken to an authorised Triumph dealer for repair or inspection. Any accident can cause damage to...
  • Page 20: Electrical Precautions

    General Information Electrical Precautions Connectors and Harness - The engine of a motorcycle is a particularly hostile environment for electrical components The following guidelines are intended to ensure the safety and connectors. Always ensu re these items are dry and oil of the operator whilst preventing damage to the electrical free before disconnecting and connecting test equipment.
  • Page 21: Electrical Wires

    General Information For example, if a battery of 1 2V is connected to a bulb of Electrical Wires 60W: All the electrical wires are either single-colour or two­ colour and, with only a few exceptions, must be • the cu rrent flowing in the circuit can connected to wires of the same colour.
  • Page 22: Circuit Diagrams

    Due to the complex circuits and the number of individual numbers in the box relate to the terminal numbers of the wires, Triumph uses two types of circuit diagram in its connector pins. On ECMs with two connectors, the service manuals.
  • Page 23 Over Open Closed LED <Light Emitting Diode) �0 Triumph use LEDs for the alarm warning light, instrument illumination and warning lights, gear change lights and rear light/brake lights on various models. Cf---0 Motor A mechanical device for completing or breaking a circuit.
  • Page 24: Tracing Circuits

    General Information Tracing Circuits To Check Continuity: The following is a description of two types of common electrical failures, and some of the methods which may be used to find them. Ensure the circuit being tested is switched off before measuring continuity.
  • Page 25: To Measure Voltage

    General Information To Measure Voltage: Splices In the example below, the circu it voltage is being Splices are probably the most common cause of wiring measured at the bulb positive (+) terminal. faults after connectors. Splices are made where two or more wires come together and diverge in different directions, usually to feed a different circuit.
  • Page 26: Can

    DTC <Diagnostic Trouble Code). This saves cost, weight and space, and makes the system Triumph currently use CAN for communication between more reliable, as the physical number of wires and the engine ECM and the instruments.
  • Page 28: Starting Circuit

    Starting Circuit All Triumph models are equipped with an electric start system. This system consists of a starter relay, starter motor, starter switch, sidestand switch, engine stop switch, cl utch switch and the sprag cl utch. The starter motor is connected to the starter relay and the battery by heavy duty cables in order to su pply the large currents required by the motor to start the engine.
  • Page 29: Diagnosis - Starter Circuit

    General Information Diagnosis - Starter Circuit WITH T H E I G N IT I O N SWITCH ON AN D U S I N G A S U I TABLE H EAVY DUTY THE E N G I N E STO P SWITCH AT ' RU N ' Cl icks J U M P E R CABLE, C O N N ECT T H E CHECK FOR A CLICK AT T H E STARTE...
  • Page 30: Inspection

    The terms of the motorcycle warranty will be invalidated damage of any nature. by the fitting of other than genuine Triumph parts. Al l genu ine Triumph parts have the full backing of the Replacement Parts motorcycle warranty. Triumph dealers are obliged to supply only genuine Triumph recommended parts.
  • Page 31: Se Ivice Tools And Garage Eq Uipment

    General Information Service Tools and Garage Equipment Special service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical components in a practical manner without causing damage. Some operations in this Service Manual cannot be carried out without the aid of the relevant service tools. Where this is the case, the tools required will be described during the procedure.
  • Page 32 General Information T3 880102 - Wrench, Camshaft Tu rning T3 880026 - Clutch Holding Tool, Universal cdpr T3 8803 65 - Puller, Alternator Rotor T3 880375 - Alternator Rotor Holder T3 88031 3 - Oil Filter Wrench T3 8800 5 7 - Engine Management Diagnostics gahc 1.24 Manual...
  • Page 33 General Information T3 8 8002 7 - Chain Link Took Kit T3 880166 - Wrench, Engine Mounting Adjuster 3 8 801 60-T0301 - Fork Filler/Evacuator T3 8801 58 - Collet, Nylon, Fork S upport - Tiger 800 ccha T3 8801 54 - Collet, Nylon, Fork Support - Tiger 800XC T3 880067 - Fork Spring Compressor ccgw 1.25...
  • Page 34 General Information T3 8801 5 3 - Support Plate T3 880003 - Fork Seal and Bush Fitment - Tiger 800 ccxb ccxa_1 T3 8801 5 7 - Fork Seal and Bush Fitment - Tiger 800XC T3 88005 3 - Extraction Kit, Wheel Bearing ccxb 3 880070 - T03 01 - Bearing Installer 3 880065 - T0301 - Bearing Installer...
  • Page 35 General Information T3880023 - Socket 50 mm T38801 2 3 - Extension Cable cdbp BatteryMate Battery Charger - See Latest Parts Catalogue T3 880001 - Fuel Pressure Gauge for Part Number Information T3 880147 - Radiator and Cap Tester cg wp 1 .27 Manual 800 and...
  • Page 36: Full Specification

    General Information Full Specification Full Specification Tiger 800 Tiger SOOXC Engine Engine Configu ration 3 Cylinder 12 valve D O H C 3 Cylinder 1 2 valve D O H C Arrangement Transverse in-line Transverse in-line Displacement 800 cc 800 cc Bore x Stroke 74 x 61.94 mm 74 x 61.94 mm...
  • Page 37: Cyli Nder Head Valves

    General Information Full Specification Tiger 800 Tiger 800XC & Cylinder Head Valves Valve Head Diameter 3 0.50 mm 30.50 mm 25.50 mm 25.50 mm Valve Lift Z59 mm Z59 mm Z25 mm Z25 mm Valve Stem Diameter 3 .975-3.990 mm 3 .975-3 .990 mm Service Limit 3.965 mm...
  • Page 38: Cyli Nder Head Valves

    General Information Full Specification Tiger 800 Tiger SOOXC & Cylinder Head Valves (contin ued) Valve Bucket Diameter 25.380 - 25.406 mm 2 5 . 3 8 0 - 2 5 .406 mm Service Limit 2 5 . 3 6 8 mm 2 5 .
  • Page 39: Clutch/Primary Drive

    General Information Full Specification Tiger 800 Tiger SOOXC Clutch/Primary Drive Primary Drive Type Gear Gear Reduction Ratio 1.667: 1 (85/51 ) 1.667: 1 (85/51 ) Clutch Type Wet multi-plate Wet multi-plate No. of Friction Plates Plate Flatness Within 0.2 mm Within 0.2 mm Friction Plate Th ickness 3.00 mm...
  • Page 40: Crankshaft

    General Information Full Specification Tiger 800 Tiger 800XC Crankshaft Crankshaft Big End Journal Diameter 3 2 .984-3 3.000 mm 3 2.984-3 3 .000 mm Service Limit 3 2.960 mm 3 2.960 mm Crankshaft Big End Bearing Clearance 0.03 5-0.065 mm 0.03 5-0.065 mm Service Limit 0.070 mm...
  • Page 41: Lubrication

    General Information Tiger SOOXC Full Specification Tiger 800 Lubrication Type Pressure Lubrication, Wet Sump Pressure Lubrication, Wet Sump Oil Capacity (dry fill> 3.75 litres 3 . 75 litres Oil Capacity (wet fill including filter) 3.6 litres 3.6 litres Oil Ca pacity <wet fi ll excluding filter) 3 .4 litres 3 .4 litres Recommended Oil Approval Rating...
  • Page 42: Coolant System

    Coolant System Coolant Mixture 5 0150 <pre-m ixed as supplied 50150 <pre-mixed as su pplied by Triumph by Triumph Anti-Freeze Type Triumph H D4X Hybrid Triumph H D4X Hybrid OAT coolant OAT coolant �, Freezing point -3 5 ° C -35 °...
  • Page 43: Fuel Injection System

    General Information Full Specification Tiger 800XC Tiger 800 Fuel Injection System Type Electronic, sequential Electronic, sequential 1,100 rpm Idle Speed 1,1 00 rpm Injector Type Twin jet, solenoid operated Twin jet, solenoid operated plate valve plate valve Cable/twist grip/electronic Throttle Cable/twist grip/electronic throttle potentiometer throttle potentiometer...
  • Page 44: Brakes (Continued)

    General Information Full Specification Tiger 800 Tiger 800XC Brakes (continued) �r., Rear Type Hyd raulically actuated single Hydraulically actuated single piston caliper, single disc piston ca liper, single disc Caliper Piston Diameter 3 8.18 mm 3 8.1 8 m m Disc Diameter 2 5 5 mm 255 m m...
  • Page 45: Frame

    General Information Full Specification Tiger 800 Tiger SOOXC Frame Frame Type Steel trellis Steel trellis Overall Length 2215 mm (8Z2 in) 2 2 1 5 mm (8Z2 in) Overall Width 79 5 mm (31�3 in) 865 mm (34.1 in) Overall Height 1 3 9 0 mm (54.
  • Page 46: Torque Wrench Settings

    General Information Torque Wrench Settings Cylinder Head Area Application Torque <Nm> Notes Camshaft cover to cylinder head Camshaft drive chain tensioner to head Camshaft bearing ladder to head Refer to section 5 Camshaft sprocket to camshaft Replace fixing(s) i f removed Camshaft drive chain rubbing blade to crankcase Replace fixing(s) if removed Camshaft drive chain top pad to cylinder head...
  • Page 48: Final Drive

    General Information Lubrication System Application Torque <Nm> Notes Sump to crankcase Sump drain plug to sump Replace sealing washer(s) if removed Oil pressure relief valve to crankcase Apply ThreeBond 1 3 05 t o the th reads Low oil pressure warning light switch to cran kcase Replace sealing washer(s) if removed Oil filter to adapter...
  • Page 50: Fuel System, Exhaust System And Ai Rbox

    General Information Fuel System, Exhaust System and Airbox Application Torque <Nm> Notes Fuel tank to frame (rear fixing) Fuel cap to fuel tank Fuel pump mounting plate to fuel tank Throttle body transition piece to cylinder head Throttle body adaptor clip Fuel rail to throttle body Throttle position sensor Idle speed control stepper motor...
  • Page 51: Rear Suspension

    General Information Rear Suspension Application Torque <Nm> Notes removed fixing<s> Swinging arm spindle nut 1 1 0 Replace <locknut> Chain rubbing strip to swinging arm Rear suspension unit upper mounting bolt Rear suspension unit lower mounting bolt to drop link Rear suspension reservoir Drag link pivot at frame Drop links to swinging arm...
  • Page 52: Front Brakes

    General Information Front Brakes Application Torque <Nm) Notes Front brake caliper to fork Front brake pad retaining pin Front brake pad retaining pin plug Front brake caliper bleed screw Front brake hose to caliper washer(s) Replace sealing removed Front brake master cylinder to handlebar Front brake hose to master cylinder Replace sealing...
  • Page 54: Electrical

    General Information Electrical Application Torque <Nm> Notes Alternator rotor to crankshaft 1 2 0 Alternator stator t o cover Replace fixing(s) i f removed Alternator regulator to bracket Starter motor to crankcase Starter motor power lead connection Starter motor solenoid lead connection Spark plug to cylinder head Horn Immobiliser ECU...
  • Page 55: Bodywork

    General Information Bodywork Notes Application Torque <Nm> Replace fixing<s> if removed Mudguard extension bracket Replace fixing<s> if removed Front mudguard to forks - Tiger 800 Replace fixing(s) if removed Front mudguard to forks - lower - Tiger 800XC Replace fixing<s> if removed Front mudguard to forks - upper - Tiger 800XC Handguard bracket to lever pivot bolt Handguard to bracket...
  • Page 56: Clutch Cable Routing

    General Information Clutch Cable Routing 1 .48 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 57: Throttle Cable Routing

    General Information Throttle Cable Routing 1 .49 SeiVice Manual Tiger 800 and Tiger SOOXC...
  • Page 58: Main Wiring Harness Routing

    General Information Main Wiring Harness Routing 1 .50 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 59: Front And Rear Brake Hose Routing - Models Without Abs

    General Information Front and Rear Brake Hose Routing - Models Without ABS Rear brake ­ Tiger 800 and Tiger 800XC Front Brake - Front Brake - Tiger 800 Tiger 800XC 1 .5 1 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 60: Abs Hose Routing

    General Information ABS Hose Routing 1 .52 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 61: Fuel Tank Breather Hose Routing

    General Information Fuel Tank Breather Hose Routing 1 .53 SeiVice Manual Tiger 800 and Tiger SOOXC...
  • Page 62 General Information Th is page intentionally left blan k 1 .54 Service Manual Tiger 800 and Tiger 800XC...
  • Page 63 2 Scheduled Maintenance Table of Contents ................Introduction .
  • Page 64 Triumph dealer will have this knowledge and this motorcycle. equipment, Triumph strongly recommends that you r authorised Triumph dealer carries o u t all scheduled maintenance. dangerous riding condition could result from incorrect maintenance leading to loss of motorcycle control and an accident.
  • Page 66 Scheduled Maintenance Operation Description Every Odometer Read ing in Miles <Kmsl or time period, whichever comes first 6,000 1 2,000 1 8,000 24,000 (800) ( 1 0,000) (20,000) (30,000) (40,000) 1 month 1 year 2 years 3 years 4 years •...
  • Page 67: Seivice Manual - Tiger 800 And Tiger 800Xc

    3 Cylinder Head Table of Contents Exploded View - Cyli nder Head and Valves ........... . .
  • Page 68 Cylinder Head · · · · · · · · · · · · · · · 3. 25 Valve to Valve G u ide Cleara nce · · · · · · · · · · · · · ·...
  • Page 69: Exploded View - Cylinder Head And Valves

    Cylinder Head Exploded View - Cylinder Head and Valves See text 1 5 Nm 10 Nm 12 Nm 10 N m �0 1 2 N m SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 70: Exploded View - Camshaft Cover

    Cylinder Head Exploded View - Camshaft Cover 10 N m SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 71: Exploded View - Ca Mshaft And Camshaft Drive

    Cylinder Head Exploded View - Camshaft a nd Camshaft Drive 9 Nm SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 72: Cylinder Head Description

    Cylinder Head Cylinder Head Description Camshaft Cover The engine is fitted with an aluminium alloy cylinder head, which carries the camshafts, valves and spark plugs. The Removal cylinder head is cast as a single entity and various components are permanently added after machining. Remove the rider's seat <see page 16-13).
  • Page 73: Installation

    Cylinder Head Note: Installation • Two shorter bolts are fitted at the end Refit the three dowels to the camshaft ladder. adjacent to the camshaft drive chain. 1. Dowels Camshaft Cover Bolt Release Sequence Fit a new camshaft cover seal to the cylinder head. Remove the camshaft cover from the motorcycle.
  • Page 74: Camshaft Drive Chain Tensioner - All Models

    Cylinder Head Inspect the ignition coils seal for damage and replace Camshaft Drive Chain Tensioner - all if necessary. Models Fit the ignition coils and reconnect the electrical connectors. Removal Remove the camshaft cover <see page 3-6). Remove the right hand cran k cover. Discard the gasket.
  • Page 75: Installation

    Cylinder Head Note: Installation • In addition to the 'dot' mark alignment, at Check that number 1 cylinder is still at top dead TDC, the alignment marks on the camshaft centre <TDC>. sprockets will point inwards at a point level Ensu re that the wedge fitted earlier is still holding the camshaft drive chain tensioner blade in contact with •...
  • Page 76 Cylinder Head Remove the spring. Hold the resister ends together and push the plunger through the resister ring until the groove for the snap ring aligns with the snap ring. cfhp cfei_2 1. Spring While holding the resister ring in place, pour out the 1.
  • Page 78: Camshaft Drive Chain Tensioner Blade

    Cylinder Head Release the three side locating devices. Camshaft Drive Chain Tensioner Blade Disassembly Note: • For the purpose of this instruction, the top of the tensioner blade is where the pad is located. Release the clips a n d remove t h e pad. cfeg 1.
  • Page 80 Camshaft and earing p Inspection ' Piastigage' <Triumph part number 3 8801 5 0-T03 01 > as follows: Inspect the camshaft sprockets for damaged and worn teeth. Replace as necessary. Ensuring that the camshaft sprocket align ment marking is located as for removal, assemble one...
  • Page 81: Installatio

    Cylinder Head Camshaft journal clearance Repeat the proced ure for the other camshaft. Standard: 0.040 - 0.081 mm Service limit: 0.1 70 mm If the camshafts and ladder are fitted without first If the clearance measured is within the specified aligning the timing marks on both the crankshaft and tolerance, remove the ladder and clean off all traces camshaft sprockets, the inlet and exhaust valves will...
  • Page 82: Stage 2

    Cylinder Head Note: Stage • In addition to the 'dot' mark alignment, at I n the sequence shown above, tighten the bolts to TDC, the alignment marks on the camshaft 10 Nm. sprockets will point inwards at a point level Before fitting the camshaft drive chain tensioner, with the joint face.
  • Page 84: Valve Clearance Adjustment

    Cylinder Head Valve Clearance Adjustment Camshaft Drive Chain Note: • Removal To adjust the valve clearances the camshafts must be removed. Follow the camshaft Remove t h e camshafts (see page 3-13>. removal procedure. Remove the bolt from the centre of the camshaft Remove the camshafts (see page 3-13>.
  • Page 85 Cylinder Head Inspection Measure across 2 3 links as shown in the diagram below. If the chain is within limits, the measurement Visual in-situ checks can also be made as follows: should longer than 149.48 mm. Measurements beyond 149.48 m m indicate that the Check for significant discolouration of the chain chain must be replaced.
  • Page 86: Installation

    Cylinder Head Check for severe wear of the plates in the area Cylinder Head shown below. Removal Note: • Removal of the cylinder head is not possible with the engine in the frame. Remove the engine from the frame (see page 9-3>. Remove the camshafts <see page 3-13).
  • Page 87 Cylinder Head Release the screws securing the outside of the Inspection cylinder head to the upper crankcase. Thoroughly clean the surface of the head and check for damage and pitting of the combustion chambers. Using a straight edge, check the cylinder head gasket face for wa rp which could lead to gasket failure.
  • Page 88 Cylinder Head The cylinder head bolts must be tightened in the Installation following sequence: Thoroughly clean the upper faces of the crankcase, taking care not to da mage the mating surfaces. Fit a new cylinder head gasket ensuring that the head to crankcase location dowels are correctly in place.
  • Page 89: Valves And Valve Stem Seals

    Cylinder Head Fit the tool between the Torx socket and the Valves and Valve Stem Seals drive handle and locate the Torx drive to the head bolt. Pick an increment point on the Removal from the Cylinder Head torque turn gauge which aligns with...
  • Page 90: Installation

    Cylinder Head Note: • Ensure inlet and exhaust valve components do not become mixed. Incorrect fitment of the valve stem oil seals could lead to h igh oil consumption and blue smoke emissions from the exhaust system. Do not use excessive force in fitting the seal as this may break the seal ring.
  • Page 91 Cylinder Head Valve to Valve Guide Clearance Valve Guides If a valve guide is found to be worn beyond the service If the valve gu ides are worn beyond the service limit given below, the cylinder head must be replaced. limit, the complete cylinder head m ust be renewed.
  • Page 92 Cylinder Head This page i ntentionally left bla n k 3.26 SeNice Manual Tiger 800 and Tiger SOOXC...
  • Page 93 4 Ciutch Table of Contents ............. Exploded View - Clutch Cover.
  • Page 94: Exploded View - Clutch Cover

    Clutch Exploded View - Clutch Cover 1 2 N m 9 Nm 9 Nm SeiVice Manual Tiger 800 and Tiger SOOXC...
  • Page 95: Exploded View - Clutch Assembly

    Clutch Exploded View - Clutch Assembly 9 8 Nm SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 96: Exploded View - Clutch Controls

    Clutch Exploded View - Clutch Controls 1 2 Nm 1 N m � 3 . 5 N m SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 97: Clutch Cable

    Clutch Remove the cable from the motorcycle noting the Clutch Cable cable routing. Removal Inspection Remove the rider's seat <see page 16- 13). Check the inner cable for free movement th rough Disconnect the battery, negative <black> lead first. the outer cable. Slacken the cable locknut and release the adjuster at Examine the inner cable for frayed strands.
  • Page 98: Clutch

    Clutch Clutch Note: • Record the orientation of all components as they are removed. plates must be Disassembly assembled in the same order. Remove the rider's seat (see page 16- 13). Disconnect the battery, negative (black> lead first. Release the clutch cable from t h e actuating arm (see page 4-S>.
  • Page 99: Clutch Plate Inspection

    Clutch Engage second gear and l o ck the i n ner and outer clutch drums together usi n g servi c e 1 1. Slide the clutch outer drum assembly gently tool backwards and forwa rds to dislodge the inner T3880306.
  • Page 100: Steel Plate Bend/Warp

    Clutch Steel Plate Bend/warp Clutch Pack Height Check all plates for bend and warp as follows: The clutch pack height should only be measured if the friction plates and the steel plates have been replaced. Place the plate being checked on a clean surface The clutch pack height is critical for a smooth operation of plate and attempt to pass a feeler gauge of the the transmission and m ust be measured prior to...
  • Page 101 Clutch Place the assembled clutch pack on a flat surface and Clutch Pack Height Too Low measure its height as shown below. Note: A t least one 1 . 6 m m steel plate must b e in • the clutch pack. If the clutch pack height is too low, replace the 1.6 mm steel plate indicated below with a new 2.0 mm steel plate.
  • Page 102: Assembly

    Clutch While holding the clutch outer drum in position and Assembly ensuring correct engagement with the oil pump drive, refit the bearing sleeve and bearing. To fully engage the outer drum, insert a suitable tool to preload and align the primary gear and backlash eliminator gear through the hole shown in the illustration below.
  • Page 103 Clutch Lock the inner and outer drums together using three outer steel plates • service tool T3 8803 06. Depress the rear brake pedal different to the other plates, depending on to prevent the engine from turning, and tighten the the clutch pack height settings used during 4-8).
  • Page 104 Clutch Refit the clutch cable to the actuating arm at the 1 1. Refit the clutch pul l-rod. clutch end <see page 4-5>. Refit the clutch pressure plate together with the 1 5 . Set the clutch adjustment (see page 4-5>. springs and bolts.
  • Page 105 5 Crankshaft, Connecting Rods and Pistons Table of Contents 5 . 2 Exploded View - Cra nkshaft, Connecti ng Rod, Piston and Liner........5 .
  • Page 106: Exploded View - Crankshaft, Connecting Rod, Piston And Liner

    Crankshaft, Connecting Rods and Pistons Exploded View - Crankshaft, Connecting Rod, Piston and Liner 27 Nm Service Manual Tiger 800 and Tiger 800XC...
  • Page 107: Exploded View - Crankcase

    Crankshaft, Connecting Rods and Pistons Exploded View - Crankcase 22 Nm 22 Nm SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 108: Crankcases

    Crankshaft, Connecting Rods and Pistons Note: Crankcases this point transmission shafts, • balancer, crankshaft, bearings etc. can be removed. The upper and lower crankcases are machined as a Note: matched set and must never be assembled to non­ matching halves. Doing so may cause seizure of the The position of each individual bearing shell •...
  • Page 110: Crankshaft

    Crankshaft, Connecting Rods and Pistons Stage 2 screws only Crankshaft I n the correct sequence, tighten only the M8 size crankcase screws (numbers 1 to 8) to 22 Nm. Removal In the correct sequence, tighten only the M8 size Remove the alternator rotor from the crankshaft (see crankcase screws (number 9 to 14) to 22 Nm.
  • Page 111 Crankshaft, Connecting Rods and Pistons Install the crankshaft ensuring that the crank pins align with the big ends and that the crankshaft and balancer gear markings align as shown in the next illustration. Ensure the three piston cooling jets are installed. If the piston cooling jets are omitted, oil pressure will be reduced.
  • Page 112: Connecting Rods

    Crankshaft, Connecting Rods and Pistons Connecting Rods Installation Note: Removal Connecting rod bolts are treated with an • anti-rust solution which must Connecting rods may be removed from the engine after removed. first removing it from the frame. The cylinder head must Clean the connecting rod with high flash­...
  • Page 113 120° of bolt rotation as measured Fit the bearing shells to the connecting rod and big using the Triumph torque turn gauge end cap and lubricate with a 5 0/50 solution of 3 8 8 0 105 -T 0 3 0 1 .
  • Page 114: Connecting Rod Big End Bearing Selection/Crankshaft Journal Wear Check

    0.070 mm Service limit: Note: Note: crankshaft journal clearances measured clearance exceeds • • measured using ' Piastigage ' <Triumph part service limit, measure the crankshaft journal number 3880150-T0301 ). diameter. turn connecting • Crankshaft Journal diameter crankshaft during clearance...
  • Page 115: Connecting Rod Bearing Selection

    Crankshaft, Connecting Rods and Pistons Install the new bearings in the connecting rod. Connecting Rod Bearing Selection Minor differences crankshaft dimensions compensated for by using selective bearings. For further information bearing part num ber colour cross-references, see the latest parts information. Select the correct big end bearing shell as follows: Measure eac h cra nkshaft journal dia meter.
  • Page 116: Crankshaft Main Bearing/Journal Wear

    3 2 .960 mm Service limit: Measure the bearing to cran kshaft main • Note: journal clearance using Plastigage <Triumph If any journal has worn beyond the service • part nu mber 3 8 8 0 15 0-T 0 3 0 1) <see...
  • Page 117: Pistons

    Crankshaft, Connecting Rods and Pistons Note: Pistons lt is normal for the bearings selected to • differ from one journal to another. Disassembly lt is also normal for there to �e two options • Note: of bearing shell colour. In such cases, pick shell size which...
  • Page 118: Piston Wear Check

    Crankshaft, Connecting Rods and Pistons Piston Rings/Ring Grooves Piston Wear Check Check the pistons for uneven groove wear by visually Measure the piston outside d iameter, 8 mm up from inspecting the ring grooves. the bottom of the piston and at 90° to the direction If all the rings do not fit parallel to the groove upper and of the gudgeon pin.
  • Page 119 Crankshaft, Connecting Rods and Pistons Piston Ring Gap Piston Assembly Note: Clean the piston ring grooves and fit the piston rings to the piston. The piston ring gap, with the piston ring • fitted in the liner, must be checked before Note: final assembly.
  • Page 120: Cylinder Wear

    Crankshaft, Connecting Rods and Pistons The piston ring gaps must be arranged as shown in Cylinder Wear the diagram below. Measure the inside diameter of each cylinder using an internal micrometer or similar accurate measuring FRONT equipment. Cylinder bore diameter �- ·...
  • Page 121: Cylinder Liners

    Crankshaft, Connecting Rods and Pistons Turn the crankshaft u ntil the piston in the liner to be Cylinder Liners removed is at the bottom of its stroke. Removal Assemble the frame from tool T3 880315 to tool T3 880101 as shown below. 1.
  • Page 122: Installation

    Crankshaft, Connecting Rods and Pistons Installation Crankcase Breather The upper crankcase is fitted with a labyrinth type Thoroughly clean the liner removing all traces o f old breather system, which requires no maintenance. During silicone sealer. engine disassembly and overhaul, check the oil d rain tube Remove all traces of sealer from the crankcase bores.
  • Page 123 6 Balancer Table of Contents 6 . 2 Exploded View - Balancer Shaft............. . Balancer .
  • Page 124 Balancer Exploded View - Balancer Shaft Service Manual Tiger 800 and Tiger 800XC...
  • Page 125 Balancer To strip the backlash eliminator from the drive gear, Balancer release the circlip and remove the wave-washer, The balancer is fitted to control 'pulsing' within the engine. backlash gear and spring. Without any form of balancer, the engine would 'pulse' each time the crankshaft rotated.
  • Page 126 Balancer Using a press and press bars, fit the right hand Assembly/Installation bearing to the shaft, with the circl ip positioned Note: nearest to the drive gear. Ensure the inner race of the bearing is supported when installing the bea ring. Before assembling the backlash gear to the •...
  • Page 127 Balancer With the drive and backlash eliminator gears still Note: correctly aligned, locate the balancer to the When in alignment, the line on the backlash • crankcase. Align the balancer gears and crankshaft gear must be located directly above the as shown in the illustration below.
  • Page 128 Balancer 1 1. Ensure that the left hand bearing circlip and dowel 1 2 . Remove the secu ring fixture. locate correctly in the corresponding groove in the 1 3 . Check that the bala ncer a n d cran kshaft are correctly crankcase aligned before continuing to assemble the crankcase halves.
  • Page 129 7 Transmission Table of Contents 7 . 2 Exploded View - Input and Output Shafts ........... . . 7 .
  • Page 130: Exploded View - Input And Output Shafts

    Transmission Exploded v· 1ew - In put and 0 utput Shafts ��\ 85 Nm 12 Nm · r · SeJVic anual - Ti ger 800 and •ger 800XC...
  • Page 131: Exploded View - Sprag Clutch And Starter Gears

    Transmission Exploded View - Sprag Clutch and Starter Gears 16 N m SeiVice Manual Tiger 800 and Tiger BOOXC...
  • Page 132: Exploded View - Gear Selectors And Drum

    Transmission Exploded View - Gear Selectors and Drum \ � 12 Nm \l;) � 12 Nm 12 Nm Service Manual Tiger 800 and Tiger 800XC...
  • Page 133: Exploded View - Gear Change Mechanism

    Transmission Exploded View - Gear Change Mechanism 6 Nm 22 Nm Seavice Manual Tiger 800 and Tiger 800XC...
  • Page 134: Selector Shaft

    Transmission Selector Shaft Installation Rotate the selector drum to the neutral position. Removal Note the position and orientation of the gear pedal crank in relation to the shaft, then remove the cran k. Remove the E-clip and washer from the gear pedal end of the gear change -shaft.
  • Page 135: Selector Forks And Drum

    Transmission drum as the selector shaft is fully installed, and Selector Forks and Drum · ensure the selector shaft spring fits either side of the abutment bolt. Removal Remove the engine from the frame <see page 9-3>. Separate the two halves of the cran kcase (see page 5-4>.
  • Page 136: Inspection

    Transmission Noting the positions of the selector forks, slide the Remove the gear position sensor. output selector shaft from the crankcase in the direction of the clutch. Collect the two selector forks as they are released by the selector fork shaft. the selector drum from within the 1.
  • Page 137: Installation

    Transmission Rotate the selector drum and ensu re a smooth Selector fork to groove clearance movement. Rectify as necessary. Service limit 0.47 mm max Examine the gear change shaft seal for damage and/or wear. Replace the seal if damaged and/or The selector forks can be fitted incorrectly.
  • Page 138: Input And Output Shafts Assemblies

    Transmission Fit two new selector shaft retaining fixings, ensuring Input and Output Shafts Assemblies the washer and the selector drum keeper plate are fitted in the positions noted during removal. Tighten the fixings to Removal 12 Nm. Note: input output shafts •...
  • Page 140: Input Shaft

    Transmission Refit the output shaft to the crankcase ensuring the Input Shaft snap-ring locates in the corresponding groove in the crankcase, and the dowel locates in the slot in the upper crankcase. Disassembly Ensure the output shaft seal aligns with its recess in Note: the crankcase.
  • Page 142: Exploded View - Input Shaft

    Transmission Exploded View - Input Shaft � 1 6 8 � ----o 6 -o ----@ ----0> 2 � G- 1 2 ____ __- -© 1. Thrust washer 10. Circlip 2. Second gear 1 1. Splined thrust washer 3. Lock washer 12.
  • Page 143: Assembly

    Transmission Support the housing on press bars as shown below Assembly and press the bearing fully into the housing in the Note: direction of the arrow. The numbers in brackets in the following • text refer exploded view 7-14. page Lubricate each gear, thrust washer and bush •...
  • Page 144 Transmission 10. Fit the splined thrust washer (7) to the input shaft Fit a new circlip ( 10> to the input shaft ensuring that the clip is located in the circlip groove as shown and slide up the shaft until in contact with the circlip. below.
  • Page 145: Output Shaft

    Transmission 1 3 . Remove the splined thrust washer ( 19). Output Shaft 14. Mark one side of second gea r to denote its correct Note: orientation. Remove second gear (21 > from the shaft, complete with the plain bush (20> which runs inside The numbers in brackets in the following •...
  • Page 146: Exploded View - Output Shaft

    Transmission Exploded View - Output Shaft o- 23 11 ----o 12 ___- --© � ::===8 @-___ 28 � 1. Bearing 16. Circlip 2. Thrust washer 1 7. Sixth gear 3. First gear 18. Circlip 4. Plain bush 19. Splined thrust washer 5.
  • Page 147: Assembly

    Transmission If removed, working from the output sprocket end of Assembly the shaft, fit a new bearing (24) and a new sprocket Note: spacer (25) to the shaft using a press and press bars. Fit the sleeve with the large chamfer facing outwards. The numbers in brackets in the following •...
  • Page 148 Transmission Fit sixth gear ( 1 7) as noted during disassembly, with 1 2 . Fit fourth gear (9) a s noted during disassembly, with the selector fork groove facing away from the output the larger step side facing towards the output sprocket end.
  • Page 149: Starter Drive Gears/Sprag Clutch

    Transmission Starter Drive Gears/Sprag Clutch !b_,e Remove alternator rotor (see page 17-19). Withdraw the starter drive gea r from the sprag clutch. Removal Note: The sprag clutch may be detached after first • removing the rider's seat and the battery <disconnect the negative <black>...
  • Page 150: Installation

    Transmission With the sprag clutch mounted in the housing, check Fit the housing to the alternator rotor. the sprag clutch for smooth, free movement in one Ensure that the housing is squarely seated · a nd is not direction only (as indicated by the arrow marked on jammed on the rotor.
  • Page 151 Transmission 1 1. Refit the bottom hose bracket to the front two bolts. Refit the alternator rotor <see page 17-20>. I nstall the cover bolts, using new 3 5 mm bolts as Lubricate the idler gear shaft with a 50/50 solution noted during removal (the 2 5 mm bolts may be re­...
  • Page 152 Transmission Th is page i ntentionally left bla n k 7.24 SeJVice Manual Tiger 800 and Tiger 800XC...
  • Page 153 Triumph Engine Oil ........
  • Page 154: Exploded View - Sump

    Lubrication Exploded View - Sump � 25 Nm � 12 Nm---! SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 155: Exploded View - Oil Pump/Water Pump, Gears And Heat Exchanger

    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...
  • Page 156: Engine Oil Circuit

    Lubrication Engine Oil Circuit .A. - COOLED O I L 6. - U NCOOLED O I L cdah Service Manual Tiger 800 and Tiger 800XC...
  • Page 157: Engine Oil Circuit Description

    Lubrication Engine Oil Circuit Description Oil is collected from the sump and is drawn through a mesh strainer into the oil pump rotor. The oil pump is fitted with a single pumping rotor which supplies pressurised oil to the lubrication circuit via the oil pressure relief valve. The relief valve is set to open at 5.1 bar (75 lb/in2) and when open, returns high pressure oil direct to the sump.
  • Page 158: Engine Oil

    Triumph Engine Oil Your Triumph Motorcycle is a quality engineered product Running the engine with insufficient oil will cause engine which has been carefully built and tested to exacting damage. If the low oil pressure indicator remains on, standards.
  • Page 159: Oil And Oil Filter Change

    With the motorcycle on level ground, and on the sidestand, allow the oil to com pletely drain. Unscrew and remove the oil filter using Triumph service tool T3 8803 1 3 . Dispose o f the o l d filter in an environmentally friendly way.
  • Page 160: Disposal Of Used Engine Oil

    Lubrication Fill the engine with new oil of the type and grade Oil Pump listed previously and in the specification section. 1 1. Start the engine and allow it to idle for a minimum of 3 0 seconds. • Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis.
  • Page 161 Lubrication Remove and discard the bolt securing the coolant in let elbow to the cran kcase and withdraw the elbow. Remove and discard the 0-ring from the elbow . • Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition used engine oil contains potentially harmful contaminants which can ca use cancer.
  • Page 162 Lubrication 1 1. Release the fixings securing the drive chain guide to 1 3 . Carefully remove the bearing while supporting the the crankcase and remove the guide. oil pump drive sprocket. 1. Oil pump drive chain guide 1. Needle roller bearing 2.
  • Page 163: Inspection

    Lubrication � . ble tool, slide the 1 5 . Using a dowel upwards to Inspection � � release t e I pump from the nkcase. lt is not necessary to remove the dowe c pletely from the Release the fixmg remove the drive sprocket ·...
  • Page 164: Assembly

    Lubrication Measure the rotor tip clearance using feeler gauges. Assembly Rotor Tip Clearance If all clea rances are within service limits, liberally apply clean engine oil to all internal components and Standard: 0.1 5 mm refit the oil pump body to the oil pump rotor. Refit the fixings and tighten to 12 Nm.
  • Page 165: Installation

    Lubrication Refit the oil pump drive chain cover to the oil pump Installation and fit new bolts. Tighten the bolts to 12 Nm. Before fitting the oil pump to the crankcase ensure the pump internal surfaces have been 'wetted' with clean engine oil.
  • Page 166: Low Oil Pressure Warning Light Switch

    Lubrication Install three new 0-rings to the coolant outlet pipe Low Oil Pressure Warning Light and position the pipe through the crankcase, locating Switch it to the water pump outlet. Install a new fixing and tighten to 12 Nm. The low oil pressure warning light switch is located in the upper crankcase, behind the cylinder head.
  • Page 167: Sump

    Lubrication Release the fixings securing the sump to the lower Sump crankcase. Removal Remove the rider's seat <see page 16- 13). Disconnect the battery, negative <black> lead first. Drain the engine o i l <see page 8-7>. The oil may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned.
  • Page 168: Installation

    Lubrication Refit the sump guard bracket and secure with the Installation three fixings. Tighten to 15 Nm. Incorporating new 0-rings (two each end of the tube), position the water pump drain tube to the oil pump. 1. Sump guard bracket 2.
  • Page 169 Lubrication Remove the centre bolt from the heat exchanger Heat Exchanger and withdraw it from the crankcase. Remove and discard the heat exchanger 0-ring and the centre bolt sealing washer. Removal Note: Prior to disassembly of the coolant hoses, • note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on...
  • Page 170 Lubrication Fit the heat exchanger to the crankcase and tighten Installation the centre bolt to Fit a new 0-ring to the heat excha nger, a n d a new Fit the coolant hoses to the heat exchanger and sealing washer to the centre bolt. tighten the coolant hose clips.
  • Page 171 9 Engine Removal/ Refit Table of Contents 9. 2 Exploded View - Frame Fixings ............. . Engine Removal/Refit .
  • Page 172 Engine Removal/Refit Exploded View - Frame Fixings 48 Nm � 48 Nm 48 Nm 48 Nm Service Manual Tiger 800 and Tiger 800XC...
  • Page 173 Engine Removal/Refit Engine Removal/Refit Removal To prevent chain damage, do not al low the chain to come into contact with dirt, road grit etc. Set the drive chain adjustment to allow maximum free play in the chain <see page 12-8>. Remove the swinging arm (see page Before starting work, ensure the motorcycle is stabilised 12-13).
  • Page 174 Engine Removal/Refit frame fitted with conventional Models Fitted with a Frame Adjuster Sleeve adjuster sleeve, located on the left hand side Using tool T3 8801 66 loosen the frame adjuster and of the frame; unscrew it ful ly to allow clearance between the frame the frame is fitted with a shim (available in •...
  • Page 176 Engine Removal/Refit Fit new exhaust seals to the cylinder head. Ensure All models that the face of the seal with the tab is facing the Fully insert the lower rear gearbox mounting bolt, cylinder head. refit the hardened washer and fit a new nut. Do not fully tighten at this stage.
  • Page 177 Engine Removal/Refit Refill the cooling system <see page 1 3 . Check throttle ca ble adjustment <see 1 1 -S>. page 10-104>. Remove the motorcycle from the paddock stand and Refit the airbox <see page place on the side stand. 10-101).
  • Page 178 Engine Removal/Refit Th is page intentionally left bla n k SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 179 1 0 Fuel System/ Engine Management Table of Contents Exploded View - Fuel Ta nk and Fuel Pu mp ........... 10.
  • Page 180 Fuel System/Engine Management Ignition timing ..............1 0 .1 4 Immobiliser and Tyre Pressure Monitoring System <TPMS>...
  • Page 181 Triumph Diagnostic Software ........
  • Page 182 Fuel System/Engine Management Fuel Pump ................1 0.70 EMS Main Relay Circuit .
  • Page 183 Fuel System/Engine Management 10. 10 1 Removal ............... . . Installation.
  • Page 184 Fuel System/Engine Management 1 0.1 21 Evaporative Emissions Control System ........... . . Cal ifornia Models Only .
  • Page 185 Fuel System/Engine Management Exploded View - Fuel Tank and Fuel Pump 1 0.7 SeiVice Manual Tiger 800 and Tiger 800XC...
  • 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 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 10.9 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 188 Fuel System/Engine Management Exploded View - Exhaust System 10 Nm � 25 Nm See text See text 10.10 Se1Vice Manual Tiger 800 and Tiger 800XC...
  • Page 189 Fuel System/Engine Management Exploded View - Evaporative System 10.11 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 190: Fuel Requirements

    Triumph motorcycles as damage to components in the Tiger 800 and Tiger 800XC are designed to run on fuel system can be caused by contact with methanol.
  • Page 191 Fuel System/Engine Management Glossary of Terms Coolant temperature The coolant temperature in the cylinder head. The following terms and abbreviations will be found in this section. Below is given a brief explanation of what some of the more common terms and abbreviations Coolant temperature sensor mean.
  • Page 192: Ignition Timing

    Fuel System/Engine Management Idle fueling Adjustment of fueling at idle to suit the actual air inducted. Malfunction Indicator Lamp. Illu minates when most Diagnostic Trouble Codes <DTCs) are set. Idle reference speed The target idle speed as determined by the Electronic Control Module <ECM>.
  • Page 193: Short Circuit

    Fuel System/Engine Management Short circuit Throttle position A 'short cut' in an electrical circuit - current by-passes the The position of the throttle butterfly given as a percentage intended circuit (usually to earth>. of the movement range. When the data is displayed on the diagnostic software, fully open need not be 100% nor fully closed 0%.
  • Page 194: Engine Management System

    Fuel System/Engine Management Engine Management System relation to the point where fuel is injected and ignition of the fuel occurs. Engine coolant temperature sensor • System Description situated at the rear of the cylinder head. The Tiger 800 and Tiger 800XC models are fitted with an Coolant temperature information, received by electronic engine...
  • Page 195: Sensor Locations

    Fuel System/Engi ne Managemen t Sensor Locations MAN I FOLD CLUTCH ABSOLUTE PRESSU RE TH ROTTLE POSITION <MAP> SEN SOR SWITCH SENSOR CRAN K POSITION ROAD SPEED SIDE STAN D G EAR POS ITION SENSOR SENSOR SWITCH SENSOR FAll I NTAKE AI R BAROM ETRIC DETECTION TEMPERATU R E...
  • Page 196: System Actuators

    Fuel System/Engine Management when the engine is operating and is a lso run System Actuators briefly when the ignition is first switched on In response to signals received from the sensors, the ECM to ensure that 3 bar is avai lable to the system controls and directs messages to a series of electronic and soon engine...
  • Page 197: Actuator Locations

    Fuel System/Engine Management Actuator Locations TH ROTILE STEPPER I G N ITIO N MOTOR COILS COOLI NG EMS MAI N POWER FUEL PUMP RELAY FUEL CAN I STER I N J ECTO RS PURG E VALVE 10.19 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 198: Immobiliser System

    The Triumph diagnostic tool is the only way these components can be paired. Do not put a ny other ignition key with a...
  • Page 199: Components Location

    Fuel System/Engine Management Components Location E N G I N E CONTROL MODU LE 10.21 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 200: Tyre Pressure Monitoring System

    When fitting the TPMS, the installation flow-chart detailed has wheel sensors fitted and that the option for the TPMS in the Triumph diagnostic tool user guide must be has been enabled in the immobiliser/TPM S control followed.
  • Page 201: Component Locations

    Fuel System/Engine Management Component Locations TYRE SYMBOL TYRE PRES S U RE D I S PLAY IMMOBI I SERITPMS CONTROL MOD U LE TYRE PRESS U RE S ENSOR 10.23 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 202 Fuel System/Engine Management En g ine Management Circuit Diagram - Tiger 800 and Tiger SOOXC Key To Wiring Circuit Diagram Key To Wiring Colour Codes Item Description Code Wiring Colour Engine Control Module Black Diagnostic Connector Blue Road Speed Sensor ·...
  • Page 203 Fuel System/Engine Management Engine Management Circuit Diagram - Tiger 800 and Tiger SOOXC ' il l � _r -B BG m 9 All -KP l 1 2 5 IJEJ y {] AIO GY � 10.25 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 204 Fuel System/Engine Management Engine Management Circuit Diagram - Tiger 800 CABS> and Tiger SOOXC CABS> Key To Wiring Circuit Diagram Key To Wiring Colour Codes Item Description Code Wiring Colour Engine Control Module Black Diagnostic Connector Blue ABS Modulator Brown Instrument Assembly Green Clutch Switch...
  • Page 206: System Diagnostics

    The engine management system has an on-board remain illuminated until sufficient non-fault diagnostics feature which allows se rv ice techn icians to warm-up cycles have taken place to turn it retrieve stored data from the ECM using the Triumph off. M I L will immediately diagnostic sof t w are.
  • Page 207: Diagnostic Tool Connection

    Diagnostic Tool Connection Triumph Diagnostic Software Described on the following pages is the range of To connect the Triumph diagnostic interface to the information wh ich can be retrieved from the ECM's 16-1 3) motorcycle, remove the pillion seat <see page...
  • Page 208: Current Data

    Fuel System/Engine Management Current Data The data available under Current Data is: Function Examined Result Reported <Scale) Fuel system status 1 open or closed loop operation Calculated load value Engine coolant temperature - Short term fuel trim -Bank 1 Intake manifold absolute pressure m m/hg Engine speed Vehicle speed...
  • Page 209: Sensor Data

    Fuel System/Engine Management Sensor Data When using this function it is possible to check the status of various sensors and actuators. The data sets are divided i nto seven groups - Sensor Voltages ; Sensor Readings ; I njector Data ; Ignition Data ; Idle Speed, Throttle Data and Inputs and Adaption Status.
  • Page 210 Fuel System/Engine Management Injector Data The data available under injector data is: Item Checked Result Unit Injector 1 pulse time milliseconds Injector 2 pulse time milliseconds Injector 3 pulse time milliseconds Ignition Data The data available under ignition data is: Item Checked Result Unit Ignition timing cyl 1...
  • Page 212: Function Tests

    Fuel System/Engine Management Function Tests The system allows the diagnostic software to perform a series of fu nction tests on various actuators in the engine management system. In some cases it is necessary to make a visual observation of a component and in others, if faults are present, DTCs will be logged.
  • Page 214: Diagnostic Trouble Codes

    The n umber of warm-u p cycles required to extinguish the M I L will always be less than the number required to remove a DTC from the ECM memory. DTCs can be removed at any time using the Triumph diagnostic software.
  • Page 216 Fuel System/Engine Management Number of M I L Diagnostic Fault Description Number of Trouble no-fault no-fault illuminated when fault Code cycles cycles before is logged <DTC> before turning off DTC is M I L erased P 1 685 EMS main relay circuit malfunction P 1 659 EMS ignition·voltage input malfunction Nee>...
  • Page 218: Reconnection O F Ecm Con Nectors

    Fuel System/Engine Management Fit the first connector into its socket a nd, whilst Reconnection of ECM connectors holding the connector in place, insert it ful ly into the Note: ECM until the locking device retains it. • different coloured shaped Repeat the above for the second connector.
  • Page 219 6 6 Reconnect harness, clear fault code and ru n O K Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Engine Crankshaft sub-harness Sensor connector 10.4 1...
  • Page 220: Idle Speed Control

    7 Reconnect harness, clear fault code and run OK Action complete - quit test diagnostic software fu nction test to visually verify operation of stepper motor Fault still present Contact Triumph service 10.42 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 221 Fuel System/Engine Management Circuit Diagram Idle S p eed Control Ste pp er Motor 10.43 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 222 Renew relevant injector, proceed to test 7 7 Reconnect harness, clear fault code and run O K Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service 10.44 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 223: Fuel Injectors

    Fuel System/Engine Management Circuit Diagram EMS Main Relay Fuel Injectors 10.45 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 224: Throttle Position Sensor

    Locate and rectify wiring fault, proceed to Short circuit test 5 5 Reconnect harness, clear fault code and run O K Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service 10.46 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 225 Fuel System/Engine Management Circuit Diagram Throttle Position Sensor 10.47 SeiVice Manual Tiger 800 and Tiger SOOXC...
  • Page 226: Purge Valve

    7 Reconnect harness, clear fau lt code and run O K Action complete - q uit test diagnostic software function test to visually verify operation of purge valve Contact Triumph service Fault still present 10.48 Service Manual Tiger 800 and Tiger 800XC...
  • Page 227 Fuel System/Engine Management Circuit Diagram EMS Main Relay Purge Valve 10.49 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 228: Ignition Coils

    Renew relevant ignition coil, proceed to test 7 7 Reconnect harness, clear fault code and ru n O K Action complete - q uit test engine to verify fault cleared Fault still present Contact Triumph service 10.50 Service Manual Tiger 800 and Tiger SOOXC...
  • Page 229 Fuel System/Engine Management Circuit Diagram EMS Main Relay � � Ignition Coils 10.5 1 Service Manual Tiger 800 and Tiger 800XC...
  • Page 230: Coolant Temperature Sensor

    - ECM pin A29 to ground Short circuit test 7 7 Reconnect harness, clear fau lt code and run OK Action complete - q uit test engine to verify fault cleared Fault still present Contact Triumph service 10.52 Service Manual Tiger 800 and Tiger 800XC...
  • Page 231 Fuel System/Engine Management Circuit Diagram Resistance data under typical conditions: Warm engine: 200 to 400Q Cold engine: 20°C ambient 2 . 3 5 to 2.65KQ -10oC ambient 8.50 to 10.2 5 KQ Engine Coolant sub-harness Temperature connector Sensor []= � : 10.53 Service Manual Tiger 800 and Tiger 800XC...
  • Page 232: Intake Air Temperature Sensor

    - ECM pin A 1 1 to ground Short circuit test 7 Action complete - q uit test 7 Reconnect harness, clear fault code and run O K engine to verify fault cleared Fault still present Contact Triumph service 10.54 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 233 Fuel System/Engine Management Circuit Diagram If engine is warm, remove sensor and allow time to cool to ambient prior to test. Resistance data: Ambient temp Resistance value 80°C 200 to 400Q 20°C 2 . 3 5 to 2.6SKQ -10°C 8.50 to 10.2SKQ Inlet Air Temperature Sensor...
  • Page 234: System Voltage

    3 3 Reconnect harness, clear fault code and run OK Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram EMS Main Relay 10.56 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 235: Cooling Fan Relay

    5 Reconnect harness, clear fault code and ru n OK Action complete - quit test diagnostic software function test to visual ly verify operation of cooling fan Fault still present Contact Triumph service Circuit Diagram Cooling Fan Relay EMS Main Relay 10.57...
  • Page 236: Oxygen Sensor

    - ECM pin 820 to sensor pin 1 4 Reconnect harness, clear fault code and run OK Action complete - quit test engine. Check adaptation status Fault stil l present Contact Triumph service Circuit Diagram EMS Main Relay Lambda Sensor 10.58...
  • Page 237: Oxygen Sensor Heater

    Short circuit test 5 5 Reconnect harness, clear fault code and ru n OK Action complete, quit test engine. Check adaption status Fault still present Contact Triumph service Circuit Diagram EMS Main Relay Lambda Sensor 10.59 Service Manual Tiger 800 and Tiger 800XC...
  • Page 238: Eeprom Error

    Fuel System/Engine 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 Tiger SOOXC...
  • Page 239: Fall Detection Switch

    - Sensor pin 4 and sensor pin 6 Less than 4.8V Locate and rectify wiring fault, proceed to test 6 6 Reconnect harness, clear fault code Action com plete, quit test Fault still present Contact Triumph service Circuit Diagram Fall Detection Switch ffi=;=tJ 10.6 1 SeiVice Manual...
  • Page 240: Vehicle Speed Sensor

    - Sensor pin 2 to ground - Instruments pin 9 to sensor pin 1 4 Reconnect harness, clear fault code and run OK Action complete, quit test engine Fault still present Contact Triumph service Circuit Diagram Engine ·stop Alarm Switch Control Unit �...
  • Page 241: Can Communication

    Locate and rectify wiring fault, proceed to test - ECM pin B27 to ground 3 Check cable resistance: More than 50Q Contact Triumph service - ECM pin B28 to ECM pin B27 Locate and rectify wiring fault, proceed to test Faulty <short circuit or...
  • Page 242: Instrument Communication

    4 - ECM pin B27 to ground - ECM pin B28 to ground 3 Check cable continuity: Contact Triumph service - ECM pin B 2 8 to I nstrument pin 4 Locate and rectify wiring fault, proceed to Open circuit...
  • Page 243: Fuel Level Sensor

    Locate and rectify wiring fa ult, proceed to - Sensor pin 1 to sensor pin 2 Short circuit test 5 5 Reconnect harness, clear fault code Action complete, quit test Fault still present Contact Triumph service Circuit Diagram Fuel Level Sensor 10.65 SeJVice Manual...
  • Page 244: Ambient Pressure Senso

    Locate and rectify wiring fault, proceed to Short circuit test 5 5 Reconnect harness, clear fault code and run OK Action complete, quit test engine Fault still present Contact Triumph service Circuit Diagram Ambient Pressure Sensor 10.66 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 245: Manifold Absolute Pressure Sensor

    Locate and rectify wiring fault, proceed to Short circuit test 5 5 Reconnect harness, clear fault code and run OK Action complete, quit test engine Contact Triumph service Fault still present Circuit Diagram Sensor 10.67 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 246: Gear Position Sensor

    - Sensor pin 1 to sensor pin 3 Short circuit Locate and rectify wiring fault, proceed to test 5 5 Reconnect harness, clear fault code Action complete, quit test Fault still present Contact Triumph service 10.68 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 247 Fuel System/Engine Management Circuit Diagram � G ear Position Sensor 10.69 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 248: Fuel Pump

    5 5 Reconnect harness, clear fault code and run O K Action complete - quit test diagnostic software function test to verify operation of fuel pump Fault still present Contact Triumph service 10.70 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 249 Fuel System/Engine Management Circuit Diagram Fuel Pump Main Relay Alarm Q=· 10.7 1 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 250 Action complete - quit test ignition off for longer than one minute. Switch ignition on and check that the EMS main relay operates. Start engine as final check Fault still present Contact Triumph service 10.72 Service Manual Tiger 800 and Tiger 800XC...
  • Page 251 Fuel System/Engine Management Circuit Diagram Fuse box r - - -, 20 A I 10.73 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 252 'RU N ' position and any Alarm fitted must be disarmed 5 Reconnect harness, clear fault code and run O K Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Engine Alarm Stop Control Unit Switch �...
  • Page 253 5 Reconnect harness, clear fault code and use OK Action complete - quit test service software to check for correct sensor outputs and 5V sensor supply voltage level Fault still present Contact Triumph service Circuit Diagram Exhaust Valve Ambient Throttle...
  • Page 254 This is also identified by a fast flashing M I L indication, and a disabled engine motorcycle from being operated management system. Unlock ECM using the diagnostic software supplied unlock code from Triumph service. 10.76 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 255 Update tune using the diagnostic software, Incorrect proceed to test 3 3 Clear fault code, check for normal operation Action complete - quit test Fault still present Contact Triumph service 10.77 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 256 Locate and rectify wiring fault, proceed to test - ECM pin 827 to ground 3 Check cable continuity: Contact Triumph service - ECM pin 828 to immobiliser pin 6 Fault stil l present Locate and rectify wiring fault, proceed to test...
  • Page 257 Pinpoint Tests Test Result Action Follow the Pair ECM and Immobilise Action complete, quit test procedure as described in the Triumph Diagnostic Tool user guide Fault still present Contact Triumph service 10.79 SeiVice Manual Tiger 800 and Tiger SOOXC...
  • Page 258 Fuel System/Engine Management ABS Modulator I D Incompatible Fault Code Possible cause Action P 1 520 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 motorcycle from being operated 10.80...
  • Page 259 Locate and rectify wiring fault, proceed to test - ECM pin B27 to ground 3 Check cable continuity: Contact Triumph service - ECM pin B 2 8 to ABS modulator pin 1 Locate and rectify wiring fault, proceed to test...
  • Page 260 Fuel System/Engine Management Fault Finding - Non Electrical Symptom Possible cause<s> Poor throttle response at low RPM Low fuel pressure caused by filter blockage/leaks Cutting out at idle Throttle bodies out of balance ISC <Idle Speed Control> actuator inoperative Low fuel pressure Weak mixture caused by air lea k at the throttle body/transition piece to cylinder head face Idle speed too low/high...
  • Page 261 Front Wheel Unit Sensor Battery Alert Note: • All the fault codes for the tyre pressure monitoring system and the immobiliser system can only be viewed in the Safety/Security section of the Triumph diagnostic software. Fault Code Possible cause Action...
  • Page 262 L0002 Low battery voltage Replace the rear wheel pressure sensor following the procedure described in the Triumph diagnostic The TPMS tyre symbol in the tool. user gu ide. instrument pack will be on for 8 Record the new sensor's ID number...
  • Page 263 Replace the front wheel pressure Note: This DTC wil l automatically be sensor fol lowing the procedure generated if DTC L0007 occurs described in the Triumph diagnostic tool user guide. Record the new sensor's ID number into the owner handbook before fitting.
  • Page 264 Replace the rear wheel pressure Note: This DTC will automatically be sensor following the procedure generated if DTC L0007 occurs described in the Triumph diagnostic tool user guide. Record the new sensor's I D number into the owner handbook before fitting.
  • Page 265 Action LOOOS lmmobiliser/TPMS control module If the problem persists: has lost communication with the front Using the Triumph diagnostic tool, wheel sensor unit. check that the correct I D number for Low battery voltage. the front wheel pressure sensor is...
  • Page 266 Replace the rear wheel pressure sensor following the procedure described in the Triumph d iagnostic tool user guide. Record the new sensor's I D number into the owner handbook before fitting. 10.88...
  • Page 267 Refer to the owner's handbook for the wheel pressure sensors I D numbers . Fault Code Possible cause Action Using t h e Triumph diagnostic tool, L0007 l mmobiliser/TPMS control module check that the correct I D num bers for has lost communication with the front and rear wheel sensor units.
  • Page 268 If available, try to start the motorcycle with Transponder chip in the key not fu nctioning correctly. Register a new key using the the second registered key: Triumph diagnostic tool then proceed to test 5 Faulty Proceed to test 2...
  • Page 269: Fuel Tank

    Fuel System/Engine Management Ease the double check clip latch away from the Fuel Tank con nector until the release buttons are exposed. Removal Observe the warning · advice given in the general information section on the safe handling of fuel and fuel containers.
  • Page 270 Fuel System/Engine Management Note: Installation • Before disconnection, note the position of Position the fuel tank to the frame. the two breather hoses so that they can be Connect the two breather hoses as previously noted. returned same locations when refitting the tank.
  • Page 272 Fuel System/Engine Management Ensure the locating peg on the fuel pump assembly Installation is located in the cut out on the mountin g p late and the offset hole is positioned as shown below. I nstall a new sealing ring i n the fuel p u m p assembly, with the seal lip facing u ppermost, and ensure that it is correctly seated.
  • Page 273 Fuel System/Engine Management Fuel Level Sender Assembly Assembly Refit the fuel l evel sender assembly to the fuel tan k Removal ensuring that t h e u p per tang and two side tangs a re correctly attached to the bracket inside the fuel tan k. Remove the seat (see page 16-9).
  • Page 274 Fuel System/Engine Management Connect the ada pter hose to the fuel p u m p plate Fuel Pressure Checking outlet as shown in the illustration below. Observe the fuel handling general information section. Fuel pressu re is checked using service tool T3 880001 .
  • Page 275: Fuel Delivery System

    Fuel System/Engine Management Connect the fuel pressu re gauge to the ada ptor hose Fuel Delivery System as shown below by pushing the gauge spigot into Fuel is del ivered to the injectors by a p u m p located inside ada pter until a click ca n be heard.
  • Page 276 Fuel System/Engine Management Disco n nect the MAP sensor m u lti-plug a n d hose. Airbox ---- -- - Removal Remove the rider's seat (see page 16-13). Disconnect t h e battery, negative (black> lead first. Remove the fixing a n d remove the a i r inta ke d u ct from the airbox.
  • Page 277 Fuel System/Engine Management Release the s i x fixings and remove t h e airbox intake 1 1 . Ra ise the ai rbox a n d disconnect the engine breather tru mpets. hose at the airbox. cooo cgot 1. Engine breather hose 1.
  • Page 278: Air Filter Element

    Fuel System/Engine Management Air Filter Element Installation Position the airbox to the motorcycle. Removal Connect the engine breather hose and refit the spring hose clip. Note: • Align the airbox to the engine breather cover and The air filter element can be accessed after secure using the rear fixing.
  • Page 279 Fuel System/Engine Management Intake Air Temperature Sensor MAP Sensor Removal Removal Remove the rider's seat <see page 16-13). Remove the rider's seat (see page 16-73). Disconnect t h e battery, negative (black> lead first. Disconnect t h e battery, negative (black> lead first. Remove t h e fuel ta n k (see p a g e 10-9T>.
  • Page 280 Fuel System/Engine Management Barometric Pressure Sensor Fall Detection Switch Removal Removal Note: Note: • • The barometric pressure sensor is located The fall detection switch is located below on the battery tray, under the battery. the rear rack, forward of the rear light unit. Remove the rider's seat (see page 16-13).
  • Page 282 Fuel System/Engine Management Ignition Switch and Immobiliser Throttle Cable Antenna Adjustment Note: • Note: The immobiliser antenna is integral to the • ignition switch cannot serviced Minor adjustments to the opening cable can separately. be made using the adjuster near the throttle grip end of the throttle.
  • Page 283 Fuel System/Engine Management Set the 'open ing' cable adjuster at the throttle body Removal end to give mm of play at the throttle grip. Note: Tighten the locknut. • Before beginning to remove the throttle cables, note the exact routing and location of both cables to help ensure that they are returned to the same locations and routing on assembly.
  • Page 284 Fuel System/Engine Management At the th rottle gri p end, slide off the rubber boot and Installation release the screws which secu re the two ha lves of the throttle grip guide to each other. Locate t h e cables t o t h e fra me following t h e routi ng noted during remova l.
  • Page 285 Fuel System/Engine Management Locate the outer cables to the bracket and adjust Throttle Bodies/lniectors until the start of the thread is mm away from the back of the throttle cable bracket. Secure the adjuster and locknuts. Removal Note: • Because fuel stored in the fuel rail will be at 3 bar pressure, it is essential that the fuel pressure is reduced before any dismantling of the fuel...
  • Page 286 Fuel System/Engine Management Remove the throttle bodies. To detach the tra nsition pieces from the head, 1 1. 1 5 . release the screws, raise the tra nsition pieces and If req uired, release the screws securing the fuel rai l to collect the 0-ri ngs.
  • Page 287 Fuel System/Engine Management Refit the i n jectors and fuel ra il t o the throttle bodies. Installation Tighten the fuel rail screws to 3 . 5 Nm. Thoroughly clea n the tra nsition piece to cyl inder head mating faces. Refit the transition pieces t o the head incorporating new 0-ri ngs to the joint face.
  • Page 288 Fuel pump connection Fuel pump plate outlet Attach exhaust extraction hoses to the silencer. 10. Attach the Triumph diagnostic tool to the dedicated plug, refer to the Triumph Diagnostic Tool User Guide. Start the engine, and allow to idle. 1 1.
  • Page 289 Fuel System/Engine Management 1 3 . Click the Adjust button. Using the throttle adjusters, make adjustments to the two outer cylinders u ntil the word 'TH ROTILES BALAN CED' in green text appears. Adjust T une Procedure Adjust the throttle balance as described i n the service manual until balanced Press cancel to cancel the adjustment process Press...
  • Page 290 Reconnect the battery, positive (red) lead first. Attach the Triumph diagnostic tool to the ded icated plug, refer to the Triumph Diagnostic Tool User Guide. Turn the ignition to the 'ON' position.
  • Page 291 Refit the fuel tank (see page 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 G uide. 16-13). 20. Refit the rider's seat <see page 1.
  • Page 292 Fuel System/Engine Mana· g ement Leave the plastic collar and spring on the stepper If removed, loosely fit the spring and collar on the motor arm. stepper motor arm. cdax cdax 1. Collar 1. Collar 2. Spring 2. Spring Locate the stepper motor t o its bracket and tighten the fixings to 3 .
  • Page 293 1Z If the reading is not within first. this range, adjustment must be made as described in Attach the Triumph diagnostic tool to the dedicated steps 14 to 1 6. plug, refer to the Triumph Diagnostic Tool User Slacken the screws on the throttle position sensor.
  • Page 294 Fuel System/Engine Management 20. Click the 'OK' button to fully close the idle speed Engine Management Adaption control stepper motor. After a minimum 15 seconds (the tool will show 'Adapting' and not General Information allow further actions to take place during this period), click the 'OK' button again to return the ECM to The engine management system fitted to this model is normal control.
  • Page 296: Exhaust System

    Fuel System/Engine Management Exhaust System Support the right hand silencer and release the bolt and nut securing the silencer mounting bracket to the rear frame. Removal If the engine has recently been running, the exha ust system will be hot. Before working 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.
  • Page 297 Fuel System/Engine Management Remove the bolt from the header pipe rear Assembly mounting point. If removed, install the oxygen sensor and tig hten to 2 5 Nm. Fit new seals to the cylinder head. Ensure that the face of the seal with the tab is facing the cylinder head.
  • Page 298 Fuel System/Engine Management Tighten the header pipe to cylinder head nuts in the 1 1. Align the silencer mounting bracket to the rear frame bracket. Refit the nut. Tig hten the fixings to sequence shown below: 1 5 Nm. Stage 1 : Tighten the header pipe nuts to •...
  • Page 299 Fuel System/Engine Management Evaporative Emissions Control System California Models Only All California models are fitted with a system to control the evaporation of fuel vapour to the atmosphere. A carbon filled canister absorbs vapour while the engine is not running. When the engine is started, the vapour is returned to the engine and burnt.
  • Page 300 Fuel System/Engine Management Evaporative Control System - Engine Off When the engine is stationary any pressure increase in the fuel tank due to a rise in am bient temperature will cause the fuel vapour to pass down the breather hose (1 > to a carbon filled canister (2) which stores the va pour. Once in the canister, vapour cannot enter the engine because the purge valve is closed .
  • Page 301 Fuel System/Engine Management Evaporative Control System - Engine Running When the engine is running, engine vacuum is appl ied to the purge hose (4) from the throttle bodies. At certain times, the ECM opens the purge valve. The vacuum applied to the purge hose (4) now begins to draw stored vapour from the carbon filled area of the canister and returns it to the throttle bodies for burning in the engine.
  • Page 302 Fuel System/Engine Management This pag e intentionally left blank 10. 124 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 303 11 Cooling Table of Contents Exploded View - Cooling System ............11.2 Coolant .
  • Page 304: Exploded View - Cooling System

    Cooling Exploded View - Cooling System � 2 Nm -· 2 Nm Tiger SOO XC Only 11.2 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 305: Coolant

    HD4X Hybrid OA T coolant, as supplied by The coolant mixture contains a corrosion inhibitor which Triumph, is pre-mixed and does not need to helps prevent damage to the metal surfaces inside the be diluted prior to filling or topping up the coq ling system.
  • Page 306: Radiator Hoses

    Cooling Radiator Hoses Coolant Level Inspection Regularly check all radiator hoses and hose clips for cracks, leaks or deterioration in accordance with the scheduled maintenance chart. • Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside Radiator and Cooling Fan the radiator is hot and also under pressure.
  • Page 307: Coolant Replacement

    Cooling Slacken the clip then release the bottom hose from Coolant Replacement the radiator and al low the coolant to d rain. Drainage Note: • Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help e .
  • Page 308 Cooling Remove the bleed screw from the right hand side of Note: the radiator. • A hand operated vacuum pump or similar should be used to syphon the coolant through the system. If necessary, top up the system through the filler and refit the pressure cap.
  • Page 309: Water Pump

    Cooling Water Pump Coolant Pressure Cap and Coolant System Testing Note: • The oil pump and water pump are supplied as an assembly and cannot be separated. For Inspection and Testing additional information, refer to Oil Pump 8-13 <see page for removal and page for installation>.
  • Page 310 Cooling Coolant Pressure Cap Test Coolant System Pressure Test Select the bayonet type adaptor and securely fasten to the radiator. Carefully connect the hand pump to the bayonet connector ensuring an air tight seal is mainta ined. �((®) �� cgwp 1.
  • Page 311: Thermostat

    Cooling Depressurise the coolant test kit using the pressure Thermostat release valve. Removal Note: • Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly.
  • Page 312: Inspection

    Cooling Remove the thermostat from the cylinder head. Refit the thermostat housing and tighten the fixings Discard the seal. 9 Nm. Reconnect the top hose and tighten the cl ip. Tighten 2 Nm. Refit the throttle bodies (see page 10-101>. Refit the airbox <see page 10-101>.
  • Page 313: Radiator

    Cooling Release the radiator lower mou nting. Radiator Removal Note: • Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly.
  • Page 314: Inspection

    Cooling Inspection Installation Check the radiator for stone damage. Align the radiator grommet to the frame stud. Fit the upper mounting bolt and tighten the bolt to 6 Nm. Check the radiator core for damage to the fins or obstructions to air flow. Align the radiator lower mou nting to the bracket on the engine.
  • Page 315 12 Rear S uspension Table of Contents Exploded View - Sw inging Arm ............12.2 Exploded View - Rear Hub and Wheel -Tiger 800.
  • Page 316: Exploded View - Swinging Arm

    Rear Suspension Exploded View - Swinging Arm 9 Nm 110Nm 9 Nm 12.2 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 317: Exploded View - Rear Hub And Wheel -Tiger 800

    Rear Suspension Exploded View - Rear Hub and Wheel - Tiger 800 110Nm L--------------------------------------- - ----- - - - ----- - --- � -------- ----- __.) 12.3 Service Manual Tiger 800 and Tiger 800XC...
  • Page 318: Exploded View- Rear Hub And Wheel -Tig Er 800 Xc

    Rear Suspension Exploded View - Rear Hub and Wheel - Tiger SOOXC _______________________________________ l �--------------------------------------� __.J 12.4 SeiVice Manual Tiger 800 and Tiger SOOXC...
  • Page 319: Exploded View- Rear Suspension Unit -Tiger 800

    Rear Suspension Exploded View - Rear Suspension Unit - Tiger 800 48Nm 48Nm 12.5 Service Manual Tiger 800 and Tiger 800XC...
  • Page 320: Exploded View - Rear Suspension Unit -Tiger 800Xc

    Rear Suspension Exploded View - Rear Suspension Unit - Tiger SOOXC 48Nm 12.6 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 321: Exploded View - Drop/Drag Link

    Rear Suspension Exploded v· lew - Dr op Drag Link 80Nm 80Nm 80Nm ()) � 80Nm � tD C CD c:==J ()) [) 80Nm � aoNm 80Nm SeiVice M anual - Ti ger 800 and T •ger800XC 12.7...
  • Page 322: Drive Chain

    Rear Suspension Drive Chain Chain Adiustment For safety and to prevent excessive wear, the drive chain must be checked, adjusted and lubricated in accordance Chain Free-movement Inspection with scheduled maintenance req uirements. Checking, adjustment and lubrication must be carried out more frequently for extreme conditions such as salty or heavily gritted roads.
  • Page 323: Chain Free-Movement Adjustment

    Release the locknuts on both the left hand and right brakes; you must have your authorised Triumph dealer hand chain adjuster bolts. take remedial action before you attempt to ride the motorcycle again.
  • Page 324: Rear Suspension Unit

    Loosen the two clips a n d detach the rear suspension unit remote reservoir from the frame. Use a genuine Triumph supplied chain as specified in the Triumph Parts Catalogue. Never neglect chain maintenance and always have chains installed by an authorised Triumph dealer.
  • Page 325: Inspection

    Rear Suspension Reposition the drop link plates and position the drag Check the drag link bearings for wear. Overhaul as link clear of the rear suspension unit. necessary (see page 12-13>. Never attempt to disassemble the rear suspension unit or remote reservoir. lt conta ins fluid under pressure and serious injury could result if any pa rt of the system is disturbed.
  • Page 326: Drag Link And Drop Links

    Rear Suspension Locate the drag link to the rear All models: Drag Link and Drop Links suspension unit and, from the left hand side, loosely fit the bolt and a new nut. Removal Reposition the drop link plates and, from the left hand side, loosely fit the bolt and a new n ut.
  • Page 327: Inspection

    Rear Suspension Inspection Swinging Arm Clean all components and inspect the drag link and bearings for damage/wear. Removal Check the rear suspension unit lower bearings for wea r. Check the drop link bearings for wear. Renew as necessary. If the engine has recently been running, the exhaust system will be hot.
  • Page 328: Inspection

    Rear Suspension Remove the bearings by drifting through from the outside. Do not allow the caliper to hang on the brake hose as this may damage the hose and could lead to an accident. Release the brake hose clips from the swinging arm and tie the rear bra ke c aliper to one side.
  • Page 329: Assembly

    (see page 14-23). lt is dangerous to operate the motorcycle with defective brakes; you must have you r a uthorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.
  • Page 330 Rear Suspension Position the chain to the tool ensuring that the chain Note: link pin which is to be removed is aligned with the • The replacement chain is supplied in a split holes in the chain cutting tail piece and the large condition, complete with a link kit to join the pressure screw.
  • Page 331 Rear Suspension Insert the link plate holder (marked PH5060R> into Locate the split link pins such that the pins will enter the large pressure screw. the groove in the link plate holder when the link plate is pressed on to the link. 1.
  • Page 332 Rear Suspension 20. Retain the tool body and tighten the large pressure Remove the tool from the chain and check that screw until the split link end is riveted-over. split link both the pins a re correctly riveted as shown below. cdqn cana Correct riveting...
  • Page 333 13 Front S uspension Table of Contents Exploded View - Front Fork -Tiger 800 ............13.
  • Page 334 Front Suspension Exploded View - Front Fork - Tiger 800 See text See text � t;§;J � � 35 Nm 22 Nm � 2 0Nm 13.2 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 336: Exploded View - Handlebars

    Front Suspension Exploded View - Handlebars 5 Nm � 35 Nm 5 Nm .L � 9 0Nm � 2 0Nm � � 2 0Nm 13.4 Service Manual Tiger 800 and Tiger 800XC...
  • Page 337: Fork Inspection

    Raise and support the front of the motorcycle. If any damage or oil leakage is found, strip and repair as Remove the front wheel <see page 15- 10>. described in this section or consult an authorised Triumph Remove the front mudguard (see page 16- 19 Tiger dealer.
  • Page 338: Installation

    Front Suspension Slacken the top yoke clamp bolts. Installation Position 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. Care must be taken when removing the forks, to ensure that the outer surfaces do not become scratched.
  • Page 339: Fork Oil Change

    Front Suspension Position the brake hose to the fork l e g clip a n d Fork Oil Change secure with the bolt, tightening to 6 Nm. Draining Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
  • Page 340: Fork Oil Level Chart

    Front Suspension Refer t o the fork o i l level chart a n d set the scale o n Fork Oil Level Chart tool 3 8801 60-T03 01 to the relevant distance, a s shown below. Tiger 800 Refer to fork oil Oil Grade Fork Pull level chart...
  • Page 341: Front Fork

    Front Suspension Front Fork Note: • The top cap is not under spring tension and will not spring upwards when the threads Disassembly disengage. Slacken the locknut, unscrew a n d remove the top cap. If necessa ry, remove the 0-ring seal from the top cap assembly.
  • Page 342 Front Suspension 1 1. Fit both halves of tool T3 8801 5 8 (for Tiger 800 models> or tool T3 8801 5 4 (for Tiger 800XC models> to the outer tube as shown below and hold in position. While compressing fork spring always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork.
  • Page 343 Front Suspension 1 3 . Remove the fork from the tool and, using a slide Raise the inner tube a n d remove the dust seal from the outer tube. hammer action to release the oil seal and bushes from the outer tube, separate the inner and outer tubes leaving the seals and bushes in place on the inner tu be.
  • Page 344: Inspection

    Front Suspension If removal of the damping cylinder is required, Assembly unscrew the damping cylinder bolt from the bottom of the lower fork, then slide the damping cylinder out of the inner tube. Collect the centering collar from the lower end of the damping cylinder.
  • Page 345 Front Suspension Invert and position the fork tube outer to tool Using the narrow end of tool T3 880003 <Tiger 800 T3 8801 5 3 . models) or T3 8801 5 7 <Tiger 800XC models), guide the lower bush, washer and seal into place. cgrd_1 1.
  • Page 346 Front Suspension If removed, the damping rod locknut must be fitted with While compressing the fork spring always wear the flat face facing to the top of the fork. The slightly protective equipment for the face and eyes and never tapered face must face the fork spring.
  • Page 347: Headstock Bearing Check/Adjustment

    Front Suspension Headstock Bearing Check/ Adjustment Adiustment Check Always return the handlebars and risers to their original Raise and support the front of the motorcycle. position as noted in paragraph 1. Operating the motorcycle with a handlebar position that is unfamiliar may lead to loss of control or an accident.
  • Page 348 Front Suspension Adjust the bearing free-play as follows, all using tool T3 88002 3 : Remove the locknut and tab w asher. Slacken the adjuster nut then tighten to 4 0Nm. • Slacken the adjuster nut, then re-tighten to 15 Nm. •...
  • Page 349: Headstock Bearing Removal

    Front Suspension Refit the top yoke assembly to the forks. Headstock Bearing Removal 10. Tighten the top nut to 90 Nm. 1 1. Tighten the top yoke clamp bolts to 2 0 Nm. Locate the handlebar assembly in the lower halves of the clamps.
  • Page 350: Inspection

    Front Suspension Using tool T3 880023, remove the locknut and tab Inspection washer. Discard the tab washer. r • 1 : · r � Only remove raised witness marks from within the fra me. Removal of material below any raised areas will reduce the level of interference between the frame and the bearings.
  • Page 351: Installation

    Front Suspension Lubricate the u pper bearing using multi-purpose Installation grease. Fit a new dust seal to the steering stem on the Insert the lower yoke to the frame, fit the upper bottom yoke. bearing and race. Fit a new upper d ust seal and bearing cover, and retain with the adjuster nut.
  • Page 352: Handlebars

    Front Suspension Slide off the rubber boot and release the screws Handlebars which secure the two halves of the twist grip g uide to each other. Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
  • Page 354 Front Suspension Ti ger 800 only: Reconnect the inner throttle cables as noted during Fit the handlebar end weights, removal. Ensure that the positions of the opening tighten ing the fixings to 5 Nm. and closing cables are not transposed. Ti ger SOO XC only: Position the handguards t o the handlebar and secure with the two fixings, using...
  • Page 355 14 Brakes Table of Contents Exploded View - Front Brake Master Cylinder - Tig er 800 ........14.4 Exploded View - Front Brake Master Cylinder -Tiger 800 XC .
  • Page 356 Brakes Bleeding the Rear Brakes, Renew ing Brake Fluid ..........14.23 Rear Brake Pads .
  • Page 357 Triumph D iagnostic Tool........
  • Page 358 Brakes Exploded View - Front Brake Master Cylinder - Tiger 800 12 Nm 25 Nm 6 Nm 6 Nm .J' 1 Nm � 25 Nm 25 Nm 14.4 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 359 Brakes Exploded View - Front Brake Master Cylinder - Tiger SOOXC 12 Nm 25 Nm JIP 7 Nm 6 Nm 2 5 Nm SeNice Manual - Tiger 800 and Tiger 800XC 14.5...
  • Page 360: Exploded View - Front Brake Caliper

    Brakes Exploded View - Front Brake Caliper 28Nm 22 Nm �• 14.6 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 361: Exploded View - Rear Brake Master Cylinder

    Brakes Exploded View - Rear Brake Master Cylinder 15 Nm 7 Nm 2 2 Nm 16 Nm 14.7 Setvice Manual Tiger 800 and Tiger 800XC...
  • Page 362: Exploded View - Rear Brake Caliper

    Brakes Exploded View - Rear Brake Caliper 18Nm 27 Nm 14.8 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 363: Exploded View - Abs System

    Brakes Exploded View - ABS System 9 Nm 14.9 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 364: Braking System Maintenance Safety Precautions

    If there has been an appreciable drop in the level of the fluid in either brake fluid reservoir, consult your authorised Triumph dealer for advice before riding. If the brake lever or pedal feels soft when it is applied, or if the lever/pedal travel becomes excessive, there may be air in the brake lines or the brake may be defective.
  • Page 366: Changing Brake Fluid

    Brakes Changing Brake Fluid Bleeding the Front Brakes, Renewing Brake Fluid Brake fluid should be changed at the interval specified in the scheduled maintenance chart. Brake Pads Before starting work, ensure the motorcycle is stabilised Front and rear pad wear is automatically compensated for and adequately supported.
  • Page 367 When all air has been expelled from the system, lt is dangerous to operate the motorcycle with defective hold the lever fully against the handlebar and close brakes; you must have your authorised Triumph dealer the bleed nipple. take remedial action before you attempt to ride the Note: motorcycle again.
  • Page 368: Front Brake Pads

    Brakes Slacken a n d remove the caliper mounting bolts and Front Brake Pads slide the caliper off the disc. Removal Before starting work, ensure the motorcycle is stabilised and adequately supported. This will hel p prevent it from falling and causing injury to the operator or damage to the motorcycle.
  • Page 369: Inspection

    Brakes Inspection Installation Check the pad retainer, anti-rattle spring and retaining pin. Renew any component which shows signs of damage or corrosion. Check the caliper body slides easily on the mounting Never use mineral based grease (such as lithium or bracket pins and check there is no sign of leakage copper based grease) in any area where contact with the from the piston seals.
  • Page 370: Front Brake Caliper

    Check 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 motorcycle again. Failure to take remedial action may resu lt in reduced braking efficiency leading to loss of motorcycle control and an accident.
  • Page 371: Disassembly

    Brakes Disassembly Always renew caliper seals after removal of the pistons. An effective hyd raulic seal can only be made if new seals To prevent injury, never place fingers or hands inside are fitted. the caliper opening when removing the pistons. Always A dangerous riding condition leading to an accident wear eye, hand and face protection when using could result if this warning is ignored.
  • Page 372: Installation

    Bleed the front brake line <see page 14-12). Check for correct brake operation. lt is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.
  • Page 373: Front Discs

    Brakes Front Discs Removal • Before starting work, ensure the motorcycle is stabilised Do not renew front brake discs individually. Discs must and adequately supported. This will help prevent it from always be renewed in pairs even if one of a pair is falling and causing injury to the operator or damage to serviceable.
  • Page 374: Installation

    D isconnect the battery, negative (black> lead first. brakes; you must have you r authorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may resu lt in...
  • Page 375: Disassembly

    Brakes Disassembly Inspection Detach the rubber boot from the lever end of the Check the following for wear, damage, cracks or cylinder. deterioration: • Remove the circlip from beneath the boot. Cylinder bore Rubber boot • Spring • Piston • Pivot Bolt Always renew the piston and seal set if the cylinder is dismantled.
  • Page 376: Assembly

    Brakes Assembly Installation Locate the master cylinder to the handlebars and position the clamp with the ' U P' arrow pointing upwards. Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible.
  • Page 377: Bleeding The Rear Brakes, Renewing Brake Fluid

    1 2 . Check for correct brake operation. Rectify as necessary. lt is dangerous to operate the motorcycle with defective brakes; you must have you r a uthorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.
  • Page 378 Always check for fluid lt is dangerous to operate the motorcycle with defective leakage around hydraulic fittings and for damage to brakes; you must have your a uthorised Triumph dealer hoses. take remedial action before you ride the motorcycle A dangerous riding condition leading to an accident again.
  • Page 379: Rear Brake Pads

    B rakes Remove the brake caliper bolts a n d raise the caliper. Rear Brake Pads Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
  • Page 380: Installation

    Check for correct brake operation. Rectify as necessary. l t is dangerous to operate the motorcycle with defective brakes; you must have your a uthorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.
  • Page 381: Rear Brake Caliper

    Brakes Rear Brake Caliper Disassembly Remove the plug protecting the pad retaining pin. Removal Remove the pad retaining pin. Remove the brake pads and anti-rattle spring. Before starting work, ensure the motorcycle is stabilised • and adequately supported. This wil l help prevent it from To prevent injury, never place fingers or hands inside falling and causing injury to the operator or damage to the caliper opening when removing the piston.
  • Page 382: Assembly

    Brakes Assembly Ensure that the piston does not tip during assembly as this could damage the caliper. Never use mineral based g rease <such as lithium or A dangerous riding condition leading to a n accident copper based grease> in any area where contact with the could result if this warning is ignored.
  • Page 383: Installation

    Tighten the banjo bolt to 2 5 Nm. lt is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in...
  • Page 384: Rear Brake Disc

    Brakes Rear Brake Disc Rear Master Cylinder Wear Removal .::; t • Before starting work, ensure the motorcycle is stabilised Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to falling and causing injury to the operator or damage to the motorcycle.
  • Page 385: Disassembly

    Brakes Clean the master cylinder bore, piston and seals, with Disconnect the reservoir hose and remove the master cylinder. new brake fluid. Ensure all ports are clear of obstruction. Disassembly Remove the boot from the cylinder and pushrod. • " Remove the circlip retaining the pushrod to the Ensure that the piston and piston seal are fitted facing cylinder.
  • Page 386: Installation

    Connect the push rod to the brake pedal using a brakes; you must have your a uthorised Triumph dealer new clevis pin and clip. take remedial action before you ride the motorcycle again.
  • Page 388: Front Abs Wheel Sensor

    Brakes Front ABS Wheel Sensor Installation Note: • Removal Check the condition of the shim before use. Do not use a shim which is bent or damaged. Position the wheel speed sensor to the fork leg with Before starting work, ensu re the motorcycle is stabilised shim between the sensor...
  • Page 389: Front Abs Pulser Ring

    Brakes Remove a n d discard the five disc bolts and remove Front ABS Pulser Ring the pulser ring. Removal Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle Remove the front wheel (see page 15-10).
  • Page 390: Bleeding The Rear Brake Fluid - Motorcycles With Abs

    Follow the on screen menu t o A B S Diagnostics. From the menu, select B LEED SYSTEM (see the Triumph When all air has been expelled from the system, Diag nostic Tool User Guide).
  • Page 391: Rear Abs Wheel Speed Sensor

    Brakes Rear ABS Wheel Speed Sensor Installation Note: • Removal Check 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 Before starting work, ensure the motorcycle is stabilised installed between the wheel speed sensor and the and adequately support e d.
  • Page 392: Rear Abs Pulser Ring

    Brakes Rear ABS Pulser Ring Air Gap Measurement - Front and Rear Wheel Speed Sensors Removal Using feeler gauges, measure the air gap between the wheel speed sensor and the pulser ring. Before starting work, ensure the motorcycle is stabilised and adequately supported.
  • Page 393: Abs Hydraulic Modulator/Ecm

    Brakes Remove the three fixings and detach the rear brake ABS Hydraulic Modulator/ ECM hose P-clips from the rear swinging arm and ABS modulator bracket <located under rear mudguard). Removal Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
  • Page 394 Brakes 1 1. Remove the fixing and detach the battery negative Remove the left hand lower ABS modulator fixing, cable form the upper crankcase. located under the front seat bridge. cgyw 1. Battery negative cable 2. Fixing 2. Left hand lower fixing Remove the rear brake light switch and disconnect 1 5 .
  • Page 395 Brakes Remove the th ree screws and remove the bracket from the ABS modulator. To prevent body damage, do not spill brake fluid onto any area of the bodywork or wheels. 1 6. Carefully raise the modulator, with the brake lines still attached, upwards from the motorcycle until access to the underside of the modulator can be gained.
  • Page 396: Installation

    Brakes Careful ly manoeuvre the ABS mod ulator and Installation bracket assembly to its fitted position on the fra me. Ensure the brake hard lines and hoses are routed as Align the ABS modulator to its bracket, fit new noted during disassembly. screws and tighten to 9 Nm.
  • Page 398: Abs

    This stored data can then be recovered using a caliper carrier. special service tool which is mandatory for all Triumph Both front and rear wheels have a pulser ring mounted on dealers. I n this way, precise d iagnosis of a fault can be to the wheel, the front being mounted to the wheel hub, made and the fault qu ickly rectified.
  • Page 399: Component Location

    Bra kes Component Location FRO NT FRO NT PULSER RING WHEEL SPEED SENSO R FRO NT B RAKE SWITCH REAR WHEEL REAR PULSER SPEED RING SENSO R 14.45 SeiVice Manual - Tiger 800 a!ld� Tiger 800XC...
  • Page 400: Abs System Circuit Diagram

    Brakes ABS ECM Connector Pin Numbering ABS System Circuit Diagram Key to Wiring Diagram 23 1 6 24 25 Item Description ABS Modulator Rear Fuse Box <Fuses· 1 and 2) Headlamp Relay Front Brake Light Switch Brake Light Rear Brake Light Switch Front Wheel Speed Sensor cdhg Rear Wheel Speed Sensor...
  • Page 401: Abs System Circuit Diagram

    Bra kes ABS System Circuit Diagram r----- -� ' - - - ..J ..14.47 SeiVice Manual - Tiger 800 and�Tiger 800XC...
  • Page 402: System Diagnostics

    Diagnostic Tool Connection The ABS system has an on-board diagnostics feature To connect t h e Triumph diag nostic interface t o the which al lows service techn icians to retrieve stored data motorcycle, remove the pillion seat <see page 16-13>...
  • Page 403: Triumph Diagnostic Tool

    Triumph dealers from Using the Triumph diagnostic tool, it is possible to bleed www.triumphonline.net. the ABS modu lator of tra pped a i r. Th is is necessary when the hyd ra u l i c brake system has been dismantled, or the Build Data ABS mod ulator renewed.
  • Page 404: Diagnostic Trouble Codes

    Diagnostic trouble codes <DT<:s> a re logged in the ABS ECM memory when there is a confi rmed fa ult i n the system. The codes a re reported to the Triumph diagn ostic tool as a fou r digit code.
  • Page 405: Diagnostic Trouble Codes

    Bra kes Diagnostic Trouble Codes Dependant on the DTC stored, the AB$ ECM will act in one of two ways: I n hibit ABS operation immed iately, irrespective of the ABS operating mode; Al low the ABS operation to complete before inhibiting the ABS. Once the ABS ECM has inhibited ABS function, the ECM will act i n one of three ways : a>...
  • Page 406 Brakes warnmg ABS continues light operation is to operate when if fault clears illuminated inhibited fault is logged when fault is when fault is <Only when ABS logged logged is Active. When ABS is no longer active, operation is inhibited) Rear Wheel Input...
  • Page 408: Reconnection Of Abs Ecm Connector

    Brakes Reconnection of ABS ECM Connector Further Diagnosis The tables that follow will, if used correctly, help to pinpoint a fa ult in the system once a diagnostic trouble code has been stored. Damage to the connector pins may resu lt if an attempt to fit the con nectors incorrectly is made.
  • Page 409: Abs Warning Light On

    Bra kes ABS Warning Light ON <No DTCs Stored) Fault Code Possible cause Action ABS Wa rn ing Light O N <No DTCs ABS Ign ition supply fuse/circuit fa ult Ensu re ABS ECM connector is secu re. Stored) ABS Wa rn ing light ci rcu it fa u lt Disconnect ABS ECM connector and proceed to pinpoint test 1 :- Pinpoint Tests...
  • Page 410: Abs Warning Light Does Not Illuminate

    Brakes ABS Warning Light Does Not Illuminate <No DTCs Stored) Fault Code Possible cause Action ABS Warning Light OFF <No DTCs Warn ing light ci rcu it fault Ensure ABS ECM connector is secu re. Stored) ABS ECM g round circuit fault Ensure ABS ECM g round con nection is secu re.
  • Page 411 Bra kes Circuit Diagram Rear Fuse Box -· Control Module 20A I Headlamp Relay 14.57 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 412: Front Wheel Sensor Open Circuit/Short Circuit

    Reconnect ABS ECM harness, clea r fa ult O K Action complete - quit test code and test ABS to verify fault clea red Contact Triumph service Fault stil l present 14.58 800XC SeiVice Manual...
  • Page 413 Bra kes Circuit Diagram Wheel speed sensor cu rrent consumption data under typical conditions: Voltage M in Typical V> Low (4.5 3 .1 mA 4.1 mA 5 . 3 mA H i g h ( 1 6V> 8.1 mA 10.5 mA 1 3 .
  • Page 414: Rear Wheel Sensor Open Circuit/Short Circuit

    Reconnect ABS ECM ha rness, clea r fault Action complete - quit test code and test ABS to verify fault cleared Fault stil l present Contact Triumph service 14.60 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 415 Bra kes Circuit Diagram Wheel speed sensor cu rrent consumption data under typical conditions: Voltage M in Typical (4.5 3 .1 mA 4 .1 mA 5 . 3 mA High ( 1 6\/) 8.1 mA 10.5 mA 1 3 . 6 mA Rear Wheel Speed Sensor Control Module...
  • Page 416: Front Wheel Sensor Abnormal Input/Losing Contact

    Rectify the fault a n d proceed to test 5 Fau lty Check the wheel speed sensor circuit <See Contact Triumph service page 14-58) Fau lty Rectify the fault and proceed to test 5 Clear fault code a n d test ABS to verify fa ult O K...
  • Page 417: Rear Wheel Sensor Abnormal Input/Losing Contact

    Brakes Rear Wheel Sensor Abnormal Input/Losing Contact Fault Code Possible cause Action C 1 614 Rea r wheel speed sensor poor signal Ensure ABS ECM connector is secu re. I ncorrect Wheel speed sensor a i r gap Proceed to pinpoint test 1 :- Damaged or di rty pulser ring Loose or incorrectly instal led wheel speed sensor...
  • Page 418: Front Wheel Pulser Gear Missing Teeth

    Brakes Front Wheel Pulser Gear Missing Teeth Fault Code Possible cause Action C 1 6 21 I n correct Wheel speed sensor air gap Ensure ABS ECM con nector is secu re. Proceed to pinpoint test 1 :- Damaged or d irty pulser ring Loose or incorrectly installed wheel speed sensor Damaged/incorrect wheels...
  • Page 419: Rear Wheel Pulser Gear Missing Teeth

    Brakes Rear Wheel Pulser Gear Missing Teeth Fault Code Possible cause Action C 1 6 2 3 Incorrect Wheel speed sensor air g a p Ensu re ABS E C M connector is secu re. Damaged or d i rty pu lser ring Proceed to pinpoint test 1 :- Loose or incorrectly insta lled wheel speed sensor...
  • Page 420: Front Or Rear Input/Output Solenoid Open/Short Circuit

    Brakes Front or Rear I nput/Output Solenoid Open/Short Circuit Fault Code Possible cause Action Front: C 1 6 31 ; C 1 6 3 2 ABS solenoid circuit fa ult Ensure ABS ECM con nector is secu re. Rea r: C 1 6 3 3; C 1 6 3 4 Disconnect ABS ECM connector and proceed to pinpoint test 1 :- C 1 654...
  • Page 421: Front Or Rear Wheel Actuator Wheel Lock

    Bra kes Front or Rear Wheel Actuator <Hydraulic Control> Wheel Lock Fault Code Possible cause Action C 1 641 ; C 1 643 Binding bra ke Ensure ABS ECM connector is secure. I ncorrect Wheel speed sensor air gap Proceed to pinpoint test 1 : Loose or incorrectly insta lled wheel speed sensor Pinpoint Tests...
  • Page 422: Motor - Lock; Motor Stuck Off; Motor Stuck On

    - ABS ECM con nector pin 25 and G round Faulty Reconnect ABS ECM harness, clear fault code Action complete - quit test and test ABS to verify fault cleared Fault stil l present Contact Triumph service Circuit Diagram Rear Fuse Box r-------, �OA ·----- Control Module 14.68...
  • Page 423 5 Clear fa ult code and test ABS to verify fa u lt O K Action com plete - quit test clea red Fault still present Contact Triumph service Circuit Diagram Rear Fuse Box ,..--- -· Control Module...
  • Page 424: Different Tyre Diameter

    Brakes Different Tyre Diameter Fault Code Possible cause Action C 1 671 I ncorrect diameter wheels instal led Ensu re ABS ECM con nector is secu re. Incorrect tyre pressures Proceed to pinpoint test 1 : I ncorrect wheel speed sensor a i r gap Damaged or d irty pu lser rin g Pinpoint Tests Test...
  • Page 425: Abnormal Ecu

    Rectify the fault and proceed to test 4 Clear fault code and test ABS to verify fau lt Action com plete - q u i t test cleared Fault stil l present Contact Triumph service 14.71 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 426: Abs Hydraulic Circuit Layout

    Brakes ABS Hydraulic Circuit Layout A. Front Brake Circuit from Master Cylinder to ABS Modulator B. Front Brake Circuit from ABS Modulator to Front Calipers C. Rear Brake Circuit from Master Cylinder to Modulator D. Rear Brake Circuit from ABS Modulator to Rear Caliper E.
  • Page 427 1 5 Wheels/Tyres Table of Contents 1 5.2 Exploded view - Front Wheel - Tiger 800 ........... . Exploded view - Front Wheel - Tiger 800 XC .
  • Page 428: Exploded View - Front Wheel - Tiger 800

    Wheels/Tyres Exploded view - Front Wheel - Tiger 800 65 N m 15.2 SeiVice Manual Tiger 800 and Tiger SOOXC...
  • Page 429: Exploded View - Front Wheel - Tiger 800 Xc

    Wheels/Tyres Exploded view - Front Wheel - Tiger SOOXC 6 5 Nm 15.3 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 430: Exploded View - Rear Wheel Final Drive - Tiger

    Wheels/Tyres Exploded View - Rear Wheel & Final Drive - Tiger 800 1 10 Nm _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ---' �...
  • Page 431: Exploded View - Rear Wheel Final Drive - Tiger 800 Xc

    Wheels/Tyres Exploded View - Rear Wheel & Final Drive - Tiger SOOXC 1 10 Nm _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ l - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --, _..J 15.5...
  • Page 432: Tyres

    Wheels/Tyres aooxc Tiger models a re fitted with spoked wheels which Tyres require a tyre su itable for use with a n inner tube. Tiger 800 models a re equipped with tubeless tyres, valves and wheel rims. Use only tyres ma rked 'TU B E LESS' and tubeless va lves rims...
  • Page 433: Tyre Pressures

    Wheels/Tyres Tyre Pressures Correct inflation pressu re wi ll provide maxi m u m stabil ity, rider com fo rt and tyre l ife. Inner tubes m ust only be used on moto rcycles fitted Always check tyre pressures before riding when the tyres with spoked wheels and with tyres ma rked 'TU B E a re cold.
  • Page 434: Tyre Wear/Wheel Inspection

    • Triumph m otorcycles must not be operated a bove the legal road speed l i m it except in authorised closed cou rse conditions. I mportant Tyre Information...
  • Page 435 When wheel balancing is req u i red, such as after tyre replacement, see you r authorised Triumph dealer. Only use self-adhesive weig hts. Clip on weig hts will damage the wheel and tyre resu lting in tyre deflation, loss of control and a n accident.
  • Page 436: Front Wheel

    Wheels/Tyres Release and remove the wheel spindle, which is Front Wheel th readed into the left hand fork. Remove the wheel a nd the wheel spacers. Removal Before starting work, ensure the motorcycle is stabil ised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
  • Page 437 Position the wheel between the forks ensuring the brakes; you must have your a uthorised Triumph dealer spacers remain in position on both sides. take remedial action before you attempt to ride the motorcycle again.
  • Page 438: Installation

    Wheels/Tyres Rear Wheel Removal Do not allow the ca liper to hang o n the brake hose as this may damage the hose. Damaged hoses could cause brake fai l u re leading to loss of control and an accident. Before starti ng work, ensure the motorcycle is stabil ised Withd raw the wheel and collect the fla nged spacer and adequately supported.
  • Page 439 Triumph dealer take remedial action before you attempt to ride the motorcycle again. Fai l u re to take remedial action may red uce braking efficiency leading to l oss of motorcycle contro l and an accident.
  • Page 440: Installation

    Wheels/Tyres Inspection Front Wheel Beari ngs Removal • Remove the front wheel <see page 15- 10>. O n ly remove raised witness ma rks from with i n the wheel. Rem oval of material below any ra ised a reas will reduce the level of i nterference between the wheel and the beari ngs.
  • Page 441: Rear Wheel Bearings

    Wheels/Tyres Fit the wheel bearings and centre sleeve using the Rear Wheel Bearings method described opposite. Removal Remove t h e rear wheel <see page 15- 12). Do not allow the wheel to rest on the bra ke disc, as this may damage the disc.
  • Page 442: Inspection

    Wheels/Tyres Inspection Fit the wheel bearings and centre sleeve using the method described on the previous page. Only remove raised witness marks from with i n the wheel. Removal of material below any raised a reas will reduce the level of interference between the wheel and the bearings.
  • Page 443: Final Drive

    Wheels/Tyres Remove the cush d rive ru bber. Final Drive Removal Before startin g work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from fa lling and causing injury to the operator or damage to the motorcycle.
  • Page 444 Wheels/Tyres Th is page intentionally left blank 15.18 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 445 1 6 Frame and Bodywork Table of Contents Exploded View - Frame - all Models ............1 6.3 Exploded View - Cockpit and Mountings - Tiger 800 .
  • Page 446 Frame and Bodywork Removal ................1 6.1 8 1 6.18 Installation .
  • Page 447: Exploded View - Frame - All Models

    Fram e and Bodywork Exploded View - Frame - all Models 48 N m �� 48 Nm 48 Nm 48 Nm 16.3 Service Manual Tiger 800 and Tiger 800XC...
  • Page 448: Exploded View - Cockpit And Mountings - Tiger 800

    Frame and Bodywork Exploded View - Cockpit and Mountings - Tiger 800 � 3 Nm '--- -- • " � 5 Nm 3 Nm 5 Nm � 3 � � � � 5 Nm 5 Nm 5 Nm 16.4 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 449: Exploded View - Cockpit And Mountings - Tiger 800 Xc

    Fra me and Bodywork Exploded View - Cockpit and Mountings - Tiger SOOXC S Nm � Nm ----! !-- S Nm 3 Nm 16.5 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 450: Exploded View - Lower Panels And Sumpguard - All Models

    Frame and Bodywork Exploded View - Lower Panels a nd Sumpguard - all Models [.. � 3 Nm 3 N m � 3 Nm 3 Nm 3 Nm 10 N m 10 Nm 16.6 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 451: Exploded View - Rear Panels - All Models

    Frame and Bodywork Exploded View - Rear Panels - all Models 20 N m S Nm 20 N m 16.7 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 452: Exploded View - Footrests And Mountings - All Models

    Frame and Bodywork Exploded View - Footrests and Mountings - all Models 16.8 Service Manual Tiger 800 and Tiger 800XC...
  • Page 453: Exploded View - Sidestand - All Models

    Fram e and Bodywork Exploded View - Sidestand - all Models 45 Nm 7 Nm 20 N m 16.9 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 454: Exploded View - Front Mudguard - Tiger 800

    Frame and Bodywork Exploded View - Front Mudguard - Tiger 800 16.10 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 456: Exploded View - Rear Mudguard - All Models

    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 458: Removal

    Frame and Bodywork Lower Radiator Panel Upper Radiator Pa nel Removal Removal Remove t h e two radiator infill fixings. Remove t h e rider's seat (see page 76- 13). Discon nect the battery, negative (black> lead first. Remove the lower radiator panel (see page 16- 14). Remove and d isca rd the radiator i nfi ll panel fixing.
  • Page 459: Removal

    Frame and Bodywork Installation Radiator lnfill Panel Reconnect the d i rection ind icator connectors. Removal Hook the front edge o f the panel behind the cockpit panel and hook the tangs into the grommets on the Remove t h e rider's seat (see page 16- 13). fuel tan k.
  • Page 460: Removal

    Frame and Bodywork Remove the two fixi ngs and remove the rad iator infill Beak - Tiger SOOXC only panel. Removal Remove t h e fou r fixings and remove t h e beak in a n u pwards direction. c gxt Radiator infill panel 2.
  • Page 461: Removal

    Fra me and Bodywork Remove the front u pper fixi ngs, located Cockpit Assembly All models: below the headlig ht. Collect the nuts from the inside of the cockpit. Removal Note: • This procedure describes the removal and installation procedure for both Tiger 800 and Tiger SOO)_(C models.
  • Page 462: Assembly

    Frame and Bodywork Remove the three fixings and sepa rate the cockpit Fuel Ta nk l nfil l Pa nel infill and cockpit screen panels from the cockpit panel. Removal Rem ove the rider's seat (see page 76- 13>. Remove t h e rea r fixing, located t o t h e rea r of the airbox.
  • Page 463: Windscreen

    Fra me and Bodywork Windscreen Front Mudguard - Tiger 800 Removal Removal Release the two u pper mou nti ng fixings, collecting Detach t h e front brake hose from t h e two cl ips o n the n uts from the inside of the mou nting as you do t h e front mudguard .
  • Page 464: Front Mudguard - Tiger 800Xc

    Frame and Bodywork Front Mudguard - Tiger 800XC Rear Rack Removal Removal Detach t h e front brake hose from t h e two cl ips o n Rem ove t h e rea r seat (see p a g e 16- 13>. t h e front mudguard.
  • Page 465: Rear Side Panel

    Fra m e and Bodywork Rear Side Pa nel Installation Refit the side panel and secu re with the lower fixing. Removal Do not tighten the fixing at this stage. Refit the pan nier mounting plates to the bolts and Remove t h e rider's seat <see page 16- 13}.
  • Page 466: Rear Mudguard

    2. Mudguard extension or reflector bracket fixing (only if as standard, or is available as an accessory from fitted> >-' your Triumph dealer. The mudguard extension Noting cable routing, d iscon nect...
  • Page 467: Installation

    Frame and Bodywork Lift the rea r mudguard off the two rear seat rai l lugs, Installation along with the rea r light and seat lock assembly. A l i g n t h e rea r mudguard t o t h e rear l ight and seat lock assembly.
  • Page 468: Sump Guard

    Frame and Bodywork Sump Guard Frame, Footrests a nd Fixi ngs Removal Inspection Remove and d iscard t h e two front fixi ngs. I nspect the fra me, footrests and bodywork for damage, cracks, chafin g other dangerous Remove and discard the fou r n uts and remove the conditions.
  • Page 469 1 7 Electrical Table of Contents Exploded View - Instru ments............. . . 17.3 Exploded View - Headlight .
  • Page 470 Electrical Removal ................17.16 Installation .
  • Page 471: Exploded View - Instru Ments

    Electrical Instruments Exploded VIe 2 Nm � 17.3 Se1V1ce Manual T•ge r 800 and Tiger 800XC...
  • Page 472: Exploded View - Headlight

    Electrical Exploded View - Headlight 3 . 5 Nm 3 . 5 Nm 3 Nm 17.4 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 473 Electrical Exploded View - Rear Light & Reflectors � g 3 Nm 3 Nm 17.5 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 474: Exploded View - Direction Indicators

    Electrical Exploded View - Direction I ndicators 3 Nm 3 Nm � 3 Nm � 17.6 SeNice Manual Tiger 800 and Tiger 800XC...
  • Page 475: Exploded View - Alternator, Starter And Immobiliser

    Electrical Exploded View - Alternator, Starter and Immobiliser 9 Nm 12 Nm 120 Nm 17.7 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 476: Battery

    Electrical Battery Battery Removal The battery g ives off explosive gases; keep sparks, flames and ciga rettes away. Provide adequate ventilation when charging or using the battery in a n enclosed space. The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns.
  • Page 477: Battery Commissioning And Charging

    After starting to fill the battery with electrolyte, al low commissioning procedure that Triumph recom mends. the battery to sta nd for 30 minutes with the filling The procedure is designed to ensure that the battery is at conta i ner in place.
  • Page 478: Battery Maintenance

    Electrical withi n the battery. Battery Maintenance Sulphation is a normal chemical reaction inside the battery The battery is a sea led type and does n ot requ i re a ny and over a period of time sul phate will crystal l ise on to the maintenance other than routine recharg i n g...
  • Page 479: Relays

    Electrical Relays Fuses The relay pack is located beneath the rider's seat, ad jacent If a fuse fails d u ring operation, inspect the electrica l to the fuse boxes. To gain access to the relays, remove the system to determ ine the cause, and then replace it with a rider's seat (see page 16-13).
  • Page 480: Front Fuse Box

    Electrical Front fuse box Rear fuse box Fuse No. Circuits Protected Circuits Protected Fuse Fuse Fuse No. Rating Rating Cooling fan -1 5 Accessory lights Auxiliary lighting Ala rm, i nstru ments, H eated g rips Engine managem ent Accessory sockets Alarm, diagnostic Not used con nector, instruments...
  • Page 481: Instrument Pack

    Electrical I nstrument Pack Remove the screw and release the instru ment pack from the bracket bayonet fixi ngs. Removal Remove t h e rider's seat (see page 1 6-13). Disco n nect t h e battery, negative (black> lead first. Remove t h e windscreen (see page 16-19).
  • Page 482: Headlights

    Electrical Headlights Headlight Bulb Replacement Headlight Adiustment Note: • The headlight can be adjusted by means of vertical and horizontal adjustment screws located on the real;' of the headlight. 1. Bulb retainer {right hand shown> 2. Bulb retainer hook 3. Bulb Each headlight bulb can be replaced as fol lows : Horizontal adjustment screw 2.
  • Page 483: Position Lam P Bulb Replacement

    Electrical Position Lam p Bulb Replacement Headlight Assembly Note: • Removal The position lamp is fitted to the centre of the headlight. Remove t h e rider's seat (see p a g e 16-13). Remove the rider's seat (see-page 16-13). Disconnect t h e battery, negative <black>...
  • Page 484: Rear Light

    Electrical Rear Light Direction I ndicators Removal Bulb Replacement Note: • The rear light is a sealed for life unit and must be replaced in the event of a failure. Remove the seats (see page 76-13). Disconnect t h e battery, negative (black> lead first. Remove the rear mudguard (see page 1 6-22>.
  • Page 485: Rear Direction Indicator

    Electrical Rear Direction I ndicator Front Direction I ndicator Removal Removal Remove the seat <see page 16-13). Remove the rider's seat <see page 76-13>. Disconnect t h e battery, negative <black) lead first. Disconnect the battery, negative (black) lead first. Remove t h e rear rack <see' p a g e 76-20>.
  • Page 486: Starter Motor

    Electrical Starter Motor Inspection Ensure the starter turns freely and without binding. Removal Check starter 0-ring damage deterioration. Replace as necessa ry. Remove t h e rider's seat <see page 16-13). Disconnect t h e battery, negative (black) lead first. Installation Remove the fuel tan k <see page 10-91).
  • Page 487: Alternator

    Electrical Alternator Removal Do not use tools to tig hten service tool T3 880375. Tig hten the tool by hand on ly. Over-tig htening of the 16-13>. Remove the rider's seat <see page tool wil l lead to damage to the a lternator rotor. Disconnect the battery, 1;\egative (black) lead first.
  • Page 488: Assembly

    Electrical Note: Assembly • Ensure that the thrust pad does not fall out Refit t h e Wood ruff key t o t h e cran kshaft. during assembly of the tool. Assemble t h e rotor t o t h e keyway o n t h e cra n kshaft, 1 1 .
  • Page 489: Alternator Rectifier

    Electrical Position a new gasket to the cra n kcase dowels then Alternator Rectifier refit the left hand engine cover. The rectifier does not conta i n a ny servicea ble parts and 1 1. Refit the bottom hose bracket to the front two bolts. must be replaced if faulty.
  • Page 490: Alternator Stator

    Electrical Alternator Stator The stator is an assembly of 18 coils, arranged into three phases. lt is possible to check for continuity and short circu its through the coils and to earth. Note: • Only repair the stator harness between the rectifier and where the harness goes into the crankcase. •...
  • Page 491 Electrical Test Result Action Check the alternator AC output Voltage at 1 5V AC to Test rectifier/regu lator <see page 17-24> 850 rpm by probing the 3-pin stator 2 5V AC connector as follows : Less tha n Replace unit. Proceed t o test 6 - Positive (+) probe to pin 1 negative (-) probe 1 5V AC to pin 2...
  • Page 492: Rectifier/Regulator

    Electrical Rectifier/Regulator I nterna l ly the rectifier/reg u lator consists of three diodes, one between each input and the positive terminal, and three Field Effect Transistors <FETs), one between each input and the g round terminal. As the voltage of the AC signal from the generator rises, the voltage controller switches the FETs to avoid over voltage on the output.
  • Page 493 Action complete - q u it test 17-22) the cha rg ing Voltage at 2,000 rpm: Fa ult still present Test alternator stator <see page If a lternator stator is servicea ble, contact Triumph service Circuit Diagram Black Socket for Rectifier Out Grey...
  • Page 494: Lighting Circuit

    Electrical Lighting Circuit Key to circuit diagram Key to wiring colours Item Description Wiring Colour Fuses <Front, Fuses 2 And 3 ) Black I g nition Switch Blue Rear Light Brown Instrument Assem bly G reen Oil Pressure LED Slate G rey Oil Pressure Switch O range...
  • Page 495 Electrical Lighting Circuit 'j - - j - -� � - - � � 1 H.!--- --' 17.27 Service Manual Tiger 800 and Tiger 800XC...
  • Page 496: Starting And Charging Circuit

    Electrical Starting and Charging Circuit Key to circuit diagram Key to wiring colours Item Description Wirin g Colour Battery Black Starter Solenoid Blue Starter Motor Brown Regulator/ Rectifier G reen Fuse Box <Rear) Slate G rey Fuse Box <Front> Orange Starter Relay Pink Engine Control Module Relay...
  • Page 497 Electrical Starting and Charging Circuit · · � r N ' 5 � 00 00 00 P WR 8 1 5 1 5 14 A1 7 � 1I] 1a 17.29 SeiVice Manual - Tiger 800 and Tiger 800XC...
  • Page 498: Key To Wiring Colours

    Electrical Auxiliary and Accessory Circuit Key to wiring colours Wiring Colour Key to circuit diagram Black Blue Item Description Brown Fuse box <Front) G reen Accessory Socket Slate G rey Accessory Socket 2 Orange Heated G rips Pink Front Brake Light Switch Brake Light Purple Rear Brake Light Switch...
  • Page 500: Engine Management Circuit Diagram - Tiger 800 A Nd Tiger 800Xc

    Electrical Engine Management Circuit Diagram - Tiger 800 a nd Tiger SOOXC Key To Wiring Circuit Diagram Key To Wiring Colour Codes Item Description Code Wiring Colour Eng ine Contro l Module Black Diag nostic Connector Blue Road Speed Sensor Brown I nstru ment Assembly G reen...
  • Page 501 Electrical Engine Management Circuit Diagram -Tiger 800 and Tiger SOOXC � : rn 3 � Bf1J � · m � All f-eo � _r--- 8 l � � "{] � � � =[] 1 A29 -KG � 17.33 Manual SeiVice Tiger 800 Tiger 800XC...
  • Page 502: Key To Wiring Colour Codes

    Electrical Engine Management Circuit Diagram - Tiger 800 CABS> and Tiger SOOXC CABS> Key To Wiring Circuit Diagram Key To Wiring Colour Codes Item Description Code Wiring Colour Engine Control Module Black Diagnostic Connector Blue ABS Modulator Brown Instrument Assembly Green Clutch Switch Slate/Grey...
  • Page 503 Electrical Engine Management Circuit Diagram - Tiger 800 <ABS> and Tiger 800XC <ABS> UP U NK�YR ArK> NK� NK � YP -- NK� _r -8 NK-E3-GP NK-E3-GB � 22 [] , = == = ; m 21 ::(] f] 1 3 17.35 SeiVice Manual Tiger 800 and Tiger 800XC...
  • Page 504: Complete System - Tiger 800 And Tiger 800Xc - Without Abs

    Electrical Complete System - Tiger 800 and Tiger SOOXC - without ABS Key to circuit diagram Alarm Starter Motor Item Description Starter Solenoid Instrument Assembly Battery Road Speed Sensor Regulator/Rectifier Front Brake Switch Alternator Engine Stop Switch Starter Relay Start Switch Fuse box <Rear) Engine Control Module Fuse box <Front>...
  • Page 506: Complete System - Tiger 800 And Tiger 800Xc - With Abs

    Electrical Complete System - Tiger 800 and Tiger SOOXC - with ABS Key to circuit diagram Alarm Starter Motor Item Description Starter Solenoid Instrument Assembly Battery Accessory Lights Regulator/Rectifier Front Brake Switch Alternator Engine Stop Switch Starter Relay Start Switch Fuse box <Rear>...
  • Page 508 Electrical This page intentionally left blank 17.40 Setvice Manual Tiger 800 and Tiger 800XC...