Connecting Rods; Removal; Installation - Triumph 2012 Tiger 800 Service Manual

Crankshaft, Connecting Rods and Pistons

Connecting Rods

Removal

Connecting rods may be removed from the engine after
first removing it from the frame. The cylinder head must
be removed and the cran kcase halves separated.
1. Mark each big end cap and connecting rod to
identify both items as a matched pair and to identify
the correct orientation of the bea ring cap to the
connecting rod.
2. Release the con necting rod bolts and remove the big
end cap. Ensure that the bearing shell remains in
place in the cap.
1. Big end cap
2. Connecting rod bolt
Note:
lt may be necessary to gently tap the big
•
end cap with a rubber mallet to release the
cap.
3. Push the connecting rod u p through the crankcase
and collect the piston and connecting rod from the
top.
4. Label the assembly to identify the cylinder from
which it was removed.
Never re-use connecting rod bolts. If the con necting rod
cap is disturbed, always renew the bolts. Using the
original bolts may lead to severe engine damage.
5. Remove the l iner
page 5-17>.
6. Detach the piston from the connecting rod <see
page 5-13>.
5.8
using tool T3 8801 01 (see
SeJVice Manual
-

Installation

Note:
Connecting rod bolts are treated with an
•
anti-rust solution
removed.
Clean the connecting rod with high flash­
•
point solvent.
Remove all
•
damage, wear and any signs of deterioration
and replace as necessary.
Connecting rod bolts M U ST only be used once. If the
bolts are removed or undone for a ny reason, new bolts
M U ST always be used.
Re-using bolts can cause connecting rods and their caps
to detach from the crankshaft causing severe engine
damage, loss of motorcycle control and an accident.
Note:
Ensure the piston is fitted correctly to the
•
connecting rod.
If a previously run engine is being rebuilt,
•
always ensure that the piston and con-rod
are assembled in the same orientation, and
to the same cylinder, as prior to strip-down.
1. Fit the piston onto the connecting rod (see
page 5-15>.
2. Apply silicone sealer to the liner-to-cran kcase mating
face <At the factory, Three Bond 1 21 5 is used>.
cbef_1_1
1. Liner
2. Sealer area
3 .
Fit t h e piston and connecting rod assembly into the
liner from the bottom.
4. Fit the liner into the crankcase ensuring that the
arrow on the piston faces forward.
Tiger 800 and Tiger 800XC
which must not
bearings and inspect
·
be
for