Page 1 2016-2017 Triumph Tiger Explorer XR /XRX / XRT Motorcycle Service Man i u al...
Page 3: Table Of Contents
Table of Contents Introduction General Information Scheduled Maintenance Cylinder Head Clutch Crankshaft Balancer Transmission Lubrication Engine Removal and Refit Fuel System/Engine Management Cooling Front Suspension Rear Suspension Brakes Final Drive Wheels/Tyres Frame and Bodywork Electrical System...
Page 5: Introduction
Where accurate measurements are required, they can only be made using calibrated, precision instruments. For the duration of the warranty period, an authorised Triumph dealer must perform all repairs and scheduled maintenance.
Page 6 When replacement parts are required, it is essential that only genuine Triumph parts are used. Safety features and corrosion prevention treatments embodied in the motorcycle may be impaired if parts other than genuine Triumph parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification.
Page 7: General Information
Tiger Explorer XR Series tightened to a snug fit, evenly and in a cross pattern. This is to avoid distortion of the part and/or gas or oil leakage. Conversely, bolts, nuts, or screws, should all be loosened (in sequence if specified) by about a quarter of a turn and then removed.
Page 8 Tiger Explorer XR Series WARNING Fluoroelastomer material is used in the manufacture of various seals in Triumph motorcycles. In fire conditions involving temperatures greater than 315°C this material will decompose and can then be potentially hazardous. Highly toxic and corrosive decomposition products, including hydrogen fluoride, carbonyl fluoride, fluorinated olefins and carbon monoxide can be generated and will be present in fumes from fires.
Page 9 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 10 Tiger Explorer XR Series WARNING Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
Page 11 Tiger Explorer XR Series CAUTION Distilled water must be used with the antifreeze (see specification for antifreeze) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Reduced cooling system efficiency may lead to the engine overheating and engine damage.
Page 12 When installing circlips and retaining rings, take care to compress or expand them only enough to install them. Always use the correct replacement circlip as recommended in the Triumph parts catalogue. Self-Locking Nuts Self-locking nuts can be reused, provided resistance can be felt when the locking portion passes over the thread of the bolt or stud.
Page 13 Tiger Explorer XR Series Lubricate the sealing lips with a recommended lubricant. This will help to prevent damage in initial use. On dual lipped seals, smear the area between the lips with appropriate grease. When pressing in a seal which has manufacturer's marks, press in with the marks facing out. Seals must be pressed into place using a suitable driver.
Page 14 Tiger Explorer XR Series Below/overleaf several common bearing types and the lubrication procedures for each are identified: ceon Sealed Bearings Note Sealed bearings can be identified by their integrated seals. Sealed bearings are lubricated for life by the manufacturer. Any attempt to change the grease in a sealed bearing will damage the integrated seals. If the seals are damaged, dirt and water will ingress and the life of the bearing will be greatly reduced.
Page 15 Tiger Explorer XR Series ceon Angular Contact and Ball Bearing Grease the bearing races and the ball bearing carrier. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts. ceop Needle Roller Bearings Coat the needle rollers with grease.
Page 16 Chassis Repairs WARNING 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 the motorcycle, which if not correctly repaired, may cause a second accident which may result in injury or death.
Page 17 Tiger Explorer XR Series Electrical Precautions The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and electronic components fitted to the motorcycle. Where necessary, specific precautions are detailed in the relevant sections of this manual which should be referred to prior to commencing repair operations. Equipment - Prior to commencing any test procedure on the motorcycle ensure that the relevant test equipment is working correctly and any harness or connectors are in good condition, in particular mains leads and plugs.
Page 18 Tiger Explorer XR Series Disciplines Switch off the ignition prior to making any connection or disconnection in the system. An electrical surge can be caused by disconnecting 'live' connections which can damage electronic components. Ensure hands and work surfaces are clean and free of grease, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts.
Page 19 Circuits diagrams may look confusing at first but when they are studied closely they soon become logical. Due to the complex circuits and the number of individual wires, Triumph uses two types of circuit diagram in its Service Manuals.
Page 20 Glossary of Circuit Diagram Symbols The following is a description of the symbols found in the circuit diagrams used in all Triumph Service Manuals. Connector This illustration is used to show all multiplug type electrical connectors on Triumph circuit diagrams. The numbers in the box relate to the terminal numbers of the connector pins.
Page 21 An additional number outside the box will identify the component. LED (Light Emitting Diode) Triumph use LEDs for the alarm warning light, instrument illumination and warning lights, gear change lights and rear light/brake lights on various models.
Page 22 Tiger Explorer XR Series A device placed in a cable to reduce a voltage or restrict the maximum current a device can draw. Splice A hard cable joint where two or more cables are joined in the wiring harness. A potential source of both open and short circuits.
Page 23 Tiger Explorer XR Series that it is also possible for a 5 Volt sensor reference voltage to short to an adjacent circuit, which can also cause electrical failures and DTCs (Diagnostic Trouble Code) to be stored. When tracing a wire that is suspect, carefully check the circuit diagram before starting. Remember: a wire may diverge at a splice and go off to feed other circuits.
Page 24 Tiger Explorer XR Series Turn the circuit to be tested 'ON'. Set the Digital Multi Meter (DMM) to Voltage Check (V). Ensure the multi meter is set to DC Volts for direct current circuits (most circuits) or AC Volts for alternating current circuits (typically alternator output voltage tests).
Page 25 This stops the ECM from clogging the network with incorrect data and preventing other messages from getting through. The fault would then be reported by a DTC (Diagnostic Trouble Code). Triumph currently uses CAN for communication between the following ECMs: Engine ECM...
Page 26 Where this is the case, the tools required will be described during the procedure. Special Service Tools T3880105 - Angular Torque Gauge T3880371 - Oil Pump Drive Gear Holder T3880057 - Triumph Diagnostic Interface T3880207 - Pliers, Hose Clip cemy4 T3880208 - Slide Hammer T3880317 - Damper Tube Clamp...
Page 27 Tiger Explorer XR Series ccha 3880160 -T0301 - Fork Oil Filler/Evacuator T3880660 - Clutch Restraint T3880602 - Alternator Wrench T3880313 - Oil Filter Wrench cczh 3880070-T0301 - Bearing Installer T3880365 - Alternator Housing Puller cjkh SERVICE TOOLS 23 of 746...
Page 28 Tiger Explorer XR Series T3880603 - Oil Pump Restraint T3880605 - Cylinder Liner Extractor (use with the frame from Cylinder Liner Extractor T3880315) cdoa2 T3880377 - Engine Mounting Adjuster T3880606 - Flywheel Restraint cdgh T3880023 - 50 mm Socket T3880001 - Fuel Pressure Gauge T3880607 - Camshaft Timing Tensioner T3880608 - Flywheel Pin Set SERVICE TOOLS...
Page 29 Tiger Explorer XR Series cczb T3880609 - Torque Limiter T3880053 - Wheel Bearing Extraction Kit T3880123 - Extension Cable BatteryMate Battery Charger - See Latest Parts Catalogue for Part Number Information T3880620 - Adjuster Socket, 48 mm T3880624 - Housing Support SERVICE TOOLS 25 of 746...
Page 30 Tiger Explorer XR Series cgwp T3880147 - Radiator and Cap Tester Kit T3880625 - Bearing Installer, 39 mm T3880626 - Bearing Installer, 46 mm T3880627 - Bearing Puller, 32-42 mm T3880628 - Bearing Installer, 26 mm T3880601 - Crankshaft Timing Pin SERVICE TOOLS 26 of 746...
Page 31 Tiger Explorer XR Series T3880630 - Fuel Hose Clamp T3880631 - Blanking Cap T1343 T3880640 - Camshaft Timing Plate T3880643 - Fork Top Cap Socket T3880661 - Fork Seal Installer T3880662 - Fork Seal Guide cjix T3880629 - Bearing Installer Handle T3880171 - Fork holding Tool SERVICE TOOLS 27 of 746...
Page 32 Tiger Explorer XR Series cjkh T3880315 - Cylinder Liner Extractor T3880637 - Kit, Engine to Frame Alignment Bars ccgu T3880062 - Lock Ring Wrench, 38 mm Specifications Engine Engine Configuration 3 cylinder 12 valve DOHC Arrangement Transverse in-line Displacement 1215 cc Bore x Stroke 85 x 71.4 mm Compression Ratio...
Page 33 Tiger Explorer XR Series Cylinder Head Flatness Tolerance 0.030 mm Valve Head Diameter Inlet 35.600 mm Exhaust 28.600 mm Valve Lift Inlet 8.75 mm Exhaust 8.00 mm Valve Stem Diameter Inlet 4.975 - 4.990 mm (standard) 4.965 mm (service limit) Exhaust 4.970 - 4.980 mm (standard) 4.960 mm (service limit)
Page 34 Tiger Explorer XR Series Valve Clearance Inlet 0.10 - 0.15 mm Exhaust 0.275 - 0.325 mm Valve Bucket Diameter Inlet and Exhaust 28.476 - 28.490 mm (standard) 28.468 mm (service limit) Valve Bucket Bore Diameter Inlet and Exhaust 28.507 - 28.527 mm 28.541 mm (service limit) Camshafts Camshaft Timing...
Page 35 Tiger Explorer XR Series No. of Friction Plates Steel Plate Flatness Within 0.15 mm (standard) 0.20 mm (service limit) Friction Plate Thickness (2 x inner and 1 x outer) 3.80 mm (standard) 3.60 mm (service limit) Friction Plate Thickness (all others) 3.80 mm (standard) 3.60 mm (service limit) Clutch Pack Height...
Page 36 Tiger Explorer XR Series Second 0.350 - 0.550 mm (standard) 0.670 mm (service limit) 0.200 - 0.700 mm (standard) 0.84 mm (service limit) Gudgeon Pin Bore Diameter in Piston 19.010 - 19.015 mm (standard) 19.043 mm (service limit) Gudgeon Pin Diameter 19.000 - 19.005 mm (standard) 18.985 mm (service limit) Connecting Rods...
Page 37 Tiger Explorer XR Series Crankshaft Run-out 0.020 mm or less (standard) 0.050 mm (service limit) Transmission Final Drive Type 6 Speed, Constant Mesh Gear Ratios 2.846:1 (13/37) 2.056:1 (18/37) 1.583:1 (24/38) 1.2916:1 (24/31) 1.138:1 (29/33) 1.037:1 (27/28) Gear Selector Fork Thickness Input shaft 5.8 - 5.9 mm (standard) 5.7 mm (service limit)
Page 38 Tiger Explorer XR Series Front Bevel Box Ratio 1.042:1 Rear Bevel Box Ratio 2.455:1 Drive System Universal-jointed shaft with torsional damper Final Drive Oil Castrol SAF-XO Fully Synthetic Hypoid Final Drive Oil Capacity 0.17 litres Lubrication Type Pressure Lubrication, Wet Sump Oil Capacity (dry fill) 3.9 litres Oil Capacity (wet fill including filter)
Page 39 Tiger Explorer XR Series Spark Plug Gap 0.7 mm Gap Tolerance +0.05/-0.1 mm Fuel System Fuel Type Unleaded, 91 RON (U.S. 87 CLC/AKI) Fuel Tank Capacity 20.0 litres (motorcycle upright) Low Level Warning Lamp 3.5 litres remaining Fuel Pump Type Submerged Fuel Pressure (nominal) 3.5 bar...
Page 40 Tiger Explorer XR Series Anti-Freeze Type Triumph HD4X Hybrid OAT coolantT Cooling System Capacity 2.4 litres Radiator Cap Opening Pressure 1.1 bar Thermostat Opening Temperature 71°C (nominal) Cooling Fan Switch On Temperature 103°C Temperature Gauge Sensor Resistance 2.9 - 3.3 K/Ohms @ 15°C...
Page 41 Tiger Explorer XR Series Rear Type Twin piston sliding caliper acting on single disc Rear Caliper Piston Diameter 27.0 mm Rear Disc Diameter 255.0 mm Rear Disc Thickness 6.0 mm (standard) 5.0 mm (service limit) Rear Disc Run-out Max. 0.5 mm Rear Wheel Speed Sensor Air Gap 0.1 mm - 1.5 mm (Non adjustable) Rear Master Cylinder Diameter...
Page 42 Tiger Explorer XR Series (130km/h) Front Tyre Minimum Tread Depth Over 80 mph 2mm (0.08in) (130km/h) Rear Tyre Minimum Tread Depth Over 80 mph 3 mm (0.12 in) (130km/h) Frame Frame Type Steel trellis Rake 23.1° Trail 99 mm Max. Payload (rider, passenger, luggage & accessories) 227 kg (500 lb) Electrical Equipment Battery Type...
Page 43 Tiger Explorer XR Series Application Torque (Nm) Notes Flywheel cover 11 Nm Crankcase cover to crankcase 11 Nm Balancer cover to crankcase 11 Nm Clutch cover to crankcase 11 Nm Breather cover to crankcase 11 Nm Fit new fixing(s) if loosened or removed Sump to crankcase 12 Nm...
Page 44 Tiger Explorer XR Series Application Torque (Nm) Notes Clutch centre nut 160 Nm Fit new fixing(s) if loosened or removed Fit new Belleville washer Clutch release plate to pressure plate 10 Nm Clutch master cylinder clamp bolts 12 Nm Clutch lever nut 6 Nm Clutch lever pivot bolt 1 Nm...
Page 45 Tiger Explorer XR Series Application Torque (Nm) Notes Crankcase dry seal plug 25 Nm Fit new fixing(s) if loosened or removed Camshaft drive sprocket to crankshaft 27 Nm Fit new fixing(s) if loosened or removed Oil retainer plate 12 Nm Fit new fixing(s) if loosened or removed Face seal plug...
Page 46 Tiger Explorer XR Series Application Torque (Nm) Notes Selector shaft retainer 12 Nm Fit new fixing(s) if loosened or removed Lubrication System Application Torque (Nm) Notes Sump plug 25 Nm Fit new sealing washer(s) Oil pressure relief valve 15 Nm Apply ThreeBond 1305 to the threads Low oil pressure warning light switch to crankcase...
Page 47 Tiger Explorer XR Series Application Torque (Nm) Notes Throttle body transition piece to cylinder head 9 Nm Throttle body to transition piece clip 1.5 Nm Throttle balance blanking screw 5 Nm Fuel rail to throttle bodies 3.5 Nm Exhaust downpipe to cylinder head - Stage 1 6 Nm See Exhaust System - Installation Exhaust downpipe to cylinder head - Stage 2...
Page 48 Tiger Explorer XR Series Application Torque (Nm) Notes Crankshaft position sensor 6 Nm Fit new fixing(s) if loosened or removed Seat bridge to frame 5 Nm Evaporative cannister 8 Nm Purge valve 3 Nm Gear position sensor 5 Nm Sump cable tidy 3 Nm Fit new fixing(s) if loosened or removed...
Page 49 Tiger Explorer XR Series Front Suspension Application Torque (Nm) Notes Upper yoke pinch bolt 25 Nm Lower yoke pinch bolt 25 Nm Fork top cap to fork outer tube 40 Nm Fork top cap to damping rod 2.5 Nm Fork top cap locknut 25 Nm Fork damping rod bolt 22 Nm...
Page 50 Tiger Explorer XR Series Rear Suspension Application Torque (Nm) Notes Swinging arm to frame, left hand pivot pin 170 Nm See Swinging Arm - Installation Swinging arm to frame, right hand pivot pin 45 Nm See Swinging Arm - Installation Swinging arm to frame pivot locking ring 110 Nm See Swinging Arm - Installation...
Page 51 Tiger Explorer XR Series Application Torque (Nm) Notes See Rear Bevel Box - Installation Back plate to bevel box housing 30 Nm Rubber boot clip 1.5 Nm Front Brakes Application Torque (Nm) Notes Front brake caliper to fork 50 Nm Front brake pad retaining pin 6 Nm Front brake caliper bleed screw...
Page 52 Tiger Explorer XR Series Application Torque (Nm) Notes Rear brake hose to master cylinder union 25 Nm Fit new sealing washer(s) Brake pedal pivot bolt 22 Nm Fit new fixing(s) if loosened or removed Brake hose P-clip bolt 7 Nm Fit new fixing(s) if loosened or removed Rear brake disc...
Page 53 Tiger Explorer XR Series Application Torque (Nm) Notes Rear wheel to final drive unit 70 Nm Tyre valve - models without tyre pressure monitoring 6 Nm Apply ThreeBond 1305 to the system threads Tyre valve - models with tyre pressure monitoring 4.5 Nm system Frame and Bodywork...
Page 54 Tiger Explorer XR Series Application Torque (Nm) Notes Windscreen support to motor fixing 5 Nm Windscreen motor infill fixings 3 Nm Wind deflector clear panel fixings 3 Nm Cockpit panel fixings 3 Nm High level mudguard to inner fixings 1.2 Nm Finisher to high level mudguard fixing 1.2 Nm Clear panel to high level mudguard finisher fixings...
Page 55 Tiger Explorer XR Series Application Torque (Nm) Notes Engine bar centre mounting 18 Nm Engine bars link bar 5 Nm Rear panel to frame fixings 7 Nm Luggage rack fixings 27 Nm Luggage rack cover fixings 7 Nm Pannier rail fixings 27 Nm Rear mudguard upper fixings 7 Nm...
Page 56 Tiger Explorer XR Series Application Torque (Nm) Notes Aluminium pannier mounting frame mechanism 20 Nm fixings Aluminium pannier mounting frame bobbin fixings 9 Nm Seat bridge moulding to frame 5 Nm Seat lock to frame 9 Nm Fit new fixing(s) if loosened or removed Side panel brackets to radiator 7 Nm...
Page 57 Tiger Explorer XR Series Application Torque (Nm) Notes Fog light bracket fixings 5 Nm If fitted Fog light shroud to bracket 6 Nm If fitted Fog light to shroud 3 Nm If fitted Fit new fixing(s) if loosened or removed Electrical accessory socket(s) 2 Nm Inertial measurement unit to bracket...
Page 58 Tiger Explorer XR Series cipf Main Wiring Harness Routing ROUTINE MAINTENANCE 54 of 746...
Page 59 Tiger Explorer XR Series cjrs ABS and Brake Hose Routing cjma ROUTINE MAINTENANCE 55 of 746...
Page 60 Weather, terrain and geographical location affects maintenance. The maintenance schedule should be adjusted to match the particular environment in which the vehicle is used and the demands of the individual owner. For advice on adjusting the service schedule, consult your authorised Triumph dealer. WARNING...
Page 61: Scheduled Maintenance
In order to correctly carry out the maintenance items listed in the Scheduled Maintenance chart, special tools and specialist knowledge will be required. As only an authorised Triumph dealer will have this knowledge and equipment, Triumph strongly recommends that your authorised Triumph dealer carries out all scheduled maintenance.
Page 62 48,000) Fuel System and Engine Management Autoscan - Carry out a full Autoscan • • • • • using the Triumph Diagnostic Tool (print a customer copy) Fuel system - check for leaks • • • • • Fuel system - check fuel hoses for •...
Page 63 Tiger Explorer XR Series Operation Description Odometer Reading in Miles (Km) or Time Period, whichever comes first First Annual Mileage Based Service Service Service Every 500 (800) Year 10,000 and 20,000 40,000 1 month 30,000 (32,000) (64,000) (16,000 and 48,000) Clutch fluid levels - check •...
Page 64 General Instruments, chassis ECM and • • • • • engine ECM - check for latest calibration download using the Triumph diagnostic tool Bank angle indicators - check for • • • • • wear Fasteners - inspect visually for •...
Page 65 Tiger Explorer XR Series Operation Description Odometer Reading in Miles (Km) or Time Period, whichever comes first First Annual Mileage Based Service Service Service Every 500 (800) Year 10,000 and 20,000 40,000 1 month 30,000 (32,000) (64,000) (16,000 and 48,000) Centre stand flanged sleeves - •...
Page 66 Tiger Explorer XR Series Exploded View – Clutch Cover ENGINE COVERS 62 of 746...
Page 67 Tiger Explorer XR Series Exploded View – Engine Covers Exploded View – Sump ENGINE COVERS 63 of 746...
Page 68 Tiger Explorer XR Series Camshaft Cover - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the rider’s seat (see Rider’s Seat - Removal). Disconnect the battery, negative (black) lead first.
Page 69 Tiger Explorer XR Series Electrical connectors Ignition coils Detach the secondary air injection hose from the reed valves on top of the camshaft cover. Spring-close clip Secondary air injection hose Reed valve assemblies Detach the connectors from the connector bracket and position aside, then release the fixings and remove the connector bracket.
Page 70 Tiger Explorer XR Series Connector bracket Fixings Noting the position of the fuel transfer pipe bracket, release the fixings securing the reed valve covers to the camshaft cover. Position the fuel transfer pipe bracket aside. Fuel transfer pipe bracket Fixings Reed valve covers Ease the reed valve covers from the valves.
Page 71 Tiger Explorer XR Series Cam cover Camshaft Cover Bolt Release Sequence Carefully manoeuvre the camshaft cover towards the front of the motorcycle. Then manoeuvre the cover to the right to remove it from the motorcycle. CAUTION Never use a lever to remove the camshaft cover from the cylinder head. Using a lever will cause damage to the head and camshaft cover which could lead to an oil leak.
Page 72 Tiger Explorer XR Series Refit the dowels to the cylinder head. Dowels Fit a new camshaft cover seal to the groove in the camshaft cover. chdk Camshaft cover seal groove Apply silicone sealer to the areas shown in the diagram below (at the factory, ThreeBond 1215E is used). chdk ENGINE COVERS 68 of 746...
Page 73 Tiger Explorer XR Series Silicone sealer areas Fit the camshaft cover, ensuring that the dowels, gasket and seals remain in the correct positions. Apply a thin film of engine oil to both sides of the new seals for the camshaft cover bolts. Fit the camshaft cover screws and screw seals, then tighten until finger tight.
Page 74 Tiger Explorer XR Series Electrical connectors Ignition coils Reconnect the right hand coolant hose, refit the constant tension hose clamp. Refill the cooling system (see Coolant Replacement). Refit the throttle bodies (see Throttle Bodies/Injectors - Installation). Refit the airbox (see Airbox - Installation). Refit the fuel tank (see Fuel Tank - Installation).
Page 75 Tiger Explorer XR Series chhw Clutch cover Encapsulated fixing position Clutch Cover - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Clean and refit the clutch cover incorporating a new gasket.
Page 76 Tiger Explorer XR Series Disconnect the battery, negative (black) lead first. Remove the three fixings and remove the expansion tank cover. Discard the upper M5 fixing. Retain the lower M6 fixings for reuse. chgw_2 Expansion tank cover Upper fixing (M5) Lower fixings (M6) Remove the lower expansion tank fixing.
Page 77 Tiger Explorer XR Series Thoroughly clean the flywheel cover. Position a new gasket to the crankcase dowels then refit the flywheel cover. Refit the expansion tank bracket and secure the cover and bracket with the fixings. chek Flywheel cover Expansion tank fixing Expansion tank bracket Tighten the cover fixings in the following sequence: Tighten the fixings in the sequence shown below to 11 Nm.
Page 78 Tiger Explorer XR Series chgw_2 Expansion tank cover Upper fixing (M5) Lower fixings (M6) Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Crankshaft Cover - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 79 Tiger Explorer XR Series Position a new gasket to the crankcase dowels. Refit the crankshaft cover, installing a new encapsulated fixing to the position shown below. chel Crankshaft cover Encapsulated fixing Tighten the cover fixings in the following sequence: Tighten the fixings in the sequence shown below to 11 Nm Tighten fixings one and two again to 11 Nm.
Page 80 Tiger Explorer XR Series chel_2 Balancer cover Fixings WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Thoroughly clean the balancer shaft cover. Position a new gasket to the crankcase dowels.
Page 81 Tiger Explorer XR Series chel_4 Balancer Cover Tightening Sequence Breather Cover - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the alternator (see Alternator - Removal).
Page 82 Tiger Explorer XR Series Refit the breather cover, installing new M6 x 16 mm and M6 x 35 mm encapsulated fixings as noted during removal. Tighten the new fixings in the sequence shown below to 11 Nm. cige Breather Cover Tightening Sequence Refit the alternator (see Alternator - Installation).
Page 83 Tiger Explorer XR Series Remove the sump guard (see Sump Guard - Removal). Remove the fixing and detach the starter motor cable P-clip from the sump. chha Starter motor cable P-clip Fixing Note For models fitted with engine bars as standard, the lower front mounting point of the harness guide is secured with a fir tree clip instead of a bolt.
Page 84 Tiger Explorer XR Series chhd Sump Fixings Detach the sump and collect the water pump drain tube. Remove and discard the four drain tube O-rings. Note The water pump drain tube may remain attached to the water pump or become detached with the sump.
Page 85 Tiger Explorer XR Series Water pump drain tube O-rings Thoroughly clean the sump. Incorporating a new sump gasket, position the sump to the lower crankcase. Tighten the sump fixings in the following sequence: Tighten the fixings in the sequence shown below to 12 Nm. Tighten fixings one, two, three and four again to 12 Nm.
Page 86: Cylinder Head
Tiger Explorer XR Series chhb_1 Harness guide Scrivet Bolt Bolt/fir tree clip Reposition the starter motor cable P-clip to the sump and secure with a new fixing. Tighten to 6 Nm. chha P-clip Fixing Refit the sump guard (see Sump Guard - Installation). Fill the engine with the correct grade of engine oil (see Oil and Oil Filter Change).
Page 87 Tiger Explorer XR Series Exploded View - Camshaft, Camshaft Drive and Valves CYLINDER HEAD 83 of 746...
Page 88 Tiger Explorer XR Series Cylinder Head Description The engine is fitted with an aluminium alloy cylinder head, which carries the camshafts, valves and spark plugs. The cylinder head is cast as a single entity and various components are permanently added after machining. The camshafts run directly in the cylinder head without separate bearings.
Page 89 Tiger Explorer XR Series encapsulated bolt. chel Right hand crankshaft cover Encapsulated bolt Rotate the crankshaft clockwise (the normal direction of rotation) using the bolt fitted to the end of the crankshaft. Stop rotation just before the marks on the camshaft bosses point inwards at a point level with the joint face.
Page 90 Tiger Explorer XR Series choi T3880601 - Crankshaft Timing Pin Timing hole in crankcase Note In addition to T3880601 - Crankshaft Timing Pin being installed in to the crankshaft at TDC, the alignment marks on the camshaft bosses will point inwards at a point level with the joint face. gaaa_2 Alignment marks Place a suitable wedge between the camshaft drive chain tensioner blade and crankcase, to hold the...
Page 91 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. To set the camshaft drive chain tensioner onto the first tooth of the ratchet (i.e. minimum extension) carry out the following: Note If installing a new camshaft drive chain tensioner, do not release the plunger before fitting.
Page 92 Tiger Explorer XR Series cfho Resister ring Refit the spring. Hold the resister ends together and insert the plunger into the tensioner housing. Place the tensioner in a soft jawed vice. While holding the resister ends together, use the vice to push the plunger through the resister ring until the groove for the snap ring aligns with the snap ring.
Page 93 Tiger Explorer XR Series cfej Groove for snap ring Snap ring Fit a new O-ring and gasket to the camshaft drive chain tensioner. Fit the camshaft drive chain tensioner to the cylinder head as noted for removal. Tighten the bolts to 9 Nm. Remove the wedge, taking care not to move or damage the tensioner blade.
Page 94 Tiger Explorer XR Series gaaa_2 Camshaft Boss to Cylinder Head Alignment Marks Re-check the tensioner plunger location against the tensioner blade. Remove T3880601 - Crankshaft Timing Pin. Refit the camshaft cover (see Camshaft Cover - Installation). Refit the crankshaft cover (see Crankshaft Cover - Installation). Camshafts - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 95 Tiger Explorer XR Series Rotate engine until the remaining two fixings are accessible. CAUTION Do not rotate the engine further once the four camshaft sprocket bolts have been loosened. Rotation of the engine with the four sprocket bolts loose will result in valve to piston contact and serious engine damage. Loosen the two remaining camshaft sprocket fixings.
Page 96 Tiger Explorer XR Series chej Camshaft drive chain Inlet camshaft Remove the camshaft drive chain and if necessary the tensioner blade and rubbing strip (see Camshaft Drive Chain, Tensioner Blade and Rubbing Strip - Removal). Rotate the crankshaft and insert T3880601 - Crankshaft Timing Pin. Ensure the crankshaft can no longer rotate.
Page 97 Examine all camshaft and camshaft bearing caps for excessive wear and damage. Check the journal-to-head clearances, using 'Plastigauge' (Triumph part number 3880150-T0301) as follows: Wipe the exposed areas of both the camshaft journal and a single cap or cap area of the ladder.
Page 98 Tiger Explorer XR Series cbpg Measuring the Compressed Plastigauge Note The camshaft ladder is unique to each cylinder head and is, therefore, not available separately. If the camshaft ladder is worn or damaged, the complete cylinder head must be replaced. Calculate the journal clearance using the Plastigauge chart supplied with the Plastigauge kit.
Page 99 Tiger Explorer XR Series Ensure there is no slack between the crankshaft and exhaust sprocket when the sprocket fixings are centrally located within the slotted holes. Refit the inlet camshaft to the cylinder head, hooking the chain over the sprocket as you do so. Ensure the fixings on the inlet sprocket are also centrally located within the slotted holes when there is no slack between the exhaust and inlet sprockets.
Page 100 Tiger Explorer XR Series Removal screw Assemble the camshaft ladder in the same location and orientation as prior to removal. Do not fit the top pad at this stage. Fit and evenly tighten the camshaft ladder fixings to 10 Nm, in the sequence shown below, ensuring that T3880640 - Camshaft Timing Plate remains centrally located between the camshafts.
Page 101 Tiger Explorer XR Series chog T3880607 - Camshaft Timing Tensioner CAUTION The torque value stated is very important to accurate timing. Always use the correct value of 0.6 Nm, as set using the Torque Limiter T3880609. Using an incorrect torque value will result in incorrect valve timing being set, or damage to the tensioner blade or other valve train components.
Page 102 Tiger Explorer XR Series chei Uppermost fixings Remove T3880640 - Camshaft Timing Plate by rotating the removal screw clockwise as shown below. choj T3880640 - Camshaft Timing Plate Removal screw Remove T3880601 - Crankshaft Timing Pin. CAUTION Always check that T3880640 - Camshaft Timing Plate has been removed before rotating the engine. Severe damage will result to the camshafts or T3880640 - Camshaft Timing Plate if engine rotation is attempted with the tool installed.
Page 103 Tiger Explorer XR Series clearance becomes too great, the engine will become noisy and will not run correctly. Valve Clearance Measurement Note Valve clearance measurement must be carried out with the engine cold. Remove the camshaft cover (see Camshaft Cover - Removal). Remove the crankshaft cover (see Crankshaft Cover - Removal).
Page 104 Tiger Explorer XR Series as measured (mm) as measured (mm) Valve Clearance Adjustment Note To adjust the valve clearances the camshafts must be removed. Remove the camshafts (see Camshafts - Removal). Remove the tappet bucket from the cylinder head. Note The shim may withdraw with the tappet bucket.
Page 105 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the camshafts (see Camshafts - Removal). Remove the tensioner blade pin and remove the tensioner blade through the right hand crankshaft cover opening in the crankcase.
Page 106 Tiger Explorer XR Series Measure across 23 links as shown in the diagram below. If the drive chain is within limits, the measurement should be no longer than 150.14 mm. Measurements beyond 150.14 mm indicate that the drive chain must be replaced.
Page 107 Tiger Explorer XR Series Camshaft Drive Chain Tensioner Blade and Rubbing Strip - Inspection Check the camshaft drive chain tensioner blade and rubbing strip for wear or damage. Renew if worn or damaged. 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.
Page 108 Tiger Explorer XR Series cfeg Locating devices Facing blade Release the three hooks and remove the facing blade. cfeh Hooks Camshaft Drive Chain Tensioner Blade - Assembly Assembly is the reverse of disassembly (see Camshaft Drive Chain Tensioner Blade - Disassembly). Camshaft Drive Chain, Tensioner Blade and Rubbing Strip - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 109 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Note The cylinder liners must be resealed once the cylinder head has been removed. Remove the engine from the frame (see Engine - Removal).
Page 110 Tiger Explorer XR Series Cylinder Head Bolt Release Sequence Lightly tap the cylinder head with a rubber mallet to break the seal of the gasket. Lift the head directly upwards until clear of the camshaft drive chain rubbing blades. Cylinder Head - Inspection Cylinder Head - Installation Thoroughly clean the surface of the head and check for damage and pitting of the combustion chambers.
Page 111 Tiger Explorer XR Series cheh Cylinder head gasket TOP marking Ensure that the cylinder head face is completely clean. Carefully lower the cylinder head over the cylinder head gasket and locate it onto the dowels. CAUTION Using the correct procedure to fit and tighten the cylinder head bolts will ensure the long term reliability of the cylinder head gasket.
Page 112 Tiger Explorer XR Series Note turn' method is used. The bolts must be turned by 90° to reach the final setting. To accurately gauge the 90° turn, use T3880105 - Angular Torque Gauge as follows: Stage C Fit the torque turn gauge between the Torx socket and the drive handle and locate the Torx drive to the head bolt.
Page 113 Tiger Explorer XR Series Valve Removal Once the collets are released, remove the following items: Collets Valve spring retainer Valve spring Valve stem seal Spring platform Valve (de-burr before removal). carr Valve stem seal Note Ensure inlet and exhaust valve components do not become mixed. ccrx Collets Valve spring retainer...
Page 114 Tiger Explorer XR Series Perform the following operations: Remove the cylinder head, see Cylinder Head - Removal. Remove the cylinder head valve springs, see Valves and Valve Stem Seals - Removal from the Cylinder Head. Note Do not remove the valve or valve stem seal. Position the valve so that the valve stem end is level with the valve stem seal (the valve must remain in this position for the duration of the test).
Page 115 Tiger Explorer XR Series ckcb Dial gauge Flat ended contact point Direction valve rocked to valve guide Zero the dial gauge. Gently rock the valve to the opposite side of the valve guide in line with the camshaft and note the reading on the dial gauge.
Page 116: Clutch
Tiger Explorer XR Series Note the valve guide. Greater resistance is felt at this contact point and further gentle pressure is then required to locate the seal over the top end of the valve guide. On application of this pressure, the seal can be felt to positively locate over the top face of the valve guide.
Page 117 Tiger Explorer XR Series Exploded View – Clutch Controls CLUTCH 113 of 746...
Page 118 It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph dealer before riding the motorcycle. Failure to take remedial action may impair clutch operation leading to loss of motorcycle control and an accident.
Page 119 Tiger Explorer XR Series WARNING The clutch switch is an integral part of the cruise control system. To ensure the clutch switch functions correctly after a replacement, the cruise control switch test must be carried out (see Cruise Control Switch Check).
Page 120 Tiger Explorer XR Series Turn the handlebars to bring the fluid reservoir to a level position. Remove the five fixings and remove the slave cylinder cover. Discard the fixings. chhu Slave cylinder cover Fixings Remove the dust cap from the bleed nipple on the slave cylinder. Attach a transparent plastic tube to the bleed nipple.
Page 121 Tiger Explorer XR Series WARNING any period of time. Always check for fluid leakage around hydraulic fittings and for damage to hoses. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
Page 122 Tiger Explorer XR Series chhv Bleed nipple dust cap Bleed nipple Bleed tube Container Note During bleeding, do not allow the fluid level to fall below the lower level mark in the reservoir. If the level is allowed to fall below this mark, air may enter the system and the sequence of bleeding must be repeated.
Page 123 Tiger Explorer XR Series WARNING Always return the lever adjuster to the original setting as noted in step 1. Operating the motorcycle with lever settings which are unfamiliar may lead to loss of control or an accident. Clutch Lever - Pivot Bolt Lubrication WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 124 Tiger Explorer XR Series Handguard (left hand shown) Handlebar end fixing Handguard to bracket fixing Remove the fixing and remove the switch housing for the heated grips and fog lights from the clutch master cylinder clamp. Without disconnecting any wiring, lay the switch housing aside. cis v_1 Fixing Clutch master cylinder clamp...
Page 125 Tiger Explorer XR Series chpz Fixing Clutch switch Release the clamp fixings and remove the clamp and master cylinder. chid_1 Clamp Fixings Clutch Master Cylinder - Disassembly Note Note the order and orientation of each component as it is removed. It is essential for correct clutch operation that each component is installed in the correct order and orientation during reassembly.
Page 126 Tiger Explorer XR Series chhr Dust cover/boot Circlip Pushrod Washer Piston, seal and spring Clutch Master Cylinder - Inspection Check the following for wear, damage, cracks or signs of deterioration and replace as necessary: Cylinder bore and piston Seals Dust cover Spring.
Page 127 Tiger Explorer XR Series Pushrod Washer Piston, seal and spring Clutch Master Cylinder - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Locate the master cylinder to the handlebars and position the clamp with the 'UP' arrow pointing upwards.
Page 128 Tiger Explorer XR Series cis v_1 Fixing Clutch master cylinder clamp Switch housing Position the handlebar end weight, handguard and spacer to the handlebar and secure with new fixings. Tighten the new handguard to bracket fixing to 6 Nm. Tighten the new handlebar end fixing to 5 Nm Handguard Handlebar end fixing Handguard to bracket fixing...
Page 129 Tiger Explorer XR Series Remove the five fixings and remove the slave cylinder cover. Discard the fixings. chhu Slave cylinder cover Fixings Position a suitable container for the collection of brake and clutch fluid. CAUTION To prevent body damage, do not spill clutch fluid onto any area of the bodywork. Release the union bolt from the clutch slave cylinder.
Page 130 Tiger Explorer XR Series WARNING The clutch slave cylinder contains no user serviceable parts and replacement piston and dust seals are not available. If disassembled, never attempt to reassemble the clutch slave cylinder using the original seals as this could cause a fluid leak.
Page 131 Tiger Explorer XR Series Lifter piece Bearing carrier Carefully de‑stake the clutch centre nut. Loosen the locating pins of T3880660 - Clutch Restraint sufficiently to allow them to adjust on the tool’s mounting plate. T3880660 - Clutch Restraint Note When positioning T3880660 - Clutch Restraint to the clutch centre, ensure that the tool’s locating pins are positioned into the openings for the clutch centre ramps.
Page 132 Tiger Explorer XR Series cjih T3880660 - Clutch Restraint Locating pin nuts Hold the service tool to prevent clutch rotation then loosen and remove the centre nut and Belleville washer from the input shaft. Discard the nut and washer. cjih Hold the Service Tool and Loosen the Centre Nut Remove T3880660 - Clutch Restraint.
Page 133 Tiger Explorer XR Series cjik_1 Clutch centre and pressure plate assembly Remove the thrust washer (and shim(s) if fitted) from the input shaft. Slide the clutch outer drum assembly gently backwards and forwards to dislodge the inner bearing sleeve. Carefully remove the bearing sleeve while supporting the clutch drum. chib_2 Outer drum Bearing sleeve...
Page 134 Tiger Explorer XR Series Remove the fixings and lift off the release plate. Collect the springs. Remove the clutch centre. Note The one outermost and two innermost friction plates differ from the six centre plates and must not be fitted in any other positions. The innermost steel plate differs from the seven other steel plates and cannot be fitted in any other position.
Page 135 Tiger Explorer XR Series Clutch friction plate Steel Plate Bend/Warp Check all plates for bend and warp as follows: Place the plate being checked on a clean surface plate and attempt to pass a feeler gauge of the maximum specified thickness between the steel plate and surface plate at several points around the plate. If the feeler gauge can be passed beneath the steel plate at any point, renew the plates as a set.
Page 136 Tiger Explorer XR Series Outer friction plate Friction plates Steel plates, 2.0 mm thickness Inner friction plates Inner steel plate, 2.0 mm thickness Place the assembled clutch pack on a flat surface and measure its height as shown below. T0943_1 Clutch pack height The correct clutch pack height for this clutch assembly is shown in the specification table see Clutch/Primary Drive.
Page 137 Tiger Explorer XR Series Clutch Pack Height Too Low Note No more than one 2.3 mm thick steel plate may be used in the clutch pack. The 2.3 mm steel plate cannot be used to replace the inner most steel plate. Replace one 2.0 mm steel plate with a 2.3 mm steel plate.
Page 138 Tiger Explorer XR Series Clutch centre Anti-judder spring Steel plate Curved edge Outer friction plate Assemble the following to the clutch centre in the same order and orientation as noted for removal: Anti-judder washer Anti-judder spring Outer friction plate 7 x steel plates 6 x friction plates.
Page 139 Tiger Explorer XR Series Pressure plate Inner friction plates Inner steel plate While holding the innermost friction and steel plates in position, invert the pressure plate and locate it onto the clutch centre. cjhx Locating the Pressure Plate Ensure the pressure plate ramps engage correctly with the clutch centre. cjhy Pressure plate ramps Note...
Page 140 Tiger Explorer XR Series Support Clutch centre (underside) Pressure plate Note During the next instruction step, the release plate fixings should be tightened until a small amount of preload is applied to the springs. The amount of preload applied should be sufficient to prevent the clutch centre and pressure plate from separating, while allowing movement/rotation of the friction plates.
Page 141 Tiger Explorer XR Series Note clutch outer drum while it is removed from the motorcycle. This allows alignment of the friction plate outer tabs prior to installation to the motorcycle. With the clutch outer drum assembly removed from the motorcycle, fit the clutch centre and pressure plate assembly to the outer drum assembly.
Page 142 Tiger Explorer XR Series refit the bearing sleeve, shim(s) (if fitted) and thrust washer. chib_2 Outer drum Bearing sleeve Shim (if fitted) Thrust washer Note To align the clutch centre splines with the input shaft splines, It may be necessary to rotate the input shaft.
Page 143 Tiger Explorer XR Series Note When tightening the three release plate fixings, care must be taken to tighten the fixings evenly and progressively. This is to ensure that the chamfered edge on the underside of the release plate is correctly seated into the machined face on the inside edge of the pressure plate fixing towers. Failure to ensure that the release plate is correctly seated will cause the clutch friction plates to release and re-engage at an angle, resulting in severe clutch judder.
Page 144 Tiger Explorer XR Series T3880660 - Clutch Restraint Note When positioning T3880660 - Clutch Restraint to the clutch centre, ensure that the tool’s locating pins are positioned into the openings for the clutch centre ramps. When correctly located, the tool’s mounting plate will sit flush against the clutch centre.
Page 145 Tiger Explorer XR Series cjih Retain the Service Tool and Tighten the Centre Nut Remove T3880660 - Clutch Restraint from the pressure plate. Stake the clutch centre nut to the shaft. Fit the lifter piece and bearing carrier, ensuring they are correctly installed in the release plate. Refit the clutch cover (see Clutch Cover - Installation).
Page 146 Tiger Explorer XR Series Exploded View – Crankcases Crankcases - Disassembly WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. CRANKSHAFT / RODS / PISTONS 142 of 746...
Page 147 Tiger Explorer XR Series CAUTION The upper and lower crankcases are machined as a matched set and must never be assembled to non- matching halves. Doing so may cause seizure of the engine. Remove the engine from the frame (see Engine - Removal). Remove the sump (see Sump - Removal).
Page 148 Tiger Explorer XR Series Lower Crankcase Bolt Release Sequence Separate the lower and upper crankcases ensuring that the three locating dowels remain in the upper crankcase. CAUTION Do not use levers to separate the upper and lower sections of the crankcase or damage to the crankcases could result.
Page 149 Tiger Explorer XR Series chds Locating dowels Apply a thin bead of silicone sealant to the lower crankcase mating faces (at the factory, ThreeBond 1215E is used). chdt Sealer areas CAUTION Do not use excessive amounts of sealer. The extra sealer may become dislodged and could block the oil passages in the crankcases causing severe engine damage.
Page 150 Tiger Explorer XR Series CAUTION Failure to follow the correct screw tightening sequence may result in permanent crankcase damage. Stage 1 - M8 screws only Invert the engine. In the correct sequence, tighten the M8 size lower crankcase screws (numbers 1 to 14) to 14 Nm. Stage 2 - M6 screws only In the correct sequence, tighten the M6 size lower crankcase screws (numbers 15 to 22) to 12 Nm.
Page 151 Tiger Explorer XR Series Stage 3 - M8 screws only Invert the engine. In the correct sequence, tighten the M8 size lower crankcase screws (numbers 1 to 14) to 36 Nm. Stage 4 - M6 screws only In the correct sequence, tighten the M6 size lower crankcase screws (number 15 to 22) to 12 Nm. 14 13 15 6 11 2 Lower Crankcase Bolt Tightening Sequence...
Page 152 Tiger Explorer XR Series Refit the clutch (see Clutch - Installation). Refit the flywheel cover (see Flywheel Cover - Installation). Refit the crankshaft cover (see Crankshaft Cover - Installation). Refit the balancer shaft cover (see Balancer Shaft Cover - Installation). Refit the sump (see Sump - Installation).
Page 153 Tiger Explorer XR Series Note Connecting rod bolts and nuts are treated with an anti-rust solution which must not be removed. Clean the connecting rod with high flash-point solvent. Remove all bearings and inspect for damage, wear and any signs of deterioration and replace as necessary.
Page 154 Tiger Explorer XR Series chdu Big end Connecting rod nuts CAUTION The torque characteristics of the connecting rod nuts and bolts are sensitive to the rate at which they are tightened. If all the torque is applied in one action, the bolt may be stretched and the nut may become loose when in service resulting in an expensive engine failure.
Page 155 Do not turn the connecting rod and crankshaft during the clearance measurement as this will damage the Plastigauge. The crankshaft journal clearances are measured using Plastigauge (Triumph part number 3880150-T0301). Remove the big end cap from the journal to be checked.
Page 156 Tiger Explorer XR Series Connecting Rod Marking Connecting Rod Bore 41.000 41.000 41.009 41.009 Dia. 41.008 41.008 41.018 41.018 Crankshaft Journal Dia. 38.029 38.020 38.029 38.020 38.036 38.028 38.036 38.028 Running Clearance 0.030 0.030 0.031 0.031 0.053 0.054 0.055 0.056 Connecting Rod Bearing Selection Example Connecting Rod Mark Connecting Rod Bore Diameter...
Page 157 Tiger Explorer XR Series Crankshaft - Installation Remove the engine from the frame (see Engine - Removal). Separate the two halves of the crankcase (see Crankcases - Disassembly). Remove the connecting rods (see Connecting Rods - Removal). Remove the camshaft drive chain (see Camshaft Drive Chain, Tensioner Blade and Rubbing Strip - Removal).
Page 158 Tiger Explorer XR Series chdy Big end bearing Lubricate all bearings with clean engine oil. Ensure that the crankshaft is clean, and that the oil ways within the crankshaft are clean and free from blockages and debris. Refit the balancer (see Balancer - Installation). Install the crankshaft ensuring that the crankshaft journals align with the big ends and that the crankshaft and balancer gear markings align as shown in the next illustration.
Page 159 Tiger Explorer XR Series Apply a thin smear of grease to each journal and a small quantity of silicone release agent to each bearing. Trim a length of the Plastigauge to fit across each journal. Fit the strips to each journal using the grease to hold the Plastigauge in place.
Page 160 Tiger Explorer XR Series For example: Crankshaft Journal diameter 37.962 mm Crankcase Bore 41.125 mm Bearing Required Blue Note It is normal for the bearings selected to differ from one journal to another. It is also normal for there to be two options of bearing shell colour. In such cases, pick the shell size which gives the greater running clearance.
Page 161 Tiger Explorer XR Series Note If the gudgeon pin is found to be tight in the piston, check the piston for a witness mark caused by the circlip. Carefully remove the mark to allow the pin to be removed. Remove the gudgeon pin by pushing the pin through the piston and rod toward the side from which the circlip was removed.
Page 162 Tiger Explorer XR Series Always refer to the specifications table (see Pistons). Replace the piston if the measured diameter falls outside the specified limit. Check the pistons for uneven groove wear by visually inspecting the ring grooves. If all the rings do not fit parallel to the groove upper and lower surfaces, the piston must be replaced. Clean the piston ring grooves.
Page 163 Tiger Explorer XR Series ccvj Aligning Piston Rings using the Piston Remove the piston and measure the gap between the ends of the piston ring using feeler gauges. When checking the piston ring end gap, always refer to the specification table (see Pistons). Note If the end gap is too large, replace the piston rings with a new set.
Page 164 Tiger Explorer XR Series chdx Assembly markers Align the small end in the connecting rod with the gudgeon pin hole in the piston. Lubricate the piston, small end and gudgeon pin with clean engine oil and fit the gudgeon pin. Fit new circlips on both sides of the gudgeon pin ensuring the circlips are correctly fitted in the grooves.
Page 165 Tiger Explorer XR Series ched Paint mark Turn the crankshaft until the piston in the liner to be removed is at the bottom of its stroke. chee T3880315 - Extractor, Cylinder Liner Extraction nut Locking nut Check that the locking nut on T3880315 - Extractor, Cylinder Liner is loose, then fully unscrew the extraction nut.
Page 166 Tiger Explorer XR Series Measure the inside diameter of each cylinder liner, 15 mm from the top, using an internal micrometer or similar accurate measuring equipment. 15 mm Test Positions for Bore Wear Check (bore shown in section) When measuring the cylinder liner internal diameter, always refer to the specifications table (see Pistons). If any reading is outside the specified limits, replace the liner and piston as an assembly.
Page 167: Balancer
Tiger Explorer XR Series ccvl Arrowed: Liner-Piston Fitment Note The liners have a large chamfer at the bottom of the bore enabling fitting of the piston without need for a piston ring compressor. CAUTION Fit each liner over whichever piston is at TDC. When turning the engine, do not allow the pistons to contact the inside of the crankcase and also do not allow fitted liners to lift off the crankcase base.
Page 168 Tiger Explorer XR Series Balancer The balancer is fitted to control 'pulsing' within the engine. Without any form of balancer, the engine would 'pulse' each time the crankshaft rotated. This 'pulsing' would be felt as a vibration which would amplify as the engine speed was increased.
Page 169: Transmission
Tiger Explorer XR Series chdq Balancer drive gear markings Crankshaft markings CAUTION If the balancer and crankshaft are not correctly aligned, severe engine vibration will occur leading to damage to components. chhs Circlip (left hand shown) Crankcase circlip groove Pin groove Check that the balancer and crankshaft are correctly aligned before continuing.
Page 170 Tiger Explorer XR Series Exploded View – Flywheel, Sprag Clutch and Starter Gears TRANSMISSION 166 of 746...
Page 171 Tiger Explorer XR Series Exploded View – Gear Selectors and Drum TRANSMISSION 167 of 746...
Page 172 Tiger Explorer XR Series Exploded View – Gear Change Mechanism Description The transmission is of a cassette type design, which allows removal of the complete transmission as an assembly with the front bevel box, without separating the crankcase halves. Removal of the input shaft can be TRANSMISSION 168 of 746...
Page 173 Tiger Explorer XR Series achieved after first removing the output shaft first gear and its bearing. The output shaft is an integral part of the front bevel box assembly and cannot be removed. The front bevel box assembly contains no user serviceable parts, and must be replaced if any wear or damage are found.
Page 174 Tiger Explorer XR Series chmh Pinch bolt Transmission linkage Gear change mechanism Punch mark Note Do not allow the side stand to hang on the harness for the side stand switch. Note the routing of the harness for the side stand switch for installation. Release the fixings, detach the side stand and position aside.
Page 175 Tiger Explorer XR Series Fixings Control plate Remove the upper ball joint from the gear change linkage (left hand thread). Remove the gear change linkage from the lower ball joint (right hand thread). Lock nut, left hand thread Lock nut, right hand thread Machined rings Transmission linkage Upper ball joint...
Page 176 Tiger Explorer XR Series ckbq Gear change shaft Circlip Flat washer Remove the flat washer. ckbn Gear change shaft Flat washer Housing Remove the gear change shaft from the housing and remove the wavy washer. ckbp Shaft Wavy washer Using Castrol Metal Parts Cleaner or an equivalent, thoroughly clean the gear change bushes, shaft and washers and dry using a lint free cloth.
Page 177 Tiger Explorer XR Series ckbo Outer bush Inner bush Housing Inspect all parts for wear and replace as necessary. Refit the wavy washer. ckbp Shaft Wavy washer Fit the shaft into the housing and refit the flat washer as noted during removal. TRANSMISSION 173 of 746...
Page 178 Tiger Explorer XR Series ckbn Shaft Flat washer Housing Compress the components until the circlip groove is visible and then fit the circlip. ckbr Shaft Flat washer Circlip Refit the gear change pedal ensuring the punch mark on the pedal is aligned with the punch mark on the gear change shaft.
Page 179 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. If removed, fit the lock nuts to the gear change linkage. Screw the right hand threaded end of the gear change linkage into the lower ball joint by three complete turns.
Page 180 Tiger Explorer XR Series Fit the side stand and tighten its fixings to 70 Nm. chme Fixings Side stand Tighten the upper fixings for the left hand control plate to 18 Nm. Fit the transmission linkage to the gear change mechanism as noted for removal. Fit the pinch bolt and tighten it to 9 Nm.
Page 181 Tiger Explorer XR Series Punch marks Gear change pedal Pivot Refit the expansion tank cover. Secure the upper mounting with a new M5 encapsulated fixing. Secure the lower mounting with the two original fixings. Tighten the upper fixing to 3 Nm and the lower fixings to 4 Nm. chgw_2 Expansion tank cover Upper fixing (M5)
Page 182 Tiger Explorer XR Series chmh Pinch bolt Transmission linkage Gear change mechanism Punch mark Remove the gear position sensor (see Gear Position Sensor - Removal). Remove the two upper selector cover fixings and detach the starter solenoid and bracket. Position the starter solenoid aside.
Page 183 Tiger Explorer XR Series chfu Selector shaft cover Fixings Copper washer position Collect the washer from the outer end of the selector shaft. CAUTION Take care to ensure that the washer fitted to the inner end of the selector shaft remains in position during removal of the shaft.
Page 184 Tiger Explorer XR Series chmz Washer CAUTION Take care to ensure that the washer remains in position during installation of the shaft. Should the washer become dislodged during installation, it is possible for it to drop in to the transmission housing. Should this happen, it will be necessary to remove the transmission and/or sump to recover the washer.
Page 185 Tiger Explorer XR Series Fit the abutment sleeve between the ends of the abutment spring and install fully in to the transmission casing. Refit the washer to the outer end of the selector shaft. chmu Abutment sleeve Washer Ensure that the two dowels are in position in the selector shaft cover. Check the condition of the selector shaft seal;...
Page 186 Tiger Explorer XR Series Refit the starter solenoid and secure with the two remaining fixings. chjc Starter solenoid Fixings Tighten the four 28 mm fixings to 11 Nm, and the 90 mm fixing to 11 Nm. Fit the transmission linkage to the gear change mechanism as noted for removal. Fit the pinch bolt and tighten it to 9 Nm.
Page 187 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the rider’s seat (see Rider’s Seat - Removal). Disconnect the battery, negative (black) lead first.
Page 188 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the transmission from the engine (see Transmission - Removal). Remove the selector shaft (see Selector Shaft - Removal).
Page 189 Tiger Explorer XR Series CAUTION The selector forks and shafts can be fitted incorrectly. Ensure the position and orientation of the selector forks are marked prior to removal. Incorrect fitting of the selector forks or shafts will cause gearbox damage or incorrect operation.
Page 190 Tiger Explorer XR Series Note Prior to installation, lubricate both ends of each selector shaft, and their locating holes in the transmission housing, with a 50/50 solution of engine oil and molybdenum disulphide grease. Push the input shaft selector shaft into the transmission housing, with the two grooves facing towards the housing, from the input shaft side.
Page 191 Tiger Explorer XR Series Check that the pins on each selector fork face inwards towards each other, as shown below. Selector fork pins If removed, refit the selector drum bearing to the transmission housing. Install the keeper plate and secure with a new fixing.
Page 192 Tiger Explorer XR Series Remove the output shaft needle bearing and thrust washer. chfo Snap ring Needle bearing Thrust washer Remove the output shaft first gear, needle bearing and thrust washer. chfo First gear Needle bearing Thrust washer Withdraw the input shaft assembly from its bearing and remove from the transmission housing. TRANSMISSION 188 of 746...
Page 193 Tiger Explorer XR Series chfn Input Shaft Removal Input Shaft - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Place the input shaft in position in the transmission housing, and insert the shaft fully in to the bearing.
Page 194 Tiger Explorer XR Series Circlip Needle roller bearing Thrust washer First gear Needle roller bearing Thrust washer Fifth gear Circlip Thrust washer Splined bush Fourth gear Lock washer Splined washer Splined bush Third gear Thrust washer Circlip Sixth gear Circlip Thrust washer Second gear Note...
Page 195 Tiger Explorer XR Series chfm Fifth gear Circlip Splined thrust washer Remove fourth gear. Remove the splined bush. Note their orientation and remove the splined lock washers. Note the 'UP' mark on the lower splined lock washer. Fourth gear Splined bush Splined lock washer Slide third gear off the shaft and also remove the splined bush and thrust washer.
Page 196 Tiger Explorer XR Series Splined thrust washer Remove the circlip from in front of sixth gear. Remove sixth gear. chfj Circlip Sixth gear Remove the circlip from in front of second gear. Remove the thrust washer and slide off second gear. chfg Circlip Thrust washer...
Page 197 Tiger Explorer XR Series Note Lubricate each gear and bush with clean engine oil during assembly. Examine all gears, bearings and sleeves for damage, chipped teeth and wear beyond the service limits. Replace all suspect components and always use new circlips to assemble the shaft. The splined thrust washer fitted next to second gear is different to the two other splined thrust washers fitted elsewhere on the output shaft.
Page 198 Tiger Explorer XR Series chfj_1 Sixth gear Circlip Fit the splined thrust washer. Fit the splined bush for third gear, ensuring that the oil hole in the shaft DOES NOT align with the hole in the bush. Fit third gear to the shaft with the dog slots facing towards the bevel box. chfk_1 Thrust washer Splined bush...
Page 199 Tiger Explorer XR Series Fit the thrust washer and retain with a new circlip. Fit fifth gear. chfm_1 Thrust washer Circlip Fifth gear Refit the input shaft (see Input Shaft - Installation). Bevel Box Damper Shaft Oil Seal - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 200 Tiger Explorer XR Series chii Oil feed O-ring Front cover O-ring Withdraw the damper shaft from the bevel box. chig Damper shaft Drift out the oil seal. chij TRANSMISSION 196 of 746...
Page 201 Tiger Explorer XR Series Oil seal Thoroughly clean the seal housing. Flywheel, Starter Drive Gears and Sprag Clutch - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Protect the front cover mating face of the bevel box against damage and place it in a press.
Page 202 Tiger Explorer XR Series chik Damper shaft splines and groove Seal running area Refit the damper shaft to the bevel box, taking care not to damage the oil seal. Remove the protective tape from the damper shaft splines. Fit a new O-ring to the oil feed. Fit a new O-ring to the front cover.
Page 203 Tiger Explorer XR Series chgh Idler shaft Idler gear Withdraw the starter motor torque limiter from the crankcase, collecting the washers from each end of the shaft as you do so. chgg Starter motor torque limiter Flat washers (outer shown) Assemble T3880608 - Flywheel Pin Set (flywheel pin set) to T3880606 - Flywheel Restraint (flywheel restraint), ensuring the shorter pin is fitted to the short arm of T3880606 - Flywheel Restraint.
Page 204 Tiger Explorer XR Series and remove the flywheel fixing and washer from the end of the crankshaft. chgj T3880606 - Flywheel Restraint T3880608 - Flywheel Pin Set Flywheel fixing Locate the spigot from the larger of the two thrust pads supplied with T3880365 - Alternator/Flywheel Rotor Puller to the crankshaft.
Page 205 Tiger Explorer XR Series chfr Flywheel T3880365 - Alternator/Flywheel Rotor Puller Withdraw the flywheel and tool as an assembly and then separate the tool from the flywheel. Collect the Woodruff Key and the tool thrust pad from the crankshaft. Remove the starter gear from the flywheel. Remove the sprag retaining clip and remove the sprag clutch.
Page 206: Lubrication
Tiger Explorer XR Series Check that the two flat washers are fitted to the starter motor torque limiter, one at each end. Refit the starter motor torque limiter, engaging the gear teeth to the starter motor shaft. Lubricate the idler gear shaft. Fit the small idler gear and shaft to the crankcase.
Page 207 Tiger Explorer XR Series 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 and the heat exchanger. Pressurised oil is delivered to the heat exchanger near to where the oil pressure relief valve is fitted.
Page 208 JASO MA, such as Castrol Power 1 Racing 4T, sold as Castrol Power RS Racing 4T in some countries. Triumph recommends the fully synthetic 10W/40 motorcycle engine oil for most conditions. The oil viscosity may need to be changed to accommodate the ambient temperatures in your riding area.
Page 209 Ensure no foreign matter enters the crankcase during an oil change or top up. Triumph Engine Oil Your Triumph motorcycle is a quality engineered product which has been carefully built and tested to exacting standards. Triumph Motorcycles are keen to ensure that you enjoy optimum performance from your motorcycle and with this objective in mind have tested many of the engine lubricants currently available to the limits of their performance.
Page 210 Tiger Explorer XR Series chgz Sight glass Filler plug Oil level (correct level shown) Crankcase oil level lines Note An accurate indication of the level of oil in the engine is only shown when the engine is at normal operating temperature and the motorcycle is upright (not on the side stand). Start the engine and run at idle for approximately five minutes.
Page 211 Tiger Explorer XR Series chgy Oil drain plug Oil filter Unscrew and remove the oil filter using T3880313 - Oil Filter Wrench. Dispose of the old oil filter in an environmentally friendly way. Pre-fill a new oil filter with clean engine oil. Apply a smear of clean engine oil to the sealing ring of the new oil filter.
Page 212 Tiger Explorer XR Series chhc Low oil pressure warning light switch Low Oil Pressure Warning Light Switch - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Incorporating a new copper washer, fit the switch and tighten to 13 Nm.
Page 213 Tiger Explorer XR Series Disconnect the battery, negative (black) lead first. Drain the coolant (see Coolant Replacement). Remove the clutch (see Clutch - Removal). Remove the sump (see Sump - Removal). Remove the oil pick-up and seal. chhg Oil pick-up Seal Release and discard the two fixings and remove the oil feed pipe.
Page 214 Tiger Explorer XR Series chhi Oil pump drive sprocket Needle roller bearing Detach the drive chain from the oil pump. Release the three oil pump fixings. chhe Oil pump Fixings Using a suitable tool, slide the dowel upwards to release the oil pump from the crankcase. It is not necessary to remove the dowel completely from the oil pump.
Page 215 Tiger Explorer XR Series Detach the oil pump from the coolant inlet and outlet tubes. Carefully withdraw the oil pump from the crankcase. Oil Pump - Inspection Prevent the oil pump sprocket from turning using T3880603 - Oil Pump Restraint and remove the centre fixing.
Page 216 Tiger Explorer XR Series chhk Oil pump rotor housing Fixings CAUTION If any part of the oil pump is found to be outside the service limit, the complete pump must be replaced. Severe engine damage may result from the continued use of a faulty oil pump. Measure the rotor tip clearance using feeler gauges.
Page 217 Tiger Explorer XR Series chhp Pump Body Clearance For specifications refer toLubrication. Measure the pump end clearance. If any clearance measured is outside the service limits, renew the complete pump. For specifications refer toLubrication. If all clearances are within service limits, liberally apply clean engine oil to all internal components. Refit the oil pump rotor housing to the oil pump body and secure with new fixings.
Page 218 Tiger Explorer XR Series CAUTION Do not use excessive force to insert the dowel into the crankcase. Severe dowel or crankcase damage may result from the use of excessive force. Using a suitable pin punch, gently tap the dowel downwards into the crankcase until it seats. Secure the oil pump with new bolts.
Page 219 Tiger Explorer XR Series Refit the sump, ensuring the water pump drain tube is correctly installed (see Sump - Installation). Refill the engine with oil (see Oil and Oil Filter Change). Refill the cooling system (see Coolant Replacement). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation).
Page 220 Tiger Explorer XR Series Refit the sump, ensuring the water pump drain tube is correctly installed (see Sump - Installation). Refill the engine with oil (see Oil and Oil Filter Change). Reconnect the battery, positive (red) lead first. Start the engine and check for oil leaks. Once a leak check has been made, stop the engine and allow to stand for 10 minutes.
Page 221 Tiger Explorer XR Series Rear brake line Bracket Crankcase tidy Fixing Disconnect all electrical connections to the engine, noting the connection locations and the position of cable ties securing the harnesses in position. Place a support beneath the engine and ensure that the frame is still adequately and securely supported. Note The washers and a spacer are only fitted to the right hand side of the frame.
Page 222 Tiger Explorer XR Series CAUTION To prevent damage to components, lower the engine very carefully. Temporarily refit the mounting bolts to the front mountings of the cylinder head and frame. Note If fitted, note the routing of the evaporative canister hoses for installation. Carefully partially lower the rear of the engine to gain access to the rear cable tidy on the crankcase.
Page 223 Tiger Explorer XR Series Detach the oxygen sensor harness from the cable tidy. Oxygen sensor harness Blue tape Support the engine and remove the front mounting bolts for the cylinder head. Discard the mounting bolts. Note Note the routing of the clutch hose for installation. Lower the engine while feeding the clutch hose around the frame and remove the engine.
Page 224 Tiger Explorer XR Series Cable tidy Flanged sleeves Fit the oxygen sensor harness to the cable tidy. Ensure that the blue tape on the oxygen sensor harness is positioned as noted for removal. Note When fitting the cable tidy, ensure its left hand mounting is aligned correctly to its threaded hole for the brake line clip.
Page 225 Tiger Explorer XR Series T1053 T3880062 - Lock Ring Wrench, 38 mm Locking ring Loosen the right hand pivot pin but do not fully remove. Note If fitted, ensure that the evaporative canister hoses are routed as noted for removal while raising the rear of the engine.
Page 226 Tiger Explorer XR Series Left hand front cylinder head bolt Left hand rear cylinder head bolt Right hand front cylinder head bolt Right hand rear cylinder head bolt Upper crankcase bolt Lower crankcase bolt Note The T3880637 - Kit, Engine to Frame Alignment Bars is required to correctly align the engine to the frame for the following tightening sequence.
Page 227 Tiger Explorer XR Series Crankcase alignment bar Frame to crankcase mounting (lower mounting shown - left hand side of frame) Crankcase adjuster (lower mounting shown - right hand side of frame) Remove the right hand front cylinder head bolt that was temporarily fitted earlier in this procedure. Insert the cylinder head alignment bar into the left hand side of the right hand front cylinder head mounting point.
Page 228 Tiger Explorer XR Series Fit the left hand rear cylinder head bolt. Do not fully tighten at this stage. Fit a new lock nut to the left hand front cylinder head bolt and tighten to 24 Nm. Tighten the left hand rear cylinder head bolt to 85 Nm. Note If, after tightening each adjuster and frame fixing, any of the engine to frame alignment bars and frame fixings cannot be removed and inserted freely, check that the engine is still adequately...
Page 229 Tiger Explorer XR Series Lower crankcase mounting bolt Bolt, M8 x 33 mm Spacer, 13 mm Ensure that the radiator mounting bracket is located between the upper mounting for the engine protection bar and the engine as noted for removal. Fit an M8 x 25 mm bolt, do not fully tighten at this stage. Radiator mounting bracket Bolt, M8 x 25 mm Hold the lower crankcase mounting bolt to prevent rotation and tighten its locknut to 100 Nm.
Page 230: Fuel System/Engine Management
Tiger Explorer XR Series Swinging arm pivot pin Locking ring Pivot pin alignment mark Frame alignment mark Note If the pivot pin and frame markings do not align after final tightening of the locking ring, loosen the locking ring and right hand pivot pin and repeat steps 30 to 34 of this procedure. Using T3880062 - Lock Ring Wrench, 38 mm, tighten the locking ring to 110 Nm.
Page 231 Tiger Explorer XR Series FUEL SYSTEM / ENGINE MANAGEMENT 227 of 746...
Page 232 Tiger Explorer XR Series Exploded View – Airbox FUEL SYSTEM / ENGINE MANAGEMENT 228 of 746...
Page 233 Tiger Explorer XR Series Exploded View – Exhaust System Exploded View – Evaporative System FUEL SYSTEM / ENGINE MANAGEMENT 229 of 746...
Page 234 Tiger Explorer XR Series Exploded View – Secondary Air Injection FUEL SYSTEM / ENGINE MANAGEMENT 230 of 746...
Page 235 Tiger Explorer XR Series Fuel Requirements Fuel Requirements - all countries except USA This model must be run on 91 RON or higher unleaded fuel. Fuel Requirements - USA In the United States of America where the octane rating of fuel is measured in a different way, the following information may be applied: This model is designed to run on unleaded gasoline with a CLC or AKI octane rating (R+M)/2 of 87 or higher.
Page 236 'ethanol enhanced', or 'contains ethanol'. This fuel may be used in Triumph motorcycles. Methanol CAUTION Fuels containing methanol should not be used in Triumph motorcycles as damage to components in the fuel system can be caused by contact with methanol. MTBE (Methyl Tertiary Butyl Ether) The use of gasolines containing up to 15% MTBE (Methyl Tertiary Butyl Ether) is permitted in Triumph motorcycles.
Page 237 Tiger Explorer XR Series the exhaust gases. Chassis ECM Chassis Electronic Control Module. Closed throttle position Throttle position at idle (i.e. against end stop), measured as a Voltage and expressed as a percentage. Coolant temperature The coolant temperature in the cylinder head. Coolant temperature sensor Sensor which detects coolant temperature.
Page 238 Tiger Explorer XR Series Inertial Measurement Unit. Injector pulse time The time during which an injector remains open (i.e. delivering fuel). Intake air temperature The air temperature in the airbox and intake system. MAP sensor Manifold absolute pressure (the air pressure in the intake system). Malfunction Indicator Light.
Page 239 ECM memory. This stored data can then be recovered using a special service tool which is mandatory for all Triumph dealers. In this way, precise diagnosis of a fault can be made and the fault quickly rectified.
Page 240 IMU is constantly monitored by the optimised cornering traction control system, optimised cornering ABS and Triumph Semi Active Suspension (TSAS). The IMU also provides fall detection. Power to the ignition and fuel delivery systems is cut if the IMU detects that the motorcycle is on its side. This prevents the engine from running and the fuel pump from delivering fuel.
Page 241 Tiger Explorer XR Series Engine Management System Actuators Engine Management System Actuator Locations Immobiliser System In response to signals received from the sensors, the engine ECM controls and directs messages to a series of electronic and electro-mechanical actuators. The function and location of the actuators is given below. Throttle actuator motor - situated at the left end of the throttle bodies.
Page 242 ECM and the ignition key which contains a transponder chip. If all the components are correctly paired, the immobiliser will allow the engine to start. The Triumph diagnostic tool is the only way these components can be paired.
Page 243 When the motorcycle is delivered from the factory it is supplied with two keys. Keys can be deleted or added to the immobiliser system using the Triumph diagnostic tool. A maximum of four keys can be added to the system.
Page 244 Use of the TPMS system to set inflation pressures may lead to incorrect tyre pressures leading to loss of motorcycle control and an accident. When fitting the TPMS, the installation flow-chart detailed in the Triumph Diagnostic Tool User Guide must be followed.
Page 245 Tiger Explorer XR Series Key to Engine Management Circuit Diagram Item Description Engine Control Module Manifold Absolute Pressure Sensor Ambient Air Pressure Sensor Gear Position Sensor Throttle Position Sensor Accelerator Position Sensor Diagnostic Connector Fuel Level Sender FUEL SYSTEM / ENGINE MANAGEMENT 241 of 746...
Page 246 Tiger Explorer XR Series Item Description Intake Air Temperature Sensor Clutch Switch Side Stand Switch Throttle Actuator Motor Crankshaft Position Sensor Cooling Fan Fuel Pump Chassis ECM Oxygen Sensor Secondary Air Injection Solenoid Engine Sub Harness Coolant Temperature Sensor Injector 1 Injector 3 Injector 2 Purge Valve...
Page 247 Tiger Explorer XR Series Code Wiring Colour Blue Brown Green Slate/Grey Orange Pink Purple White Yellow Light Green Light Blue Engine Management Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 243 of 746...
Page 248 The tables indicate which tests are performed by the on-board system and what information can be retrieved by the Triumph diagnostic software. Note Full details of how to operate the software can be found in the Triumph Diagnostic Tool User Guide, which can be downloaded by authorised Triumph dealers from www.triumphonline.net. Build Data...
Page 249 Tiger Explorer XR Series Calculated load value Engine coolant temperature °C Short term fuel trim Intake manifold absolute pressure mmHg Engine speed Vehicle speed km/h Ignition timing advance degrees Intake air temperature °C Absolute throttle position Oxygen sensor Volts Sensor Data When using this function it is possible to check the status of various sensors and actuators.
Page 250 Tiger Explorer XR Series Throttle position sensor 1 Voltage Volts Throttle position sensor 2 Voltage Volts Twist grip position sensor 1 Voltage Volts Twist grip position sensor 2 Voltage Volts Sensor Readings The data available under Sensor Readings is: Item Checked Result Unit Air temperature °C...
Page 251 Tiger Explorer XR Series Ignition timing cyl 3 degrees BTDC Coil 1 dwell time milliseconds Coil 2 dwell time milliseconds Coil 3 dwell time milliseconds Idle Speed and Throttle Data The data available under Idle Speed and Throttle Data is: Item Checked Result Unit Engine speed...
Page 252 Tiger Explorer XR Series Brake switch 1 status on/off Brake switch 2 status on/off Cruise control accelerate switch status on/off Cruise control deccelerate switch status on/off Cruise control ON/OFF switch status on/off Twist grip cruise control cancel switch status on/off Cruise control status on/off Outputs...
Page 253 Operate the cruise control switches as instructed. Observe the relevant switch response and rectify as necessary * If a fault is detected. Adjust Tune Using the Triumph diagnostic software, it is possible to: Reset the adaptions Balance the throttle bodies. To reset the adaptions, see Engine Management Adaption.
Page 254 Tiger Explorer XR Series Coolant temperature °C Short term fuel trim Intake manifold absolute pressure mmHg Engine speed Vehicle speed km/h Ignition advance degrees Intake air temperature °C Throttle position Oxygen sensor output Voltage Volts Oxygen sensor short term fuel trim The cruise control switch check is required after certain DTCs or defects have been repaired which relate to the ride by wire system or cruise control system, or after the adaptions have been reset.
Page 255 ECM using Triumph diagnostic software. Full details of the Triumph diagnostic software operation and how to interpret the results are given in the Triumph Diagnostic Tool User Guide. The software is connected, via an interface cable, to the motorcycle using a dedicated diagnostic plug situated beneath the seat.
Page 256 Tiger Explorer XR Series Diagnostic Trouble Codes To connect the Triumph diagnostic interface to the motorcycle, remove the rider’s seat (see Rider’s Seat - Removal) and release the diagnostic connector from its locating tang. cjlb Diagnostic connector Plug the Triumph diagnostic interface directly into the diagnostic connector.
Page 257 Tiger Explorer XR Series Code cycles fault when fault (DTC) before cycles is logged turning off before DTC is erased P0030 Oxygen sensor 1 Oxygen Sensor heater open circuit or short to ground P0032 Oxygen sensor 1 Oxygen Sensor heater short circuit to vBatt P0105 Manifold...
Page 258 Tiger Explorer XR Series P0122 Throttle position Throttle Position Sensors 1 and 2 sensor 1 short circuit to ground or open circuit P0130 Oxygen sensor 1 Oxygen Sensor open circuit or short circuit to vBatt P0131 Oxygen sensor 1 Oxygen Sensor short circuit to ground P0201...
Page 259 Tiger Explorer XR Series P0443 Purge valve Purge Valve short circuit to ground or open circuit P0459 Purge valve Purge Valve short circuit to vBatt P0460 Fuel level sensor Fuel Level Sensor Circuit circuit Malfunction malfunction P0500 Vehicle speed Vehicle Speed Sensor sensor malfunction P0510...
Page 260 Cruise Control Disabled Until disabled until Button Press Sequence Completed button press sequence completed P1604 ECM tamper Engine ECM Tamper Detected detected - return to Triumph P1605 ECM locked by Only if Flashing Tune Lock the tune lock tune lock function unlocked...
Page 261 Tiger Explorer XR Series P1650 CAN fault - lost Chassis ECM Communication communication Error/Malfunction with Immobiliser P1659 Ignition power EMS Ignition Voltage Input Circuit supply malfunction P1685 Main relay circuit EMS Main Relay Circuit malfunction P1690 CAN Fault CAN Communication P1695 CAN fault - lost Instrument Communication (CAN)
Page 262 Tiger Explorer XR Series P2102 Throttle actuator Throttle Valve Drive Error control internal motor relay does not operate P2103 Throttle actuator Throttle Valve Drive Error control internal motor relay operates continually P2111 Throttle valve Throttle Valve Drive Error drive error (stuck open) P2119 Throttle valve...
Page 263 Tiger Explorer XR Series sensor supply P2228 Ambient air Ambient Air Pressure Sensor pressure sensor circuit short circuit to ground Electrical Connectors Before beginning any diagnosis, the following connector related information should be noted: Note A major cause of hidden electrical faults can be traced to faulty electrical connectors. For example: Dirty/corroded terminals Damp terminals For example, the engine electronic control module (engine ECM) relies on the supply of accurate information to...
Page 264 Tiger Explorer XR Series Turn the ignition to the OFF position and wait at least 1 minute for the engine ECM to complete its power down sequence. Detach the engine ECM from it’s location under the front seat support (see Engine Electronic Control Module (ECM) - Removal).
Page 265 Tiger Explorer XR Series Connector B (large) Connector A (small) Refit the engine ECM (see Engine Electronic Control Module (ECM) - Installation). Further Diagnosis The tables that follow will, if used correctly, help to pinpoint a fault in the system once a diagnostic trouble code has been stored.
Page 266 Tiger Explorer XR Series Test Result Action and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fuel Injectors Fault Code Possible Cause Action P0201/02/03 Injector 1/2/3 circuit malfunction View and note diagnostic tool 'freeze frame' data if available...
Page 267 Renew relevant injector, proceed to test Reconnect harness, clear fault code and Action complete - quit test run engine to verify fault cleared Fault still Contact Triumph service present Circuit Diagram Throttle Position Sensors 1 and 2 Fault Code Possible Cause...
Page 268 - Engine ECM pin B19 to sensor pin 5 to test 5 - Engine ECM pin B33 to sensor pin 2 Check cable for short circuit: Contact Triumph service - Engine ECM pin B33 to Engine ECM pin B20 Short circuit...
Page 269 Tiger Explorer XR Series Twist Grip Position Sensor 1 Twist Grip Position Sensor 2 Fault Code Possible Cause Action P2120 Twist grip position sensor 1 short View and note diagnostic tool circuit to ground or open circuit 'freeze frame' data if available View and note diagnostic tool 'sensor' data Ensure accelerator position...
Page 270 Tiger Explorer XR Series Test Result Action and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fault Code Possible Cause Action P2125 Twist grip position sensor 2 short View and note diagnostic tool circuit to ground or open circuit...
Page 271 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Twist Grip Position Sensor 1 Correlation Error with Twist Grip Position 2 Fault Code Possible Cause...
Page 272 Rectify fault, proceed to test 3 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Throttle Actuator Motor Circuit Fault Code Possible Cause Action...
Page 273 View and note 'sensor' data. P2119 Throttle valve drive error Check throttle body for mechanical malfunctions. Clear fault code and contact Triumph service if fault is still present. P2102 Throttle actuator control internal motor relay does not operate P2103 Throttle actuator control internal...
Page 274 Renew purge valve, proceed to test 7 Reconnect harness, clear fault code Action complete - quit test and run diagnostic tool function test to visually verify operation of purge valve Fault Contact Triumph service Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 270 of 746...
Page 275: Check Cable And Terminal Integrity: Ok
Tiger Explorer XR Series Gear Position Sensor Fault Code Possible Cause Action P0914 Gear position sensor short circuit View and note 'freeze frame' data if to ground or open circuit available View and note 'sensor' data Ensure gear position sensor connector is secure Disconnect Engine ECM and proceed to pinpoint test 1:...
Page 276: Faulty
- Engine ECM pin B23 to Engine ECM pin to test 5 Reconnect harness, clear fault code and run Action complete - quit test engine Fault still Contact Triumph service present Circuit Diagram Ignition Coils Fault Code Possible Cause Action...
Page 277: Check Cable Continuity: Ok
Renew relevant ignition coil, proceed to test 7 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 273 of 746...
Page 278: Action
Tiger Explorer XR Series Coolant Temperature Sensor Inlet Air Temperature Sensor System Voltage Fault Code Possible Cause Action P0115 Engine coolant temperature View and note diagnostic tool sensor open circuit or short circuit 'freeze frame' data if available to 5 Volt sensor supply View and note diagnostic tool 'sensor' data Ensure sensor connector is...
Page 279 Tiger Explorer XR Series Circuit Diagram Resistance data under typical conditions: Warm engine: 200 to 400Ω Cold engine: 20°C ambient 2.22 to 2.71 KΩ -10°C ambient 8.50 to 10.25 KΩ Oxygen Sensor Fault Code Possible Cause Action P0110 Intake air temperature sensor View and note diagnostic tool open circuit or short circuit to 5 'freeze frame' data if available...
Page 280 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service 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 400 Ohms...
Page 281 3 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Cornering Traction Control and Roll-over Detection Disabled Vehicle Speed Sensor Fault Code...
Page 282 Locate and rectify wiring fault, proceed to test 5 pin B02 Reconnect harness, clear fault code Action complete - quit test and run engine. Check adaption status Fault still present Contact Triumph service Circuit Diagram CAN Communication Fault Code Possible Cause Action P1136...
Page 283 Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 279 of 746...
Page 284 Tiger Explorer XR Series Instrument Communication (CAN) Fault Code Possible Cause Action P0500 Vehicle speed sensor malfunction Refer to the following ABS diagnostic trouble codes C1611 (see Front Wheel Sensor Open Circuit/Short Circuit) C1612 (see Front Wheel Sensor Incorrect or Missing Signal) C1613 (see Rear Wheel Sensor Open Circuit/Short Circuit) C1614 (see Rear Wheel Sensor...
Page 285 Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram Ambient Air Pressure Sensor FUEL SYSTEM / ENGINE MANAGEMENT 281 of 746...
Page 286 Short circuit Locate and rectify wiring fault, proceed to test 6 Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 282 of 746...
Page 287 Locate and rectify wiring fault, proceed - Ground to sensor pin 2 to test 4 Reconnect harness, clear fault code Action complete - quit test Fault still present Contact Triumph service Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 283 of 746...
Page 288 - Engine ECM pin B41 to sensor pin 2 to test 4 Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 284 of 746...
Page 289 - ECM pin B36 to MAP sensor pin 2 to test 4 Reconnect harness, clear fault code and run Action complete - quit test engine. Fault still Contact Triumph service present Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 285 of 746...
Page 290 Tiger Explorer XR Series Fault Code Possible Cause Action P044F Secondary air injection short View and note diagnostic software circuit to Vbatt 'freeze- frame' data if available. Ensure secondary air solenoid connector is secure P0412 Secondary air injection short Disconnect Engine ECM and circuit to ground or open circuit proceed to pinpoint test 1: Pinpoint Tests...
Page 291 Reconnect harness, clear fault code Action complete - quit test and run diagnostic tool function test to visually verify operation of SAI valve Fault still present Contact Triumph service Circuit Diagram EMS Main Relay Circuit EEPROM Error Fault Code Possible Cause...
Page 292 Action complete - quit test Switch ignition off for longer than 90 seconds. Switch ignition on and check that the EMS Main Relay operates. Fault still present Contact Triumph service Start engine as final check Circuit Diagram Fault Code Possible cause...
Page 293 'RUN' position and any alarm fitted must be disarmed Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 289 of 746...
Page 294 Reconnect harness, clear fault code Action complete - quit test and use service tool to check for correct sensor outputs and 5 V sensor Fault still present Contact Triumph service supply Voltage level Circuit Diagram FUEL SYSTEM / ENGINE MANAGEMENT 290 of 746...
Page 295 Tiger Explorer XR Series Inertial Measurement Unit (IMU) Incompatible Fault Code Possible Cause Action P16A0 Engine ECM detects Inertial Proceed to pinpoint test 1: Measurement Unit (IMU) present but ID incompatible Pinpoint Tests Inertial Measurement Unit (IMU) Circuit Malfunction Fault Code Possible Cause Action P16A1...
Page 296 Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code Action complete - quit test and run engine. Fault still present Contact Triumph service Circuit Diagram Chassis ECM Communication Error/Malfunction Fault Code Possible Cause Action P16A3...
Page 297 Short circuit Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code Action complete - quit test and run engine. Fault still present Contact Triumph service Circuit Diagram Tune Lock Fault Code Possible cause Action P1605...
Page 298 Pinpoint Tests Test Result Action Follow the Pair ECM and Immobiliser Action complete - quit test procedure as described in the Triumph Diagnostic Tool user guide Fault still present Contact Triumph service ABS Modulator ID Incompatible Fault Code Possible cause...
Page 299 Incorrect Update calibration using service tool, proceed to test 3 Clear fault code, check for normal operation. Action complete - quit test Fault still Contact Triumph service present ABS Modulator Communication Fault Code Possible Cause Action P1521 CAN fault - lost communication...
Page 300 - ABS fuse box to ABS modulator pin - Main fuse box to ABS modulator pin Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram Brake Switches Fault Code Possible Cause Action...
Page 301 Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram Twist Grip – Cruise Cancel Switch Fault Code Possible Cause Action...
Page 302 8 to 8 way connector pin Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram Cruise Control Prevented Due to Other Malfunction FUEL SYSTEM / ENGINE MANAGEMENT 298 of 746...
Page 303 P1135 Traction Control prevented due to Check that there is no other DTC linked to malfunction the ABS system or CAN communication stored. Contact Triumph service. Engine ECM Internal Error Fault Code Possible cause Action P0606 Engine ECM internal error Contact Triumph service.
Page 304 Tiger Explorer XR Series Symptom Possible Cause(s) Low fuel pressure Weak mixture caused by air leak at the throttle body/transition piece to cylinder head face Idle speed too low/high Incorrect closed throttle position setting Mechanical fault with the throttle linkage Diagnostic software malfunctions during tune Low battery Voltage download procedure...
Page 305 Tiger Explorer XR Series Remove the seat infill panels (see Seat Infill Panel - Removal). Note Due to the shape of the fuel tank, a small amount of fuel may remain in the fuel tank after draining. Note the routing of the fuel tank's drain hose for installation. Detach the fuel drain hose from its retaining clips on the seat bridge and gently pull out the drain hose.
Page 306 Tiger Explorer XR Series chjy Fixing, left hand shown Raise the rear of the fuel tank to access the fuel lines and electrical connectors to the fuel pump. Note Before disconnection, note that the right hand breather hose has a larger diameter than the left hand hose.
Page 307 Tiger Explorer XR Series chpm Fuel pump connection Fuel gauge connection WARNING If the fuel rail is dismantled without first reducing pressure, fuel may escape causing clothing and components to be coated with fuel. This would represent a serious fire hazard which could lead to burn injuries and damage to property. Note Because fuel stored in the fuel rail will be at 3.5 bar pressure, it is essential that the fuel pressure is reduced before any dismantling of the fuel rail takes place.
Page 308 Tiger Explorer XR Series the fuel transfer pipe. Ensure there is enough space to move the clip off the spigot. chpn T3880630 - Fuel Hose Clamp Clip Fuel transfer pipe Release the clip and detach the transfer pipe from the spigot. At the same time fit a cap, from T3880631 - Blanking Cap, to the fuel tank spigot.
Page 309 Tiger Explorer XR Series Raise the rear of the fuel tank and carefully slide the fuel tank rearwards to release its front mountings. Place the fuel tank onto a clean flat surface ensuring that the spigots and their caps do not make contact with the flat surface.
Page 310 Tiger Explorer XR Series therefore be refitted correctly. Remove the covering used to cover the components under the rear of the fuel tank. Lower the rear of the fuel tank onto the frame, fit the two fixings and tighten to 12 Nm. Check to ensure that the latch on the connector to the fuel pump is in the locked position.
Page 311 Tiger Explorer XR Series chjw Fuel pump Fuel pump spigot Mounting plate Mounting plate fixings Lift the fuel pump and filter assembly and manoeuvre it from the fuel tank aperture. Disconnect the fuel level sensor electrical connector and remove the fuel pump and filter assembly. cegz Fuel level sensor electrical connector Noting its orientation, remove and discard the sealing ring from the fuel pump assembly.
Page 312 Tiger Explorer XR Series ccxh Fuel pump and filter assembly Sealing ring location Fuel Pump and Filter Assembly - Installation Install a new sealing ring into the fuel pump assembly, with the seal lip facing uppermost, and ensure that it is correctly seated.
Page 313 Tiger Explorer XR Series Tighten the fixings in the sequence shown below to 9 Nm. chjw_2 Pump Mounting Plate Tightening Sequence Refit the fuel tank (see Fuel Tank - Installation). Reconnect the battery, positive (red) lead first. Start the engine and check carefully for fuel leaks. Rectify as necessary. Refit the rider's seat (see Rider’s Seat - Installation).
Page 314 Tiger Explorer XR Series ccsw Invert the assembly and allow the float unit to slide free. Discard the old float unit. Insert the new float unit in the orientation shown below ensuring the magnet cover on the face of the unit faces towards the bottom of the support tube.
Page 315 Tiger Explorer XR Series Align the lower lug first to the bracket then the upper lug. Ensure that the locking device is fully engaged to the bracket and is secure. chjv Level sender Bracket, inside fuel tank Locking device Upper lug Lower lugs Refit the fuel pump and filter assembly (see Fuel Pump and Filter Assembly - Installation).
Page 316 Tiger Explorer XR Series T3880001 - Fuel Pressure Gauge Remove the fuel tank (see Fuel Tank - Removal) and place on a suitable support, close to the motorcycle. Using T3880123 - Extension Cable, carefully connect the fuel pump connection on the main harness to the fuel tank.
Page 317 Tiger Explorer XR Series chpl_1 Motorcycle fuel hose Adaptor hose 'B' Fuel pump connection T3880123 - Extension Cable Fuel pump connection Fuel pump plate outlet Note To release the fuel pressure gauge from the adapter, slide the outer ferrule downwards. This will allow the gauge to spring upwards from the adapter.
Page 318 Tiger Explorer XR Series Direction of Fuel Flow WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the rider’s seat (see Rider’s Seat - Removal). Disconnect the battery, negative (black) lead first.
Page 319 Tiger Explorer XR Series Hose Breather drain hose Remove the MAP sensor (see Manifold Absolute Pressure (MAP) Sensor - Removal). Remove the rear fixings of the airbox. chjh Fixings Gently lift the rear of the airbox to release it from the throttle bodies. Detach the air intake duct from the frame and slide the airbox rearwards to release it from its front mounting for complete removal.
Page 320 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Position the airbox to its forward mounting and push home. Refit the air intake duct to the frame.
Page 321 Tiger Explorer XR Series Multiplug Air temperature sensor Release the ten fixings and remove the airbox upper section. Fixings Airbox upper section Note Note the orientation of the air filter for installation. Lift the air filter out of the airbox lower section. Airbox lower section Air filter element Air Filter Element - Installation...
Page 322 Refit the rider's seat (see Rider’s Seat - Installation). Note If a new Engine ECM is fitted it will need to be paired with the Chassis ECM as described in the Safety/Security section of the Triumph diagnostic software. Intake Air Temperature Sensor - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 323 Tiger Explorer XR Series Remove the fuel tank (see Fuel Tank - Removal). Disconnect the multiplug from the air temperature sensor. chkb Multiplug Fixing Air temperature sensor Release the fixing and remove the sensor from the airbox. Intake Air Temperature Sensor - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 324 Tiger Explorer XR Series chkd Multiplug Air hose MAP sensor Fixing Manifold Absolute Pressure (MAP) Sensor - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Refit the air hose.
Page 325 Tiger Explorer XR Series cjib Ambient air pressure sensor Multiplug Fixing Ambient Air Pressure Sensor - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Fit the sensor and tighten its fixing to 1.5 Nm.
Page 326 Tiger Explorer XR Series From the top of the motorcycle, follow the route of the hose to the roll over until near the top of the crankcase tidy. Then gently push the hose towards the rear of the motorcycle to release the roll over valve from the crankcase tidy.
Page 327 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. CAUTION The roll over valve must be fitted in the correct orientation. An inverted roll over valve will prevent the fuel tank from breathing causing engine running problems and possible fuel tank damage.
Page 328 Tiger Explorer XR Series Disconnect the battery, negative (black) lead first. Remove the coolant expansion tank (see Expansion Tank - Removal). Remove the flywheel cover (see Flywheel Cover - Removal). Remove and discard the two fixings securing the sensor to the crankcase. chgh Sensor Fixings...
Page 329 Tiger Explorer XR Series Remove the coolant expansion tank (see Expansion Tank - Removal). Set the transmission in neutral. Disconnect the gear position sensor electrical connector. Remove the two fixings and remove the gear position sensor. chfs Gear position sensor Fixings Gear Position Sensor - Installation WARNING...
Page 330 Tiger Explorer XR Series Disconnect the throttle actuator motor multiplug. Disconnect the electrical connector from each injector. Note Before disconnection, note the position of the MAP sensor and evaporative emissions control system hoses. Ensure they are returned to the same locations when refitting the throttle bodies. Detach the MAP sensor and evaporative emissions control system hoses from the throttle bodies.
Page 331 Tiger Explorer XR Series Ease the fuel rail and injectors from the throttle bodies. To detach the injectors from the fuel rail, gently pull the injector out of the fuel rail using a twisting action. chir Injector Fuel rail Injector front seal Injector rear seal Discard the injector seals.
Page 332 Tiger Explorer XR Series Fit a new injector O-ring and seal to each injector. Refit the injectors to the fuel rail using a twisting action. Refit the injectors and fuel rail to the throttle bodies. Tighten the fuel rail fixings to 3.5 Nm. Fuel rail Fixings Throttle Bodies/Injectors - Installation...
Page 333 Temporarily reconnect the battery, positive (red) lead first. Attach exhaust extraction hoses to the silencers. Attach the Triumph diagnostic tool, start the engine and navigate to ADJUST TUNE (see Triumph Diagnostic Software - Engine ECM). Select BALANCE THROTTLES.
Page 334 Tiger Explorer XR Series Note set at the factory during manufacture, and must not be adjusted. WARNING Total cleanliness must be observed at all times whilst the throttle balance blanking screw is removed, and adjustment must take place in a dirt/dust-free environment. Dirt or dust ingress to the throttle motor housing will cause the throttles to stick, leading to loss of motorcycle control and an accident.
Page 335 Tiger Explorer XR Series Refit the airbox (see Airbox - Installation). Refit the fuel tank (see Fuel Tank - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Throttle Actuator Motor CAUTION The fixings for the throttle position sensor must not be loosened or removed.
Page 336 Tiger Explorer XR Series major adjustments from a fixed baseline setting. Adaptive changes can become necessary because of changing rider behaviour, changes in the region in which the bike is operated (i.e. operation at high altitude where it was previously used at sea level) or because a new part may have been fitted which has slightly different characteristics to the old part.
Page 337 As an alternative to the above process, connect the diagnostic tool, select ADJUST TUNE (see the Triumph Diagnostic Tool User Guide) and select RESET ADAPTIONS. This will force a fast adaption routine to take place in around five seconds. For this to happen, the engine MUST be running, it must be at normal operating temperature and in closed loop control mode.
Page 338 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. WARNING If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin.
Page 339 Tiger Explorer XR Series cjka Silencer Bolt Remove the silencer and collect its gaskets. Note Note the routing of the harnesses and drain pipes for installation. Remove the scrivet, bolt(s) and fir tree clip (if fitted) and remove the harness guide from the right hand side of the engine.
Page 340 Tiger Explorer XR Series Oxygen sensor Remove the bolt from the rear mounting point on the header pipe. chjq Bolt Header pipe Release the header pipe fixings at the cylinder head. Detach the header pipe assembly and collect the seals from the cylinder head ports. WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 341 Tiger Explorer XR Series Locate the header pipe and align the flanges to the cylinder head. Fit the header pipe nuts loosely, then tighten the top centre nut hand tight to retain the header pipes in position. Top centre nut Fit the rear mounting point bolt such that it is positioned to the front of the mounting lug.
Page 342 Tiger Explorer XR Series Exhaust to Cylinder Head Tightening Sequence Ensure that the rear mounting point bolt is positioned to the front of the mounting lug, then tighten the bolt to 15 Nm. Check the condition of the exhaust gasket for the silencer, replace if necessary, and fit it to the header pipe. Position the silencer clamp to the header pipe.
Page 343 Tiger Explorer XR Series chjr Oxygen sensor Attach the harness for the oxygen sensor to the cable tidy for the sump as noted for removal. Connect oxygen sensor electrical connector to the main harness. Secure the cable tidy to the sump with its fixings and tighten the bolt(s) to 3 Nm. Ensure that the routing of the harnesses and drain hoses are as noted for removal.
Page 344 Tiger Explorer XR Series secondary air system where, each time a pair of exhaust valves open, the exhaust gases in the exhaust port create a depression which causes reed valves in the secondary air injection system to open. When open, the depression in the exhaust port draws air from the control valve, through the open reed valves, into the exhaust port.
Page 345 Tiger Explorer XR Series chkn Seal Airbox Fit the screws and tighten to 2 Nm. Reconnect the electrical connector and the hose to the valve. Refit the fuel tank (see Fuel Tank - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation).
Page 346 Tiger Explorer XR Series Secondary air injection hose Reed valve assemblies Note the position of the connector bracket and release the fixings securing the valve covers to the camshaft cover. Connector bracket Fixings Reed valve assemblies Ease the valve covers from the valves. Note the orientation of the valves and remove them from the camshaft cover.
Page 347 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Fit the reed valves to the camshaft cover as noted for removal. Refit the valve covers and the connector bracket as noted for removal.
Page 348 Tiger Explorer XR Series chjk Canister Cable tie Fixing Note Note the orientation of the canister for installation. Slide the canister to the right to disengage its locating lugs from the frame. chjm Lugs Canister Frame, left hand side Disconnect the vacuum and purge hoses from the canister. FUEL SYSTEM / ENGINE MANAGEMENT 344 of 746...
Page 349 Tiger Explorer XR Series chjl Canister Vacuum hose Purge hose Remove the canister from the right hand side of the motorcycle. Evaporative Canister - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 350 Tiger Explorer XR Series chjk Canister Cable tie Fixing Secure the canister in place with the cable tie and trim off any excess cable tie. Refit the rear suspension unit (see Rear Suspension Unit - Installation). Refit the exhaust silencer (see Exhaust System - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm.
Page 351 Tiger Explorer XR Series Carefully feed the electrical connector and harness upwards and out from beneath the front edge of the battery tray. Press the wire locking device fully in and disconnect the electrical connector. Release the fixing securing the purge control valve to the frame. Note Note the position of the purge control valve hoses for installation.
Page 352 Tiger Explorer XR Series There are two distinct phases to the system's operation, engine off and engine running. See Evaporative Emissions Control System - Engine Off and Evaporative Emissions Control System - Engine Running. Component Locations Carbon Canister - on the frame above the centre stand. Purge Control Valve - (electronically controlled by the Engine ECM) mounted beneath the fuel tank, to the right hand side of the frame.
Page 353: Cooling
Tiger Explorer XR Series Evaporative Emissions Control System - Engine Running Cooling Exploded View – Cooling System Evaporative Control System – Engine Running When the engine is started, a vacuum is applied to the purge hose from the throttle bodies. At certain times, the Engine ECM opens the purge valve.
Page 354 Tiger Explorer XR Series Coolant COOLING 350 of 746...
Page 355 Always use the antifreeze listed in the Specification section and never use a methanol based antifreeze as this does not contain the required corrosion inhibition properties. Note HD4X Hybrid OAT coolant, as supplied by Triumph, is premixed and does not need to be diluted prior to filling or topping up the cooling system. CAUTION If hard water is used in the cooling system, it will cause scale accumulation in the engine and radiator and considerably reduce the efficiency of the cooling system.
Page 356 Tiger Explorer XR Series CAUTION engine to overheat and suffer severe damage. Check the radiator hoses for cracks or deterioration, and hose clamps for tightness in accordance with scheduled maintenance requirements. Radiator and Cooling Fan Inspection Radiator CAUTION Using high pressure water, such as from a pressure-washer, can damage the radiator fins and impair the radiator's efficiency.
Page 357 Tiger Explorer XR Series Position the motorcycle on level ground and in an upright position. The coolant level within the expansion tank can be inspected on the left hand side of the motorcycle without removing any covers. Check the coolant level in the expansion tank. The coolant level must be between the MAX and MIN level marks moulded into the expansion tank cover.
Page 358 Tiger Explorer XR Series chgw_4 Expansion tank Expansion tank cap Refit the cap. Note If the coolant level is being checked because the coolant has overheated, also check the level in the radiator and top up if necessary. In an emergency, distilled water can be added to the cooling system. However, the coolant must then be drained and replenished with HD4X Hybrid OAT coolant as soon as possible.
Page 359 Tiger Explorer XR Series Coolant pressure cap Position a container to collect the displaced coolant. Remove the drain screw located on the left hand side of the radiator and allow the coolant to drain. To drain the crankcase, remove the drain screw shown in the illustration below. Discard the washer. Crankcase coolant drain screw Radiator coolant drain screw Note...
Page 360 Tiger Explorer XR Series Fit a new washer to the drain screw and refit to the crankcase. Tighten to 8 Nm. Remove the bleed screw from the right hand hose. Bleed screw With the motorcycle positioned on its side stand, slowly add coolant mixture to the system, through the filler opening in the radiator, until the system is full.
Page 361 Tiger Explorer XR Series Connect the adapter hose to the fuel pump plate outlet as shown in the illustration below. cdve Adaptor hose 'B' Fuel pump plate outlet T3880123 - Extension Cable Connect the fuel hose to the adaptor hose as shown in the illustration below. chpl_1 Motorcycle fuel hose Adaptor hose 'B'...
Page 362 Tiger Explorer XR Series Fuel pump connection Fuel pump plate outlet Start the motorcycle and allow to run for approximately 20 to 30 seconds. Briefly raise the engine speed several times to allow any air to be expelled from the system. Stop the engine.
Page 363 Tiger Explorer XR Series cdbu Lower seal Upper seal Spring Note If there is any sign of damage or deterioration replace the cap. Pressure test the cap and cooling system to the blow off pressure of 1.1 bar as described below using T3880147 - Radiator and Cap Tester Kit.
Page 364 Tiger Explorer XR Series cgwq Pressure cap Test adaptor Hand held pump Pressure test the coolant cap to the blow off pressure. If the coolant cap opens at a lower pressure, fails to open at the correct pressure or the seal leaks, replace the cap. Coolant System Pressure Test Select the bayonet type adaptor and securely fasten to the radiator.
Page 365 Tiger Explorer XR Series cgwr_1 Radiator filler Bayonet type connector Hand held pump Pressure release valve Refit the coolant cap. Fill the coolant to the maximum mark (see Coolant Level Adjustment). Thermostat - Removal WARNING Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure.
Page 366 Tiger Explorer XR Series Thermostat - Inspection Inspect the thermostat at room temperature. If the valve is open, the thermostat must be replaced. To check the valve opening temperature, suspend the thermostat in a container of water and raise the temperature of the water until the thermostat opens.
Page 367 Tiger Explorer XR Series chim Thermostat housing Fixings Tighten the fixings to 9 Nm. Reconnect the top hose and refit the hose clip using T3880207 - Pliers, Hose Clip. Refit the throttle bodies (see Throttle Bodies/Injectors - Installation). Refill the cooling system (see Coolant Replacement). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm.
Page 368 Tiger Explorer XR Series Left hand hose Expansion tank hose Remove the two fixings securing the radiator to the lower radiator brackets. Fixing (left hand shown) Remove the air deflector firtree clip. Release the two upper bolts securing the radiator to the frame. Fixings Lower the radiator and disconnect the cooling fan connection, located below the headstock.
Page 369 Tiger Explorer XR Series CAUTION To avoid overheating and consequent engine damage, replace the radiator if the cores are blocked or if the fins are badly deformed or broken. Check that the fan spins freely and without tight spots. Check the fan blades for signs of heat distortion. Expansion Tank - Removal Position the radiator to the frame and connect the fan connector.
Page 370 Tiger Explorer XR Series Refit the fuel tank (see Fuel Tank - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Expansion Tank - Installation Remove the rider’s seat (see Rider’s Seat - Removal).
Page 371: Front Suspension
Tiger Explorer XR Series chjg Expansion tank Fixings Upper hose Lower hose Release the clip, disconnect the lower hose and remove the expansion tank. Front Suspension Exploded View - Front Fork Align the expansion tank to the frame, fit the lower hose and secure in position with its clip. Position the expansion tank to the engine and secure with the two washers and fixings.
Page 372 Tiger Explorer XR Series chgw_2 Expansion tank cover Upper fixing (M5) Lower fixings (M6) Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Exploded View – Handlebars FRONT SUSPENSION 368 of 746...
Page 373 Tiger Explorer XR Series Exploded View – Hand Guards FRONT SUSPENSION 369 of 746...
Page 374 Examine each fork for any sign of damage or scratching of the slider surface or for oil leaks. If any damage or oil leakage is found, strip and repair as described in this section or consult an authorised Triumph dealer. Check for smooth operation of the forks as follows: Place the motorcycle on level ground While holding the handlebars and applying the front brake, pump the forks up and down several times.
Page 375 Tiger Explorer XR Series Remove the rider’s seat (see Rider’s Seat - Removal). Disconnect the battery, negative (black) lead first. Raise and support the front of the motorcycle. Release the fixing and detach the front wheel sensor from the left hand fork leg. Collect the shim from between the sensor and fork leg and discard the fixing.
Page 376 Tiger Explorer XR Series Loosen the upper yoke clamp bolt. cjja Upper yoke clamp bolt Remove the TSAS damping motor connector cover. cjja TSAS damping motor connector cover Disconnect the TSAS damping motor connector. cjjc FRONT SUSPENSION 372 of 746...
Page 377 Tiger Explorer XR Series TSAS damping motor connector (rebound shown) If the fork is to be dismantled carry out the following: Note the orientation of the adjustable handlebar risers, in order that they can be returned to the same position when the repair operation is complete. Note The bolt positions shown below are in the standard position, as delivered from the factory.
Page 378 Tiger Explorer XR Series Lower yoke clamp bolts CAUTION Care must be taken when removing the forks, to ensure that the outer surfaces do not become scratched. Using a downward, twisting action, withdraw the forks from between the yokes. Front Fork - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 379 Tiger Explorer XR Series of the upper yoke. Retighten the lower yoke clamp bolts to 25 Nm. Refit the handlebars and secure with the clamps. Tighten the M10 fixings first to 35 Nm, then the M8 fixings to 26 Nm. If removed, tighten the lower damping cylinder bolt to 22 Nm.
Page 380 Tiger Explorer XR Series Remove the fork (see Front Fork - Removal). Remove the top cap assembly from the fork outer tube (see Front Fork - Disassembly). Holding the inner and outer tubes together, invert the fork and pour out the fork oil into a suitable container. Remove the top cap assembly from the damping rod and remove the spring guide, upper spring preload spacer(s) and spring (see Front Fork - Disassembly).
Page 381 Tiger Explorer XR Series Fork Oil Level (fork fully compressed with spring guide, upper spring preload spacer(s) and spring removed) Fork Oil Level 105 mm Fill the fork with the grade of oil specified in the fork oil table, to a level above that which will finally be required.
Page 382 Tiger Explorer XR Series 3880160 -T0301 - Fork Oil Filler/Evacuator Adjustment plate Scale area Hole (zero position) Note Zero level on the tool is set at the small exit hole in the side of the scale tube, NOT AT THE END TIP. Do not attempt to block this side hole as this will cause the final fluid level to be incorrect.
Page 383 Tiger Explorer XR Series Note described in Front Fork - Removal. Remove the front forks (see Front Fork - Removal). Using a soft jawed vice, clamp T3880171 - Fork Holding Tool such that the fork can be mounted vertically. With the top cap facing upwards, very gently clamp the fork outer tube into T3880171 - Fork Holding Tool. Note The top cap is not under spring tension and will not spring upwards when the threads disengage.
Page 384 Tiger Explorer XR Series Holding the inner and outer tubes together, invert the fork and pour out the fork oil into a suitable container. Return the fork to the fork holding tool. Counterhold the top cap to prevent it from turning and loosen the top cap lock nut. Remove the top cap.
Page 385 Tiger Explorer XR Series Dust seal Remove and discard the circlip. ciqc Circlip Cut out Fork outer tube Fork inner tube Remove the fork from the fork holding tool. WARNING The air from a heat gun, and the heat gun itself, are very hot. Wear suitable protective clothing and gloves and do not point the heat gun at any part of your body as serious burns to the skin may result.
Page 386 Tiger Explorer XR Series ccuw Inner tube Outer tube To allow the removal of the seals and bushes, carefully remove the upper bush from the inner tube. Discard the circlip, seal, washer and dust cap. Once removed, these components must not be reused. ccup_2 Dust seal Circlip...
Page 387 Tiger Explorer XR Series Front Fork - Inspection Front Fork - Assembly Headstock Bearing Check/Adjustment Headstock Bearing - Removal Inspect the inner tube for stone chips, scoring, scratches, excessive wear and any other damage. Renew as necessary. Note Small inclusions in the inner tube may be removed using a fine grade stone or similar. Inspect the spring for damage, cracks and deformation.
Page 388 Tiger Explorer XR Series Holes (compression damper only) Rebound damper - right hand fork Fit the damping cylinder to the inner tube. Fit a new damping cylinder bolt and a new sealing washer. Tighten the damping cylinder bolt to 22 Nm. Invert the fork outer tube and very gently clamp it into T3880171 - Fork Holding Tool.
Page 389 Tiger Explorer XR Series Upper bush Position the fork inner tube assembly to the fork outer tube. Using the long (small diameter) end of T3880661 - Fork Seal Installer, drive the lower bush into the fork outer tube. T3880661 - Fork Seal Installer Long (small diameter) end Short (large diameter) end T1323_2...
Page 390 Tiger Explorer XR Series T1323_2 T3880661 - Fork Seal Installer Seal Dust seal Remove T3880661 - Fork Seal Installer. Retain the bush, washer and seal with a new circlip. ciqc Circlip Cut out Fork outer tube Fork inner tube Position the dust seal to the fork outer tube. Using hand pressure only, push the dust seal squarely into the fork outer tube.
Page 391 Tiger Explorer XR Series cirb_3 Main damper rod assembly Inner damper rod Note A new spring may be supplied with or without spacer(s) to maintain the correct spring length. New springs must be fitted only with any spacers supplied with it. Spacers removed with an original spring must not be used with a replacement spring.
Page 392 Tiger Explorer XR Series Spring Spring guide Spacer(s) Nut and washer Spanner Remove the spanner used to compress the spring. Fit a new O-ring to the top cap. Remove the fork from the fork holding tool. With the aid of an assistant, compress the spring and fit T3880317 - Damper Tube Clamp to the damper rod, then secure in a soft jawed vice.
Page 393 When refitting the fork, tighten the top cap as described in Front Fork - Installation. Refit the front fork (see Front Fork - Installation). Turn the ignition on and allow the Triumph Semi Active Suspension (TSAS) system to calibrate. WARNING Always return the TSAS system to its original settings as noted prior to disassembly.
Page 394 Tiger Explorer XR Series WARNING Always return the handlebars and risers to their original position. Operating the motorcycle with a handlebar position that is unfamiliar may lead to loss of control or an accident. Note the orientation of the adjustable risers, in order that they can be returned to the same position when the repair operation is complete.
Page 395 Tiger Explorer XR Series chnr Headstock upper nut Ease the top yoke from the forks and support while detached. Adjust the bearing free play as follows, all using T3880620 - Adjuster Socket, 48 mm: Ensure that the threads are free from grease. Remove the lock nut and tab washer.
Page 396 Tiger Explorer XR Series Locate the handlebar assembly in the risers. Fit the upper clamps and the 10 mm bolts. Rotate the handlebar so that the alignment marking on the handlebar aligns with the front left hand split line of the clamp riser. chiu_2 Upper clamp Clamp split line...
Page 397 Tiger Explorer XR Series chiv_2 10 mm bolts 8 mm bolts As an assembly, raise the handlebars until clear of the top yoke. Rest the assembly forward of the steering stem such that access to the headstock top nut and the adjustment nuts is unrestricted. Ensure the master cylinder remains in an upright position.
Page 398: Rear Suspension
Tiger Explorer XR Series Adjuster nut Lock nut Tab washer Using the same tool, remove the adjuster nut. Remove the bearing cover and dust seal. Remove the bottom yoke from below the frame headstock. WARNING Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment.
Page 399 Tiger Explorer XR Series Steering stem Dust seal CAUTION Protect the threads of the bottom yoke when using a press or puller as damaged threads may mean replacing the yoke completely. Press a new lower bearing inner race onto the steering stem of the bottom yoke. cdnu Bearing Bottom yoke...
Page 400 Tiger Explorer XR Series chiu_2 Upper clamp Clamp split line Alignment marking Tighten the 10 mm bolts to 35 Nm. Fit the 8 mm bolts and tighten to 26 Nm. Recheck the bearing adjustment. Exploded View – Drop/Drag Link WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 401 Tiger Explorer XR Series cis v_1 Fixing Clutch master cylinder clamp Switch housing CAUTION To prevent paint damage, do not spill brake and clutch fluid onto any area of the bodywork. Spilled brake and clutch fluid will damage paintwork. Release the handlebar clamp screws and remove the clamp from the clutch master cylinder. Taking care to not invert the clutch fluid reservoir, lay the assembly aside.
Page 402 Tiger Explorer XR Series Fixing (one of two shown) Slide the heated grip off the handlebar while carefully feeding the harness into the handlebar. Disconnect the electrical connector and remove the heated grip. ciqf Heated grip (left hand) Harness Electrical connector Note the setting of the brake lever adjuster to ensure it is returned to the same position for installation.
Page 403 Tiger Explorer XR Series chnq Fixings Rear of switch cube Note Note the position and orientation of the twist grip to the switch cube for installation. Slightly roll the twist grip rearwards until its guide is clear of the switch housing. chnn Guide, twist grip Switch housing...
Page 404 Tiger Explorer XR Series brake fluid reservoir, lay the assembly aside. Note the routing of the heated grips harness, then carefully remove the harness from the handle bars and lay aside. WARNING Always return the risers to their original position. Operating the motorcycle with a handlebar position that is unfamiliar may lead to loss of control or an accident.
Page 405 Tiger Explorer XR Series chiu_2 Upper clamp Clamp split line Alignment marking Tighten the 10 mm bolts to 35 Nm. Fit the 8 mm bolts and tighten to 26 Nm. Feed the heated grips harness into the handlebar as noted during removal. Connect the electrical connector of the left hand heated grip to the main harness.
Page 406 Tiger Explorer XR Series Handlebar clamp 'UP' arrow Alignment mark Refit the heated grips and fog lights switch housing and secure with the fixing. Tighten the fixing to 3 Nm. cis v_1 Fixing Clutch master cylinder clamp Switch housing Position the front brake master cylinder assembly to the handlebar. Fit the clamp ('UP' arrow pointing upwards) and clamp fixings.
Page 407 Tiger Explorer XR Series Connect the electrical connector of the heated twist grip to the main harness. Carefully fit the heated twist grip while pulling the harness out of the left hand side of the handlebar. Partially engage the locating lugs on the twist grip into their slots in the spring housing. chnm Locating lugs Slots...
Page 408 Tiger Explorer XR Series Handguard Handlebar end fixing Handguard to bracket fixing Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Note Check for correct operation of the front brake and clutch. Check that the throttle opens and closes without sticking.
Page 409 Tiger Explorer XR Series REAR SUSPENSION 405 of 746...
Page 410 Tiger Explorer XR Series Drag and Drop Links - Removal Drag and Drop Links - Inspection Drag and Drop Links - Installation REAR SUSPENSION 406 of 746...
Page 411 Tiger Explorer XR Series Rear Suspension Unit - Removal WARNING If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin. To avoid skin damage, always allow the hot parts to cool before working on the exhaust system.
Page 412 Tiger Explorer XR Series Heel guard Temporarily detach the right hand control plate from the frame. chmy Control plate Fixings Remove the fixings securing the drag link to the frame and remove the drag link. Discard the lock nut. chnw_1 Drag link Drop links Lock nuts...
Page 413 Tiger Explorer XR Series the sleeves. Remove the swinging arm drop link sleeve and pack the bearings with fresh grease (NLGI 2 specification grease). Refit the sleeve. Refit the drag link to the frame. Fit the bolt and a new lock nut from the right hand side. Do not fully tighten at this stage.
Page 414 Tiger Explorer XR Series Refit the heel guard and tighten its fixings to 7 Nm. chgp_1 Fixings Heel guard Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Rear Suspension Unit - Installation Rear Suspension Unit Preload Motor Calibration WARNING...
Page 415 Tiger Explorer XR Series cjjz Electrical connector Remove the bolt securing the rear suspension unit to its upper mounting and remove the unit. Discard the lock nut. chnx Rear suspension unit Lock nut Rear Preload Motor Up/Down Function Tests Swinging Arm - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 416 Tiger Explorer XR Series Release the two fixings and remove the stone protector. cjks _1 Cable tie Fly lead Fixings Stone protector Disconnect the fly lead from damping solenoid electrical connector. Release the fixing from the damping solenoid electrical connector. cjkm Fixing Electrical connector...
Page 417 Tiger Explorer XR Series Note The split collar is positioned in such a way to allow for the correct fitment of the electrical connector. Noting the orientation of the split collar, compress the spring until the split collar is accessible. Taking care not to damage the split collar slide it from the damper rod.
Page 418 Tiger Explorer XR Series cjkl Preload adjuster Damper assembly WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. WARNING When using a spring compressor, always wear overalls, eye, face and hand protection.
Page 419 Tiger Explorer XR Series Note Manufacturing tolerances of the spring require spacers to be placed at both ends of the spring. If for any reason the spring is replaced. the original spacers must be discarded and the new spacers supplied with the spring must be used. Refit the flanged sleeve and spacers as noted during removal.
Page 420 Tiger Explorer XR Series Note The electrical connector is a push fit and sealed with an o-ring. Locate the electrical connector to the rear suspension unit and tighten the fixing to 1 Nm. cjkm Fixings Electrical connector Reconnect the fly lead. Refit the stone protector and tighten the fixings to 5 Nm.
Page 421 The Rear Suspension Unit (RSU) preload motor must be calibrated: After installation and setup of a new chassis ECM. After performing the Rear Preload Motor Up/Down function tests using the Triumph Diagnostic Tool. After removal/installation of the RSU. Before calibration of the swinging arm position sensor.
Page 422 RSU preload motor is being recalibrated due to low battery voltage. Wait for the warning light to stop flashing before turning the engine off. When the calibration has successfully completed, reconnect the Triumph Diagnostic Tool and check for any stored DTCs. Rectify as necessary.
Page 423 Disconnect the Triumph Diagnostic Tool. Refit the rider’s seat (see Rider’s Seat - Installation). Swinging Arm - Inspection The Rear Preload Motor Up/Down function tests provided in the Triumph Diagnostic Tool may be used as follows: Test rear preload motor operation.
Page 424 If the rear preload motor still doesn’t function correctly, contact Triumph service. Turn the ignition off and disconnect the Triumph diagnostic tool. Allow 15 seconds for the chassis ECM to power down. Note With the ignition switch turned off, the Triumph diagnostic tool will prevent the chassis ECM from powering down if it is left connected to the motorcycle.
Page 425 Tiger Explorer XR Series CAUTION If the rear preload motor adjustment position reaches its maximum or minimum adjustment end stop, do not continue to drive the motor towards the end stop. Select the test direction that will drive motor away from the end stop as described later in this procedure. Repeatedly driving the rear preload motor against an end stop may cause the motor to overheat, which can result in permanent damage.
Page 426 DTCs, rectify as necessary and repeat the rear preload motor test. If the rear preload motor still doesn’t function correctly, contact Triumph service. Turn the ignition off and disconnect the Triumph diagnostic tool. Allow 15 seconds for the chassis ECM to power down.
Page 427 Tiger Explorer XR Series cjjy Electrical connector Remove the drag and drop links (see Drag and Drop Links - Removal). Carefully remove the cover from the swinging arm's right hand pivot pin. T1052 Cover Using the T3880062 - Lock Ring Wrench, 38 mm, remove the locking ring from the right hand pivot pin. T1053 T3880062 - Lock Ring Wrench, 38 mm Locking ring...
Page 428 Tiger Explorer XR Series CAUTION unit. Use a soft cloth or other suitable material to protect the swinging arm and rear suspension unit while the swinging arm is being removed. Remove the swinging arm from the motorcycle, carefully passing the rear suspension unit through the opening in the swinging arm as you do so.
Page 429 Tiger Explorer XR Series chod T3880627 - Bearing Puller, 32-42 mm T3880208 - Slide Hammer Swinging arm Bearing outer race Remove the bearing end cap from the swinging arm. Repeat steps 3 and 4 for the other side. Drop Link Bearings Remove the bearing sleeve for the drop links from the swinging arm.
Page 430 Tiger Explorer XR Series threads. Press in the new bearing fully onto its locating shoulder. choa T3880629 - Bearing Installer Handle T3880625 - Bearing Installer, 39 mm Swinging arm Repeat for the other side. Fit the seal and inner race assembly to their bearings outer race on both sides of the swinging arm. chnz Seal and inner race assembly Drop Link Bearings...
Page 431 Tiger Explorer XR Series threads. Position a new bearing to T3880628 - Bearing Installer, 26 mm, with the marked side of the bearing facing towards the tool. chob T3880629 - Bearing Installer Handle T3880628 - Bearing Installer, 26 mm Bearing Position the service tools and bearing to the swinging arm on a press.
Page 432 Tiger Explorer XR Series choe Seal Lubricate the bearings with grease to NLGI 2 specification and fit the bearing sleeve. Rear Bevel Box and Drive Shaft Exploded View – Rear Bevel Box and Drive Shaft WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 433 Tiger Explorer XR Series Locking ring, right hand side only CAUTION Do not allow the swinging arm to drop as this may cause damage to the swinging arm and rear suspension unit. Position a suitable strap to support the swinging arm during the installation procedure. Tighten the left hand pivot pin to 170 Nm.
Page 434 Tiger Explorer XR Series T1052 Cover Remove and discard the rear suspension unit upper mounting lock nut. Fit a new nut but do not fully tighten at this stage. Refit the drag and drop links (see Drag and Drop Links - Installation). Do not fully tighten the linkage fixings at this stage.
Page 435 WARNING It 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 436 Tiger Explorer XR Series chni Rear Bevel Box Oil Specification This model is fitted with a drive shaft coupling the transmission to the rear bevel box. The drive shaft is fitted with single Hookes universal joints which require no maintenance. The rear bevel box consists of a crown wheel and pinion arrangement that has no dealer serviceable parts.
Page 437 Tiger Explorer XR Series WARNING Failure to observe the above warning could lead to a malfunction of the rear bevel box causing lock-up of the rear wheel leading to loss of motorcycle control and an accident. Rear Bevel Box Oil Level Check The rear bevel box must be filled and topped up with 75W/90 fully synthetic hypoid oil that meets specification API Service Level GL5, such as Castrol SAF-XO fully synthetic hypoid oil.
Page 438 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Position a container beneath the rear bevel box oil drain plug. chew_2 Drain plug Remove the drain plug and allow all the oil to fully drain out.
Page 439 Tiger Explorer XR Series hose. Caliper mounting bolts Detach the P-clip securing the harness for the rear wheel speed sensor to the rear bevel box. Release the fixing, detach the rear wheel speed sensor and position it aside. Discard the fixing. chnb P-clip Fixing...
Page 440 Tiger Explorer XR Series chll_1 Fixings Brake disc Remove and discard the five fixings and remove the pulser ring. Fixings Pulser ring Remove the three fixings and remove the expansion tank cover. Discard the upper M5 fixing. Retain the lower M6 fixings for reuse. chgw_2 Expansion tank cover Upper fixings (M5)
Page 441 Tiger Explorer XR Series Note mechanism. Select neutral, remove the pinch bolt and disconnect the transmission linkage from the gear change mechanism. chmh Pinch bolt Transmission linkage Gear change mechanism Punch mark Note Do not allow the side stand to hang on the harness for the side stand switch. Note the routing of the harness for the side stand switch for installation.
Page 442 Tiger Explorer XR Series Fixings Control plate Note Note the position and orientation of the clamps for installation. Release the two clamps and detach the rubber boot from the front of the swinging arm and the transmission. chmc Clamps Boot Detach the rubber boot from the rear of the swinging arm.
Page 443 Tiger Explorer XR Series chna_1 Boot Swinging arm Note It is possible that the swinging arm may obstruct the drive shaft detaching from the transmission. To allow for movement of the swinging arm, position a suitable strap to support the swinging arm then remove the lock nut and bolt securing the drop links to the swinging arm.
Page 444 Tiger Explorer XR Series chml T3880620 - Adjuster Socket, 48 mm Locking ring Note The drive shaft is secured to the rear bevel box by a spring clip and will also be removed with the bevel box. While supporting the rear bevel box, remove both pivot pins and move the bevel box rearwards to disengage the drive shaft from the transmission.
Page 445 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Apply a smear of grease, to NLGI 2 specification, to the splines of the drive shaft and the transmission output shaft.
Page 446 Tiger Explorer XR Series Attach the torque arms to the rear bevel box. Fit the bolt and new lock nut but do not fully tighten at this stage. Attach the drop links to the swinging arm with the original bolt and a new lock nut. Do not fully tighten at this stage.
Page 447 Tiger Explorer XR Series Fixings Control plate Route the harness for the side stand switch as noted for removal. Fit the side stand and tighten its fixings to 70 Nm. chme Fixings Side stand Tighten the upper fixings for the left hand control plate to 18 Nm. Fit the transmission linkage to the gear change mechanism as noted for removal.
Page 448 Tiger Explorer XR Series chmh Pinch bolt Transmission linkage Gear change mechanism Punch mark Refit the expansion tank cover. Secure the upper mounting with a new M5 encapsulated fixing. Secure the lower mounting with the two original fixings. Tighten the upper fixing to 3 Nm and the lower fixings to 4 Nm. chgw_2 Expansion tank cover Upper fixing (M5)
Page 449 Tiger Explorer XR Series Fixing Wheel speed sensor Position the caliper over the disc ensuring the pads are correctly aligned on both sides of the disc. Fit the caliper retaining bolts and tighten to 40 Nm. Fit the rear wheel (see Rear Wheel - Installation). With the weight of the motorcycle on its wheels, hold the drop link to swinging arm bolt while tightening the nut to 85 Nm.
Page 450 Tiger Explorer XR Series chmm T3880627 - Bearing Puller, 32-42 mm T3880208 - Slide Hammer Bearing outer race Repeat for the other bearing race. Rear Bevel Box Bearings - Installation Note The left hand replacement bearing is supplied with the cap attached to the outer race by means of an adhesive.
Page 451 Tiger Explorer XR Series chmo WARNING When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body. Never wear loose clothing which could become trapped in the press and cause a crushing injury to the hand, arms or other parts of the anatomy.
Page 452 Tiger Explorer XR Series chng Snap ring Apply a smear of grease, to NLGI 2 specification, to the splines of the drive shaft. With the aid of an assistant holding the rear bevel box, align the drive shaft to the bevel box such that it is straight.
Page 453 Tiger Explorer XR Series chne Universal joint yoke Remove the drive shaft. Remove the cap from the bevel box housing. chnf Housing Note A shim or shims are fitted between the back plate assembly and the bevel box housing. Ensure the shims are kept clean when removed from the bevel box.
Page 454 Tiger Explorer XR Series chmg Boss Back plate assembly Release the nine fixings and remove the back plate assembly. Collect the shim(s) and ensure they are kept clean. chnd Fixings Back plate assembly Shim (one shown) Housing Remove and discard the O-ring. chmy O-ring Working from the opposite side of the housing to the seal, drift out the oil seal.
Page 455 Tiger Explorer XR Series chnv Seal Rear Bevel Box Oil Seal - Installation WARNING When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.
Page 456 Tiger Explorer XR Series chmj Shim(s) Boss Lubricate a new O-ring with clean oil for the rear bevel box and fit it to the back plate assembly. chmy O-ring Lubricate the sealing lips of the new seal with clean oil for the rear bevel box. Align the back plate to the bevel box housing and shim(s) as noted for removal.
Page 457: Brakes
Tiger Explorer XR Series chmk Seal Shaft Fit the fixings and tighten in the sequence shown below to 30 Nm. Tightening Sequence Refit the cap to the bevel box housing. chnf Housing Fit the rear bevel box to the motorcycle (see Rear Bevel Box - Installation). Fill the rear bevel box with 75W/90 fully synthetic hypoid oil that meets specification API Service Level GL5, such as Castrol SAF-XO fully synthetic hypoid oil (see Rear Bevel Box Oil Change).
Page 458 Tiger Explorer XR Series Exploded View – Front Brake Caliper Exploded View – Rear Brake Master Cylinder BRAKES 454 of 746...
Page 459 Tiger Explorer XR Series BRAKES 455 of 746...
Page 460 Tiger Explorer XR Series Exploded View – Rear Brake Caliper BRAKES 456 of 746...
Page 461 Tiger Explorer XR Series Exploded View – ABS System Braking System Maintenance Safety Precautions WARNING Brake fluid is hygroscopic which means it will absorb moisture from the air. The absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction in braking efficiency. Replace brake fluid in line with the Scheduled Maintenance chart.
Page 462 It is dangerous to operate the motorcycle under such conditions and you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 463 Tiger Explorer XR Series WARNING ∙Alternator rotor ∙Magnetic fuel tank bags ∙Audio speakers ∙Magnetic dial test indicator stand ∙Magnetic parts tray. If the ABS is not functioning, the brake system will continue to function as a non-ABS braking system. Do not continue to ride for longer than is necessary with the indicator light illuminated.
Page 464 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. In accordance with the scheduled maintenance chart, inspect the brake fluid level in the front and rear master cylinder reservoirs.
Page 465 Tiger Explorer XR Series cbmz_1 Brake pads Minimum thickness line WARNING Do not replace individual brake pads; replace both pads in the brake caliper. On the front where two calipers are mounted on the same wheel, all the pads in both calipers must be replaced simultaneously. Replacing individual pads will reduce braking efficiency and may cause loss of motorcycle control and an accident.
Page 466 Tiger Explorer XR Series Replace any brake disc if worn beyond the service limit. For specifications refer toBrakes. WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Support the motorcycle on a stand so the wheel is raised clear of the ground.
Page 467 Tiger Explorer XR Series chdd_1 Adjuster wheel Arrow mark Turn the handlebars to bring the fluid reservoir to a level position. CAUTION To prevent paint damage, do not spill brake and clutch fluid onto any area of the bodywork. Spilled brake and clutch fluid will damage paintwork.
Page 468 Tiger Explorer XR Series WARNING leading to loss of motorcycle control and an accident could result if this warning is ignored. CAUTION To prevent paint damage, do not spill brake and clutch fluid onto any area of the bodywork. Spilled brake and clutch fluid will damage paintwork.
Page 469 ABS System Bleed Procedure Connect the Triumph diagnostic tool (see System Diagnostics). Follow the on screen menu to ABS Diagnostics. From the menu, select 'BLEED SYSTEM' (see the Triumph Diagnostic Tool User Guide). Note On pressing the Start button, the diagnostic software will send a command to the ABS ECM to begin the ABS bleed sequence.
Page 470 WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 471 Tiger Explorer XR Series Remove the clip from the brake pad retaining pin. While pressing down on the anti‑rattle spring, remove the brake pad retaining pin. Clip Anti‑rattle spring Brake pad retaining pin Collect the anti‑rattle spring. CAUTION In the following operation, never lever directly against the disc, caliper or pad lining material. Always use a levering tool made from a soft material that will not cause damage to the load bearing surfaces.
Page 472 Check for correct brake operation. Rectify as necessary. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 473 Tiger Explorer XR Series Caliper Bolts Manoeuvre the caliper clear of the disc, taking care not to damage the wheel. Front Brake Caliper - Disassembly Front Brake Caliper - Inspection WARNING To prevent injury, never place fingers or hands inside the caliper opening when removing the pistons. Always wear eye, hand and face protection when using compressed air.
Page 474 Tiger Explorer XR Series Dust seal Piston seal Pistons Caliper Extract the dust seals and piston seals, taking care not to damage the caliper bores. Discard the old seals, these must not be re-used. Note The piston seals are slightly thicker than the dust seals. chbc Piston seals Dust seals...
Page 475 Tiger Explorer XR Series WARNING motorcycle control and an accident. WARNING Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders.
Page 476 Tiger Explorer XR Series L0309_1 Caliper body Brake disc Slide the caliper body inwards or outwards against its fixings as required to achieve the most equal clearances possible on either side of the brake disc. Holding the caliper in position against its mounting fixings, tighten the fixings to 50 Nm. Note When the brake caliper is fitted, there must be a minimum gap of 0.3 mm between the caliper and brake disc.
Page 477 Check the brakes for correct operation. Rectify any faults as necessary. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 478 Check for correct brake operation. Rectify as necessary. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 479 Tiger Explorer XR Series Handguard end fixing Handguard to bracket fixing Handguard (right hand shown) Spacer Handlebar end weight Note the setting of the brake lever adjuster to ensure it is returned to the same position when the overhaul operation is complete. If fitted, Note the position of the handguard bracket for installation. Remove the pivot lock nut and bolt securing the brake lever to the master cylinder, and remove the lever.
Page 480 Tiger Explorer XR Series cequ Master cylinder Spring and piston assembly Circlip Rubber boot Front Brake Master Cylinder - Inspection Check the following for wear, damage, cracks or deterioration: Cylinder bore Rubber boot Spring Piston Pivot bolt. Always renew the piston and seal set if the cylinder is dismantled. Check that the two ports in the master cylinder bore are not blocked.
Page 481 Tiger Explorer XR Series WARNING motorcycle control and an accident. WARNING Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake and clutch fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders.
Page 482 Tiger Explorer XR Series 25 Nm. Position the brake lever ensuring that the pivot boss is correctly aligned to the push rod. If fitted, position the handguard bracket as noted during removal. Apply a smear of silicone grease to the shank of the brake lever pivot bolt. Fit and tighten the pivot bolt to 1 Nm.
Page 483 Tiger Explorer XR Series WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 484 Tiger Explorer XR Series chlh Fixings Rear reservoir cap Upper level Lower level Check the condition of the sealing diaphragm. Replace the diaphragm as necessary. Core Activity WARNING Ensure absolute cleanliness when adding brake fluid to the brake fluid reservoir. Do not allow moisture or debris to enter the cylinder as this will adversely affect the fluid properties.
Page 485 ABS System Bleed Procedure Connect the Triumph diagnostic tool (see System Diagnostics). Follow the on screen menu to ABS Diagnostics. From the menu, select BLEED SYSTEM (see the Triumph Diagnostic Tool User Guide). Note On pressing the Start button, the diagnostic software will send a command to the ABS ECM to begin the ABS bleed sequence.
Page 486 Observe the brake fluid handling warnings given earlier in this section of the manual. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 487 Tiger Explorer XR Series WARNING Do not allow a brake component to hang unsupported on the brake hose or line. Brake hoses or lines that are not supported may become damaged or bent. Bent or damaged brake hoses or lines lead to reduced braking efficiency causing loss of motorcycle control and an accident.
Page 488 Tiger Explorer XR Series Brake pads Anti-rattle spring Rear Brake Pads - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. WARNING 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 489 Tiger Explorer XR Series WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 490 Tiger Explorer XR Series WARNING direct contact with compressed air. Remove the brake pads and anti-rattle spring (see Rear Brake Pads - Removal). Cover the caliper opening with a clean, heavy cloth and, using either compressed air or by reconnecting the master cylinder and pumping the brake lever, remove the piston.
Page 491 Carefully push the piston into the caliper by hand. Lubricate the mounting bracket pins with silicone based grease (such as T2022021 supplied by Triumph) then reassemble the bracket and caliper. Ensure the pin gaiters are correctly located on both the bracket and caliper.
Page 492 Check for correct brake operation. Rectify as necessary. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 493 Check for correct brake operation. Rectify as necessary. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 494 Tiger Explorer XR Series WARNING from falling and causing injury to the operator or damage to the motorcycle. Remove the rider’s seat (see Rider’s Seat - Removal). Disconnect the battery, negative (black) lead first. CAUTION To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.
Page 495 Tiger Explorer XR Series Clip Clevis pin Brake hose Sealing washers Fixings Master cylinder Reservoir bracket Disconnect the reservoir hose from the master cylinder. Rear Master Cylinder - Inspection Remove the boot from the cylinder and pushrod. Remove the circlip retaining the pushrod to the cylinder. Discard the circlip. Remove the pushrod and piston set from the master cylinder bore, noting the relative position of the seals and piston components.
Page 496 Tiger Explorer XR Series Apply a small amount of brake grease to the pushrod. Install the pushrod in the master cylinder and retain with a new circlip. Refit the boot. cdlu1 Reservoir hose Piston set Dust boot Push rod Clevis pin Clip Circlip If the pushrod has been disassembled, set the pushrod free length to 73.5 mm, as shown below:...
Page 497 Check for correct brake operation. Rectify as necessary. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 498 Tiger Explorer XR Series cjjm Wheel speed sensor multiplug Release the wheel speed sensor harness from its clips on the upper radiator mounting and front brake hoses. Release the fixing and remove the sensor. Collect the shim from between the sensor and fork leg and discard fixing.
Page 499 Check that the brakes operate correctly. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 500 Tiger Explorer XR Series sensor. If removed, install a new fixing and tighten to 9 Nm. Repeat the air gap measurement. Re-adjust as necessary. Once the wheel speed sensor air gap measurement is correct, install a new bolt (if not already replaced during air gap adjustment) and tighten to 9 Nm.
Page 501 Check for correct brake operation. Rectify as necessary. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 502 Tiger Explorer XR Series ABS sensor Pulser ring Bevel box CAUTION Do not install shims. If the specified air gap cannot be achieved, investigate and rectify the cause before proceeding. If the rear wheel speed sensor has been removed, install a new fixing and tighten to 9 Nm. Re-check the air gap measurement.
Page 503 Tiger Explorer XR Series chgw_2 Expansion tank cover Upper fixings (M5) Lower fixings (M6) Note Note the routing of the harness and its retaining clips for installation. Detach the brake line and the harness for the rear wheel speed sensor from the cable guide. chle Harness Brake line...
Page 504: Final Drive
Check for correct brake operation. Rectify as necessary. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 505 Check that the brakes operate correctly. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 506 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the rider’s seat (see Rider’s Seat - Removal). Disconnect the battery, negative (black) lead first.
Page 507 Tiger Explorer XR Series CAUTION To prevent body damage, do not spill brake fluid onto any area of the bodywork or wheels. Drain the brake fluid from the front and rear master cylinders (for front brake master cylinder see Front Brake Master Cylinder - Removal, and for rear brake master cylinder see Rear Master Cylinder - Removal).
Page 508 Tiger Explorer XR Series cjjk Lower fixing ABS modulator Carefully remove the ABS modulator and bracket assembly from the motorcycle. If removal of the mounting brackets is required, release the fixings shown below, collect the flanged sleeve and remove the mounting bracket from the ABS modulator. Discard the fixings. cjjn M6 x 10 fixings M6 x 25 fixing...
Page 509 Tiger Explorer XR Series cjjj Fixings Brake hose guide WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. If removed, refit the brake hose guide to the ABS modulator. Tighten the fixings to 3 Nm. cjjj Fixings Brake hose guide...
Page 510 Tiger Explorer XR Series M6 x 25 fixing Flanged sleeve Bracket Carefully manoeuvre the ABS modulator and bracket assembly to its fitted position on the frame. Fit the lower fixing and tighten to 9 Nm. cjjk Lower fixing ABS modulator Incorporating new sealing washers to either side of the unions, refit the brake lines to the ABS module as marked for removal.
Page 511 Check for correct brake operation. Rectify as necessary. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 512 This stored data can then be recovered using a special service tool which is mandatory for all Triumph dealers. In this way, precise diagnosis of a fault can be made and the fault quickly rectified.
Page 513 Tiger Explorer XR Series Key to ABS System Circuit Diagram Item Description ABS Modulator Diagnostic Connector Rear Wheel Speed Sensor Front Wheel Speed Sensor Engine ECM ABS Fuse Box Key To Wiring Colour Codes Code Wiring Colour Black Blue Brown Green Slate/Grey Orange...
Page 514 Tiger Explorer XR Series Code Wiring Colour Purple White Yellow Light Green Light Blue ABS ECM Connector Pin Numbering The above illustration shows the pin numbering system used in the ABS circuit diagram. As viewed on the mating face with the ABS ECM (as per the illustration), pins are numbered from left to right with number one in the bottom left hand corner.
Page 515 The tables indicate which tests are performed by the on-board system and what information can be retrieved by the Triumph diagnostic software. Note Full details of how to operate the software can be found in the Triumph Diagnostic Tool User Guide, which can be downloaded by authorised Triumph dealers from www.triumphonline.net. Build Data...
Page 516 On/Off Bleed System Using the Triumph diagnostic tool, it is possible to bleed the ABS modulator of trapped air. This is necessary when the hydraulic brake system has been dismantled, or the ABS modulator renewed. Full details of this procedure are provided on page Bleeding the Front Brakes, Renewing Brake Fluid for front brakes or page Bleeding the Rear Brakes, Renewing Brake Fluid for rear brakes.
Page 517 Tiger Explorer XR Series Rear wheel Rear wheel pulser ring missing teeth Rear Wheel Pulser pulser ring Ring Missing Teeth missing teeth Front wheel Front wheel input solenoid short circuit to ground or open circuit Front or Rear input solenoid Input/Output short circuit to Solenoid...
Page 518 Tiger Explorer XR Series Run; Motor Runs Continually Motor - does Motor - does not run Motor - Lock; not run Motor Does Not Run; Motor Runs Continually Motor - runs Motor - runs continually Motor - Lock; continually Motor Does Not Run;...
Page 519 Tiger Explorer XR Series Modulator - Modulator - active pressure control malfunction ABS Modulator active Malfunction pressure control malfunction Modulator Modulator input (master cylinder) pressure sensor malfunction ABS Modulator input (master Malfunction cylinder) pressure sensor malfunction Modulator Modulator output (wheel) pressure sensor malfunction ABS Modulator output (wheel) Malfunction...
Page 520 Tiger Explorer XR Series Note ABS manoeuvre means that the ABS system is in its active state and is controlling brake pressure to prevent the wheel(s) from slipping (skidding). Once ABS operation has been inhibited, the ABS ECM will act in one of three ways: Allow the ABS to resume operation immediately if the fault clears.
Page 521 Tiger Explorer XR Series Fault code and ABS warning ABS operation is ABS continues ABS will automatically description light inhibited to operate if resume operation if fault Illuminated immediately when performing an clears(DTC still stored when fault is fault is logged for 40 cycles) logged manouevre...
Page 522 Tiger Explorer XR Series Fault code and ABS warning ABS operation is ABS continues ABS will automatically description light inhibited to operate if resume operation if fault Illuminated immediately when performing an clears(DTC still stored when fault is fault is logged for 40 cycles) logged manouevre...
Page 523 Tiger Explorer XR Series Fault code and ABS warning ABS operation is ABS continues ABS will automatically description light inhibited to operate if resume operation if fault Illuminated immediately when performing an clears(DTC still stored when fault is fault is logged for 40 cycles) logged manouevre...
Page 524 Tiger Explorer XR Series Fault code and ABS warning ABS operation is ABS continues ABS will automatically description light inhibited to operate if resume operation if fault Illuminated immediately when performing an clears(DTC still stored when fault is fault is logged for 40 cycles) logged manouevre...
Page 525 Tiger Explorer XR Series Fault code and ABS warning ABS operation is ABS continues ABS will automatically description light inhibited to operate if resume operation if fault Illuminated immediately when performing an clears(DTC still stored when fault is fault is logged for 40 cycles) logged manouevre...
Page 526 Tiger Explorer XR Series If testing with a voltmeter, the voltage across a connector should be virtually battery Volts (unless a resistor is fitted in the circuit). If there is a noticeable change, suspect faulty/dirty connections. When Disconnecting a Connector: Check for a security device that must be released before the connector can be separated e.g.
Page 527 Tiger Explorer XR Series Locking device Lever CAUTION The ABS ECM is an integral part of the ABS modulator. Under no circumstances should the ECM be removed from the ABS modulator. If a new ECM is required, repair is by replacement of the ABS modulator and ECM as an assembly only.
Page 528 Tiger Explorer XR Series Front Wheel Sensor Open Circuit/Short Circuit Rear Wheel Sensor Open Circuit/Short Circuit Fault Code Possible Cause Action Front wheel sensor short circuit to Front wheel sensor short circuit to Ensure wheel speed sensor ground or open circuit ground or open circuit connector is secure Disconnect ABS ECM connector...
Page 529 Reconnect ABS ECM harness, clear Action complete - quit test fault code and test ABS to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Wheel speed sensor current consumption data under typical conditions: Supply Voltage Typical 10 - 16 V 5.9 mA...
Page 530 Reconnect ABS ECM harness, clear Action complete - quit test fault code and test ABS to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Wheel speed sensor current consumption data under typical conditions: Supply Voltage Typical 10 - 16 V 5.9 mA...
Page 531 Faulty Rectify the fault and proceed to test 5 Check the wheel speed sensor circuit Contact Triumph service (see Front Wheel Sensor Open Circuit/Short Circuit) Faulty Rectify the fault and proceed to test 5...
Page 532 Faulty Rectify the fault and proceed to test 5 Check the wheel speed sensor circuit Contact Triumph service (see Rear Wheel Sensor Open Circuit/Short Circuit) Faulty Rectify the fault and proceed to test 5...
Page 533 Rectify the fault and proceed to test 5 Clear fault code and test ABS to verify Action complete - quit test fault cleared Fault still present Contact Triumph service Front or Rear Input/Output Solenoid Open/Short Circuit Fault Code Possible cause Action...
Page 534 Rectify the fault and proceed to test 5 Clear fault code and test ABS to verify Action complete - quit test fault cleared Fault still present Contact Triumph service Fault Code Possible Cause Action Front wheel input solenoid short Front wheel input solenoid short...
Page 535 5 Clear fault code and test ABS to verify Action complete - quit test fault cleared Fault still present Contact Triumph service Circuit Diagram Front or Rear Wheel Actuator (Hydraulic Control) Wheel Lock Fault Code Possible Cause Action...
Page 536 Rectify the fault and proceed to test 4 Clear fault code and test ABS to verify Action complete - quit test fault cleared Fault still present Contact Triumph service Motor - Lock; Motor Does Not Run; Motor Runs Continually Fault Code Possible Cause Action...
Page 537 Tiger Explorer XR Series Circuit Diagram Power Source Voltage Drop/Voltage Rise Fault Code Possible Cause Action Power source voltage too low Power source voltage too low Ensure ABS ECM connector is secure Disconnect ABS ECM connector Power source voltage too high Power source voltage too high and proceed to pinpoint test 1: Power source - short term under-...
Page 538 Rectify the fault and proceed to test 5 - Air gap between 0.1 mm to 1.5 mm Clear fault code and test ABS to verify Action complete - quit test fault cleared Fault still present Contact Triumph service BRAKES 534 of 746...
Page 539 Rectify the fault and proceed to test 4 Clear fault code and test ABS to verify Action complete - quit test fault cleared Fault still present Contact Triumph service ECM Communication (CAN) Fault Code Possible Cause Action CAN fault - lost communication CAN fault - lost communication View and note ‘freeze-frame’...
Page 540 Locate and rectify wiring fault, proceed to test 7 Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram Instrument Communication (CAN) Fault Code Possible Cause Action CAN fault - lost communication CAN fault - lost communication View and note ‘freeze-frame’...
Page 541 - ABS pin 11 to ABS pin 10 Short Circuit Locate and rectify wiring fault, proceed to test 6 Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram BRAKES 537 of 746...
Page 542 Tiger Explorer XR Series All Communication Lost (CAN) Fault Code Possible Cause Action CAN fault - all communication lost CAN fault - all communication lost View and note ‘freeze-frame’ data if available Disconnect Chassis ECM and proceed to pinpoint test 1: Pinpoint Tests Test Result...
Page 543 Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram ABS Modulator Malfunction Fault Code Possible Cause Action Modulator - active pressure...
Page 544 Incorrect Replace ABS modulator with correct part and proceed to test 2 Clear fault code, check for normal operation. Action complete - quit test Fault still Contact Triumph service present Inertial Measurement Unit (IMU) Incompatible Fault Code Possible Cause Action...
Page 545 Locate and rectify wiring fault, proceed to test 6 Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram Fault Code Possible Cause Action Inertial Measurement Unit (IMU) Inertial Measurement Unit (IMU) View and note ‘freeze-frame’...
Page 546 - Ignition switch pin 4 to IMU pin 4 Reconnect harness, clear fault code Action complete - quit test and run engine Fault still present Contact Triumph service Circuit Diagram Inertial Measurement Unit (IMU) Signal Error Prior to ABS Initialisation Fault Code Possible Cause...
Page 547: Wheels/Tyres
Clear fault code and check for normal Action complete - quit test operation. Fault still present Contact Triumph service ABS Hydraulic Circuit Layout Wheels and Tyres Exploded View – Front Wheel Exploded View – Rear Wheel WHEELS / TYRES...
Page 548 Tiger Explorer XR Series WHEELS / TYRES 544 of 746...
Page 549 Tiger Explorer XR Series Tyres This model is equipped with tubeless tyres, valves and wheel rims. Use only tyres marked 'TUBELESS' and tubeless valves on rims marked 'SUITABLE FOR TUBELESS TYRES'. chez Typical Wheel Marking WHEELS / TYRES 545 of 746...
Page 550 Tiger Explorer XR Series ccom Typical Tyre Marking WARNING Tyres that have been used on a rolling road dynamometer may become damaged. In some cases, the damage may not be visible on the external surface of the tyre. Tyres must be replaced after such use as continued use of a damaged tyre may lead to instability, loss of control and an accident.
Page 551 Important Tyre Information All Triumph motorcycles are carefully and extensively tested in a range of riding conditions to ensure that the most effective tyre combinations are approved for use on each model. It is essential that approved tyre combinations are used when purchasing replacement tyres as the use of non-approved tyres or approved tyres in non-approved combinations may lead to motorcycle instability.
Page 552 If tyre or inner tube damage is suspected, such as after striking the kerb, ask your authorised Triumph dealer to inspect the tyre both internally and externally and to also inspect the inner tube. Remember, tyre damage may not always be visible from the outside.
Page 553 WARNING When replacement tyres are required, consult your authorised Triumph dealer who will arrange for the tyres to be fitted according to the tyre manufacturer’s instructions. When tyres are replaced, allow time for the tyre to seat itself to the rim (approximately 24 hours). During this seating period, ride cautiously as an incorrectly seated tyre could cause loss of motorcycle control or an accident.
Page 554 Tiger Explorer XR Series chon Fork pinch bolts Release and remove the wheel spindle, which is threaded into the left hand fork. Note The right hand spacer is longer than the left. To identify the spacers, the right hand spacer has two machined rings while the left has a single machined ring.
Page 555 Tiger Explorer XR Series CAUTION Do not allow the wheel to rest on the brake discs, as this may damage the discs. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake discs are raised above the ground. Place the wheel on wooden blocks to prevent damage to the brake discs.
Page 556 Tiger Explorer XR Series Front Wheel - Installation Note Refer to the chart below for the correct tool and tool face when inserting bearings. Bearings are inserted by means of a draw-bolt acting on the insertion tool. A support tool is located on the opposite side of the wheel to the insertion tool and as the bolt is tightened, the bearing is drawn into the wheel.
Page 557 Refit the front brake calipers, see Front Brake Caliper - Installation. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 558: Frame And Bodywork
Lower the motorcycle to the ground. WARNING It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action...
Page 559 Tiger Explorer XR Series WARNING may reduce braking efficiency leading to loss of motorcycle control and an accident. Check the operation of the rear brake. Inform the owner to check and, if necessary, tighten the rear wheel nuts to 70 Nm. Exploded View –...
Page 560 Tiger Explorer XR Series Exploded View – Cockpit and Mountings FRAME / BODYWORK 556 of 746...
Page 561 Tiger Explorer XR Series Exploded View - Mirrors FRAME / BODYWORK 557 of 746...
Page 562 Tiger Explorer XR Series Exploded View – Side Fairings Exploded View – Sump Guard FRAME / BODYWORK 558 of 746...
Page 563 Tiger Explorer XR Series Exploded View – Engine Protection Bars FRAME / BODYWORK 559 of 746...
Page 564 Tiger Explorer XR Series Exploded View - Front and Rear Footrests FRAME / BODYWORK 560 of 746...
Page 565 Tiger Explorer XR Series Exploded View – Side Stand and Centre Stand FRAME / BODYWORK 561 of 746...
Page 566 Tiger Explorer XR Series Exploded View - Seat and Tool Kit Exploded View – Rear Panels and Luggage Rack FRAME / BODYWORK 562 of 746...
Page 567 Tiger Explorer XR Series Exploded View – Rear Mudguard and Battery Tray Exploded View - Pannier Mounting Frames FRAME / BODYWORK 563 of 746...
Page 568 Tiger Explorer XR Series FRAME / BODYWORK 564 of 746...
Page 569 WARNING If the motorcycle is involved in an accident or collision it must be taken to an authorised Triumph dealer for inspection and repair before it is ridden again.
Page 570 Tiger Explorer XR Series Seat lock To refit the passenger seat, reconnect the heated seat’s electrical connector (if equipped), engage the seat's two outer brackets under the loops on the subframe and the two inner brackets to the brackets on the rider's seat.
Page 571 Tiger Explorer XR Series CAUTION seats against the motorcycle or any surface which may damage the seats or seat covers. Instead, place the seats, with the seat cover facing upwards, on a clean, flat surface which is covered with a soft cloth. Do not place any item on the seats which may cause damage or staining to the seat covers.
Page 572 Tiger Explorer XR Series chpc Brake hoses Locating lug Shouldered bolts Front fork protector (left hand shown) Fixing (left hand shown) Front mudguard Note Note the routing of the front brake hoses for installation. Carefully manoeuvre the mudguard and fork protector assembly towards the front to remove it from the motorcycle.
Page 573 Tiger Explorer XR Series chpc Brake hoses Locating lugs Shouldered bolts Front fork protector (left hand shown) Fixing Front mudguard Mirror - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 574 Tiger Explorer XR Series Mirror boss (external right hand thread) Master cylinder housing Mirror arm (left hand thread) Lock nut (left hand thread) Repeat the procedure for the other mirror. Mirror - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 575 Tiger Explorer XR Series Mirror boss Master cylinder housing Mirror arm (left hand thread) Lock nut (left hand thread) Loosen the mirror arm by one complete turn. Position the mirror arm to give rear visibility in the riding position. CAUTION Use an open ended spanner to counter-hold the mirror boss as the mirror lock nut is tightened.
Page 576 Tiger Explorer XR Series Windscreen Fixings Cockpit Panels - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Fit the windscreen to its mounting frame and tighten its fixings to 4 Nm.
Page 577 Tiger Explorer XR Series Cockpit panel (right hand shown) Fixing Carefully move the cockpit panel outwards to disengage its locating lugs and remove from the motorcycle. High Level Mudguard - Removal High Level Mudguard - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 578 Tiger Explorer XR Series Cockpit panel (inside of right hand panel shown) Locating lugs Fit the fixing and tighten to 3 Nm. Cockpit panel (right hand shown) Fixing Refit the windscreen (see Windscreen - Installation). WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 579 Tiger Explorer XR Series Masked Area (Left Hand Side Fairing Shown with High Level Mudguard Removed for Clarity) Remove the four fixings securing high level mudguard to the cockpit sub‑frame. Fixings Lower the high level mudguard and disconnect the ambient air temperature sensor’s electrical connection. Ambient air temperature sensor FRAME / BODYWORK 575 of 746...
Page 580 Tiger Explorer XR Series High level mudguard With the high level mudguard lowered sufficiently to allow the ambient air temperature sensor to pass below the cockpit subframe, carefully remove the high level mudguard towards the front of the motorcycle. Noting their position and orientation, collect the four flanged sleeves from the high level mudguard. Fuel Tank Infill Panels - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 581 Tiger Explorer XR Series Secure the high level mudguard with the four fixings and tighten to 5 Nm. Fixings Carefully remove the masking tape from the side fairings. Refit the cockpit panels (see Cockpit Panels - Installation). Fuel Tank Infill Panels - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 582 Tiger Explorer XR Series chpg Electrical connector Auxiliary socket Front panel Release the three fixings and remove the fuel tank infill panel. Infill panel (right hand shown) Fixings Repeat step 3 for the other infill panel. Side Fairings - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 583 Tiger Explorer XR Series Fuel tank infill panel (right hand shown) Fixings Repeat step 1 for the other infill panel. Connect the electrical connector to the auxiliary socket on the front panel. Position the front panel onto the fuel tank, ensuring that its locating lug fits into its bracket on the fuel tank. chpg_1 Locating lug Bracket...
Page 584 Tiger Explorer XR Series Masked Area (Left Hand Side Fairing Shown with High Level Mudguard Removed for Clarity) Remove the fixings and remove the badge from the side fairings. Fixings Badge (left hand shown) Note Note the orientation of the mounting bracket for the fuel tank infill panels for installation. Release the fixing and remove mounting bracket for the fuel tank infill panel.
Page 585 Tiger Explorer XR Series chpp Mounting bracket Fixing Release the two fixings. Fixings Raise the upper edge of the side fairing to release its upper mounting from the fuel tank. Release the side panel from the lower locating lug on the radiator and remove the side panel. Upper mounting Lower locating lug Seat Infill Panel - Removal...
Page 586 Tiger Explorer XR Series WARNING from falling and causing injury to the operator or damage to the motorcycle. Ensure that the rubber grommet is fitted to its bracket on the lower fairing. Align the slot with the rubber grommet in the lower fairing to its locating lug on the radiator mounting bracket. Rubber grommet Bracket Locating lug...
Page 587 Tiger Explorer XR Series Fixings Fit the mounting bracket for the fuel tank infill panel as noted for removal and tighten the fixing to 3 Nm. chpp Mounting bracket (left hand shown) Fixing Fit the badge to the side fairing and tighten the fixings to 3 Nm. Fixings Badge (left hand shown) FRAME / BODYWORK...
Page 588 Tiger Explorer XR Series Refit the fuel tank infill panels (see Fuel Tank Infill Panels - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Seat Infill Panel - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 589 Tiger Explorer XR Series Front locating lug Rubber grommet Centre locating lug Mounting screw Seat infill panel (left hand shown) Seat Bridge - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 590 Tiger Explorer XR Series chpv Flanged sleeve Fixing Seat infill panel (left hand shown) Fit the side fairings (see Side Fairings - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Seat Bridge - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 591 Tiger Explorer XR Series Rider’s seat front mounting Fuel drain hose Multiplug Fixings Place the seat mounting and IMU assembly on a flat surface, in a location that is isolated from shock and vibrations caused by other workshop processes. Sump Guard - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 592 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the four fixings securing the sump guard to the engine and remove the sump guard. Collect the flanged sleeves from the front fixings.
Page 593 Tiger Explorer XR Series Fixings (left hand shown) Sump guard Engine Bars - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the rider’s seat (see Rider’s Seat - Removal).
Page 594 Tiger Explorer XR Series Centre mounting bolt Spacer, 25 mm Upper mounting bolt Side stand bolt Engine bar, left hand side Radiator mounting bracket Right Hand Engine Bar Note To access the lock nut for the lower crankcase mounting bolt, the left hand control plate must be removed.
Page 595 Tiger Explorer XR Series Select neutral, remove the pinch bolt and disconnect the transmission linkage from the gear change mechanism. chmh Pinch bolt Transmission linkage Gear change mechanism Punch mark Note Do not allow the side stand to hang on the harness for the side stand switch. Note the routing of the harness for the side stand switch for installation.
Page 596 Tiger Explorer XR Series Fixings Control plate Remove and discard the lock nut for the lower crankcase mounting bolt. Lock nut While holding down the rear brake pedal, remove the lower crankcase mounting bolt. Note Note that there is a 13 mm spacer between the right hand engine bar's centre mounting and the engine for installation.
Page 597 Tiger Explorer XR Series Lower crankcase mounting bolt Centre mounting bolt Spacer, 13 mm Note Note that the radiator mounting bracket is positioned between the engine bar and the engine for installation. Release the upper mounting bolt and remove the right hand engine bar and link bar assembly. Radiator mounting bracket Upper mounting bolt Pannier Mounting Frames - Removal...
Page 598 Tiger Explorer XR Series Note It is necessary to loosen the radiator so that it can be positioned to allow access to the front cylinder head mountings and lock nuts. Remove the two fixings securing the radiator to the lower radiator brackets. Discard the lock nuts. Fixing (left hand side shown) Loosen the two upper fixings securing the radiator to the frame.
Page 599 Tiger Explorer XR Series Left hand front cylinder head bolt Left hand rear cylinder head bolt Right hand front cylinder head bolt Right hand rear cylinder head bolt Upper crankcase bolt Lower crankcase bolt Note Make sure the engine is still adequately supported. Remove and discard the lock nuts from the front cylinder head bolts.
Page 600 Tiger Explorer XR Series chma Lower crankcase adjuster Upper crankcase adjuster Cylinder head front right hand adjuster Adjuster Note The right hand swinging arm pivot pin must be loosened before the frame bolts can be tightened. Release the fixings and remove the right hand heel guard. chgp_1 Fixings Heel guard...
Page 601 Tiger Explorer XR Series T1052 Cover Using T3880062 - Lock Ring Wrench, 38 mm, remove the locking ring from the right hand swinging arm pivot pin. T1053 T3880062 - Lock Ring Wrench, 38 mm Locking ring Loosen the right hand swinging arm pivot pin but do not fully remove. CAUTION Unless the following engine mounting bolt tightening sequence is precisely followed, severe frame damage can occur.
Page 602 Tiger Explorer XR Series T3880637 - Kit, Engine to Frame Alignment Bars Crankcase alignment bars Cylinder head alignment bar Insert the crankcase alignment bars into the upper and lower crankcase mountings from the left hand side of the frame. Ensure the alignment bars are located through the engine and into the crankcase adjusters on the right hand side of the frame.
Page 603 Tiger Explorer XR Series Right hand front cylinder head mounting point Cylinder head alignment bar (end of bar shown) Cylinder head adjuster Fit a new lock nut to the left hand front cylinder head bolt and tighten to 24 Nm. Tighten the left hand rear cylinder head bolt to 85 Nm.
Page 604 Tiger Explorer XR Series 33 mm bolt, do not fully tighten at this stage. Lower crankcase mounting bolt Bolt, M8 x 33 mm Spacer, 13 mm Ensure that the radiator mounting bracket is located between the upper mounting for the engine protection bar and the engine as noted for removal.
Page 605 Tiger Explorer XR Series CAUTION If the right hand pivot pin moves during the tightening of the locking ring, both the locking ring and pivot pin must be loosened and re-tightened as described in steps 29 to 33 of this procedure. Failure to tighten the swinging arm pivot pin and locking ring correctly may lead to severe frame damage.
Page 606 Tiger Explorer XR Series Fixings Control plate Route the harness for the side stand switch as noted for removal. Align the side stand to the frame and fit its rear fixing only. Do not fully tighten at this stage. chme_2 Rear fixing Side stand Tighten the upper fixings for the left hand control plate to 18 Nm.
Page 607 Tiger Explorer XR Series chgw_2 Expansion tank cover Upper fixing (M5) Lower fixings (M6) Refit the two fixings securing the radiator to the lower radiator brackets and secure with new lock nuts. Tighten to 9 Nm. Tighten the radiator upper fixings to 9 Nm. Remove the support from beneath the engine.
Page 608 Tiger Explorer XR Series Side stand bolt Engine bar, left hand Radiator mounting bracket Refit the fixing securing the left hand engine bar to the link bar. Do not fully tighten at this stage. Fixing Link bar Engine bar, left hand side Loosen the fixing securing the right hand engine bar to the link bar.
Page 609 Tiger Explorer XR Series Fixings Pannier link bar Noting the position of the spacer, remove the fixings and washers and remove the right hand rear footrest hanger. Collect the spacer from the front fixing. Fixings Rear footrest hanger (right hand shown) Washers Spacer Repeat step 3 for the left hand side.
Page 610 Tiger Explorer XR Series Upper clamps Pannier Rails - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. If removed, fit the pannier mounting frame’s upper clamps to the motorcycle.
Page 611 Tiger Explorer XR Series Rear footrest hanger (right hand shown) Washers Spacer Repeat step 4 for the left hand side. Tighten the pannier mounting frame fixings in the following sequence: Tighten the fixings in the sequence shown below to 12 Nm. Tighten fixing 1 again to 12 Nm.
Page 612 Tiger Explorer XR Series chpq Fixings Pannier rail Luggage Rack - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Align the pannier rail to the frame.
Page 613 Tiger Explorer XR Series T1044 Fixings Rack cover Release the four fixings and remove the luggage rack. T1045_1 Fixings Luggage rack Luggage Rack - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 614 Tiger Explorer XR Series Fixings Luggage rack Position the cover to the luggage rack. Fit the bolts and new lock nuts and tighten to 7 Nm. T1044 Fixings Rack cover Refit the passenger seat (see Passenger Seat - Installation). Rear Panel - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 615 Tiger Explorer XR Series Fixings Rear panel Rear Panel - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Note If fitted, reconnect the electrical connectors for the rear heated seat switch and rear electrical accessory socket.
Page 616 Tiger Explorer XR Series Rear panel Refit the luggage rack (see Luggage Rack - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Rear Mudguard - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 617 Tiger Explorer XR Series chpy_1 Outer cable Subframe Fixings Washers Note Note the position of the adjustable bracket for the rear reflector. It may have the under seat tray between it and the rear mudguard. Remove the two fixings shown below and detach the rear mudguard from the frame. Collect the side reflectors bracket if fitted.
Page 618 Tiger Explorer XR Series chpr Connector block Bracket Rear Mudguard - Installation Battery Tray - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Attach the rear light connector block to the rear light bracket.
Page 619 Tiger Explorer XR Series chpy_1 Outer cable Subframe Fixings Washers Fit the lower fixings (and side reflectors bracket if fitted) and tighten to 5 Nm. Fixings Tighten the fixings at the top of the rear mudguard to 7 Nm. Attach the seat latch outer cable to the subframe. Attach the seat latch inner cable to the seat's latch.
Page 620 Tiger Explorer XR Series Fit the pannier rails (see Pannier Rails - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Battery Tray - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 621 Tiger Explorer XR Series Detach the battery leads from their channel on the main harness and position aside. cjid Battery leads Channel Remove the scrivet securing the harness channel to the battery tray. Scrivet Release the harness clip. FRAME / BODYWORK 617 of 746...
Page 622 Tiger Explorer XR Series cjid_1 Clip Harness Carefully withdraw the rear section of the harness from the battery tray and position aside. Note If fitted, the heated seats sub harness may remain attached to the battery tray during removal. Remove the six fixings and washers. Discard the fixings. Fixings Lower the battery tray and remove towards the rear of the motorcycle.
Page 623 Tiger Explorer XR Series Fixings Position the rear section of the harness to the battery tray as noted during removal and secure with the clip. cjid_1 Clip Harness Ensure that the harness channel is located correctly to the battery tray and secure with a new scrivet. Scrivet Route the battery leads into their channel on the main harness as noted during removal.
Page 624 Tiger Explorer XR Series cjid Battery leads Channel Position the ambient air pressure sensor to its mounting on the battery tray and secure with the fixing. Tighten the fixing to 1.5 Nm. cjib Ambient air pressure sensor Fixing Route and attach the following to the battery tray as noted during removal: Main fuse box ABS fuse box Heated seats main harness electrical connectors...
Page 625 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Raise and support the motorcycle. WARNING Wear hand, eye and face protection when unhooking the stand spring.
Page 626 Tiger Explorer XR Series Side stand carrier bracket Side stand Pivot pin Lubrication areas Electrical Exploded View - Battery, Horn and Wiring WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Perform the following operations: Side Stand - Lubrication Fit the side stand to the motorcycle and insert the pivot pin.
Page 627 Tiger Explorer XR Series WARNING Wear hand, eye and face protection when fitting the stand spring. Take great care to minimise the risk of personal injury and loss of components. With the side stand in the up position, hook the spring onto its frame lug then carefully hook it onto the side stand lug.
Page 628 Tiger Explorer XR Series Exploded View – Headlight ELECTRICAL 624 of 746...
Page 629 Tiger Explorer XR Series Exploded View – Rear Light and Reflectors ELECTRICAL 625 of 746...
Page 630 Tiger Explorer XR Series Exploded View – Direction Indicators Exploded View – Alternator and Starter Motor ELECTRICAL 626 of 746...
Page 631 Tiger Explorer XR Series Battery WARNING Under some circumstances, the battery can give off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an enclosed space. The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
Page 632 Tiger Explorer XR Series WARNING The battery contains harmful materials. Always keep children away from the battery whether or not it is fitted in the motorcycle. Do not attach jump leads to the battery, touch the battery cables together or reverse the polarity of the cables as any of these actions may cause a spark which would ignite battery gases causing a risk of personal injury.
Page 633 In order to correctly and safely commission a new battery, the battery commissioning procedure listed below must be carefully followed. This is the only battery commissioning procedure that Triumph recommends. The procedure is designed to ensure that the battery is at its best when fitted to the motorcycle, and will provide the best possible performance and reliability.
Page 634 Tiger Explorer XR Series WARNING when charging or using the battery in an enclosed space. The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. If electrolyte gets on your skin, flush with water immediately. If electrolyte gets in your eyes, flush with water for at least 15 minutes and SEEK MEDICAL ATTENTION IMMEDIATELY.
Page 635 Tiger Explorer XR Series With normal use of the motorcycle, the charging system will keep the battery charged. If the motorcycle is unused, the battery will gradually discharge due to battery self discharge and the continuous current drain for the clock and the engine control module memory. The rate of battery discharge can be greatly increased by the addition of electrical security systems or other accessories.
Page 636 Note This model is equipped with an Engine Management System (EMS) relay only. The starter, fuel pump, cooling fan, lighting, windscreen adjustment motor, Triumph Semi Active Suspension (if fitted), and accessory systems are all controlled by the chassis ECM. The EMS relay is located beneath the rider’s seat, forward of the battery. To gain access to the relay: Remove the rider’s seat (see Rider’s Seat - Removal).
Page 637 Tiger Explorer XR Series ciuu_2 40 Amp main fuse ABS Fuse Box The 40 Amp ABS fuse is located beneath the rider's seat and behind the main fuse box. To allow access to the ABS fuse box the rider’s seat and chassis ECM cover must be removed. ciuu_3 ABS fuse box Main Fuse Box...
Page 638 Tiger Explorer XR Series shown below. Spare fuses are located on the inside of the fuse box cover and should be replaced if used. Note See Chassis Electronic Control Module (Chassis ECM) for details of the systems protected by fuses PS1 to PS5.
Page 639 Tiger Explorer XR Series the chassis ECM will automatically cut power to the affected system. The chassis ECM can be reset by turning the Ignition off then on again. Power will be restored to the inoperative system, providing that the condition that caused the fault has been rectified. The systems controlled by the chassis ECM are also provided with a secondary level of protection, by fuses PS1 to PS5 in the main fuse box (see Fuse Identification).
Page 640 DTCs are then erased from the ECM memory at another (higher) count. To connect the Triumph diagnostic interface to the motorcycle, remove the rider’s seat (see Rider’s Seat - Removal) and release the diagnostic connector from its locating tang.
Page 641 The tables indicate which tests are performed by the on-board system and what information can be retrieved by the Triumph diagnostic software. Note Full details of how to operate the software can be found in the Triumph Diagnostic Tool User Guide, which can be downloaded by authorised Triumph dealers from www.triumphonline.net. Build Data...
Page 642 Tiger Explorer XR Series Total Application Downloads Since Manufacture TSAS Calibration Name TSAS Calibration Version Date of last TSAS Calibration Download Total TSAS Calibration Downloads since Manufacture. Sensor Data When using this function it is possible to check the status of various sensors and actuators. The data sets are divided into four groups - Sensor Voltages, Lighting, Direction Indicators, Inputs/Outputs, Switches, Heating and Pulse Width Modulation (PWM) Data.
Page 643 Tiger Explorer XR Series Fog Lights On/Off Brake Light On/Off Front Position Light On/Off Rear Position Light On/Off Direction Indicators The data available under Direction Indicators is: Function Examined Result Unit Direction Indicators Cancel Switch On/Off Direction Indicators Left Switch On/Off Direction Indicator Left Front On/Off...
Page 644 Tiger Explorer XR Series Rear Preload Motor Down On/Off Rear Preload Motor Up On/Off Starter Solenoid On/Off Starter Switch On/Off Windscreen Motor Down On/Off Windscreen Motor Up On/Off Switches The data available under Switches is: Function Examined Result Unit Instruments Select Switch On/Off Instruments Scroll Up Switch On/Off...
Page 645 Diagnostic Trouble Codes (DTCs) are logged in the chassis ECM memory when there is a confirmed fault in the system. The codes are reported to the Triumph diagnostic tool as a four digit code. As mentioned earlier, when the system detects a fault, it begins to count the number of times the fault occurs before confirming the fault and storing a fault code.
Page 646 Tiger Explorer XR Series Trouble Description Switch Switch Light/Instrument Code Cycles Cycles Message/Visual (DTC) Before Before Indication Clearing DTC is Fault Erased C1001 Main power Power Supply Rail supply Overvoltage/Undervoltage overvoltage C1002 Main power Power Supply Rail supply Overvoltage/Undervoltage undervoltage C1009 Ambient Blank or incorrect...
Page 647 Tiger Explorer XR Series C1025 Windscreen Windscreen Motor motor Undercurrent/Overcurrent overcurrent C1027 5V sensor TSAS 5 Volt Sensor Supply supply light/warning malfunction message C1028 Preload motor TSAS Rear Suspension Unit (RSU) undercurrent light/warning Preload Motor message C1029 Preload motor TSAS Rear Suspension Unit (RSU) overcurrent light/warning...
Page 648 Tiger Explorer XR Series C1044 Front position Headlight light Undercurrent/Overcurrent undercurrent C1045 Front position Headlight light Undercurrent/Overcurrent overcurrent C1046 Rear light Rear Light undercurrent Undercurrent/Overcurrent C1047 Rear light Rear Light overcurrent Undercurrent/Overcurrent C1050 Brake light Brake Light undercurrent Undercurrent/Overcurrent C1051 Brake light Brake Light overcurrent...
Page 649 Tiger Explorer XR Series C1059 Right rear Remaining Direction Indicators direction direction Undercurrent/Overcurrent indicator indicators flash at overcurrent a faster rate C1060 Horn Horn Undercurrent/Overcurrent undercurrent C1061 Horn Horn Undercurrent/Overcurrent overcurrent C1062 Rider heated Heated seat Rider Heated Seat seat symbol displayed Undercurrent/Overcurrent undercurrent...
Page 650 Tiger Explorer XR Series indicators empty C1070 Cooling fan MIL* (and coolant Cooling Fan undercurrent temperature Undercurrent/Overcurrent warning light if fault long term) C1071 Cooling fan MIL* (and coolant Cooling Fan overcurrent temperature Undercurrent/Overcurrent warning light if fault long term) C1072 Fuel pump MIL*...
Page 651 Tiger Explorer XR Series C1083 Rear preload TSAS Rear Suspension Unit (RSU) motor position light/warning Preload Motor error - motor message travel during initialisation procedure was outside normal limits C1084 Rear preload TSAS Rear Suspension Unit (RSU) motor position light/warning Preload Motor error - motor message...
Page 652 Tiger Explorer XR Series C1095 Chassis ECM Bike continues to Chassis ECM Internal Error internal error run when fault logged but will not start after first ignition cycle. Other DTCs will be stored C1097 Front wheel Information Tyre Pressure Monitoring sensor unit message System (TPMS) Wheel Sensors...
Page 653 Tiger Explorer XR Series Unit (IMU) message implausible signal C1108 TSAS - ABS TSAS ABS Communication (CAN) implausible light/warning signal message C1109 TSAS - engine TSAS Engine ECM Communication light/warning (CAN) implausible message signal C1110 TSAS general TSAS TSAS Error error light/warning message...
Page 654 Tiger Explorer XR Series C1118 Left fork TSAS Left Fork Stepper Motor stepper motor light/warning (Compression Damping) (compression) message driver error C1119 Left fork TSAS Left Fork Stepper Motor stepper motor light/warning (Compression Damping) overcurrent message C1120 Right fork TSAS Right Fork Stepper Motor stepper motor light/warning...
Page 655 Tiger Explorer XR Series parameters to Default reset to default C1131 Rear preload Rear Preload Motor motor minimum Maximum/Minimum End Stop end stop Detection Error detection error. Preload motor not inhibited. C1132 Rear preload TSAS Rear Preload Motor motor minimum light/warning Maximum/Minimum End Stop end stop...
Page 656 Tiger Explorer XR Series When Connecting a Connector: Ensure there is no dirt around the connector/seal. Push together squarely to ensure terminals are not bent or incorrectly located. Push the two halves together positively. Chassis ECM Connectors Identification of the Chassis ECM connectors Chassis ECM connectors A and B can be identified as shown below: Connector A Connector B...
Page 657 Tiger Explorer XR Series Wing nut Chassis ECM cover Press down on the locking device and gently pull back on the connector’s lever to release it from the chassis ECM. cjls Locking device Lever Reconnection of the Chassis ECM Connectors CAUTION Damage to the connector pins may result if an attempt to fit the connectors incorrectly is made.
Page 658 Tiger Explorer XR Series Chassis ECM Pin Numbering The above illustration shows the pin numbering system used for the chassis ECM The rear connector's pins are prefixed A and the front connector’s pins are prefixed B. As viewed on the mating face with the chassis ECM (as per the illustration), pins are numbered from right to left with number one in the top right corner.
Page 659 Open circuit Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code Greater than 14.6 Contact Triumph service and run engine. Measure the battery V or Less than voltage while the engine is running 13.9 V 13.9 V - 14.6 V...
Page 660 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram If engine is warm, remove sensor and allow time to cool to ambient prior to test. Resistance data: Ambient temperature resistance value 80°C - 200 to 400 Ohms...
Page 661 Refer to DTC 1027 (see 5 Volt Sensor pin 5 harness side and ground Supply) Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 657 of 746...
Page 662 Open circuit Locate and rectify wiring fault, proceed to test 4 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 658 of 746...
Page 663 - Chassis ECM pin B07 to Chassis to test 5 ECM pin B08 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 659 of 746...
Page 664 - Main fusebox, fuse 3 (PS3) to Chassis ECM pin B01 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 660 of 746...
Page 665 - Windscreen motor pin 6 to ground Reconnect Chassis ECM, turn ignition 4.9 - 5.1 V Proceed to test 6 to ON position and measure the voltage between windscreen Faulty Contact Triumph service connector pins 8 and 7 (harness side) ELECTRICAL 661 of 746...
Page 666 8 (harness side) Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fault Code Possible Cause Action C1028 Preload motor undercurrent...
Page 667 Tiger Explorer XR Series Fault Code Possible Cause Action C1083 Rear preload motor position error Allow rear preload motor to - motor travel during initialisation calibrate, see Rear Suspension procedure was outside normal Unit Preload Motor Calibration limits If fault still occurs, disconnect Chassis ECM and proceed to pinpoint test 1: C1084...
Page 668 Locate and rectify wiring fault, proceed to test 6 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fog Lights Undercurrent/Overcurrent Fault Code Possible Cause Action...
Page 669 Tiger Explorer XR Series Fault Code Possible Cause Action C1034 Right headlight (high beam) overcurrent C1036 Left headlight (low beam) overcurrent C1038 Right headlight (low beam) overcurrent C1045 Front position light overcurrent Pinpoint Tests Test Result Action Check bulb integrity, Left/Right Proceed to test 2 /Position Faulty...
Page 670 - Chassis ECM pin A30 to ground Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Rear Light Undercurrent/Overcurrent Brake Light Undercurrent/Overcurrent Fault Code...
Page 671 Chassis ECM pin B01 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Replace fog lights If fault still present, contact Triumph service Circuit Diagram Fault Code Possible Cause Action...
Page 672 - Rear light connector pin 2 to ground to test 5 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Direction Indicators Undercurrent/Overcurrent Fault Code Possible Cause Action...
Page 673 Chassis ECM pin A02 - Rear light connector pin 2 to ground Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 669 of 746...
Page 674 Tiger Explorer XR Series Horn Undercurrent/Overcurrent Fault Code Possible Cause Action C1052 Left front direction indicator Ensure direction indicator undercurrent connectors are secure Proceed to pinpoint test 1: C1056 Right front direction indicator undercurrent C1054 Left rear direction indicator undercurrent C1058 Right rear direction indicator undercurrent...
Page 675 - Chassis ECM pin A31 to ground to test 6 - Chassis ECM pin A32 to ground Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 671 of 746...
Page 676: Check Fuse Integrity: Ok
- Main fusebox fuse 5 (PS5) to Chassis ECM pin B03 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 672 of 746...
Page 677: Check Cable Continuity: Ok
- Main fusebox fuse 4 (PS4) to Chassis ECM pin B02 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 673 of 746...
Page 678 Short circuit Locate and rectify wiring fault, proceed to test 6 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 674 of 746...
Page 679 Tiger Explorer XR Series Passenger Heated Seat Switch Fault Code Possible Cause Action C1064 Passenger heated seat Proceed to pinpoint test 1: undercurrent C1065 Passenger heated seat overcurrent Pinpoint Tests Test Result Action Check fuse integrity: Disconnect chassis ECM and passenger heated seat connectors, proceed to test - Main fusebox, fuse 4 (PS4) Faulty...
Page 680 Test Result Action Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Heated Grips Undercurrent/Overcurrent Fault Code Possible Cause Action C1114 Passenger heated seat switch...
Page 681 Locate and rectify wiring fault, proceed to test 6 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Cooling Fan Undercurrent/Overcurrent Fault Code Possible Cause Action...
Page 682: Replace Fuse, Proceed To Test 5
- Main fusebox fuse 4 (PS4) to Chassis ECM pin B02 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fuel Pump Undercurrent/Overcurrent Fault Code Possible Cause Action...
Page 683 - Main fusebox fuse 5 (PS5) to Chassis ECM pin B03 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 679 of 746...
Page 684 - Main fusebox fuse 5 (PS5) to Chassis ECM pin B03 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 680 of 746...
Page 685 - USB socket pin 2 to ground to test 3 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Top Box Accessory Power Socket Overcurrent Fault Code Possible Cause Action...
Page 686 - Power socket pin 1 to ground to test 3 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Starter Motor Solenoid Undercurrent/Overcurrent Fault Code Possible Cause Action...
Page 687 - Top box power socket pin 1 to to test 3 ground Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram TSAS Error Fault Code Possible Cause Action C1077...
Page 688 5 Chassis ECM pin B03 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Instrument Communication (CAN) Fault Code Possible Cause Action...
Page 689 Short circuit Locate and rectify wiring fault, proceed to test 8 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 685 of 746...
Page 690 Tiger Explorer XR Series Inertial Measurement Unit (IMU) ID Incompatible Fault Code Possible cause Action C1088 CAN fault - lost communication Disconnect Chassis ECM with ABS module connectors and proceed to pinpoint test 1: C1108 TSAS - ABS implausible signal Disconnect Chassis ECM connectors and proceed to pinpoint test 3:...
Page 691 Locate and rectify wiring fault, proceed to test 7 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Inertial Measurement Unit (IMU) Signal (CAN) Fault Code Possible Cause Action...
Page 692 Test Result Action Clear fault code, check for normal Action complete - quit test operation Fault still present Contact Triumph service Engine ECM Communication (CAN) Fault Code Possible Cause Action C1107 TSAS - Inertial Measurement Unit Ensure IMU is fixed in its proper...
Page 693 Tiger Explorer XR Series Test Result Action and run engine to verify fault cleared Fault still present Replace IMU If fault still present, contact Triumph service Circuit Diagram Fault Code Possible cause Action C1091 CAN fault - lost communication Disconnect Chassis ECM and...
Page 694 Front wheel sensor unit fault alert If the problem persists: Replace the relevant wheel pressure sensor following the procedure described in the Triumph diagnostic tool user guide C1100 Rear wheel sensor unit fault alert Record the new sensor's ID number into the owner handbook...
Page 695 If available, try to start the motorcycle Transponder chip in the key not with the second registered key functioning correctly Register a new key using the Triumph Diagnostic Tool, proceed to test 7 Faulty Proceed to test 2 Check cable and terminal integrity:...
Page 696 Locate and rectify wiring fault, proceed to test 7 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Left Fork Stepper Motor (Compression Damping) Fault Code Possible Cause Action...
Page 697 A Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Right Fork Stepper Motor (Rebound Damping) Fault Code Possible Cause Action...
Page 698 - Chassis ECM pin B24 to right fork stepper motor pin A Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram ELECTRICAL 694 of 746...
Page 699 Unexpected chassis ECM restart Note and investigate any other stored DTCs Erase DTC and monitor for further issues If the fault fails to clear or reoccurs, contact Triumph service Fault Code Possible Cause Action C1129 Chassis ECM power supply Ensure voltage across battery is interrupted acceptable.
Page 700 5 Reconnect harness, clear fault code Action complete - quit test and run engine to verify fault cleared. Fault still present Contact Triumph service Circuit Diagram Rear Preload Motor Maximum/Minimum End Stop Detection Error Fault Code Possible Cause...
Page 701 Tiger Explorer XR Series Fault Code Possible Cause Action Erase stored DTCs from all ECMs Fault Code Possible Cause Action C1131 Rear preload motor minimum end Rear preload motor calibration is stop detection error. Preload started automatically after next motor not inhibited. ignition cycle Allow rear preload motor to calibrate, see Rear Suspension...
Page 702 Register the tyre pressure sensor ID numbers, activate TPMS and enable the TPMS instrument display (if TPMS is fitted). For models fitted with Triumph Semi-Active Suspension (TSAS), it its also necessary to complete the following operations in order: Calibrate the rear suspension unit preload motor (see Rear Suspension Unit Preload Motor Calibration).
Page 703 Tiger Explorer XR Series CAUTION When releasing or tightening fixings, use suitable hand tools only. Do not use air or battery powered tools. When removed from the motorcycle, place the IMU on a flat surface in a location that is isolated from shock and vibrations caused by other workshop processes.
Page 704 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. CAUTION The Inertial Measurement Unit (IMU) is a highly sensitive device. Exposure to excessive shock and vibration can cause permanent damage to IMU internal components.
Page 705 Tiger Explorer XR Series cjju Fixings Bracket Inertial measurement unit (IMU) Seat bridge Refit the seat bridge (see Seat Bridge - Installation). Refit the fuel tank (see Fuel Tank - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation).
Page 706 Tiger Explorer XR Series CAUTION The swinging arm position sensor’s actuator arm operates vertically. Do not allow the actuator arm to twist or bend during removal of the ball stud. Twisting or bending the actuator arm may cause damage to the actuator arm or the internal components of the swinging arm position sensor.
Page 707 Tiger Explorer XR Series cjlx Position sensor Electrical connector Tangs Swinging Arm Position Sensor - Calibration WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Note Prior to installing the position sensor the electrical connector must first be connected.
Page 708 Tiger Explorer XR Series cjlw Position sensor Fixings CAUTION The swinging arm position sensor’s actuator arm operates vertically. Care should be taken to not allow the actuator arm to twist or bend during removal of the ball stud. Twisting or bending the actuator arm may cause damage to the actuator arm or the internal components of the swinging arm position sensor.
Page 709 Tiger Explorer XR Series cjlv Sensor cover Tangs Grommets Reconnect the battery, positive, (red) lead first and tighten the terminals to 4.5 Nm. Calibrate the rear suspension unit preload motor (see Rear Suspension Unit Preload Motor Calibration). Calibrate the swinging arm position sensor (see Swinging Arm Position Sensor - Calibration). Refit the rider’s seat (see Rider’s Seat - Installation).
Page 710 Raise and support the rear of the motorcycle so that the rear wheel is off the ground and the rear suspension is allowed to hang freely. Connect the Triumph Diagnostic Tool (see System Diagnosis) and turn the ignition On. Navigate to CHASSIS DIAGNOSTICS - CHASSIS ECM DIAGNOSTICS - FUNCTION TEST and select CALIBRATE SWINGING ARM POSITION SENSOR.
Page 711 Tiger Explorer XR Series High level mudguard assembly Windscreen Motor - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Refit the ambient air temperature sensor to the high level mudguard assembly and tighten its fixing to 1.5 cjlr Fixing...
Page 712 Tiger Explorer XR Series cjlk Fixings Windscreen support bracket Release the fixings and remove the windscreen motor cover. cjlj Fixings Windscreen motor cover Release the fixings and remove the clear wind deflector panels. Wind deflector panel (right hand shown) ELECTRICAL 708 of 746...
Page 713 Tiger Explorer XR Series Fixings Note The instrument cover is held in place by a bayonet type fixing. Gently pull on the cover to release it. Remove the cover attached to the rear of the instruments. Release the four windscreen motor fixings. cjlf Fixings Windscreen motor...
Page 714 Tiger Explorer XR Series cjli Windscreen motor Locating lug (left hand shown, right hand similar) Front subframe holes Refit the four windscreen motor fixings and tighten to 12 Nm. Refit the instrument cover and gasket to the rear of the instruments, ensuring the bayonet fixings are fully inserted into the grommets on the front subframe.
Page 715 Tiger Explorer XR Series cjlj Fixings Windscreen motor cover Position the windscreen support bracket upper mountings to the windscreen pivot bar and secure with the two fixings and flanged sleeves. Do not fully tighten at this stage. Position the windscreen support bracket lower mounting to the windscreen motor and secure with the fixing. Tighten the fixing to 5 Nm.
Page 716 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the rider’s seat (see Rider’s Seat - Removal). Disconnect the battery, negative (black) lead first.
Page 717 Tiger Explorer XR Series cjlh Fixings Electrical connector Instruments Refit the windscreen motor (see Windscreen Motor - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation). Headlight Bulb Replacement Position Light Bulb Replacement WARNING...
Page 718 Tiger Explorer XR Series chfb_1 Horizontal adjustment screw Vertical adjustment screw Headlight adjuster lever for loaded conditions Switch the headlight dipped beam on. Turn the vertical adjustment screw on the headlight clockwise to raise the beam or anti-clockwise to lower the beam.
Page 719 Tiger Explorer XR Series cgjn Bulb retainer (right hand shown) Bulb retainer hook Bulb Remove the bulb from the bulb retainer. Installation Installation is the reverse of removal. Note When reconnecting the battery, connect the positive (red) lead first. Headlight Assembly - Installation WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 720 Tiger Explorer XR Series Installation is the reverse of removal, noting the following: Note Tighten the headlight surround fixings to 3 Nm. Reconnect the battery, positive (red) lead first. Rear Light - Removal WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 721 Tiger Explorer XR Series cjle Fixings (left hand shown) Washers Refit the high level mudguard (see High Level Mudguard - Installation). Refit the cockpit panels (see Cockpit Panels - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation).
Page 722 Tiger Explorer XR Series Fixings Bracket Rear light If necessary, release the fixings and remove the bracket. chlz_2 Fixings Bracket LED Direction Indicators WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 723 Tiger Explorer XR Series noted during removal. Tighten the fixings to 4 Nm. chlz_4 Fixings Bracket Rear light Refit the rear mudguard (see Rear Mudguard - Installation). Reconnect the battery positive, (red) lead first and tighten the terminals to 4.5 Nm. Refit the rider’s seat (see Rider’s Seat - Installation).
Page 724 Tiger Explorer XR Series Fixing Release the fixing and remove the lens to gain access to the bulb for replacement. Rear Direction Indicator - Removal The LED direction indicators are sealed for life units and must be replaced in the event of a failure. Rear Direction Indicator - Installation Starter Motor - Removal WARNING...
Page 725 Tiger Explorer XR Series Note Ensure that the drain hole in the indicator lens is at the bottom. Position the direction indicator to the cockpit subframe and secure with the fixing. Tighten the fixing to 5 Nm. cjlt Direction indicator (right hand shown) Fixing Route the direction indicator harness as noted during removal and secure into the clips on the cockpit subframe.
Page 726 Tiger Explorer XR Series chlz_5 Fixings Direction indicators Remove the direction indicators. WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Note Ensure that the drain hole in the indicator lens is at the bottom.
Page 727 Tiger Explorer XR Series WARNING Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the rider’s seat (see Rider’s Seat - Removal). Disconnect the battery, negative (black) lead first.
Page 728 Refit the rider’s seat (see Rider’s Seat - Installation). All Triumph models are equipped with an electric start system. This system consists of a starter relay, starter motor, starter switch, side stand switch, engine stop switch, clutch switch and the sprag clutch. The starter motor is connected to the starter relay and the battery by heavy duty cables in order to supply the large currents required by the motor to start the engine.
Page 729 Tiger Explorer XR Series Symptom Possible cause(s) Defective starter motor Starter cable open circuit Defective starter relay Starter motor turns but engine does not turn over Starter motor or starter ring gear Alternator - Assembly Note Prior to carrying out the diagnosis, ensure the battery voltage is 12 - 13.5 V, the immobiliser system (if fitted) is functioning correctly, the transmission is in neutral and the clutch lever is pulled fully to the handlebar.
Page 730 Tiger Explorer XR Series Remove the rider’s seat (see Rider’s Seat - Removal). Remove the battery (see Battery Removal). Remove the coolant expansion tank (see Expansion Tank - Removal). Remove the throttle bodies (see Throttle Bodies/Injectors - Removal). Remove the battery tray (see Battery Tray - Removal). Remove the two upper selector cover fixings and detach the starter solenoid and bracket.
Page 731 Tiger Explorer XR Series chje Alternator Fixings Withdraw the alternator from the crankcase and remove from the motorcycle in an upwards direction. Alternator Diagnosis Remove and discard the rubber cap from the alternator decoupler and drive gear assembly. Fit T3880602 - Alternator Wrench to the splines of the alternator decoupler and drive gear assembly. T3880602 - Alternator Wrench Prevent the alternator from turning using a spanner on T3880602 - Alternator Wrench, and loosen the decoupler and drive gear assembly nut using an 8 mm Allen key.
Page 732 Tiger Explorer XR Series Alternator decoupler T3880602 - Alternator Wrench 8 mm Allen key Remove T3880602 - Alternator Wrench and fully remove the nut. Discard the nut. Remove the decoupler and drive gear assembly from the alternator spline. Release the fixings and remove the drive gear from the decoupler. Drive gear De-coupler Fixings...
Page 733 Tiger Explorer XR Series chje Alternator Fixings Refit the alternator cable and secure with the nut. Tighten to 10 Nm. Refit the alternator cable boot. Reconnect the alternator multiplug. chjd Alternator multiplug Cable nut Reposition the starter solenoid to the selector cover and secure with the two fixings. Tighten to 11 Nm. chjc ELECTRICAL 729 of 746...
Page 734 Tiger Explorer XR Series Starter solenoid Fixings Refit the battery tray (see Battery Tray - Installation Refit the throttle bodies (see Throttle Bodies/Injectors - Installation). Refit the coolant expansion tank (see Expansion Tank - Installation). Refit and connect the battery (see Battery Installation). Refit the rider's seat (see Rider’s Seat - Installation).
Page 735 Proceed to test 5 plugged and secured. Run the engine. Check the charging Voltage at 2,000 rpm: Fault still Contact Triumph service - Through the regulator/rectifier terminal present and the engine ground Ensure the alternator control connector is 13 V - 15 V Action complete - quit test plugged and secured.
Page 736 Tiger Explorer XR Series Item Description Chassis ECM Main Fuse Box Front Electrical Accessory Socket Rear Electrical Accessory Socket Top Box Power USB Socket Right Heated Grip Left Heated Grip Heated Seat Switch - Rider Heated Seat - Rider Heated Seat Switch - Passenger Heated Seat - Passenger Windscreen Motor Engine ECM...
Page 737 Tiger Explorer XR Series Item Description Dipped Beam - Right Main Beam - Right Front Light Unit Key To Wiring Colour Codes Code Wiring Colour Black Blue Brown Green Slate/Grey Orange Pink Purple White Yellow Light Green Light Blue CIRCUIT DIAGRAMS 733 of 746...
Page 738 Tiger Explorer XR Series TSAS Circuit Diagram Key to Circuit Diagram Item Description Battery Starter Solenoid Starter Motor Chassis ECM Engine Control Module - Connector B Alternator Control Alarm Right Hand Switch Housing Starter Switch Engine Stop Switch Inertial Measurement Unit (IMU) - if fitted Instruments ABS ECM Blueooth Module Connector...
Page 739 Tiger Explorer XR Series Key To Wiring Colour Codes Code Wiring Colour Black Blue Brown Green Slate/Grey Orange Pink Purple White Yellow Light Green Light Blue Key to Engine Management Circuit Diagram 40.0 Amp GB Y W WB CIRCUIT DIAGRAMS 735 of 746...
Page 740 Tiger Explorer XR Series B B B 4 2 5 Engine Management Circuit Diagram Item Description Chassis ECM Left Hand Switch Housing Left Direction Indicator Switch Right Direction Indicator Switch Direction Indicator Cancel Switch Scroll Up Switch Scroll Down Switch Select Switch Main/Dipped Beam Switch Pass Switch...
Page 741 Tiger Explorer XR Series Item Description Horn Ambient Air Temperature Sensor Alarm Oil Pressure Switch Instruments Bluetooth Module Connector Diagnostic Connector Main Fuse Box Key To Wiring Colour Codes Code Wiring Colour Black Blue Brown Green Slate/Grey Orange Pink Purple White Yellow Light Green...
Page 742 Tiger Explorer XR Series Complete System Circuit Diagram Item Description Chassis ECM Left Hand Fork - Compression Damping Motor Right Hand Fork - Rebound Damping Motor Rear Suspension Unit Damping Valve Rear Suspension Unit Preload Motor Inertial Measurement Unit Engine ECM Swinging Arm Position Sensor Windscreen Motor Key To Wiring Colour Codes...
Page 743 Tiger Explorer XR Series Code Wiring Colour Blue Brown Green Slate/Grey Orange Pink Purple White Yellow Light Green Light Blue CIRCUIT DIAGRAMS 739 of 746...
Page 744 Tiger Explorer XR Series Item Description Engine Control Module Manifold Absolute Pressure Sensor Ambient Air Pressure Sensor Gear Position Sensor Throttle Position Sensor Accelerator Position Sensor Diagnostic Connector Fuel Level Sender Intake Air Temperature Sensor Clutch Switch Side Stand Switch Throttle Actuator Motor Crankshaft Position Sensor Cooling Fan...
Page 745 Tiger Explorer XR Series Item Description Coil 3 Coil 2 Coil 1 Engine Management Relay Main Fuse Box Key To Wiring Colour Codes Code Wiring Colour Black Blue Brown Green Slate/Grey Orange Pink Purple White Yellow Light Green Light Blue CIRCUIT DIAGRAMS 741 of 746...
Page 746 Tiger Explorer XR Series Item Description Chassis ECM Rear Suspension Unit Damping Valve Right Hand Front Fork Rebound Damping Motor Left Hand Front Fork Compression Damping Motor Swinging Arm Position Sensor Windscreen Motor Heated Seat Switch - Passenger Heated Seat - Passenger Heated Seat Switch - Rider Heated Seat - Rider Left Heated Grip...
Page 747 Tiger Explorer XR Series Item Description Cooling Fan Fuel Pump Front Electrical Accessory Socket Fusebox 1 Rear Light Left Rear Indicator Right Rear Indicator Alternator Control Alternator Power Starter Motor Starter Solenoid Battery 40 Amp Main Fuse Fuse Box 2 Fog Light Switch Heated Grips Switch Fog Light/Heated Grips Connector...
Page 748 Tiger Explorer XR Series Item Description Left Indicator Switch Scroll Down Button Scroll Up Button Clutch Switch Left Handlebar Switch Housing Ignition Switch Hazard Switch Start Switch Cruise Control Switch Engine Stop Switch Right Handlebar Switch Housing Cruise Control Cancel Switch Accelerator Position Sensor Throttle Position Sensor Inertial Measurement Unit...
Page 749 Tiger Explorer XR Series Item Description Front Light Unit Main Beam - Left Dipped Beam - Left Front Position Light Dipped Beam - Right Main Beam - Right Right Front Indicator Left Front Indicator Horn Heated Oxygen Sensor Coolant Temperature Sensor Oil Pressure Sensor Injector 1 Injector 2...
Page 750 Tiger Explorer XR Series Item Description Side Stand Switch Fuel Level Sender Intake Air Temperature Sensor Secondary Air Injection Solenoid Throttle Control Engine ECM Engine Management System Relay CIRCUIT DIAGRAMS 746 of 746...

This manual is also suitable for:

Tiger explorer xr 2016 Tiger explorer xrt 2017 Tiger explorer xrx 2016 Tiger explorer xrx 2017 Tiger explorer xrt 2016

Triumph Tiger Explorer XR 2017 Service Manual

Table of Contents

Twist Grip Position Sensor 1 Twist Grip Position Sensor 2

Replace Fuse, Proceed to Test 5/Rectify Fault, Proceed to Test 5

1 Check Fuse Integrity: OK

2 Check Cable and Terminal Integrity: OK

3 Check Cable for Short Circuit: OK

4 Check Cable Continuity: OK

5 Reconnect Harness, Clear Fault Code OK and Run Engine to Verify Fault Cleared

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Chapters

Summary of Contents for Triumph Tiger Explorer XR 2017

Page 3: Table Of Contents

Page 5: Introduction

Page 7: General Information

Page 61: Scheduled Maintenance

Page 86: Cylinder Head

Page 116: Clutch

Page 167: Balancer

Page 169: Transmission

Page 206: Lubrication

Page 230: Fuel System/Engine Management

Page 275: Check Cable And Terminal Integrity: Ok

Page 276: Faulty

Page 277: Check Cable Continuity: Ok

Page 278: Action

Page 353: Cooling

Page 371: Front Suspension

Page 398: Rear Suspension

Page 457: Brakes

Page 504: Final Drive

Page 547: Wheels/Tyres

Page 558: Frame And Bodywork

Page 676: Check Fuse Integrity: Ok

Page 677: Check Cable Continuity: Ok

Page 682: Replace Fuse, Proceed To Test 5

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Triumph Tiger Explorer XR 2017 Service Manual

Table of Contents

Twist Grip Position Sensor 1 Twist Grip Position Sensor 2

Replace Fuse, Proceed to Test 5/Rectify Fault, Proceed to Test 5

1 Check Fuse Integrity: OK

2 Check Cable and Terminal Integrity: OK

3 Check Cable for Short Circuit: OK

4 Check Cable Continuity: OK

5 Reconnect Harness, Clear Fault Code OK and Run Engine to Verify Fault Cleared

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Summary of Contents for Triumph Tiger Explorer XR 2017

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Table of Contents