Triumph TIGER Service Manual
  1. Manuals
  2. Brands
  3. Triumph Manuals
  4. Motorcycle
  5. Tiger
  6. Service manual

Triumph TIGER Service Manual

Hide thumbs Also See for TIGER:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
Table of Contents

Advertisement

Quick Links

Mp
H
U
TIGER
TIGER (ABS)

Advertisement

Table of Contents
loading

Related Manuals for Triumph TIGER

Summary of Contents for Triumph TIGER

  • Page 1 TIGER TIGER (ABS)
  • Page 2 Part Number 385736S Issue 1, 11.2006 Service. Manual - Tiger...
  • Page 3 Table of Contents Manual - Tiger Service pT1IIIIbi I l...

  • Page 4: Table Of Contents

    Howto use this manual ..............iv Warnings, Cautions and Notes ..............iv Tamperingwith Noise Control System Prohibited ..........v References................. v Dimensions................v airsand Replacements............v Force••••••••••• ♦••••...••••.•••••••..•.••••.••.•.•.••..••••.•••••••••••••••••••••••V Edges• ................v Tighteningprocedures ..............v Service Manual - Tiger TRJUMPON...

  • Page 5: Warnings, Cautions And Notes

    Whenever the owner has insufficient experience or doubts the tool. his ability to do the work, an authorised Triumph dealer must undertake all adjustments, maintenance, and repair Where usage is not obvious, the tool is shown in use.

  • Page 6: Tamperingwith Noise Control System Prohibited

    Triumph parts are fitted. In certain territories, the ultimate purchaser or while it is in use; and legislation prohibits the fitting of parts not to the b) the use of the vehicle after such device or element manufacturer's specification.
  • Page 7 This page intentionally left blank Service Manual - Tiger...
  • Page 8 [Lci ir i I TI11MI'I1i X1 1 ^ ^ ^^ .^ P': IgnitionSystem Safety Precautions ............DangerousSubstances ..............Fluoroelastomers................Oils..................Protection Precautions ............... Health EnvironmentalProtection Precautions ............Brakes................... yInstructions ................. Safet and Lifting ..............1.5 Jacking Precautionsagainst Damage ............Coolant ..........0 ......0 ... 1.5 Cleaningcomponents ..............
  • Page 9 Fuel Tank Breather Hose Routing - Models without Evaporative Emissions ......1.41 Mainwiring Harness Routing .............. FrontBrake Hose Routing - Models without ABS Brakes ........1.42 Rear Brake Hose Routing - Models without ABS Brakes ........1.43 BrakeHose Routing - Models with ABS Brakes ..........1.44 Service Manual - Tiger...

  • Page 10: Health Protection Precautions

    Do not put oily rags in pockets. • Overalls must be eaned regularly. Discard heavily soiled clothing and oil impregnated footwear. • rst aid treatment should be obtained immediately for open cuts and wounds. Always be aware of who your nearest first- Service Manual - Tiger...

  • Page 11: Environmentalprotection Precautions

    Precautions .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 12: Safet Yinstructions

    Coolant Coolant mixture, which is blended with anti-freeze and corrosion inhibitors contains toxic chemicals which are harmful to the human body. Never swallow anti-freeze, corrosion inhibitors or any of the motorcycle coolant Service TMumpi Manual - Tiger...

  • Page 13: Lubrication

    The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. Liquid gasket, Non-permanent Locking Agent Follow manufacturer's • directions for cleaning and preparing surfaces where these compounds will be used. 1 .6 Service Manual - Tiger...

  • Page 14: Locking Devices

    Always use the correct replacement circlip as Ball Bearing recommended in the Triumph parts catalogue. When installing a ball bearing, the bearing race which is an interference fit should be pushed by a suitable driver. Self Locking Nuts This prevents severe stress or damage to the load carrying components.

  • Page 15: Petrol - Gasoline

    If the motorcycle is involved in an accident or collision it the site of the work to warn others that petrol is being must be taken to an authorised Triumph dealer for openly handled. The notice must instruct the reader of repair or inspection.

  • Page 16: Batterydisconnecting

    Never force connectors apart either by using tools or by pulling on the wiring itself. Always ensure locking mechanisms are disengaged before removal and note the orientation to enable correct reconnection. Ensure that Service Manual - Tiger...

  • Page 17: Electrical Wires

    By transposing either of these formulae, the value of any unit can be calculated if the other two values are known. For example, if a battery of 12V is connected to a bulb of 60W: 1.10 Service Manual - Tiger...

  • Page 18: Glossaryof Circuit Diagram Symbols

    Due to the complex circuits and the number of individual Electromagnetic Winding (solenoid) wires, Triumph uses two types of circuit diagram in its service manuals. manual ® Within the conventional circuit...

  • Page 19: Tracingcircuits

    Normally Over Open Closed 1•- Triumph use LEDs for the alarm warning light, instrument illumination and warning lights, gear change lights and rear light/brake lights on various models. 0-----0 Motor An electric motor. This could be the starter motor or a A mechanical device for completing or breaking a circuit.

  • Page 20: Tocheck Continuity

    Set the Digital Multi Meter (DMM) to Read the voltage from meter. resistance check (9). • Probe each end of the wire. • If there is continuity, the meter will usually bleep or register the resistance of the cable. 1.13 Service Manual - Tiger 71tiumeH...

  • Page 21: Can(Controller Area Networking)

    CAN (sometimes called CANbus) is a protocol for data reported by a DTC (Diagnostic Trouble Code). communication between Electronic Control Modules Triumph currently use CAN for communication between (ECMs). Each ECM on the network is connected by a the engine ECM and the instruments.
  • Page 22 • t:iiiI Information uses diodes to convert the alternator output to dc volts and limit the resulting output to the correct figure The charging system consists of an alternator and a required for optimal battery charging. rectifier/ regulator assembly and the battery. The If the charging circuit does not operate correctly, the alternator is made up of two parts, the stator, which is following basic checks must be carried out before further...
  • Page 23 :T1iDi;1 • Check the frame and engine earth connections are clean, tight and free from All Triumph models are equipped with an electric start corrosion. • system. This system consists of a starter relay, starter • Ensure the battery is fully charged and in motor, starter switch, sidestand switch, engine stop switch, condition.
  • Page 24 BAD CONTACT AT CONNECTOR STARTER RELAY SWITCH OPEN CIRCUIT IN WIRING LOOM CONNECTOR FAULTY ALARM Voltage Measured Normal CHECK THE STARTER RELAY LOOSE OR POOR CONTACT AT OPERATION STARTER RELAY Abnormal FAULTY STARTER RELAY 1.17 Service Manual - Tiger 11tiumem...

  • Page 25: Replacement Parts

    Triumph parts. All genuine Triumph parts have the full backing of the motorcycle warranty. Triumph dealers are obliged to Replacement Parts supply only genuine Triumph recommended parts.

  • Page 26: Specialservice Tools

    i.iDitii r. c a ge e vice age Equiprnert Special service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical components in a practical manner without causing damage. Some operations in this Service Manual cannot be carried out without the aid of the relevant service tools.
  • Page 27 T3880250 —Engine Management/ABS Diagnostics T3880105 —Angular Torque Gauge Increment /markings 3880160 — Fork Filler / Evacuator T3880027 - Chain Link Took Kit cdob ccha T3880003 -.Fork Seal and Bush Fitment 3880085-T0301 - Fork Damper / Holder cogs ccxb 1.20 Service Manual - Tiger...
  • Page 28 General Information T3880067 - Fork Spring Compressor T3880104 — Wrench, Swinging Arm Adjuster cdoa T3880377 — Wrench, Engine Mounting Adjuster caoa, T3880315 — Extractor, Cylinder Liners gakh 1.21 Service Manual - Tiger...
  • Page 29 General Information BatteryMate Battery Charger - See Latest Parts Catalogue T3880002 — Support Plate for Part Number Information T3880371 — Holder, Oil Pump Drive Gear cczb 3880053 — Extraction Kit, Wheel bearings 1.22 Service Manual - Tiger...
  • Page 30 3880070 — T0301 — Bearing Installer T3880004 - Holder, Damping Cylinder T3880023 - Headstock Bearing Wrench T3880123 — Extension Cable cdbp 1.23 Service Manual - Tiger l^Mr...
  • Page 31 ValveClearance ......In..... 0.10-0.20 mm ........Ex ..... 0.20-0.30 mm ValveBucket Diameter ........28.476-28.490 mm ServiceLimit .......... 28.549 mm ValveBucket Bore Diameter ........ 28.515-28.535 mm ServiceLimit .......... 28.549 mm 1.24 Service Manual - Tiger...

  • Page 32: Clutch

    General Informat ion Tiger 10 FQflSpecification Camshafts CamTiming 9.25° BTDC (@ 1.0 mm lift) ....Open Inlet ......Close 39.25° ABDC (@1.0 mm lift) ........Duration ..228.50° BBDC (@ 1.0 mm lift) Exhaust ....Open 31° CamTiming ....Close 1° ATDC (@ 1.0 mm lift) ........

  • Page 33: Transmission

    ....0.05 mm Transmission Type............ 6 Speed, Constant Mesh GearRatios ......1st ....2.733:1 (15/41) ........2nd .....1.947:1 (19/37) ........3rd ....1.545:1 (22/34) ........4th ..... 1.292:1 (24/31) ........5th ..... 1.154:1 (26/30) ........6th ..... 1:1 (28/28) 1.26 Service Manual - Tiger...
  • Page 34 I ai9 Specificadon Tiger 1050 cc Gear Selector Fork Thickness .......5.8-5.9 mm ....5.7 mm ServiceLimit .........6.0-6.1 mm Gear Selector Groove Width ....ServiceLimit .......... 6.25 mm Gear Selector Fork to Groove Clearance ..
  • Page 35 OilVolume (dry fill) ........581 cc ForkPull Through ........(see section 13) RearWheel Travel ........150 mm Rear Suspension Bearing Grease ......Mobil grease HP 222 1.28 Service Manual - Tiger...
  • Page 36 Specan Full FllI Tiger 1050 cc FrontType ..........Two hydraulically actuated four piston calipers acting on twin discs CaliperPiston Diameter ........33.96 mm / 30.23 mm DiscDiameter........320 mm DiscThickness ........... 4.5 mm ServiceLimit ......
  • Page 37 ........#4 ....Blank ........#5 ....Blank ......; ..#b ....Accesso socket, heated grips ........#7 ....Cooling fan ........#8 ....Engine management system ........#9 ....Alarm, diagnostic connector, instruments 1.30 Service Manual - Tiger...
  • Page 38 See section 6 Connecting rod big end nut See section 6 Balancer retaining bolt Apply ThreeBond 1305 to the threads Big end bearings See section 6 Sprag clutch to crankshaft Starter drive cover to crankcase Service Manual - Tiger 1.31...

  • Page 39: Lubricationsystem

    Oil cooler pipe union bolts Oil cooler to mounting bracket/radiator Oil pump to crankcase 13.7 Oil pump drive sprocket • to pump shaft Oil feed pipe union to head Transmission oil feed pipes crankcase Oil cooler bracket to crankcase 1.32 Service Manual - Tiger...

  • Page 40: Coolingsystem

    Airbox to bracket Airbox upper to lower section Exhaust downpipe to frame clamp Exhaust to downpipe bracket Silencer mounting to frame Catalyst heatshield to downpipe (only if catalyst fitted) pipe Exhaust heatshield Silencer heatshield 1.33 Service Manual - Tiger 11J%qjjkI...

  • Page 41: Rear Suspension

    Lower yoke pinch bolt Fork top cap to inner tube Upper yoke centre Damping cylinder bolt Application Torque (Nm) Notes Front wheel spindle / axle bolt pinch Front wheel spindle bolts Rear wheel spindle/axle bolt 1.34 Service Manual - Tiger...

  • Page 42: Rearbrakes

    Front pulser ring to front wheel hub Rear pulser ring to rear brake disc ABS modulator to mounting bracket ABS modulator mounting bracket to frame Use new fixings Brake line unions to ABS modulator 1.35 Service Manual - Tiger TWUMEH...

  • Page 43: Footrests, Control Plates And Engine Mountings

    Rear panel to subframe Infill panels to cockpit Mirrors to handlebars Windscreen to cockpit subframe Cockpit subframe to frame Rear mudguard to frame Rear mudguard end section to bracket Rear hugger to swinging arm Belly pan to brackets 1:36 Service Manual - Tiger...
  • Page 44 Ii iI 1.37 Service Manual - Tiger...
  • Page 45 1.38 Service Manual - Tiger LiMM...
  • Page 46 TrI Service Manual - Tiger 1.39...
  • Page 47 General Information 1.40 Service Manual - Tiger...
  • Page 48 C I TI kiiiiThitii 1.41 Service Manual - Tiger . Tq!Lm^...
  • Page 49 GeneralInformation uI : 1.42 Service Manual - Tiger UN[P...
  • Page 50 11111 IitThTt(eTiiiMi 1.43 Service Manual - Tiger UNf^...
  • Page 51 General Information 1.44 Service Manual - Tiger I UMW...
  • Page 52 2 Scheduled M Table of Contents Introduction ............... ScheduledMaintenance Chart ............Service Manual - Tiger...
  • Page 53 TLffl I Service Manual - Tier...
  • Page 54 • • Tyre pressures - checkladjust • Clutch cable - check/adjust • • • • Stand — check operation • • • Secondary exhaust clamp bolt - check/adjust • • • • • • Service Manual - Tiger • TWUMEM...
  • Page 55 (60000) 1 month 1 year 2 years 3 years 4 years 5 years 6 years Secondary air injection system - check Fuel and evaporative loss* hoses - renew --tvaporaave system nuea to c.aiirornia models only Service Manual - Tiger LUMP...
  • Page 56 CylinderHead ........: ........3.17 Removal................3.17 Inspection................ 3.18 Installation................. 3.18 Valves Valve Stem Seals ............... 3.20 Removalfrom the Cylinder Head ............. 3.20 Installation................. 3.20 Valveto Valve Guide Clearance ............3.21 ValveFace Inspection ............... 3.21 Service Manual - Tiger I - Mr...
  • Page 57 Cylinder Head 10 Nm 10 Nm Manual - Tiger Service...
  • Page 58 Cylinder Head Lubricate sea with engine c Service Manual - Tiger...
  • Page 59 Cylinder Head iuui C ain 18 Nm Service Manual - ^ Ti g er...
  • Page 60 1. Spring-close hose clip 2. Secondary air injection hose 3. Reed valve assembly 10. Release the throttle cables at the throttle bodies (see page 10-111). 11. Progressively release the cam cover bolts in the sequence shown below. Service Manual - Tiger TWUMBH...

  • Page 61: Installation

    1. Check the condition of the cam cover gasket and plug tower seals. Replace as necessa 2. Check the condition of the cam cover bolt seals. Replace as necessa CBS) Fit the cam cover, ensuring that the gasket and seals remain in the correct positions. Service Manual - Tiger...
  • Page 62 11. Refit the throttle cables and adjust (see a e 20. Refit the seat (see page 16-9). 12. Refit secondary air injection hose reed to the valves (see page 10-124). 1.Spring-close hose clip 2. Secondary air injection hose valve assembly 3. Reed Service Manual - Tiger Twumem...
  • Page 63 5. Carefully remove the centre nut from the tensioner and withdraw the tensioner spring. 1. 'T1' Mark 2. Marker line caom I. Centre nut 2. Spring 6. Remove the bolts securing the tensioner to the cylinder head. Remove the tensioner and gasket. Service Manual - Tiger...
  • Page 64 Fit a new sealing washer to the centre nut. Using finger pressure only, push the ratchet section of the tensioner into firm contact with the tensioner blade. Check that number 1 cylinder is still at top dead Refit the spring and centre nut to the tensioner. centre (TDC).

  • Page 65: Camchain Tensioner

    • A be used to marker or similar 1. Cam chain mark positions. camshaft Inlet • Progressively release each of the remaining fasteners securing the individual caps to the cylinder head. Remove the caps. 3.10 Service Manual - Tiger...
  • Page 66 1. Inlet camshaft bolt holes cap and ladder bolts to 10 Nm in the correct 2. Exhaust camshaft bolt holes sequence (see camshaft installation). 3.11 Service Manual - Tiger •IRt!:!!.!?kI...

  • Page 67: Installation

    ..'ki''`• ,: S:s .v,,;<.,;,.,,p,.t;;...::.x R.^:.\^•y:,xw::43if... •^.S^ Yv'...,..d:>Id'itiM: :.. .\;2?i.n..::^y:,•<}Ai:.:::;.,.;:.nH>i::..x%i•..tr1..nl.^..:y:y.C..:!M :..:. :,y, Although Plastigage is oil soluble; all traces of the material must be removed to prevent blockage of the oil drillings and resultant engine damage. 3.12 Service Manual - Tiger...

  • Page 68: Removal

    5. Assemble the_cam caps, dowels, cam ladder and top 9. Rotate the engine through 4 full revolutions, and pad in the same location and orientation as prior to reset number 1 cylinder to TDC. Ensure that the 'T1' removal. mark on the sprag clutch aligns with the line at the om of the cover.

  • Page 69: Valveclearance Adjustment

    (see page Exhaust: 0.20 - 0.30 mm 3-10). Remove the camshafts (see page Remove the tappet bucket from the cylinder head. 6. Record the measured valve clearances on a chart similar to the example shown. 3.14 Service Manual - Tiger...

  • Page 70: Camchain

    Lubricate the tappet bucket(s) with a 50/50 solution of engine oil and molybdenum disulphide grease. Refit the tappet bucket. Refit the camshafts (see page 3-12). Re-check all valve clearances. 10. Repeat the procedure if the valves require further adjustment. 3.15 Service Manual - Tiger :rRt!:!.H...
  • Page 71 Cylinder Head Inspection 3. Measure across 23 links as shown in the diagram below. If the chain is within limits, the measurement Visual in-situ checks can also be made as follows: should be . no longer than 150.14 mm. Measurements beyond 150.14 mm indicate that the Check for significant blue discolouration of the chain chain must be replaced.
  • Page 72 Remove all the tappet buckets and shims. 1. Shim Note: • To prevent the tappet buckets and shims from becoming mixed, place the shim and tappet together in a marked container. The components must be refitted- in their original positions. 3.17 Tiger Service Manual -...

  • Page 73: Inspection

    3. Ensure that the cylinder head face is completely clean. 4. If removed, install the cam chain rubbing strips. 5. Carefully lower the cylinder head over the cam chain and rubbing strips and locate the head onto the dowels. 3.18 Service Manual - Tiger IUMP...
  • Page 74 ` to release the a 'torque turn' method is used. The bolts must be turned through 90 to reach the final setting. To turn, accurately -gauge the 90 use service tool 3880105-T0301 as follows: 3.19 Service Manual - Tiger TWUMOH...
  • Page 75 • Note: • Ensure inlet and exhaust valve components do not become mixed. g \ 4 1. Collets 2. Valve spring retainer 3. Valve spring 4. Valve spring platform gadh S. Stem oil seal 6. Valve Valve Removal 2. Once the collets are released, remove the following items: Installation •...

  • Page 76: Valveto Valve Guide Clearance

    If not fitted correctly, the collets may become dislodged when the engine is running allowing the valves to contact the pistons. Any such valve to piston contact will cause severe engine damage. 3.21 Tiger Service Manual - •Tt.iH...
  • Page 77 Cylinder Head This page intentionally left blank 3.22 Service Manual - Tiger...
  • Page 78 ExplodedView - Clutch Cover ............... View Clutch Assembly ............Exploded Clutch Controls ............Exploded Cable ................Clutch ................Removal Inspection..............................Assembly ................... Clutch ................ Disassembly Plate Insection ..............Friction ................Thickness Bend/warp ..............................Assembly Tiger Service Manual -...
  • Page 79 Clutch Ixmi Service Manual - Tiger IUM^...
  • Page 80 Service Manual -Tiger...
  • Page 81 Clinch Cantrols Eloded - Clutch 15 Nm 1 Nm Service Manual - Tiger Limp...

  • Page 82: Clutch Cable

    3. Examine the two inner cable nipples for signs of from the bracket. looseness and damage. Replace the cable if necessary. 1.Actuating arm 2. Inner cable 5. Align the lever adjuster and lever bracket slots. Service Manual- Tiger •I RL!:!! H...

  • Page 83: Assembly

    Undo the bolts and springs and remove the clutch pressure plate. Remove the clutch pull rod. 1.Clutch lever 2. Correct setting, 2-3 mm Reconnect the battery positive (red) lead first. Refit the seat (see page 16-9). kaik 1. Clutch pull rod Service Manual - Tiger Twumem...

  • Page 84: Friction Plate Insection

    T3880305. 1. Outer drum 2. Bearing sleeve 11. Remove clutch outer drum leaving the oil pump drive sprocket, bearing and sleeve in place on the input shaft. 1. Service tool T3880305 Manual - Service Tiger 11RIUMEM...

  • Page 85: Bend/Warp

    Standard 2. Feeler gauge 3. Surface plate 3.60 mm Service limit Friction plate bend/warp Friction late thickness all other plates up to 0.15 mm Standard Standard 3.30 mm 0.20 mm limit Service Service limit 3.10 mm Manual - Tiger Service...

  • Page 86: Assembly

    UUoo Belleville Washer 'OUT Mark 1.Alignment hole 2. Outer drum While holding the clutch outer drum in position and ensuring correct engagement with the oil pump drive, refit the bearing sleeve. Service Manual - Tiger •flLqJ3H...
  • Page 87 • The clutch fitted tags plate are such that the outer of the engaged with the corresponding -individual tags in the clutch outer drum. 1. Outer clutch friction plate a. Outer drum 3. Individual tags 4.10 Manual - Tiger Service...
  • Page 88 Connecting Rod Big End Bearing Selection/Crankpin Wear Check ....... 5.11 ConnectingRod Bearing Selection ............. Pistons.................. 5.13 Disassembly................ 5.13 Piston Wear Check ..............5.13 ..Piston Ring Gap 5.14 5.14 PistonAssembly ..............5.15 CylinderLiners ................5.16 Removal................5.16 Installation............, ....5.17 5.18 CrankcaseBreather ............... Service TOUMM Manual - Tiger...
  • Page 89 Crankshaft, Connecting Rods and Pistons iAIk Manual - Tiger Service LIMP...
  • Page 90 5.3` Service Manual - Tiger Tq^!M^p...
  • Page 91 2. Invert the engine to give access to the lower circlip groove on the crankcase. crankcase bolts. Ensure that the transmission is in neutral. Service Manual - Tiger IUM^...
  • Page 92 Stage I - all screws Install and lubricate the crankshaft bearing shells with clean engine oil (see bearing selection before Invert the engine. proceeding). Lubricate the crankshaft journals with clean engine oil. Service Manual - Tiger...
  • Page 93 Refit the engine covers. Refit the sump. 9. Install the engine in the frame (see page 9-6). Lower Crankcase Bolt Tightening Sequence Invert the engine. 4. In the correct sequence, tighten all upper crankcase screws to 12 m. Service Manual - Tiger...
  • Page 94 Ensure that the crankshaft is clean, and that the disturbed crank and gear • the oilways within the crank are clean and free from individually serviceable. blockages and debris. Refit the balancer (see page 6-4). Manual - Service Tiger • Twumem...
  • Page 95 Using the original nuts and bolts may lead to severe engine damage. Remove the liner using tool 13880315 (see page 5- 16). Detach the piston from the connecting rod (see page 5-13). Service Manual - Tiger Twumem...
  • Page 96 • Avoid touching any bearing surfaces of the bearing shells with the hand. Apply silicone sealer to the liner-to-crankcase mating face. ccvk 1. Liner 2. Sealer area Service Manual - Tiger TwumeH •...
  • Page 97 Tighten to 14 Nm. number 3880150-T0301) e) Tighten through 120° of nut rotation as measured Remove the big end from the journal to be using the Triumph torque turn gauge 3880105- checked. T0301. Wipe exposed areas of the crankpin, and the bearing face inside the cap.
  • Page 98 Severe engine damage could result from incorrect Colour clearance. Marking Con-rod 38.008 38.008 38.018 38.018 38.000 38.000 38.009 38.009 Dia. Bore Crankpin 35.000 34.991 35.000 34.991 Dia. 34.992 34.984 34.992 34.984 Running 0.066 Clearance 0.036 Service Manual - Tiger TRLqj311...
  • Page 99 Due end float crankshaft is outside the specified to the techniques used during manufacture, limit, the crankshaft and/or crankcases cannot be re-ground and no the crankshaft must be replaced. oversize bearings are available. 5.12 Service Manual - Tiger...
  • Page 100 Carefully remove the mark to allow the pin to be removed. 5. Piston rings must be removed from the piston using hand pressure only. 5.13 Service Manual - Tiger T1ty! H...
  • Page 101 If gap is too large, replace the rings with a new set. If the gap remains too large with new rings fitted, both the piston and liner must be ,replaced. 5.14 Service Manual - Tiger...
  • Page 102 .iii iiiiii iflhi1 T q11T1 FRONT — cagj 1.Top 2. Second ring 3. Steel oil control rings 4. Oil control ring expander Note: Piston Ring Identification • The top ng gap should be positioned in the Fit the piston onto the connecting rod. 7 o'clock position, the second ring gap in the I o'clock position and the steel oil control Note:...
  • Page 103 fITI (!Ii 1. Paint mark 1. Mark each liner to identify correct orientation and the cylinder number from which it has been removed. gaep Turn the crankshaft until the piston in the liner to be Test Positions For Bore Wear Check (bore shown in removed is at the bottom of its stroke.
  • Page 104 Arrowed: Liner-piston tment 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. 5.17 Service Manual - Tiger Twumm...
  • Page 105 However, when assembling the crankcases, ensure that the breather hose is not damaged and is securely fitted to the breather as follows: 1. The hose should be pushed fully on to the breather outlet. 5.18 Service Manual - Tiger...
  • Page 106 ,' S ° ° r.wi ExplodedView - Balancer Shaft .............. Balancer................................Removal Inspection................Assembly/Installation ..............Service Manual - Tiger TRJUM8H...
  • Page 107 Balancer E^plm ^d Vae Balancer Shaft C^ J' 60 Nm •2 Manual - Service Tiger...
  • Page 108 A damaged seal track will cause from oil to be ejected the engine. To strip the backlash eliminator from the drive gear, wave- release the circlip remove the washer, backlash gear and spring. Service Manual - Tiger TRIUMEH...
  • Page 109 Asse ly/In Ilation If the backlash gear was disassembled, fit the backlash spring the balancer drive gear, positioning spring ends on either side of the peg. Fit the backlash gear, ensuring its peg is located i/,7 clockwise of the balancer gear peg and also between the spring ends.
  • Page 110 \(o/ 1. Circlips 2. Crankcase circlip grooves 11. Remove the securing fixture. 12. Check that the balancer and crankshaft are correctly aligned before continuing to assemble the crankcase halves. Service Manual - Tiger TwUmem...
  • Page 111 This page intentionally left blank Service Manual - Tiger...
  • Page 112 Removal.........., ......7.20 Inspection ................ Installation........:......... Tiger Service Manual - 1•Rt!:!! H...
  • Page 113 Transmission Manual - Service Tiger...
  • Page 114 Transmission - ;^ 54 Nm Service Manual - Ti er...
  • Page 115 Transmission,: r;: r liJillili I'AIWA (']'I *1iT! I*iJ 12 Nm N '. Service Manual -Tiger...
  • Page 116 L a m' Service Manual - Tiger...

  • Page 117: Selectorshaft, Selector Forks And Drum

    3. Selector shaft The selector forks be fitted incorrectly. Ensure the orientation of the selector forks are marked- position prior to removal. Incorrect fitting of the selector forks will cause gearbox damage. 1.Gear change shaft 2. E-clip Service Manual - Tiger •...
  • Page 118 (discard the fixing) and withdraw the wheel. Note: • To prevent drum rotation, use a stout rod through one of the through-holes in the drum. Care must be taken not to damage the oil pressure relief valve. Manual - Tiger Service TuM M...

  • Page 119: Inspection

    Refit the bearing retainer. Secure with a new bolt and tighten to 12 Nm. 1. Bearing retaining bolt 5. Fit the detent wheel engaging the wheel with the locator pin in the selector drum. Tighten a new fixing to 12 Nm. Manual - Tiger Service...
  • Page 120 Take care to avoid damaging the lip of the seal when Gear change shaft inserting the gear change shaft into the crankcase. A 2. Detent arm damaged seal will lead to oil loss and could result in 3 Abutment bolt damage. engine 4. Spring Service Manual - Tiger...
  • Page 121 The selector forks can be fitted incorrectly. Ensure the position and orientation of the selector forks are the same as noted during removal. Incorrect fitting of the selector forks will cause gearbox damage when changing gear. 7.10 Service Manual - Tiger...

  • Page 122: Removal

    1.Groove in crankcase 2. Retaining ring 3. Seal Ensure the dowel in the output shaft needle roller bearing is positioned to locate in the hole provided in the upper crankcase. 1.Roller bearing 2. Dowel 7.11 Service Manual -Tiger UMW'...
  • Page 123 Transmission..Remove the circlip (11) from in front of fifth gear. 7.12 Manual - Service Tiger...
  • Page 124 10. Third/Fourth Gear 3.Needle Roller Bearing 11. Circlip 4. Thrust Washer 12. Thrust Washer 5. Second Gear 13. Fifth Gear 6. Sixth Gear 14. Input Shaft 7. Splined Bush 15. Input Shaft Bearing 8. Thrust Washer 7.13 Service Manual - Tiger TWUMPOjot...
  • Page 125 Reduced oil pressure and gear lubrication will cause engine damage and could also lead to engine seizure resulting in loss of motorcycle control and an accident. 7.14 Service Manual - Tiger UMI^...
  • Page 126 Fit sixth gear (6) with the dog teeth facing third/ fourth gear. 1. Sixth gear 2. Splined bush 10. Fit second gear (5) with the stepped side facing away from the clutch end of the input shaft. 7.15 Service Manual - Tiger IUM^...

  • Page 127: Disassembly

    Remove the circlip (13) from in front of sixth gear. face and any unprotected parts of the body. 10. Remove sixth gear (14) from the shaft. 11. Remove the circlip (15) from in front of second gear. 7.16 Service Manual - Tiger...
  • Page 128 8. Third gear 21. Output sprocket 9. Third gear bush 22. Oil seal 23. Retaining ring 10. Fourth gear 11. First gear bearing & washer 24. Bearing 25. Sleeve 12. Thrust washer 13. Circlip Service 7.17 Manual - Tiger • :IRL!!: H...

  • Page 129: Assembly

    6. Fit sixth gear (14) with the selector fork groove facing away from the output sprocket end. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft. 7.18 Service Manual - Tiger...
  • Page 130 12. Fit the first gear thrust washer and bearing (11). 1. Fourth gear 2. Thrust washer 9. Fit third gear (8) with the larger step side facing away from the output sprocket. 1. Fifth gear 2. Thrust washer 3. Bearing 7.19 Service Manual - Tiger Tty!H 9M . -...

  • Page 131: Disassembly

    , negative (black) lead first (see nside the cover There are two bolts located i page 17-7) in the area behind the starter idler9ear. Remove the starter cover. 1. Right hand crank cover 1. Starter cover 2. Aluminium washer position 7.20 Service Manual - Tiger...
  • Page 132 Examine all bearings for chipped, broken or seized rollers, overheating (going blue) and for any other damage. Examine the end of the crankshaft for damage. kajk 1. Tool T3880017 2. Sprag fixing Slide the sprag clutch and gear from the crankshaft. 7.21 Service Manual - Tiger IDUUM...

  • Page 133: Starter Drive Gears /Sprag Clutch

    Position a new gasket to the crankcase dowels then refit the right hand crank cover. Ensure the bolt with the aluminium washer is correctly located then tighten the cover bolts to 9 Nm. kajI 1. Right hand-crank cover 2. Aluminium washer position 7.22 Service Manual - Tiger l^M^...
  • Page 134 Switch ............. 8.11 Oil Pressure Warning Light Installation................8.11 Sump.................. 8.12 ..........Removal 8.12 . . . 00..0....0..Inspection................8.12 Installation....... 8.13 .8.13 OilCooler ................8.14 ................Removal 8.14 Inspection................8.14 Installation................8.14 Tiger Service Manual -...
  • Page 135 Su m a-_________________ 25 Nm 12 Nm 10 Nm 10 Nm Service Manual - Tiger...
  • Page 136 13.7 Nm 13.7 Nm 15 Nm Service Manual - Tiger...
  • Page 137 Lubricati IA [4 i11:T;1 10 Nm 10Nm 1ONm 'J1 I i.i u 25 Nm 13 Nm 8 Nm Service Manual - Tiger...

  • Page 138: Engineoil Circuit

    Oil Circuit Ent ine - COOLED OIL Q - UNCOOLED OIL Service Manual - Ti - Tiger TR!!.M^...

  • Page 139: Specification

    Mobil 1 Racing 4T, specially filled for Triumph, is available On the Tiger, oil is also fed to the alternator cover to aid from your authorised Triumph dealer. cooling of the alternator. The oil is taken from the...

  • Page 140: Oiland Oil Filter Change

    Warm up the engine thoroughly, and then stop the engine and secure the motorcycle in an upright position on level ground. Place an oil pan beneath the engine. Service Manual - Tiger 1•RW!w^H...

  • Page 141: Disposalof Used Engine Oil

    Oil drain plug ground, down sewers or drains, or into water courses. 2.Oil filter Dispose of used oil sensibly. If in doubt contact your local Unscrew and remove the oil filter using Triumph authority. service tool T3880312. 1. Oil filter 2.

  • Page 142: Removal

    Remove the tool, upper and lower sprockets, upper sprocket bearing and the drive chain by sliding all components off the shaft together. Release the bolts securing the oil pump to the crankcase and withdraw the oil pump. 1. Pump bolts Service Manual - Tiger INJUMeti...

  • Page 143: Installation

    brication Clearance Body 1. Release the screw and withdraw the oil pump plate Standard: 0.15 - 0.22 mm from the pump body. Service limit: 0.35 mm Measure the pump end clearance. Pump Clearance Standard: 0.02 - 0.07 mm Service limit: 0.10 mm (a) If all clearances are within service limits, liberally apply clean engine oil to all internal components and...

  • Page 144: 1. Oil Pump

    15 Nm. Remove the tool. Assemble the clutch (see page 4-9). Reconnect the battery, positive (red lead) first. Refill the engine with oil (see page 8-7). 8.11 Service Manual - Tiger TRJUMPM...

  • Page 145: Sump

    Inspect the oil pick-up for correct fitment in the lower system. crankcase. Contact with a hot exhaust could result in burn injuries. Remove the oil filter (see page 8-7). Release the bolts securing the sump to the lower crankcase. 8.12 Tiger Service Manual - lu1^iP...
  • Page 146 Pre-fill a new oil filter with clean engine Installation oil. Apply a smear of clean engine oil to the seal of the Fit the oil transfer tube to the crankcase. new oil filter. Fit the oil filter and tighten to 12 Nm using tool T3880012.

  • Page 147: Inspection

    10 minutes. 1.Oil cooler hose (right hand shown) 2. Fixings Adjust the engine oil level (see page 8-7). Refit the seat (see page 16-9). 8.14 Service Manual - Tiger...
  • Page 148 ExplodedView - Engine Mountings ............Adjuster Sleeves ............ExplodedView - Frame EngineRemoval/Refit ..............EngineInstallation ................. Service Manual - Tiger...
  • Page 149 ^ ))ill)) ^! +1 Refer to text for bolt tightening sequence Expioded View -Frame Adjuster Sleeves CwI- Refer to text for frame adjuster tightening sequence Service Manual - Tiger...
  • Page 150 13. Remove the three fixings and remove the left hand 2. Brake pedal clevis pin control plate, heel guard, gear lever and linkage as 3. Control plate fixings an assembly. 1. Left hand control plate 2. Control plate fixings 3. Gearchange lever fixing Service Manual - Tiger...
  • Page 151 (see page 10-113). Note: • It is not necessary to disconnect the throttle cables. position the throttle bodies aside. 26. Disconnect the clutch cable (see page 4-5). 1. Right hand rear engine mounting bolts Service Manual - Tiger...
  • Page 152 13880377 as shown below. / / ( cylinder 1. Rear head frame adjuster position 31. Remove and discard the nuts securing the two left hand crankcase mounting bolts. 1. Special tool T3880377 Service Manual Tiger g er...
  • Page 153 Raise the engine and insert the two front cylinder head bolts to support the engine. Fit a new nut to the left hand side only, but do not tighten at this stage. Raise the engine and loop the drive chain over the output sprocket. Service Manual - Tiger...
  • Page 154 Any of these conditions could result in loss thro of control of the motorcycle and an ac dent. Service Manual - Tiger • :I L!:! ..H...
  • Page 155 17-7). 34. Remove the motorcycle from the paddock stand and place on the side stand. 35. Set the drive chain adjustment (see page 12-12). 36. Refit the seat (see page 16-9). 1. Starter motor connection Service Manual - Tiger 1^MM...
  • Page 156 Circuit Diagram - Engine Management System - Tiger - without ABS ...... 10.20 10.21 Engine Management Circuit Diagram - Tiger - with ABS ........Circuit Diagram - Engine Management System - Tiger - with ABS ......10.22 SystemDiagnostics ..............10.23 On-board Fault Detection System ..
  • Page 157 InletAir Temperature Sensor .............. 10.78 PinpointTests ..............10.78 FuelPump Relay ................ 10.80 PinpointTests ...:..............10.80 SystemVoltage................10.81 PinpointTests ..............10.81 Coolin Relay ............... 10.82 PinpointTests ..............10.82 LambdaSensor ................. 10.83 PinpointTests ..............10.83 LambdaSensor Heater ..............10.84 10.2 Service Manual - Tiger...

  • Page 158: Removal

    Inspection................ Installation................ 10.99 AirFilter Element ................ 10.99 ................. Removal 10.99 Installation................ 10.100 IntakeAir Temperature Sensor ............10.100 ................. Removal 10.100 Assembly................. 10.100 10.100 MapSensor .............................. Removal..10.100 Installation................ 10.100 10.101 BarometricPressure Sensor ............... 10.3 Service Manual - Tiger TLqj3H...
  • Page 159 SecondaryAir Injection Reed Valves ............10.115 Removal................. 10.115 Inspection................ 10.116 Installation............... 10.116 Evaporative Emissions Control System ............CaliforniaModels Only ............. 10.117 ComponentLocations .............. 10.117 EvaporativeControl System - Engine Off ..........10.118 EvaporativeControl System - Engine Running ......... 10.119 10.4 Service Manual - Tiger lUM'.
  • Page 160 System/Engine Management Service Manual - Tiger TRuM...
  • Page 161 Fuel System/Engine Management 3.5 Nm 3.5 Nm C•^rr^rif^^ 10.6 Service Manual - Ti er...
  • Page 162 Service Manual -Tiger...
  • Page 163 Fuel System/Engine Management . ;1 r;; r IA e text 15 Nn 25 Nm Apply anti-sieze 8 Nm compound to threads 15 Nm See text 5 Nm 10.8 Service Manual - Tiger LUMP...
  • Page 164 JI'anagemen 10.9 Service Manual - Tiger...
  • Page 165 1 0.1 0 Service Manual - Tiger...
  • Page 166 ,J,;: ^:^.,v^», 4,YOf components. 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 167 The percentage above or below the nominal fuel requirement for the volume of air entering at . engine Engine speed speeds other than idle. This function is not currently used The crankshaft revolutions per minute. in the Triumph system. 1 0.1 2 Service Manual - Tiger...
  • Page 168 Vbatt Sensor reference voltage Batte voltage. Supply voltage to the system sensors (nominally 5 volts). Short circuit A 'short cut in an electrical circuit - current by-passes the intended circuit (usually to earth). 10.13 Service Manual -Tiger...
  • Page 169 ECM memory. This stored data can then be requirements. recovered using a special service tool which is mandato for all Triumph dealers. In this way, precise diagnosis of a • Throttle position sensor - situated at the left fault can be made and the fault quickly rectified.
  • Page 170 Sensor Locations - ® a LAMBDA SENSOR 10.15 Service Manual - Tiger TWUMEH...
  • Page 171 ECM allows sufficient time for the coils to charge to a level where a spark can be produced. The coils are switched off at the point of ignition, the timing of which is optimised for good engine performance. 1 0.1 6 Service Manual - Tiger...
  • Page 172 Management TFWTI COOLING PRIMARY THROTTLE MAIN STEPPER MOTOR AIR INJECTION SOLENOID FALL DETECTION CANISTER PURGE SWITCH VALVE Service Tiger Manual -...
  • Page 173 B. As viewed on the mating face with the ECM (as per the illustration), pins are numbered from Code Wiring Colour right to left with number one in the top right corner. Black Blue Brown Green Slate/Grey Orange Pink 1 0.1 8 Service Manual - Tiger LUMP...
  • Page 174 BW _-^ NK -GP ---- B20 -KB Al ' A 23 ::: :L1III1 M 2 B ,---B 10.19 Service Manual -Tiger INJUmem...
  • Page 175 B. As viewed from the mating Black face with the ECM (as per the illustration), pins are Blue numbered from right to left with number one in right corner. Brown Green Slate/Grey 10.20 Service Manual - Tiger...
  • Page 176 Management Tiger - with ABS Circuit Dagrarn Engine Management System - BG -II Manual - 10.21 Service Tiger 1'Rt!:!.! H...
  • Page 177 If the fault clears, the warm-up cycle using the Triumph service diagnostic tool. counter will extinguish the MIL (Malfunction Indicator The tables indicate which tests are performed by the on-...
  • Page 178 Currert By using the Triumph diagnostic tool, live engine data When a fault occurs which causes a DTC to be stored in the memory, the engine condition data at that instant is (engine running) can be recovered from the motorcycle.
  • Page 179 The following items of build data can also be read. Checks/Adjustments Function Examined Adjustments Vehicle Identification Number WIN) Using the Triumph diagnostic tool, it is possible to reset Triumph ECM part number the ECU to the facto default se ings and to balance the throttle bodies.
  • Page 180 Volts Idle reference speed Fuel sensor voltage Volts numeric Idle speed control target steps Purge valve duty cycle °/o numeric value Gear position Neutral switch gear/neutral grip/release Clutch switch Low fuel alarm status on/off 10.25 Service Manual - Tiger INJUMEM...
  • Page 181 ECM memory until the required number of no-fault warm-up cycles have taken place. The number of warm- The codes are reported to the Triumph diagnostic tool as a up cycles required to extinguish the MIL will always be four digit code.
  • Page 182 Voltage control circuit short to ground P1697 Voltage control circuit short to Vbatt Voltage control circuit malfunction P1698 Flashing P 1602 Tunelock Only if Tunelock is unlocked Flashing P1614 ECM or tune ID Incorrect Only if Instrument Matching 10.27 Service Manual - Tiger • MquMpt...
  • Page 183 At the left of the screen, one or more symbols as detailed below be displayed. Typical Screen Showing Symbol Examples 10.28 Service Tiger Manual -...
  • Page 184 Any such memory is only retained in the motorcycle's ECM. • The following seven pages describe the tool ;.4-ThJ operations in flow chart form. gaef Validation Key 10.29 Service Manual - Tiger TRJUMOH...
  • Page 185 SYSTEM ERROR False CHECK CARD Absent Present SELECT LANGUAGE ENGLISH FRANCAIS DEUTSCH INSERT MEMORY CARD ESPANOL NEDERLANDS ITALIANO TRIUMPH MOTORCYCLES DIAGNOSTIC TOOL SOFTWARE VERSION 2006_02 SELECT ECU ABS, DIAGNOSTICS SEE SECTION 14 ENGINE ENGINE SWITCH ON BIKE I GNITION False...
  • Page 186 FUEL SYSTEM STATUS OXYGEN SENSOR OUTPUT VOLTAGE INTAKE MANIFOLD ABSOLUTE PRESSURE FUEL SYSTEM STATUS STORED ERRORS RETURN TO DTCS Return CLEAR DTCS STOP ENGINE Clear STORED ERRORS ERASE ALL DTC DATA RESET DTCS 10.31 Service Manual - Tiger 11UU Mj...
  • Page 187 Fuel System/Engine Management ur ct © Test Main Menu MAIN MENU DIAGNOSTICS CHECK/ADJUST QUIT Diagnostics DIAGNOSTICS CURRENT DATA FAULT CODES FUNCTION TEST QUIT Function test FUNCTION TEST DTCs present TEST DTC COUNT DTCS PRESENT CLEAR BEFORE TEST ACTION No DTCs present FUNCTION TEST INSTRUMENT PANEL IDLE SPEED CONTROL STEPPER MOTOR...
  • Page 188 XXXXX)0(XXX O(X TRIUMPH ECU PART NUMBER x OOO(X KEIHIN ECU PART NUMBER x) xxXXXXX OO ( ECU SERIAL NO VOLTAGES XXXXXXXXXX(X THROTTLES/COILS/INJECTORS SOFTWARE VERSION NUMBER OTHER )OUC^►XXXXXXX DATE OF MANUFACTURE XX)CXXXXXXXX CALIBRATION ID XXXXXXX)OO X 10.33 Service Manual - Tiger 11RIUMEH...
  • Page 189 ISC STEPPER RENEW BALANCE THROTTLES QUIT REPLACE ISC STEPPER THROTTLE CLOSED CURRENT VOLTS 0.54 V THROTTLE OPEN CURRENT VOLTS 0.51 V THROTTLE BALANCE MM/HG THROTTLE 1 1234 MM/HG THROTTLE 2 1234 MM/HG THROTTLE 3 1234 10.34 Service Manual - Tiger tUM^...
  • Page 190 SELECTED - PLEASE RESELECT ??????? UPDATE TUNE Cancel TUNE XXXX CONFIRM CANCEL Pass QUIT TEST PASSWORD Confirm Fail UPDATE TUNE DOWNLOADING..10% COMPLETE SECURITY ACCESS DENIED DOWNLOAD OK? UPDATE TUNE UPDATE TUNE DOWNLOAD COMPLETE DOWNLOAD FAILED 10.35 Service Manual - Tiger...
  • Page 191 INVALID UNLOCK CODE Three Valid Invalid Unlock Unlock Code Codes Entered UNLOCK ECU UNLOCK ECU INVALID UNLOCK CODE ECU SUCCESSFULLY ECU TAMPER UNLOCKED DETECTED RE-DOWNLOAD TUNE UPDATE TUNE 55555555 Main Menu MAIN MENU DIAGNOSTICS CHECK/ADJUST QUIT 10.36 Service Manual - Tiger...
  • Page 192 L!! I 1.Connection to main harness 2. Triumph service diagnostic tool Connect the tool to the dedicated multiplug, located in the storage compartment beneath the seat. A message appears on the screen and certain checks are made automatically, e.g. Is the memory card fitted? then be displayed.
  • Page 193 Fuel S Management MOTORCYCLES r° The screen will display the message 'Triumph Motorcycles Use the 'Up' and 'Down' keys to scroll the text until the Diagnostic Tool' and will also give the diagnostic software horizontal arrowhead is positioned opposite the version and the software release year.
  • Page 194 ECM. Either 'UNLOCK ECU' (operation 7) will be displayed if the ECM is locked, or the 'MAIN MENU' (operation 10) will be displayed if the ECM has previously been unlocked. 10.39 Service Manual - Tiger 71PJUMEH...
  • Page 195 Use the 'Up' and 'Down' keys to position either Enter the numerical password supplied by Triumph using 'Up' 'CONFIRM' or 'CANCEL' opposite the cursor. and 'Down' keys as described below. If 'CONFIRM' is selected, press the Validation key '*' to The number '55555555' is displayed, with the cursor unlock the ECM.
  • Page 196 Either 'DIAGNOSTICS' (operation 11) or 'CHECK/ ADJUST' (operation 29) will be displayed, dependent on the selection. Note: • if 'QUIT' is selected and the validation key '*' pressed, the display will return to 'TRIUMPH MOTORCYCLES'. 10.41 Service Manual - Tiger 110UMEH...
  • Page 197 Press any key to return to the 'CURRENT DATA' text. If 'QUIT' is selected, the display will return to When all information has been noted, press either the 'TRIUMPH MOTORCYCLES'. Validation '*' or Return (J) keys. 1'0.42 • Service Manual - Tiger luM^...
  • Page 198 'DIAGNOSTICS'. Press the Validation key '*' to display 'DIAGNOSTICS' menu. Select 'READ STORED DTCS', and press the Validation key '*'. 'STORED DTCS' will be displayed. 10.43 Service Manual - Tiger Twumem ,...
  • Page 199 DTC was stored is fault available to aid your diagnosis. To access this information, press the Validation key '*' to go to operation 16 and open 'FREEZE FRAME DATA'. 10.44 Service Manual - Tiger...
  • Page 200 Help key (?) as before. Press the Validation key'*' to display STORED DTCS' (operation 18). For a complete list of the items reported, see the table titled 'FREEZE FRAME DATA earlier in this section. 10.45 Service Manual - Tiger j3PI L!:!!!
  • Page 201 If one or more DTCs are stored, the message 'DTCS PRESENT CLEAR BEFORE TEST ACTION' will be displayed (operation 21). Note: • The diagnostic tool will not allow Function Tests to be accessed until all DTCs in the memory are removed. 10.46 Service Manual - Tiger LIMP...
  • Page 202 10 second period. DTCs are set if a malfunction is found. Fuel pump operation: This test provides you with the means to physically check the pump operation. DTCs are 10.47 Service Manual - Tiger Twumpm...
  • Page 203 If you wish to cancel that selection, scroll to 'CANCEL' and press the Validation key '*'. The display will return to operation 22. If you wish to test the component selected, scroll to 'PROCEED' and press the Validation key'*'. 10.48 Service Manual - Tiger...
  • Page 204 After a of time, the screen automatically will change to either 'TEST COMPLETE' (operation 25) which will indicate a satisfactory completion, or to 'TEST FAILED' (operation 27) which will indicate failure 10.49 Service Manual - Tiger nty!.K...
  • Page 205 • Any DTCs logged in the system will be automatically cleared at this point. To return to the 'DIAGNOSTICS' menu, Select 'QUIT' and press the Validation key '*' to return to the 'MAI N MENU' (operation 10). That completes the 'FUNCTION TESTS' cycle. 10.50 Service Manual - Tiger...
  • Page 206 Press the Validation key *'; the 'CHECK/ADJUST' menu Opposite 'CHECK' - 'CHECKS' will be displayed will be displayed. (operation 30). Opposite 'ADJUST' - 'ADJUSTS' will be displayed (operation 34). Opposite 'QUIT' - to return to 'MAIN MENU' (operation 10). 10.51 Service Manual - Tiger IIRJUMBH...
  • Page 207 'PLEASE WAIT, key'*': CHECKING Opposite 'READ SENSORS' -'SENSOR DATA' (operation Vehicle Identi cation Number WIN) 32) will be displayed. • Triumph ECM part number Opposite 'READ BUILD DATA' - 'BUILD DATA' (operation will be displayed. • Manufacturer's ECM pa number Opposite 'ADAPTION STATUS' - 'ADAPTION DATA' •...
  • Page 208 Once the correct temperature range has been reached, the 'ADAPTION STATUS' screen (operation 34) will That completes examination of the Checks. automatically be displayed. Press the Validation key':' to return to 'CHECK/ADJUST (operation 29). 10.53 Service Manual - Tiger 1•Rt!:!!!j3H...
  • Page 209 See page for additional information on forcing 10-24 adaption. The data displayed under this option are: 10.54 Service Manual - Tiger II^M^...
  • Page 210 The following allow adjustments to be made to items TUNE (operation 35). which affect the engine operation In special circumstances, Triumph will request you to Position the cursor opposite the se ing you wish to adjust introduce a completely new engine tune. Given this and press the Validation key'*'.
  • Page 211 • Resetting values the adaption does not indicating that the throttles require balancing. done can only adapt the motorcycle. This method explained later this section. Adaption reset only returns adaption values to their 'start' point. 10.56 Service Manual - Tiger...
  • Page 212 If the password number entered is invalid, the screen shown in operation 38 will be displayed. If the password number is valid, the tool will briefly display the message, 'PLEASE WAIT, CHECKING ECM TYPE' then, 'UPDATE TUNE' (operation 39) will be displayed. 10.57 Service Manual - Tiger GIMP...
  • Page 213 '*' to move on to operation 41. correct, press the validation key'*'. information on applicability Press help key for Once a model has been selected and the validation key each tune number. screen will pressed, be displayed. 10.58 Service Manual - Tiger...
  • Page 214 If 'CONFIRM' has been selected, downloading will begin. If downloading has been unsuccessful the screen will display 'DOWNLOAD FAILED'. Should this message appear, refer to 44, restarting tune download. Press the Validation key '*' to return to the 'MAIN MENU' (operation 10). 10.59 Service Manual - Tiger...
  • Page 215 'OFF' and disconnect the tool. Reconnect the tool, switch to this procedure. All versions of the the motorcycle ignition to 'ON', and scroll through to the diagnostic software will operate in the way screen shown below. described. 10.60 Service Manual - Tiger TuMTH...
  • Page 216 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. 10.61 Service Manual - Tiger 1mRL!:!! H...
  • Page 217 1. ECM 2. ECM raining tang Fit the connector into its socket and, whilst holding the connector in place, insert it fully into the ECM until the locking device retains it. 10.62 Service Manual - Tiger...
  • Page 218 Clean/renew toothed wheel, proceed to test 6 6 Reconnect harness, clear fault code and run Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Crankshaft Engine Sensor Control Module 10.63 Service Manual - Tiger...
  • Page 219 - Motor pin B to motor pin B 1 test 7 7 Reconnect harness, clear fault code and run OK Action complete - quit test diagnostic tool function test to visually verify operation of stepper motor Fault still present Contact Triumph service 10.64 Service Manual - Tiger...
  • Page 220 Engine Idle Speed Control Control Module Stepper Motor 10.65 Service Manual Tiger. I MP...
  • Page 221 Renew relevant injector, proceed to test 7 - Injector pin 1 to injector pin 2 7 Reconnect harness, clear fault code and run OK Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service 10.66 Service Manual - Tiger Ul^^...
  • Page 222 EMS Relay Fuel Injectors 10.67 Service Manual - Tiger tl1M...
  • Page 223 Short circuit Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code and run OK Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service 10.68 Service Manual - Tiger...
  • Page 224 Throttle Position Sensor 10.69 Service Manual - Tiger...
  • Page 225 Renew purge valve, proceed to test 7 7 Reconnect harness, clear fault code and run Action complete - quit test diagnostic tool function test to visually verify Fault still present Contact Triumph service operation of purge valve 1 0.70 Service Manual - Tiger...
  • Page 226 L IT.iA EMS Relay PurgeValve 10.71 Service Manual - Tiger TwumeH...
  • Page 227 7 Renew relevant igni 7 Reconnect harness, clear fault code and run OK Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service 10.72 Service Manual - Tiger luM^...
  • Page 228 Circuit Diagram EMS Relay -t-j 1141% Ignition Coils Service Manual - 10.73 Tiger •...
  • Page 229 Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service Resistance data under typical conditions: Warm engine: 200 to 400Q Cold engine: 20°C ambient 2.35 to 2.65KQ -10°C ambient 8.50 to 10.25KQ 10.74 Service Manual - Tiger...
  • Page 230 Coolant Temperature Sensor Service Manual - Tiger 10.75...
  • Page 231 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 4005 2.35 to 2.65KQ 20°C -10°C 8.50 to 10.25KQ 10.76 Service Manual - Tiger IuM^...
  • Page 232 £^ I nlet Air Temperature Sensor 10.77 Service Manual - Tiger TI.ty! kI...
  • Page 233 5 Reconnect harness, clear fault code and run Action complete - quit test diagnostic tool function test to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fuel Pump Relay EMS Relay FrT1 10.78 Service Manual - Tiger liNit...
  • Page 234 - ECM pin A6 - than battery' voltage Action complete - quit test 3 Reconnect harness, clear fault code and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram EMS Relay !__.. 10.79 Service Manual - Tiger Twumm...
  • Page 235 Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code and run Action complete - quit test diagnostic tool function test to,visually verify operation of cooling fan Fault still present Contact Triumph service EMS Relay Cooling Fan Relay 10.80 Service Manual -Tiger IkIUM8H...
  • Page 236 - ECM pin A26 to sensor pin 4 4 Reconnect harness, clear fault code and run Action complete - quit test engine. Check adaptation status. Fault still present Contact Triumph service Circuit Diagram EMS Relay Lambda Sensor B -26 10.81 Service Manual - Tiger TwumeH,...
  • Page 237 Short circuit Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code and run Action complete, quit test engine. Check adaption status. Fault still present Contact Triumph service Circuit Diagram EMS Relay Lambda Sensor W B14 10.82...
  • Page 238 • Fault Code Possible cause Action P0603 EEPROM error View & note 'freeze frame' data if available. No tests available - contact Triumph service. 10.83 Service Manual - Tiger IrRJUMM...
  • Page 239 Less than 4.8V Locate and rectify wiring fault, proceed to test - Sensor pin 4 6 Reconnect harness, clear fault code. Action complete, quit test Fault still present Contact Triumph service Circuit Diagram Fall Detection Switch 10.84 Service Manual - Tiger...
  • Page 240 4 Reconnect harness, clear fault code and run OK Action complete, quit test engine. Fault still present Contact Triumph service Circuit Diagram Alarm Kill Switch Control Unit Fuse Box 0° Instruments Road Speed Sensor 10.85 Service Manual - Tiger Twumm...
  • Page 241 Locate and rectify wiring fault, proceed to test - ECM pin B27 to Instrument pin 5 5 Reconnect harness, clear fault code and run OK Action complete, quit test engine Contact Triumph service Fault still present Circuit Diagram Instruments 10.86 Service Manual - Tiger...
  • Page 242 - Sensor pin 3 to sensor pin 4 Short circuit Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code Action complete, quit test Fault still present Contact Triumph service Circuit Diagram Fuel Level Sensor EIJ=;L;I 10.87 Service Manual - Tiger Twummi...
  • Page 243 Short circuit Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code and run OK Action complete, quit test engine Fault still present Contact Triumph service Circuit Diagram Ambient Pressure Sensor Service Manual - Ti er 1 0.88...
  • Page 244 - ECM pin A28 to ECM pin B1 Short circuit Locate and rectify wiring fault, proceed to test 5 Reconnect harness, clear fault code and run OK Action complete, quit test engine Fault still present Contact Triumph service Sensor 10.89 Service Manual - Tiger er Twumpm...
  • Page 245 Renew SAI valve, proceed to test 7 7 Reconnect harness, clear fault code and run Action complete - quit test diagnostic tool function test to visually verify operation of SAI valve Fault still present Contact Triumph service 1 0.9 Service Manual - Tiger...
  • Page 246 System/Engine ,. • • EMS Main Relay Secondary AirValve 10.91 Service Manual - Tiger...
  • Page 247 7 Reconnect harness, clear fault code. Switch OK Action complete - quit test ignition off for longer than one minute. Switch ignition on and check that the EMS main relay operates. Start engine as final check Fault still present Contact Triumph service 10.92 Tiger Service Manual -...
  • Page 248 1Tri i Fuse box EMS Main Relay 10.93 Service Manual - Tiger TwumeH...
  • Page 249 Action complete - quit test 5 Reconnect harness, clear fault code and run OK engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Engine Alarm Stop Control Unit Switch 4-ij Fuse Box GN-b £ 10.94 Service Manual - Tiger...
  • Page 250 5V sensor supply voltage level Fault still present Contact Triumph service Circuit Diagram ExhaustValve Ambient Fall Detection Throttle Pressure MAP Sensor Position Sensor Switch Sensor Position Twi t i m pm 10.95 Service Manual - Tiger...
  • Page 251 This is also identified by a fast flashing motorcycle from being operated MIL indication, and a disabled engine management system. Unlock ECM using the service tool and supplied unlock code from Triumph service 10.96 Service Manual - Tiger...
  • Page 252 Incorrect Update tune using service tool, proceed to test 3 3 Clear normal operation OK Action complete - quit test fault code, check for Fault still present Contact Triumph service 10.97 Service Manual - Tiger TRJUMM...
  • Page 253 ISC motor stuck fuel pressure caused by filter blockage/leaks Abnormally high fuel pressure Fuel pressure regulator inoperative Temperature gauge reads cooler than normal Cooling system air—locked resulting coolant temperature sensor operating in air instead of coolant 10.98 Tiger Service Manual -...
  • Page 254 1. Fuel hose 2. Fuel pump electrical connection 3. Fuel level sender electrical connection Note: • When the hose is disconnected, the fuel tank is self-sealing although some fuel may dribble from the hose. 10.99 Service Manual - Tiger T1L!:!!!j3K...
  • Page 255 10. Refit the side fairings (see page 16-13). 11. Reconnect the battery, positive (red) lead first. 12. Start the engine and check carefully for fuel leaks. Rectify as necessary. 13. Refit the seat (see page 16-9). 10.100. Service Manual - Tiger...
  • Page 256 1. Fuel pump 2. Mounting plate 3. Mounting plate fixings Lift the fuel pump and filter assembly and manoeuvre it from the fuel tank aperture. 1.Sealing 2. Seal lip 10.101 Service Manual - Tiger...
  • Page 257 Refill the fuel tank with the fuel drained earlier. Reconnect the battery, positive (red) lead first. Start the engine and check carefully for fuel leaks. Rectify as necessa Refit the seat (see page 16-9). 0.1 02 Service Manual - Tiger •...
  • Page 258 T3880001. use the correct fuel pressure gauge adapter Always (adapter 'B' for 2007-onwards Tiger). Use of an incorrect adapter will result in a fuel leak. A fuel leak can result in a fire causing damage to property and injury to persons..
  • Page 259 1. Map sensor connector 2. Intake air temperature connector Disconnect the map sensor hose. Release the fixings secu ng the airbox to its bracket. 1. Airbox fixings 1 0.1 04 Service Manual - Tiger...
  • Page 260 9. Gently lift the rear of the airbox to release it from the throttle bodies. 1. Secondary air injection control valve 2. Valve retainer 3. Hose 12. Release the secondary air injection control valve from the retainer on the airbox and remove the airbox. 10.105 Service Manual - Tiger TwUmem...
  • Page 261 11. Refit the fuel tank (see page 10-100). 12. Reconnect the batte , positive (red) lead first. 13. Refit the seat (see page 16-9). cdau 1. Airbox upper section 2. Airbox lower section 3. Air filter element 0.1 06 Service Manual - Tiger...
  • Page 262 Fit the air temperature sensor to the airbox. Tighten to 4 Nm. Reconnect the air temperature sensor. Refit the fuel tank (see page 0-100). Reconnect the battery, positive (red) lead first 16-9). Refit the seat (see page Service Manual - Tiger tl1M^...
  • Page 263 Refit the air hose. Refit the seat (see page 16-9). Reconnect the multi-plug. Refit the fuel tank (see page 10-100). Reconnect the battery, positive (red) lead first. Refit the seat (see page 16-9). 1 0.1 08 Service Manual - Tiger 11M'...
  • Page 264 PIc eto a Switch Cranks aft positionsensor Note: Removal The air gap for the crankshaft position sensor is not adj ustable 16-9). Remove the seat (see page Disconnect the battery, negative (black) lead first. Removal Remove the battery (see page 177). Disconnect the fall detection switch multiplug.
  • Page 265 Set the 'opening' cable adjuster at the throttle end to give 2-3 mm of play at the twist grip. Tighten the locknut ccwq 1. 'Opening' cable adjuster (throttle end) 2. 'Closing' cable adjuster (throttle end) 10.110 Service Manual - Tiger tUl^[t...
  • Page 266 Detach the inner portion of the cables from the throttle cam. 1.Throttle cam 2. Closing cable 3. Opening cable 10.111 Service Manual - Tiger TWUMEH...
  • Page 267 10-106). Refit the fuel tank (see page 10-100). Locate the cables to the frame following the routing noted during removal. 10. Reconnect the ba ery, positive (red) lead first Refit the seat (see page 16-9). 10.112 Service Manual - Tiger...
  • Page 268 1.Throttle body throttle plates. 2. Transition piece (one per cylinder) 3. Clip (one per cylinder) Check the 0-rings for damage. 9. Ease the throttle bodies from the transition pieces and lay the assembly on the crankcase. 10.113 Service Manual - Tiger...
  • Page 269 Refit the airbox (see page 10-106). Refit the fuel tank (see page 10-100). 10. Refit all bodywork. 11. Reconnect the battery, positive (red) lead first. .1 2. Refit the seat (see page 16-9). 1 0.1 14 Manual - Tiger • Service...
  • Page 270 Position the throttle body assembly near to its -fitted position and reconnect the sensor. Reconnect the battery, positive (red) lead first. Attach the Triumph service diagnostic tool to the dedicated plug. Turn the ignition to the ON' position. tool Connect .
  • Page 271 20. Check and clear any stored faults using the same tool. 21. Refit the seat (see page 16-9). cdaw 1. Idle speed control stepper motor 2. Bracket 3. Fixings 4. Direction of removal 10.116 Service Manual - Tiger luM^...
  • Page 272 Mount the throttle body onto the engine. Temporarily reconnect the battery, positive (red) lead first Turn the ignition to the 'ON' position. Connect the service diagnostic tool and scroll through to, and select the 'ADJUST TUNE' option. cdgs 10.117 Service Manual - Tiger TRiumem...
  • Page 273 ECM to normal control. paragraphs 13 to 15. 13. Slacken the screws on the throttle position sensor. 10.118 Service Manual - Tiger...
  • Page 274 5. Support the silencer and release the bolt and nut securing the silencer mounting bracket to the rear subframe. Discard the nut. 1. Silencer mounting bracket/fixing 6. Move the silencer rearwards to disengage it from the header pipes and remove. 10.119 Service Manual - Tiger...
  • Page 275 8. Fit a new gasket to the exhaust header pipe. . 1 2. Detach the exhaust pipe assembly and collect the 9. Position and engage the silencer to the exhaust pipe. seals from the head ports. 1 0.1 20 Service Manual - Tiger...
  • Page 276 15. Start the engine and check for exhaust gas leaks. Rectify if necessary. 1. Silencer mounting bolt 10.121 Service Manual - Tiger TLY.!:WkI...
  • Page 277 If air was fed to the exhaust system when the oxygen sensor was operational, the incoming air would cause inaccuracies in the readings sensed by the oxygen sensor (which requires access to 'raw' combustion gases) which would lead to rough running. 1 0.1 22 Manual - Tiger Service...
  • Page 278 Refit the valve to the hose. Reconnect the electrical connector. Refit the airbox (see page 10-106 Refit the fuel tank (see page 10-100). Reconnect the battery, positive (red) lead first. Refit the seat (see page 16-9). cbqx 1. Valves 10.123 Service Manual - Tiger...
  • Page 279 Fit the reed valves to the cam cover. 2. • Refit the valve covers and tighten the fixings to Refit the air hoses to the reed valves. 1. Spring-close hose clip 2. Secondary air injection hose 3. Reed valve assembly 1 0.1 24 Service Tiger Manual -...
  • Page 280 Purge Control Valve - Behind the carbon canister, mounted to the same bracket (electronically controlled by the ECM) To Throttle bodies To fuel to Purge control valve Vacuum pipe Carbon canister 10.125 Manual - Tiger Service IRUU...
  • Page 281 A to a carbon filled canister which stores the vapour. Once in the canister, vapour cannot return to the fuel tank because of a one-way valve in the canister. Pipe A Carbon Canister 1 0.1 26 Service Manual -Tiger...
  • Page 282 In order to control the speed at which vapour is purged from the canister, the engine management system regularly shuttles the purge control valve between open and closed positions. e control valve pe A Carbon Canister 10.127 Service Manual - Tiger Twumm...
  • Page 283 ___j This page intentionally left blank 1 0.1 28 Service Manual - Ti er ^iMP...
  • Page 284 Ca ............................. 11.6 ection... Water Pump ................11.6 11.6 Removal.., ............... Inspection................Installation..s ..............11.7 11.7 Thermostat................Removal ................11.7 Inspection................11.8 Installation................. 11.8 Radiator................Removal ................11.9 Inspection................Installation........... 1 1.9 .......60.69... 11.1 Service Manual - Tiger Twumem...

  • Page 285: Cooling

    Cooling r; i' 10Nm X ° I 2Nm 'iiii 11.2 Service Manual - Tiger...

  • Page 286: Coolant

    • It is not necessary to remove the left hand cooling system efficiency may cause the engine to cockpit infill panel in order to remove the overheat and suffer severe damage. coolant expansion tank cap. cecv Coolant Expansion Tank Cap 11.3 Service Manual - Tiger TwumeH...

  • Page 287: Water Pump

    Loss of coolant may cause the engine to overheat and suffer severe damage. 1. Radiator cap Position a container to collect the displaced coolant 1. Bottom hose Release the bleed screw on the right hand side of the Water pump radiator. 11.4 Service Manual - Tiger luM^...
  • Page 288 Stop the engine and top up the coolant level in the radiator as necessary. Fit the coolant pressure cap. 10. Check the expansion tank level and top up if necessary. 11. Refit the seat (see page 16-9). 12. Refit both side fairings (see page 16-13). 11.5 Service Manual - Tiger...

  • Page 289: Inspection

    6. Withdraw the water pump. Inspection Check the water pump shaft and shaft bearings for side and end float. Renew if necessary Check for corrosion and scale build-up around the impeller and in the pump body. Renew if necessary. 11.6 Service Manual - Tiger...

  • Page 290: Installation

    The thermostat should start to open at 88°C +/- 5°C. If the temperature at which thermostat opening takes place is incorrect, replace the thermostat Installation Locate the thermostat into the cylinder head. 11.7 Service Manual - Tiger ..?^I1...
  • Page 291 5. Disconnect the bottom hose, expansion tank and Remove the seat (see page 16-9). bypass hose from the radiator. Refill the cooling system (see page 11-5). 1.Bottom hose 2. Expansion tank hose 3. Bypass hose 11.8 Service Manual - Tiger lliN[t...

  • Page 292: Installation

    Tighten the hose clips. Refill the cooling system (see page 11-5). Reconnect the battery, positive (red) lead first. Remove the seat (see page 16-9). Fill the cooling system (see page 11-5). 9. Remove the radiator. 11.9 Manual-Tiger Service TRL!!+!j3H...
  • Page 293 This page intentionally left blank 11.10 Service Manual - Tiger...

  • Page 294: Removal

    ChainFree-movement adjustment ............ 12.12 ChainWear Inspection ........12.12 12.12 Arm/Drive Swin Chain ..............12.13 ................Removal 12.13 ................12.14 Inspection..........:......12.14 Assembly Assembly......... 12.15 DriveChain Replacement ..............12.16 Rivetlink ..............12.16 12.1 Service Manual - Tiger • INJUMEN...
  • Page 295 4.5 Nm 110 Nm 12.2 Service Manual - Tiger...
  • Page 296 12.3 'Service Manual - Tiger TRMMO...
  • Page 297 48 N m 12.4 Service Manual - Tiger er...
  • Page 298 48 Nm Service Manual - Tiger 12.5 Twummi...

  • Page 299: 1. Rear Suspension Unit

    Discard the nut. It is NOT necessary to remove the silencer completely. 1. Rear suspension unit 2. Rear suspension unit upper bolt 10. Slacken the two lower rear subframe bolts. 1. Silencer mounting bracket/fixing 12.6 Service Manual - Tiger...
  • Page 300 ® Renew parts as necessary, ''`--may 1. Rear suspension unit 2. Rear suspension unit lower bolt Tighten the rear suspension unit upper mounting to 48 Nm. 12.7 Service Manual - Tiger l^Mr...
  • Page 301 2. Remove the nut (discard the nut) and bolt securing the drag link to the drop link. Remove the bolt and nut (discard the nut) securing the drag link to the frame. Detach the drag link from the frame and drop link. 12.8 Service Manual - Tiger er...

  • Page 302: Inspection

    Discard the nut. Ease the suspension unit and spacer forward to clear the drop link plates. Remove the nut and bolt securing the drop link plates to the swinging arm. Discard the nut 12.9 Service Manual -Tiger TRIUMEM...
  • Page 303 2. Drop link plate 3. Rear suspension unit 4. Fixings Tighten the three drop link fixings to 48 Nm. Remove the support block from the rear wheel and lower the motorcycle to the ground. 1 2.1 0 Service Manual - Tiger...

  • Page 304: Chainlubrication

    : k..Y. `'m s..:f ..5..:. ..x w..:^*... 7,R..::S... :..£r'S7,11^`..:..::..c.., v,: .°.`^ Do not use a power 'jet' wash to clean the chain as this may cause damage to the chain components. 12.11 Service Manual - Tiger IRUU...

  • Page 305: Chainfree-Movement Adjustment

    2. Release the locknuts on both the left hand and right It is dangerous to operate the motorcycle with defective hand chain adjuster bolts. brakes; you must have your authorised Triumph dealer take remedial action before you a empt to ride the motorcycle again.
  • Page 306 Also examine the sprockets for damaged teeth. chains installed by an authorised Triumph dealer. If there is any irregularity found in any of the components, replace the drive chain and/or any other damaged components. Refit the chain guard, tightening the fixings to 4.S Nm.
  • Page 307 Check both sprockets for wear, damage etc. Replace 15. Remove the right hand bearing by drifting through as necessary. from the left. Check the drive chain rubbing strip for wear and damage. Replace as nec sary. 12.14 Service Manual - Tiger tuM^...
  • Page 308 (see page 14- 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 1.
  • Page 309 Repeat steps 3 to 5 on the remaining chain link pin. Remove the tool and separate the two ends of the chain. Remove the chain cutting tail piece from the body. 2.1 6 Service Manual - Tiger l^M^...
  • Page 310 1. 0-rings 2. Link 3. Link plate cdor 1.Tool body 2. Link plate holder (marked PHSO60R) 3. Link plate 4. Link S. Large pressure screw Service Manual - Tiger 12.17 TWUMEH...
  • Page 311 Ensure the split condition leading to loss of control and an accident. link pin is centrally located the flare pin. 1 2.1 8 Service Manual - Tiger...

  • Page 312: Removal

    Installation..: ..............13.1 Service Manual - Tiger Th.L!:!!
  • Page 313 Suspension 90 N m --^ See text \ ¶\\ \ \\\ \ \\\ \ \\\ 20 Nm 13.2 Service Manual - Tiger...
  • Page 314 Exploded View -Handlebars 13.3 Service Manual - Tiger :mI!:!
  • Page 315 ;r.rtt1;T;k The Tiger 1050 is equipped with hydraulic, adjustable, telescopic front forks. Both forks are adjustable for spring pre-load; the right hand fork is adjustable for compression damping and the left hand fork for rebound damping. Periodic inspection for damage and fluid leaks is essential for safe riding.
  • Page 316 Lower the motorcycle to the ground and park it on I U I \ the side stand. 1. Bottom yoke clamp bolts Using a downward, twisting action, withdraw the forks from between the yokes. 13.5 Service Manual - Tiger TWUMEH...
  • Page 317 3. Pump the fork assembly and damper several times to expel any trapped air then fully compress the fork and support it in an upright position. Leave the fork for a few minutes to allow the oil to stabilise. 13.6 Service Manual - Tiger...
  • Page 318 2. Preload adjuster marks container. Pump the damper rod to remove all the 3. Fork top cap oil. Return the fork to the soft jawed vice. Allow the outer tube to slide down into the inner. 13.7 Service Manual - Tiger er TWUMBM...
  • Page 319 If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user. 13.8 Service Manual - Tiger...
  • Page 320 • Tool T3880004 is designed to fit over the 3. Inspect all the bushes and seals for damage. Renew any damaged items if necessary. top of the damper rod locknut 1. Tool T3880004 2. Damping cylinder bolt location 13.9 Service Manual - Tiger Iltlu...
  • Page 321 2. Damping cylinder bolt location Invert and position the fork tube outer to tool T3880002. 1.Tool T38800031 2. Seal Apply a smear of fork oil to the bushes and seals. 3. Washer 4. Bush 5. Tool T3880002 1 3.1 0 Service Manual - Tiger...
  • Page 322 If removed, the damping rod locknut must be fitted with the flat face facing to the top of the fork. The slightly tapered face must face the fork spring. Incorrect orientation may lead to a loosening of the locknut. 13.11 Service Manual -Tiger...
  • Page 323 If the lower yoke fixings are also slackened, the forks will no longer support the weight of the motorcycle. Do not slacken the lower yoke fixings as, in this condition, the motorcycle could topple over causing damage and/or risk of injury. 1 3.1 2 Service Manual - Tiger...
  • Page 324 Front Suspension 3. Release the fixings securing the handlebar clamps to the risers, detach the clamps and carefully position the handlebars clear of the headstock top nut. It is essential that the adjuster nut is not over-tightened. if the adjuster is over-tightened it will cause a pre-load on the headstock bearings.
  • Page 325 1.Upper clamp Using a suitable drift, evenly and progressively drive 2. Fixings the bearing races from the frame headstock 10. Remove the inner race and dust seal from the om yoke using a press or puller. 13.14 Service Manual - Tiger...
  • Page 326 2. Bearing 3. Press bed 3. Evenly and progressively drive a new upper bearing outer race into the frame headstock. Evenly and progressively drive a new lower bearing outer race into the frame headstock. 13.15 Service Manual - Tiger er INJUMM...
  • Page 327 Note the. position of the guide relative to the handlebar then separate the two halves of the twist grip guide. Note and mark the position of each cable relative to the twist grip in order to correctly identify their location during reassembly. 13.16 Service Manual - Tiger...
  • Page 328 4. Reconnect the inner throttle cables as noted during removal. Ensure that the positions of the opening and closing cables are not transposed. ° 1. Upper clamp 1.Closing inner cable 2. Fixings 2.Opening inner cable 14. Remove the left hand handlebar grip. 13.17 Service Manual - Tiger...
  • Page 329 (UP arrow pointing upwards) and clamp bolts. 12. Align the split line of the clutch lever with the punch mark on the upper surface of the handlebar, then tighten the clamp bolts, upper first, to 15 Nm. 13.18 • Service Manual - Tiger...
  • Page 330 Installation................. 14.20 Front Brake Master Cylinder .............. 14.21 ................Removal 14.21 Disassembly....:............. 14.21 Inspection................ 14.22 Assembly................. 14.22 Installation...............0.. 14.22 Bleedingthe Rear Brakes, Renewing Brake Fluid ..........14.23 RearBrake Pads ................. 14.25 14.1 Service Manual - Tiger 714MM . 0,00M...
  • Page 331 SystemDescription ..............14.38 ComponentLocations 14.39 ....0..000. , ........System Circuit Diagram - Tiger ............14 . 40 ABSSystem Circuit Diagram - Tiger ........... 14.41 SystemDiagnostics ..............14.42 TriumphDiagnostic Tool ..........14.42 0 0..0..0..CurrentData ..............14.42 1 4:2...
  • Page 332 Front or Rear Wheel Actuator (Hydraulic Control) Wheel Lock ..00..00..14.73 PinpointTests ........0.0..00....14.73 Motor- Lock; Motor Stuck OFF; Motor stuck ON ..........14.74 PinpointTests ..............14.74 PowerSource Voltage DropNoltage Rise ........... 14.75 PinpointTests ..............14.75 14.3 Service Manual - Tiger...
  • Page 333 Brakes 14.76 DifferentTyre Diameter ..............14.76 PinpointTests ..............14.77 AbnormalECU ................. PinpointTests ..............14.77 14.78 Hydraulic Circuit Layout ............. 14.4 Service Manual - Tiger...
  • Page 334 Expbded View - Front Brake Master Cylinder 5 Nm - '- 1 Nm 15Nm 25 Nm IJ - - - 25Nm 1.2 Nm 14.5 Service Manual - Tiger TWumpt...
  • Page 335 °m O (y ^ ^ ^ ^ O o ^ o ° m ^O^ m m O' ^ °o ^ m m 0° m m ^^O mo 22 Nm m o 0 14.6 Service Manual - Tiger...
  • Page 336 25 Nm 15 Nm 35 Nm 22 Nm 14.7 Manual - Service Tiger TRRM ...,P O A...
  • Page 337 Brakes 5.5 Nm 17Nm 4O Nm oo°000^ o° ° ° ° • 22 Nm 14.8 Service Manual - Tiger...
  • Page 338 View - 14-7E also page 14.9 NUMM Service Manual - Tiger...
  • Page 339 It is dangerous 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 reduce braking efficiency leading to an accident 14.10...
  • Page 340 Replacing individual pads will reduce braking efficiency and may cause an accident. 1. Rear reservoir 2. Rear reservoir upper level 3. Rear reservoir lower level 14.11 Service Manual - Tiger...
  • Page 341 2. Remove the rubber cap from the bleed nipple on the right hand caliper. laic Front reservoir upper level 2. Front reservoir lower level 3. Safety clip 6. Remove the safety clip from the brake reservoir cover. Service Manual - Tiger...
  • Page 342 17. Whilst supporting the caliper, attach a transparent fluid. tube to the bleed nipple and place the other end of the tube in a suitable receptacle containing new brake fluid. Keep the tube end below the level of fluid. 14.13 Service Manual -Tiger...
  • Page 343 It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you de the motorcycle again. Failure to take remedial action may result in...
  • Page 344 To prevent body damage, ensure that the displaced fluid does not come into contact with any part of the bodywork. force Ease the brake pads apart to the caliper pistons back and allow withdrawal of the pads. 14.15 Service Manual - Tiger 1t!WH...
  • Page 345 Disconnect the brake hose at the caliper, and place the free end of the hose in a suitable container to It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer collect brake fluid. take remedial action before you ride the motorcycle Remove the 'R' clip and slacken the pad retaining again.
  • Page 346 Fit the piston seals and the dust seals to the caliper time. bores in the position shown above and apply a smear of silicone seal grease (Triumph part number T2020338) to the face of each seal which will contact the caliper piston in use.
  • Page 347 Position the caliper over the disc and tighten the caliper bolts to 35 Nm. Ensure that the silicone seal grease (Triumph part number T2020338) is applied to the face of the piston seal and dust seal which will contact the caliper piston in use, this will help to prevent the caliper piston from sticking.
  • Page 348 Thickness Standard: 4.5 mm Service Limit: It is dangerous to operate the motorcycle with defective Disc Run-out brakes; must have your authorised Triumph dealer action before ride the take remedial motorcycle Standard: 0.1 mm again. Failure to take remedial action may result in 0.3 mm...
  • Page 349 • The discs are handed. Observe the offset of each disc to its hub the orientation of the cooling holes, for correct installation. Remove and discard the bolts. Detach the disc. Repeat for the other disc. 14.20 Service Manual -Tiger...
  • Page 350 3. Circlip 4. Piston 1. Pivot bolt 2. Nut Disconnect from the master cylinder: • brake hoses, • brake light switch connections. Release the clamp screws from the handlebar to remove the master cylinder. 14.21 Service Manual - Tiger 1%quMpi •...
  • Page 351 Ensure that the piston and piston seal are fitted facing the same way as noted during removal. A dangerous riding condition leading to an accident could result from incorrect assembly of the master cylinder. 14.22 Service Manual - Tiger IUMp...
  • Page 352 Attach a transparent tube to the bleed nipple. it is dangerous to operate the motorcycle with defective brakes and you must have your. authorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may...
  • Page 353 It is the motorcycle with defective fluid to Ensure absolute cleanliness when adding brake brakes and you must have your authorised Triumph the brake fluid reservoir. Do allow moisture debris Dealer take remedial action. Failure to take remedial...
  • Page 354 gaedl pads 1. Brake 2. Anti rattle spring anti-rattle spring and inspect for 5. Remove the damage, replace if necessary. 2. Remove the caliper mounting bolts and position Installation of the pad pins. caliper to allow withdrawal retaining Never use mineral based grease any part braking system or any area where contact with the...
  • Page 355 Remove the caliper mounting bolts. Remove the brake caliper assembly. It is dangerous to operate the motorcycle with defective brakes and you must have your authorised Triumph Dealer take remedial action. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident 1.
  • Page 356 Do not apply more than a minimum coating of grease to the pad retaining pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced braking efficiency and an accident. 14.27 Service Manual - Tiger • TPt.H...
  • Page 357 Check that the brake operates correctly. It is dangerous to operate the motorcycle with defective brakes and you must have your authorised Triumph Dealer take remedial action. Failure to take remedial efficiency action may reduce braking leading to loss of motorcycle control and accident.
  • Page 358 It is dangerous to operate the motorcycle with defective 7 Note the setting of all brake lines and hoses to brakes and you must have your authorised Triumph ensure they are returned to the same position when Dealer take remedial action. Failure to take remedial the overhaul operation is complete.
  • Page 359 9. M©dels without ABS brakes: Release the rear models: Remove the two bolts securing the brake light switch and disconnect the rear brake master cylinder to the frame and collect the master cylinder. hose from the master cylinder. Remove and discard the sealing washers from the brake light switch.
  • Page 360 10. Fit the seat page 16-9). (see It is dangerous to operate the motorcycle with defective and you must have your authorised Triumph brakes Dealer take remedial action. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
  • Page 361 Complete the brake bleed procedure as for models without ABS brakes (see page 14-12). Remove the seat (see page 16-9). Disconnect the battery, negative (black) lead first. Connect the Triumph service diagnostic tool (See page multiplug. 14-50). speed sensor Disconnect the wheel Follow the on screen menu to ABS diagnostics.
  • Page 362 1. Wheel 2. Support block 14.33 Service Manual - Tiger...
  • Page 363 Complete the brake bleed procedure as for models without ABS brakes (see page 14-23). Remove the seat (see page 16-9). Connect the Triumph service diagnostic tool (See Disconnect the battery, negative (black) lead first. page 14-50). Remove the fuel tank (see page 10-99).
  • Page 364 Renew the pulser ring as necessa Installation Locate the pulser ring on to the rear brake disc and tighten the fixings to 5 Nm. Refit the rear wheel (see page 15-10). 1.ABS modulator 2. Multiplug. 14.35 Service Manual - Tiger...
  • Page 365 1. Right hand rear engine mounting bolt 2. Nut housing 3. ABS modulator bracket 1. Front brake hose connector 2. Fixing 3. Front brake line from master cylinder 4. Front brake line to calipers 14.36 Service Manual - Tiger tutor...
  • Page 366 15. Reconnect the battery, positive (red) lead first. defective It is dangerous to operate the motorcycle with brakes and you must have your authorised Triumph Dealer take remedial action. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
  • Page 367 Under normal operation, the ABS warning light will stay illuminated after ignition on until the vehicle speed The ABS versions of the Tiger are fitted with an electronic exceeds 6 mph (10 km/h). The ABS performs a self check anti-lock brake system (ABS) which is designed to prevent and if no faults are found the light is extinguished.
  • Page 368 Brakes Component Lccations FRONT BRAKE REAR SWITCH MODULATOR BRAKE REAR PULSER SWITCH RING Nf c: REAR FRONT FRONT WHEEL PULSER WHEEL SPEED RING SPEED SENSOR SENSOR 14.39 -Tiger Service Manual...
  • Page 369 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. 14.40 Service Manual - Tiger...
  • Page 370 'i L' iii L___: • r--WU. RU 16 ----J iii1 14.41 Service Manual - Tiger...
  • Page 371 Brakes Current Data By using the Triumph diagnostic tool, live ABS data can be The ABS system has an on-board diagnostics feature recovered from the motorcycle. The data available is: which allows service technicians to retrieve stored data from the ECM using a Triumph service tool. Full details...
  • Page 372 The system will log the diagnostic trouble codes listed ECM memory when there is a confirmed fault in the below: system. The codes are reported to the Triumph diagnostic tool as a four digit code. Diagnosti Trouble Code Fault Description (DTC)
  • Page 373 Yes, if after ignition cycle, no Missing Teeth fault is detected for 1 second and speed exceeds 30 km/h. DTC remains stored Front Wheel Input Solenoid Open / Short Circuit Front Wheel Output Solenoid Open / Short Circuit 14.44 Service Manual - Tiger...
  • Page 374 10 seconds Power Source Voltage Rise Yes, Light will Yes, if voltage drops below extinguish for more preset threshold than fault clears 10 seconds Different Tyre Diameter Abnormal ECU 14.45 Service Manual - Tiger Tt!:...
  • Page 375 The screen comprises four horizbntal lines and twenty vertical columns forming a series of boxes into which ^ r r letters and numbers can be displayed to provide the necessary question, message, answer etc. 9a& Return Key 14.46 Service Manual - Tiger UMI^...
  • Page 376 The tool does not retain any memory of faults, diagnosis etc. carded out on any particular motorcycle. Any such memory is only retained in the motorcycle's ECM. gaef' The following pages describe the tool Validation Key operation in flow chart form. 14.47 Service Manual-Tiger TRIUMpm...
  • Page 377 2005 01 SELECT ECU ENGINE DIAGNOSTICS ENGINE SEE SECTION 10 SWITCH ON BIKE IGNITION False DATA LINK FAULT VALIDATE RETRY ABS DIAGNOSTICS CURRENT DATA READ STORED DTCS CLEAR CODES BLEED SYSTEM READ BUILD DATA 14.48 Service Manual - Tiger 1l^MP...
  • Page 378 ERASE ALL DTC DATA READ BUILD DATA BLEED SYSTEM ECU ID XXXXXXXXXXXXX DTCS PRESENT CLEAR BEFORE TEST ACTION BLEED SYSTEM BLEED SYSTEM? CANCEL PROCEED BLEED SYSTEM BLEEDING SYSTEM RUNNING ... BLEED SYSTEM SYSTEM BLEED COMPLETE 14.49 Service Manual - Tiger...
  • Page 379 2 SELECT LANGUAGE 1. Connection Power-Up 1. Connection to main harness 2. Triumph service diagnostic tool Connect the tool to the dedicated multiplug in the storage compartment under the seat. A message appears on the screen and certain checks are made automatically, e.g.
  • Page 380 3 TRIUMPHMOTORCYCLES S j® Use the Up and Down' keys to scroll the text until The screen display the message' Triumph Motorcycles will horizontal arrowhead is positioned opposite the 'ABS Diagnostic Tool' and will also give the diagnostic software and press theValidation key's'.
  • Page 381 Rectify the problem and press the Validation key '*' to return to 'SWITCH ON BIKE IGNITION'. Press the Validation key '*' again. If the tool accepts that the problem has been rectified, 'ABS DIAGNOSTICS' will be displayed (see operation 7). 14.52 Service Manual - Tiger...
  • Page 382 FRONT WHEEL • 'BLEED SYSTEM' (see operation REAR WHEEL • 'READ BUILD DATA' (see operation 18) BRAKE SWITCH ON/OFF • If 'QUIT' is selected, the display will return to 'TRIUMPH MOTORCYCLES'. ABS LIGHT ON/OFF 14.53 Service Manual - Tiger :rRtq^H...
  • Page 383 Scroll to 'CLEAR DTCS' and press the Validation key'*' to go on to operation 11 Note: A full list of all the pos ble DTCs can be found earlier in this section (see page 14-43. 14.54 Service Manual - Tiger Tq! ^M...
  • Page 384 If one or more DTCs are stored, the message 'DTCS PRESENT CLEAR BEFORE TEST ACTION' will be displayed (see operation 14-56). Note: • diagnostic tool will not allow the 'BLEED SYSTEM' command to be accessed until all DTCs in the memory are removed. 14.55 Service Manual - Tiger TR!Lm^...
  • Page 385 SYSTEM' again pressing the Validation key '*' each time. Note: Because the DTCs have now been erased, the 'BLEED tool SYSTEM?' (see operation will now be displayed. • If the Return key (.1) is pressed, the will return to 'TRIUMPH MOTORCYCLES' (operation 3). 14.56 Service Manual - Tiger...
  • Page 386 Return key (.1). The display will return to page for the front brakes or 14-32 for the rear 14-34 'TRIUMPH MOTORCYCLES' menu (operation 3). brake). Note: • If the Return key (J) is pressed, the tool will return to 'DIAGNOSTICS' menu (operation 7).
  • Page 387 ' key to return to 'ABS Press the Validation Use the 'Up' and 'Down' keys to position the cursor DIAGNOSTICS' menu (operation 7). opposite 'READ BUILD DATA'. Press the Validation key'*'. 'BUILD DATA' will be displayed. 14.58 Service Manual - Tiger...
  • Page 388 When Connecting a Connector. • Ensure there is no dirt around the connector/seal. ® Push together squarely to ensure terminals are not bent or incorrec y located. ' • Push the two halves together positively. 14.59 Service Manual - Tiger...
  • Page 389 Ride the motorcycle at a road speed in excess of 30 Km/h. If the DTC is repeated proceed to the relevant pinpoint test If a DTC is stored there is a further fault Read the stored DTC and refer to the relevant pinpoint test. 14.60 Service Manual - Tiger luM^...
  • Page 390 ABS to verify fault cleared Fault still present Contact Triumph service Circuit Diagram --• ABS Fuse Box 1 234 i [J] 20A I I Control Module Li_____ Rugulator/Rectifier Main Fuse Box •- L-----I Instruments Ignition Switch 14.61 Service Manual - Tiger :1uRt p,t...
  • Page 391 Locate and rectify fault proceed to test 6 Turn Ignition 'ON' Faulty 6 Reconnect ABS ECM harness, clear fault Action complete - quit test code and test ABS to verify fault cleared Contact Triumph service Fault still present 1 4.62 Manual - Tiger Service...
  • Page 392 ABS Fuse Box 1 234 Control Module Rugulator/Rectifier Main Fuse Box : wu L----J 1 4 5 Instruments Ignition Switch 14.63 Service Manual - Tiger Tt!!?H...
  • Page 393 Reconnect ABS ECM harness, clear fault OK Action complete - quit test code and test ABS to verify fault cleared Fault still present Contact Triumph service 14.64 Service Manual - Tiger !iM!
  • Page 394 Brakes Circuit agram Wheel speed sensor current consumption data under typical conditions: FrontWheel Speed Sensor Control Module 14.65 Service Manual - Tiger TOUMEH...
  • Page 395 4 Check the wheel speed sensor circuit (See OK page 14.64) Faulty Rectify the fault and proceed to test 5 5 Clear fault code and test ABS to verify fault OK Action complete- quit test cleared Fault still present Contact Triumph service 14.66 Service Manual - Tiger...
  • Page 396 Replace the wheel speed sensor, proceed to between 4.5 V and 16 v between ABS ECM test 9 connector pin 2 (positive) and pin .18 (negative), measure current consumption of the wheel speed sensor Test continued overleaf 14.67 Service Manual - Tiger...
  • Page 397 Contact Triumph service Fault still present Circuit Diagram Wheel speed sensor current consumption data under typical conditions: Typica Voltage Low (4. 3.1 m .--. 13.6mA High (16V) Rear Wheel Speed Sensor Control Module UR -- 14.68 Service Manual - Tiger...
  • Page 398 14.67) Faulty Rectify the fault and proceed to test 5 5 Clear fault code and test ABS to verify fault OK Action complete - quit test cleared Fault still present Contact Triumph service 14.69 Service Manual - Tiger 1'kty...
  • Page 399 Faulty Rectify the fault and proceed to test 5 5 Clear fault code and test ABS to verify fault OK Action complete - quit test cleared Fault still present Contact Triumph service 1 4.70 Service Manual - Tiger I MP...
  • Page 400 Faulty Rectify the fault and proceed to test 5 5 Clear fault code and test ABS to verify fault OK Action complete - quit test cleared. Fault still present Contact Triumph service 14.71 Service Manual - Tiger • TWUMEM...
  • Page 401 Locate and rectify fault, proceed to test 5 5 Clear fault code and test ABS to verify fault Action complete - quit test cleared Fault still present Contact Triumph service Circuit Diagram Control Module Rugulator/Rectifier 4.72 Service Manual - Tiger...
  • Page 402 Faulty Rectify the fault proceed to test 4 4 Clear fault code test ABS to verify fault OK Action complete - quit test cleared Fault still present Contact Triumph service 14.73 Service Manual - Tiger GIMP...
  • Page 403 5 Reconnect ABS ECM harness, clear fault Action complete - quit test code and test ABS to verify fault cleared Fault still present Contact Triumph service Circuit Diagram BS Fuse Box E--, Control Module Rugulator/Rectifier Service Manual - Tiger X 4.74 IUM^...
  • Page 404 Contact Triumph service I ABS, Fuse Box 1 2 3 4 2oa I I Control Module Rugulator/Rectifier Main Fuse Box RU 16 G -- -- L----^ 1 4 5 B 24 Instruments Ignition Switch 14.75 Service Manual - Tiger TRJ,UMBH...
  • Page 405 Air gap between 0 to 1.5 mm Faulty Rectify the fault and proceed to test 5 5 Clear fault code and test ABS to verify fault Action complete - quit test cleared Fault still present Contact Triumph service 14.76 Manual - Service Tiger...
  • Page 406 Faulty Rectify the fault and proceed to test 4 4 Clear fault code and test ABS to verify fault OK Action quit complete - test cleared. Fault still present Contact Triumph service 14.77 Service Manual - Tiger...
  • Page 407 Cylinder to ABS Modulator B. Front Brake Circuit from ABS Modulator to Front Calipers C. Rear Brake Circuit from Master Cylinder to Modulator D. Rear Brake Circuit from ABS Modulator to Rear Caliper E. ABS Modulator 1 4.78 Service Manual - Tiger...
  • Page 408 15.9 Removal..' ..............15.9 15.10 Installation................. 15.11 RearWheel Bearings ..............15.11 Removal................15.11 Inspection 15.11 0 ..15.11 Installation................. 15.12 FinalDrive ................Removal................15.12 Inspection.......... 1 5.13 ....0.... Installation................. 15.13 15.1 Service Manual - Tiger TWUMEH...
  • Page 409 Wheels/Tyres o»> _1 95 Nm 15.2 Service Manual - Tiger...
  • Page 410 Wheels/Tyres 15.3 Service Manual - Tiger TREM..OPOOH...
  • Page 411 Inspect wheels for cracks, splits and kerb damage. , Always replace wheels that are suspected of having become damaged. 15.4 Service Manual - Tiger...
  • Page 412 Always consult your Triumph dealer for tyre replacement, or for a safety inspection of the tyres. Minimum Recommended Tread Depth The following chart can be used as a guide to the The use of tyres other than those listed in the minimum safe tread depth.
  • Page 413 When wheel balancing is required, such as after tyre replacement, see your authorised Triumph dealer. Do not allow the calipers to hang the brake hoses adhesive Only use self- weights. Clip on weights will as this may damage the hoses.
  • Page 414 8. Thoroughly clean all components and inspect for wear or damage. 1. Fork pinch bolts Thoroughly clean and degrease the brake discs. Fit the brake calipers (see page 14-18). 15.7 Service Manual - Tiger Tziumm...
  • Page 415 Wheels/Tyres Using a suitable pin punch, through the centre of the it Wheel Bearing wheel, drift out the right hand wheel bearing. Collect the centre sleeve. Remove the left hand wheel bearing in the same way. Remove the front wheel (See page 15-6).
  • Page 416 Support the wheel and withdraw the wheel spindle.. Noting its position, release the brake caliper carrier from the slot on the swinging arm and roll the wheel forward until the chain can be detached from the rear sprocket. 15.9 Service Manual - Tiger...
  • Page 417 5. Refit the wheel spacers, flanged spacer to the right hand side (flange facing outwards) and plain spacer to the left. It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer empt to ride the take remedial action before you a O^^QQ motorcycle again.
  • Page 418 Using a suitable pin punch, through the centre of the Right T3880053 3880075-T0301 wheel, drift out the wheel bearings. Collect the bearing Large face to Large face centre sleeve. __________ bearing wheel gaeo Rear Wheel Bearing Removal • 15.11 Service Manual - Tiger nW.!:!iH...
  • Page 419 2. Place the wheel on wooden blocks with the drive Refit the final drive assembly (see page 15-1,2). sprocket uppermost. Fit the rear wheel (see page 15- 10) 3. Gently lever the drive flange from the wheel hub. 1.Rear wheel 2. Drive flange Service Manual - Tiger IUM^...
  • Page 420 Check the wheel and drive flange for wear, cracks and damage. Installation Install the cush drive rubbers to the wheel. Refit the drive flange to the wheel. Refit the rear wheel (see page 1S-9). 15.13 Service Manual - Tiger TR4Lqj3H...
  • Page 421 Wheels/Tyres This page intentionally left blank 15.14 Manual Service -Tiger...
  • Page 422 Cockpit................16.14 Removal................16.14 Installation............:....16.15 16.1 Service Manual - Tiger TWUMEH...
  • Page 423 Removal....• ............16.17 Installation................ 16.17 16.2 Service Manual - Tiger...
  • Page 424 I : . ir.iriim kv v ,]j All engine mounting fixings - see text in section 9 IIIIIIII^I Service Manual - Tiger 1603 TRjumw •...
  • Page 425 64 Nm 48 Nm 48 Nm 16.4 Service Manual - Tiger tUM^...
  • Page 426 25 Nm 1.5Nm 1.5 Nm 30 Nm 16.5 Service Manual - Tiger IDUUMEM...
  • Page 427 ;s' i.iifl a;i-' • All fixings 3 Nm 16.6 Service Manual - Tiger IUMp...
  • Page 428 6 Nm i Nm 16.7 Service Manual - Tiger...
  • Page 429 Liiiiii im I;: e €ifl Tiii 27 Nm 4 Nm c' \ /9Nm \ LL7 --'`' 9 Nm 7 Nm '1/! 16.8 Service Manual - Tiger...
  • Page 430 Triumph dealer for repair or inspection. Any accident can cause damage to the motorcycle which, if not correctly repaired, may cause another accident which may result in injury or death. 16.9 Service Manual - Tiger Numm...
  • Page 431 Withdraw the panel assembly from the rear of the motorcycle. Installation Installation is the reverse of removal noting the following: Note: • Tighten the fixings to 3 Nm. • Reconnect the battery, positive (red) lead first. 1 6.1 0 Service Manual - Tiger •...
  • Page 432 Note: To ensure correct fitment of the fairing infill panel, the following installation sequence must be adhered to: 16.11 Service Manual - Tiger Twumem...
  • Page 433 2. Bayonets 3. Grommets 6. Remove the panel. Installation Installation is the reverse of removal noting the following: Note: • Tighten fixing to 3 Nm. • Reconnect the battery, positive (red) lead first. 1 6.1 2 Service Manual - Tiger...
  • Page 434 Remove the two screws securing the fairing fuel tank. 1. Side fairing (right hand shown) . 2. Side fairing retaining screws Ease the side fairing forwards to release it from the radiator securing hook on the 16.13 Service Manual -Tiger...
  • Page 435 1. Cockpit 2. Headlight 3. Cockpit lower screws 5. Remove the two upper screws securing the cockpit to the headlight assembly. 1. Cockpit 2. Cockpit upper screws 6. Remove the cockpit in a forward direction. 16.14 Service Manual - Tiger...
  • Page 436 Connect the battery, positive (red) lead first. mudguard fixings 1. Lower rear Refit the seat (see page 16-9). Remove the fixings securing the rear panel bracket and remove the bracket. 1.Rear panel bracket 2. Fixings 16.15 Service Manual - Tiger TRJUMEM...
  • Page 437 • Connect the indicator and licence plate electrical connectors as noted during removal. • Tighten the rear mudguard fixings to 6 Nm. • Tighten the rear panel bracket fixings to 9Nm. • Reconnect the battery, positive (red) lead first. 1 6.1 Service Manual - Tiger IUM^...
  • Page 438 Removal Note: Tighten the belly pan fixings 3 Nm. Remove the four fixings securing the belly pan to the mounting brackets. Remove the belly pan. rahc 1. Belly pan 2. Fixings (right hand shown) 16.17 Service Manual - Tiger INJUMEM...
  • Page 439 Frame and Bodywork This page intentionally left blank 16.18 Service Manual - Tiger...
  • Page 440 HeadlightAssembly Removal ............... Removal................17.12 Installation................. 17.13 RearLight ................17.13 Removal 17.13 ................Installation................. 17.14 17.14 IndicatorBulb Replacement ..............NumberPlate Light Bulb ..............17.14 Alternator ................17.15 Removal..17.15 ..............Assembly................17.15 17.16 AlternatorRectifier ............... 17.1 Service Manual - Tiger...
  • Page 441 Main Wiring Circuit Diagram - Models without ABS Brakes ........Keyto circuit diagram ............... 17.24 to wiring colours ..............17.24 MainWiring Circuit Diagram - Models with ABS Brakes ........17.26 17.26 to circuit diagram ............... Keyto wiring colours ..............17.26 17.2 Service Manual - Tiger...
  • Page 442 Electrical 17.3 Service Manual - Tiger Twumpj4...
  • Page 443 Electrical 10 Nm 17.4 Service Manual - Tiger...
  • Page 444 1r ! 1Yi ^^Lllll 17.5 Service Manual - Tiger TR!!M^p...
  • Page 445 Electrical , ,1 rrrrr^ 1.5 Nm 17.6 Service Manual - Tiger...
  • Page 446 Place the battery in the battery case. Reconnect the battery, positive (red) lead first Apply a light coat of grease to the terminals to prevent corrosion. Cover the positive terminal with the protective cap. Refit the seat (see page 16-9). 17.7 Service Manual - Tiger 71tiumpli...
  • Page 447 This is the only battery commissioning procedure that Triumph recommends. Battery Maintenance The procedure is designed to ensure that the battery is at The battery is a sealed type and does not require any...
  • Page 448 Electrical Table of Battery Charging Tomes of charge Voltage Action Charge time (using State BatteryMate 150-9) None required 100% 12.8V - 13.OV None. Check at 6 months from date of manufacture 75% -100% 12.5V - 12.8V May need slight charge. 3 - 6 hours If no charge given, check in 3 - 4 months...
  • Page 449 1.Engine Management System (EMS) relay 2. Cooling fan relay 3. Starter relay The indicator relay is located inside the cockpit, attached to a blade on the right hand side of the headlight. 1. Indicator Relay 17.1 0 Service Manual - .Tiger...
  • Page 450 • On the left hand headlight turn the horizontal adjustment screw clockwise to move the beam to the left or anti-clockwise to move the beam to the right. • Switch the headlights off when the beam settings are satisfactory. 1711 Tiger ice Manual -...
  • Page 451 When reconnecting the battery, connect the positive (red) lead first. Do not reconnect the battery until the assembly process has been completed. Premature battery reconnection could result in ignition of the battery gases causing risk of injury. 1 7.1 2 Service Manual - Tiger uM!'...
  • Page 452 Refit the cockpit (see page 1615). Reconnect the battery, positive (red) lead first. Refit the seat (see page 16-9). 1.Headlight assembly 8. Check the headlight adjustment (see page 17-11). 2. Fixings (left hand shown) 17.13 Service Manual - Tiger TWUMEH...
  • Page 453 4 Nm. rear panel • Tighten the bracket fixings to 9Nm. 1.Seat lock mechanism (red) • Connect the battery positive lead first. 2. Fixings 5. Disconnect the wiring harness. 17.14 Service Manual - Tiger er...
  • Page 454 Installation is the reverse of the removal procedure. // r . cedm 1. Lower rear mudguard fixings 2. Licence plate light fixing screw 6. Detach the licence plate light from the rear mudguard. 17.15 S e ice Manual -Tiger...
  • Page 455 Tighten the lower rear mudguard fixings to 6 Nm. ® Reconnect the battery, positive (red) lead first 1. Stator 2. Stator bolts 3. Cable bracket 4. Cable bracket bolt 7. Withdraw the stator. 17.16 Service Manual - Tiger...
  • Page 456 10. Reconnect the battery positive (red) lead first. 11. Refit the seat (see page 16-9). 1. Rotor 2. Tool T3880375 3. Tool T3880203 11. Withdraw the rotor and tool as an assembly and then separate the tool from the rotor. 17.17 Service Manual - Tiger TRJUMM...
  • Page 457 5. Refit the low oil pressure warning light switch (see out of the way. page 8-11). 6. Refit the fuel tank (see page 10-100). Reconnect the battery, positive (red) lead first. 8. Refit the seat (see page 16-9). 7.1 8 . Service Manual - Tiger...
  • Page 458 1.Instrument pack 2. Instrument pack connector 3. Instrument pack fixing 6. Ease the instrument pack away from the bayonet and grommet fixings and remove the instrument pack. 17.19 Service Manual - Tiger 11t!:!!!?^It...
  • Page 459 Number Plate Light Left-hand Switch Cube Assembly Pink Beam Switch Main I Pass Purple Switch Assembly White Instrument Yellow Oil Pressure Switch Oil Pressure Warning Light Light Green Light Blue Main Beam Warning Light Headlight Assembly 17.20 Manual - Tiger Service...
  • Page 460 Electrical. IQ P I . , 1 UY-^ 17.21 Service Manual - Tiger 71kIUMBH...
  • Page 461 Slate / Grey Ignition Switch Orange Fuse Box Pink Cooling Fan Relay Engine Control Module Relay Purple Engine Control Module White Instrument Assembly Yellow Engine Kill Switch Light Green Starter Switch Light Blue Alarm Fuel Pump Relay 17.22 Manual - Service Tiger...
  • Page 462 Electrical m m m m 17.23 Service Manual - Tiger...
  • Page 463 Rear brake light switch Brake light Instrument Assembly Diagnostic connector Direction indicator (Instruments) Alarm LED Front right direction Indicator Front left direction Indicator Alarm unit Rear right direction ind icator Rear left direction indicator 17.24 Service Manual - Tiger IUMr...
  • Page 464 Electrical 17.25 Service Manual - Tiger TL!:...
  • Page 465 Electrical Main Wiring Circuit Diagram - Models with ABS Brakes Key to circuit diagram Rectifier I Regulator Alternator Item Description Fuse Box Instrument Assembly Ignition Switch Vehicle Speed Sensor Accessory Socket Front Brake Lever Switch Satellite Navigation Connector (Accessory) Engine Kill Switch Heated Handlebar Grips Connector (Accessory) Starter Button Fuel Pump...
  • Page 466 • I^ cv • 10► ^=1 a,...„..,a..a .^.^' 81" I -_____ LrJTl -^^ aM ^^^Anwe l IEiiiiiii : I : ,raa gM r •An, 1111_ill LIiUL ^^ I^11 '!" 1^ _ II.I ih . i: 1u 11111 RI _____ " II _- •...
  • Page 467 ozv no tC f^ £zv Mo M ('+) — m ZZH NO ^v do • 9 b 5£`d 9 5£9 ® ®ii ® ® ^N z z£d 89 6l9 e ^ bzH `08 lIN Z h IA N • sad do --^--^ aM a Z L! ,1 Wf...
  • Page 468 Idle Speed Control Actuator White Diagnostic Connector Yellow Rear Brake Lever Switch Light Green RH Rear Indicator Light Blue Rear Light Number Plate Light LH Rear Indicator Alarm Connector (Accessory) Starter Motor Starter Solenoid Battery Starter Relay 17.26 Tiger Service Manual - lump...

This manual is also suitable for:

Tiger (abs)

Table of Contents