Triumph 2010 Tiger 800XC Manuals

Manuals and User Guides for Triumph 2010 Tiger 800XC. We have 1 Triumph 2010 Tiger 800XC manual available for free PDF download: Service Manual

Triumph 2010 Tiger 800XC Service Manual

Triumph 2010 Tiger 800XC Service Manual (508 pages)

Brand: Triumph | Category: Motorcycle | Size: 20.77 MB

Table of Contents

Introduction

5
- Table of Contents
  5
- Warnings, Cautions and Notes
  6
- How to Use this Manual
  6
- Tampering with Noise Control System Prohibited
  7
- References
  7
- Dimensions
  7
- Repairs and Replacements
  7
- Force
  7
- Edges
  7
- Tightening Procedure
  7
1 General Information

9
- General Information
  10
- Dangerous Substances
  12
- Fluoroelastomers
  12
- Ignition System Safety Precautions
  12
- Oils
  12
- Third Party Products
  12
- Brakes
  13
- Environmental Protection Precautions
  13
- Health Protection Precautions
  13
- Coolant
  14
- Jacking and Lifting
  14
- Precautions against Damage
  14
- Safety Instructions
  14
- Cleaning Components
  15
- Gaskets, 0-Rings
  15
- Joints and Joint Faces
  15
- Liquid Gasket, Non-Permanent Locking Agent
  15
- Lubrication
  15
- Screw Threads
  15
- Ball Bearings
  16
- Chassis Bearing Lubrication
  16
- Circlips, Retaining Rings
  16
- Encapsulated Bolts
  16
- Fitting a Split Pin
  16
- Locking Devices
  16
- Oil and Grease Seals
  16
- Press
  16
- Self Locking Nuts
  16
- Fuel Handling Precautions
  18
- Genera
  18
- Metal Bushes
  18
- Petrol - Gasoline
  18
- Chassis Repairs
  19
- Fuel Tank Removal
  19
- Battery Disconnecting
  20
- Disciplines
  20
- Electrical Precautions
  20
- Basic Electrical Circuits
  21
- Electrical Testing
  21
- Electrical Wires
  21
- Ohm's Law
  21
- Circuit Diagrams
  22
- Glossary of Circuit Diagram Symbols
  22
- To Check Continuity
  24
- Tracing Circuits
  24
- Splices
  25
- To Measure Voltage
  25
- CAN <Controller Area Networking
  26
- General Fault Finding - Starter Motor and Relay
  28
- Starting Circuit
  28
- Diagnosis - Starter Circuit
  29
- Inspection
  30
  - Service Data
    30
- Replacement Parts
  30
- Specification
  30
- Se Ivice Tools and Garage Eq Uipment
  31
- Engine
  36
- Full Specification
  36
- Cyli Nder Head Valves
  37
- Camshafts
  38
- Cyli Nder Head Valves <Continued
  38
- Clutch/Primary Drive
  39
- Connecting Rods
  39
- Pistons
  39
- Crankshaft
  40
- Final Drive
  40
- Transmission
  40
- Fuel System
  41
- Ignition System
  41
- Lubrication
  41
- Coolant System
  42
- Suspension
  42
- Brakes
  43
- Emissions Controls
  43
- Fuel Injection System
  43
- Brakes (Continued)
  44
- Wheels and Tyres
  44
- Frame
  45
- Clutch
  46
- Cylinder Head Area
  46
- Torque Wrench Settings
  46
- Final Drive
  48
- Transmission
  48
- Fuel System, Exhaust System and Ai Rbox
  50
- Front Suspension
  51
- Rear Suspension
  51
- Wheels
  51
- Front Brakes
  52
- Rear Brakes
  52
- Electrical
  54
- Bodywork
  55
- Clutch Cable Routing
  56
- Throttle Cable Routing
  57
- Main Wiring Harness Routing
  58
- Front and Rear Brake Hose Routing - Models Without ABS
  59
- ABS Hose Routing
  60
- Fuel Tank Breather Hose Routing
  61
3 Cylinder Head

67
- Seivice Manual - Tiger 800 and Tiger 800XC
  67
- Exploded View - Cylinder Head and Valves
  69
- Exploded View - Camshaft Cover
  70
- Exploded View - Ca Mshaft and Camshaft Drive
  71
- Camshaft Cover
  72
- Cylinder Head Description
  72
- Removal
  72
- Installation
  73
- Camshaft Drive Chain Tensioner - All Models
  74
- Removal
  74
- Installation
  75
- Assembly
  78
- Camshaft Drive Chain Tensioner Blade
  78
- Disassembly
  78
- Installatio
  81
- Stage 1
  81
- Stage 2
  82
- Camshaft Drive Chain
  84
- Removal
  84
- Valve Clearance Adjustment
  84
- Installation
  86
- Removal from the Cylinder Head
  89
- Valves and Valve Stem Seals
  89
- Installation
  90
4 Ciutch

93
- Exploded View - Clutch Cover
  94
- Exploded View - Clutch Assembly
  95
- Exploded View - Clutch Controls
  96
- Assembly
  97
- Clutch Cable
  97
- Inspection
  97
- Removal
  97
- Clutch
  98
- Disassembly
  98
- Clutch Plate Inspection
  99
- Friction Plate Thickness
  99
- Clutch Pack Height
  100
- Steel Plate Bend/Warp
  100
- Assembly
  102
5 Crankshaft, Connecting Rods and Pistons

105
- Exploded View - Crankshaft, Connecting Rod, Piston and Liner
  106
- Exploded View - Crankcase
  107
- Assembly
  108
- Crankcases
  108
- Disassembly
  108
- Crankshaft
  110
- Installation
  110
- Removal
  110
- Connecting Rods
  112
- Installation
  112
- Removal
  112
- Checking the Measured Clearance
  114
- Connecting Rod Big End Bearing Selection/Crankshaft Journal Wear Check
  114
- Connecting Rod Bearing Selection
  115
- Crankshaft Main Bearing/Journal Wear
  116
- Disassembly
  117
- Pistons
  117
- Piston Wear Check
  118
- Cylinder Wear
  120
- Cylinder Liners
  121
- Removal
  121
- Crankcase Breather
  122
- Installation
  122
7 Transmission

129
- Exploded View - Input and Output Shafts
  130
- Exploded View - Sprag Clutch and Starter Gears
  131
- Exploded View - Gear Selectors and Drum
  132
- Exploded View - Gear Change Mechanism
  133
- Installation
  134
- Removal
  134
- Selector Shaft
  134
- Removal
  135
- Selector Forks and Drum
  135
- Inspection
  136
- Installation
  137
- Input and Output Shafts Assemblies
  138
- Removal
  138
- Disassembly
  140
- Input Shaft
  140
- Exploded View - Input Shaft
  142
- Assembly
  143
- Disassembly
  145
- Inspection
  145
- Output Shaft
  145
- Exploded View - Output Shaft
  146
- Assembly
  147
- Inspection
  149
- Removal
  149
- Starter Drive Gears/Sprag Clutch
  149
- Installation
  150
8 Lu Brication

153
- Exploded View - Sump
  154
- Exploded View - Oil Pump/Water Pump, Gears and Heat Exchanger
  155
- Engine Oil Circuit
  156
- Engine Oil Circuit Description
  157
- Heat Exchanger
  157
- Engine Oil
  158
- Oil Level Inspection
  158
- Specification
  158
- Triumph Engine Oil
  158
- Oil and Oil Filter Change
  159
- Disposal of Used Engine Oil
  160
- Oil Pump
  160
- Removal
  160
- Inspection
  163
- Assembly
  164
- Installation
  165
- Installation
  166
- Low Oil Pressure Warning Light Switch
  166
- Removal
  166
- Removal
  167
- Sump
  167
- Installation
  168
Purge Valve Duty Cycle

180
- Fuel Requirements
  190
- Ignition Timing
  192
- Immobiliser and Tyre Pressure Monitoring System <TPMS> Control Module
  192
- La Mbda 02 Sensor
  192
- Long Term Fuel Trim
  192
- MAP Sensor
  192
- Open Circuit
  192
- Over Temp
  192
- Primary Throttle Position Sensor
  192
- Primary Throttle Stepper Motor
  192
- Purge Valve Duty Cycle
  192
- Short Circuit
  193
- Short Term Fuel Trim
  193
- Sidestand Status
  193
- Target Dwell Time
  193
- Tdc
  193
- Throttle Position
  193
- Throttle Voltage
  193
- Tpms
  193
- Transponder
  193
- Vbatt
  193
- Engine Management System
  194
- System Description
  194
- System Sensors
  194
- Sensor Locations
  195
- System Actuators
  196
- Actuator Locations
  197
- Diagnostics
  198
- Further Diagnosis
  198
- Immobiliser System
  198
- Keys
  198
- System Components and Operation
  198
- System Description
  198
- Components Location
  199
- Compliance
  200
- Diagnostics
  200
- Further Diagnosis
  200
- System Components and Operation
  200
- System Description
  200
- Tyre Pressure Monitoring System <TPMS
  200
- Component Locations
  201
- On-Board Fault Detection System
  206
- System Diagnostics
  206
- Diagnostic Tool Connection
  207
- Triumph Diagnostic Software
  207
- Current Data
  208
- Sensor Data
  209
- Function Tests
  212
- Diagnostic Trouble Codes
  214
- Further Diagnosis
  218
- Reconnection O F ECM con Nectors
  218
- Idle Speed Control
  220
- Fuel Injectors
  223
- Throttle Position Sensor
  224
- Purge Valve
  226
- Ignition Coils
  228
- Coolant Temperature Sensor
  230
- Intake Air Temperature Sensor
  232
- System Voltage
  234
- Cooling Fan Relay
  235
- Oxygen Sensor
  236
- Oxygen Sensor Heater
  237
- EEPROM Error
  238
- Fall Detection Switch
  239
- Vehicle Speed Sensor
  240
- CAN Communication
  241
- Instrument Communication <CAN
  242
- Fuel Level Sensor
  243
- Ambient <Barometric> Pressure Senso
  244
- Manifold Absolute Pressure <Map> Sensor
  245
- Gear Position Sensor
  246
  - Fuel Pump
    248
  - Fuel Tank
    269
  - Fuel Delivery System
    275
  - Air Filter Element
    278
  - Exhaust System
    296
11 Cooling

303
- Exploded View - Cooling System
  304
- Coolant
  305
- Coolant Level Inspection
  306
- Radiator and Cooling Fan
  306
- Radiator Hoses
  306
- Coolant Replacement
  307
- Drainage
  307
- Filling
  307
- Coolant Pressure Cap and Coolant System
  309
- Inspection and Testing
  309
- Water Pump
  309
- Removal
  311
- Thermostat
  311
- Inspection
  312
- Installation
  312
- Radiator
  313
- Removal
  313
- Inspection
  314
- Installation
  314
12 Rear S Uspension

315
- Exploded View - Swinging Arm
  316
- Exploded View - Rear Hub and Wheel -Tiger 800
  317
- Exploded View- Rear Hub and Wheel -Tig er 800 XC
  318
- Exploded View- Rear Suspension Unit -Tiger 800
  319
- Exploded View - Rear Suspension Unit -Tiger 800XC
  320
- Exploded View - Drop/Drag Link
  321
- Chain Adjustment
  322
- Chain Free-Movement Inspection
  322
- Chain Lubrication
  322
- Drive Chain
  322
- Chain Free-Movement Adjustment
  323
- Chain Wear Inspection
  323
- Rear Suspension Unit
  324
- Removal
  324
- Inspection
  325
- Installation
  325
- Drag Link and Drop Links
  326
- Removal
  326
- Inspection
  327
- Installation
  327
- Removal
  327
- Swinging Arm
  327
- Inspection
  328
- Assembly
  329
- Drive Chain Replacement
  329
- Rivet Link Type
  329
13 Front S Uspension

333
- Exploded View - Handlebars
  336
- Front Suspension
  336
- Fork Inspection
  337
- Front Fork
  337
- Installation
  338
- Draining
  339
- Fork Oil Change
  339
- Oil Refilling
  339
- Fork Oil Level Chart
  340
- Disassembly
  341
- Front Fork
  341
- Assembly
  344
- Inspection
  344
- Adjustment
  347
- Check
  347
- Headstock Bearing Check/Adjustment
  347
- Headstock Bearing Removal
  349
- Inspection
  350
- Installation
  351
- Handlebars
  352
- Removal
  352
14 Brakes

355
- Exploded View - Front Brake Caliper
  360
- Exploded View - Rear Brake Master Cylinder
  361
- Exploded View - Rear Brake Caliper
  362
- Exploded View - ABS System
  363
- Braking System Maintenance Safety Precautions
  364
- Bleeding the Front Brakes, Renewing Brake Fluid
  366
- Brake Pads
  366
- Brake Wear Inspection
  366
- Breaking-In New Brake Pads and Discs
  366
- Changing Brake Fluid
  366
- Front Brake Pads
  368
- Removal
  368
- Inspection
  369
- Installation
  369
- Front Brake Caliper
  370
- Removal
  370
- Disassembly
  371
- Installation
  372
- Front Discs
  373
- Removal
  373
- Wear
  373
- Front Brake Master Cylinder
  374
- Installation
  374
- Removal
  374
- Disassembly
  375
- Inspection
  375
- Assembly
  376
- Installation
  376
- Bleeding the Rear Brakes, Renewing Brake Fluid
  377
- Rear Brake Pads
  379
- Installation
  380
- Disassembly
  381
- Inspection
  381
- Rear Brake Caliper
  381
- Removal
  381
- Assembly
  382
- Installation
  383
- Rear Brake Disc
  384
- Rear Master Cylinder
  384
- Removal
  384
- Wear
  384
- Assembly
  385
- Disassembly
  385
- Inspection
  385
- Installation
  386
- Front ABS Wheel Sensor
  388
- Installation
  388
- Removal
  388
- Front ABS Pulser Ring
  389
- Inspection
  389
- Installation
  389
- Removal
  389
- Bleeding the Rear Brake Fluid - Motorcycles with ABS
  390
- Installation
  391
- Rear ABS Wheel Speed Sensor
  391
- Removal
  391
- Air Gap Measurement - Front and Rear Wheel Speed Sensors
  392
- Inspection
  392
- Installation
  392
- Rear ABS Pulser Ring
  392
- Removal
  392
- ABS Hydraulic Modulator/Ecm
  393
- Removal
  393
- Installation
  396
- Abs
  398
- System Description
  398
- Component Location
  399
- ABS System Circuit Diagram
  400
- Key to Wiring Diagram
  400
- ABS System Circuit Diagram
  401
- Diagnostic Tool Connection
  402
- System Diagnostics
  402
- Bleed System
  403
- Build Data
  403
- Current Data
  403
- Triumph Diagnostic Tool
  403
- Diagnostic Trouble Codes
  404
- Diagnostic Trouble Codes
  405
- Further Diagnosis
  408
- Reconnection of ABS ECM Connector
  408
- ABS Warning Light on <No Dtcs Stored)
  409
- ABS Warning Light Does Not Illuminate <No Dtcs Stored)
  410
- Front Wheel Sensor Open Circuit/Short Circuit
  412
- Rear Wheel Sensor Open Circuit/Short Circuit
  414
- Front Wheel Sensor Abnormal Input/Losing Contact
  416
- Rear Wheel Sensor Abnormal Input/Losing Contact
  417
- Front Wheel Pulser Gear Missing Teeth
  418
- Rear Wheel Pulser Gear Missing Teeth
  419
- Front or Rear Input/Output Solenoid Open/Short Circuit
  420
- Front or Rear Wheel Actuator <Hydraulic Control> Wheel Lock
  421
- Motor - Lock; Motor Stuck OFF; Motor Stuck on
  422
- Different Tyre Diameter
  424
- Abnormal ECU
  425
- ABS Hydraulic Circuit Layout
  426
1 5 Wheels/Tyres

427
- Exploded View - Front Wheel - Tiger 800
  428
- Exploded View - Front Wheel - Tiger 800 XC
  429
- Exploded View - Rear Wheel Final Drive - Tiger
  430
- Exploded View - Rear Wheel Final Drive - Tiger 800 XC
  431
- Tyres
  432
- Tyre Pressures
  433
- I Mportant Tyre Information
  434
- Tyre Wear/Wheel Inspection
  434
- Front Wheel
  436
- Removal
  436
- Installation
  438
- Rear Wheel
  438
- Removal
  438
- Front Wheel Bearings
  440
- Inspection
  440
- Installation
  440
- Removal
  440
- Rear Wheel Bearings
  441
- Removal
  441
- Inspection
  442
- Installation
  442
- Final Drive
  443
- Inspection
  443
- Installation
  443
- Removal
  443
1 6 Frame and Bodywork

445
- Exploded View - Frame - All Models
  447
- Exploded View - Cockpit and Mountings - Tiger 800
  448
- Exploded View - Cockpit and Mountings - Tiger 800 XC
  449
- Exploded View - Lower Panels and Sumpguard - All Models
  450
- Exploded View - Rear Panels - All Models
  451
- Exploded View - Footrests and Mountings - All Models
  452
- Exploded View - Sidestand - All Models
  453
- Exploded View - Front Mudguard - Tiger 800
  454
- Exploded View - Rear Mudguard - All Models
  456
- Removal
  458
- Installation
  459
- Radiator Lnfill Panel
  459
- Removal
  459
- Beak - Tiger 800 XC Only
  460
- Installation
  460
- Removal
  460
- Cockpit Assembly
  461
- Disassembly
  461
- Removal
  461
- Assembly
  462
- Fuel Tank L Nfill Pa Nel
  462
- Installation
  462
- Removal
  462
- Front Mudguard - Tiger 800
  463
- Installation
  463
- Removal
  463
- Windscreen
  463
- Front Mudguard - Tiger 800XC
  464
- Installation
  464
- Rear Rack
  464
- Removal
  464
- Installation
  465
- Rear Side Panel
  465
- Removal
  465
- Rear Mudguard
  466
- Removal
  466
- Installation
  467
- Frame, Footrests and Fixings
  468
- Inspection
  468
- Installation
  468
- Removal
  468
- Sump Guard
  468
1 7 Electrical

469
- Exploded View - Instru Ments
  471
- Exploded View - Headlight
  472
- Exploded View - Direction Indicators
  474
- Exploded View - Alternator, Starter and Immobiliser
  475
- Battery
  476
- Battery Refit
  476
- Battery Removal
  476
- Battery Commissioning and Charging
  477
- New Battery
  477
- Battery Already in Service
  478
- Battery Maintenance
  478
- Table of Battery Charging Times
  478
- Direction Indicator Unit
  479
- Fuse Identification
  479
- Fuses
  479
- Relay Identification
  479
- Relays
  479
- Front Fuse Box
  480
- Rear Fuse Box
  480
- Installation
  481
- Instrument Pack
  481
- Removal
  481
- Headlight Adjustment
  482
- Headlight Bulb Replacement
  482
- Headlights
  482
- Installation
  482
- Headlight Assembly
  483
- Installation
  483
- Position Lam P Bulb Replacement
  483
- Removal
  483
- Bulb Replacement
  484
- Direction Indicators
  484
- Installation
  484
- Rear Light
  484
- Removal
  484
- Front Direction Indicator
  485
- Installation
  485
- Rear Direction Indicator
  485
- Removal
  485
- Inspection
  486
- Installation
  486
- Removal
  486
- Starter Motor
  486
- Alternator
  487
- Removal
  487
- Assembly
  488
- Alternator Rectifier
  489
- Alternator Stator
  490
- Rectifier/Regulator
  492
- Key to Circuit Diagram
  494
- Key to Wiring Colours
  494
- Lighting Circuit
  494
- Key to Circuit Diagram
  496
- Starting and Charging Circuit
  496
- Auxiliary and Accessory Circuit
  498
- Key to Circuit Diagram
  498
- Key to Wiring Colours
  498
- Engine Management Circuit Diagram - Tiger 800 a Nd Tiger 800XC
  500
- Key to Wiring Circuit Diagram
  500
- Key to Wiring Colour Codes
  500
- Key to Wiring Colour Codes
  502
- Complete System - Tiger 800 and Tiger 800XC - Without ABS
  504
- Key to Circuit Diagram
  504
- Complete System - Tiger 800 and Tiger 800XC - with ABS
  506
- Key to Circuit Diagram
  506

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