Sign In
Upload
Manuals
Brands
Triumph Manuals
Motorcycle
2012 Tiger 800
Triumph 2012 Tiger 800 Manuals
Manuals and User Guides for Triumph 2012 Tiger 800. We have
1
Triumph 2012 Tiger 800 manual available for free PDF download: Service Manual
Triumph 2012 Tiger 800 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
Advertisement
Advertisement
Related Products
Triumph 2012 Tiger 800XC
Triumph 2010 Rocket III
Triumph 2011 Tiger 800
Triumph 2010 Tiger 800
Triumph 2013 Tiger 800
Triumph 2011 Tiger 800XC
Triumph 2010 Tiger 800XC
Triumph 2013 Tiger 800XC
Triumph 2007 ROCKET III
Triumph 2007 ROCKET III Classic Tourer
Triumph Categories
Motorcycle
Motorcycle Accessories
Automobile
Sports & Outdoors
Game
More Triumph Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL