2011-2014 Triumph Tiger 800 Tiger 800XC ABS Service & Repair Manual

Triumph T iger 800 and Tiger SOOXC (Including ABS models) Motorcycle Service Manual Pa Number 3856760, issue 1, 12.2010 This document is protected by copyright and may not, in whole or part be stored in a retrieval system, or transmitted in any form or by any means, copied, photocopied, translated or reduced to any machine-readable form without prior consent in writing from Triumph Motorcycles Limited. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your authorised Triumph dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations in this publication are intended for reference use only and may not depict actual model component parts. © Triumph Motorcycles Ltd. 2010 Seice Manual - Tiger 800 and Tiger 800XC

11 · Seice Manual - Tiger 800 and Tiger 800XC

Table of Contents Introduction General Information Scheduled Maintenance Cylinder Head Clutch Crankshaﬅ, Connecting Rods and Pistons Balancer Transmission Lubrication . Engine Removal/Refit Fuel System/Engine Management Cooling Rear Suspension Front Suspension Brakes Wheelsyres Frame and Bodywork Electrical Seice Manual - Tiger 800 and Tiger 800XC iii

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Introduion Table of Contents How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Tampering with Nois e Control System Prohibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Dimensions ............................................................................ . .vii Repairs and Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii Edges .......................................................................... : . . . . . . . .vii Tightening procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii I� Seice Manual � Tiger 800 and Tiger 800XC V

Introduion This manual is designed primarily for use by trained technicians in a properly equipped workshop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools to complete the job. A basic knowledge of mechanics, including the proper use of tools and worhop procedures is necessa in order to car out maintenance and repair work satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, an authorised Triumph dealer must undertake all adjustments, maintenance, and repair work. In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work. All work should be performed with great care and in a clean working area with adequate lighting. Always use the correct special seice tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of substitutes may adversely affect safe operation. Where accurate measurements are required, they can only be made using calibrated, precision instruments. For the duration of the warran period, an authorised Triumph dealer must perform all repairs and scheduled maintenance. To maximise the life of your Motorcycle: • • Accurately follow the maintenance requirements of the periodic maintenance chart in the seice manual. Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the motorcycle. Recti  all problems as soon as possible (immediately if safe related). Use only genuine Triumph parts as listed in the parts catalogue/parts microfiche. • Follow the procedures in this manual carefully and completely. Do not take short cuts. Keep complete records of all maintenance and repairs with dates and any new parts installed. Use only approved lubricants, as specified in the owner's handboo in the maintenance of the motorcycle. How to use this manual To assist in the use of this manual, the section title is given at the top of each page. Each major section starts with a contents page, listing the information contained in the section. The individual steps comprising repair operations are to be followed in the sequence in which they appear. Adjustment and repair operations include reference to seice tool numbers and the associated illustration depicts the tool. Where usage is not obvious, the tool is shown in u.se. Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, specialist information and useful assembly details. Warnings, Cautions and Notes Particularly important information is presented in the following form: This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. Note: • This note symbol indicates points of particular interest for more efficient and convenient operation. VI Seice Manual - Tiger 800 and Tiger 800XC

Tampering with Noise Control System Prohibited Owners are warned that the law may prohibit: a> The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delive to the ultimate purchaser or while it is in use; and b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. References References to the left-hand or right-hand side given in this manual are made when viewing the motorcle from the rear. Operations covered in this manual do not always include reference to testing the motorcycle after repair. lt is essential that work is inspected and tested after completion and if necessary a road test of the motorcle is carried out particularly where safety related items are concerned. Dimensions The dimensions quoted are to design engineering specification with seice limits where applicable. During the period of running-in from new, certain adjustments may vary from the specification figures given in this manual. These will be reset by the dealer at the 500 mile/800 km service, and thereafter should be maintained at the figures specified in this manual. Repairs and Replacements Before removal and disassembly, thoroughly clean the motorcle. Any dirt entering the engine gr other parts will work as an abrasive and shorten the life of the motorcycle. Particular attention should be paid when installing a new part, that any dust or metal filings are cleared from the immediate area. Introduction Force Common sense should dictate how much force is necessa in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Never lever a component as this will cause damage both to the component itself and to the surface being levered against. Whenever tapping to aid removal of an item is necessary, tap lightly using a hide or plastic faced mallet. Edges Watch for sharp edges, especially during engine disassembly and assembly. Protect the hands with industrial quality gloves. When replacement parts are required, it is essential that only genuine Triumph parts are used. Safety features and corrosion prevention treatments embodied in the motorcycle may be impaired if other than genuine Triumph parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification. Tightening procedure Generally, when installing a part with several bolts, nuts or screws, they should all be started in their holes and tightened to a snug fit, evenly and in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely, bolts, nuts, or screws, should all be loosened (in sequence if specified) by about a quarter of a turn and then removed. Where there is a tightening sequence specified in this Seice Manual, the bolts, nuts, or screws must be tightened in the order and by the method indicated. Torque wrench setting figures given in this Manual must be obseed. The torque tools used must be of accurate calibration. Locking devices, where specified, must be fitted. If the efficien of a locking device is impaired during removal it must be renewed. This applies particularly to micro- encapsulated fixings which must always be replaced if disturbed. Where necessa, the text in this manual will indicate where such a fixing is used. Seice Manual - Tiger 800 and Tiger 800XC VII

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1 General Information Table of Contents Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Dangerous Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Third Party Products ........................................................... , . . . . . . . . . . . 1.4 Fluoroelastomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Oils ..................................................................................... 1.4 Health Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Environmental Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Brakes ................................................................................... 1.5 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Jacking and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Precautions against Damage ....... �............................ . . . . . . . . . . . . . . . . . . . . . . . 1.6 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Cleaning Components ................................................................. 1.7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Joints and Joint Faces _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Gaskets, 0-rin gs ........... . .......................... ·. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Liquid Gasket, Non-permanent Locking Agent ............................................ 1.7 Screw Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Locking Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Fitting a Split Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Circlips, Retaining Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Self Locking Nuts ..................... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Encapsulated Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 · Oil and Grease Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Ball Bearings ............................................. , . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Chassis Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Metal bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 0 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 0 Petrol - Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 0 Fuel Tank Removal ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1 Chassis Repairs ..................................... . ....... .' . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1 Electrical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 2 Seice Manual - Tiger 800 and Tiger 800XC 1.1

General Information 1.2 Batte Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disciplines ......................................................................... . Electrical Wires ..................................................................... . Electrical Testing ........................................................................ . Ohm's Law ........................................................................ . Basic Electrical Circuits .............................................................. . Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . Glossa of Circuit Di ag ram Symbols ....................................................... . Tracing Circuits ......................................................... : . . . .. : . . . . . . . . . . . To Check Continuity: ................................................................ . To Measure Voltage: ................................................................ . Splices ....................................... , . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . CAN <Controller Area Networking) ........................................................ . Alternator/Charging System .............................................................. . Diagnosis - Charging Circuit ......................................................... . Starting Circuit ......................................................................... . General Fault Finding - Starter Motor and Relay ............................................. . Diagnosis - Starter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection ........................................................................... : . . . Replacement Parts ...................................................................... . Seice Data . . . . .. . . . .. . . . . . . . . . . :·...................................................... . Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seice Tools and Garage Equipment ....................................................... . Full Specification ........................................................................ . 1. 12 1.1 2 1.1 3 1.1 3 1.1 3 1.1 3 1.1 4 1.1 4 1.16 1.1 6 1.17 1.17 1.18 1.19 1.19 1.20 1.20 1.21 1.22 1.22 1.22 1.22 1.23 1.28 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 Cylinder Head & Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 Cylinder Head & Valves <continued> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 Clutch/Prima Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 Transmission . . . . ... . . . . . . . . . . . . . . .. . .... ,, ........................................... 1.32 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33 Fuel System . . . . . . .. . . . . . . . . . . . . . .... . . .... . . . . .. . . . . . . . . ... . : . . . . . . . . . . . . . . . . . . . . . . 1.33 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34 Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35 Emissions Controls ................................................................... 1.35 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35 Brakes (continued). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 Wheels and Tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 Frame . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . ... . . . . . ... . . . . . . . . . . . . . . . . . � . . . . . . . . . . . . . . . . 1.37 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37 Seice Manual - Tiger 800 and Tiger 800XC

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2011-2014 Triumph Tiger 800 Tiger 800XC ABS Service & Repair Manual

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