2005-2014 Triumph Motorcycle Tiger/SE/Sport Service & Repair Manual

U H Mp TIGER TIGER (ABS)

Part Number 385736S Issue 1, 11.2006 UMW Service. Manual - Tiger

Table of Contents pT1IIIIbiIl Service Manual - Tiger iii Table of Contents Introduction General Information Scheduled Maintenance Cylinder Head Clutch Crankshaft Balancer Transmission lubrication Engine Removal/Refit Fuel System/Engine Management Cooling Rear Suspension Front Suspension Brakes Wheels/Tyres Frame and Bodywork Electrical Service Manual - Tiger iii

t1 rTii i.iii Table oof Contents Howto use this manual ......................................................................iv Warnings, Cautions and Notes ................................................................. iv Tamperingwith Noise Control System Prohibited ................................................ v References................................................................................. v Dimensions...........................................................................v Re p airsand Replacements.. . .. . . .. ... ....... .............. ............................v Force••••••••••• ♦••••...••••.•••••••..•.••••.••.•.•.••.. ..••••.•••••••••••••••••••••••V Edges• ............................................................................. v Tighteningprocedures .................................................................v TRJUMPON Service Manual - Tiger V

1 1 rrr .i 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 necessa ry hand and special service tools to complete the job. A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessa ry in order to carry 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 service 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 warranty 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 service manual. • Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the motorcy cl e. Rectify all problems as soon as possible (i mmediately if safety 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 lub ri cants, as specified in the owner's handbook, in the maintenance of the motorcycle. To assist in the use of this manual, the section title is given at the top. 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 service tool numbers and the associated illustration depicts the tool. Where usage is not obvious, the tool is shown in use. Adjustment and repair operations also in cl ude 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 inju ry, or loss of life. t.^ ^..^.v ; ^1.X';.;r. :1s.: ..X ,a::i{: .,'` :',:.Y.•<:,. n:W ^ ,+'^ i:;++'h d:4fwc::? ?f .'i:t 1 :: ; A ^ , ; } : a3: },' ^i ^:? s^+ ru .w,q :{:., 'r. ^.: ^ ^.^ , .} n.. .+y, : n t: • v: ' • v.: a •. i fi... V: , '" t• • :•^;.tia.s'szr{::,v^; •?'• ` ` ^{,}^: £^... ' : . t t' ^ +X. ^.:' $$ is :.3T.% ^ `., it ^: `' : J + ifi. Y! § £x. :fi•,.. to >X ^:n..,•,a V ^w. • :3;'+'+ J: ,. N .^. f ^.^<'^t`, 2G' ^" ^ ^.:;^.4..., ^ ^^r, a.a:. «,,t:#...ah: ''t :.4......,. '^... ^', :1§. : +5 r.., ^ay^fi•.. ..::^, > ^^ n +a 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 Service Manual - Tiger •

Tampering with Noise Control system Prohibited Owners are warned that the law may prohibit: Edges Watch for sharp edges, disassembly and assembly. industrial quality gloves. especially during engine Protect the hands with 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 delivery to the ultimate purchaser or while it is in use; and b) the use of the vehicle after such device or element ofdesign has been removed or rendered inoperative by any person. References to the left-hand or right-hand side given in this manual are made when viewing the motorcycle from the rear. Operations covered in this manual do not always include reference to testing the motorcycle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the motorcycle is carried out particularly where safety related items are concerned. The dimensions quoted are to design engineering specification with service 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 motorcycle. Any dirt entering the engine or 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. Force Common sense should dictate how much force is necessary 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. 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 Procedures 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 Service 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 observed. The torque tools used must be of accurate calibration. Locking devices, where specified, must be fitted. If the efficiency 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 necessary, the text in this manual will indicate where such a fixing is used. Twumm Service Manual - Tiger VI'

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[Lci ir i I TI11MI'I1i ^^ .^ P': ^ X11 ^ ^ Y 'w IgnitionSystem Safety Precautions ........................................................... 1.3 DangerousSubstances ..................................................................... 1.3 Fluoroelastomers.......................................................................... 1.3 Oils..................................................................................... 1.3 Health Protection Precautions ............................................................... 1.3 EnvironmentalProtection Precautions ........................................................ 1.4 Brakes................................................................................... 1.4 Safet yInstructions ......................................................................... 1.5 Jacking and Lifting .................................................................... 1.5 Precautionsagainst Damage ........................................................... 1.5 Coolant .............................................. 0 .......................... 0 ... 1.5 Cleaningcomponents ................................................................. 1.6 Lubrication........................................... 0 ..................... 0 ........ 1.6 Joints and Joint Faces ..................................... 0 ........................... 1.6 Gaskets, O- ri ngs ................................................. 0 ................... 0 1.6 Liquidgasket, Non-permanent Locking Agent ............................................ 1.6 ScrewThreads ........................................................0.............. 1.6 Locking Devices ...................................................................... 1.7 Fittin g a Split Pin ..................................................................... 1.7 Circlips, Retaining Rings .......................................... 0 .............. 0 ..... 1.7 Self Locking Nuts ...............................................0..................... 1.7 Encapsulated Bolt ..................................................................... 1.7 Oil and Grease Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.7 Press. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BallBearing .......................................... 0 ............................... 1.7 FuelHandling Precautions .................................................................. 1.7 General.. ............................................................................ 1.7 Petrol - Gasoline ...........................................0.......................... 1.8 FuelTank Removal .......... ...... ... .... ... .................................. .... .... 1.8 Chassis Repairs .... . . . . .. . . . 1.8 0 ........................ 1.8 Electrical Precautions ...................................................................... 1.9 BatteryDisconnecting ................................................................. 1.9 Disciplines..................................................................... 0 ..... 1.9 Electrical Wires ................................................... 0 .................. 1.10 Manual Service M l -Ti9er 1.1 uP

General Information ElectricalTesting ......................................................................... 1.10 BasicElectrical Circuits ......................... . ......................................1.10 CircuitDiagrams ......................................................................... 1.11 Glossaryof Circuit Diagram Symbols ........................................................ 1.11 TracingCircuits .......................................................................... 1.12 ToCheck Continuity :................................................................. 1.13 ToMeasure Voltage :................................................................. 1.13 CAN(Controller Area Networking) ......................................................... 1.14 Alternator/Charging System ............................................................... 1.15 StartingCircuit .......................................................................... 1.16 GeneralFault Finding - Starter Motor and Rela .............................................. 1.16 Inspection......... . ... . . . ........ .................................................. 1.18 Replacement Parts . . 1.18 1.18 ServiceData ........................................................................ 1.18 Specification........................................................................ 1.18 ServiceTools and Garage Equipment ......................... ................................ 1.19 SpecialService Tools ................................................................. 1.19 Full Specification.. 1.24 1.24 TorqueWrench Settings .................................................................... 1.31 CylinderHead Area .................................................................. 1.31 Clutch .. . , 1.31 Balancer, Crankshaft and Crankcase .................................................... 1.31 EngineCovers ...................................................................... 1.3 2 Transmission........................................................................ 1.32 LubricationSystem .................................................................. 1.32 FinalDrive .......................................................................... 1.33 CoolingSystem ..................................................................... 1.33 FuelSystem, Suspension..... ......... System and Airbox ................................................ 34 1 1.33 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .-. . . . FrontSuspension .................................................................... 1.34 Wheels............................................. ...............0000....,..000.6 1.34 FrontBrakes ........................................................................ 1.35 RearBrakes ...............................................I......................... 1.35 ABS System ........................................................................ 1.35 Footrests, Control Plates and Engine Mountings ............ . ............................. 1.36 Electrical............... . ......................................................... . . 1.36 Bodywork.......................................................................... 1.36 ThrottleCable Routing ............................. ..............................0 0 0 0 ...... 1.37 ClutchCable Routing...... ................................................................. 1.38 Fuel Tank Breather Hose Routing - Models without Evaporative Emissions ........................ 1.39 Fuel Tank Breather Hose Routing - Models without Evaporative Emissions ........................ 1.40 Mainwiring Harness Routing .............................................................. 1.41 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 1.2 Service Manual - Tiger . uM

jiiiIi'i ii Th ^gf l i ci © ^n System safety Precautions The ignition system produces extremely high. voltages. Do not touch any part of the ignition system or any cables while the engine is running. An electric shock caused by contact with the ignition system may lead to illness, inju ry or death. Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and or diagnostic equipment. The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death. Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far as . possible, be kept from contact with the skin. These substances among others include acid, anti-freeze, asbestos, brake fluid, fuel., lubricants, and various adhesives. Always pay dose attention to the instructions printed on labels and obey the instructions contained within. These instructions are included for your safety and well-being. NEVER DISREGARD THESE INSTRUCTIONS! Health Protection Precautions • Avoid p rolonged and re peated contact with oils, particularly used engine oils.. • Wear protective cl othing, including i mpervious gloves where practicable. • Do not put oily rags in pockets. • Overalls must be cl eaned regularly. Discard heavily soiled clothing and oil impregnated footwear. • Fi rst aid treatment should be obtained i mmediately for open cuts and wounds. Always be aware of who your nearest first- Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition used engine oil contains potentially harmful contaminants which can cause cancer. Wear suitable clothing and avoid skin contact. U Service Manual - Tiger 1.3

2005-2014 Triumph Motorcycle Tiger/SE/Sport Service & Repair Manual

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