Escolar Documentos
Profissional Documentos
Cultura Documentos
TIGER
TIGER (ABS)
UMW
Table of Contents
pT1IIIIbiIl
iii
t1 rTii
i.iii
References................................................................................. v
Dimensions...........................................................................v
Re airsand
Replacements.. . ..
. . .. ... ....... .............. ............................v
Force ............. ...V
Edges ............................................................................. v
Tighteningprocedures .................................................................v
TRJUMPON
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This caution symbol identifies special instructions or
procedures which, if not strictly observed, could result in
damage to or destruction of equipment.
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Note:
This note symbol indicates points of
particular interest for more efficient and
convenient operation.
vi
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:1s.:
^1.X';.;r.
^:?
^.^
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 Procedures
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.
Twumm
VI'
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Vile
UP
[Lci ir i I
^^ .^ P':
X11 ^ ^
TI11MI'I1i
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1.3
DangerousSubstances .....................................................................
1.3
Fluoroelastomers..........................................................................
1.3
Oils.....................................................................................
1.3
1.3
1.4
Brakes...................................................................................
1.4
Safet
yInstructions
.........................................................................
Jacking and Lifting ....................................................................
1.5
1.5
1.5
1.6
1.7
Split Pin ..................................................................... 1.7
Circlips, Retaining Rings .......................................... 0 .............. 0 ..... 1.7
Self Locking Nuts ...............................................0..................... 1.7
Encapsulated Bolt ..................................................................... 1.7
Oil
Fittin
Press. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BallBearing .......................................... 0 ...............................
1.7
1.7
1.7
1.7
FuelTank Removal .......... ...... ... .... ... .................................. .... .... 1.8
Chassis Repairs ....
.
.
.
.0 ........................
..
. .
. 1.8
1.8
Electrical Precautions ......................................................................
1.9
uP
Manuall -Ti9er
Service M
1.1
General Information
ElectricalTesting .........................................................................
1.10
1.11
1.11
TracingCircuits ..........................................................................
ToCheck Continuity :.................................................................
ToMeasure Voltage :.................................................................
1.12
1.13
1.13
1.14
1.15
StartingCircuit ..........................................................................
1.16
1.16
GeneralFault Finding - Starter Motor and Rela ..............................................
Inspection......... . ... . . . ........ .................................................. 1.18
1.18
1.18
.
.
Replacement Parts
ServiceData ........................................................................ 1.18
Specification........................................................................ 1.18
1.19
ServiceTools and Garage Equipment ......................... ................................
SpecialService Tools ................................................................. 1.19
1.24
1.24
Full Specification..
1.31
TorqueWrench Settings ....................................................................
CylinderHead Area .................................................................. 1.31
1.31
Clutch .. .
1.31
Balancer,
Crankshaft
and
Crankcase
....................................................
,
1.3
2
EngineCovers ......................................................................
Transmission........................................................................ 1.32
LubricationSystem .................................................................. 1.32
FinalDrive .......................................................................... 1.33
CoolingSystem ..................................................................... 1.33
System and Airbox ................................................ 1.33
FuelSystem,
. . . . . . . . . . . . . . . . . . . . ..........
. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .-. . . 1 . 34
Rear Suspension.....
FrontSuspension .................................................................... 1.34
1.34
Wheels.............................................
FrontBrakes ........................................................................ 1.35
RearBrakes ...............................................I......................... 1.35
ABS System ........................................................................ 1.35
Footrests, Control Plates and Engine Mountings ............ . ............................. 1.36
. . 1.36
Electrical............... .........................................................
.
Bodywork.......................................................................... 1.36
...............0000....,..000.6
1.2
..............................0
......
1.37
1.38
Fuel Tank Breather Hose Routing - Models without Evaporative Emissions ........................
1.39
Fuel Tank Breather Hose Routing - Models without Evaporative Emissions ........................
1.40
1.41
1.42
1.43
1.44
uM
jiiiIi'i
^gf
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System
safety P
iiTh
recautio ns
including
Wear
protective
clothing,
impervious gloves where practicable.
1.3
Environmental Protection
Precautions
1.4
t1M
General Information
Safety Instructions
Jac ing and Lifting
Do not remove the radiator cap when the engine is. hot.
When the engine is hot, the coolant inside the radiator is
hot and also under pressure. Contact with the
pressurised coolant will cause scalds and skin damage.
TMumpi
1.5
[iTTh1
I rirtim-r11
Cea1ng components
A high flash-point solvent is recommended to reduce fire
hazard.
Always follow container directions regarding the use of
any solvent.
Threads
Gaskets, 0-rings
Do not re-use a gasket or 0-ring once it has been in
service. 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
LiM
Lockig Devices
Always release locking tabs and fit new locking washers,
do not re-use locking tabs.
Fitting a Split Pin
Always fit new split-pins of the correct size for the hole in
the bolt or stud. Do not slacken back castle nuts when
fitting split pin, except in those recommended cases when
this forms part of an adjustment.
Always fit new roll pins of an interference fit in the hole.
Ball Bearing
mty!!j3H
1.7
:cii:t;i I
'EiTh}i1
Petrol - Gasoline
When petrol (gasoline) evaporates it produces 150 times
its own volume in vapour which when diluted with air
1.8
1UM^
iIiii1']iiiM
UMW
1.9
General Information
Electrical Wires
All the electrical wires are either single-colour or twocolour and, with only a few exceptions, must be
connected to wires of the same colour. On any of the twocolour wires there is a greater amount of one colour and a
lesser amount of a second colour. A two- colour wire is
identified by first the primary colour and then the
secondary colour. For example, a yellow wire with thin
red stripes is referred to as a 'yellow/red' wire; it would be
a 'red/yellow wire if the colours were reversed to make
red the main colour.
Volts M.
Current
60
=5
12
Electrical Testing
=1
=R
12
=2.4
V
I
1.10
UMW
to the motorcycle.
At the back of the service manual a full
colour layout circuit diagram is used to show
motorcycle.
Both of these circuit diagrams use similar symbols to
illustrate the various system components and will be
accompanied by a key to circuit diagram components and
wiring colour codes.
Circuit diagrams also depict the inner workings of a switch
cube (I.E. which wire connects to which when a switch is
turned from one position to another) so that a . test of that
switch can be made using the wire terminals in the
connector instead of disassembling the switch itself.
or
t
11
A fuse is a device which protects a circuit in the event of a
fault. The fuse will 'blow' should a short circuit occur,
protecting that circuit from further damage. The number
next to the fuse on the circuit diagram indicates the
position of the fuse in the fusebox.
Ground or Earth Point
Ion
Connector
Lamp or Bulb
2
3
4
TwumeH
1.11
Genera l Information
Switches
Normally
Closed
Normally
Open
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]
Motor
Change
Over
1-
0-----0
0 0
or
or
or
..0
0 0
Relay
Tracing Circuits
Open circuit
Break
Relays are used when the electrical current is too great for
a mechanical switch, usually when the switching must be
done quickly to prevent arcing across the switch contacts.
If a mechanical switch were used, the mechanical switch
contacts would quickly burn away.
Resistor
Short circuit
Splice
1.12
UMP
General
A short to Vbatt is a short to battery voltage (12 Volts)
and is caused by a live power supply wire contacting an
adjacent cable. Note that it is also possible for a 5 Volt
sensor reference voltage to short to an adjacent circuit,
which can also cause electrical failures and DTCs
(Diagnostic Trouble Code) to be stored.
To Measure Voltage:
In the example below, the circuit voltage is being
measured at the bulb positive (+) terminal.
Voltage Check
71tiumeH
1.13
ate R
B27
Pair of Twisted
Wires ^_
Instrumentt
Pack
Switches
16
ECM
A34
3
B
1.14
Vehicle Speed
Sensor
Extract from the circuit diagram showing CAN
connection between ECMs
l^l'Kr
1s
Information
t:iiiI
Not OK
OK
OK
i
i
WITH THE ENGINE RUNNING AT
AROUND 2000 RPM, MEASURE THE
BATTERY VOLTAGE AT THE BATTERY.
THE BATTERY VOLTAGE SHOULD BE
14.5 0.5 VOLTS
Above
15 Volts
Below
14 Volts
STOP THE ENGINE AND DISCONNECT THE
ALTERNATOR CONNECTOR. RE-START
THE ENGINE AND ALLOW TO IDLE.
MEASURE THE ALTERNATING CURRENT
(AC) VOLTAGE FROM THE 3 ALTERNATOR
OUTPUT.WIRES IN TURN.
THE OUTPUT VOLTAGE MUST EXCEED 10
VOLTS AC FROM EACH WIRE
Above 10
Volts AC
Below 30
Volts AC
FAULTY ALTERNATOR
Above 30
Volts AC
nW!I1
1.15
:T1iDi;1 I
Using
switches.
Note:
51aii ii I
Symptom
Possible cause(s)
Starter relay does not click, starter motor does not turn
1.16
UMw
General
Diag
ic ^i
ta
r ^r Orcult
Clicks
IS PRESSED
Starter
motor turns
Starter motor
does not turn
LOOSE OR
DISCONNECTED
WIRE OR CABLE.
FAULTY
STARTER
MOTOR
FAULTY
STARTER
RELAY/
No Click
SOLENOID
No
Continuity
Continuity
No
Voltage
FAULTY ALARM
Voltage
Measured
Normal
Abnormal
11tiumem
1.17
iiITI imirTn
r
following:
Abrasions, cracks, hardening, warping, bending, dents,
scratches, colour changes, deterioration, seizure or
damage of any nature.
Replacement Parts
Specification
Only Triumph genuine parts should be used to service,
repair or convert Triumph motorcycles. To ensure that
Triumph genuine parts are used, always order parts,
accessories and conversions from an authorised
Triumph dealer. The fitting of non-approved parts,
accessories or conversions may adversely affect the
handling, stability or other aspects of the motorcycle
operation which may result in an accident causing
serious injury or death.
1.18
UMW
i.iDitii r.
c a age
ge Equiprnert
e vice
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. Where this is the case, the tools required will be described during the
procedure.
Special Service
ice Tools
T3880375 Alternator Rotor Holder
cche
*Older versions of tool T3880017 require modification to function correctly with later models. Refer to Technical News
issue 86 (April 2006) for information.
lP,L!j
}I
Service Manual - Ti g er
9
1.19
aI
TtiiJi
Increment
/markings
9 ae 9
rr
cb
cdob
ccha
T3880003 -.Fork Seal and Bush Fitment
ccxb
1.20
cogs
UMP
General Information
T3880067 - Fork Spring Compressor
cdoa
caoa,
.^
gakh
uM
1.21
General Information
BatteryMate Battery Charger - See Latest Parts Catalogue T3880002 Support Plate
for Part Number Information
cczb
1.22
rep
cd
et
cdbp
l^Mr
1.23
iT;Thi I
mitiT
Tiger 1050 cc
lI specification
Engine
Engine Configuration
................1050 cc
........ 0.10-0.20 mm
1.24
luM
General Information
Tiger 10
FQflSpecification
cc
Camshafts
CamTiming Inlet
.........................
....................................... Duration
CamshaftJournal Diameter .................
....... 212
................ 22.930-22.960 mm
22.953-22.956 mm (outrigger)
CamshaftJournal Clearance ................ Std............... 0.040-0.091 mm
ServiceLimit .... .......................
................ 0.13 mm
................ 0.13 mm
................ 23.000-23.021 mm
................ 0.20 mm
................ 0.05 mm max.
................1.750 (60/105)
................10
PlateFlatness ............................
................ 3.80 mm
ServiceLimit ..........................
................ 3.60 mm
................ 3.30 mm
ServiceLimit ..........................
................ 3.10 mm
................ Cable
................ 2.0-3.0 mm
Balancer
EndFloat ................................
................ 0.06-0.41 mm
................ 79.040-79.060 mm
................ 79.110 mm
................ 78.970-78.980 mm
................ 78.930 mm
TwumaH
er
Service Manual - Tiger
g
1.25
General Information
Full Specification
Tiger 1050 cc
ServiceLimit ......................... .
. . . . . . . . . . . . . . . 0
0.075
................ 0.43-0.64 mm
................ 0.76
............ 16.993-17.001 mm
...... 34.984-35.000 mm
0.10 mm
1.26
UM
EI imii I
e
ai9 Specificadon
Tiger 1050 cc
................6.0-6.1 mm
. . . . . .................I
Oil Capacity (wet fill including filter) .......... ................ 3.20 litres
Oil Capacity (wet fill excluding filter) .......... ................ 3.00 litres
Oil pressure (in main gallery) ............... ................ 40.0 lb/in 2 min. @ 80C oil temperature @ 5000
RPM
OilPump Rotor Tip Clearance .............. ................ 0.15 mm
ServiceLimit .......................... ................ 0.20 mm
OilPump Body Clearance. . . .............................. 0.15-0.22 mm
ServiceLimit .......................... ................ 0.35 mm
OilPump Rotor End Float .................. ................ 0.02-0.07 mm
ServiceLimit .......................... ................ 0.10 mm
Ignition System
Type..................................... ................ Digital Inductive
ElectronicRev Limiter .................... . ................ 9,500 (r/min)
Pick-up Coil Resistance ................... .
..........
.....
Fuel System
FuelType ................................................ Unleaded, 95 RON (U.S. 89 CLC/AKI
FuelTank Capacity ........................ ................ 20 litres
LowLevel Warning Lamp .................. ................ 3.5 litres remaining
1.27
iiNI11
I
Tiger 1050 cc
Full Specification _
Emissions Controls*
Catalysts.............................. .
Oxygensensor............................
................ -35C
................150 mm
Oil Level (fork fully compressed) ........... . ................ 30 mm (with springs installed)
OilVolume (dry fill) ...................... .
................ 581 cc
1.28
I
FllI
Full
Specan do
iiTI
Tiger 1050 cc
............. .. ...
............. 320 mm
mm
x 17
Twumm
1.29
Ge
^!
Information
Full Specification
Tiger 1050 cc
.......
Castor ................................. .
................ 23.2
Trail
................................ . ................87.7mm
Maximum
Payload........................
Electrical Equipment
BatteryType ............................. ................ YUASA YTX12-BS
BatteryRating ............................ ................12V 10 Amp. Hour
Alternator Ratin g ............. ............ ................ 34A
Fuses..... .............................. #1.. ............ Starter solenoid, dip I main beam headlights
#2
1.30
uMT
General Information
H 1 :
v
Torque (Nm)
10
Application
Cam cover to cylinder head
Secondary air injection valve covers to cam cover
Cam chain tensioner to crankcase
9
9
23
See section 5
15
18
10
10
See section 3
10
25
Notes
Lubricate seals with
engine oil
Lubricate threads
Use new fixings
Use new fixings
Use new fixings
12
Torque (Nm)
9
105
10
15
1
3.5
Notes
Application
Crankcase lower to upper (M8 fixings)
Torque (Nm)
See section 6
Notes
See section 6
See section 6
See section 6
Application
Clutch cover to crankcase
Clutch centre nut
Clutch pressure plate to centre
Clutch lever to handlebar
Clutch lever pivot bolt
Clutch lever pivot nut_
Bala n cer,
60
^r
Apply ThreeBond
1305 to the threads
54
9
1.31
-. I
Torque (Nm)
9
9
Application
Clutch cover to crankcase
Clutch cover sound suppression plate to cover
Sprocket cover to crankcase
Notes
9
9
9
9
9
18
Torque (Nm)
132
Notes
Use new tab
12
12
12
12
23
10
9
6
22
Torque (Nm)
12
25
15
Notes
Application
washers
Lubrication System
Application
Sump to crankcase
Sump drain plug to sump
Oil pressure relief valve to crankcase
Low oil pressure warning light switch to crankcase
Oil filter to adapter
Oil cooler pipe union bolts
Oil cooler to mounting bracket/radiator
Oil pump to crankcase
Oil pump drive sprocket to pump shaft
Oil feed pipe union to head
Transmission oil feed pipes to crankcase
Oil cooler bracket to crankcase
1.32
13
10
10
9
13.7
15
25
8
9
UMr
Ieiii r
Application
Rear sprocket to sprocket carrier
Rear sprocket studs to sprocket carrier
Chain guard bolts
ii
Im(.Tn;ir;11
Torque (Nm)
Notes
55
30
4.5
Torque (Nm)
Notes
Cooling System
Application
Water pump to crankcase
Radiator to frame
Water elbow to head
10
9
12
12
2.5
4
Fuel System,
, Exhaust System and Airbox
Application
Fuel tank to frame (front fixing)
Fuel tank to frame (rear fixing)
Fuel tank brackets to frame (rear)
Fuel cap to fuel tank
Fuel pump mounting plate to fuel tank
Throttle body transition piece to cylinder head
Fuel rail to bracket
Torque (Nm)
9
9
9
3
9
12
6
2
2
19
5
Airbox to bracket
Airbox upper to lower section
Exhaust downpipe to frame
Exhaust clamp to downpipe
Silencer mounting bracket to frame
Catalyst heatshield to downpipe (only if catalyst fitted)
Exhaust pipe heatshield
Silencer heatshield
11J%qjjkI
Notes
Apply ThreeBond
1360 to the threads
See section 10
3
15
22
15
5
5
5
1.33
General Information
Rear Suspertson
Application
Torque (Nm)
110
6
4.5
20
4.5
48
48
48
48
Notes
Front Suspension
Application
Torque (Nm)
26
35
5
20
20
35
90
19
Application
Front wheel spindle / axle bolt
Torque (Nm)
110
1.34
Notes
Notes
20
110
IuM
Front ra ges
Torque
22
35
17
Application
Front brake disc to wheel
Front brake caliper to fork
Front brake pad retaining pin
Front brake caliper bleed screw
Front brake hose to caliper
5.5
25
15
5
25
1
6
Notes
Use new fixings
Rear Brakes
Application
Rear brake disc to wheel
Application
Front wheel speed sensor to fork leg
Rear wheel speed sensor to caliper carrier
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
Brake line unions to ABS modulator
TWUMEH
Torque (Nm)
Notes
22
40
17
5.5
25
27
9
15
22
Torque (Nm)
9
9
5
5.
9
Notes
9
17
1.35
Torque (Nm)
See section 9
See section 9
See section 9
9
7
Notes
27
40
20
Application
Alternator rotor to crankshaft
Alternator stator to cover
Torque (Nm)
Notes
105
12
7
10
9
3.5
4
3
18
Bodywork
Application
Torque (Nm)
3
3
3
3
3
3
25
1.5
30
6
6
7
3
1:36
Notes
UMW
sIiijNt.
Ii iI-
UMW
1.37
o1^j
1.38
LiMM
l TrI
1.39
General Information
1.40
C I
Tq!Lm^
p
TI kiiiiThitii
1.41
GeneralInformation
uI :
1.42
;mJi
UN[P
11111 IitThTt(eTiiiMi
tt
UNf^
1.43
General Information
1.44
I UMW
2 Scheduled M
Table of Contents
Introduction .......................................................................
2-2
2-3
2.1
TLffl I
2.2
uMp
500
(800)
1 month
6,000
(10000)
1 year
12,000
(20000)
2 years
18,000
(30000)
3 years
24,000
(40000)
4 years
Day
Operation Description
Coolant - renew
Day
Day
Day
Every 2 years
Day
Day
Day
Day
Day
Day
Day
-
Day
Day
Day
Day
36,000
(60000)
6 years
30,000
(50000)
5 years
2.3
scheduled Maintenance
Odometer Reading in Miles (Kms) or time period,
whichever comes first
Operation Description
Every
500
(800)
1 month
6,000
(10000)
1 year
12,000
(20000)
2 years
.
18,000
(30000)
3 years
24,000
(40000)
4 years
.
30,000
(50000)
5 years
36,000
(60000)
6 years
2.4
LUMP
1=
3.2
3.3
3.4
ylind rHe a d
Description ...................................................................
3.5
CamCover ...............................................................................
Removal ...........................................................................
Installation..........................................................................
3.5
3.5
3.8
3.8
3.9
3.6
3.17
3.17
3.18
3.18
Valves
3.20
3.20
3.20
3.21
3.21
I- Mr
3.1
Cylinder Head
ru
10 Nm
10 Nm
3.2
Service
Manual - Tiger
uM
Cylinder Head
Lubricate sea
with engine c
3.3
Cylinder Head
=
iuui
5 Cain
n d
rir
N
9Nm
18 Nm
3.4
Service Manual - ^ Ti g er
9
UP
1.
2.
3.
4.
5.
6.
7.
8.
rirt
Single valve springs are used to close the inlet valves and
single springs to close the exhaust valves. These valve
springs have close wound coils at one end to assist in the
prevention of valve bounce at high engine speed and to
give a smooth valve actuation. When assembling the
cylinder head it is important that the close wound, colour
coded ends of the springs are fitted downwards (towards
the piston). Both the tip and seating face of the valves are
hardened to give a long service life.
Due to the methods used to assemble the valve seat and
valve guides to the head, these parts cannot be replaced.
1. Coils
9. Detach the secondary air injection hose from the
reed valves on top of the cam cover (see page 10123).
TWUMBH
3.5
Cylinder Head
f L
1
capb
ca9a
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Cam
'. Pl ug tower seals
5. Apply silicone sealer to the areas arrowed in the
diagram below.
Installation
..
1. Check the condition of the cam cover gasket and
plug tower seals. Replace as necessa ry.
2. Check the condition of the cam cover bolt seals.
Replace as necessa ry.
a o
CBS)
6.
3.6
f2
Fit the cam cover, ensuring that the gasket and seals
remain in the correct positions.
uM
cast
1. Coils
1. Dowels
8.
9.
valve assembly
Twumem
3.7
1. Inspection plate
3. Rotate the crankshaft clockwise (the normal direction
of rotation), using the bolt fitted to the end of the
crankshaft Stop rotationwhen number 1 cylinder is
at top dead centre (TDC), that is when the 'T1 mark
on the sprag clutch aligns with the line at the bottom
of the cover.
gaaa
Camshaft to Cylinder Head Alignment Marks
Place
a suitable wedge between the tensioner blade
4.
and crankcase, to hold the cam chain taut during
removal of the tensioner.
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.
3.
UMW
6.
1.
2.
3.
7.
8.
it-i
2
gabh
4.
Note:
If fitting a new tensioner, observe the
following:
Remove the new tensioner assembly from
the packaging. On examination, it can be
seen that the tensioner nut will not be
tightened fully into the tensioner body and
that the tensioner 'nose (i.e., the part which
actually contacts the chain rubbing strip) is
fully retracted into the housing.
Prior to assembly into the engine it is
necessary to disassemble the tensioner nut,
washer and spring. To do this without
damaging the internal components, turn the
tensioner nut at least a half turn clockwise
(i.e. tighten it further into the housing) until
the plunger springs outwards. The tensioner
nut can then be withdrawn safely without
causing internal damage to tensioner
components.
5. Remove the tensioner blade wedge, taking care not
to move or damage the tensioner blade.
kaid
1.`T1'Mark
2. Marker line
gaaa
Camshafts
AMP
Service Manual - Ti 9 r
3.9
Cylinder Head
6. Progressively release the bolts securing the cam cap
ladder to the head in the sequence shown below.
ovaI
1.
Mote:
11
an assembly.
Before commencing work, ensure the
crankshaft T1 mark is in alignment with the
line in the crank cover inspection plate.
2.
Remove the cam chain top pad from the cam caps
and cylinder head.
42
\
12
10
caqm
Cam Ladder Bolt Release Sequence
7 Remove the cam cap ladder and collect the dowels
(if loose) and spark plug tower 0-rings.
8.
9.
Note:
A
4.
Progressively
9
Y release each of the remaining9 fasteners
securing the individual cam caps to the cylinder
head.
5.
3.10
1. Cam chain
2 Inlet camshaft
UMW
..
JiT ,:r=: Y a
I Standard:
22.953 - 22.956 mm
Standard:
I 22.93 - 22.96 mm
::,
q,
gabo
1. Exhaust camshaft
2. Plain section
3. Inlet camshaft
4. Grooved section
Camshaftand Bearing
Cap Inspection
1. Outrigger journal
2. Standard journal
3.
4.
The same sprocket is used for both inlet and exhaust
camshafts. To attach the sprocket to the different
camshafts, different bolt holes are used.
Never fit a camshaft sprocket to a camshaft using
incorrectly identified bolt holes. Severe engine damage
will result from incorrect attachment.
2
gaab
IRt!:!!.!?kI
3.11
tTri :
Release the cap bolts and remove the cap/
ladder. Using the gauge provided with the
Plastigage kit, measure the width of the now
compressed Plastigage.
,
Installation
1.
ote:
The camshaft caps and ladder are unique to
2.
3.
0.040 - 0.091 mm
Service limit:
0.13 mm
1.Cam chain
2. Inlet camshaft
4. Repeat the procedure for the other camshaft
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If the camshafts and caps/ladder are fitted without first
aligning, the timing marks on both the crankshaft and
camshaft sprockets, the inlet and exhaust valves will
contact each other causing damage to both the head
and the valves.
af:"
Standard:
0.044 - 0.068 mm
Service limit:
0.13 mm
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^:,
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3.12
uM^
.- ., ^
1. Cam chain top pad
'
l 1.^
1. 11' Mark
6.
2. Marker line
10. Check that the camshaft timing marks align as
illustrated below. Rectify any misalignment before
proceeding.
11
^1
Ilni
13
15
16
10
4 2 `12
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7.
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Camshaft to Cylinder Head Alignment Marks
11. Check the valve clearances. Adjust as necessary (see
page 3-14).
12. Re fi t the cam chain tensioner{s ee pagee 39)
-.
Valve
alve C
Clearances
Camshaft, valve, valve shim and valve seat wear affects the
valve clearances. The effect of this wear is to change the
gap between the camshaft and tappet bucket, causing
engine noise and improper running. If the valve
clearances become too small, permanent damage to the
valve and valve seat will take place. If the valve clearance
becomes too great, the engine will become noisy and will
not run correctly.
Service Manual - Ti g er
3.13
Cylinder Head
Typical Valve Clearance Chart
Inlet:
Exhaust:
Gap Measured
1
2
3
as measured (mm)
as measured (mm)
as measured (mm)
as measured (mm)
as measured (mm)
as measured (mm)
Gap Measured
as measured (mm)
2
3
4
5
as measured (mm)
as measured (mm)
as measured (mm)
as measured (mm)
as measured (mm)
0.10 - 0.20 mm
0.20 - 0.30 mm
1.
2.
3.14
UP
r ri
Cam Chaim
Removal
1.
2.
3.
4.
20).
1 __Li Z 2_
I/
I'
.
A
1. Shim
Ft a thicker shim.
Note:
1. Centre bolt
6. The cam chain is removed from inside the headspace or through the crankcase, after first detaching
the chain from the crankshaft gear.
3.15
Cylinder Head
___
Inspection
Visual in-situ checks can also be made as follows:
1.
2.
3.
4.
5.
6.
0
0
00
oo
OO
3.16
Service Manual - Ti g er
g
UMP
Cylinder Head
Cylinder K
Ins atio
1.
Fit the cam chain and locate the lower end around
the crankshaft gear.
Removal
2.
Note:
3.
ad
frame.
1.
2.
3.
1. Shim
Note:
original positions.
TWU ^i^
Service Manual -
Tiger
3.17
'mTri : rri
^^^^ ^
^
^^,
Inspection
5.
In-n
1. Straight edge
2. Cylinder head gasket face
ca rt
3.18
IUMP
: r .I
Using the correct procedure to fit and tighten the
cylinder head bolts will ensure the long term reliability of
the cylinder head gasket.
Clean each bolt, paying particular attention to the
threads and under-bolt-head areas. If any of the threads
or bolt-head areas are damaged, replace the bolt(s).
Lubricate the threads with engine oil, and then wipe
clean with a lint-free cloth leaving minimal oil on the
threads (that is, almost dry to touch).
Tighten the bolts using the three-stage procedure given
below.
Failure to observe these important items may lead to
engine damage through a damaged head gasket.
cary
7.
r h```.
ars
, ' -I
1. Rubbing strips
6. Fit the bolts to the head and tighten until finger tight.
The head bolts are finally tightened in three stages.
This is to ensure that the cylinder head gasket seals
correctly to the head and crankcase. The three stages
are as follows:
Note:
For stages A and B of the head bolt
tightening operation, a torque wrench of
known, accurate calibration must be used.
Tighten the head bolts, in the same
numerical sequence used to release the
bolts, to 20 Nm.
Tighten the head bolts in the same
numerical sequence used to release the
bolts, to 35 Nm.
For the final torque operation, which again is
carried out in the same numerical sequence
used ` to release the bolts, a 'torque turn'
method is used. The bolts must be turned
0
through 90 to reach. the final setting. To
0
accurately -gauge the 90 turn, use service
tool 3880105-T0301 as follows:
TWUMOH
3.19
Note:
Ensure inlet and exhaust valve components
do not become mixed.
\3
^^g \ 45
1. Collets
Valve Removal
2. Once the collets are released, remove the following
items:
collets
valve spring
spring platform
6. Valve
Installation
1.
2.
3.
Note:
3.20
Service Manual - Ti g er
.
-
t^P
Cylinder Head
r
t
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.v...},
a::..h;.:ji.
.0 i:. }^... v.::C: Yh ^}if::)::'^irc
Inlet:
0.010 - 0.040 mm
Exhaust:
0.030 - 0.060 mm
Valve Guides
If a valve guide is found to be worn beyond the service
limit, the complete cylinder head must be renewed.
:.,^..
WNv
'
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'
Rem ve
o
a nV ca r b on build J
head
checking in
area. Examine the valve seat face, the
3.21
Cylinder Head
3.22
u Mp
4.2
4.3
4.4
4.5
Assembly ...........................................................................
4.6
...................................................................................
4.6
Clutch
4.5
4.5
........................................................................
4.6
4.8
.
.
Thickness ..........................................................................
Bend/warp .........................................................................
4.8
4.8
Assembly ...........................................................................
4.9
Disassembly
.
TqU M^
Service Manual -
Tiger
4.1
Clutch
Ixmi
S
1
i/
/-
9Nm
4.2
IUM^
UMW
4.3
Clinch
Eloded
V c^w
- Clutch
Cantrols
15 Nm
1 Nm
6Nm
4.4
Limp
6. Pull in the clutch lever and turn the inner cable, anticlockwise through the slots in the adjuster and lever
bracket, until the cable can be detached from the
lever by pushing downwards.
:,
1.
gaau
1.Adjuster slot
2. Cable release point
7. Remove the cable from the motorcycle noting the
cable routing.
Inspection
1.Clutch cable
2. Adjuster
4. Release the clutch cable from the actuating arm by
pushing the inner cable nipple through the arm and
sliding the cable out of the slot Detach the cable
from the bracket.
aij
1.Actuating arm
2. Inner cable
5. Align the lever adjuster and lever bracket slots.
I RL!:!! H
4.5
Clutch
Clutch
Assembly
1.
2.
3.
Disassembly
Release the clutch cable from the a ct uating arm (see
page 4-5).
Remove the sta rter cover, right hand crank cover
and associated sta rter gears to gain access to the
clutch cover bolt at the centre-right hand side.
1.
2.
dote:
4.
5.
6.
7.
^^/
0
Q
._ 2
p
i
'k
"
1
Imp
XN
5.
1
iav
1.Clutch lever
2. Correct setting, 2-3 mm
8. Reconnect the battery positive (red) lead first.
9. Refit the seat (see page 16-9).
kaik
4.6
Twumem
, o
(7 ,
T("/
2
1
i
-wry
1. Centre nut
2. Belleville washer
3. Inner drum
scan
4. Thrust washer
1.Friction plate
2. Steel plate
3. Anti-judder spring
Note:
The outermost and innermost friction plates
differ from all others and must not be fitted
in any other positions. They are thicker and
are also darker in colour.
o
Refer to the following page of this section
for details of dutch friction plate checking.
It is not normally necessary to disassemble
the clutch further, but if the clutch inner and
outer drums are to be removed, proceed as
follows:
7. Engage second gear and lock the inner and outer
clutch drums together using service tool T3880305.
1. Outer drum
2. Bearing sleeve
ii
11RIUMEM
4.7
Clutch
Bend/wairp
hpection
is ess
If any friction plate thickness is outside the service
limit, replace the friction plates as a set.
1.
H-if
ga
L1%
; NA
Fri ion
Baas
Standard
3.80 mm
1. Friction plate
2. Feeler gauge
Service limit
3.60 mm
3. Surface plate
3.30 mm
Service limit
3.10 mm
4.8
Service
up to 0.15 mm
Service limit
0.20 mm
Manual - Tiger
uM
Assembly
1. Position the clutch outer drum assembly to the input
shaft and align the oil pump d ri ve pegs with the
corresponding holes in the rear of the clutch outer
drum.
0
0
tch outer drum
ri;;
i ^
Wo
1. Outer drum
2. Bearing sleeve
Note:
will be visible.
4.
illustration below.
UUoo
1.Alignment hole
2. Outer drum
3. While holding the clutch outer drum in position and
ensuring correct engagement with the oil pump
drive, refit the bearing sleeve.
flLqJ3H
4.9
Clutch
7. Lock the inner and outer drums together using
service tool T3880305. Depress the rear brake pedal
to prevent the engine from turning, and tighten the
clutch centre nut to 105 Nm. Remove the service
tool.
incorporating a new
gasket Tighten the clutch cover bolts to 9 Nm.
13. Refit the starter cover and gears (see page 7-22).
14. Refit the outer cable to the adjuster bracket at the
clutch end (see page 4- 6) .
15. Set the clutch adjustment (see page 4-6).
12. Clean and refit the clutch cover
gaaz
1. Service
8.
9.
tool T388030S
Disengage second gear and check for free rotation
of the clutch inner drum.
Coat all clutch friction plates in clean engine oil
before fitting the friction plates, steel plates, antijudder spring and anti- judder seat washer to the
clutch basket in the same order and orientation as
noted during removal.
Note:
The innermost and outermost friction plates
are different to the remainder.. For
identification, they are darker in colour and
are thicker.
The outermost clutch friction plate is fitted
such that the outer tags of the plate are
engaged with the corresponding -individual
tags in the clutch outer drum.
Kan
4.10
UMW
Ztrti _;
M ii ir
TiJ;!1 ('I'
;]1T' I -I(.]Th
5.2
5.3
Crankcases...............................................................................
Disassembly........................................................................
Assembly...........................................................................
5.4
5.4
5.4
Crankshaft...............................................................................
Removal...........................................................................
Installation..........................................................................
5.7
5.7
5.7
R ds
Con n ecting o . .........................................................................
Installation..........................................................................
5.8
5.8
5.9
5.10
5.11
Pistons..................................................................................
Disassembly........................................................................
Piston Wear Check ...................................................................
.
Piston Ring Gap....
PistonAssembly .....................................................................
5.13
CylinderLiners ...........................................................................
5.16
5.16
5.17
Removal.......... ..................................................................
Removal............................................................................
Installation..........................................................., ...............
CrankcaseBreather .......................................................................
TOUMM
5.13
5.13
5.14
5.15
5.18
5.1
iAIk
5.2
Service
Manual - Tiger
LIMP
Tq^!M^p
5.3`
'
[iiii
rii
al
1.
2.
3.
4.
5.
26
28
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^ W\v`'vp.^ ^, ^ S:.^Z'i
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,..,oS;i;:':'\sA,`,;%^ ; ^':a^iE^,.v3i2y.o4,,.
,vy.
h`f
' r^ \
'^
f;
i
^^UJ^v
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x:;X,,:,.nYY.t`t:'i^3'^^v3
Y.
t
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29
27
fik .v:
F.
$
:'t'JF: i i:
;:' ^;.r4':.YS'y^.1:'Cn
'<):nc',^^^
:'
"K "
v11.
t >.C$t} ,h:j^ +
r+:
v
,. v:,
. : :^?.,s ^
Do not use levers to separate the upper and lower
sections of the crankcase or damage to the crankcases
could result.
i
r v
.:,5.
'\r
^'
k x'
r
f
^s'..i5i
1`
So- ",i
to-
v\1
r a
s.
'^+'
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( iJ h^'
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h\, ^j.^
,.,
'`a's,"r.^'.+^`
5
. r... ;,
v. ^: ^'s tY,^
v; '<
y^. .
,t, ...
^Jt.,t,),
^t^f
xis
Note:
10
Assembly
11
2
1.
1 3 6
5.4
sS
= :..
Separate
SePa a e tthe lower
e and upper crankcases ensuring
that the 3 locating dowels remain in the upper
crankcase.
4.
^,,;' x
^::.uK\'.' 5:(.
^:;^cai:
nk
damage.
result inPpermanent crankcase
9e
1.
25
,:
30
32
Disassembly
+
24
22
2.
3.
IUM^
iiirii 1T
ii
ti ii
iiii
ccyr
cc
't
^\
I! _ nti
If
1. 0-ring
9.
1. Locating dowels
5. Apply a thin bead of silicone sealant to the lower
crankcase mating faces. (At the factory, Three Bond
12155 is used).
Note:
1. Sealer areas
a.,
:,
uv 5t`Cihr
v;:'
xW."'}i! :aa. rfi
:;
:,^vnt
>,"?tt^.'.n:,,.
:r}'^
:: .
.'`:.
^5.3 :
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!,si;;:
:,.{:Yv'
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h
:
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b.
CS:f ma
<
"^
,Q
fif?' ^5"
A S,
,,
A x...
,.. ^.:`l.'.::.:
.vW:.
":^?:
rx, ..,h
..^
, aMv.
t^'t"..n n
:v:n.:,^^.i:..S,i<..:.SSV::y..:::..:..a^^,',.:?':,
::::.^,..... C'.tn.
L.#.....::n.
:k .:....
:SYS.:'4R
Caution
C
.oi;:..?.:ADC,
S:
it^ ^
c` u`Si:
Sii
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7.
<,,^^^
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(,
k
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, i:. ..:f ."...?.:}.v..r.n.
n .# ...
^+1:::
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"tee'"'
fit
^
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7t"
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,..,a35ff;` '
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^.....^::^.
n f`^'
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rc; amt..::
...s::^;,t.t.::.
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y ,
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,..{::f:. t:. `^
YL,..
. 'i .. t. r.)a..'Y.a...
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MM
5.5
screws to 12 Nm.
1.
14 20 18 16 15 17 19 13 10
12
\\
11
1
'
s
2
28Nm.
9
/ 3
2. Invert the engine.
3. In the correct sequence, tighten only the M8 size
7
lower crankcase screws (number 1 to 14) to 28 Nm.
8
^^' j
4. Rotate the crankshaft clockwise. Check for tight spots
4
and rectify as necessary.
5. Refit the oil
a e 8p um
P drive chain and9 ears (seep9
21
1Q).
6.
7.
8.
5.6
Connelitting Rods
Installation
e oval
1. Remove the sprag clutch (see page 7-20).
Always check the bearing journal clearance (see page 512), before final assembly of the crankshaft. Failure to
correctly select crankshaft bearings will result in severe
engine damage.
1.
kaji
2.
3.
4.
5.
6.
Note:
Identify the location of each bearing shell.
Remove all bearings, and inspect for
damage, wear, overheating (blueing) and
any other signs of deterioration. Replace the
bearings as a set if necessary.
7. Remove the balancer (see page 6-3).
8. Collect the piston cooling jets from the crankcase
oilways beneath the crankshaft bearings.
Note:
This engine is fitted with a balancer drive
gear that is bolted on to the crankshaft.
Under no circumstances should the bolts be
disturbed as the crank and gear are not
individually serviceable.
Twumem
5.7
iii
thtIt
1i..tTikI
1iP1
2.
7.
8.
9.
10.
11.
12.
3.
4.
5.8
Twumem
4.
5.
Note:
Ensure that the piston/liner/connecting rod
assembly aligns correctly with the crankpin
during assembly into the crankcase.
^vni
9ote:
tei' rr r If
-ter
\\\i t ^
1. Big end
connecting rod.
6.
7.
8.
9.
3.
ccvk
1. Liner
2. Sealer area
TwumeH
5.9
ii I
1.
Note:
Tighten to 22 Nm.
Release by 1400.
Tighten to 10 Nm.
Tighten to 14 Nm.
2.
3.
4.
Increment
markings
5.
6.
7.
cbxt
number 3880150-T0301)
Remove the big end cap from the journal to be
checked.
Wipe the exposed areas of the crankpin, and the
bearing face inside the cap.
Apply a thin smear of grease to the journal and a
small quantity of silicone release agent to the
bearing.
Trim a length of the Plastigage to fit across the
journal. Fit the strip to the journal using the grease to
hold the Plastigage in place.
Release the nuts and remove the cap being
measured. Using the gauge provided with the
Plastigage kit, measure the width of the compressed
Plastigage.
Lubricate the threads of the bolt and the face of the
nut with molybdenum disulphide grease. Refit the
bearing and cap and tighten the big end nuts (see
page 5-9).
9a_
5.10
Standard:
0.036 - 0.066 mm
Service limit:
0.1 mm
uMP
!Ti1
rote:
I=
(.1i
For instance:
34.984 - 35.000 mm
34.960 mm
Con-rod Mark
38.002
Crankpin Diameter
34.987
Required Bearing
Red
Note:
Repeat the measurements for all connecting
rods and their respective crankpins.
It is normal for the bearings selected to
differ from one connecting rod to another.
3.
2.
White
Red
Red
Blue
Con-rod
Big End
Bore Dia.
38.008
38.000
38.008
38.000
38.018
38.009
38.018
38.009
Crankpin
Dia.
35.000
34.992
34.991
34.984
35.000
34.992
34.991
34.984
Running
Clearance
TRLqj311
0.066
0.036
511
ir.r
iii
flt1
Th*iiI! I TI(.I1T
Shell Colour
Crankcase
Bore
Journal Dia.
Running
Clearance
White
41.121
41.113
37.976
37969
Red
41.121
41.113
37.968
37960
0.043
0.020
0.044
0.020
Red
Blue
Blue
Green
41.130
41.130
41.139
41.139
41.122
37.976
37969
0.044
0.021
41.122
41.131
37.976
37969
41.131
37.968
37.960
0.043
0.020
0.044
0.020
37.968
37960
0.043
0.019
37972 mm
Crankcase Bore
41.135 mm
Bearing Required
Blue
Note:
It is normal for the bearings selected to
differ from one journal to another.
It is also normal for there to be two options
of bearing shell colour. In such cases, pick
the shell size which gives the greater
running clearance.
Checking Crankpin Clearance Using Plastigage
Crankshaft main bearing/journal clearance
Standard:
Service limit:
0.019 - 0.044 mm
0.07 mm
37.960 - 37976 mm
Service limit:
37936 mm
Note:
If any journal has worn beyond the service
limit, the crankshaft must be replaced. Due
to the techniques used during manufacture,
the crankshaft cannot be re-ground and no
oversize bearings are available.
5.12
0.05 - 0.20 mm
0.40 mm
Note:
Crankshaft end float is controlled by the
tolerances in crankshaft and crankcase
machining. No thrust washers are used. If
crankshaft end float is outside the specified
limit, the crankshaft and/or the crankcases
must be replaced.
uM
ii ii iiI1t;'I
t1j1
i&j
jThn
isassemby
Note:
2.
16).
Remove the gudgeon pin cirdip from one side of the
3.
piston.
capf
All Cylinders
Service limit
( 78.980 78.970 mm
78.930 mm
OIII lI\t
4.
w
^: r^ ao.
v ; . !r3
.i^ ^`
7 ^ ^ ^.,
.s.7^.S
a ^^'
3 ^y ^w)y}^
: Fe, f
^v^`^.
v^^'
^:xfy:$2:k'';
:\ >t :#E^v
N ^'f:):^^a}^
+n4::;;`':^4:^....,....r........,,.:^^+...,..,..
:,,,. .:::^:.:J.<;,
^e
....:....
:v`
r ^a3 ^u' YF
^ .$
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<t^a
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a<
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u
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q
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1,: ...:..
',a
r ti ev
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N
:S
^.vS'yaytti$ 4E;i r.. C{.5yi"W..4^?:., r^ ^'w.y'
^i^i^',^:,<
y^^ , ^>:: :yn, Caution'-M
). `
i::.
^.
'"'
,,
^
,...,:,
.w
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,; g ^(v`''k
t
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:':: .k',':^t:l`'..^:.:..
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:.. 'fS ::x.':h:;,.
: 2f. ^wx
.,:nS;?^:' ':5,:'t
^^'0'^.,f3..e
r.A..::.,^'fti.:x.:..r.,..a
^,,c
a ,9
,:.
..:.... .:....n:.
^ ^ :.:..x f .....x
^.tii.....,.aa:
^.'^
F`Rfivf YQ'K
.:.
.. `^ ' ^ ,P^ $
T1ty! H
5.13
rankshaft,
Pistons
on ectin g9 Rods and
Note;
Before final assembly the piston ring gap,
when fitted in the liner, must first be
checked.
If all the rings do not fit parallel to the groove upper and
lower surfaces, the piston must be replaced.
Clean the piston ring grooves.
.
Fit the piston ringsto the pistons. Check using feeler
gauges, for the correct clearance between the ring
grooves and the rings. Replace the piston and rings if
outside the specified limit.
____ %_
capg
Piston Ring to Ring Groove Clearance Check
MA
Top ring
Service limit
0.02 - 0.06 mm
0.075 mm
1.
Second
Service limit
0.02 - 0.06 mm
0.0.75 mm
with a new set. If the gap remains too large with new
rings fitted, both the piston and liner must be
,replaced.
5.14
lu
q11T1
.iii
iiiiii iflhi1 T ti iI
1
2
FRONT
2
K
3 ^t
4
cagj
1.Top ri ng
2. Second ring
3. Steel oil control rings
4. Oil control ring expander
Piston Ring Identification
1.
Note:
The top ri ng gap should be positioned in the
7 o'clock position, the second ring gap in the
I o'clock position and the steel oil control
ring gaps in the 9 & 3 o'clock positions (one
in each position).
Note:
Connecting rods may be fitted either way
around. However, ensure all three are fitted
the same way.
2.
3.
4.
rPt!:!.
6.
5.15
'
fITI
(!Ii
V,
1. Paint mark
gaep
Test Positions For Bore Wear Check (bore shown in
section)
1.
nalw
1. Tool T3880315
\mil
2. Extraction nut
3. Locking nut
3. Check that the locking nut on tool T3880315 is
loose, then fully unscrew the extraction nut.
4. Carefully fit the tool fully into the cylinder bore,
positioning the tool legs on the crankcase. Turn the
locking nut clockwise until the rubber sleeve on the
tool tightly grips the bore of the liner.
5. Check that the tool legs are positioned to allow
withdrawal of the liner, then turn the extraction nut
clockwise to extract the liner. Take care to ensure that
the piston / connecting rod is not allowed to fall
against the inside of the crankcase.
6. Turn the locking nut anticlockwise to release the liner.
5.16
I T ']iT1
Note:
:z i'J
e tool
nstaaion
1.
2.
3.
. .
'ik
M x`
.C'2y
f
v "t
s
a^tn , v t.
4f"Y
^t1^'u
Y}h
"h
< i
s
`Q'`
Caution<`S:'
.
t.
,' {'
^
fiSi} ia
,` mnJ
i .
,t
ti
.S
t vn. ^. :.vv.f1^}I.'t
,.X,v....
n.v:.:;..:^N.f.::iii.v:a.
v)
9ka;A.y
,.x,a
fr: : : 'rti:;
r.::;.r,:,,....,:tv.. v,,:
:: .,,Nt.:.:..
,
v'\nip"y:v:tvvv}A:::
t2 r^2 >:}:....._,. :i:c;6:=,^ff.y f:^.: raF
. Q' .v .,;t' ^,.{:
h ;. n:::G.I
r.;::h
:,
^#:.. ,
nfa^^
+.4tnf}R'K:.....
' S%Ya
. :...u,,.r::a.:,^tiik
.i;..:
:':\
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sf:': F:,,:..;..:...:::.::..a.s,a.a}
:.. :. li:^";.f
ai':,.
.'^.`Kx^:s:
...af;:yf^
,x,:. 0:
^`
act:Y
'tib.;::x.
%'X':a"?::
^,
v:...x
. : . }:.
:: a.:;:nd;;}}}f f; ...;:.^;rt.; :;,::;.
.,..t:.:
..,}:....
,..?.aw'1;;n,tf:^;:>.,
..
Y ?.
to- h
.,
a:::.
h:rb:
. .:..
`i?'2?i
.,,k^
; ,s t
^'::D
u>.
:
i4:
r<::
s
.;,
't'a'Y^:.,
}.:g
S2
.,.K^:%
..;:;^^xr....,.
ki::";'.^ro:>i;^;'F,%f;sAC.p'}..,.
,v'x.::^.x.^E.
.v
;^.n,}ku..:3..
,'C
trr
^fi^.a^ ,ff 4'^iif;
:+ nt:.^.::
.<x\U;Cn.^.ti:i^t'.i.}1;.;; y0i^5:nw;i<::r;:.:^i{.,:n:.:n..{xN:i:Gp: ^{nriv::::: ::..}.x......
:::` : :
h> c
^ t o rrh
< ).
1 .
: : ,
:
:
. . . : n. : . ):}Y.v^te:,ny0.n: :.}^:: .:r.: :.t}:q: :i.,n rn. :.: : b'. hn.\:.v
Fit each liner over whichever piston is at TDC. When
I turning
the engine, do not allow the pistons to contact
the inside of the crankcase and also do not allow fitted
liners to lift off the crankcase base.
5.
p
y} .
T
,ft^
N2^,^.a
"'}. ^w:f . Hra
::.x.A{:t.;}
t.;:;,:$
::.n
2!..G:.ai.i
v}r:^i..,;.u;.,;
.;
":.ar.:n., x,
,.:.v.
}r :w . y . t ;;.:::
: ;
:L^..re;ld...:.
'
as;G:;:;
,{
'^.
^p.
Note:
When the liners have been fitted, they
should not be dis tu rbed. If it is necessary to
remove the liner after fitting, the sealer
must be re-applied.
1.Liner
2. Sealer area
El
Twumm
5.17
1 R.TiTi
Crankcase Breather
The upper crankcase is fitted with a labyrinth type
breather system, which requires no maintenance.
However, when assembling the crankcases, ensure that
the breather hose is not damaged and is securely fitted to
the breather as follows:
0(
5.18
uM^
p`
,' S r.wi
6.2
Balancer......................................................................... . .......
Removal ...........................................................................
Inspection..........................................................................
Assembly/Installation .................................................................
6.3
6.3
6.3
6.4
TRJUM8H
6.1
Balancer
E^plm d ^d Vae w - Balancer Shaft
C^ J'
60 Nm
6 2
uM
iiwi
ii
1.
2.
t I
1 i
1.Wave washer
2. Circlip
. ,
^ .
kajq
Inspection
1.
2.
Note:
As the shaft is released from the crankcase,
the backlash eliminator gear will spring out
of alignment with the crankshaft.
3. To remove the left hand bearing, slide the bearing,
circlip and bearing sleeve from the balancer shaft.
4. To remove the right hand bearing, remove the bolt
and slide the circlip, bearing race and inner ring from
the shaft.
3.
4.
etc.
5.
discolouration).
Note:
TRIUMEH
6.3
2.
3.
i/,7
k
ii
kalb
1.Wave washer
2. Circlip
4. Lubricate and fit the right hand bearing and circlip to
the shaft.
5. Apply Threebond TB1305 locking compound to the
threads of the balancer bearing bolt.
6. Fit the bolt and tighten to 60 Nm.
7. Lubricate and fit the left hand bearing and circlip.
Note:
Prior to installation in the crankcase, it is
essential that the markings on the backlash
1. Tool T3880016
2. Securing fixture
6.4
Service Manual - Ti er
9
Up
kajp
y:s
.;:ti
+S:vO.,.
:s.Fx:<c:ia.,
.JN::
'Ytfv'ftiS`+::uU'.^5::,'!r:i':,S'n'
w..:.
^;^. ., :
":S
^
},:"P
,^.;k;>n
.,^;'^'':
x...
i.^:
'^`
^'!%R:\
:::.
;'C:..:?'
.:: q
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iF.7^:^
`\':i;!:aY':.:
#!uf;,;'Fr
J^Jd;;i:" .. 'G39::3.^f'Y
.."+^'Y'J+
:4.n?
l..K
:^
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:.:
;::v.'x."v.',,.'.;>:::v:;if::. ".:lS::'YRt'^ ..
na \x....,,k?,
,
f::
k:.Yt.:xk\
Y;ke
k.ta^..,
;n.
f ^ts ` f ..
':;: "f:..
' ?`Sn.:
^ :.Y
' ^F?A.
^'^ # ' n.
;r; e^^."^^ ::E<^:
x...w':.:1..3.15
O: is
.?ni.t^
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J ;
y ' <
:.f.ia" v
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. 5^:,'.' .^`,^^^.',`i i
.
`:'. J1:
't 0,:;^A,4x
:
:3:'u:
5:..
.S^:k;':^::.:..:,;!'.
,3;:'^.:::k.,'.,`.'.i
,u\.. c'.f;.,
>;:.a ,.,
A .^d
`C.#.i
, .;e:,H,r.
,x >.x
;,
'F:.,
: ;;.:9.
:i :::.^">w`:f
:.`k?.Y..:
:.vn
kkf^:,^;o
^i;::'\i^:k:,^4,'y':
}.vf ';:?k:
v'}.. :::4.+:.
'x^i?e..::^av ..^:Ji.
+^T;
..k..^ ... :4..
s :..,:.. ^:. ?.a:^^^'.... ..\^,ix:^kf;.f^tv:>x...
:..2,,..,?:S:f%:? ^:;.Y?k..
v
S:yc .
;..:.0,,.:,. <fvs'^3':.,. J.... xt^ ,` y
,'
.:ax::?3f,,.'4^.:.K^::,...S,:::
',U:
^'^
i' ; .:.
/p)
\(o/
1. Circlips
2. Crankcase circlip grooves
TwUmem
6.5
6.6
7 Transissi - n
Table
Contents
View
72
View
7.3
Ex lo edView
74
75
Ex p l oded
Exploded
p d
7.6
.... .. ......................
7.11
Removal.. ..............................................................................
7.11
7.11
InputShaft ..............................................................................
Disassembly.........................................................................
Assembly..........................................................................
7.12
7.12
714
7.16
716
718
0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1Rt!:!! H
7.1
Transmission
I!!
7.2
p-
Transmission
q
_
- ;^
_^
_^
^,
r.^
t:
J,.
it
^.
54 Nm
uM
7.3
Transmission,:
r;: r
I'AIWAV
I*iJb3
(']'I *1iT!
liJillili
12 Nm
N '.
!'1
7.4
i^r
L1M
Lam'
uM
7.5
Transmission-
Note:
The centre selector fork locates in the
selector drum as shown below:
removal
1.
2.
3.
4.
ka
11
1. Fixing
2. Keeper plate
3. Selector shaft
17
7.6
Service Manual -
Tiger
UM'
1. Bolt
13. Ease the selector drum backwards and forwards to
push the drum bearing out of the crankcase.
14. Withdraw the drum from within the crankcase.
1.Washer
2. Detent arm
3. Spring
4. Fixing
9.
TuM M
Service
Manual - Tiger
7.7
Transmission
Installation
Inspection
Note:
1.
1.
Gtar selector fork thickness
Standard
5.80 - 5.90 mm
Service limit
5.70 mm
6.00 - 6.10 mm
Service limit
6.25 mm
kakn
3.
4.
7.8
Service Manual -
Tiger
UMW
Transmission
11. Feed the washer onto the shaft and insert the gear
6. Assemble the detent arm as noted on removal and
place up to the crankcase. change shaft into the crankcase. Gently push the
gr
\ \\
kaje
1. Washer
2. Detent arm
3. Spring
4. Fixing
7.
E,
;,,2,
,.,.^.:,:. ....r.'.4t
n,. T.
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'%C
+
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>.... ,?
n.f..:^`^:;r:^^.;;:R;i:Mb::^^,t:,^^ :to'wt.,::
.,:;^
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.,...wo.::... . .,,>x.,..,..3+>q
' . ::..., .:^:..J;,+;+:i;.u.
damage.
UMW
2
(
We
7.9
I Ii Ti
1TTI)1
17. Push the selector shaft into the crankcase from the
13. Fit the large washer and e-clip to the gear pedal end
of the gear change shaft. keeper plate end. As the shaft is inse rted locate the
selector forks and also fit a new O- ri ng (0-ring
located at the keeper plate end). Ensure the forks are
2
fitted in the positions noted during removal.
2. -clip
3. Washer
1. 0-ring
14. Fit the gear pedal crank to the shaft in the same
orientation as noted prior to removal. Tighten the
fixing to 9 Nm.
15. Position the selector drum in the neutral position.
Note:
The centre selector fork locates in the
selector drum as shown below:
kaks
1. Raised profile
2. Detent arm
t ^ j,;w"r.^ 4 d^1^^
?i^
h ^^ y"^5,,^n;3;. :
a
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7.10
UMW
Lam'
5.
Input
6.
Removal
1.
2.
3.
Installation
llation
1.
2.
3.
//
1. Groove in crankcase
2. Retaining ring
3. Seal
4.
'
k*
1.Roller bearing
2. Dowel
UMW'
7.11
Transmission......
8.
7.12
Transmission
ccsa
1.Bearing Sleeve
2. Half Cirdip
3.Needle Roller Bearing
4. Thrust Washer
5. Second Gear
6. Sixth Gear
7. Splined Bush
8. Thrust Washer
TWUMPOjot
9. Circlip
10. Third/Fourth Gear
11. Circlip
12. Thrust Washer
13. Fifth Gear
14. Input Shaft
15. Input Shaft Bearing
7.13
I u iiiiirsT1
f ^
cosh.
ccsi
Fit fifth gear (13) to the input shaft with the dog teeth
pointing away from the input shaft bearing.
3.
4.
Assembly
tote:
Lubricate each gear and bush with clean
engine oil du ri ng assembly.
Examine all gears, bea ri ngs and sleeves for
damage, chipped teeth and wear beyond
the service limits. Replace all s us pect
components and always use new circlips to
assemble the shaft.
1.
2
3
\
1
II
,
1. Fifth gear
2. Thrust washer
3. Cirdip
5.
7.14
UMI^
11. Fit the thrust washer (4) adjacent to second gear and
slide on the needle roller bearing (3).
ccwa
1 Third/forth gear
2. Thrust washer
1. Second gear
2. Thrust washer
3. Circlip
7. Fit the thrust washer (8) to the input shaft and slide
up the shaft until in contact with the circlip.
12. Finally, fit the bearing sleeve (1) to the needle roller
bearing.
8.
Fit the splined bush (7) from sixth gear taking care
that the oil hole in the shaft aligns with the hole in
the bush.
9.
Fit sixth gear (6) with the dog teeth facing third/
fourth gear.
vz
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.
IUM^
7.15
Cutput Thaft
Working from the opposite end to the drive sprocket,
dismantle the output shaft as follows.
Disassembly
1.
7.16
12. Remove thrust washer (16) and slide off second gear
(17).
13. Position the output shaft (18) in a vice with soft jaws
fitted. Tighten the vice to prevent the shaft from
turning and release the lock tab (20) from the output
sprocket nut (19), then release the nut.
14. Remove the transmission sprocket nut (19), locktab
(20) and sprocket (21).
15. Collect the oil seal (22) and retaining ring (23).
16. If it is found necessary to replace the large bearing
(24) at the end of the shaft, use a press to remove
both the bearing and output sprocket sleeve
together.
UMW
Transmission
1. Bearing sleeve
2. Needle roller bearing
3. Thrust washer
4. First gear
5. Fifth gear
6. Circlip
7. Thrust washer
8. Third gear
9. Third gear bush
10. Fourth gear
11. First gear bearing & washer
12. Thrust washer
13. Circlip
:IRL!!: H
7.17
i^ y
r i1
Assembly
Mote:
0
^,
\\V
ccww
1. Second gear
2. Thrust washer
3. Grchip
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
Transmission
7.
ccvp
^-1
cowe
1. Third gear
2. Thrust washer
1. Sixth gear
2. Thrust washer
3. Circlip
8.
10. Fit the thrust washer (7) and retain with a new circlip
(6).
3 Circlip
11. Fit the fifth gear (5) to the shaft with the groove
facing towards the output sprocket. Ensure that the
oil holes in the gear DO NOT align with the
corresponding oil hole in the output shaft.
If the oil holes in the fifth gear are aligned with the
corresponding hole in the input shaft, engine oil
pressure and gear lubrication will be reduced.
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.
12. Fit the first gear thrust washer and bearing (11).
wnu
1. Fourth gear
2. Thrust washer
9. Fit third gear (8) with the larger step side facing away
from the output sprocket.
Cm
1. Fifth gear
2. Thrust washer
3. Bearing
Tty!H
9M
.-
7.19
0
^
3 1
2
c^
ccwg
1. Idler shaft
2. Wave washer
1. First gear
2. Thrust washer
14. Finally fit the thrust washer (3), needle roller bearing
(2) and bearing cap (1) to the end of the shaft.
Starter Dr8,
/ ra
utch
Removal
3. Flat washer
4. Idler gear
5. Bearing
6. Flat washer
securingthe ririgh
ht hand crank
4. Remove the boltssecurin
noting the position of the aluminium washer
under the head of one of the upper bolts.
Note:
1.
2.
1. Starter cover
7.20
Transmission
'c_
trail
Needle roller bearing
1. Idler shaft
2. Gear
3. Wave washer
6. Using tool T3880017, prevent the sprag from
turning and remove the sprag fixing and washer
from the end of the crankshaft
4.
kajk
1. Tool T3880017
2. Sprag fixing
7. Slide the sprag clutch and gear from the crankshaft.
IDUUM
7.21
Transmissionl
10. Lubricate then refit the large starter idler gear
ensuring that all components are located in the
positions noted on removal.
Installation
1.
2.
3.
0
0
Note:
The sprag clutch wi ll only fit with the
crankshaft when the master splines on both
components are aligned.
p
3
62I
1. Idler shaft
2. Wave washer
3. Fl at washer
4. Gear
5. Bearing
6. Flat washer
kajm
1. Sprag clutch
2. Crankshaft end
4.
54 Nm.
5.
6.
7.
8.
9.
kajI
e^
7.22
l^M^
Ts L mTZ
ExplodedView - Sump .....................................................................
8.2
8.3
8.4
8.5
8.6
EngineOil ...............................................................................
8.6
Specification........................................................................
TriumphEngine Oil ..................................................................
8.6
8.6
8.7
8.7
8.8
8.11
8.11
Sump..................................................................................
8.12
Removal ............................................
8.12
Inspection.......................................................................... 8.12
..
Installation...................
. ....
8.13
.8.13
. . . 00..0............0..........
OilCooler ...............................................................................
Removal ...........................................................................
Inspection..........................................................................
Installation..........................................................................
.
Twu MJ
8.14
8.14
8.14
8.14
8.1
{-.
E2 p^ o d^ d Vi
Su m ^
a-_________________
25 Nm
12 Nm
10 Nm
10 Nm
8.2
UMP
T T
13.7 Nm
13.7 Nm
15 Nm
UMW
8.3
Lubricati on
i11:T;1 r
IA [4
II
:::
^
10 Nm
10Nm
1ONm
IA[
'J1 I i.i u
25 Nm
13 Nm
8 Nm
8.4
Ent ine
Oil Circuit
TR!!.M^
p
17
17
Service Manual - Ti
Tiger
-
111
A - COOLED OIL
Q - UNCOOLED OIL
8.5
r.ra
Specification
Use semi or fully synthetic 1OW/40 or 15W/50 motorcycle
engine oil which meets specification API SH (or higher)
and JASO MA, such as Mobil 1 Racing 41
^so
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:
J`
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Triump h high
g performance fuel injected engines are
designed to use : semi or fully synthetic motorcycle
engine oil which meets specification API SH (or higher)
::;1... '
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1.
2.
'^ss
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^.^:.:r:.:.,:.::::.:.:::,::.,:.::.,::'.}d':;:Y..fi^14:::"'
gasket.
8.6
^"\
..:
>S;:
Filtered oil is then fed into the lower crankcase galle ry and
from here is distributed around the engine:
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C:^`ci`ti .
^;i.)c::.
L1M
1:
1. Filler
2. Filler plug/dipstick
3. Upper marking
4. Lower marking
Note:
An accurate indication of the level of oil in
the engine is only shown when the engine
oil is at normal operating temperature, the
motorcycl e is upright (not on the side stand)
and the filler plug/dipstick has been fully
screwed home.
1.
2.
1RW!w^H
8.7
10. Fill the engine with new oil of the type and grade
listed previously and in the specification section.
11. Start the engine and allow to idle.
oil may
Avoid
contact
i
with the
Theoi
abe
hoto the touch.
och.
od
Y ehot
hot oil by wearing suitable protective clothing, gloves,
eye protection, etc. Contact with hot oil may cause the
skin to be scalded or burned.
3.
t
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ra
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Racing the engine before the oil reaches eve ry part can
cause engine damage or seizure.
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If the engine oil pressure is too low, the low oil pressure
warning light will illuminate. If this light stays on when
the engine is running, stop the engine immediately and
investigate the cause. Running the engine with low oil
pressure will cause engine damage.
13. Stop the engine and check the oil level. Adjust if
necessary.
Disposal of Used Engine Oil
1.
2.Oil filter
4.
1. Oil filter
2. Tool T3880312
8.8
UMt
Lubrication
01
Removal
Pump
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5.
6.
1. Pump bolts
INJUMeti
8.9
^^
brication
Body
Clearance
0.15 - 0.22 mm
Standard:
0.35 mm
Service limit:
4. Measure the pump end clearance.
Pump
End
Clearance
Standard:
0.02 - 0.07 mm
0.10 mm
Service limit:
5. (a) If all clearances are within service limits, liberally
apply clean engine oil to all internal components and
refit the oil pump plate to the oil pump body.
(b) If any clearance measu re d is outside the service
limits, renew the complete pump.
6.
Installation
;i:::..
/Ol
0.15 mm
0.20 mm
Fill the oil pump with new engine oil, turning the
pump rotor as the oil is poured in to ensure all
surfaces are coated with oil.
2.
Note:
Use the sprocket end of the oil pump shaft
to turn the drive peg into alignment with
the drive on the water pump.
1. Rotor ti p clearance
2. Pump body clearance
3.
-8.10
Service Manual - Ti er
g
Lubrication
3. Fit the oil pump to the crankcase, ensure the water
pump drive peg locates into the drive on the water
pump shaft. Tighten the bolts to 13.7 Nm.
'r
//
'
:::-
0
,
'
Pump Insertion
,-_== \/_
O
1
cc
D
1.
2.
3.
p
4.
C0
Installation
2
ka
1.
2.
3.
4.
4. Tool T3880371
5.
6.
7.
8.
9.
TRJUMPM
8.11
10. If necessa ry, remove the oil transfer pipe and collect
the sealing washer from either side of each joint.
Inspection
1.
The exhaust system will be hot if the engine has
'
been running. Always allow sufficient time for the
exhaust to cool before working on or near the exhaust
system.
Contact with a hot exhaust could result in burn injuries.
6.
7.
2.
3.
8.12
lu1^iP
L
S.
6.
Installation
1.
7.
8.
1Ti
1
Note:
Use new exhaust gaskets at the downpipe
connections with the cylinder head.
9.
Fill the engine with the correct grade of engine oil
10. Reconnect the battery positive (red) lead first.
11. Start the engine and ensure that the low oil pressure
warning light goes out shortly after starting.
12. Stop the engine and adjust the engine oil level.
13. Refit the belly pan (see page 16-17).
14. Refit the seat (see page 16-9).
2.
3.
4.
1.Sump
2. Fixings
TWUMEH
8.13
Lubrkation
5.
Inspection
1.
2.
Installation
1.
brackets.
2.
3.
8.14
UM
9.2
9.2
EngineRemoval/Refit ......................................................................
9.3
EngineInstallation .........................................................................
9.6
9.1
' d
fl
1
=^
^ t
^ 1
I)
^1
v^l
^ ))ill))
9.2
,iJ
^! +1
5.
6.
7.
8.
9.
1.Sprocket cover
2. Fixings
15. Remove the clip from the clevis pin at the lower end
of the brake pushrod. Remove the clevis pin.
16. Remove the three fixings and remove the right hand
control plate and brake pedal as an assembly.
Note:
Secure the hoses to prevent damage as the
engine is removed.
^{
t^
^autioii .3
Y4.
A:::.: i':}i: C.:.v. .i :. . . . :. .: : : :.:.: 5}.. ..::.^..,.?.^.. : n.:. : . . . . . "F'4/fi:. . : :^'n A.:.v. 1 N.. n.: ,: . :.: 5y~Y$::.:. : :. : . ^.,?;,
To prevent chain damage, do not allow the chain to
come into contact with dirt, road grit etc.
^
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12. Remove the bolt and, noting its position, detach the
gear change lever from the transmission shaft.
13. Remove the three fixings and remove the left hand
d9a
UMr
9.3
17. Ease the boot from the starter lead and release the
lead nut. Detach the lead.
18. Disconnect the alternator multiplug.
Failure to ensure adequate support for either the engine
or motorcycle could cause both components to fall or
move unexpectedly. A fall or sudden movement could
lead to inju ry.
27. Place a support beneath the engine and ensure that
the frame is still adequately and securely supported.
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1. Alternator multiplug
2. Starter motor connection
19. Ease the boot from the low oil pressure warning light
switch and disconnect the electrical connector.
2. Fixings
1. Low oil pressure switch connection
Note:
It is not necessary to disconnect the throttle
9.4
UMW
position
Cjp
/ / (
1. Rear
1 )
'
31. Remove and discard the nuts securing the two left
hand crankcase mounting bolts.
Service Manual
Tiger
g er
9.5
ifl
EngLi
OE1 Itb1
4.
Mote:
.:. }+"i' .^
F ) l :h. .
A^u
r'
.....
:`r
i^i
^.
;X,:
,, .
.s'^ .
. F.
i:i^^ ":
6.
,^"
s7A: i' YF
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f.,
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.,^^^,.`'
F
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,.`a^. :.` K^.
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. t;`^}'.. p..
.:.}.,^;:}^
a,.:: . SS.:
Sit
,a.:.," ^ Kt
.f.;,..^. y
:x.: tx.`
Unless the following engine mounting bolt tightening
sequence is precisely followed, severe frame damage
will occur.
^^Ir ^
%$;"
.: .nn. h
., Y. '. ^:.,..
:.):..
x. .. a
^ >
z ',..,. \;f:'
^\
7.
Note:
Do not fit the left hand cylinder head
bracket until instructed to do so.
Do not fit nuts to the right hand side bolts
until instructed to do so, as these bolts will
be removed during engine installation to
tighten the frame adjuster sleeves.
2. 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.
3. Raise the engine and loop the drive chain over the
output sprocket.
9.6
8.
9.
Apply
thet e
four
copper
t e threads
th ead of
ounew
PP Y
PP 9grease to the
'
ifl
10. Tighten the two smaller cylinder head bracket bolts
to 3 Nm.
Nm
1. Sprocket cover
2. Fixings
17. Reposition the left hand control plate and gear
change linkage to the frame. Tighten the fixings to
9 N.
18. Refit the gear change lever to the transmission shaft
in the position noted during removal and refit the
bolt. Tighten to 9 Nm.
a
JJ
DD
3
cd9a 0,
s2
^//^
:I L!:! ..H
9.7
Removal/Refit
25. Using new seals at the cylinder head end, refit the
exhaust system (see page 10-120).
1. Cylinder head
2. Seals
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
9.8
1^MM
........................610...0.
10.6
10.7
10.8
10.9
10.10
10.11
FuelRequirements .......................................................................
10.12
.....0........................
10.13
TWUMBH
10.1
10.29
ToolKeys .........................................................................
10.29
Initialisation.............................................................................
10.31
Diagnostics.............................................................................
10.32
FunctionTests ...................................................................:......
10.33
Checks................................................................................
10.34
d u
Tune
............................................................................
10.35
UpdateTune ...........................................................................
10.36
UnlockECU .............................................................................
10.37
ElectricalConnectors ....................................................................
BeforeDisconnection :..............................................................
WhenDisconnecting a Connector....................................................
WhenInspecting a Connector: ................................................. . .....
WhenConnecting a Connector.......................................................
Disconnectionof ECM connectors ....................................................
Reconnectionof ECM connectors ....................................................
10.62
10.62
10.62
10.62
10.62
10.62
10.63
10.63
CrankshaftSensor .......................................................................
PinpointTests .....................................................................
10.64
10.64
10.66
1 0.66
FuelInjectors ...........................................................................
PinpointTests .....................................................................
10.68
10.68
10.70
10.70
PurgeValve ............................................................................
PinpointTests .....................................................................
10.72
10.72
IgnitionCoils ...........................................................................
PinpointTests .....................................................................
10.74
10.74
10.76
10.76
A j st
PinpointTests .....................................................................
InletAir Temperature Sensor ..............................................................
PinpointTests .....................................................................
10.78
10.78
10.80
10.80
SystemVoltage.... .......................................................................
10.81
PinpointTests ......................................................................
10.81
Coolin
10.2
Fan
Relay .......................................................................
g
PinpointTests .....................................................................
10.82
LambdaSensor .........................................................................
PinpointTests .....................................................................
10.83
10.83
10.84
10.82
uMt
iiTA
iiiit
xT1irzn
PinpointTests .....................................................................
10.84
EEPROMError ...........................................................................
10.85
10.86
10.87
10.87
10.88
10.88
10.89
10.89
10.90
10.90
10.91
10.91
10.92
10.92
10.93
10.93
10.94
10.94
Assembly.........................................................................
10.86
10.94
10.95
10.95
10.95
Removal..........................................................................
Inspection....:................................................................... 10.96
10.96
Assembly..........................................
...................0...........
10.96
......................................................................................
10.97
10.97
Airbox.................................................................................
Removal.........................................................................
Inspection........................................................................
Installation........................................................................
10.98
10.99
10.99
10.100
10.100
10.100
10.100
MapSensor ............................................................................
Removal......... ..................................................................
Installation........................................................................
10.100
10.101
TLqj3H
10.98
10.99
10.99
10.100
10.100
10.3
Removal.........................................................................
Installation.........................
nstallation .......................................................................
10.101
10.101
10.101
Removal.........................................................................
Installation.......................................................................
10.101
10.101
10.102
10.102
ThrottleCable ..........................................................................
10.102
Adjustment.......................................................................
Removal.........................................................................
Examination......................................................................
Installation.......................................................................
10.102
10.103
10.104
10.104
ThrottleBodies/Injectors ................................................................
Removal.........................................................................
Inspection........................................................................
Installation.......................................................................
10.105
10.105
10.105
10.106
10.106
10.107
Removal.........................................................................
Installation.......................................................................
10.107
10.107
10.108
10.108
10.109
10.111
Removal........................................................................
Assembly........................................................................
10.111
10.112
10.114
10.114
10.115
Removal.........................................................................
Installation.......................................................................
10.115
10.115
10.115
Removal.........................................................................
Inspection........................................................................
Installation.......................................................................
10.115
10.116
10.116
10. 117
10.117
10.117
10.118
10.119
10.4
10.102
Removal.........................................................................
Installation.......................................................................
lUM'.
9Nm
9Nm
se
TRuM
ii
It'
3.5 Nm
3.5 Nm
C^rr^rif^^
\^
10.6
1=1
5Nm
ii
107
[t1
JTe
15 Nn
Nm
OA
Ao
e text
25 Nm
Apply anti-sieze
compound to threads
8 Nm
15 Nm
5Nm
40
4A
See text
5 Nm
10.8
LUMP
JI'anagemen
.fl
10.9
Th
9Nm
1 0.1 0
IUP
Lf
Fuel
Requirements
iiiiA TJ1TI
Oxygenated
Gasoline
Note:
If 'knocking' or 'pinking' occurs at a steady
engine speed under normal ` load, use a
different brand of gasoline or a higher
octane rating.
Ethanol
Ethanol fuel is a mixture of 10% ethanol and 90%
gasoline and is often described under the names
'gasohol', 'ethanol enhanced', or 'contains ethanol'. This
fuel may be used in Triumph motorcycles.
r rrii
y
u
,^^`^ z ^
,^w < j^ ^
l^. T
.AF^^t ^:?,'ik'i!''R.e.:
^1^^^^^^' ,v:
,tia, ^.J ^ ^*^1.
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.
"^
x
,!^
.Y^
"^`
y
z3plrai:.
+^d
,,:r^.: :
,.+..JS K:$
^"^ f.^:
^;^!3.
. } + ,.`'
.^,J,;:
^::'
.a
TWUMBH
10.11
iiiAs
ci
Freeze frame
mean.
Air temperature
Idle fueling
Barometric pressure
Ignition advance
Battery voltage
The voltage at the input to the Electronic Control Module
(ECM).
BTDC
Catalyst
Coolant temperature
The coolant temperature in the cylinder head.
MAP sensor
MIL
DTC
Diagnostic Trouble Code.
ECM
Engine Control Module.
Engine speed
The crankshaft revolutions per minute.
1 0.1 2
UM'
^.
Open circuit
Over temp .
High temperature within the Electronic Control Module
(ECM) caused by an internal or external failure.
PrimaryThrottle Position Sensor
Sensor for the primary (lower) throttle position.
Primary Throttle Stepper Motor
Stepper motor used to vary throttle opening at idle and
when the engine is cold.
Sidestand status
The 'up' or 'down' position of the side stand.
Target dwell time
The actual time from coil 'on' to coil 'off'.
Throttle position
0%1.
Throttle voltage
Vbatt
Batte ry voltage.
Short circuit
A 'short cut in an electrical circuit - current by-passes the
intended circuit (usually to earth).
uP
10.13
System Sensors
Intake air temperature sensor - situated in
the top of the airbox. As the density of the air
(and therefore the amount of oxygen
available to ignite the fuel) changes with
temperature, an intake air temperature
sensor is fitted. Changes in air temperature
(and therefore air density) are compensated
for by adjusting the amount of fuel injected
to a level consistent with clean combustion
and low emissions.
Barometric pressure sensor - situated
beneath the battery. The barometric pressure
sensor measures atmospheric air pressure.
With this information, the amount of fuel per
injection is adjusted to suit the prevailing
conditions.
Manifold Absolute Pressure (MAP) sensor
- situated at the left side of the airbox,
connected to each of the three throttle
bodies by equal length tubes. The MAP
sensor provides information to the ECM
which is used at shallow throttle angles (very
small throttle openings) to provide accurate
engine load indications to the ECM. This
degree of engine load accuracy allows the
ECM to make very small adjustments to fuel
Engine coolant temperature sensor situated at the rear of the cylinder head, on
the left hand side. Coolant temperature
information, received by the ECM, is used to
optimise fueling at all engine temperatures
and to calculate hot and cold start fueling
requirements.
Throttle position sensor - situated at the left
end of the throttle body. Used to relay
throttle position information to the ECM.
Throttle opening angle is used by the ECM to
determine fueling and ignition requirements
for all throttle positions.
Road speed sensor - situated in the upper
crankcase, on the left hand side, above the
sprocket cover. The road speed sensor
provides the ECM with data from which road
speed is calculated and displayed on the
speedometer.
Lambda sensor - situated in the exhaust
header system upstream of the catalyst. The
lambda sensor constantly feeds information
to the ECM on the content of the exhaust
gases. Based on this information, adjustments
to air/fuel ratio are made.
Side stand switch - situated at the top of the
sidestand leg. If the sidestand is in the down
position, the engine will not run unless the
transmission is in neutral.
Fall detection switch - situated beneath the
battery. The fall detection switch will detect if
the motorcycle is on its side and will cut
power to the ECM immediately. This
prevents the engine from running and the
fuel pump from delivering fuel. In the event
of a fall, the switch is reset by returning the
bike to an upright position and switching the
ignition off then back on again.
10.14
UMW
Sensor Locations
-a
LAMBDA SENSOR
TWUMEH
10.15
1 0.1 6
uMP
f ` S TFWTI
Management
-'
COOLING FAN
PRIMARY THROTTLE
STEPPER MOTOR
MAIN
AIR INJECTION
SOLENOID
FALL DETECTION
SWITCH
CANISTER PURGE
VALVE
Management
.
m!
1ri
t pi a 9i
Code
Wiring Colour
Red
Purple
White
Yellow
5
6
Diagnostic Connector
Vehicle Speed Sensor
Instrument Assembly
Clutch Switch
Starter Relay
LG
Light Green
7
8
Sidestand Switch
Fuel level Sender
LU
Light Blue
9
10
11
12
MAP Sensor
13
14
Lambda Sensor
Throttle Position Sensor
Key
kern
Item
2
3
4
D escription
A18
\0=_J 13
((S*a a
__
Fuel Pump
16
17
Fuse Box (fuse 5)
18
Cooling Fan
Cooling Fan Relay
19
20
Idle Speed Control Stepper Motor
Ignition Coils
21
22
Exhaust Air Injection Solenoid
Fuel I njectors
23
24
Purge Valve
25
26
z___
28
29
Code
Wiring Colour
Black
Blue
Brown
Green
Slate/Grey
Orange
Pink
1 0.1 8
A01
a 0Oaa0000000000a
O O OooaOaO"oooP
A36
A19
Connector B (Grey)
B18
B01
IL
-^
O a aOM0`OOD000OOODOG
II l
a00000a000000000c^
(^
B36
Connector A (Black)
B19
LUMP
w
r
6 1
27
UP
UB
iii:: ffl
.,
i_
YS
BW_-^
3
26
25
B28
24
`t
YR
B9
B27
23
NK
21
YK
A15
NK
2 2.
YP
A14
NK
'
YB
A33
BO
5
( ''' B
B6
YN
A32
BR
J_.
A13
22
Y
NK
B8
NK
W
4
NK
-BG
14
1 1 GK
2
NK -GP
---- GP
A18
GB
BIB
817
21
A4
20
19
1 6
ON
KU
K
KB
5
4 9
6
K
Bi
A27
B20 -KB
KB
1
2
10
A22
Al
' A23
OU
B2
A20
B3
OK
A21
821
Ym
Y
All
48
'
Kg
NK
NK
7_
A6
314
P28
B-
KO
KB
1
2
KB
K
K
i
3
KB
KB
1
2
11
12
17
830
BY
fl
5
29
A29
`
A26
16
::: :L1III1
14
M 2 B
A10
INJUmem
13
BP
329
B19
,---B
B35
-GY
15
10.19
iITI,
f^r^gic^^
(:;;iiA
Management CrcuftDiagram
Tiger - with
ABS
Item Description
Code
Wiring Colour
Orange
2
3
4
Diagnostic Connector
Vehicle Speed Sensor
Instrument Assembly
Clutch Switch
Starter Relay
Pink
Red__
Purple
White
Yellow
LG
Light Green
LU
Light Blue
5
6
7
8
9
10
11
12
13
Sidestand Switch
Fuel level Sender
Fall Detection Switch
Ambient Air Temperature Sensor
Intake Air Temperature Sensor
MAP Sensor
Coolant Temperature Sensor
14
15
Lambda Sensor
Throttle Position Sensor
19
20
21
22
23
24
25
26
27
28
!___
30
Wiring Colour
Black
Blue
Brown
Green
.S
10.20
Connector A (Black)
A18
\:::: n
16
17
18
A01
n3
ooaoaoaooaa
((ica a a^^oa
a000000o00000=
A36
A19
Connector B (Grey)
B01
B18
>;E
(e13
LJI
I LPJ TE/
aaaaaaaaaaaaaa
^oaaaoaooaooaooaa
c'
B36
B19
Slate/Grey
UMW
Management
Circuit Dagrarn
r
i
BG -II
30
1'Rt!:!.! H
Service
Manual - Tiger
10.21
this section.
The tool is connected to the motorcycle using a dedicated
diagnostic plug situated beneath the seat. By using a
dedicated plug, no electrical connectors associated with
the system are disturbed, reducing potential connector
damage.
Note:
In most cases, when a fault is detected, the
a _. !
Ic'
'/,"
The tables indicate which tests are performed by the onboard system and what information can be retrieved by
the Triumph diagnostic tool.
Triumph Diagnostic
Tool
10.22
Service
Manual - Tiger
UMW
iirA ;r;
iii:;j
iiiiiI
Currert
By using the Triumph diagnostic tool, live engine data
(engine running) can be recovered from the motorcycle.
The data available is:
Function Examined
Engine speed
RPM
Calculated load
Coolant temperature
^/o
Function Examined
Engine speed
RPM
Vehicle speed
km/h
Calculated load
Ignition advance
degrees
Coolant temperature
Heated oxygen
output voltage
sensor volts
Throttle position
open or
operation
closed
loop
Vehicle speed
km/h
Ignition advance
degrees
Heated oxygen
output voltage
MUMM
sensor volts
mm/hg
open or
operation
closed
loop
10.23
rr
'.,
Adaption status
Function Examined
Report Method
Closed throttle
reference status
adapted/not adapted
position
Function Examined
Report Method
Instrument panel
inspection
Visual
instruments
Stored fault
pressure test
code*/Fuel
Cooling fan
Stored fault
operation
code*/fan
of
It a tault is detected.
speed
Idle
adaption status
control
status (idle)
Oxygen sensor adaption
range (idle)
Build data
The following items of build data can also be read.
Checks/Adjustments
Function Examined
Adjustments
Using the Triumph diagnostic tool, it is possible to reset
the ECU to the facto ry default se tt ings and to balance the
throttle bodies.
Further facilities are provided to allow correct
replacement/adjustment of the prima ry throttle position
sensor and the prima ry throttle stepper motor. These
facilities are needed as, after replacement of the parts
concerned, adjustments have to be made to specific
voltage settings, all with the throttles in a specific position.
10.24
^uMr
Checks
When using this function it is possible to check the status
of various sensors and actuators and also check certain
items of factory data logged during vehicle assembly.
Item Checked -
Result Unit
milliseconds
milliseconds
milliseconds
degrees BTDC
Result Unit
degrees BTDC
Volts
degrees BTDC
Throttle position
% open
milliseconds
Volts
milliseconds
milliseconds
pressure
sensor Volts
Item Checked
Result Unit
Atmospheric pressure
mmHg
MIL off/on
Battery voltage
Volts
fan off/on
Volts
starter on/off
normal/over
heater on/off
SAI on/off
Engine rpm
RPM
Vehicle speed
km/h
+/-100%
Calculated load
RPM
numeric
/o
Gear position
numeric value
Neutral switch
gear/neutral
Clutch switch
grip/release
on/off
Coolant
voltage
temperature
sensor Volts
Volts
Volts
Volts
Volts
Volts
Volts
Volts
INJUMEM
10.25
L!
iiiiA 1'
1 =
uiri
^_
Diagnostic
Number of
no-fault
cycles
before
turning off
MIL
Fault Description
Trouble
Code (DTC)
Number of
MIL
no-fault
illuminated
when fault
is logged
cycles
before DTC
is erased
P0201
40
Yes
P0202
40
Yes
P0203
40
Yes
P0335
40
Yes
P0032
40
Yes
P0031
40
Yes
P0030
40
Yes
P0122
40
Yes
P0123
40
Yes
P0351
40
Yes
P0352
40
Yes
P0353
40
Yes
P0107
40
Yes
P0108
40
Yes
P1105
40
Yes
P1107
40
Yes
P1108
40
Yes
P0112
40
Yes
P0113
40
Yes
P0117
40
Yes
P0118
40
Yes
P0500
40
Yes
10.26
LIM
TTA
1iII
iiiIn
dumber of
no-fault
cycles
before
turning off
MIL
Numberof
no-fault
cycles
before
DTC is
erased
MIL
illuminated
when fault
is logged
40
Yes
P1553
40
Yes
P1231
40
Yes
P1232
40
Yes
PO444
40
Yes
PO445
40
Yes
PO414
40
Yes
PO413
40
Yes
P0505
40
Yes
P1631
40
Yes
P1632
40
Yes
P0560
40
Yes
PO460
40
No
P0603
EEPROM fault
40
No
P1690
40
No
P1696
40
Yes
P1697
40
Yes
P1698
40
Yes
P 1602
Tunelock
Only if
Tunelock is
unlocked
Flashing
P1614
Only if
Instrument
ID Matching
Flashing
Diagnostic
Trouble
Code (DTC)
Fault Description
P1552
MquMpt
u
10.27
i. >t
gale
1. Memory card
2. Screen
3. Return key
4. Up key
5. Down key
6. Validate key
7. Help key
I f::J \
Diagnose faults
Obtain data
gaei
Return Key
10.28
The Help key can be used when the '?' symbol shows, to
get more information about that line of text. To return to
the diagnostic screen from the help area, press the help'?'
button again.
i:I)
^I
9 aeg FI
p/do wn Keys (2 separate keys)
scr
ee
I'
fr/
Help Key
Test Procedure
The following describes the procedure to follow when
using the service diagnostic tool. It does not cover the
further diagnosis that must be carried out once a fault
area has been identified. For details of the procedure to
follow when a fault area or fault code has been identified,
refer to the diagnosis details later in this section.
^A
;.4-ThJ
gaef
Note:
The tool does not retain any memory of
faults, diagnosis etc carried out on any
particular motorcycle. Any such memory is
only retained in the motorcycle's ECM.
The following seven pages describe the tool
iii
Validation Key
TRJUMOH
10.29
CONNECT BIKE
SELF TEST
SYSTEM ERROR
False
CHECK CARD
Absent
Present
SELECT LANGUAGE
ENGLISH
FRANCAIS
DEUTSCH
ESPANOL
NEDERLANDS
ITALIANO
TRIUMPH MOTORCYCLES
DIAGNOSTIC TOOL
SOFTWARE VERSION
2006_02
SELECT ECU
ABS
ENGINE
ABS
ABS, DIAGNOSTICS
SEE SECTION 14
False
ENGINE
VALIDATE
CHECK ECU
LOCK STATUS
ECU
Unlocked
RETRY
ECU
Locked
UNLOCK ECU?
CONFIRM
Confirm
CANCEL
Cancel
55555555
Main Menu
MAIN MENU
DIAGNOSTICS
CHECKIADJUST
QUIT
10.30
Service Manual -
Tiger
UNLOCK ECU
Quit
iiTA 1
rri
!r_
1agrcstics
Main Menu
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Error Count
STORED ERRORS
FAULT COUNT 02
IGNITION COIL 1 OPEN CIRCUIT
INJECTOR 3 OPEN CIRCUIT
Diagnostics
Stored DTC
DIAGNOSTICS
CURRENT DATA
FAULT CODES
FUNCTION TESTS
QUIT
Fault codes
STORED ERRORS
FREEZE FRAME DATA
CLEAR DTCS
Current data
CURRENT DATA
ENGINE SPEED
CALCULATED LOAD
COOLANT TEMPERATURE
SHORT TERM FUEL TRIM
THROTTLE POSITION
INTAKE AIR TEMPERATURE
VEHICLE SPEED
IGNITION ADVANCE
OXYGEN SENSOR OUTPUT VOLTAGE
INTAKE MANIFOLD ABSOLUTE PRESSURE
FUEL SYSTEM STATUS
STORED ERRORS
Return
RETURN TO DTCS
CLEAR DTCS
STOP ENGINE
Clear
STORED ERRORS
ERASE ALL DTC DATA
YES
NO
No
RESET DTCS
11UUMj
Yes
10.31
FUNCTION TEST
DTCs present
No DTCs present
FUNCTION TEST
INSTRUMENT PANEL
IDLE SPEED CONTROL STEPPER MOTOR
PURGE CONTROL VALVE
FUEL PUMP OPERATION
COOLING FAN
SECONDARYAIR INJECTION
AIR FLAP CONTROL SOLENOID
EXHAUST BUTTERFLY VALVE TEST
EXHAUST VALVE CABLE REPLACE OR
ADJUST
Cancel
Error Count
Screen
FUNCTION TEST
"TEST NAME"
PROCEED
CANCEL
Proceed
FUNCTION TEST
TEST NAME
TESTING......
OBSERVE
TEST DTCS
Zero DTCs
DTC present
FUNCTION TEST
TEST NAME
TEST FAILED P1111
SIC TO VBATT
FUNCTION TEST
TEST NAME
TEST COMPLETE
CLEAR DTC
FUNCTION TEST
PERFORM ANOTHER TEST
YES
NO
Yes I
10.32
No
Service Manual - Ti er
SLIM
g
Main Menu
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Check/Adjust
Check/Adjust menu
CHECK/ADJUST
CHECK
ADJUST
QUIT
Quit
Check
Check menu
CHECK
READ BUILD DATA
READ SENSORS
READ ADAPTION STATUS
QUIT
Quit
Adaption status
Build data
Read
sensors
ADAPTION STATUS
ECU RESET CLOSED THROTTLE POSITION REF STATUS
IDLE SPEED CONTROLADAPTION STATUS
02 SENSOR ADAPTION STATUS - OFF IDLE
02 SENSOR ADAPTION RANGE - OFF IDLE
02 SENSORADAPTION STATUS - IDLE
02 SENSORADAPTION RANGE - IDLE
BUILD DATA
VIN
XXXXX)0(XXX O(X
TRIUMPH ECU PART NUMBER
x OOO(X
KEIHIN ECU PART NUMBER
x) xxXXXXX OO
(
ECU SERIAL NO
XXXXXXXXXX(X
SOFTWARE VERSION NUMBER
)OUC^^XXXXXXX
DATE OF MANUFACTURE
XX)CXXXXXXXX
CALIBRATION ID
XXXXXXX)OO X
11RIUMEH
VOLTAGES
THROTTLES/COILS/INJECTORS
OTHER
10.33
Main Menu !
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Check/Adjust
Check/Adjust menu
CHECK/ADJUST
CHECK
Quit
ADJUST
QUIT
Adj ust
ADAPTION RESET?
YES
NO
Adjust menu
Quit CHECK/ADJUST
ADJUST TUNE
UPDATE TUNE
QUIT
No
Yes
Adjust menu
ADJUST TUFIE
RESET ADAPTIONS
THROTTLE BALANCE
THROTTLE 1 1234 MM/HG
THROTTLE 2 1234 MM/HG
THROTTLE 3 1234 MM/HG
10.34
tUM^
ii1
' hDJ
i Til
Main menu
4,
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
LECT
I Check/Adjust
UPDATE TUNE
MODEL
SELECT
TIGER 1050
Check/Adjust menu
CHECK/ADJUST
ADJUST TUNE
UPDATE TUNE
UNLOCK ECU
QUIT
TIGER 1050
SELECT VIN RANGE
VIN < XXXXXX
VIN > XXXXXX
Quit
11!
Update
tune
TIGER 1050
TUNE XXXXX
TUNE XXXXX
TUNE XXXXX
TIGER 1050
INCOMPATIBLE TUNE
SELECTED - PLEASE
RESELECT
CHECK ECU
STARTUP VERSION
UPDATE TUNE
???????
1!,
TEST PASSWORD
UPDATE TUNE
TUNE XXXX
CONFIRM
CANCEL
QUIT
Pass
Cancel
Confirm
Fail
UPDATE TUNE
DOWNLOADING.....
10% COMPLETE
SECURITY
'I,
ACCESS DENIED
DOWNLOAD OK?
Yes
AMP
UPDATE TUNE
UPDATE TUNE
DOWNLOAD COMPLETE
DOWNLOAD FAILED
10.35
Check/Adjust menu
CHECK/ADJUST
ADJUST TUNE
UPDATE TUNE
UNLOCK ECU
QUIT
SELECT ECU
ENGINE
ABS
Engine
CHECK ECU
LOCK STATUS
ECU
Unlocked
I Quit
Unlock
ECU
ECU
UNLOCK ECU?
CONFIRM
CANCEL
Cancel
Confirm
Invalid
Unlock
Code
UNLOCK ECU
55555555
F-
UNLOCK ECU
j INVALID UNLOCK CODE
Three
Invalid
Unlock
Codes
Entered
Valid
Unlock
Code
UNLOCK ECU
ECU SUCCESSFULLY
UNLOCKED
UNLOCK ECU
INVALID UNLOCK CODE
ECU TAMPER
DETECTED
RE-DOWNLOAD TUNE
UPDATE TUNE
55555555
Main Menu
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
10.36
UMW
L!! I
then be displayed.
Note:
The tool will always select English as the
default language, and it is only necessary to
use the cursor to select one of the other
languages. The entire diagnostic session will
then continue in the chosen language.
Press the validation key'*' to move on.
TWUMEM
10.37
Fuel S
r
Management
r
MOTORCYCLES
Use the 'Up' and 'Down' keys to scroll the text until the
horizontal arrowhead is positioned opposite the
'ENGINE', and press the Validation key '*'.
10.38
IuM^
71PJUMEH
10.39
galu )
Use the 'Up' and 'Down' keys to position either
'CONFIRM' or 'CANCEL' opposite the cursor.
gain
Enter the numerical password supplied by Triumph using
the 'Up' and 'Down' keys as described below.
10.40
TuMPH
i
L
LOCC
iIi
CM
110UMEH
10.41
L rr F
ii71
ThII
iI- I
m
1'0.42
luM^
I
'J
_Y
-
ii k!kEII
in
ui.it
i LIi
I iii
Twumem
,
10.43
ii A1
i fttNiL4iT
lir
to
to 'STORED DTCS'
P0117
Help text
17RPSENSOR
LOlPOLTA GE
10.44
uM
Tiir4i1i
Note:
A full list of all the possible DTCs can be
found earlier in this section.
TR
L!:!!!j3PI
10.45
o
I
-`
been erased.
10.46
LIMP
iiA
1 ji
Twumpm
10.47
1TT.imi
set if a malfunction is found. The pump is energised when
the test is confirmed and ended when the Validation key
'*' is pressed for a second time.
Press the Help key (?) for more information.
Note:
10.48
UM!
iiTk11!I1I1
gai
10.49
Press the Validation key ' ' if you wish to test another
component (operation 26).
Note:
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
I' niA
ga iu
]1I
1ih
iIi1
'
10).
IIRJUMBH
10.51
1-c
1IIH1IIIIIUEIE
s
h
^v
^v v^^.
hi IIIIIINI
f, 7
C
gaiu
'
gain
Providing
9 the information was recorded at the time of
build, the display will show the following information
relating to the motorcycle under test by scrolling up and
down. Before displaying the recorded information, the
tool will briefly display the message, 'PLEASE WAIT,
CHECKING
.
Vehicle Identi fi cation Number WIN)
Triumph ECM part number
ECM Se ri al number
Tune Number
10).
10.52
Service Manual - Ti g er
9
UME
ii
k
*'
1Rt!:!!!j3H
L'I^1il
-L W
10.53
Function Examined
Report Method
adapted/not adapted
Idle
speed
adaption status
control
10.54
II^M^
+S y
.'
a ^ p'
gain
gain
UMW
10.55
37 BALANCE THRCTTLES
BRLRI
THROTTLES
THROTTLE
1 23t{f7f /HG
THROTTLE
7 23t'17/H6
THRO T TL 8
1 23 t1f7f /HG
10.56
rr i'
'
4iII fItI1T
GIMP
10.57
40 UPDATE T NE
10.58
DATTUNE
UMW
w_ij
IL J
, : I I:l
'V
10.59
L 'r I
.-
10.60
TuMTH
Note:
o Two different shaped connectors are used in
the ECM which ensures correct connection
is always made.
Note:
A m ajor cause of hidden elect ri cal faults can
connectors
connectors. For
toofaulty
be traced
au aelectrical
ectr
a
example:
Dirty/corroded terminals.
Damp terminals.
Broken or bent cable pins within multi-
::. a
:...,^kx::
.:,.<:
,..
_;:^'.'
^"kas:;
pq'
'h:::T1i,
SRS L \
t^`^^.,
^'x'
'
..,.^
.,o^`^w
>,^,",c y:^;if2,.:6;^^`ai:ii"^^^l
:v
^ ^ 7: :ay., ^,p ^?
n{^ ,y J
xv f3:'F,C`.7x.
.r';,+`L`ZC;..M,s;"Y
:a ..si}
+^.
h.;\x.t;;..
#''`r:::.
,..o
: ,.^ .:.
1^
.Jt.Y rol. l , ox..9^Jx Jx .,br.,s,.^.."Ssr^
.{,:^.:^tx:nx":,
;.^! Y:A`.a:.u,:;nY.
^,;.,.
,,
av
_:,.
Caution
.:
:^C'y^,Q^
L^\^^^^:u^a^^f';,',c'^h . Yk.^G;.u`.w4<;.
a y"^ . !
N
2 `^t^'3.y^L''.r 4.. y Akvhl'l L^1
{^
^ ^u"^[a;. : ti^
^;y;, :::`r^;:{
,J
' .
\.a ..%3......,
: v'. .r. .,?; .:.<:,x,..;^
^
..
;:a.... .:,..,x::.:
.i
.^.^,^Yri^.:r::x;:, .:.,^ :7.1,`N4,.xs`,;:^`x:"^.C'.s^;..:..v,...^.'1,si
plugs.
For example, the electronic control module (ECM) relies
on the supply of accurate information to enable it to plan
the correct fuelling and ignition timing. One dirty terminal
r - 1
e:
2.
bent.
Check for dampness/dirt/corrosion.
1. Locking device
Note:
1mRL!:!! H
10.61
'
,.:.^ ^
Further Dagnosis
m:9::..
^p
^:',:..
.,.^ ,,.,
5:k>..
..,.:i.Cc,....:...:......,
:....,
,;'55x:
za+'$:^I
..
Caution
^t..,. :$?^.
.,,.r ..t:.aw^ff
:.1,f
}n,
:kK;.S
., t.N':O.n.a..,.t?^q_.n.::.
}u>:.:a:c.+: 5.
%.:
i:,,
J...
. C^ti`^
:^ ....
,
v'v:a^.vw^::<l},:l..:
N..^,<
3^n}f$ik:Can.
,54`x:.;:..
avt..,.,3Y;t.,.
.:n' :n ... x ^::.r..
..?):::
E;^:}.:.
.o+?:
, ........
+:::
. . r^`
.u;tf^t...
.0.:"\:f.
k :i :3'S ?
,: (^
: JJis SAf i
^.
}$.`.k^f v!>?} C:IJ.I::
+,<:^.:S.:k.
#t \+Y.6
L$`i$$`}'
,i}}k'v'"a
' Y.>
%:
':
ri;<{ i5...}
^1
...., (
v',.:tia1.'L
^ .:.
}?'^i.... n }:..}.,::..
i.rYh:..
^i}i :Si'2..
..i....<ae.$s$:o^^k..,
}iY,.
:ft2Y.
t :N:..:6'S:F:
t:6i t:t:
. t..::$o'C.k n n:
.. tGt,...i:^
^.i.,..Y,.:.:}YFd::v.v:.......p...A.
v.... ..
... b
r.., .<a.:.
"C
"N5
,+r}.;y?
v.:.1,
,.:J:::
?'^
P oint
f ul
in
s stem once a d ia
nostic trou
a
0
1. ECM
2. ECM raining tang
3.
10.62
UMW
to
I2iiA
WTi
iiti
iiii I
Fault Code
Possible cause
Action
P0335
';T
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
Proceed to test 6
Faulty
Circuit Diagram
Crankshaft
Sensor
Engine
Control Module
1
2
UMW
UP
UB
At
A9
10.63
Fault Code
Possible cause
Action
P0505
Test
Result
Action
OK
Proceed to test 2
Faulty
49 to 125
Open circuit
Proceed to test 4
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
4 to 12Q
Proceed to test 7
Faulty
10.64
UM
I MP
Engine
Control Module
er.
Service Manual - Tiger.
10.65
Fault Code
Possible cause
Action
P0201/02/03
Test
Result
Action
OK
Proceed to test 2
Faulty
12.59 to 14.OQ
Proceed to test 3
Open circuit
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
12.55 to 14.O
Proceed to test 7
Faulty
OK
10.66
Ul^^
EMS Relay
ECM
NK
NK
2^
2 2
2
Fuel Injectors
tl1M
10.67
iiA1ri'tii
Fault Code
Possible cause
Action
P0122
P0123
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
-ECM pin B1
- ECM pin B20
-ECM pinA10
10.68
UM
Throttle
Position Sensor
t!:! M .H
ECM
GY
A10
KB
B20
B1
10.69
ii*''T
1i
TI:iiI:1iT
Puree
Fault Code
Possible cause
Action
PO444
PO445
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
- ECM pin B9
Faulty
245 to 28Q
Open circuit
Proceed to test 4
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
245 to 285
Proceed to test 7
Faulty
1 0.70
!iM
L IT.iA
EMS Relay
ECM
1 6
4 a
PurgeValve
NK
TwumeH
YR
B9
NK
A6
10.71
Fuel S
Management
Fault Code
Possible cause
Action
P0351/52/53
Test
Result
Action
OK
Proceed to test 2
Faulty
0.8Q to 1.2Q
Proceed to test 3
Open circuit
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
-ECM pinA18
-ECM pinB18
2 Check resistance value:
ECM pin A6 to
- ECM pin (ign coil 1) B17
- ECM pin (ign coil 2) B18
- ECM pin (ign coil 3) B18
O.8
1.2Q
Faulty
10.72
Proceed to test 7
luM^
Circuit Diagram
EMS Relay
ECM
A6
B17
A18
1141%
VN
Ignition Coils
IMP
%J
-t-j
10.73
System/Engine
'- 1
Fault Code
Possible cause
P0118
Open circuit,
battery+
P0117
Action
or short circuit to View & note diagnostic tool 'freeze
frame' data if available.
View & note diagnostic tool 'sensor'
data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test 1:
Disconnect sensor and proceed to test
6:
Test
Result
Action
OK
Proceed to test 2
Faulty
OK
Open circuit
Short circuit
OK
Proceed to test 5
Open circuit
OK
Proceed to test 5
Short circuit
OK
Proceed to test 7
Faulty
OK
Proceed to test 7
Short circuit
200 to 400Q
Cold engine:
20C ambient
2.35 to 2.65KQ
-10C ambient
8.50 to 10.25KQ
10.74
UM'
Coolant
ECM
Temperature
Sensor
UP
KB
B20
KG
A29
10.75
e-iiA
1
I^vlet Air
aI
Iziiii ffl
Temperature Sensor
Fault Code
Possible cause
Action
P0113
Open circuit, or short circuit to View & note diagnostic tool 'freeze
frame data if available.
battery+
View & note diagnostic tool 'sensor'
data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test 1:
P0112
^ f
Test
Result
Action
OK
Proceed to test 2
Faulty
OK
Open circuit
Short circuit
OK
Proceed to test 5
Open circuit
OK
Proceed to test 5
Short circuit
OK
Proceed to test 7
Faulty
OK
Proceed to test 7
Short circuit
10.76
Resistance value
200 to 4005
2.35 to 2.65KQ
8.50 to 10.25KQ
IuM^
..
I nlet Air
ECM
TI.ty!
kI
Temperature
Sensor
B20
KB
A11
K0
10.77
Action
Fault Code
Possible cause
P1231
Fuel pump relay open circuit, or short Check if pump runs briefly when
circuit to ground
ignition is switched on.
Ensure fuel pump relay connector is
secure.
Disconnect ECM and proceed to
pinpoint test 1:
P1232
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
OK
Proceed to test 5
Short circuit
Circuit Diagram
EMS Relay
FrT1
3 1
ECM
2 5
BP
10.78
B29
liNit
. Action
Fault Code
Possible cause
P0560
Test
Result
Action
OK
Proceed to test 2
Faulty
ECM pin A6
2 With Ignition 'ON', check voltage at
- ECM pin A6 -
Circuit Diagram
EMS Relay
!__..
NK
Ab
Twumm
B19
B35
A3S
10.79
System/Engine
[
i i';i
Fault Code
Possible cause
P1552
Fan relay open circuit, or short circuit View & note diagnostic tool 'sensor'
to ground
data.
Ensure fan relay connector is secure.
Disconnect ECM and proceed to
pinpoint test1:
P1553
Action
pinpoint test 4:
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Proceed to test 5
Short circuit
EMS Relay
1 6
ECM
4 8
10.80
B30
A6
IkIUM8H
iii
i iit
flI ii
Fi
[1ThLFlI
]u
Fault Code
Possible cause
Action
P0130
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
Circuit Diagram
EMS Relay
Lambda Sensor
ECM
B14
B -26
TwumeH,
KB
B20
NK
A6
10.81
i 4
L ! i
rm;; . :
1iitz
Sensor
_
Action
Fault Code
Possible cause
P0031
Lambda sensor heater circuit short View & note 'freeze frame' data if
available.
circuit to ground or open circuit
View & note 'sensor' data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test 1:
P0032
and
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 5
Open circuit
OK
Short circuit
OK
Circuit Diagram
EMS Relay
Lambda Sensor
ECM
W B14
10.82
KB
B20
NK
LAM
y^
: e
Fault Code
Possible cause
Action
P0603
EEPROM error
IrRJUMM
10.83
Fault Code
Possible cause
Action
P1631
P1632
Fall
detection
switch
high
input
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
6
OK
Proceed to test 5
Short circuit
5V
OK
Circuit Diagram
Fall
Detection
Switch
ECM
10.84
B20
KB
B21
KU
Bl
uM^
. Action
Fault Ce
Possible cause
P0500
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Faulty
OK
Open circuit
OK
engine.
Circuit Diagram
Kill
Switch
Alarm
Control Unit
4
Fuse Box
Instruments
^
3
GR
16
BY
1I
KM
1
3
KY
Road
Speed Sensor
Twumm
10.85
i -
^4
iii
Action
Fault Code
Possible cause
P1690
Fault in CAN communication between View & note 'freeze frame' data if
available.
View & note 'sensor' data.
Ensure Instrument connector is secure.
Disconnect ECM and proceed to
pinpoint test 1:
P ^
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Faulty
OK
Open circuit
OK
Circuit Diagram
ECM
Instruments
4
S
10.86
R
U
B28
B27
UM'
1Tftt!I4iI!Frni
Fault Code
Possible cause
Action
PO460
Test
Result
Action
OK
- ECM pin B4
- ECM pin B20
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
Circuit Diagram
Fuel
Level
ECM
EIJ=;L;I
Sensor
Twummi
10.87
iiA
miinriu
Fault Code
Possible cause
P1 107
Ambient pressure sensor circuit short View & note 'freeze frame' data if
available.
circuit to ground
View & note 'sensor' data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test1:
P1108
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Open circuit
5
OK
Short circuit
Circuit Diagram
Ambient
Pressure
ECM
Sensor
B20
KB
A27
KP
B1
1 0.88
Service Manual - Ti er
9
iLIMP
IciiiA
Fault Code
Possible cause
P0107
MAP sensor circuit short circuit to View & note 'freeze frame' data if
ground
available.
View & note 'sensor' data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test1:
P0108
MAP sensor circuit, short circuit to Disconnect MAP sensor and proceed
supply or open circuit
to test 4:
P1105
Action
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Open circuit
OK
Short circuit
MAP
Sensor
ECM
B20
KB
A28
K5
B1
Twumpm
10.89
II$Ijj i!
ir;iiwi
Fault Code
Possible cause
Action
P00413
PO414
Pinpoint
oint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
20Q to 25Q
Open circuit
Proceed to test 4
Short circuit
OK
Proceed to test 6
Short circuit
OK
Proceed to test 6
Open Circuit
OK
Proceed to test 6
Short circuit
205 to 25Q
Proceed to test 7
Faulty
1 0.9
IUP
.
System/Engine
1'?
,.
ii i iriii
ia a
^..
ECM
3 1
^ 5
Secondary AirValve
NK
UMm
YO
B08
NK
A06
10.91
Possible cause
Action
P1685
Test
1
Proceed to test 2
Faulty
OK
Faulty
OK
Short circuit
OK
Faulty
OK
Proceed to test 6
Short circuit
OK
Action
Result
10.92
l uP
1Tri i
Fuse box
KM
A06
615
TwumeH
10.93
1 ._
Circul
Action
Fault Code
Possible cause
P1659
EMS Ignition Voltage input circuit fault Disconnect ECM and proceed to
pinpoint test 1:
Test
Result
Action
OK
Proceed to test 3
Faulty
Proceed to test 2
OK
Short circuit
OK
Proceed to test 4
Faulty
OK
Proceed to test 5
- ECM pin A19 to fuse box Fuse 2, note that Open circuit
the engine stop switch must be in the
'RUN' position and any Alarm fitted must
be disarmed
Circuit Diagram
Engine
Stop
Switch
Fuse Box
I
Alarm
Control Unit
4-ij
ECM
GN-b
10A
10.94
UP
Fault Code
Possible cause
Action
P1696/P1697/P1698
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
OK
Proceed to test 4
Faulty
Proceed to test 3
OK
- MAP sensor
- Ambient pressure sensor
- Throttle position switch
- Exhaust control valve actuator
-Fall detection sensor and retest for
circuit
- ECM pin B01 to ECM pin B20
Faulty
Proceed to test 4
OK
Proceed to test 5
Short circuit
short
Circuit Diagram
Ambient
Pressure
Sensor
2
ECM
Twitimpm
B20
KB
B01
i j
MAP Sensor
Fall Detection
Switch
Throttle
Position
2
ExhaustValve
Position Sensor
I
10.95
rr i
jiiiri i i
Iiti
Fault Code
Possible cause
P1602
ECM
10.96
is locked to prevent
motorcycle from being operated
Action
the This is also identified by a fast flashing
MIL indication, and a disabled engine
management system. Unlock the
ECM using the service tool and
supplied unlock code from Triumph
service
UM
L IW
Action
Fault Code
Possible cause
P1614
ECM or Tune is incorrect, causing the This is also identified by a fast flashing
ECM to be disabled to prevent the MIL indication, and a disabled engine
management system.
motorcycle from being operated.
Pinpoint Tests
Test
1
Result
TRJUMM
Action
Proceed to test 2
Replace ECM with correct part and proceed
to test 3
Proceed to test 3
Incorrect
OK
10.97
Fit F
- N n E rc 6
Symptom
Possible cause(s)
10.98
u p
'c
\ ' ,/ 1 ! 1
9.
cegn
1. Fuel hose
2. Fuel pump electrical connection
3. Fuel level sender electrical connection
Note:
T1L!:!!!j3K
10.99
2.
mounting points.
Connect the two breather hoses as noted prior to
removal.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
10.100.
UMP
imi
Fuel Pump
8.
`^--
Removal
ote.
complete assembly.
1.
2.
3.
4.
._
9.
6.
1
arch
Assembly
ceha
1. Fuel pump
2. Mounting plate
3. Mounting plate fixings
7.
P'
1.Sealing ri ng
2. Seal lip
TwuMW
10.101
ii
Fiii
it
Iffl
2.
3.
4.
1.
2.
3.
4.
0
nh.a
2. Locating peg
5. Tighten the fixings in the sequence shown below to
m.
ceax
Assembly
1. Refit the fuel level sender assembly to the fuel tank
ensuring that the upper tang and two side tangs are
correctly attached to the bracket inside the fuel tank.
7.
8.
9.
1. Upper tang
2. Side tangs
2. Refit the fuel pump and filter assembly (see page 10101).
3.
4.
5.
6.
1 0.1 02
M^
r
4. Connect the adapter between the fuel pump plate
outlet and fuel hose as shown in the illustration
below. Insert the gauge to the adapter also as shown
in the illustration.
1.
2.
can be heard.
Ensuring the gauge is visible to the side of the
motorcycle.
Start the engine and observe the fuel pressure
reading on the gauge.
Note:
The fuel pressure should be 3.0 bar
nominally.
7. When fuel pressure checking is complete, disconnect
the fuel pressure gauge adapter.
8. Reconnect the fuel hose and refit the seat (see page
16-9).
1. Fuel hose
3. Select the fuel pressure gauge adapter marked 'B'
from service tool T3880001.
1Rt!:!!!J3H
10.103
1 ^A
Fuel loe^ery
SystemAorx
Removal
1.
4.
5.
6.
1. Airbox fixings
1 0.1 04
1.Breather hose
2.Airbox
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
TwUmem
10.105
Fuel S
Management
Air Fiter Egeirnent
1.
2.
3.
Installation
1.
2.
3.
4.
5.
ir
+,
}k.
^5
Removal
1. Remove the seat (see page 16-9).
2. Disconnect the batte ry, negative (black) lead first.
3. Remove the fuel tank (see page 10-99).
4. Remove the airbox (see page 10-104).
5. Release the ring of bolts securing the upper half of
the airbox to its corresponding lower section.
6. Release the airbox centre fixing which is accessed
through the centre hole in the airbox upper section.
2f
AS.4
^
^,w..,
;3::
a.
u
s. z^e: ....... .:n+..:.....c< ^}.
'}v:+. r^
:>......}:::n.::,::....
A.::n+:'}rp^'!2e.....:n,:..:.v:::e:...:e`.:.v..
/:..,.^.E.:,,.5.<:,.::...f..,:::.>.>..'^
.R:.,
..Y
9.
10.
11.
12.
13.
4
k':b,rw^L. ^,^^f,,j^q.} ,^. r,^
, , +.^:., . : ,<}
ti ^C"v.v. v,i :}:.y: ,:.0>.n.;. .kv.. 'n^i,'. ; :a ?:{:hv; .p `t:+
Always ensure that 0all 3 intake rubbers seal to the
throttles through 360 . as poor performance and lack of
power can result from incorrect sealing.
6.
7.
8.
.,n....'
..^ ^,.)....,?x>:^rv?:
...sn,.. H t ?r h?.
'
p. .:Wt.;.+^2ctl.
,^
}^:;^;^.,sv:+e;+..v}..t:^R::1,3c::r:^Fc,,:>>:CC'e
"q^^'ps^:.>^
..,n3i..v:..vvi..F}i:.:..
.v......vv..n.E:A,
f.. t...
,...
.... o...,,::.:.r.
5.:^,,w.+>:a.+s...a.}:..::..,
.:ti,,.... C.
'^..
2^
War
^2
2
1. Airbox`
2. Ring of bolts
3. Centre fixing location
.1
3
2
cdau
1 0.1 06
UMW
Intake fir
nstaHatEon
1.
2.
3.
4.
5.
6.
7.
Tempture
Sensor
a oval
1.
Z.
sensor.
Note:
The intake air temperature sensor has a
threaded base.
5. Unscrew the sensor to remove it from the airbox.
Assembly
tl1M^
1.
2.
3.
4.
5.
Fuel System/Engine
Management
Removal
Removal
1.
2.
3.
4.
1.
2.
3.
4.
5.
1.Map sensor
2. Multi-plug
3. Air hose
5.
6.
7.
1.
2.
3.
4.
5.
6.
1 0.1 08
3.
4.
5.
6.
11M'
Note:
Removal
1.
2.
3.
4.
1.
5.
2.
Removal
Y 'A
e
1. Fall detection switch
1. Sensor
2. Sensor bracket
Installation
1.
2.
3.
4.
5. Refit
Installation
1
or
'\ \
2
ccwy
1 . Sensor
2. 0-ring
Tkiumm
Manual - Ti er
9Servic
10.109
2.
Adjustment
3.
Note:
10 m.
4.
5.
6.
1.
2.
3.
egs
4.
5.
6.
locknut
ccwq
10.110
tUl^[t
ii!k11 iIJ
7. With the throttle fully closed, ensure that there is 23mm of free play in the 'closing' cable. Adjust if
necessary ensuring that the locknut is secure
afterwards.
Removal
Note:
Before beginning to remove the throttle
cables, note the. exact routing and location
of both cables to help ensure that they are
returned to the same locations and routing
on assembly.
1.
2.
3.
4.
5.
6.
1.Throttle cam
2. Closing cable
3. Opening cable
TWUMEH
10.111
i'r
Ifi
Fi t!IiiitIil
At the twist grip end, slide off the rubber boot and
7.
1.Twist grip
2. Twist grip guide
3. Screws
8. Separate the two halves of the guide then release the
inner cables from the twist grip.
,t
11 W- '
1. Closing cable
cc
vuqq
1. Twist grip
Opening cable
Detach the cables from the motorcycle.
9.
2.
Examination
1.
Installation
1.
6.
7.
8.
9.
10.112
uM^
Y Fa
iiFTilI
10. Release the bolts securing the fuel rail to its bracket.
bolts
11. Ease the fuel rail and injectors from the cylinder
head.
12. To detach the injectors from the fuel rail, release the
clip at the fuel rail end of each injector and ease the
injector from the rail.
1. Fuel rail
1
1. Injector
2. Clip
3. Fuel rail
13. To detach the transition pieces from the head,
release the screws, ` raise the transition pieces and
collect the 0- rings.
Inspection
1.Throttle body
2. Transition piece (one per cylinder)
3. Clip (one per cylinder)
9. Ease the throttle bodies from the transition pieces
and lay the assembly on the crankcase.
uM
1.
2.
3.
Check all joints and seals for splits, cuts and damage.
Check the throttles for sticking, loose or damaged
throttle plates.
Check the 0-rings for damage.
10.113
1.
2.
1.Transition piece
2. 0-ring
3.
4.
5.
7.
8.
9.
pieces and
1 0.1 14
Service
Manual - Tiger
up
Installation
1.
2.
3.
4.
5.
6.
8.
9.
113).
TMUMBH
10.115
1.
2.
3.
4.
5.
6.
cdav
3
cdaw
10.116
luM^
2.
F
I
cdax
1.Collar
1.Collar
2. Spring
2. Spring
3.
-x1 i
II-,.J
nstaationn
1. Ensure the Idle speed control lever is correctly
positioned in relation to the throttle cam as shown
below.
`.!,L v
cday
cdgr
Fit the plastic washer through the lever then fit the
metal washer and nut.
5.
6.
7.
8.
cdgs
TRiumem
10.117
cda
cdba
1. Adjustment nut
19. Press the validation key marked '*' to fully close the
idle speed control stepper motor. After a minimum
of 15 seconds (the tool will not allow further actions
to take place during this period), press the validation
key again to return the ECM to normal control.
10.118
uM^
iiiA TThmi
cegv
1. Silencer
2. Clamp
3. Exhaust pipe
ty
10.119
1. Oxygen sensor
8. Remove the oil cooler (see page 8-14).
9. Remove the radiator (see page 11-8).
10. Release the fixings securing the exhaust pipe joints
to the cylinder head.
1.Cylinder head
2. Seals
2. Locate the exhaust pipes and align the exhaust pipe
flanges to the fixing points.
3. Assemble the rear mounting point fixings but do not
tighten at this stage.
4. Tighten the exhaust pipe to cylinder head fixings in
the following sequence:
Tighten the nuts numbered 1 to 6 to 23 Nm
in the sequence shown below, then tighten the
nuts numbered 1 to 3 again to 23 Nm.
1.Down pipes
2. Fixings (upper fixings shown)
11. Remove the bolt from - the exhaust pipe rear
mounting point.
cegt
1 0.1 20
v
10. Align the silencer mounting bracket to the frame and
.
refit the bolt and a new nut. Tighten to 15
Management
TLY.!:WkI
15. Start the engine and check for exhaust gas leaks.
Rectify if necessary.
10.121
Management _________
Fuel S
-
' ..`
'
Vii .. x
The secondary air injection system is an aid to reducing levels of pollutants in the exhaust gases. It does this by
introducing a small amount of air into each exhaust port as the exhaust valve opens. The introduced air helps promote
further combustion of the fuel mixture in the exhaust system after it has left the combustion chamber.
At certain specific engine speeds above idle (determined by the factory programming of the engine management
system), the secondary air injection control valve is opened by the ECM and allows an air feed into the secondary air
system where, each time a pair of exhaust valves open, the exhaust gases in the exhaust port create a depression which
causes reed valves in the secondary air injection system to open. When open, the depression in the exhaust port draws air
from the control valve, through the open reed valves, into the exhaust port. This air promotes secondary combustion of
the exhaust gases in the ports and the header system.
At other engine speeds, the system is disabled by closing the control valve in the system. This allows an oxygen sensor to
control air to fuel ratios. 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
UMW
L
Secon&5'y AEr Q p ' n eid
iii
iii
jjjj
Values
Valve
Removal
Removal
1.
2.
3.
4.
5.
6.
1.
1. Spring-close dip
2. Secondary air injection hose
3. Reed valve assembly
1. Solenoid valve
2. Electrical connector
3. Secondary air injection hose dip
7.
Installation
8.
1.
9.
2.
3.
4.
5.
6.
cbqx
1. Valves
UP
10.123
Fuel System/Engine
Management
Inspection
1.
2.
3.
Installation
1. Fit the reed valves to the cam cover.
2. Refit the valve covers and tighten the fixings to
9
.
3. Refit the air hoses to the reed valves.
1 0.1 24
System/Engine . .
71
iiTh
.71 .
To fuel to
\\\
Vacuum pipe
Carbon canister
IRUU Mr
Service
Manual - Tiger
10.125
Tr
When the engine is stationary any pressure increase in the fuel tank due to a rise in ambient temperature will cause the
fuel vapour to pass down the breather pipe 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
una
e control valve
pe A
Carbon Canister
Twumm
10.127
___j
1 0.1 28
Service Manual - Ti er
9
^iMP
11 Cooling
ExplodedView - Cooling System ...........................................................
11.2
Coolant.................................................................................
11.3
11.3
CoolantReplacement .....................................................................
Drainage ...........................................................................
Filling..............................................................................
11.4
11.4
11.4
RadiatorHoses ...........................................................................
11.5
11.5
CoolantPressure Ca
p .....................................................................
Ins ection... ........................................................................
p
11.6
11.6
11.6
Removal.., .......................................................................
Inspection..........................................................................
Installation....s ....................................................................
11.6
116
11.7
Thermostat..............................................................................
Removal ...........................................................................
Inspection..........................................................................
Installation.........................................................................
11.7
11. 7
11.7
11.8
11.8
Radiator................................................................................
Removal ........................................................................... 11. 8
Inspection.......................................................................... 11.9
11.9
Installation...........................................
. ......................60.69...
Twumem
11.1
Cooling
r; i'
10Nm
Ir
ij
I 2Nm
'iiii
9Nm
11.2
UM
L1
2.
1.Expansion tank
2. 'Max' mark
3. 'Mm' mark
3. If the level of coolant is low, coolant must be added
as follows:
Note:
It is not necessary to remove the left hand
cockpit infill panel in order to remove the
coolant expansion tank cap.
cecv
Coolant Expansion Tank Cap
TwumeH
11.3
1 1:
4=
R)) ^ A
R \ 'n ^'
a
..^:3^3."
<^
} ^x'.
s
x^
,
'Y:
.f.^Q'`.,Y^.
(.;.^.:;
:
A^
'F)U:in:r' :3} ,
' '
.:,.dfH^r`;$:i'}t:3"Y a;.
3^::%^'G:Y c;::
1. Radiator cap
5.
6.
11.4
1. Bottom hose
2. Water pump
luM^
^ 1 1
1.
2.
3.
4.
Radiator
radiator.
Note:
11.5
1. Lower seal
2. Upper seal
3. Spring
Note:
If there is any sign of damage or
deterioration replace the cap.
2. Pressure test the cap to the blow off pressure of 1.1
bar. If the cap opens at a lower pressure or fails to
open at 1.1 bar, replace the cap.
1. Bottom hose
22. Bypass hose
3. Water pump
5. Release the bolts securing the water pump to the
crankcase.
6. Withdraw the water pump.
Inspection
11.6
1.
2.
UM
Cooling
Sae
3.
4.
5.
1. Top hose
5.
6.
7.
Inspection
1.
2.
3.
Installation
1.
NI
:mw..?^I1
11.7
1 1
I I
Removal
1.
2.
1. 0-ring/groove
3. Tighten the bolts to 12 Nm.
4. Reconnect the top hose clips.
5. Reconnect the battery, positive (red) lead first.
6. Remove the seat (see page 16-9).
7. Refill the cooling system (see page 11-5).
1. Top hose
5. Disconnect the bottom hose, expansion tank and
bypass hose from the radiator.
1.Bottom hose
2. Expansion tank hose
3. Bypass hose
11.8
lliN[t
Inspection
1.
2.
3.
Q ^j
3:':',^^^'{,
:M::."'v}.1:.,.
'f
SO : i
e.Jt Si.;v
,a':S{':i,;^ .,
::.\v,.
1 e>
"v ^.;.^a
,' i. `.:,\r:S.:{:
Y,.
.:s.,
,. v.w:;;'.t+C^^.^rc
f, an.
,:.;p'.;.nv:.:`.;knit:.
.v ,v:,u r x ;'
,. t. ` ,:.?AS.:'fi,6.
..,6y.
i`:4^e ^
,
:t : \::iii' ' 'i. ':o
'4`'n^S`v.:tit;}:^.
.:{i':'%':t:a';'5.,
:`\^:^.',': i:'xti'. ^:
:::{x':;,a;.t.:^A,:'t!?":
.. , n. y;^S>
vn
, . rc. nAv..
...5$
na:::.a
^... t.:SS'+.t
n n{,, . .. zar...i,n.
;`k:;;< .
A
))o,'f::.
;<>^,::
e
.w'<v:,tn4.a^':
... FS:'.S.
.:' "^4'r;.;
;$^F:G+
.;...,5
xx:
$':
'
. M
:? , ;,:h^tay.:.\`o'^^{
t $t:ftxv^:.SA
: ^f^
, ytyk"t^<:^t5't'I :<3^
'^ 1rv^"<:
^{i:t. .za
}.,. .'1
; ^u}n fi\ y .` .. " i ':,.
\.>; 7;.
", tg`g
,.<^isy,^
+.^..t' C :
"', ^^^
:^t'3^j'e^.^d,\..tr^^
i^.},a.:
^ Cauti9n' ^^t.:
.':^:.
, ^:^
,;.:`;u^:t^
':. i^^.?^
.r.;.
nnL.\
,$ia?ti{<.'2'F:r
.aa.
.^`''s'iSir^ ?oT
`
l:
} .4,.?
n;n%,n
S :
^
^,.,
.:$ '^^+.
{,^.
+f
Sb`
,...^`3...'^1,::
r. .;,t ,; y:. :,:'?%i':::
^^
.: 6'^^.W^'h+i^ ':^,:
.;^.
7.
8.
4.
5.
Installation
1.
2.
3.
Align the oil cooler and infill panel to the radiator. Fit
the lower mounting bolts and tighten to 9 Nm.
4.
5.
6.
7.
8.
TRL!!+!j3H
Service Manual-Tiger
11.9
11.10
[fri
i#i'
1iIiN
[sIi
12.2
12.3
Exploded
Exploded
View
View
12.4
12.5
12.6
RearSuspension Unit . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal .......................................................................... 12.6
Inspection.......................................... .....................0......... 12.7
Installation.......................................... ............0.................. 12.7
DragLink ................................................................................
Removal... ........................................................................
Inspection.........................................................................
Installation.........................................................................
12.8
12.8
12.9
12.9
12.9
Removal ..........................................................................
}
Inspection .........................................................................
12.9
Installation.........................................................................
12.10
12.10
DriveChain ............................................................................
ChainLubrication .....................................................................
12.11
12.11
12.11
Swin in
12.16
12.16
12.1
7Nm
4.5 Nm
110 Nm
12.2
TRMMO
12.3
48 N m
ll
12.4
48 Nm
Twummi
12.5
, ^ , ^3
Rear
P
a 1
S pisii Unit
7.
8.
Mote:
2.
3.
4.
5.
6.
12.6
UMW
Rear Suspension
11. Remove the two upper rear subframe bolts and
allow the rear subframe to pivot downwards on the
lower bolts.
Installation
--^
Note:
1.
o
l
ce
`&,
^ ^ \\\
je ' I 1
\\
1. Rear subframe
2. Upper fixings
3. Lower fixings ef hand shown)
Inspection
1.
2.
wear to:
2.
00
o 0
1 ''`--may
^o p
3.
l^Mr
12.7
lower bolts.
Tighten the upper bolts to 60 Nm, and the
lower bolts to 40 Nm.
1.Rear subframe
2. Upper fixings
3. Lower fixings (left hand shown)
6. Align the silencer mounting bracket to the frame and
refit the bolt and a new nut. Tighten to 15Nm.
7. Refit the starter solenoid to its two retaining blades
on the rear mudguard.
.
8. Refit the rear panel (see page 16-10).
9. Refit the battery (see page 17-7).
10. Connect the battery, red (positive) lead first.
11. Refit the seat (see page 16-9).
12. Remove the support.
1. Drag link
2. Drag link bolts
12.8
SuspensiorInspection
1.
2.
fixing bolts
Renew as necessary.
1
3
Installation
1.
2.
3.
4.
2.
3.
4.
5.
6.
TRIUMEM
12.9
Note:
Both drop link plates are marked as shown
below. Both plates are identical, and must be
fitted with the bolt hole markings facing the
right hand side of the motorcycle.
1.
2.
3.
Note:
Front
L27?3
1
Front
7.
plates
\2
Inspection
1.
4.
Locate the drop link plates and, from the left hand
side, loosely fit the bolts and new nuts.
arm).
2.
3.
Renew as necessary.
Check the drop link upper bearings for wear.
tea,
1.Drag link (drive chain not shown for clarity)
2. Drop link plate
3. Rear suspension unit
4. Fixings
5.
6.
1 2.1 0
uM1
Chain Adjustment
'Y
._^
^ia a
Note:
gritted roads.
If the chain is badly worn or incorrectly adjusted (either
too loose or too tight) the chain could jump off the
sprockets or break.
Chain Lubrication
Lubrication is necessa ry eve ry 200 miles (300 km) and
also after riding in wet weather, on wet roads, or any time
that the chain appears d ry.
Use the special chain lubricant as recommended in the
specification section.
Correct application is critical for chain lubrication. Apply
the lubricant for one full chain revolution only, then leave
for eight hours before ri ding. This allows the lubricant's
solvent (used to thin the oi l) to evaporate and the oil to
'soak' into all parts of the chain. If the lub ri cant is applied
and the motorcycle is ridden shortly afterwards, the
lubricant is unlikely to reach all parts and the majority will
be flung off and wasted. Applying excessive amounts is
not helpful under any circumstances.
L'
s.....:f
k.......Y.
`'m
'ni`:,
..5..:.
e`; 5. ^,
tY
^...
.c
:i .;`
Q
..x
w......
St
^11
,.:^*...
1E
:,
1x ; w y 5 v w,
p, t
t
^tfi"..k^^ Y 5
5^^
^
5 ti
+'
.+
, 5..
.,N
:..,7,R..::S...
Caution
..
.^. ,. ,
l
w^.ti:
:. ....h...:^;:<5#:;C
r'S7,11^`....:..::..c..,:v,:
rta
}.s
yJ..v
L
.K,r.+y
.....
wL"'
}
S'i
..`^
IRUU
12.11
ceCtic
^..._
cecx
1. Measurement ac ro ss 20 links
2.10-20kg Weight
Note:
Check for equal adjustment on both sides
using ` the graduation marks on the
swinging arm.
the adjuster bolts and tighten both
adjuster locknuts to 20 Nm, and the rear wheel
spindle nut to 110 Nm.
6. Repeat the chain adjustment check. Re-adjust if
necessa ry.
5.
Counter hold
4.
1 2.1 2
^1M^
Rear Suspension
5.
6.
8.
TRIUMEM
12.13
^-^ \2 1
^^ 7
8
10
1. Seal
2. Sleeve
3. Needle roller bea ring
4. Spacer tube
5. Ball Bearing
1.Swinging arm
2. Spindle
6. Circlip
7. Seal
8. Spacer
9. Washer
10. Nut
Note:
The needle roller bearing in the left hand
side of the arm cannot be removed
undamaged.
17. if required, remove the fixings securing the chain
guard and drive chain rubbing strip and remove
both items.
18. If required, remove the fixings securing the hugger
and remove the hugger.
Inspection
1. Frame adjuster sleeve
2. Tool T3880104
1.
2.
necessary.
3.
4.
5.
6.
7.
12.14
tuM^
12. Release the caliper and refit the rear brake hose clips
to the swinging arm. Tighten the fixings to 4.5 Nm.
Assembly
1.
2.
3.
4.
5.
6.
7.
1. Frame adjuster
2. Tool T3880104
8.
9.
UMW
12.15
1. Tool T3880027
2. Large pressure screw
3. Chain
4. Chain cutting tail piece
1
cdqk
1. Tool T3880027
2. Large pressure screw
3. Chain cutting tail piece
1.Tool T3880027
2. Small pressure screw
5.
6.
7.
8.
1 2.1 6
l^M^
L
11.
Mote:
.
nra::
r#Cv'.hv:)
:::;;.:'o:a:)r:.+!v::......:::;^...:::.;
.;:.Y.o'ta..t:.. ^Y.... ...'t:.:
: ;.P. o5:e;
.
::.
:.,..
:;;Y::::. ::.n::;:C;r^,.
\
:r.+>i ,
Y:J;:.
:::
:.:wr:oS+t<. .vn:
'A)^r:3:
: a?.,,
:^0..
^'... ,.+
+::^.^:; '^.
.
...<aau;<S
:E:^"+arP..^?
,+i :+x.':;"^'^3'i ):R`.::e.3 kk,'i ^.v
+vr..
.:
':v
.v.:.
,u;^
::r:`}..;il:.u
Caution
9ote:
plate
Tool T3880027 includes two I^^ k p
holders, one is for riveted I nk plates
l:.:.".t:' P::nf
n1::,
^.+(
np
+t.::P:.'Y?i+::w.
,i.:^ y ;
3
k
,
:vi^'j'o
S' :' ^' :;:Y {!
. :, ^^' i:
v. t^'R
^ . ^
:,;4,r.; :i2:^'it3x'.t'i..x:a..;
nL?t;^5v..: '
v
,:,3f.:,:
; 't ^k ^
^?n^"i:..; ^iR). .,i r;3R...t&A.:.
3R:rS:..,.. {x:.`^e^^;,
2::^.:otL:):
u. :. wi":'
. , ::^ ;:'';rt5^:..:,
.,.ao
^:5^:..,Y:.
iti )"(:f'::^^ii ^'. .
.,.f^
.,.Y^;i
a F"
k :Y''
"::,"i2:: .+:`:iti4::.:!Yis
. (,
...E.^,u`. .>.::
.i!:;:.c.+t.."+:a3;:
\ +N ........
o.;::.
.. k..;
: ,a_ .
. Yv:..c
. :'F,r:,. . :.....kR; '.1
..w....
w ^^;:!:r^:.:+?>Y ....3......::.,^::,:...,,
:
Use the old drive chain to pull the new chain into
position as follows: Temporarily attach the end of the
new chain to a free end of the old chain using the
old connector link. Carefully pull the other end of the
old chain to pull the new chain around the sprockets.
::;.;r..
The component parts of the new link kit are coated with
a special grease which must not be removed. Removal
of this special grease will severely reduce the service life
of the chain
9.
iwr=
Insert the riveting tail piece into the tool body so its
larger diameter end is faring towards the large
pressure screw as shown.
rix3)
..
.35....
..^+^..:...
:::: .b
; +^.
.:%::i'::n:.i3Y 'oY:::,::.;E... ..
i : :'..
+ ^'':i:::::7'r
....^.+.
i..^t.:Z....",xr : `ni;.: y.
:n :
t{
12.
Note:
-Ii
1. Tool body
2. Large pressure screw
3. Link plate holder (marked PHSO60PJ
4. Riveting tail piece
13. Position the tool to the chain. Ensure the link plate
holder is correctly located in the large pressure
screw.
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
TWUMEH
12.17
Rear Suspension
14. Locate the split link pins such that the pins will enter
the groove in the link plate holder when the link
plate is pressed on to the link.
20. Retain the tool body and tighten the large pressure
screw until the split link end is riveted-over.
caqn
II I I I I
1. Tool body
3. Link plate
4. Link plate holder groove
21. Back off the large pressure screw and rivet the
remaining split link pin as described above.
22. Remove the tool from the chain and check that both
the split link pins are correctly riveted as shown
below
15. Retain the tool body and tighten the large pressure
screw until the link plate is pressed fully onto the link
16. Back off the pressure screw, slide the tool assembly
to one side and check that the split link is correctly
assembled.
17. Remove the link plate holder from the tool. Do not
remove the riveting tail piece from the tool
18. Insert the flare pin into the large pressure screw.
0
1. Correct riveting
2. Insufficient riveting
3. Excessive riveting
4. Riveting off-centre
cdqn
1.Tool body
2. Large pressure
screw
1 2.1 8
If either split link pin is not correctly riveted, the split link
must be removed and replaced with a new link. Never
operate the motorcycle with an incorrectly riveted split
link as the link could fail resulting in an unsafe riding
condition leading to loss of control and an accident.
inijri
iiiii.ii
13.2
- Handlebars ...............................................................
13.3
FrontSuspension .........................................................................
ForkInspection .....................................................................
13.4
13.4
FrontFork ..............................................................................
Installation.........................................................................
13.4
13.4
13.5
13.6
Draining...........................................................................
OilRefilling ........................................................................
ForkOil Level Chart .................................................................
13.6
13.6
13.7
13.7
13.7
13.9
13.10
13.12
13.12
1312
13.14
13.14
13.14
13.15
Handlebars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
Installation.. . .: . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .
1316
Ex lodedView
Removal...........................................
Th.L!:!!
. .........................0,.000
1316
. 1317
13.1
Suspension
90 N m --^
See text
Jm
\\
'\
\\
\\
\ \\
\ \\\
\ \\\
N
\ \\\
\
\
\\
\\ %\\
\\
13.2
\
\
\
\
20 Nm
MP
:mI!:!
13.3
;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. Always follow the inspection instructions at
the intervals stated in the scheduled maintenance chart.
WExamine each fork for any sign of damage or scratching
of the slider surface or for oil leaks.
If any damage or oil leakage is .found, strip and repair as
described in this section or consult an authorised Triumph
dealer.
Rz
13.4
uM^
installation
.
3:^
. }^
S:R
} a s . vi4
v^ "#
C
\Y
^`.\
.:::\v".'^
m
a ^x: vi,
12b?1v\
fa.^
3 X, <++E
r,?
h
`' ^Y
iG<S:C:ftia+^ )
<
} 4^S.
Y1
f
,1a,.
.^.
<nf
3. Straight edge
>
\\
^: Caution.,5x.:.`
)oyl
!a^
'` g
^' r t
^x
) :r
F 'S
aF
..
.
:;%fir
:y
^
Y',:} L
Y`foS"11aS7'f?, +,F+:
;\;:
., };...}
.
p2.:
,'.'!^"
"^N`^'.;f;:'.:H'.
..,r}^,
:i^<s^^'
"+ ^t;$.<:^.L?
a, L^> $x}.^+,.:._,
r,E
.}:.
^5rlfk: a'kk
X, x.{
$$.
.: f.
.;?,e
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f+ ..: , i .
2.
Yei
3.
r,.r?=r:s
.
4..,N`Y:
f,,'1,x,^j1.}1[
1<rly
^n % . . `;1?
+u;.fiU.r:}}
1.' ';
'^' ,'
cW}i: ' PF
., ^:i^N $:Ti.'^7
v?:r^`:
mn,l
^
v^,.
C,w
rv .:
I//I
IUI\
ffi
^i.
e
vn1+a^
y)^
'
r.:%
nCi+<.
:::
oT.,,
:p$.r'
,J
11
4.
S.
6.
7.
Flat area
clamp bolts to 20 m.
Tighten the bottom Voke clam
Tighten the top yoke clamp bolts to 20 Nm.
Refit the front mudguard (see page 16-16).
Install the front wheel (see page 15-7).
a e 14-18).
Refit the front brake calipers
P9
P (see page
Lower the motorcycle to the ground and park it on
the side stand.
_
TWUMEH
13.5
i
Before starting work, ensure the motorcycle is stabilised
and adequately supported. This will help prevent it from
falling and causing injury to the operator or damage to
the motorcycle.
1. Remove the fork (see page 13-4).
2. Remove the top cap assembly (see page 13-7).
3. Remove the fork spring (see page 13-7).
4. Holding the inner and outer tubes together, invert
the fork and pour out the fork oil into a suitable
container. Pump the damper rod to remove all the
oil.
it Refilling
The oil level is measured from the upper surface of the
fork outer tube, with the fork fully compressed and the
spring installed.
;IiiiiilIll
installed)
1. Refit the fork spring, close wound end uppermost.
2. Fill the fork with the grade of oil specified in the fork
oil table opposite, to .a level above that which will
finally be required.
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
UMP
Oil
Volume
30 mm,
measured
581 cc
Oil
Grade
Fork Pull
Showa
SS8
Top of the
outer tube
Through
with the
spring
installed
Front Fork
Disassembly
ccun
1. Fork
2. Soft jaws
3. Top cap
..i .:rv
:}
:'.>.
A..
..
,.rv:'
:...
, Caution
.. x ..
h:
..
..
:>:}}';:,;:^s>.>:. .
. ; :g
in :, <};.>
.sE
tli
ya
A'
'v.
... <s
's:. a;.
<.^ ^...
Y:,,^.er# : c:
.;.aa:.:;}
:::.^y,^,,.', sn:>.'.
^^.'^+^
}`
:^.:.
t:}';;
Never tightly clamp the outer tube as this will cause the
tube ` to permanently distort. A distorted tube is not
serviceable and must be replaced.
Note:
The top cap is not under spring tension and
will not spring upwards when the threads
disengage.
1.Compression/rebound adjuster
2. Preload adjuster marks
3. Fork top cap
TWUMBM
4.
5.
6.
er
Service Manual - Tiger
9
13.7
ccwz
1.Top cap
2. Washer
3. Nylon spacer
4. Spring cap
5. Bump rubber
12. Invert and mount the fork assembly to tool
T3880002.
1.Damper locknut
2. Tool T3880067
3. Spring holder (part of T3880067)
1. Fork
2. Tool T3880002
13. Raise the inner tube and remove the dust seal and
circlip from the outer tube.
While compressing the fork spring and while the spring
holder is in place always wear protective equipment for
the face and eyes and never stand directly above or look
directly down on the fork. 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
uMP
14. Remove the fork from the tool and, using a slide
hammer action to release the oil seal and bushes
from the outer tube, separate the inner and outer
tubes leaving the seals and bushes in place on the
inner tube. Note the relative positions of all bushes
and seals before removal.
ow
1 ',
'1
1. Damping cylinder
CC Inspectson
1. Inner tube
2.Outer tube
1.
Note:
1 i
K
CWX
1. Tool T3880004
2. Damping cylinder bolt location
Iltlu M^'
13.9
1I
1Ii
Assembly
2
3
4
5
Note:
If the damper has not been removed, omit
operations I and 2.
1.
2.
CCuP
I ,/
I j
1. Inner tube
2. Dust seal
3. Circlip
4. Seal
S. Washer
6. Bush
6. Position the inner tube assembly to the outer,
ensuring that the oil and dust seal lips do not
become damaged.
7. Using the narrow end of tool 13880003, push/tap
the bush, washer and seal into place.
2
ccux
1. Tool T3880004
2. Damping cylinder bolt location
3.
4.
1.Tool T38800031
2. Seal
3. Washer
4. Bush
5. Tool T3880002
1 3.1 0
UM
dep
1.Dust seal
2. Circlip
3. Tool T3880002
!`rat
1.Spring cap
2. Nylon spacer Gower)
33. 5Spring
p 9
14. Attach tool 3880085.TO301 to the threads of the
damper rod and pull the damper upwards.
mut
1. Damper locknut
2. Tool T3880067
3. Spring holder (part of 13880067)
13.11
M.T.l
II1J1It,
IJ-giTh
Check
1.
iit: ^
cecy
Adjustment
1.
2.
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
uMf
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. This will introduce tight
steering, which could cause loss of control and an
accident.
1.Upper clamp
2. Fixings
4. Slacken the headstock top nut.
cdbo
1.Adjuster nut
2. Locknut
3. Tool T3880024
7.
8.
9.
10.
c
5.
6.
13.13
Front Suspension
:
Ia:
ry
1;4'; 1 [!II'1
6.
1. Horn fixing
cdb /
1. Locknut
2. Adjuster nut
3. Tool T3880024
13.14
9.
!^M
nstaHationn
cdgo
1. Bottom yoke
2. Dust seal
.
. . ..
.vm.:::
..: ; y n;n
ry l vv:;s
Wt} 1^`( f^" d 2
A
,.
,..,v}pk
..
.:.
i
'.:'rl:,::
,s;..v$^:.S}:
, :s
...
^ ^^` kY.-0:,^.^'a sga;^
.{p}i5^: x:k::4;;u:;.
:.i:...:i:::,:.
, ..
S
is^^.,^r^ "ram,
\'RU^y,, i,
rr.Y?:;;5. ::.rrS
rts:,
::.a..,
Protect the threads of the bottom yoke when using a
press or puller as damaged threads may mean replacing
the yoke completely.
}"vu.{r^.i^bfr
,^'
1. Stee ri ng stem
2. Bearing
3. Press bed
INJUMM
er
Service Manual - Tiger
13.15
5.
6.
7.
8.
9.
Removal
1.
2.
13. Align the handlebar punch mark with the front right
hand split line of the clamp/riser, then tighten the
clamp bolts, front first, to 26 Nm.
3.
4.
5.
6.
1.Twist grip
2. Twist grip guide
3. Screws
13.16
7.
8.
UMr
Installation
1.
._^
' \\ t-0
O
I,
1\ \\
I
\l\ 1 I
-b'/
1. Upper clamp
2. Fixings
TWU
3. Slide the twist grip onto the right hand side of the
handlebar.
4. Reconnect the inner throttle cables as noted during
removal. Ensure that the positions of the opening
and closing cables are not transposed.
13.17
'
13. Align the left hand switch cube to the handlebar and
secure with the screws. Tighten the screws to 4 Nm.
14. Fit the handlebar end weights, tightening the
fixings to 5 Nm.
15. Check the throttle cable free play setting. Adjust as
necessary (see page 10-110).
16. Reconnect the battery, positive (red) lead first (see
page 17-7).
17 Refit the seat (see page 16-9).
18. Check for correct operation of the front brake and
clutch. Check ` that the throttle opens and closes
without sticking and that the cables do not bind or
restrict the steering when the handlebars are turned
from lock-to lock. Rectify as necessary
1.Twist grip
6.
7.
8.
9.
1.Punch mark
2. Clamp split Line
10. Fit the left hand handlebar grip.
11. Position the clutch lever to the handlebar. Fit the
clamp (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
uM
I,
iiii
- Front Brake Master Cylinder .................................................
14.5
14.6
14.7
14.8
14.9
14.10
14.11
14.11
BrakePads .............................................................................
14.11
14.11
Ex lodedView
Ex lodedView
the
14.12
14.15
Bleedin
14.16
..........................................................................
Disassembly.................:.....................................................
Inspection........................................................................
Assembly.........................................................................
Installation........ ...............................................................0..
14.19
14.19.
14.20
14.20
14.21
14.21
14.21
14.22
14.22
14.22
14.23
14.25
14.1
Removal.........................................................................
Installation.......................................................................
14.25
14.25
14.26
14.26
14.26
14.27
14.27
14.28
14.28
Wear............................................................................ 14.28
Removal.......................................... .0.0......0.0..................14.28
Installation....................................................................... 14.29
14.29
14.29
14.30
14.30
14.31
14.31
Bleeding the Front Brakes, Renewing Brake Fluid, Motorcycles with ABS ........................
14.32
14.3 2
14.3 2
14.3 2
Removal.........................................................................
Installation ........00.......0.0........0 ........... ...00..............0.0.........
14.34
14.34
14.34
14.35
14.3 5
14.3 5
14.3 5
14.35
14.35
14.37
.......................0000....
Removal.........................................................................
Installation........................................................................
ABS.......................................................... . ........................
SystemDescription ................................................................
ComponentLocations ...............0....000. , ......................................
14.38
14.38
14.39
.14 40
ABSSystem Circuit Diagram - Tiger ................................................... 14.41
SystemDiagnostics ......................................................................
TriumphDiagnostic Tool .................. . .......................... 0 0....0..0......
CurrentData .....................................................................
1 4:2
uM
14.42
14.42
14.42
^^
System
data
Build /ta .......................................................................:
Diagnostic Trouble Codes ................................:..........................
Diagnostic Trouble Codes ...........................................................
Bleed
O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.42
14.42
14
14.43
14.44
14.46
ToolKeys .........................................................................
14.46
Initialisation ............................................................................
14.48
Diagnostics.............................................................................
14.49
Connectors .....................................................................
14.59
Electrical
14.59
Disconnection . .......... ....................................................
WhenDisconnecting a Connector :................................................... 14.59
14.59
WhenInspecting a Connector .......................................................
14.59
WhenConnecting a Connector. ...................... . ...............................
.
Disconnectionof ABS ECM connector ................................................ 14.59
14.60
Reconnectionof ABS ECM connector ................................................ 14.60
Before
14.61
14.61
ABS Warning Light Does not Illuminate (No DTCs Stored) .....................................
14.62
Tests .....................................................................
14.62
14.64
Pinpoint
Pinpoint Tests
.....................................................................
14.64
1 .66
PinpointTests .....................................................................
14.66
................................. . ...........
14.67
PinpointTests .....................................................................
14.67
14.69
PinpointTests .....................................................................
14.69
.....
. .....................
14.70
PinpointTests .........................................................0........,..
14.70
...................
..
........
Tests ......................................................................
14.71
14.71
4.72
PinpointTests........0.0 ...................................04........0..0.........
14.72
14.73
PinpointTests ........................................0.0.....00...................
14.73
14.74
PinpointTests .....................................................................
14.74
14.75
PinpointTests .....................................................................
14.75
MP
14.3
Brakes
14.4
14.76
PinpointTests .....................................................................
14.76
AbnormalECU .........................................................................
PinpointTests ......................................................................
14.77
14.77
14.78
AMP
cm
0
000
^-
- '-
5 Nm
1 Nm
15Nm
o
(
0
25 Nm
IJ - - -
6Nm
1.2 Nm
TWumpt
//
25Nm
14.5
Exp^ o a^ d
Ve - Fc nt
ra ke CaUpers and
S Nm
5.5 Nm
00
I
17 Nm
///
W ?
o m oo
moo
fa/ Qf
fc
mo
o mo m o
00o
mo
0
r
oom
/^
m O
(y ^
O o
m
o 0^ o
^ ^ O o Om
o^ ^
m ^O^ m m
O' ^
^
o
moo
^mm
0
0 m m
0
^^O mo
oo
00 ^
22 Nm
14.6
moo
om
m o 0
0 0 00 0
25 Nm
15 Nm
7Nm
1)
/1
7/
35 Nm
- -
22 Nm
Service
TRRM
...,P
OA
Manual - Tiger
14.7
Brakes
5.5 Nm
17Nm
4O Nm
oo000^
00
0
o
o
^
o
o
o
^
o ^
-7
22 Nm
14.8
UMp
Ld1
xpbd e d View - ABS Syste m - see also
I^
page
41
14-7E
9Nm
NUMM
14.9
Brakes
:
^a
14.10
tUMIR
^ a
/1
\2
jajc
cbmz
1. Rear reservoir
2. Rear reservoir upper level
3. Rear reservoir lower level
l^
14.11
o
o
IcT:pI
1. Bleed nipple
2. Spanner
3 . Bleed tube
4. Container
4. Place the other end of the tube in a suitable
receptacle containing new brake flui d.
5. Turn the handlebars to bring the fluid reservoir to a
level position.
..
3
7
1. Brake lever
r^
2. Adjuster
3. Indicator mark
laic
1 4.1 2
u^r
D,
YL
:. ,
h,::
.:n:.
: ?';Caution:'
;.. . . }.
^ ^''
< htwk^{^
nx
fi
.ti
^,
x'.
<33t
YY3 X
<
# f
te
n..
t}t^^^
,Sq
' ^r
*i
iii`(^. S
a
ff' sc
^^i
)h: .^.^n"wY'3::^:q>;
:, py'
To prevent body damage, do not spill brake fluid onto
any area of the bodywork.
7.
8.
9.
'^;. .:;.^r.
Y:a.,,: ^'.
::
t.;.,.1.
.^a
` :. a.>,z
^
;t^:..,ab:,^;,h,,.r.,,+
:da;^:":..`a;p,.^.^.,m,.,},?;+r::;.,,,
~ !^. C'o'::^,'5,.,;iF...
^f F, g .
. f.{ >^':>,
,f i +}Y:.;fi
:.:n^. :q;..,.;,r,.'A..,..,yjY...
Note:
10.
11.
12.
13.
1. Plate
2. Brake pads
UMW
14.13
20.
21.
22.
23.
24.
25.
1. Bleed nipple
Note:
26. Secure the caliper to the front fork using the original
fixings. Tighten the fixings to 35 Nm.
27. Refit the transparent bleed tube and repeat steps 19
and 21 until no more air appears in the bleed tube.
1414
IIM
Note:
Complete the assembly of the brake pads to
one caliper (see assembly for details) before
removing the pads from the other caliper.
Before starting work, ensure the motorcycle is stabilised
and adequately supported. This will help prevent it from
falling and causing injury to the operator or damage to
the motorcycle.
Installation
1.Retaining pin
2. Anti-rattle spring
3. Brake pads
1.
2.
3.
4.
5.
1t!WH
14.15
Brakes
Front Brake Caliper
Removal
Use only D.O.T. 4 specification brake fluid as listed in
the general information section of this manual. The use
of brake fluids other than those D.O.T. 4 fluids listed in
the general information section may reduce the
efficiency of the braking system leading to an accident.
Observe the brake fluid handling warnings given earlier
in this section of the manual.
6.
7.
Kf ^e, y 7^yr
y,,:^"
+ 1, 3i
;:?2'f+} { 7.
,^
r'^,''.
^,<
,C
s.:a
a
., n.
ACaution
^,^q
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K..
f
^t^ ti.'i
,<" 5^ "r"^.a .
L'. . :iS,e ^:atq{.r. .^.;":,.^^f,y
^:,
,^.1^L'":!n'I''.'f
^^<+S^`r'`
3
7;
. YYa,;";^^'a^;
,Sk'
^ ^^:.`^, Tti:X'a^'fY^'?^."' ^`.^`'
.+;`.'f
\r,.>:;.93a'`'CJ, .iii; t,^
R
.i
,^as
:
t;;;
`..'
. , :`':; . r r:: .
e :`, '
..
2.
f
3
,
x`::n`S:\f'S^'"i;,`+.^,>w^:ir'.:,.^C' .
E K +
' s:. 3^
^.^.n^.iir
u:,.::v: is,.:,:v:.:.;:n::..r.,:"^n.....i;:i'<. `W:.1.: '. :,,
;;.8
.:,.E. .^^Lt
x..,n. ^
:f:i^.:..}^):y>:'.:n...::i Y.}tt;<G.;.., 1.a:vv.
:..'^r....v. ^5..:^..,R. n. .. nn i^f ' . 'sa.L.v.J^.. .:. a.,. : ^:r. :.X . , ^. nv..:. ni
Never lever directly against the disc, caliper or the pad
lining material. Always use a levering tool made from a
soft material that will not cause damage to the load
bearing surfaces.
Brake fluid will be displaced from. the hose joint as the
caliper pistons are compressed. To prevent body
damage, ensure that the displaced fluid does not come
into contact with any part of the bodywork.
S
f ,ny
n : .: y
3.
Y
;f.:: : ' ^...
:
L.
^^
.. x'.
ko r,?,..
A
r`v .>,;,..:
?a
f
S.
`^' ''.`^,^"
u3:f.:.h^U.'s`::?; i;g?
.,:k.`^'f::^`,.:.
` `^crivYil... n.::
q.^ .
,:..:::`i>....{
,ae .
^:..>..^^
::.:
'
.yw
1. Retaining pin
2. Anti-rattle spring
3. Brake pads
1 4.1 6
UMW
^ p^^:,?.2^.Q,
ra a
1. Caliper bolts
5. Manoeuvre the caliper clear of the disc, taking care
not to damage the wheel.
Disassembly
1.
2.
ii
TwumeH
odif
1. Piston seal
2. Dust seal
Note:
14.17
Ins BlatQr
1.
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.
Never omit to lubricate both seals with the seal grease.
Failure to lubricate both seals with the correct seal
grease may cause the caliper piston to stick. A sticking
caliper piston will result in a dangerous riding condition
leading to loss of motorcycle control and an accident.
1. Caliper bolts
2.
3.
the caliper.
4.
5.
Fit the brake pads to the caliper and locate the antirattle spring over the pads.
5.
6.
1 4.1 8
hUM^
4.5 mm
4.0 mm
Disc Run-out
Standard:
0.1 mm
Service Limit:
0.3 mm
vein
1.Disc
2. Dial gauge
14.19
Brakes
1.Wheel
2. Support blocks
Note:
The discs are handed. Observe the offset of
each disc to its hub and the orientation of
the cooling holes, for correct installation.
5.
6.
7.
14.20
L1M
1.
2.
., ) . 0 ,>, r.ffSSiJ;: rk'k^i:.to;x,': ,c::'.:+',>;f^`i.E, +.;x.S .^rs^y, r t,vF:,'.^, .'i:; ^'^'4,, ^k:.i3+:;ky`^ .vF'
vS;:^`^\t;{,i.:.,:.sn,:r`..,r:,.'4,t^+:,i,^.J.^Q.,;,:;,^h.^,:^i^,;a.,r:.nfsf:,.ei.":ap.f.al':^tf.,:'>:i,.kF;;:^t.'a%:^b?b^,.w'f;..,:;ay.^,+:t;.:^t2.^}'vk,:q+`S<.kiRtn:}:io,'x;.;:^v,:%;ixv`.+t..`^bl,1,.rx:.^:;fx^a:x,.y',"^`f.',<t,^7{i
.,".n , i' 2'..s^.
1.:`.+: ; : :\J:.^:u;ykr.:.; ' cniaf; x
,dtv,;
.^ t ; ^#'..i.k,:,J;::.;st,. Jt)^'
i:.^<t+9^G,
: ^:;t\.p4'.^,5x^.''^ti+Et
ia'arf'.^fx^^}aiNk:,`'+,..':^x:w^.0G.:^^`v?; `^Gt
J:R^:.^vx,<':^:Y,.)y5:" , '^+
Ai` ^ :oa;;?v
t(.FJ:,'^`k.,p.,:^G.;n^k.v`;:,5.W:}^rry
;.iYt.;:'."ni.+ji:v:,:a:.`v:lMSi:^);?tni,.i:vJ,C},%:.
kiric'.:;nnCir..J,r+9:f.:`.^'i:;{t5).:1JatuvV5:
^p^^:
!YY:f::tYl:;,.:<k^5h::K::i:;'YkS.i:>S.':^.w:4i^.,w.i:;}}h:J,:^::L^t:S:K: tv^t^.
F.,xW`^pY.^.1;^i:;f^,^\:
'
:
^
.
y
^:
};
t
:
N
f
,
+
.
^
S
Z
'
J `k,.:. .`3w`:'S<:i. ^..,f:kn':';':^.. \. roN' .:a+r;ta"'$io:%' ^.:.:^a;.:5b,. .^;.:, '^,. . . 1Y7
^::R,\?Q,J},.A:
,:A.:.^^?.. J.v^.. .>.: k,
To prevent body damage, do not spill brake fluid onto
any area of the bodywork.
v
,:
-:1:'
+
.^;;Vii..
i:A,"
.
r,.,.;^,^.`''
'^:+,a^^l'
. 5
M
'p
^i^:
,;':.\^x:^n'i^S;;;S:^:`.;:vig?;.;:iA}Rt.,.Q,N'^kY"'^+'
'J
^.
::i:`
:Ja:.
;.,;'...
:..., ;.J}
%',;;.R: :,
,^:^F ('f..,
...,.!k.G.'y^:
!:
'tYi
'k<
:Cj,:
a:;.iA:i.,
..,
'
,.,,.'
..
::.a: `.n.
r'.k^
Di
v.:::
^+
3.
4.
5.
'
G^ f
:.:. Y.:...
^"^^
'
1^,:;v
1. Circlip
lever.
1.Spring
2. Piston seals
3. Circlip
4. Piston
1. Pivot bolt
2. Nut
6.
7.
brake hoses,
1%quMpi
14.21
2.
ion
Ins
1.
deterioration:
2.
3.
Cylinder bore
Dust cover
Spring
Piston
Pivot Bolt
3.
Fit the new piston set into the master cylinder and
retain with a new circlip.
Refit the master- cylinder boot
Installation
cdtf
1. Arrow mark
1.
2.
cdfn
3.
4.
1. Port
Assembly
5.
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
IUMp
NJ
_^
1. Bleed nipple
2. Spanner
3. Bleed tube
4. Container
tr
at *Y :`
`':ir. s35:a .t.. '?2; n '
,rwi
A
Nn
,+^(p
"
'^i.<w^
.v
.; ,.. ;::
eY;s...::..
.`;^:^ ^
:
:M'^r
^v, :G. 5
^.v.
v`
,;
:'
;"S
>^tt ry.
o^..^
'o
;7#?
..Y.;.^.N :;..i>'.''`^i;'`
a;; nY
y
ry^ . .c:,, f
ff^%\.^>Iv.,' 4?Y`.
J^ Sih
,e''^`x'^t.^
,.
^ x^.;^
. ,y:J
`,S'
^S.aYf^<
.
M
^.uA' :A'1\T
^vp`v .\v,^.'^n'^':p;,g.'^
ry
q^^^.
TwuM
14.23
Brakes
the rear . brake reservoir cover taking care
not to spill any fluid.
4. Remove
Note:
During bleeding, do not allow the fluid level
to fall below the lower level mark in the
reservoir. If the level is allowed to fall below
this mark, air may enter the system and the
sequence of bleeding must be repeated.
7. Slowly depress the brake pedal and, holding the
pedal fully down, close the bleed nipple. Repeat
steps 8 and 9 until no more air appears in the bleed
tube.
8. Maintain the brake fluid level between the upper
and lower reservoir levels whilst bleeding is being
carried out.
9. When all air has been expelled from the system,
hold down the brake pedal and close the bleed
nipple. Tighten the nipple to 5.5 Nm.
10. Fill the reservoir to the maximum level with new
DOT 4 fluid.
14.24
UMr
gaedl
1. Brake pads
2. Anti rattle spring
5. Remove the
Installation
''j
3.
14.25
Brakes
Rear Brake CzElper
9.
^,^ ^ ^ k )<
'
'h. ,^iK^ a ^ Y4. i^
^fi i
of r
. vn'^2f.^Afi^ x ^y. .'n'`'`^^:'3.^^
`: y
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^ ,f<^^' .;vy;', ^4.,k
xi:^
^{ i>^y
..ut^'rh
'^ l ^ '.^U^.
C.:
.
^
^,%,
^
'w
"
^^{
^`
.ry^; C M'^',
5. i;' ti.Y^`^'
. G^^. ; t
^ ^ . y ^.. .:
'\.>,Y. ;^
^ :^`r:Y4 n.::WF`:..w3''^^: M 0,^, '
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i ^a,^t'v
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&
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'
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3, ^^A :,:..t
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t.rn?':`a^.t..cR....::^s.^..^';^\a:.c.,.i>.:^^
.oK.o`.
<:'kx^.,`
1.
2.
3.
4.
Disassembly
1. Remove the brake pads (see page 14-25).
14.26
IUM
2. Cover the
1.
Inspccon
1.
N
1.Pistons
2.Seals
15).
Assembly
uMr
TPt.H
14.27
Wear
1.
1.
2.
3.
4.
5.
Standard:
Service Limit:
6.0 mm
5.0 mm
Disc Run-out
Standard:
0.1 mm
Service Limit:
0.3 mm
Measure disc run out using an accurate dial gauge
mounted on a surface plate.
Use only D.O.T. 4 specification brake fluid as listed in
the general information section of this manual. The use
of brake fluids other than those D.O.T. 4 fluids listed in
the general information section may reduce the
efficiency of the braking system leading to an accident.
Observe the brake fluid handling warnings given earlier
in this section of the manual.
14.28
Service Manual - Ti er
9
UP
.
.
'
n ::
.e::4:!;:::
:.
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,i:'i:Y Cr:i?
4.
1.. heel
2. Support blocks
3.
4.
1.
2.
3.
4.
5.
6.
1. Heelguard
2. Fixings
5.
INJUMBH
Remove the dip from the clevis pin at the lower end
of the brake pushrod. Remove the clevis pin.
6. Carefully slide the cover off the brake light switch
and disconnect the brake light switch multiplug.
7 Note the setting of all brake lines and hoses to
ensure they are returned to the same position when
the overhaul operation is complete.
8. Disconnect the reservoir hose from the rear brake
fluid reservoir.
14.29
1 \\\ \\
:4)- J
cell
`"
ce
1. Master cylinder
2. Brake light switch
3. Brake hose
::r-
\ \\\ I \M5 ^J
^
..-- o ^
Inspection
',
\\ 2
0
^sdSSen^bly
4. Sealing
9 washers
'
1. Master cylinder
2. Fixings
1.Master cylinder
2.Brake light switch
3.Brake line
4.Sealing washers
14.30
UP
Assemby
Secure the master cylinder to the frame
studs. Tighten the securing bolts to 27 Nm.
2. Connect the reservoir hose to the rear brake fluid
reservoir.
3. Models with ABS brakes: Incoporating new
washers, fit the brake line and brake light switch to
the master cylinder. Ensuring the brake line, is located
as noted on removal, tighten the switch to 15 Nm.
4. Models without ABS brakes: Incoporating new
washers, fit the brake hose and brake light switch to
the master cylinder. Ensuring correct orientation of
the brake hose, tighten the switch to 15 Nm.
5. Refit the heelguard, tightening the fixings to 7 Nm.
b. Connect the push rod to the brake pedal using the
clevis pin and a new clip.
7
Connect the brake light switch multiplug and refit
the cover.
1.
2.
Clean
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.
3.
4.
5.
Allmodels:
1. Clip
2. Clevis pin
3. Reservoir hose
4. Dust boot
5. Cirdip
6. Piston set
TWUMEH
1 4.31
Brakes
Bleeding the Front Brakes, Renewing
Brake FlUd, Motorcycles moth ABS
1.
2.
3.
4.
1.
2.
3.
4.
55).
5.
6.
Note:
5.
6.
7.
8.
14.32
UMW
o .
1. Wheel
2. Support block
UM
14.33
Brakes
Bleeding the Rear Brakes, Renewing
Fluid, Motorcyces with ABS
1.
2.
page 14-50).
3.
4.
14-56).
^^
1.
`^
il
'
'
2.
3.
4.
5.
6.
Note:
^^i^g^
^=
5.
6.
7.
8.
2. Fixings
Installation
1.
2.
3.
4.
5.
6.
14.34
Service Manual Ti
- 9g er
UMP
B Fula c
r;iA]
Rbg
Removal
Removal
1.
2.
1.
2.
3.
,^. . .
:...^;5:
A'L^
i_-w
.
'' ^y^ >' Lr d' .^' '1,
Sto't
i:^
. ^
,
::?t:::: ?><;
3' a'} x "'
:^^'.::.^?.;^,
, :
'^s.':x:.
;^,V.:
r;:;:if6:yS{fi
J5: '
^,
^.
}
n
E. a
1
; `
'^
^ X
S
Y,^3:
^iL ?,3' a ,{5
t rya,,.
J
^^ ^ 'c. ;^^, "3:; Sk :,^53c`.: ,.3 ,^v.. :s,
. `sf{Si:s.`J'
:'`t
,^ 5 ::o,.
au,.
a.;^`''v..t^:
r ^.',^,
^, v
t fix
.#.^'t, }
r,$,^
^ "'<. ..x s..J:
^'^
.
"4.,i'
'
^ .
,.:
'ta"
:.,
x4. x^li^..,
tfu5
5.
6.
1. Pulser ring
Inspe ction
1. Check the pulser ring for damaged, missing or
cracked teeth or distortion. Renew the pulser ring as
necessa ry.
Installation
1.
2.
1.ABS modulator
2. Multiplug.
UMW
14.35
7.
cein
\\
\\ j
11. Loosen the four brake line unions and, taking care
not to bend the brake lines, detach the lines from the
ABS modulator.
j/
1.Heelguard
2. Fixings
8. Carefully slide the cover off the brake light switch
and disconnect the switch wires.
9. Release the rear brake light switch and disconnect
the rear brake line from the master cylinder, taking
care not to bend the brake line as it is disconnected.
securing
10. Remove the fixing
9 securin the front brake lines to
the frame (located behind the left hand side fairing).
It is not necessary to loosen the brake line unions or
to separate the two halves of front brake hose
connector housing.
S modulator
2
3
I yam\
14.36
tutor
1.ABS modulator
2. Upper fixings
15. Carefully manoeuvre the modulator from the frame,
taking care not to damage the brake lines. If the
modulator is to be renewed, remove the mounting
bracket from the modulator.
Installation
1.
2.
3.
4.
5.
1.Master cylinder
2. Brake light switch
3. Brake line
4. Washers
7. Connect the brake light switch multiplug and refit
the cover.
8. Refit the heelguard, tightening the fixings to 7 Nm.
9. Refit the fixing securing the front brake lines to the
frame and tighten to 9 Nm. Ensure the brake lines
are fully inserted into the retaining clip located
between the airbox and the frame, directly below the
MAP sensor.
10. Tighten the brake line unions at the modulator to
17 Nm.
11. Reconnect the ABS modulator multiplug, ensuring
the locking device is fully engaged (See page 14-59).
12. Bleed the front brakes (see page 14-32).
13. Bleed the rear brakes (see page 14-34).
14. Refit the fuel tank (see page 10-100).
15. Reconnect the battery, positive (red) lead first.
:I
ty_
14.37
i R^
Pg
VA1IIi
14.38
UMP
Brakes
Component Lccations
FRONT BRAKE
SWITCH
N
Nf
FRONT
PULSER
RING
UMW
ABS
REAR
MODULATOR BRAKE REAR PULSER
SWITCH
RING
c: \
FRONT
WHEEL
SPEED
SENSOR
REAR
WHEEL
SPEED
SENSOR
14.39
drakes
ASS System Craft
Di
a r - Tiger
Key To Wiring Colour Codes
Code
Wiring Colour
Regulator/Rectifier
Black
Blue
ABS Module
Brown
Ignition Switch
Green
Slate/Grey
Diagnostic Connector
Engine Control Module
Orange
7
8
Pink
Red
10
Instruments
Purple
White
12
Yellow
13
Brake Light
LG
Light Green
LU
Light Blue
Key
Item Description
i____
C' r:
17
\
==:I
10
23 16 24 25
^r
R
u ^^V V
IVP1JI
__
cdhg
14.40
IUM
drakes
'i L' iii
tJN
--
L___:
2
G
r--WU.
E
RU 16
10
iii1
----J
P
6
BU
B -
^B-
1
TWU
14.41
Brakes
Current Data
Function Examined
KPH
KPH
ON / OFF
ON / OFF
Bleed System
Using the Triumph diagnostic tool, it is possible to bleed
the ABS modulator of trapped air. This is necessa ry when
the hydraulic brake system has been dismantled, or the
ABS modulator renewed.
Full details of this procedure are provided later in this
section.
Build data
The following items of build data can also be read.
w^
Function Examined
ECM serial number
14.42
^M'
r
boa gnostic TroubNe Codes
Diagnostic trouble codes (DTCs) are logged in the ABS
ECM memory when there is a confirmed fault in the
system.
C1612
C1613
C1614
C1621
C1623
C1631
C1632
C1633
C1634
C1641
C1643
C1651
Motor - Lock
C1652
C1653
Motor - Stuck ON
C1654
C1661
C1662
C1671
C1681
Abnormal ECU
:mt!:
MP14
14.43
Once the ABS ECM has inhibited ABS function, the ECM
will act in one of three ways:
Diagnostic Trouble Co es
d
p
y
Inhibit
ABS
operation
immediately,
irrespective of the ABS operating mode.
Or:
Or:
Or:
ABS warning
light
ABS
operation is
illuminated
when fault is
inhibited
when fault is
lo9ged
logged
Open
Yes
Yes
Yes
Yes
Open
Yes
Yes .
Yes
Yes
Front
Wheel
Missing Teeth
Pulser
Gear
Rear Wheel
Missing Teeth
Pulser
ABS continues
to operate
when fault is
if fault clears
logged
(Only when ABS
is Active. When
ABS is no longer
active, operation
is inhibited)
No
Yes
Yes
Yes
Yes
Gear
Yes
Yes
Yes
Yes
14.44
Yes
No
Yes
No
UMW
Fault Description
ABS continues
to operate
when fault is
logged
(Only when ABS
is Active. When
ABS is no longer
.active, operation
is inhibited)
ABS warning
light
illuminated
when fault is
logged
ABS
operation is
inhibited
when fault is
logged
Yes
Yes
Yes
Yes
No
Wheel
Actuator
Front
(Hydraulic Control) Wheel
Lock
Yes
Yes
Rear
Yes
Yes
Motor - Lock
Yes
Yes
No
Yes
Yes
No
Motor - Stuck ON
Yes
Yes
No
Yes
Yes
No
Yes
Yes
Yes
Yes
No
Abnormal ECU
Yes
Yes
No
(Hydraulic
Lock
Wheel
Actuator
Control) Wheel
extinguish if
fault clears
Power Source Voltage Rise
Tt!:
No
14.45
Brakes
Se we Dia
ostic Tool
7
5
sue_
.^,.
miII iiIIIguIIIII
isiiiuu
gc
1.Memory card
2. Screen
3. Return key
4. Up key
5. Down key
6. Validate key
7. Help key
'Down' keys.
Cursor to show which line of text is 'active'.
Diagnose faults
Obtain data
Tool Keys
In most cases, the Return key ( E1) enables the user to
return to the screen last displayed.
Ii
EI__]
r ^r
9a&
Return Key
14.46
UMI^
up or down.
:
I ^^
gaeg r I
I1
iEi
gam (
Help Key
Test Procedure
The following describes the procedure to follow when
using the service diagnostic tool. It does not cover the
further diagnosis that must be carried out once a fault
area has been identified. For details of the procedure to
follow when a fault area or fault code has been identified,
refer to the diagnosis details later in this section.
Note:
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.
The following pages describe the tool
operation in flow chart form.
gaef'
Validation Key
TRIUMpm
Service Manual-Tiger
14.47
rni
CONNECT BIKE
SELF TEST
CHECK CARD
SYSTEM ERROR
False
Absent
Present
SELECT LANGUAGE
ENGLISH
FRANCAIS
DEUTSCH
ESPANOL
NEDERLANDS
TRIUMPH MOTORCYCLES
DIAGNOSTIC TOOL
SOFTWARE VERSION
2005 01
SELECT ECU
ENGINE DIAGNOSTICS
ENGINE
SEE SECTION 10
ABS
VALIDATE
False
ABS DIAGNOSTICS
CURRENT DATA
READ STORED DTCS
CLEAR CODES
BLEED SYSTEM
READ BUILD DATA
14.48
1l^MP
grtic3
ABS DIAGNOSTICS
CURRENT DATA
Current Data
CURRENT DATA
?FRONT WHEEL
0 KPH
CLEAR CODES
Clear Codes
REAR WHEEL
0 KPH
BLEED SYSTEM
Bleed System
y
BRAKE SWITCH
OFF
ABS LIGHT
OFF
t 4 DTC COUNT
? C1611
C1671
-0
CLEAR CODES
ERASE ALL DTC DATA
YES
NO
BLEED SYSTEM
ECU ID XXXXXXXXXXXXX
BLEED SYSTEM
BLEED SYSTEM?
CANCEL
PROCEED
BLEED SYSTEM
BLEEDING SYSTEM
RUNNING ...
BLEED SYSTEM
SYSTEM BLEED
COMPLETE
14.49
Brakes
1. Connection
Power-Up
2 SELECT LANGUAGE
14.50
lUM
3 TRIUMPHMOTORCYCLESS
you
4 SELECT ECU
Use the Up and Down' keys to scroll the text until the
horizontal arrowhead is positioned opposite the 'ABS
and press theValidation key's'.
:I tY. 14
14.51
Brakes
14.52
uM^
^z
T=
, , -
IHHIIIHHIHIHII
:ii
iiinini
II
I
EUIII
1I
aa
u umHhI
a iiiirivau
I
i^
7'
I ^ (1
9ai u
This display is the ' ABS DIAGNOSTICS' menu.
Use the 'Up' and 'Down' keys to scroll the text until the
horizontal arrowhead is positioned opposite the desired
choice, and press the Validation key's'.
The choices are
'TRIUMPH MOTORCYCLES'.
:rRtq^H
Function Examined
FRONT WHEEL
KPH
REAR WHEEL
KPH
BRAKE SWITCH
ON/OFF
ABS LIGHT
ON/OFF
14.53
Brakes
E!IrT
&!1L
^ fr
'I: (.1 1
;i
IiMflr; I7;Tfl;1
1
HHhuIIIIfliluHhI
IIIIIIIIIIIUIIII
IIIIIIIIIIIIIIIUIII
IIIIIIIIIIIIIIIIIII
'
C1b17
Help text:
FRONT WHEEL SENSOR OPEN / SHORT
CIRCUIT
Press the Validation key'*' to continue.
Scroll to 'CLEAR DTCS' and press the Validation key'*' to
go on to operation 11
Note:
14.54
Tq! ^M P
III il gHIH
Iu u,.Il'I
,
gain TI "''-"'
I \
gain
TR!Lm^
p
14.55
Brakes
.
Note:
The fault(s)
s which
c caused the DTCs to be set
must be rectified and cleared before
continuing the Bleed System command.
A full list of all the possible DTCs can be
found earlier in this section.
Note:
Because the DTCs have now been erased, the 'BLEED
SYSTEM?' (see operation 14) will now be displayed. If the Return key (.1) is pressed, the tool will
return to 'TRIUMPH MOTORCYCLES'
(operation 3).
14.56
Brakes
15 BLEEDING
Note:
If the Return key (J) is pressed, the tool will
return to 'DIAGNOSTICS' menu
(operation 7).
INJUMPji
14.57
Brakes
-
iTY!
:1 1] VXc1 [. ii[*iimiiui
18 READBUILD DATA
flhIfluhIflRflhIHl
iii OGIiit^G
;;
IIIII
uIIuaII
,
Ii
gaJ1(
'1
1\\J
'\
NN\`
//J
I
f/*
'
14.58
uMr
it F
followingconnector
Before beginning
be 9
9
9 any
Y diagnosis,the olio
related information should be noted:
::ys^::%
F:oud'>4x'<:::
,,{iz>
,}
SkF"i
;';,V:tt
: u}:
Dirty/corroded terminals.
Damp terminals.
."S L
<
r.
..
BtiL.::.
.iiiFh;:}attar%.
Yea...
. ,, . ` \
,^
When disconnecting a connector, never pull directly on
the wires as this may result in cable and connector
damage.
v
,::'c"
s. `
.
i}Ci^:M1:: r..i:.'\{m^"`+.
k'.'4Y"Y. `
F
rya:.:
^,:"iq^4C::<F
For example:
.n.... ::.A
^'..
.'h;:
;x;:
.,S9
ai.^:t
^:,
^.}.:^5`
^ <q^ ,`,:
^'
Aution
i:
}.^
:x<Stst^.) ,::::.w.>"tr
_?..
,c.;....?
...Q+ ,.^k:#s....:;...
:l
,:
:nFSi
^.,^ "^'.^i
:FFl.44dR^.'^i
'''
^;q
:}r}k
^' ,"
following.
Before Dsconnechon:
If testing with a voltmeter, the voltage
across a connector should be virtually
battery volts (unless a resistor is fitted in the
circuit). If there is a noticeable : change,
suspect faulty/dirty connections.
When Disconnecting
a Connector:
1. Locking device
2. ABS modulator
When
Inspecting a Connector:
Note:
UMM
14.59
Brakes
Reconnection of ABS ECM connector
S ^:\...h
+.,:ff:
S'
.0
.. a.,.:x}:;^kw.:
; .n;
A
r
. Fr
. ^...
`. ',e.x^
:;. ., .w.i.'_t:}E^:
k.t^:ar,^^
1^fM.^'Cx,;^i4i,;4cr^rrs ."' .r ;,::..y
'?.i ':^:Cir
t"^''Cw
j'
r`
u:
:bx.,..:;::. ..
..FL ,x.n
A.:F+C:
.fx
;r,(
.};
.).::x:C.
... ;^r;^r..<.'ff^7r.^^Jr.^ya;.C!. ^^:^bo;::}.. c,X..,;..2
".^Y4.: :gC9'
:^,,`yi%;;,k.f,\a:r3t^a^;w;
<:xr.:
; , x,<.;^`x. <}>T>^:<"
^ i?,:f,^,
A, .:)x..A. .,.:xA^cu' ^:^'
o}
^:
.:.rl..
i5<j;
.^
x.y)rsR#?fi`,,,...^ :%^:
.C..
.h
:. }., x
:.5, + : o:. `.S`^f7R;<;r
..
^ n`R.k'
$. ^?h.
5 ^ '^.i&3f^,: ^ `.C1, ....:..
.::?nk<
;C:i^'.vpi:ni}Y::}^:i:vfff:p^i}:^^v ^^:f
"lf1:; :::<:. ...h..
FurTher bgross
The tables that follow will, if used correctly, help to
pinpoint a fault in the system once a diagnostic trouble
code has been stored.
Pinpoint Tests
Before starting pinpoint tests:
1.
2.
1. Locking device
2. ABS modulator
2. Fit the connector into its socket and, whilst holding
the connector in place, push down gently on the
locking device until it locks.
4.
4.
14.60
luM^
Cif
N ^
^-
- Action
Possible cause
Fault Code
ABS Warning Light ON (No DTC's ABS Ignition supply fuse/circuit fault
Stored)
ABS Warning light circuit fault
Pinpoint Tests
-1
Test
Result
Action
OK
Proceed to test 2
Rectify fault, proceed to test 5
Less than 'across Locate and rectify wiring fault, proceed to test
battery' voltage
5
3 Check cable continuity of the ABS warning Voltage greater than Proceed to test 4
1.5 V
light circuit:
Check voltage between:
Voltage
1.5 V
less
ABS warning
'ON'
Circuit Diagram
N
--
r
1
1 234
Rugulator/Rectifier
[J]
20A I I
LA I
Control Module
Li_____
I
J
wu
RU
16
10A
L-----I
14
n
-^i
Instruments
Ignition Switch
:1uRt p,t
BU
PKI
21
B
24
25
14.61
1?P;rilL'j1!i
Fault Code
Action
Possible cause
ABS Warning Light OFF (No DTC's Warning light circuit fault
Stored)
ABS ECM ground circuit fault
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
Above 3 V
Proceed to test 3
Replace fuse, proceed to test 6
Proceed to test 4
Locate and rectify wiring fault, proceed to test
6
4 Check cable for short to ground: With Voltage greater than Proceed to test 5
ignition 'ON', Check the ABS warning light 1.5 V
circuit voltage between:
ABS ECM connector pin 21 and Ground
Voltage less than 1.5 Locate and rectify fault, proceed to test 6
V
Faulty
1 4.62
Proceed to test 6
Locate and rectify fault proceed to test 6
Action complete - quit test
Contact Triumph service
UP
ri
N
N
II
ILI
II
JL
I
J
1 234
A
Rugulator/Rectifier
Main Fuse Box
Control Module
R
Y
G
RU
wu
16
L----J
1 4 5
14
Instruments
Ignition Switch
Tt!!?H
21
BU
B
24
25
14.63
Brakes
Front WheelSensorOpen Coreaat / Short Corcu*rt
Fault Code
Possible cause
Action
C1611
Test
Result
Action
OK
Proceed to test 2
Faulty
OK
Proceed to test 4
Short circuit
Proceed to test 3
OK
Proceed to test 6
Short circuit
Proceed to test 5
OK
Short circuit
OK
Proceed to test 7
harness fault,
Proceed to test 8
OK
Proceed to test 9
14.64
harness fault,
!iM!
Brakes
Circuit agram
Wheel speed sensor current consumption data under typical conditions:
ABS
FrontWheel
Speed Sensor
TOUMEH
Control Module
UW
BG
12
14.65
Brakes
Fault Code
Possible cause
Action
C1612
M!
Test
1
Result
Action
Proceed to test 2
Faulty
14.66
Proceed to test 3
UM
Fault Code
Possible cause
Action
C1613
Pinpoint Tests
2
3
4
5
Test
Result
Action
OK
Proceed to test 2
OK
Proceed to test 4
Short circuit
Proceed to test 3
OK
Proceed to test 6
Short circuit
Proceed to test 5
OK
Proceed to test 7
OK
Proceed to test 8
OK
Proceed to test 9
14.67
n.
Test
Result
Action
OK
Circuit Diagram
Wheel speed sensor current consumption data under typical conditions:
Typica
m
.--.
Mm
3.1 m
Voltage
Low (4.
High (16V)
Rear Wheel
ABS
Control Module
Speed Sensor
14.68
Max
mA
13.6mA
UR --
BG
18
UMW
Brakes
^a
Fault Code
C1614
I Possible cause
Action
Pinpoint Tests
Test
Result
Action
Proceed to test 2
Faulty
Proceed to test 3
Faulty
3 Check the wheel speed sensors for correct OK
installation, and the fixings for correct
torque:
Faulty
4 Check the wheel speed sensor circuit (See OK
page 14.67)
Faulty
5 Clear fault code and test ABS to verify fault OK
cleared
Fault still present
1'kty
14.69
FaultCode
Possible cause
C1621
Incorrect Wheel speed sensor air gap Ensure ABS ECM connector is secure.
Damaged or dirty pulser ring
Proceed to pinpoint test 1:Loose or incorrectly installed wheel
speed sensor
Damaged/incorrect wheels
Action
Pinpoint Tests
Test
1
Result
Action
Proceed to test 2
Faulty
1 4.70
Proceed to test 3
I MP
Possible cause
Acti on
C1623
speed sensor
Damaged/incorrect wheels
Test
1
Result
Action
Proceed to test 2
Faulty
Proceed to test 3
torque:
Faulty
4 Check the motorcycle wheel for damage/ OK
incorrect size
Faulty
5 Clear fault code and test ABS to verify fault OK
cleared.
Fault still present
TWUMEM
14.71
Brakes
Front or Rear Input/outpt t solenoid Open /Short Crcult
Fault Code
Possible cause
Action
Test
Result
Action
OK
Proceed to test 2
Faulty
Proceed to test 3
Replace fuse, proceed to test 5
Faulty
as
Less
than 'across Locate and rectify wiring fault, proceed to test
5
batte ry' voltage
OK
Proceed to test 5
Faulty
Circuit Diagram
Box
^B
Control Module
Rugulator/Rectifier
4.72
Fault Code
Possible cause
C1641; C1643
Binding brake
Ensure ABS ECM connector is secure.
Incorrect Wheel speed sensor air gap
Proceed to pinpoint test 1:=
Loose or incorrectly installed wheel
speed sensor
Result
Test
Action
Action
Proceed to test 2
Proceed to test 3
Faulty
Proceed to test 4
GIMP
14.73
Brakes
_______
OFF; Mot
ON
Fault Code
Possible cause
Action
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
OK
Proceed to test 3
Faulty
Proceed to test 5
Faulty
Circuit Diagram
BS Fuse Box
E--,
Control Module
Rugulator/Rectifier
9
X 4.74
IUM^
Fault Code
Possible cause
Action
C1661; C1662
Pinpos t Tests
Test
Result
Action
OK
Proceed to test 2
Rectify fault, proceed to test 5
pin 24
2 Check the cable for continuity:
- ABS ECM connector pin 24 and Ground
OK
Proceed to test 3
Faulty
3 Check battery voltage: With ignition 'ON', Voltage greater than Proceed to test 4
10 V
less
1OV
pin 24
16V
1 2 3 4
I I
I I
Rugulator/Rectifier
2oa I I
-j
Control Module
A
9
8
Y
2
G -- --
RU 16
WU
IOA
L----^
1 4 5
14
BU
^^.
B 24
P
Instruments
25
Ignition Switch
TRJ,UMBH
21
14.75
Brakes
iT
Jr i
Fault Code
Possible cause
Action
C1671
Test
Result
Action
Proceed to test 2
Faulty
OK
Proceed to test 3
Faulty
Proceed to test 4
to test 5
4 Measure the air gap of the front wheel OK
speed sensor between the sensor and the
pulser ring:
Faulty
14.76
Proceed to test 5
uMt
Possible cause
C1681
Action
Result
Action
Proceed to test 1
Faulty
Proceed to test 2
Proceed to test 4
14.77
Brakes
E. ABS Modulator
1 4.78
UMP
15 Wheels/Tyres
r
iT.1I
Explodedview - Front Wheel ...............................................................
15.2
15.3
Tyres...................................................................................
TyrePressures ......................................................................
TyreWear
eel Inspection ..........................................................
ImportantTyre Information ..........................................................
15.4
15.4
15.4
15.5
FrontWheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal..........................................................................
Installation.........................................................................
1 5.6
15.6
15.7
g
......................................................................
FrontWheel Bearin
Removal... .......................................................................
15.8
Inspection.........................................................................
Installation.........................................................................
15.8
15.8
15.9
RearWheel ..............................................................................
15.9
Removal......' ....................................................................
Installation.........................................................................
15.9
15.10
15.11
15.11
15.11
15.11
15.12
Removal.......................................................................... 15.12
Inspection.......................................... . . . . ..............0............15.13
Installation......................................................................... 15.13
TWUMEH
15.1
Wheels/Tyres
o> _1
95 Nm
15.2
uMr
Wheels/Tyres
15.3
b
'.
yq
Tyres
Tyre Pressures
15.4
u^
Wheels/Tyres
combinations may lead to motorcycle instability. Always
refer to the owner's handbook data section for details of
approved tyres and tyre combinations.
.Operation with excessively worn tyres is hazardous and
will adversely affect traction, stability and handling which
may lead to loss of control or an accident.
When tubeless tyres become punctured, leakage is
often very slow. Always inspect tyres very closely for
punctures.
Check the tyres for cuts, embedded nails or other sharp
objects.
Check the rims for dents or deformation. Operation with
damaged or defective wheels or tyres is dangerous and
loss of control or an accident could result.
Always consult your Triumph dealer for tyre
replacement, or for a safety inspection of the tyres.
2 mm (0.08 in)
UMW
15.5
Front
eel
Removal
Note:
accident.
When wheel balancing is required, such as after tyre
15.6
\4
\V%
Service Manual - Ti er
9
uMP
Wheels/Tyres
6. Remove the wheel and the wheel spacers.
Installation
1.
2.
^ o
III
3.
4.
5.
6.
7.
Tziumm
15.7
Wheels/Tyres
5.
it Wheel Bearing
1.
2.
4.
Note:
The right hand wheel bearing must be
removed first. The pin punch must be
located in the cut-outs provided in the
centre sleeve.
15.8
iu
Wheels/Tyres
Left
bearing
Right
bearing
1.
Bearing insertion
tool
Support tool
3880070-10310
Small
face
to
bearing
3880075-T0310
Large face to wheel
3880070-T0310
face
Small
to
bearing
3880075-T0310
2.
3.
4.
5.
uMP
15.9
Wheels/7yres6.
7.
8.
9.
Installation
1.
8.
9.
ce a
j
1. Swinging arm
2. Caliper car ri er
\\^
0^
0^
COQ
Op
cdga 0)
1 5.1 0
uMf
Wheels/Tyres
Bahgss
Rear W
1.
2.
:f a
<Yv
Sr
Qnspec oon
'
,7
3%"'t, } M t `Y:
13. '
C.
y
V
'. , ,fC ti >:^ ^3'.
'$' .:.>1.t ^:::\.;:.
A^ kA
vl..Y.:bx
is .,i@:.,
..j' .. w is',r
^!,',.`
.Cr:':
,^1.
'
r 'fi
'
o3 .
P`
,t
YM
Y ,..^"::
' .',^i.?^"`,msF;$^..:"ts#^,t.n
,,: .:e
".c:YNS%?S,x"
). ,,i C1
`.Uf:ant;
^'ar .7^
^.
' ...b
2`
a r'"
.i'
it`:
,1
^"
i':^rc,..'
S:
>
^1..
a
M1,.^...
^"
a,.c.. .3s5
\a+.
^.S ^ ';'^it`.:
<ti
.
:^,'
'"SL
.'.,`
;:
'+,.^'
{:.
_
s,, <
R.
'
3 :y)tl'
to
S` ^,rpt
s.
r.:tf^
'
^M }4y Dt}`}tF:i
To prevent wheel damage and to aid bearing removal,
always apply force evenly on , both sides of the bearing
to prevent it from 'tipping' and becoming stuck.
Application of uneven force will lead to difficulty in
removing the bearing and to a damaged wheel.
`
,f
by {t
,
{.,
A^
r
y
^p .S ^`S
^"L^
,
Y n .^
^ Y4'
^
^ ..
l ">:.
(' :}v:.^'a.S'n}i::t^?: w^ :tip
t. :1:::>.h::Sn
:.%'3,.
...:h.i.k^.v`,^'...
.i}" ..:tZ
.. ... ^...f
{.
5.
^.
Y
( ,t Yl u ^^y
"f
^t
Installation
Note:
Refer to the chart below for the correct tool
and tool face when inserting bearings.
Bearings are inserted by means of a drawbolt acting on the insertion tool. A support
tool is located on the opposite side of the
wheel to the insertion tool and as the bolt is
tightened, the bea ring is drawn into the
wheel.
Insert the bea rings with the marked or
shielded side facing outwards and always fit
a new bearing circlip and seals.
^S,yF
^z
^q^
^>' `7.'i^ ..ry. ^^ ^'
Bearing insertion
tool
Left
bearing
Right
bearing
T3880053
Large face
bearing
T3880053
Large face
__________ bearing
Support tool
3880075-T0301
to Large
Wheel
face
to
3880075-T0301
to
Large
wheel
face
to
gaeo
nW.!:!iH
15.11
Wheels/Tyres
1.Tool T3880053
2.
3.
4.
5.
n
Fit a new circlip.
Lubricate and fit. new seals to the rear wheel.
Lubricate the seal's knife-edge with grease to NLGI 2
specification (we recommend Mobil HP222).
Refit the final drive assembly (see page 15-1,2).
Fit the rear wheel (see page 15- 10)
{
C.
....
: ., i;^,,G.rv.,Y
i 4. n :
:., ":F
,y
tiy
9. ^ti.,ai..k . .,^
^^:^.>.
^+ ^ ;
w
. .r.:.
..%: ;:dkt.+:.:.,".,,
..>. i,F..)..,^
i $Y :,.., ::.,..
.3x
u^. s
^r^
Na6:
^.,L.o::R^..} ti, v,.}:s^..,`...4,`.,;.::?.
.,:1Y y`:^
r
:`:> ` :
,e^ ,^+, \:
.,^ :.^;..rrrY:1:. \.S^r.:
a.`'^^rr.
CE"f: :.'k ^?:'<. t,., .4 ; :;'?. C: e
.....:..:.......
:.::..,
^^
^ ti
':
..:Xk
^
L.^..
,^
1.Rear wheel
2. Drive flange
1 5.1 2
IUM^
Wheels/Tyres
4. Remove the cush drive rubbers.
ce
/// /
1. Cush drive
'.
inspection
1.
2.
3.
Installation
1.
2.
3.
TR4Lqj3H
15.13
Wheels/Tyres
15.14
UM
a
iiiitii
II!
16.3
16.4
16.5
Vi w
16.6
16.8
Seat....................................................................................
Removal......................................................................... .
Installation........................................................................ .
16.9
16.9
16.9
Inspectiion........................................................................ .
16.9
16.9
RearPanel .............................................................................
Removal......................................................................... .
Installation....:................................................................... .
16.10
16.10
16.10
SidePanels ............................................................................ .
Removal......................................................................... .
Installation........................................................................ .
16.10
16.14
16.10
Installation........................................................................ .
16.11
16.11
16.11
16.12
16.12
16.12
SideFairings ........................................................................... .
Removal......................................................................... .
Installation........................................................................ .
16.13
16.13
16.13
Windscreen
Removal ......................................................................... .
Installation........................................................................ .
16.14
16.14
16.14
Cockpit. . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal......................................................................... .
Installation....................................................:....................
16.14
16.14
16.15
TWUMEH
16.7
16.1
RearMudguard ...........................:.............................................
16.15
Removal.......................................................................... 16.15
Installation......................................... . ..0.................,......... 16.16
Front Mudguard ........................................................................
Removal..........................................................................
Installation........................................................................
BellyPan ...............................................................................
16.2
16.16
16.16
16.16
16.17
Removal. . . . . .... . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.17
Installation........................................................................
16.17
uMr
ir.iriim I : . kv
v ,]j
6Nm
^^^
TRjumw
IIIIIIII^I
1603
64 Nm
48 Nm
48 Nm
16.4
tUM^
Li:ij i
iii,
o]j
25 Nm
1.5Nm
1.5 Nm
Nm
0
3Nm
3Nm
30 Nm
IDUUMEM
16.5
imiiim=i ;s'
a;i-'
i.iifl
S
All fixings 3 Nm
16.6
IUMp
6Nm
6Nm
!11
6Nm
6 Nm
i Nm
uM
16.7
Liiiiii im I;: e
ifl
Tiii Ii'
Q p4
27 Nm
4 Nm
IW
1:1
c'\
7Nm
7Nm
/9Nm
riJ
\LL7
--'`'
/!
'
9Nm
16.8
4Nm
9 Nm
7 Nm
'1/!
9Nm
4Nm
i1M
'
The seat lock is located on the left hand side of the battery
tray,. in line with the footrest mounting.
1. Insert the ignition key into the seat lock and turn it
anti-clockwise while pressing down on the rear of the
seat. This will release the seat from its lock and allow
it to be slid rearwards for complete removal from the
motorcycle.
1.
2.
1 i .
1
skY kfk.]iij
Installation
1.
2.
3.
Note:
An audible 'click'
Numm
16.9
E*i1tL
iitk
I T'AL.ri
Rear P
Removal
Removal
Note:
1.
2.
3.
4.
2.
3.
4.
1.Grab handles
2. Fixings
5. To release the rear panel assembly, remove the
fixings shown in the illustration below.
1.Side panel
2. Fixings
5. Remove the side panel.
Installation
1.
Note:
lighten
6.
7.
Installation
1.
Note:
Tighten the fixings to 3 Nm.
Reconnect the battery, positive (red) lead
first.
1 6.1 0
UMP
4.
FLIgQ lPaIs
Removal
Rote:
Follow the same procedure for both left and
right hand sides.
1.
2.
3.
4.
5.
Installation
1.
2.
3.
Note:
To ensure correct fitment of the fairing infill
panel, the following installation sequence
must be adhered to:
Twumem
16.11
L tjiit: ]iis I
iii.ii
F d I f ilkPanels
Removal
Note:
Follow the same procedure for both left and
right hand sides.
1.
n om' r
1. Infill panel
\\\
2. Side fairing
3. Front fixing
1. Infill panel
2. Bayonets
3. Grommets
6. Remove the panel.
Installation
1.
Note:
1 6.1 2
uM
N tiiiri-iii'
Installation
Sidi Fairings
1.
Removal
Note:
1.
2.
3.
4.
AL']LI1
2.
3.
4.
5.
6.
7
5.
6.
7.
IP
..
:V
16.13
Litr
imI;]=.'&x.ii
1?{
}I r
Removal
Note:
The cockpit is removed as an assembly. It is
not necessary to remove the side fairings,
instruments, windscreen or headlight unit.
1.
2.
3.
4.
1. Windscreen
2. Fixings
1.
2.
Installation
Installation is the reverse of removal noting the following.
Note:
Tighten the fixings to 1.5 Nm.
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
uMf
instanation
1.
Rear Mudguard
Removal
1.
2.
3.
4.
5.
oo
1. Cockpit
2. Cockpit locating stud
3. Headlight grommet
2.
3.
4.
5.
cedm
1. Lower rear
6.
mudguard fixings
TRJUMEM
16.15
Removal
1.
2.
3.
E!
1. Lower rear mudguard fixings
8.
cecy
1. Front mudguard
2. Fixings
3. Brake hose retaining clips
Installation
Installation is the reverse of removal noting the following:
Note:
Installation
Installation is the reverse of removal noting the following:
Note:
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 6
IUM^
' oIyFan
Installation
Installation is the reverse of removal noting the following:
Removal
1.
2.
Note:
to 3 Nm.
1
rahc
1. Belly pan
2. Fixings (right hand shown)
INJUMEM
16.17
___
16.18
UMW
17 Electrical
ExplodedView - Instruments ...............................................................
17.3
17.4
View
- Headlight ................................................................
Exploded
ExplodedView - Rear Light and Indicators ...................................................
17.5
Battery.... ..............................................................................
BatteryRemoval .....................................................................
BatteryRefit ........................................................................
17.7
17.7
17.7
17.6
17.9
17.9
17.9
RelayPack ..............................................................................
Identificationof Relays ..............................................................
17.10
17.10
HeadlightAdjustment .....................................................................
HeadlightBulb Replacement .....:...................................................
FrontPosition Light .................................................................
17.10
17.11
17.12
17.12
17.12
17.13
RearLight ...............................................................................
Removal ..........................................................................
Installation.........................................................................
17.13
17.13
17.14
17.14
17.14
Alternator ...............................................................................
17.15
Removal......... ..................................................................
Assembly..........................................................................
17.15
17.15
AlternatorRectifier .......................................................................
17.16
UMW
17.1
StarterMotor ............................................................................
17.16
Removal..........................................................................
Inspection.........................................................................
installation ........................................................................
17.16
17.16
17.16
InstrumentPack .........................................................................
17.17
Removal...........................................................................
Installation........................................................................
17.17
17.17
17.18
17.18
17.18
17.20
17.20
17.20
17.22
Keyto
Keyto
17.24
17.24
17.26
17.2
17.22
17.22
17.24
17.26
17.26
UMt
Electrical
Twumpj4
17.3
Electrical
i
10 Nm
l^J
17.4
UMp
1r ! 1Yi VAT:
^^Lllll
ro.
3Nm
TR!!M^p
17.5
Electrical
rr
(C
^rrrrrrr^
, ,1
4Nm
1!
3Nm
1.5 Nm
0
'^J
3Nm
17.6
uM
L
a LUy
BatteryRemoval.
1.Battery
2. Negative (-) terminal
Battery Refit
71tiumpli
17.7
Electrical
;U!]JjJ
17.8
UMM
Electrical
Table of Battery Charging Tomes
State of charge
Voltage
Action
100%
12.8V - 13.OV
None required
75% -100%
12.5V - 12.8V
50% - 75%
12.OV - 12.5V
None. Check at 6
months from date of
manufacture
May need slight charge.
If no charge given,
check in 3 - 4 months
Needs charge
25% - 50% V
11.5V - 12.OV
Needs charge
at least 13 hours
0% - 25%
11.5V or less
20 hours
3 - 6 hours
5 -11 hours
Fuse Identification
Position
Rating
(Amps)
15
10
10
10
Cooling fan
15
20
Circuit Protected
1. Fuse box
2. Fuse box cover
3. Spare fuses
Note:
T;tL!!j3FI
Service Manual - Ti er
17.4
1. Indicator Relay
17.1 0
Electrical
eitHeadlight
Bulb Replaceme nt
Note:
It is not necessary to remove the headlights
when bulb replacement becomes necessary.
Right Hand Side
csdg
1. Headlight unit
2. Bulb : and bulb retainer
3. Multi-plug
1.
2.
3.
4.
5.
6.
TWU
.M
1711
Electrical
.-
Iu I
c ed i
1. Headlight unit
2. Bulb
3. Multi-plug
4. Wire retainer
1.
2.
3.
4.
5.
6.
Bulb Replacement
` .,. "J^v::n,,,\
^:4,
?.;,3.. .inr^.^,;. ^+y;
,;,,'}': ,.^^,,,:;
.r^'.n^'3'a^. tf^Yr'y^c : v :i^.:'
b ^ :c..
'u ' is .,. >Sr<z
\ ;<.
}
Acauti^ri
.}\.tr :.
F Sn ": $.i:if%.
e'`.^.J:. a.H, .;,t?A.. .;,.F.ro. . . ;yl:. r. :,.;. : : +.:i}. "^.:.`}'.:' F.;' ` .;::'^5,.:^"r. `:
When reconnecting the battery, connect the positive
(red) lead first.
Y :;
;'\.f....f.
2k5
' ,^
..?:.
..vt ..},
^':ty;.f,;:\
...JC.'ri
\,,,<r : 3
. >..:,^:. "lss#},:"
`^^sx
';.Y)Ya :., :`.^C
i. ;;r ;:}>:h:,..4 \.
j<`^1..
\.
u'J;:"^"ii:{'..:.:,..
:}.
:..t1
:';^<..
.1^3p
;::
:` ^
:::v!:t!:f#'.y ^,
;Y;' :.:s"'<tf<S:
:
'St.C.'.R'ifi
C`
'Xi^ } ^(
"::i'
n,^"t':.:.): t :..
,y,^ 'e\` \fiS^
^^,,;SY
i^,'..v..y..
:.n:..+.Z..>\t>.
?X'3 n} .
} }'S^`
;J; ,,t
..^..:::; :+o.}^,...
..
: '!.,
::}:
,rf;t,
^... ::. Y^i;<r. x\
:....^^4
^':;:: ^;; ^+ {{:'s
`^S
w...f.:.
'+.fi}7
^
: ,^''t3;,:\^:?nu<.
,
,
.. .
..;
.,..iif^,i..
.
,
:.,.r;
ti. ' :. { .}Y
i3 xA!.,..
.
i
,;:^
.'\;:kY,k.:
n.M.:vt{. .......2f
,3.^''.?Si'Ck;.61SO'.:
:
: . .............
:: ;>,,3}^;t}^c:a;r..
+'ct.:::},^;"'s::::rtt.:::
^g'ifi^.^{1h
13,....r+..,.n...:
.....,, ... ?^,.ii'? ..r
.......:.....,?
`Lt.,..,.. i., 3.. ;?., .4.;.
,...,..t.....c
1 7.1 2
uM!'
1.
2.
3.
4.
1. Headlight assembly
2. Electrical connector
Installation
1.
2.
1. Indicator Relay
2. Relay mounting blade
CE
1.Headlight assembly
2. Fixings (left hand shown)
TWUMEH
17.13
Electrical
6.
Rear Lighit
Note:
The rear light is a sealed for life LED unit
and must be replaced in the event of a
failure.
Removal
1.
Remove the seat (see page 16-9).
2. Disconnect the battery, negative (black) lead first.
3. Remove the rear panel (see page 16-10).
4. Release the two fixings securing the seat lock
mechanism to the subframe and detach the seat lock
mechanism.
2. Fixings
7. Release the light from the rear mudguard and
remove the assembly upwards.
Installation
1.
Note:
Tighten the rear light fixings to 4 Nm.
Tighten the rear panel bracket fixings to
1.Seat lock mechanism
2. Fixings
5. Disconnect the wiring harness.
17.14
9Nm.
Connect the battery positive
UMP
r iri
Number Rate Light Bulb
2
Bulb Replacement
1.
2.
3.
<'
4 `L < <
^` ^< <
I. Indicator lens
2 Lens screw
The lens on each indicator light is held in place by a
securing screw located in the body of the light.
1.
2.
(4J
'
r
.
//
`
cedm
17.15
Electrical
o
cedn
ccyo
Note:
Tighten
the licencep
plate lamp
g
p fixing
9 to
3 Nm.
first
,1
1. Stator
2. Stator bolts
3. Cable bracket
4. Cable bracket bolt
17.16
^1
Assembly
1.
2.
3.
1. Rotor
2. Tool T3880375
9. With the rotor bolt removed, insert tool T3880203
to the centre of the alternator.
10. Tighten tool T3880203, while preventing the
crankshaft from turning with tool T3880375, to
release the taper seating of the rotor from the
crankshaft.
1.Rotor
2. Tool T3880375
1. Rotor
2. Tool T3880375
3. Tool T3880203
TRJUMM
17.17
Electrical
Starter M t r.
Inspection
Removal
1.
2.
1.
2.
3.
4.
5.
6.
7.
Installation
1.
2.
I/I
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t
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''"''
/1
1. Starter motor
2 . Bolts
8. Ease the starter motor from'the right hand engine
cover while gently moving the camshaft oil feed pipe
out of the way.
1 7.1 8
uM H
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I tEr
Pack
Installation
1.
2.
Removal
1. Remove the seat (see page 16-9),
2. Disconnect the battery, negative (black) lead first.
5. Reconnect the
Alternator Rectifier
Note:
The alternator rectifier is located on the left
hand side of the frame, above the gearbox.
The rectifier does not contain any
serviceable parts and must be replaced if
faulty.
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.
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17.19
Electrical
Circuit Dig r
Lighting
Key to wiring colours
Item Description
Fuse Box (Fuses 1 and 4)
Key
B
Wiring Colour
Black
Ignition Switch
Blue
Brown
Starter Relay
Green
Tail Light
Slate/Grey
Orange
Pink
Red
Pass Switch
Purple
10
Instrument Assembly
White
11
Yellow
12
LG
Light Green
13
LU
Light Blue
14
Headlight Assembly
17.20
lUM
Electrical.
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4
4
6
8
5
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17.21
Electrical
Starft & 1dharq!.nq Circu!t Diagram
Key to circuit diagram
Key
Item Description
Battery
Key
B
Wiring Colour
1
2
Starter Solenoid
Blue
Starter Motor
Brown
Regulator/rectifier
Green
Starter Relay
Slate / Grey
Ignition Switch
Orange
Pink
Fuse Box
Cooling Fan Relay
Red
Purple
10
White
11
Instrument Assembly
Yellow
12
LG
Light Green
13
Starter Switch
LU
Light Blue
14
Alarm
15
17.22
Black
UMW
Electrical
1
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17.23
Mectrical
Ats^^6ia y and Accessary
(ey to
Key
1
2
3
4
5 .
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
17.24
Corcao
circuit diagram
Item Description
Fuse Box (Fuses 3 & 4)
Accesso ry Heated Handlebar Grips
Accesso ry Satellite Navigation system
Accesso ry Socket
Ignition Switch
Indicator Relay
Front Brake Light Switch
Horn Switch
Direction Indicator Switch
Horn
Rear brake light switch
Key
Wiring Colour
B
U
N
G
S
0
K
R
P
Black
Blue
Brown
Green
Slate / Grey
Orange
Pink
Red
Purple
W
Y
LG
White
Yellow
Light Green
LU
Light Blue
Brake light
Instrument Assembly
Diagnostic connector
Direction indicator (Instruments)
Alarm LED
Front right direction Indicator
Front left direction Indicator
Alarm unit
Rear right direction indicator
Rear left direction indicator
IUMr
Electrical
TL!:
17.25
Electrical
Main Wiring Circuit Diagram - Models with ABS Brakes
Key to circuit diagram
Key
Item Description
Instrument Assembly
Starter Button
Lambda Sensor
Fuel Injector 1
Fuel Injector 2
10
Fuel Injector 3
11
12
13
14
15
Throttle Potentiometer
16
17
MAP Sensor
18
19
20
Neutral Switch
21
22
Cooling Fan
23
24
Purge Valve
25
Ignition Coil 1
26
Ignition Coil 2
27
Ignition Coil 3
28
29
Engine Earth
30
Crankshaft Sensor
31
32
Diagnostic Connector
33
34
RH Rear Indicator
35
Rear Light
36
37
LH Rear Indicator
38
39
Starter Motor
40
Starter Solenoid
41
Battery
42
Starter Relay
17.28
43
Rectifier I Regulator
44
Alternator
45
Fuse Box
46
Ignition Switch
47
Accessory Socket
48
49
50
Fuel Pump
51
52
53
Horn Button
54
55
56
57
LH Front Indicator
58
Position Light
59
Headlight
60
Horn
61
RH Front Indicator
62
63
ABS Modulator
64
65
66
Wiring Colour
Black
Blue
Brown
Green
Slate / Grey
Orange
Pink
Red
Purple
White
Yellow
LG
Light Green
LU
Light Blue
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101
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Electrical
rakes
Item Description
Instrument Assembly
. Starter Button
Lambda Sensor
Fuel Injector 1
Fuel Injector 2
10
Fuel Injector 3
11
12
13
14
15
Throttle Potentiometer
16
17
MAP Sensor
18
19
20
Neutral Switch
43
Rectifier /Regulator
44
Alternator
45
Fuse Box
46
Ignition Switch
47
Accessory Socket
48
49
50
Fuel Pump
51
52
53
Horn Button
54
55
56
57
LH Front Indicator
58
Position Light
59
Headlight
60
Horn
61
RH Front Indicator
62
21
22
Cooling Fan
Key
Wiring Colour
23
Black
24
Purge Valve
Blue
25
Ignition Coil 1
Brown
26
Ignition Coil 2
Green
27
Ignition Coil 3
Slate / Grey
28
Orange
29
Engine Earth
Pink
30
Crankshaft Sensor
Red
31
Purple
32
Diagnostic Connector
White
33
Yellow
34
RH Rear Indicator
LG
Light Green
35
Rear Light
LU
Light Blue
36
37
LH Rear Indicator
38
39
Starter Motor
40
Starter Solenoid
41
Battery
42
Starter Relay
17.26
lump