Triumph Tiger User manual

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Tiger
Motorcycle Service Manual
Part Number 3850775 issue 3, 08.99
This document is protected by copyright and may not, in whole or part be stored in a retrieval system, or
transmitted
in any form or by any means, copied, photocopied, translated or reduced to any machine-
readable form without prior consent in writing from Triumph Motorcycles Limited.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior
notice and without incurring an obligation to make such changes to products manufactured previously. See
your authorised Triumph Dealerforthe latest information on product improvements incorporated afterthis
publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations
in this publication are intendedfor reference use only and may notdepict actual
model component parts.
All rights reserved, © 1999 Triumph Motorcycles Limited

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CONTENTS
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-
Introduction
I General Information
t -
Routine Maintenance
Cylinder Head
Clutch
Balancer
Crankshafi/Rods/Pistons
Transmission
Lubrication
Fuel System/Engine Management
Cooling System
Rear Suspension/Final Drive
i:~)
Front Suspension/Steering
Brakes
Wheels/Tyres
Frame/Bodywork
Electrical System
iii

INTRODUCTION
INTRODUCTION
This manual is designed primarily for use by trained
technicians
in a properly equipped workshop.
However, it contains enough detail and basic
information to make it useful to the owner who desires
to perform his own basic maintenance and repair work.
The work can only be carried out If the owner has the
necessary hand and special service tools to complete
the job.
A basic
knowledge of mechanics, including the proper
use of tools and workshop procedures is necessary in
order to carry out maintenance and repair work.
satisfactorily. Whenever the· owner has insufficient
experience
or doubts his ability to do the work, all
adjustments, maintenance, and repair work must be
undertaken by an authorised Triumph Dealer.
In order to perform the work efficiently and to avoid
costly mistakes, read the text and thoroughly
familiarise yourself with procedures before starting
work.
All work should be performed with great care and in a
clean working area with adequate lighting.
Always use the correct special service tools or
equipment specified. Under no circumstances use.
makeshift tools or equipment since the use of
substitutes
may adversely affect safe operation.
Where accurate measurements are required, they can
only be made using calibrated, precision instruments.
For the duration ofthe warranty period, all repairs and
scheduled maintenance must be performed by an
authorised Triumph Dealer.
To maximise the life of your Motorcycle:
• Accurately follow
the maintenance requirements of
the periodic maintenance chart in the service
manual.
.• Do not allow problems to develop. Investigate
unusual noises and changes in the riding
cha.racteristics of the motorcycle. Rectify all
problems as soon as possible (immediately ifsafety
related).
• Use only genuine Triumph parts as listed in the
parts catalogue/parts microfiche.
• Follow the procedures in this manual carefully and
completely. Do not take short cuts.
• Keep complete records of all maintenance and
repairs with dates and any new parts installed.
• Use only approved lubricants, as specified in the .
owner's
handbook, in the maintenance of the
motorcycle.
iv
How to use this manual
To assist in the use of this manual, the section title is
given at the top.
Each major section starts with a contents page, listing
the information contained in the section.
The individual steps comprising repair operations are
to be followed in the sequence in which they appear.
Adjustment and repair operations include reference to
service tool numbers and the associated Illustration
depicts the tool.
Where usage is not obvious the tool is shown in use.
Adjustment and repair operations also include
reference to wear limits, relevant data, torque figures,
specialist information and useful assembly details.
Warning, Caution and Note
Particularly important information is presented in the
following form:
A WARNING: This warning symbol
~ identifies special instructions or
procedures which, if notcorrectly followed, could
result in personal injury,
or loss of life.
-1'- CAUTION: Thiscaution symbolidentifies
~ .special instructions or procedures
which,
if not strictly observed, could result in
damage
to or destruction of equipment.
NOTE:
• This nqte symbol indicates points of particular
interest
for more efficient and convenient
operation.
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TAMPERING WITH NOISE CONTROL SYSTEM
PROHIBITED
Owners are warned that the law may prohibit:
(a) The removal or rendering inoperative by any
person other than for purposes of maintenance,
repair or replacement, of any device or elefTlent
of design incorporated into any new vehicle for
the
purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while It is in
use; and
, (b) the use of the vehicle after such device or
element of design has been removed or rendered
inoperative by any person.
REFERENCES
References
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.
Dimensions
The dimensions quoted are to design engineering
specification with service limits where applicable.
During the period of running-in from new, certain
adjustments may vary from the specification figures .
given in this manual. These will be reset by the dealer
at the 500 mile/800 km service, and thereafter should
be maintained at the figures specified in this manual.
REPAIRS AND REPLACEMENTS
Before removal and disassembly, thoroughly clean the
motorcycle. Any dirt entering the engine or other parts
will work as an abrasive and shorten the life of the
motorcycle. Particular attention should be paid when
installing a new part, that any dust or metal filings are
cleared from the immediate area.
v
INTRODUCTION
Force
Common sense should dictate how much force is
necessary in assembly and disassembly. Ifa part
seems especially difficult to remove or install, stop and
examine what may be causing the problem. Never
lever a component as this will cause damage both to
the component itself and to the surface being levered
against.
Whenever tapping tO,aid removal of an item is
necessary, tap lightly using a hide or plastic faced
mallet.
Edges
Watch for sharp edges, especially during engine
disassembly and assembly. Protect the hands with
industrial quality gloves when lifting the engine or
turning it over.
When replacement parts are required, it is essential
that only genuine
Triumph parts are used.
Safety features and corrosion prevention treatments
embodied in the motorcycle may be impaired if other
than genuine Triumph parts are fitted. In certain
territories, legislation
prohibits the fitting of parts not to
the manufacturer's specification.
Tightening procedure
Generally, when installing a part with several bOlts,
nuts or screws, they should all be started in their holes
and tightened to a snug fit, evenly and in a cross
pattern. This is to avoid distortion of the part and/or
causing gas or oil leakage. Conversely, bolts, nuts, or
screws, should all be loosened (in sequence if
specified)
by about a quarter of aturn and then
removed.
Where there is a tightening sequence specified in this
Service Manual, the bolts, nuts, or screws must be
tightened in the order and by the method indicated.
Torque wrench setting figures given in this Manual
must be observed. The torque tools used must be of
accurate calibration.
Locking devices, where specified, must be fitted. If the
efficiency of a
locking device is impaired during
removal it must be renewed. This applies particularly
to micro-encapsulated fixings which must always be
replaced if disturbed. Where necessary, the text in this
manual will indicate where such afixing is used.

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GENERAL INFORMATION
CONTENTS Page
Ignition System Precautions ............................................... 1.3
Dangerous Substances ................................................... 1.3
Fluoroelastomers . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . 1.3
Engine Oils . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 1
.. 3
Health Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . 1.3
Environmental Protection . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . 1.4
Safety Instructions . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 1.5
Jacking and lifting ................................................... 1.5
Precautions against damage .......................................... 1.5
Engine coolant
.. " ........................ ;. . . . . . . . .. . . . . . . . . . . . . . . . . . 1.5
Cleaning components
................................................ 1.5
Lubrication. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 1.6
Joints and
jOint faces. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . 1.6
Gaskets, a-rings ..................................................... 1.6
Liquid gasket, non-permanent locking
agent. . . . . . . . . .. . . . . . . . . . . . . . . . . . . 1.6
Screw threads. ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . . 1.6
Locking devices ..................................................... 1.7
Fitting a split pin .......... : ................................. ". . . . . . . . . 1.7
Circlips, retaining rings ............................................... 1.7
Self locking nuts . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . 1.7
Encapsulated bolt ............................................... ".... 1.7
Oil and grease seals ................................................. 1.7
Press .............................................................. 1.7
Ball bearing . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 1.7
Fuel Handling Precautions
................................................ .
Chassis Repairs
......................................................... .
1.8
1.8
Electrical Precautions .... . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . 1.9
Battery disconnecting
................................................ 1.9
Disciplines . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 1.10
Electrical wires ...................... . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . 1.10
Inspection .......................................................... 1.10
Replacement parts ... ". . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 1.10
Service data ............................. " ................. ".......... 1.10
Specification ...................................................... :. 1.10
Service Tools ............................................................ 1.11
Specifications . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 1.13
1.1

CONTENTS cont'd Page (
Torque Wrench Settings .................................................. . 1.17
Cylinder head Area ................................................. . 1.17
Clutch ............................................................. . 1.17
Balancer, crankshaft and crankcase ................................... . 1.17
Engine covers ...................................................... . 1.17
Transmission ..................................... ; ................. . 1.18
Lubrication system .................................................. . 1.18
Final drive ....................................................... .' ..
U8
Cooling system ..................................................... . 1.18
Fuel system and airbox .............................................. . 1.19
Wheels ............................................................ . 1.19
Rear suspension ................................................... . 1.19
Front suspension ................................................... . 1.19
Brakes' ............................................................ . 1.20
Footrests, control plates and engine mountings ......................... . 1.20
Electrical ............ , .............................................. . 1.20
Bodywork .......................................................... .
1.21
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1.2
..... _ ........_ ..•.....•. ~~~~~~~~~~~~- . __ ._.

IGNITION SYSTEM SAFETY PRECAUTIONS
A WARNING: The ignition system
. produces extremely high voltages. Do
not touch any part of the ignition system or any
cables while the engine is running.
An electric shock caused by contact with the
ignitionsystem maylead
to illness, injury or death.
A WARNING:
,Wearers of surgically
implanted heart pacemaker devices
shouldnot
be in closeproximity to ignitioncircuits
and or diagnostic equipment.
The ignition system and anydiagnosticequipment
may interrupt the normal operation of such
devices causing illness
or death.
DANGEROUS SUBSTANCES
A WARNING: Many liquids and other
. substances used in motor vehicles are
poisonousand should under no circumstances be
consumed and should, as far
as possible, be kept
from contact with the skin. These substances
among others include acid, anti-freeze, asbestos,
brake fluid, fuel, lubricants, and various
adhesives. Always pay close attention
to the
instructions printed on labels and obey the
instructions contained within. These instructions
are included
for your safety and well being.
NEVER DISREGARD THESE INSTRUCTIONS!
Fluoroelastomers
A WARNING: fluoroelastomer material is
used in the manufacture
of various seals
in Triumph motorcycles.
In fire conditions. involving temperatures greater
than 315°C this material will decompose and can
then
be potentially hazardous. Highly toxic and
corrosive decomposition products, including
hydrogen fluoride, carbonyl fluoride, fluorinated
olefins and carbon monoxide can
be generated
and will be present in fumes from fires.
In thepresence of anywater orhumidityhydrogen
fluoride may dissolve to form extremely corrosive
liquid hydrofluoric acid.
If such conditions exist, do not touch the material
and avoid all skin contact. Skin contactwith liquid
or decomposition residues can cause painful and
penetrating burns leading to permanent,
irreversible skin and tissue damage.
1.3
GENERAL INFORMATION 1
ENGINE OILS
A WARNING: The oil may be
hot to the
touch. Contactwith hot oil maycausethe
skin
to be scalded or burned.
A WARNING: Prolonged
or repeated
contact with engine oil can lead to skin
dryness, irritation and dermatitis.
In addition used
engine oil contains potentially harmful
contaminants which can cause cancer. Wear
suitable clothing and avoid skin contact.
Health Protection Precautions
•
•
•
•
•
•
•
•
•
•
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.
Do not put oily rags in pockets.
Overalls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
First aid treatment should be obtained
immediately for open cuts and wounds. Always
be aware of who your nearest first aider is and
where the medical facilities are kept.
Use barrier creams, applying before each work
period to protect the skin from the effects of oil
and grease and to aid removal of the same after
completing work.
Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.
Do not use petrol, kerosene, diesel fuel, gas 011,
thinners or solvents for cleaning skin.
If skin disorders develop, obtain medical advice
without delay.
Where practicable, de-grease components prior
to handling.
A WARNING:
Any risk of eye injury mustbe
avoided. Always wear eye protection
when using a hammer, air line, cleaning agent or
where there is ANY risk
of flying debris or
chemical splashing

1 GENERAL INFORMATION
ENVIRONMENTAL PROTECTION PRECAUTIONS
'" CAUTION: Do not pour oil on the ground,
~ down sewers or drains, or into water
courses.
To prevent pollution of water courses
etc., dispose
of used oil sensibly. If in doubt
contact
your local authority.
Burning
of used engine oil in small space heaters or
boilers can be recommended only for units of
approved design. If in doubt check with the appropriate
local authority and/or manufacturer of the
approved
appliance.
Dispose of
used oil and used filters through authorised
waste disposal contractors, to licensed waste disposal
sites, or
to the waste oil reclamation trade. If in doubt,
contact the Local Authority for advice on disposal
facilities.
BRAKES
A WARNING: Brake fluid is hygroscopic
which means
it will absorbmoisturefrom
the air.
Any absorbed moisturewill greatlyreduce
the boiling point of the brake fluid causing a
reduction in braking efficiency.
Replace brake fluid in line with the routine
maintenance schedule. A dangerous riding
condition could result
if this important
maintenance item is neglected!
Do
not spill brake fluid onto any area of the
bodywork as this will damage any painted or
plastic surface.
Always use new brake fluid from a sealed
-container and never use fluid from
an unsealed
container or from one which has been previously
opened.
Do
not mix differentbrands of fluid. Check for fluid
leakage around brake fittings, seals and joints.
Check regularly for brake hose damage.
FAILURE TO OBSERVE ANY OF THE ABOVE
WARNINGS
MAY REDUCE BRAKING EFFICIENCY
LEADING
TO AN ACCIDENT.
1.4
A WARNING:
If there has been an
appreciabledropin the level of thefluid in
either brake fluid
reservoir~ consult your
authorised Triumph Dealer for advice before
riding.
If the brake lever or pedal feels soft when it is
applied, or if the lever/pedal travel becomes
excessive,there maybeairin the'brake lines orthe
brake may be defective.
It is dangerous to operate the motorcycle under
such conditions and remedial action must
be
taken by your authorised Triumph Dealer before
riding the motorcycle.
Failure to takeremedial action may reduce braking
efficiency leading
to an accident.
A WARNING: Use only
D.O.T. 4
specification brake fluid as listed in the
general information section of this manual. The
use
of brakefluids otherthan those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency
of the braking system
leading
to an accident.
Failure
to change the brake fluid at the interval
specified in the routine maintenance schedule
may reduce braking efficiency resulting
i,n an
accident.
A WARNING: Never use mineral based
grease in any part
of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.
Damage caused by contact with mineral based
grease may reduce braking efficiency resulting in
an accident.
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SAFETY INSTRUCTIONS
Jacking and lifting
A WARNING: Always ensure
th~t anylifting
apparatus has adequate load and safety
capacity for the weight
to be lifted. Ensure the
motorcycle is well supported to prevent any
possibility
of the machine falling prior to, and
during lifting
or jacking.
Never rely on a single means
of support when
workingwiththemotorcycle. Use additional safety
supports.
Do not leave tools, lifting equipment,
spilt oil, etc.
in a place where they could become a hazard
to
health. Always work inaclean, tidy area and putall
tools away when the work is finished.
Precautions against damage
Avoid spilling brake fluid or battery acid on any part of
the bodywork. Wash spillages off with water
immediately.
Disconnect the battery earth lead (black) before
starting
work, see ELECTRICAL PRECAUTIONS.
Always use the recommended service tool where
specified.
Protect
exposed bearing and sealing surfaces, and
screw threads from damage.
Engine Coolant
A
WARNING: Coolant mixture which is
blended with anti-freeze and corrosion
inhibitors contains toxic chemicals which are
harmful
to the human body. Never swallow
anti-freeze, corrosion inhibitors or any of the
motorcycle coolant.
A WARNING:
Do not remove the radiator
cap when the engine
is hot. When the
engine ishot, the coolant insidethe radiator is hot
and also under pressure. Contact with the
pressurised coolant will cause scalds and skin
damage.
1.5
GeNERAL INFORMATION 1
/\ CAUTION: The coolant anti-freeze
~ contains a corrosion' inhibitor which
helpspreventdamage
to the metal surfaces inside
the cooling system. Without
this inhibitor, the
coolantwould 'attack' the metals and the resulting
.corrosion would cause blockages in the cooling
system leading to engine overheating and
damage. Always use the correct anti-freeze as
specified in the Owner's Handbook. Never use a
methanol based anti-freeze as
this does not
contain the required corrosion inhibition
properties.
/\ CAUTION: Distilled water must be used
. ~ with the anti-freeze (see specification for
anti-freeze) in the cooling system.
If hard water is used in the system, it causes scale
accumulation in the water passages, and
considerably reduces the efficiency
of thecooling
system. Reduced cooling system efficiency may
lead to the engine overheating and suffering
severe damage
..
'Cleaning components
A high flash-point solvent
is recommended to reduce
fire
hazard.
Always follow container directions regarding the use of
any solvent.
Always
use the recommended cleaning agent or
equivalent.
Do not use degreaslng equipment for components
containing
items which could be damaged by the use
of this process. Whenever possible, clean components
and the area surrounding them before removal.
Always observe scrupulous cleanliness
when cleaning
dismantled components.

1 GENERAL INFORMATION
Lubrication
Engine wear is generally at its maximum while the
engine
is warming up and before all the rubbing
surfaces have
an adequate lubricative film. During
assembly, oil or grease (whichever
is more suitable)
should be applied to any rubbing surface which has
lost its lubricative film. Old grease and dirty
oil. should
be cleaned off. This is because used lubricants will
have lost some lubricative qualities and may contain
abrasive foreign particles:
Use recommended lubricants. Some oils and greases
in particular should be used only
in certain applications
and may be harmful if used
in an application for which
they are not intended. This manual makes reference to
molybdenum disulphide grease
in the assembly of
certain engine and chassis parts. Always check
manufacturer recommendations before using such
special lubricants.
Joints and joint faces
Assemble joints dry unless otherwise specified in this
Manual.
If gaskets and/or jointing compound is recommended
for use; remove all traces of old jointing material prior
to reassembly. Do not use a tool which will damage the
joint faces and smooth out any scratches or burrs
on
the joint faces using an oil stone. Do not allow dirt or
jointing material to enter any tapped holes.
Gaskets, O-rings
Do not re-use a gasket or O-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.
1.6
Liquid gasket, non-permanent locking agent
Follow manufacturer's directions for cleaning and
preparing surfaces where these compounds will be
used. Apply sparingly as excessive amounts of sealer
may block engine oil passages and cause serious
damage.
Prior to reassembly, blow through any pipes, channels
or crevices with compressed air.
A 'WARNING:
To preventinjury, always use
eye, face and ear protection
wh~n using
compres"sed
air. Always wear protective gloves if
thecompressed air is to be directed in proximityto
the skin.
Screw threads
Metric threads to ISO standard are used.
Damaged nuts, bolts and screws must always be
discarded.
Castellated nuts must not
be slackened back to accept
a split-pin, except
In those recommended cases when
this forms part of an adjustment.
Do not allow oil
or grease to enter blind threaded
holes. The hydraulic action
on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can affect
the torque reading.
Unless specified, threaded fixings must always be
fitted dry (no lubrication).
A
WARNING: Never lubricate a thread
unless instructed to do so.
When a thread
of a fixing is lubricated, the thread
friction is reduced. When the fixing is tightened,
reduced friction will cause overtightening and
possible fixing failure.
A fixing which fails in service could cause
component detachment leading to loss
of control
and
an accident.
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Locking 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.
Always fit new roll pins of an interference fit
in the
hole.
Circlips, retaining rings
Replace any circlips and retaining rings that are
removed. Removal weakens and deforms circlips
causing looseness in the circiip groove. When
installing circlips and retaining rings, take care to
compress or expand them only enough to install them.
Always use the correct replacement circlip as
recommended
in the Triumph parts catalogue.
Self locking nuts
Self-locking nuts can be re-used, providing resistance
can be felt when the locking portion passes over the
thread of the bolt or stud.
DO NOT re-use self-locking nuts in critical locations,
e.g. suspension components. Always use the correct
replacement self-locking nut.
Encapsulated bolt
An encapsulated bolt can be identified by a coloured
section of thread which is treated with a locking agent.
Unless a specified repair procedure states otherwise,
encapsulated bolts cannot be re-used and MUST be
replaced if disturbed or removed.
A WARNING: Failure to replace
an
encapsulated bolt could lead to a
dangerous riding condition. Always replace
encapsulated bolts.
1.7
GENERAL INFORMATION 1
Oil and grease seals
Replace any oil or grease seals that are removed.
Removal will cause damage to an oil seal which, if
re-used, would cause
an oil leak.
Ensure the surface on which the new seal is to run is
free of burrs or scratches. Renew the component if the
original sealing surface cannot be completely restored.
Protect the seal from any surface which could cause
damage over which it has to pass when being fitted.
Use a protective sleeve or tape to cover the relevant
surface and avoid touching the sealing lip.
Lubricate the sealing lips with a recommended
lubricant. This will help to prevent damage
in initial
use.
On dual lipped seals, smear the area between the
lips with grease.
When pressing
in a seal which has manufacturer's
marks, press in with the marks facing out.
Seals must be pressed into place using a suitable
driver. Use of improper tools will damage the seal.
Press
A part installed using a press or driver, such as a
wheel bearing, should first be coated with oil on its
outer or inner circumference so that it will locate
smoothly.
Ball bearing
When installing a ball bearing, the bearing race which
is an interference fit should be pushed by a suitable
driver. This prevents severe stress or damage to the
load carrying components. Press a ball bearing until it
touches the shoulder in the bore or on the shaft.
Press or drift seals to the depth of its housing, with the
sealing lip facing the lubricant to be retained if the
housing
is shouldered, or flush with the face of the
housing where no shoulder
is provided.

1 GENERAL INFORMATION
FUEL HANDLING PRECAUTIONS
General
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is issued
for basic guidance only and, if in doubt, appropriate
enquiries should
be made of your local Fire Officer.
Petrol -Gasoline
When petrol (gasoline) evaporates it produces 150
times its own volume in vapour which when diluted
with air becomes a readily ignitable mixture. The
vapour is heavier than air and will always fall to the
lowest level. It can readily
be distributed throughout a
workshop by air currents, consequently, even a small
spillage of petrol (gasoline) is potentially very
dangerous.
A WARNING: Petrol (gasoline) is highly
flammable and can be explosive under
certain conditions. When opening the fuel tank
cap always observe all the following items;
Turn the motorcycle ignition switch
OFF.
Do not smoke.
Always have afire extinguishercontaining
FOAM,
C0
2, HALON or
POWDER close at hand when
handling
or draining fuel or fuel systems. Fire
extinguishers mustalso be present in areas where
fuel is stored.
Always disconnect the vehicle battery, negative
(black) lead first, before carrying
out dismantling
or draining work ona fuel system.
Whenever petrol (gasoline) is being handled,
drained
or stored or when fuel systems are being
dismantled, make sure the area is well ventilated.
All potential forms
of ignition must be
extinguished
or removed (this includes any
appliance with a pilotlight). Any lead-lamps must
be flame-proof and .keptclear
of any fuel spillage.
Warning notices
must be posted atasafe distance
from the site
of thework to warn others that petrol
is being openly handled. The noticemustinstruct
the reader
of the precautionswhich mustbe taken.
Failure
to observe any of the above warnings may
lead
to afire hazard which could result in personal
injury.
1.8
A
WARNING: No one should be permitted
to repair components associated with
petrol/gasoline without
first· having speCialist
training on the fire hazards which may be created
by incorrect installation and repair of items
associated with petrol/gasoline.
Repairscarried out by untrained personnel could
bring about a safety hazard leading
to a risk of
personal injury. .
A
WARNING: Draining or extraction of
petrol/gasoline from a vehicle fuel tank
must
be carried out in awell ventilated area.
Thereceptacleused
to containthe petrol/gasoline
mustbe morethan adequate forthe full amount
of
fuel to be extracted or drained. The receptacle
shOUld be clearly marked with its contents, and
placed in a safe storage area which meets the
requirements of local authority regulations.
When petrol/gasoline has been extracted or
drained from a fuel tank, the precautions
governing naked lights and ignition sources
should be maintained.
Failure
to observeany ofthe abovewarningscould
bring about a safety hazard leading
to a risk of
personal injury.
Fuel tank removal
Fuel tanks should have a 'PETROL (GASOLINE)
VAPOUR' warning label attached to them as soon as
they are removed from the vehicle.
In all cases, they
must be stored
in a secured, marked area.
Chassis repairs
A
WARNING: If the motorcycle is involved
in
an accidentorcollision it must betaken
to an authorised Triumph dealer for repair or
inspection. Anyaccidentcan cause damagetothe
motorcycle which,
if not correctly repaired, may
causeasecond accidentwhich mayresult in injury
or death.
The frame must not be modified
as any
modification
to- the frame such as welding or
drilling may weaken the frame resulting in·
an
accident.
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ELECTRICAL PRECAUTIONS
The following guidelines are intended to ensure the
safety ofthe operator whilst preventing damage to the
electrical and electronic components fitted to the
motorcycle. Where necessary, specific precautions are
detailed
in the relevant sections of this manual which
should be referred to prior to commencing repair
operations.
Equipment -Prior to commencing any test procedure
on the motorcycle ensure that the relevant test
equipment
is working correctly and any harness or
connectors are in good condition,
in particular mains
leads and plugs.
A WARNING: The ignition system
produces extremely high voltages.
Do
not touch any part of the ignition system or any
cables while the engine is running.
An electric shock caused by contact with the
ignition system may lead to illness, injury ordeath.
A WARNING: Wearers of surgically
implanted heart pacemaker devices
should notbe in close proximityto ignition circuits
and or diagnostic equipment.
The ignition system
and anydiagnosticequipment
may interrupt the normal operation
of such
devices causing illness or death.
A WARNING: The battery contains harmful
materials. Always keep children away
from the battery whether or not it
is fitted in the
motorcycle.
Do not jump start the battery, touch the battery
cables together or reverse the polarity of the
cables
as any of these actions may cause a spark
which would ignitebattery gasses causing a risk of
personal injury.
High Voltage Circuits -Whenever disconnecting live
H.T. circuits always use insulated pliers. Exercise
caution when measuring the voltage
on the coil
terminals while the engine
is running, high voltage
spikes can occur on these terminals.
1.9
GENERAL INFORMATION 1
Connectors and Harness -The engine of a motorcycle
is a particularly hostile environment for electrical
components and connectors. Always ensure these
items are dry and oil free before disconnecting and
connecting test equipment. Neverforce connectors
apart either
by using tools or by pulling on the wiring
itself. Always ensure locking mechanisms are
disengaged before removal and note the orientation to
enable correct reconnection. Ensure that any
protective covers and substances are replaced if
disturbed.
Having confirmed a component to be faulty, switch off
the ignition and disconnect the battery negative (black)
lead first. Remove the component and support the
disconnected harness. When replacing the component
keep oily hands away from electrical connection areas
and push connectors home until
any locking
mechanism becomes fully engaged.
Battery disconnecting
Before disconnecting the battery, switch off all
electrical equipment.,
A WARNING: To prevent the risk of a
battery exploding and to prevent damage
to electrical components
ALWAYS disconnect the
battery negative (black) lead first. When
reconnecting the battery, always connect the
positive (red) lead first, then the negative (black)
lead. Always disconnectthe battery when working
on any part of the electrical system.
Failure to observe the above warnings may lead to
electrical damage and a fire hazard which could
cause personal injury.
Alwaysensurethat batteryleads are routed correctly and
are not close to any potential chafing points.

1 GENERAL INFORMATION
Disciplines
Switch offthe ignition prior to making any connection
or disconnection
in the system. An electrical surge can
be caused by disconnecting 'live' connections which
can damage electronic components.
Ensure hands and
work surfaces are clean and free of
grease, swarf, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.
Prior to commencing any test, and periodically during
any test, touch a good earth to discharge body static.
This is because some electronic components are
vulnerable to static electricity.
Electrical wires
All the electrical wires are either single-colour or
two-colour and, with only a few exceptions, must be
connected to wires of the same colour. On any of the
two-colour 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 ifthe colours were
reversed to make red the main colour.
Inspection
Disassembled parts should be visually inspected and
replaced with new ones if there are any signs ofthe
following:
Abrasions, cracks, hardening, warping, bending,
dents, scratches, colour changes, deterioration,
seizure or damage of any nature.
Replacement Parts
A WARNING: OnlyTriumph approved parts
should be used
to service, repair or
convert Triumph motorcycles. To ensure that
Triumph approved 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
resultin an accident causing serious injuryor
death.
1.10
A
WARNING: Always have Triumph
approved parts, accessories and
conversions fitted
by an authorised Triumph
dealer. The fitment
of parts, accessories and
conversions by a dealer who is not
an authorised
Triumph dealermayaffectthehandling, stabilityor
other aspects
of the motorcycle operation which
mayresult in
an accidentcausing serious injuryor
death.
A
WARNING: Aiways have Triumph
approved parts, accessories and
conversions fitted by a trained technician.
To
ensure that a trained technician is used, have an
authorised Triumph dealer fit the parts. The
fitment
of parts, accessories and conversions by
personnel other than a trained technician at
an
authorised .Triumph dealer may affect the
handling, stability
or other aspects of the
motorcycle operation which may result in
an
accident causing serious injury or death.
Service data
The service data listed in this manual gives
dimensions and specifications for brand new, original
parts. Where it
is permissible to allow a part to exceed
these figures, then the service limit
is given.
The terms ofthe motorcycle warranty will be
invalidated by the fitting
of other than genuine Triumph
parts.
All genuine Triumph parts have the full backing of the
motorcycle warranty. Triumph dealers are obliged to
supply only genuine Triumph recommended parts.
Specification
Triumph are constantly seeking to improve the
specification, design and production of their
motorcycles and alterations take place accordingly.
While every effort has been made to ensure the
accuracy of
this Manual, it should not be regarded as
an infallible guide to current specifica.tions
of any
particular motorcycle.
Authorised Triumph Dealers are not agents of Triumph
and have no authority
to bind the manufacturer by any
expressed or implied undertaking or representation.
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GENERAL INFORMATION 1
/~
( , Service tools and garage equipment
C~)
)
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 tools:-
T3880012 -Valve Shim Removal Tool 388007S-T0301 -Wheel Bearing Fitment
3880040-T0301 -Alternator Shaft Locking Jig T388010S -Angular Torque Gauge
T388020S .. Drive Chain Service (3 tools) 3880070-T0301 -Wheel Bearing Fitment
1.11

1 GENERAL INFORMATION
T3880250 -Engine Management Diagnostics T3880305 -Clutch Anti-rotation Tool
3880080-
T0301 -Fork Seal/Bearing Drift T3880311 -Oil Filter Wrench
3880090-T0301 -Fork Piston Holder T3880315 -Extractor -Cylinder Liners
3880160- T0301 -Fork Filler/Evacuator T3880048 -Fuel Pressure Gauge
1.12
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Full Specification Tiger
Engine ............................ 3 Cylinder 12 Valve DOHC
Arrangement. . . . . . . . . . . . ... . . . . . . . .. Transverse In-line
Displacement ..... . . . . . . ... . . . . . . . .. 885 cc
Bore x Stroke
..... . . . . . . ... . . . . . . . .. 76.0 mm x 65 mm
Compression Ratio .................. 11.3: 1
Cylinder Numbering ................. Left to Right (No.3 adjacent to camchain)
Firing order . . . . . . . . . . . . . ... . . . . . . .
.. 1-2-3
Max. Power. . . . . . . . . . . . . ... . . . . . . . .. 87 PS @ 8200 RPM
Max. Torque ........................ 85 Nm @ 6400 RPM
Cylinder Head
Valve Head Dia. ...... . . . . . .. In. .... 30.0 mm
Ex ..... 26.0 mm
Valve Lift ............. . . . . .. In. .... 8.0 mm
Ex ..... 7.6 mm
Valve Stem Dia .............. In. . ... 5.490 mm/5.475 mm (5.47 mm min.)
Ex
..... 5.470 mm/5.455 mm (5.45 mm min.)
Valve Guide Bore Dia ................. 5.515 mm/5.500 mm
Valve Stem to Guide Clearance In ..... 0.04 mm/0.01 mm (0.07 mm max.)
Ex. . .
.. 0.06 mm/0.03 mm (0.09 mm max.)
Valve Seat Width (in head) . .. . . . . . . . .. 1.1 mm/0.9 mm (1.5 mm max.)
Valve Seat Width (valve) ............. 2.5 mm/1.8 mm
Valve Seat Angle .. . . . . . . ... . . . . . . . .. 45°
Valve Spring 'Load at Length' . Inner
.. 15 kg min. at 24.0 mm
Outer 41 kg min. at 26.5 mm
Valve Clearance In. .... 0.15 mm/0.1 0 mm
Ex ..... 0.20 mm/0.15 mm
Valve Bucket Dia .................... 27.993 mm/27.987 mm
Valve Bucket Bore Dia. . . . . .. . . . . . . . .. 28.021 mm/28.000 mm
Valve Timing . . . . . .. Inlet .... Open 5° BTDC (@ 1.0 mm Lift)
Close 34° ABDC (@ 1.0 mm Lift)
Duration 219°
Exhaust Open 37° BBDC (@ 1.0 mm Lift)
Close 11 ° ATDC (@ 1.0 mm Lift)
Duration 228°
Camshaft Journal Dia. ............... 22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
Camshaft Journal Clearance . . . . . . . .
.. 0.12 Max
Camshaft Journal Bore Dia. .. . . . . . . .
.. 23.021 mm/23.000 mm
Camshaft End Float ................. 0.13 mm/0.03 mm (0.2 mm max.)
Camshaft Run-out . . . . . . . . .. .. . . . . .
.. 0.05 mm max
Camchain Tensioner Spring Free Length 73.7
mm
Clutch/Primary Drive
Primary Drive .. . . .. Type ...... . . . .. Gear
Reduction Ratio . 1.75 (105/60)
Clutch
............ Type ... . . . . . . .. Wet Multi-plate
No. of Friction Plates . . . . .. . . . . . . . .. 9
Plate Flatness ...................... 0.15 mm (0.2 mm)
Friction Plate Thickness (new) ........ 3.80mm - 0 +0.80mm
Friction Plate Thickness (service limit) .. 3.60mm
Clutch Shim Clearance . . . ... . . . . . . .
.. 0.125 mm/0.075 mm
Clutch Actuation Method ............. Cable
Cable Free Play (at lever)
............ 0.4 mm/0.8 mm
1.13
GENERAL INFORMATION 1

1 GENERAL INFORMATION
Full Specification
Tiger
Piston/Crankshaft
Cylinder Bore Dia. .. . . . .. . . . . . . . .. . .. 76.030 mm/75.9B5 mm
Piston Dia. (at 900 to gudgeon pin) .... 75.975 mm/75.960 mm Cyl. Nos. 1 & 3
Service Limit 75.920 mm
75.970 mm/75.960 mm Cyl. No.2
Service Limit 75.900 mm
Piston Ring to Groove Clearance Top .. 0.02 mm/0.06 mm _
Second 0.02 mm/0.06 mm
Piston Ring Groove Width ..... Top .. 1.03 mm/1.01 mm
Second 1.03 mm/1.01 mm
Oil ... 2.03 mm/2.01 mm
Piston Ring End Gap ......... Top .. 0.11 mm/0.26 mm
(new ring when fitted in bore) Second 0.26 mm/0.41 mm
Oil ... 0.20 mm/0.70 mm
Gudgeon Pin Bore Dla. In Piston
...... 19.00B mm/19.002 mm
Gudgeon Pin Dia.
................... 19.000 mm/1B.995 mm
Connecting Rod Small End Dia.
....... 19.034 mm/19.016 mm
Connecting Rod Big End Side Clearance 0.3 mm/0.15 mm (0.5 mm max.)
Crankshaft Big End Journal Dia. . . . . .
.. 40.960 mm/40.946 mm (40.932 mm min.)
Crankshaft Big End Bearing Clearance . 0.066 mm/0.036 mm
(0.1 mm max.)
Crankshaft Main Journal Dia
.......... 37.976 mm/37.960 mrn (37.936 mm min.)
Crankshaft Main Bearing Clearance. .
.. 0.044 mm/0.020 mm (0.1 mm max.)
Crankshaft End Float
......... ;...... 0.20 mm/0.05 mm (0.4 mm max.)
Transmission
Type. . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. 6 Speed Constant Mesh
Gear Ratios
................. 1st ... 2.733 (41/15)
2nd
.. 1.947 (37/19)
3rd .
.. 1.545 (34/22)
4th
... 1.291 (31/24)
5th .
.. 1.154 (30/26)
6th ... 1.074 (29/27)
Gear Selector Fork Thickness
......... 5.9 mm/5.B mm (5.7 mm min.)
Gear Selector Groove Width
.......... 6.1 mm/6.0 mm (6.25 mm max.)
Gear Selector Fork
to Groove Clearance 0.55 mm max.
Final
Drive. . . . . . . . . . . . . . . . . . . .. . . . .. Chain
Final Drive
Ratio. . . . .. .. . . .. . . .. . . .. 2.666 (18/4B)
Chain Type ........... .. . . .. .. .. . . .. Regina 136 ORP
No. of Links ......................... 116
20 Link Length . . . . . . . . . . . . . . .. . . . . .. 321 mm
Drive Chain Slack
................... 35-40 mm
Chain lubrication
.................... Mobil chain spray
Lubrication
Pressure Lubrication, Wet Sump
Oil Capacity (dry fill) ................. 4.00 litres
Recommended Oil . . . . . . . . . . .. .. . . .
.. Fully synthetic 15w/40 oil meeting
specification API/SH
Oil Pressure (in main gallery)
......... 40.0 Ib/in2 min. (@ 80°C Oil Temp.)
(@5000rpm)
Oil Pump Rotor Tip Clearance. . . .. . . .. 0.15 mm (0.2 mm max.)
Oil Pump Body Clearance ............ 0.22 mm/0.15 mm (0.35 mm max.)
Oil Pump Rotor End Float ............ 0.02 mm/0.007 (0.1 mm max.)
Ignition System
Type ............................... Digital Inductive
Electronic Rev-Limiter. . . . . . . . .. . . . . .. 8750 rpm
Pick up Coil Air Gap ................. 1.00 mm ± 0.2 mm
Pick up Coil Resistance .............. 1.3 KQ ± 10% @ 20°C
-Ignition Coil Type
................. '" Plug-top
Spark Plug Type .................... NGK-DPRBEA-9
Spark Plug Gap ..................... 0.9 mm
1.14
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