Triumph Tiger User manual

)
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

(

i ----~'\
CONTENTS
' )
-
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.
(
(:'
\

o
(J
( '.
.•. ~
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.