TIGER EXPLORER

'.

t •

Tiger Explorer
Motorcycle Service Manual

.. :

Part Number T3852795 issue 1, 03.2012

Table of Contents

Introduction

General Information

Scheduled Maintenance

Cylinder Head

Clutch

Crankshaft

Balancer

Transmission

Lubrication

Engine Removal and Refit

Fuel System/Engine Management

Cooling

Front Suspension

Rear Suspension

Rear Bevel Box and Drive Shaft

Brakes

Wheels/Tyres

Frame and Bodywork

Electrical System

Service Manual - Tiger Explorer iii

iv Service Manual - Tiger Explorer
 Introduction
Table of Contents
How to Use This Manual ....... . .................. .......... .......... ... ..... . .... ... . .. . .. .. vi
Warnings, Cautions and Notes .............. ....... .... .. ............................ ........ vi
Tampering with Noise Control System Prohibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Repairs and Replacements .. .. .. . .. .. . ............ ......... . .. ...... . .. .... ... . .. :. . . . . . . . . . . . vii
Force . ........ . ....... .. ........... .. .. ...... ... ... .. .... . . . .... .. ............... .... . . . vii
Edges ........ .. ......... . .... .... .. ...... . .. ..... . .... ..... . .... .... .... . .......... . .... vii
Tightening procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Seivice Manual - Tiger Explorer v

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 or her 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, an authorised Triumph dealer
must undertake all adjustments, maintenance, and repair
work
In order to perform the work efficiently and to avoid costly
mistakes, read the text and thoroughly familiarise yourself
with procedures before starting work.
All work should be performed with great care and in a
clean working area with adequate lighting.
Always use the correct special service tools or equipment
specified. Under no circumstances use makeshift tools or
equipment since the use of substitutes may adversely
affect safe operation.
Where accurate measurements are required, they can
only be made using calibrated, precision instruments.
For the duration of the warranty period, an authorised
Triumph dealer must perform all repairs and scheduled
maintenance.
To maximise the life of your motorcycle:
Accurately follow the maintenance requirements of
the periodic maintenance chart in the service
manual.
How to Use This Manual
To assist in the use of this manual, the section title is given
at the top of each page.
Each major section starts with a contents page, listing the
information contained in the section.
The individual steps comprising repair operations are to
be followed in the sequence in which they appear.
Adjustment and repair operations include reference to
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.
Warnings, Cautions and Notes
Particularly important information is presented in the
following form:
!
- . -
This warning symbol identifies special instructions or
procedures which, if not correctly followed, could result
in personal injury, or loss of life.
A Caution
This caution symbol identifies special instructions or
procedures which, if not strictly observed, could result in
damage to or destruction of equipment.

Do not allow problems to develop. Investigate Note:

unusual noises and changes in the riding
This note symbol indicates points of particular
characteristics of the motorcycle. Rectify all problems
interest for more efficient and convenient
as soon as possible (immediately if safety related).
operation.
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.

vi Service Manual - Tiger Explorer


Tampering with Noise Control
System Prohibited
Owners are warned that the law may prohibit:
The removal or rendering inoperative by any person
other than for purposes of maintenance, repair or
replacement, of any device or element of design
incorporated into any new vehicle for the purpose of
noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use; and
the use of the vehicle after such device or element of
design has been removed or rendered inoperative
by any person.
References
References to the left hand or right hand side given in this
manual are made when viewing the 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.
Service Manual - Tiger Explorer
Introduction
Repairs and Replacements
Before removal and disassembly, thoroughly clean the
motorcycle. Any dirt entering the engine or other parts
will work as an abrasive and shorten the life of the
motorcycle. Particular attention should be paid when
installing a new part, that any dust or metal filings are
cleared from the immediate area.
Force
Common sense should dictate how much force is
necessary in assembly and disassembly. If a part seems
especially difficult to remove or install, stop and examine
what may be causing the problem. Never lever a
component as this will cause damage both to the
component itself and to the surface being levered against.
Whenever tapping to aid removal of an item is necessary,
tap lightly using a hide or plastic faced mallet.
Edges
Watch for sharp edges, especially during engine
disassembly and assembly. Protect the hands with
industrial quality gloves.
When replacement parts are required, it is essential that
only genuine Triumph parts are used.
Safety features and corrosion prevention treatments
embodied in the motorcycle may be impaired if other
than genuine Triumph parts are fitted. In certain territories,
legislation prohibits the fitting of parts not to the
manufacturer's specification.
Tightening procedure
Generally, when installing a part with several bolts, nuts or
screws, they should all be started in their holes and
tightened to a snug fit, evenly and in a cross pattern. This
is to avoid distortion of the part and/or causing gas or oil
leakage. Conversely, bolts, nuts, or screws should all be
loosened (in sequence if specified) by about a quarter of a
turn and then removed.
Where there is a tightening sequence specified in this
service manual, the bolts, nuts, or screws must be
tightened in the order and by the method indicated.
Torque wrench setting figures given in this manual must
be observed. The torque tools used must be of accurate
calibration.
Locking devices, where specified, must be fitted. If the
efficiency of a locking device is impaired during removal it
must be renewed. This applies particularly to
micro-encapsulated fixings which must always be
replaced if disturbed. Where necessary, the text in this
manual will indicate where such a fixing is used.
vii
Introduction

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viii Service Manual - Tiger Explorer

 1 General Information
Table of Contents
Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Dangerous Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Third Party Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Fluoroelastomers....... . . . . ...... . . . .. ...... .. . . .... .. ..... ..... . . .... ....... .... ......... 1.4
Oils .... . .. ... .. .. . . . .... .... .. . . ..... . .. . .... .... .. . ...... ..... . . ... . . ... ... . ..... . . . .. . 1.4
Health Protection Precautions . . . ... ...... . . . . . ..... . . ... ... .. ... ... ... .......... . : . . . . . . . . . . 1.5
Environmental Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Brakes/Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Jacking and Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Precautions Against Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Cleaning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Joints and Joint Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Gaskets, 0-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Liquid Gasket, Non-permanent Locking Agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 7
Screw Threads ......... .. .. . . . . .......... .... .. .. . .. .... .. .... ........ ...... . . . . ........ 1.7
Locking Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Fitting a Split Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Circlips, Retaining Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Self-Locking Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Encapsulated Bolts... . ...... . ... . ........ . .... .... . ... . ... .. .. .. . .. . . . . .. . . ... .. .. . . .... . 1.8
Oil and Grease Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Ball Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Chassis Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Petrol - Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Chassis Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Electrical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Battery Disconnecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

Seivice Manual - Tiger Explorer 1.1

General Information

Disciplines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Electrical Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Ohm's Law... . ..... ........ ............ .... ....... .... . . ... . . .. ... .. ... ...... . . .. .. .. . 1.13
Basic Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Circuit Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Glossary of Circuit Diagram Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Tracing Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
To Check Continuity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
Splices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
CAN <Controller Area Networking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18
Alternator/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19
Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20
General Fault Finding - Starter Motor and Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20
Diagnosis - Starter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21
Specification. .............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
Replacement Parts ... . . . . .... . ......... ... ... ......... . .. .. .. . ..... ......... .. . .. ·'· . . . . . t.22
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.22
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.22
Service Tools and Garage Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23
Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.31
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31
Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31
Camshafts... . ... . .. ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.32
Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.33
Connecting Rods . . .. .... ....... . .......... . . . . ... . . ........ . . ........ ........ .... . ... . . 1.33
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35
Fuel System. . .. . .. . .... ...................... ...... ....... . . .. . . . . ........ ....... .. . .. 1.35
Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35
Emissions Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35
Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
Wheels and Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37
Frame. .. ... .. . .... .. .. .... .. . .. ........ . .. .. .. .. ... .... . . ........ .. .. .. ..... ....... . . 1.37
Electrical Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37
Torque Wrench Settings......... . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
Cylinder Head Area...... .... . .... . ....... ....... .. ... . . .... . . ... .. . ..... ..... . . ........ 1.38
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.38
Crankshaft and Crankcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.39
Engine Covers ... . . .. . .... . ... . .. ... . .. . . ...... .. . ............ .. . . . .. ........ ........ .. 1.39

1.2 Service Manual - Tiger Explorer

 General Information

Transmission . ... .. ... . . . .. ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
Fuel System, Exhaust System and Airbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
Rear Bevel Box and Drive Shaft ..... . ...... . . .... .. . .... . .... . .. ... ... .. ..... .... .. .. ... . 1.44
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45
ABS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45
Frame, Footrests, Control Plates and Engine Mountings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.47
Bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48
Clutch Hose Routing.... . .... . .. . ..... ...... .... ... . .. . ...... ........ .......... .... . ...... 1.49
Main Wiring Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
ABS and Brake Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51
Fuel Tank Breather Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52

Service Manual - Tiger Explorer 1.3

General Information

Ignition System Safety Precautions Fluoroelastomers

-- - . -- - - -- - - - - --- - - -- - - - - ~ - ...----- ----- -- - - --------- - - -- -

U-..--~------------
!, 1
. 1"r.i-~r1-1r1£
- - - ~ -~---~·
~-~-~
,
: .I
---·
. ·.',--; .-,.·1 '1·1 r1·{
-~--~-_.....___
~

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 or death.
- -- - -- -- -- -~
! f,' ,- ' • i i
- -- -------- - ----- -- -
Wearers of surgically implanted heart pacemaker
devices should not be in close proximity to ignition
circuits and/or diagnostic equipment.
The ignition system and any diagnostic equipment may
interrupt the normal operation of such devices causing
illness or death.
Dangerous Substances
_______ _
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
I '..,.
monoxide can be generated and will be present in
fumes from fires.
In the presence of any water or humidity hydrogen
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 contact with liquid or
decomposition residues can cause painful and
penetrating burns leading to permanent, irreversible
skin and tissue damage.

Ie ' ,_' I •
Oils
- - - - - -
Many liquids and other substances used in motor
vehicles are poisonous and should under no
circumstances be consumed and should, as far as
possible, be kept from contact with the skin. These The engine oil may be hot to the touch. Contact with
substances among others include acid, anti-freeze, hot oil may cause the skin to be scalded or burned.
asbestos, brake and clutch fluid, fuel, lubricants, and .- .
various adhesives. Always pay close attention to any
warnings and instructions printed on the container .
I ·-
.
. ,' ·
- -
~

labels and obey the instructions contained within. These Prolonged or repeated contact with engine oil can lead
instructions are included for your safety and well-being . to skin dryness, irritation and dermatitis. In addition,
NEVER DISREGARD THESE INSTRUCTIONS! used engine oil contains potentially harmful
contaminants which can cause cancer. Wear suitable
clothing and avoid skin contact.
Third Party Products

! . .~ :
Many proprietary products, such as chemicals, solvents
and cleaning agents, will cause damage to components
if used incorrectly or inappropriately. Always follow the
manufacturer's instructions printed on the product
container's labels and obey the instructions given. These
instructions are included for your safety and well-being.
Damage to the motorcycle components caused by the
incorrect or inappropriate use of chemicals, solvents and
cleaning agents may reduce the components efficiency,
resulting in loss of motorcycle control and an accident.

1.4 Service Manual - Tiger Explorer

 General Information

Health Protection Precautions Brakes/Clutch

Avoid prolonged and repeated contact with oils, ----- - -

particularly used engine oils. .

'
- - -
- -- --
\ ' -, J l ' :

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 first aid
equipment is 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 oil,
thinners or solvents for cleaning skin.
---- -- - -- - - - - - - --
.,I..
~----------
Brake and clutch fluid is hygroscopic which means it will
absorb moisture from the air. Any absorbed moisture
will greatly reduce the boiling point of the brake and
clutch fluid causing a reduction in braking efficiency.
Replace brake and clutch 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 or clutch fluid onto any area of the
bodywork as this will damage any painted or plastic
surface.
Always use new brake and clutch fluid from a sealed
container and never use fluid from an unsealed
container or from one that has been previously opened.
Do not mix different brands of fluid. Check for fluid
leakage around brake fittings, seals and joints.
Check regularly for brake or clutch ho~e damage.
FAILURE TO OBSERVE ANY OF THE ABOVE
WARNINGS MAY REDUCE BRAKING EFFICIENCY
LEADING TO AN ACCIDENT

If skin disorders develop, obtain medical advice ,- -

without delay.
- - -- -
.' ' '.
- -- -
- -
'
- - -
-'
Where practicable, de-grease components prior to If there has been an appreciable drop in the level of the
handling. fluid in either the brake or clutch fluid reservoirs, consult
- your authorised Triumph dealer for advice before riding.
.
I
-----
', \ "'; , r r l
'
-
If the brake or clutch lever or pedal feels soft when it is
-
applied, or if the lever/pedal travel becomes excessive,
Any risk of eye injury must be avoided. Always wear eye there may be air in the brake or clutch lines or the
protection when using a hammer, air line, cleaning brake/clutch may be defective.
agent or where there is ANY risk of flying debris or
It is dangerous to operate the motorcycle under such
chemical splashing.
conditions and remedial action must be taken by your
authorised Triumph dealer before riding the motorcycle.
Environmental Protection Failure to take remedial action may reduce braking
Precautions efficiency or clutch operation leading to an accident.
- - -

- - -
.
'

-
; '

-
'

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 licenced waste disposal sites,
or to the waste oil reclamation trade. If in doubt, contact
your local authority for advice on disposal facilities.
-
1
I I • -
Use only DOT 4 specification brake and clutch fluid as
listed in the general information section of this manual.
The use of brake and clutch fluids other than those
DOT 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 and clutch fluid at the
interval specified in the routine maintenance schedule
may reduce braking efficiency resulting in an accident

Service Manual - Tiger Explorer 1.5

General Information
---- -- -• - -.-'"- - --- -- - - --
--~~ ~

... , \
~·- ~--r

' \ ' 1- ---~-1-- -

--~---

Safety Instructions
.' 0 , : I r.t•fj '(.!
~--- ----- - - - - - - - - --- - - ·-- ~-

Never use mineral based grease in any part of the brake Jacking and Lifting
or clutch system or in any area where contact with the
brake or clutch system is possible. Mineral based grease
,.... --- -- -- -- - - - . - - - - - ----- - ---
will damage the hydraulic seals in the calipers, master 1 r ·. \,~"',:.:fr i 11 ii-je-_ _ __ __
~---------~
/

cylinders or clutch slave cylinders.

Damage caused by contact with mineral based grease
may reduce braking efficiency or clutch operation
resulting in an accident.
~ - -
Always ensure that any lifting 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 during lifting or jacking
- - -- -
or while repairs and servicing are carried out.

~----------. - ---~
.
'
--
• 'i"':-
--
I r '
I I~
-
------- - - - - -- -
Never rely on a single means of support when working
with the motorcycle. Use additional safety supports and
Before installation, all internal brake/clutch components straps to prevent toppling.
should be cleaned and lubricated with clean new DOT 4 Do not leave tools, lifting equipment, spilt oil, etc. in a
brake and clutch fluid. place where they could become a hazard to health.
Never use solvents, petrol (gasoline), engine oil, or any Always work in a clean, tidy area and put all tools away
other petroleum distillate on internal brake/clutch when the work is finished.
components as this will cause deterioration of the
hydraulic seals in the calipers, master cylinders and Precautions Against Damage
clutch slave cylinders. '
Avoid spilling brake fluid, clutch fluid or battery acid on
A dangerous riding condition leading to loss of
any part of the bodywork. Wash spillages off with water
motorcycle control and an accident could result if this
immediately.
warning is ignored.
Disconnect the battery earth lead 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.

Coolant

! - ' ' -
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.

! '
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.

1.6 Service Manual - Tiger Explorer


A Caution
The coolant anti-freeze contains a corrosion inhibitor
which helps prevent damage to the metal surfaces inside
the cooling system. Without this inhibitor, the coolant
would '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.
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 the cooling system. Reduced
cooling system efficiency may lead to the engine
overheating and engine 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 degreasing 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.
Lubrication
The majority of engine wear occurs while the engine is
warming up and before all the rubbing surfaces have an
adequate lubrication film. During assembly, oil or grease
(whichever is more suitable) should be applied to any
rubbing surface, which has lost its lubrication film. Old
grease and dirty oil should be cleaned off. This is because
used lubricants will have lost some lubrication 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.
Service Manual - Tiger Explorer
General Information
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, 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.
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.
- -- --- ~
I• r-~ 1 • • 1' 1.;
---- - ~- - . - - --- - -
To prevent injury, always use eye, face and ear
protection when using compressed air. Always wear
protective gloves if the compressed air is to be directed
in proximity to 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).
1.7
General Information
~-------~-~---,.---- -----. - -- --· --- Oil and Grease Seals
,.' 1·
•
- -
~ i·,l f-:
,_
T<:-.n,·-11·!
? ..._

~-------------- ........
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 during vehicle operation could cause
component detachment leading to loss of control and an
accident.
·---- - --- 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.

Locking Devices Lubricate the sealing lips with a recommended lubricant.

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 castellated 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.
Circlips, Retaining Rings
This will help to prevent damage in initial use. On dual
lipped seals, smear the area between the lips with
appropriate 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 or grease on its
outer or inner circumference so that it will locate smoothly.

Replace any circlips and retaining rings that are removed.

Removal weakens and deforms circlips causing looseness
in the circlip 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
recommended in the Triumph parts catalogue.
Self-Locking Nuts
Self-locking nuts can be re-used, if 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 Bolts
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.
. -
!
Failure to replace an encapsulated bolt could lead to a
dangerous riding condition. Always replace
encapsulated bolts.
Ball Bearings
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-
as carrying components. Press a ball bearing until it touches
the shoulder in the bore or on the shaft.
When installing an oil seal, always install the seal with the
sealing lip facing the lubricant to be retained . Press or drift
the seal to the depth of its housing if the housing is
shouldered, or flush with the face of the housing where
no shoulder is provided.
Chassis Bearing Lubrication
Note:
This information relates only to bearing
lubrication. For the procedures necessary to
replace a bearing, always refer to the relevant
section of this service manual.
Bearings installed in engine and transmission
applications are not covered by this
information. Refer to the lubrication chapter or
the relevant engine chapter for additional
information.

1.8 Service Manual - Tiger Explorer

 General Information

General Below/overleaf several common bearing types and the

For a bearing to be serviceable for its anticipated life span lubrication procedures for each are identified:
it must be checked, adjusted and lubricated at regular
intervals, as specified in the service schedules given in the
owner's handbook and this service manual.
A correctly lubricated bearing will have a film of
lubrication that separates the moving parts, disperses heat
and protects the bearing surfaces from corrosion.
Note:
• In all cases, use the lubricant recommended in
the service manual.
Grease the bearing, not the cavity where it is
located.
• A bearing that is not regularty checked and
lubricated will have a reduced life span.
Sealed Bearings (wheel bearings and
New Bearings swinging arm, depending on the model>
New bearings are typically protected with an oil
Note:
preservative to prevent corrosion etc. during storage. This
is NOT the lubrication for the bearing but DOES NOT • Sealed bearings can be identified by their
need to be washed off prior to assembly and in-service integrated seals.
lubrication. Sealed bearings are lubricated for life by the
When lubricating a new bearing with grease the following manufacturer.
steps should be taken : • Any attempt to change the grease in a sealed
bearing will damage the integrated seals. If the
1. Do not clean off the oil preservative. seals are damaged, dirt and water will ingress
2. Grease must be forced between the roller elements and the life of the bearing will be greatly
and the roller cage. reduced.
3. Rotate the bearing to ensure that the grease is
distributed over the entire circumference of the
internal parts.
4. Any excess grease should be smeared on the outside
of the rollers.

Lubrication and Checks While Servicing a Bearing

1. Disassemble parts as necessary to access the

bearing. Refer to the relevant service manual.
2. Inspect the old grease covering the bearing, looking
for signs of bearing damage, i.e. flakes or specks of
metal.
3. Remove the old grease.
Taper Bearings (swinging arm and headstock,
4. Check the bearing for smooth operation and visually
depending on the model>
check for corrosion, dents and flaking in the bearing
race, rollers or cage. Replace if necessary. Refer to
1. Grease must be forced between the inner race and
the relevant service manual.
the roller carrier.
2. Rotate the bearing to ensure that the grease is
distributed over the entire circumference of the
internal parts.

Service Manual - Tiger Explorer 1.9

General Information

3. Any excess grease should be smeared on the outside Fuel Handling Precautions
of the rollers.

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
Angular Contact and Ball Bearings
readily be distributed throughout any indoor environment
<headstock>
by air currents, consequently, even a small spillage of
petrol (gasoline) is potentially very dangerous.
1. Grease the bearing races and the ball bearing carrier. .

'.
.

2. Rotate the bearing to ensure that the grease is

distributed over the entire circumference of the . .' . -
.

internal parts. Petrol <gasoline) is highly flammable and can be

explosive under certain conditions. When opening the
fuel tank cap always observe all the following items:
Tum the motorcycle ignition switch OFF.
Do not smoke.
Always have a fire extinguisher containing FOAM, C0 2,
HALON or POWDER close at hand when handling or
draining fuel or fuel systems. Fire extinguishers must
also be present in areas where fuel is stored.
Always disconnect the vehicle battery, negative <black>
lead first, before carrying out dismantling or draining
work on a fuel system.
Whenever petrol (gasoline) is being handled, drained,
stored or when fuel systems are being dismantled, make
ceop
sure the area is well ventilated. All potential forms of
Needle Roller Bearings
ignition must be extinguished or removed <this includes
(swinging arm, rear hub, rear suspension
any appliance with a pilot light>. Any lead-lamps must
linkages, depending on the model>
be flame-proof and kept clear of any fuel spillage.
1. Coat the needle rollers with grease. Warning notices must be posted at a safe distance from
the site of the work to warn others that petrol is being
2. Ensure the needle rollers tum so that the grease is
openly handled. The notice must instruct the reader of
distributed over the entire circumference of the
the precautions which must be taken.
internal parts.
Failure to observe any of the above warnings may lead
3. Assemble the parts, adjust and check as necessary.
to a fire hazard which could result in personal injury.
Metal Bushes

1. Disassemble the parts as necessary to access the

bush. Refer to the relevant service manual.
2. Remove the old grease.
3. Apply fresh grease to the metal bush.

1.10 Seivice Manual - Tiger Explorer

 General Information
----- ------------- ---- -
r---------~--
Chassis Repairs
i
.
- -- - - - - - -- -- - - -- --
.
, )- ~-U C-l't. I,_!
-f f , -\\'. ~·- 1

----------- --- - - -- - - --------....---·---- -~~- - -

No one should be permitted to repair components ! \,1 1 f-;~-rf1-r·.l
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.
Repairs carried out by untrained personnel could bring
about a safety hazard leading to a risk of personal injury.
If the motorcycle is involved in an accident or collision it
must be taken to an authorised Triumph dealer for
repair or inspection. Any accident can cause damage to
the motorcycle, which if not correctly repaired, may
cause a second accident which may result 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.
Draining or extraction of petrol/gasoline from a vehicle
fuel tank must be carried out in a well ventilated area.
The receptacle used to contain the petrol/gasoline must
be more than adequate for the 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 observe any of the above warnings could
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.

Service Manual - Tiger Explorer 1.11

General Information
Electrical Precautions
The following guidelines are intended to ensure the safety
of the 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.
-- - - -- ~ - - -
f Ie , _ ,I ·-1"'
I"
~----- - - - --------- - - - - - - - - -
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 or death.
..--~- - - - - - --
I• ·; ' - ·
~ !
~ -- -- - - - ---
Wearers of surgically implanted heart pacemaker
devices should not be in close proximity to ignition
circuits and/or diagnostic equipment.
The ignition system and any diagnostic equipment may
interrupt the normal operation of such devices causing
illness or death.
- - - -
! I:
- --- ---------- --
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 ignite
battery gases causing a risk of personal injury.
High Voltage Circuits - Whenever disconnecting live High
Tension <HD circuits always use insulated pliers. Exercise
caution when measuring the voltage on the coil terminals
while the engine is running as high voltage spikes can
occur on these terminals.
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.
Never force 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.
1.12
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
r 11r I,;• . -!- '· ;~ ) r pI J r i~
~----- -------------- -- --. - - - ~
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
disconnect the 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.
Always ensure that battery leads are routed correctly and
are not close to any potential chafing points.
Disciplines
- ---
Switch off the ignition prior to making any connection or
; 1 I .\
disconnection in the system. An electrical surge, which
-- -
can damage electronic components, can be caused by
disconnecting 'live' connections.
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 if the colours were reversed to make red
the main colour.
Seivice Manual - Tiger Explorer
 General Information

Electrical Testing To use either of the following triangles, put your finger
over the value you want to find. Multiply the remaining
For any electrical system to work, electricity must be able values if side-by-side, or divide if one is over the other.
to flow in a complete circuit from the power source (the
battery) via the components and back to the battery. No
circuit means no electrical flow. Once the power has left
the positive side of the battery and run through the
component it must then return to the battery on its
negative side (this is called earth or ground). To save on
wiring, connections and space, the negative side of the
Basic Electrical Circuits
battery is connected directly to the frame or engine.
Around the frame and engine will be various other
ground points to which the wiring coming from
components will be connected. For example, the starter
motor bolts directly to the engine, which is then bolted to
the frame. Therefore the frame and engine also form part
of the earth return path.
Basic Circuit Diagram

In the above circuit an electrical reservoir (the battery) is

Ohm's Law connected via a cable to a terminal on the controlling
The relationship between voltage, current and resistance device (the switch> whose contacts are either open or
is defined by Ohm's Law. closed. The other terminal on the switch is connected via a
cable to the consumer (the bulb), and th,e other side of the
The potential of a battery is measured in Volts M . bulb filament is connected to ground (earth) by another
The flow of current in a circuit (I) is measured in cable. The ground point is usually a part of the frame or
Amperes. engine, to which the battery negative term inal is also
connected.
The power rating of a consumer is measured in
When the switch contacts are open (as shown in the
Watts <W>.
diagram), the circuit is broken and no current flows. When
The resistance (R) of a circuit is measured in the switch contacts are closed the circuit is made and
Ohms (Ql. current flows from the battery positive terminal through
the switch contacts and bulb filament to ground. The
Ohm's law, for practical work can be described as - frame completes the circuit to the battery negative
terminal and the bulb illuminates.
Voltage . Although some circu its on the circuit diagram may at first
C = Resistance
urrent seem more complicated, it will generally be found that
they can be broken down into sections which do not differ
Power is calculated by multiplying Volts x Amps - greatly from the basic circuit above.

Watts = Volts x Amps

By transposing either of these formulae, the value of any

unit can be calculated if the other two values are known .
For example, if a battery of 12V is connected to a bulb of
60 W:
the current flowing in the circuit can be calculated by
using -

W =I 60 = S
v 12
the bulb resistance can be calculated by using -

~=R g=24
5 .
I

Seivice Manual - Tiger Explorer 1.13

General Information

Circuit Diagrams Glossary of Circuit Diagram Symbols

Circuit diagrams are created to provide a 'picture' of the The following is a description of the symbols found in the
electrical system and to identify the route taken by each circuit diagrams used in all Triumph service manuals.
individual wire through the system, in order to identify
which components it feeds and which connectors the wire Connector
runs through. Circuit diagrams are an essential tool for
fault finding, as it is possible to locate start and finish
points for a circuit without having to manually trace the
wire through the motorcycle itself. Circuit diagrams may
look confusing at first but when they are studied closely
[]
they soon become logical.
This illustration is used to show all multi-plug type
Due to the complex circuits and the number of individual electrical connectors on Triumph circuit diagrams. The
wires, Triumph uses two types of circuit diagram in its numbers in the box relate to the terminal numbers of the
service manuals. connector pins. On ECMs with two connectors, the
Within the manual conventional circuit diagrams are number would be prefixed with the letters 'A' or 'B' to
used to show the layout of the main circuits of the identify each connector. An additional number outside the
motorcycle. These are: Engine Management/Ignition, box will identify the component.
Lighting, Starting and Charging, and Auxiliary and
Accessory. In these diagrams no attempt is made to Diode
show the components of the system in any particular
order or position in relation to the motorcycle.
At the back of the service manual a full colour layout
circuit diagram is used to show the main electrical
An electrical one-way valve. Diodes allow current to flow
components in a position similar to the actual
in one direction but will not allow it to return. The arrow,
position on the motorcycle.
which forms part of the diode symbol, indicates the
Both of these circuit diagrams use similar symbols to direction of current flow.
illustrate the various system components and will be
accompanied by a key to circuit diagram components and Electromagnetic Winding (solenoid)
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 An electromagnetic winding (or solenoid) is used to
connector instead of disassembling the switch itself. convert an electrical current into a lateral movement. This
can then be used to operate switches (as used in relays) or
other components such as fuel injectors or secondary air
injection solenoids.

Fuse

~2 ~
3
or

A fuse is a device which protects a circuit in the event of a

fault. The fuse will 'blow' if a short circuit occurs,
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.

1.14 Service Manual - Tiger Explorer

 General Information

Ground or Earth Point Resistor

1
This symbol is used to show ground points. This is the
negative connection to either the frame or engine, and is
a common cause of intermittent faults due to loose or
corroded connections.
A device placed in a cable to reduce a voltage or restrict
the maximum current a device can draw.
Splice

Lamp or Bulb

+
A hard cable joint where two or more cables are joined in
the wiring harness. A potential source of both open and
short circuits.
This symbol is used to show all types of light bulbs. The
numbers in the box relate to the terminal numbers of the Switches
connector pins. An additional number outside the box will
identify the component. Normally Normally Change
Open Closed Over
LED CLight Emitting Diode)
, Q ___ Q

~o 0--0 0 0
Triumph use LEDs for the alarm warning light, instrument
illumination and warning lights, gear change lights and or or or
rear light/brake lights on various models.
,,0
,,
Motor 0 0 0 0 CJ----0
A mechanical device for completing or breaking a circuit.
There are three common types of switch: Normally Open,
Normally Closed and Change Over.
An electric motor. This could be the starter motor or a
motor within an actuator, for example within the ABS
modulator.

Relay

A relay is effectively an electromagnetic switch. To close

the relay contacts and complete the circuit, an
electromagnet in the relay is energised which causes the
relay contacts to close, making the circuit complete.
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.

Service Manual - Tiger Explorer 1.15

General Information

Tracing Circuits To Check Continuity:

The following is a description of two types of common

electrical failures, and some of the methods which may be
used to find them.
A Caution
Ensure the circuit being tested is switched off before
measuring continuity. Damage to the Digital Multi
Open circuit
Meter <DMMl may result from testing a 'live' circuit with
the meter set to resistance (Q).
Break
+
1 In the example below, the ground circuit continuity is
being tested from the battery to the frame.

A break in an electrical circuit - current cannot flow.

Usually caused by a break in a wire or cable or by a loose
connection. Open circuits can often be intermittent,
making diagnosis difficult.

Short Circuit

A 'short cut' in an electrical circuit - current by-passes the

intended circuit, either to earth or to another, different
circuit. Often caused by failure of the cable insulation due Continuity (resistance) Check
to chafing or trapping of the wire. There are two different
Locate each end of the wire.
types of short circuit - short to ground and short to Vbatt.
A short to ground means that the current is going to earth Set the Digital Multi Meter <DMMl to resistance
before it reaches the component it is supposed to feed. check (Q).
These are often caused by chafing of the harness to the Probe each end of the wire.
frame or wires trapped between a bolted component, and
will often blow the fuse on that circuit. If there is continuity, the meter will usually bleep or
register the resistance of the cable.
A short to Vbatt is a short to battery voltage (12 Volts>
and is caused by a live power supply wire contacting an A high resistance figure could indicate a dirty or
adjacent cable. Note that it is also possible for a 5 Volt corroded connection.
sensor reference voltage to short to an adjacent circuit,
If there is a break in the wire, the meter will not
which can also cause electrical failures and DTCs
bleep or register a resistance.
<Diagnostic Trouble Code) to be stored.
When tracing a wire that is suspect, carefully check the By probing the wire in various places, the position of
circuit diagram before starting. Remember: a high resistance or break in the wire <open circuit)
can be narrowed down until it is found.
a wire may diverge at a splice and go off to feed
other circuits. If these circuits are working, check for
wiring faults from the splice onwards.
the circuit diagram is not an accurate guide to the
actual location of the parts when fitted on the bike. It
is a schematic diagram of the circuits.
particularly where engine management items are
concerned, the circuit is only completed by the ECM.
If the ECM is not connected, the circuit may register
as open.

1.16 Service Manual - Tiger Explorer


To Measure Voltage:
In the example below, the circuit voltage is being
measured at the bulb positive (+) terminal.
+ working correctly, the resistance should register or the
Voltage Check
Turn the circuit to be tested 'ON '.
Set the Digital Multi Meter CDMMl to voltage check
N ). Ensure the multi meter is set to DC Volts for
direct current circuits (most circuits) or AC Volts for
alternating current circuits (typically alternator output
voltage tests).
Set the range of the DMM to the range best suited
to the voltage of the circuit being tested (typically
20 Volts for most DMMsl. Refer to the DMM
manufacturers instructions.
Connect the black (ground) lead of the DMM to a
reliable ground connection <usually the battery or
frame ground).
Locate the positive terminal of the wire
component to be tested.
Conned the red <positive) lead of the DMM to the
positive terminal.
Read the voltage from the meter.
Seivice Manual - Tiger Explorer
General Information
Splices
Splices are probably the most common cause of wiring
faults after connectors. Splices are made where two or
more wires come together and diverge in different
directions, usually to feed a different circuit.
To locate a splice, it is necessary to peel back the insulation
and examine the splice for its integrity. The most common
fault is where one of the wires at the joint has come adrift
usually causing the circuit it feeds or earths to become
'dead'.
Switches
To check a switch, set the multimeter to
resistance/continuity and probe the two pins that form a
closed circuit when the switch is pushed. If the switch is
meter will bleep.
Relays
All relay cases have a circuit path engraved on them
showing the circuit path across the electromagnet and the
switch. Before making any checks, first note the pin
designations, current paths, and whether or not there is a
diode in either circuit path.
Diode
86
• • 87
Electromagnet
85 _ _ ___,
30
Make continuity checks across the electromagnet first,
usually from pin 86 <positive) to pin 85 <negative). If a
or diode appears in the circuit use the diode check on the
multimeter Nolts scale) in the direction of current flow. If
there is no diode, use the resistance check facility. An
open circuit or unusually high resistance value indicates a
faulty relay.
To check the switch side, apply a 12 Volt supply between
pins 86 and 85. With the supply connected the relay
should be heard to click and there should be continuity
between pins 30 and 87. An open circuit indicates a faulty
relay.
1.17
General Information

CAN <Controller Area Networking)
CAN (sometimes called CANbus) is a protocol for data
communication between Electronic Control Modules
CECMsl. Each ECM on the network is connected by a
single pair of twisted wires (or bus) which are used for the
transmission of vehicle sensor data. By using CAN, the
overall number of system sensors, and the amount of
cabling required to allow ECMs to communicate with
each other, is greatly reduced.
This saves cost, weight and space, and makes the system
more reliable, as the physical number of wires and
connections is reduced.
This allows for a very high speed system of
communication, which is also very reliable. Should one
ECM fail or transmit corrupted or otherwise incorrect
messages, none of the other ECMs on the network will be
affected, and after a certain time that ECM will be
prevented from transmitting further messages until the
fault is rectified. This stops the ECM from clogging the
network with incorrect data and preventing other
messages from getting through. The fault would then be
reported by a DTC <Diagnostic Trouble Code).
Triumph currently use CAN for communication between
the engine ECM, ABS ECM, and the instruments.

Pair of Twisted
R Wires
828 4
u Instrument
827 5
Pack
,.-- 16
ECM

1
KY
A34 3
2
~ Vehicle Speed
Sensor
Extract from the Circuit Diagram Showing
CAN Connection Between ECMs
CAN works by each ECM sending out 'packets' of
information <such as engine speed or fuel consumption
information) on to the network bus <note that the network
must be free of data before any ECM is allowed to
transmit). This data is given a priority according to its
importance (for example 'engine speed' may have a
higher priority than 'low fuel level'), so that even if two
ECMs send data at the same time, high priority
information is always sent first. Lower priority data is then
resent after the high priority data has been received by all
ECMs on the network.
The receiving ECM confirms the data has been received
correctly and that the data is valid, and this information is
then used by the ECM as necessary. Specific data not
required by an ECM will still be received and
acknowledged as correct but then disregarded (for
example if an ECM does not require 'clutch switch
position' information, this data packet would be ignored).

1.18 Service Manual - Tiger Explorer

 General Information

Alternator/Charging System
If the charging circuit does not operate correctly, the To check the alternator output carry out the alternator
following basic checks must be carried out before further pinpoint tests as described on page 78-24.
diagnosis is performed:
Note:
Check the battery terminals are clean and tight.
The alternator is located under the fuel tank. It
Check the frame and engine earth connections are does not contain any seiviceable parts and
clean, tight and free from corrosion. must be replaced if faulty.
Ensure the battery is fully charged and in good
condition.

Check that any fuse in the circuit is not blown and is

of the correct rating (see page 78-7 7l.

Rectify any defects as necessary.

Service Manual - Tiger Explorer 1.19

General Information

Starting Circuit
All Triumph models are equipped with an electric start Check the frame and engine earth connections are
system. This system consists of a starter relay, starter clean, tight and free from corrosion.
motor, starter switch, sidestand switch, engine stop switch,
Ensure the battery is fully charged and in good
clutch switch and the sprag clutch. The starter motor is
condition.
connected to the starter relay and the battery by heavy
duty cables in order to supply the large currents required Check that any fuse in the circuit is not blown and is
by the motor to start the engine. When the starter button of the correct rating.
is pressed the relay is energised, which then allows battery
Using the Triumph diagnostic tool, check the
current to flow to the starter motor. The starter motor will
operation of the neutral switch or gear position
not operate unless the clutch lever is pulled in. Also, the
sensor (if fitted), sidestand and clutch switches.
starter will not operate if the sidestand is down, unless the
transmission is in neutral. If the starter motor does not
Note:
operate, the following basic checks must be carried out
before further diagnosis is performed : • On all new models from Daytona 6 7 5 onwards,
which use a CAN connection between the
Check the engine stop switch is in the 'RUN'
instruments and the ECM, the engine will not
position.
crank if the instruments are disconnected.
Check the battery terminals are clean and tight. Rectify any defects as necessary.

General Fault Finding - Starter Motor and Relay

Symptom Possible cause(s)

Starter relay does not click, starter motor does not turn Battery discharged or defective
Blown main or starter relay fuse

Defective starter relay wiring or starter switch

Check that the sidestand, transmission and clutch lever are

positioned for engine starting i.e. transmission in neutral,
clutch lever pulled in and the sidestand down
Defective alarm system - ensure any alarm fitted is working
correctly

Starter motor turns slowly Battery discharged or defective

Loose, corroded or dirty battery connections

Loose, corroded or dirty starter motor or starter relay

connections

Defective starter motor

Loose, corroded or dirty battery ground connections

Starter relay clicks but engine does turn over Battery discharged or defective

Crankshaft does not turn due to engine defect

Defective starter motor

Starter cable open circuit

Defective starter relay

Starter motor turns but engine does not turn over Defective sprag clutch

Defective idler gear, reduction gear or starter motor

1.20 Service Manual - Tiger Explorer

 General Information

Diagnosis - Starter Circuit

WITH THE IGNITION SWITCH ON AND USING A SUITABLE HEAVY DUTY

THE ENGINE STOP SWITCH AT 'RUN ', Clicks • JUMPER CABLE , CONNECT THE
CHECK FOR A CLICK AT THE STARTER L - - - - - - - - - - + I . STARTER POSITIVE TERMINAL TO THE
RELAY WHEN THE STARTER SWITCH BATTERY POSITIVE TERMINAL
IS PRESSED

Starter Motor
Starter
Does Not
Motor Turns
Tum
.. ...
LOOSE OR FAULTY
DISCONNECTED STARTER
WIRE OR CABLE . MOTOR
FAULTY
No Click STARTER
RELAY/
SOLENOID

. FAULTY NEUTRAL SWITCH '

DISCONNECT THE STARTER RELAY
SWITCH CONNECTOR. CHECK THE
RELAY COIL EARTH (GROUND) WIRE
FAULTY CLUTCH SWITCH
No
Continuity FAULTY SIDESTAND SWITCH
BAD CONTACT AT CONNECTOR
OPEN CIRCUIT IN WIRING LOOM
FAULTY ALARM OR ENGINE ECM (IF
FITTED)

Continuity

•Ir FAULTY IGNITION SWITCH/ENGINE

CONNECT THE STARTER RELAY No STOP SWITCH
SWITCH CONNECTOR. MEASURE THE Voltage BROKEN STARTER SWITCH CABLE
STARTER RELAY VOLTAGE AT THE L------=-----.i. BAD CONTACT AT CONNECTOR
STARTER RELAY SWITCH OPEN CIRCUIT IN WIRING LOOM
CONNECTOR FAULTY ALARM

Voltage
Measured

Normal LOOSE OR POOR CONTACT AT

CHECK THE STARTER RELAY
OPERATION STARTER RELAY

Abnormal
. FAULTY STARTER RELAY

Service Manual - Tiger Explorer 1.21

General Information

Specification Seivice Data

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 specifications 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.
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 of the 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.

Inspection
Replacement Parts
Disassembled parts should be visually inspected and
- - - -- - - - - - - - - - - -------
'
- ---
replaced with new ones if there are any signs of the
• ' ' -~ ' ' l '' ; following :
---- ----- - - -- - -
Abrasions, cracks, hardening, warping, bending, dents,
Only Triumph genuine parts should be used to service,
scratches, colour changes, deterioration, seizure or
repair or convert Triumph motorcycles. To ensure that
damage of any nature.
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, stabil ity or other aspects of the motorcycle
operation which may result in an accident causing
serious injury or death.

- -

! - .
--- - - -
Always have Triumph genuine 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 dealer may affect the
handling, stability or other aspects of the motorcycle
operation which may result in an accident causing
serious injury or death.

~ - -
.' '' .. ' ' .
- - - - --
Always 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.

1.22 Seivice Manual - Tiger Explorer

 General Information

Se1Vice Tools and Garage Equipment

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 Seivice Tools

Oil Filter Wrench T3880313 Angular Torque Gauge T3880105

gahc

cbxt

Camshaft Timing Plate T3880600 Camshaft Timing Tensioner T3880607

Service Manual - Tiger Explorer 1.23

General Information

Crankshaft Timing Pin T3880601 Torque Limiter T3880609

Cylinder Liner Extractor T3880605 (use with the frame Flywheel Restraint T3880606
from Cylinder Liner Extractor T3880315)

gakh

Flywheel Pin Set T3880608 Alternator/Flywheel Rotor Puller T3880365

1.24 Seivice Manual - Tiger Explorer

 General Information

Oil Pump Restraint T3880603 Alternator Wrench T3880602

Clutch Restraint T3880604 Bearing Installer, 39 mm T3880625

ff fff
Bearing Installer, 46 mm T3880626 Bearing Puller 32-42 mm T3880627

Service Manual - Tiger Explorer 1.25

General Information

Adjuster Socket, 50 mm T3880023 Adjuster Socket, 48 mm T3880620

cdbp

Engine Mounting Adjuster Wrench T3880377 Bearing Installer 3880070 - T0301

"'''"

Wheel Bearing Extraction Kit T3880053 Bearing Installer 3880070 - T0301

1.26 Service Manual - Tiger Explorer

 General Information

Damper Tube Wrench T3880622 Fork Piston Holder 3880085-T0301

ccgs

Fork Spring Compressor T3880067 Support Plate T3880153

ccxa_l
ccgw

Nylon Fork Support Collets T3880621 Fork Seal Installer T3880623

ccxb

Seivice Manual - Tiger Explorer 1.27

General Information

Fork Filler/Evacuator 3880160 - T0301 Fuel Pressure Gauge T3880001

D I I l~n
~
D 11 I la j D

cdgh
ccha

Radiator and Cap Tester T3880147 Extension Cable T3880123

cgwp

BatteryMate Battery Charger - See Latest Parts Catalogue Engine Managemant Diagnostics T3880057
for Part Number Information

1.28 Seivice Manual - Tiger Explorer

 General Information

Lock Ring Wrench, 38 mm T3880062 Housing Support T3880624

ccgu

Bearing Installer, 26 mm T3880628 Bearing Installer Handle T3880629

Service Manual - Tiger Explorer 1.29

General Information

Slide Hammer T3880208 Blanking Cap T3880631

cemy4

Fuel Hose Clamp T3880630

1.30 Service Manual - Tiger Explorer

 General Information

Specifications
Full Specification Tiger Explorer

Engine

Engine Configuration 3 Cylinder 12 valve DOHC

Arrangement Transverse in-line
Displacement 1215 cc
Bore x Stroke 85 x 71.4 mm
Compression Ratio 11 :1
Cylinder Numbering Left to right (no. 3 adjacent to camshaft drive
chain)
Cylinder Sequence Number 1 at left
Firing Order 1-2-3
Maximum Power (95/1/EO 100.74 kW (137 PS/135 bhpl at 9,000 rpm
Maximum Torque 121 Nm (89 lb-ft) at 6,400 rpm

Cylinder Head and Valves

Valve Head Diameter Inlet 35.600 mm

Exhaust 28.600 mm
Valve Lift Inlet 8.75 mm
Exhaust 8.00 mm
Valve Stem Diameter Inlet 4.975 - 4.990 mm <Standard)
4.965 mm <service limit)
Exhaust 4.955 - 4.970 mm (Standard)
4.945 mm <service limit)
Valve Guide Bore Diameter Inlet 5.000 - 5.015 mm <Standard)
5.043 mm <service limit)
Exhaust 5.000 - 5.015 mm (Standard)
5.083 mm (service limit)
Valve Stem to Guide Clearance Inlet 0.068 mm
Exhaust 0.128 mm
Valve Seat Width (in head) Inlet 1.0 mm <Standard)
1.5 mm <service limit)
Exhaust 1.2 mm <Standard)
1.7 mm <service limit)
Valve Seat Width (valve) Inlet 1.03 mm
Exhaust 1.33 mm
Valve Seat Angle 45°
Inlet/Exhaust Valve Spring 'Load at Length' 580 N±29 N at 26.8 mm
Valve Clearance Inlet 0.10 - 0.15 mm
Exhaust 0.275 - 0.325 mm
Valve Bucket Diameter Inlet and Exhaust 28.476 - 28.49 mm (Standard)
28.468 mm (service limit)

Service Manual - Tiger Explorer 1.31

General Information

Full Specification Tiger Explorer

Cylinder Head and valves <continued)

Valve Bucket Bore Diameter Inlet and Exhaust 28.515 - 28.535 mm

28.549 mm <service limit)

Camshafts

Camshaft Timing Inlet Open 5.83° BTDC <@ 1.0 mm lift)

Close 35.83° ABDC <@ 1.0 mm lift)
Duration 221.7°
Exhaust Open 45.3° BBDC <@ 1.0 mm lift)
Close 4.7° BTDC (@ 1.0 mm lift)
Duration 220.6°
Camshaft Journal Diameter 23.93 - 23.96 mm
Camshaft Journal Clearance 0.040 - 0.091 mm (standard)
0.13 mm <service limit)
Camshaft Journal Bore Diameter 24.000 - 24 .021 mm
Camshaft End Float 0.03 - 0.13 <standard)
0.20 (service limit)
Camshaft Run-out 0.05 mm max.

Clutch I Primary Drive

Primary Drive I Type Gear
Reduction Ratio (98/61)
Clutch I Type Wet multi-plate
No. of Friction Plates 9
Plate Flatness Within 0.15 mm
Friction Plate Thickness (inner and outer) 3.80 mm <standard)
3.60 mm (service limit)
Friction Plate Thickness (all others) 3.80 mm (standard)
3.60 mm <service limit)
Clutch Actuation Method Hydraulic
Recommended Fluid DOT 4 brake and clutch

1.32 Service Manual - Tiger Explorer

 General Information

Full Specification Tiger Explorer

Pistons

Cylinder Bore Diameter (15 mm from top of Grade A 84.995 - 85.003 mm (standard)
bore) Grade B 84.985 - 84.994 mm (standard)
Service Limit 85.100 mm
Call grades)
Piston Diameter Cat 90° to gudgeon pin, Grade A 84.981 - 84.984 mm (standard)
12.5 from bottom of piston) Grade AB 84.972 - 84.980 mm (standard)
Grade B 84.968 - 84.971 mm (standard)
Service Limit 84.928 mm
Call grades)
Piston Ring to Groove Clearance Top 0.000 - 0.040 mm (standard)
0.085 mm <service limit)
Second 0.020 - 0.060 mm <standard)
0.075 mm (service limit)
Piston Ring End Gap Top 0.150 - 0.350 mm <standard)
0.470 mm <service limit) '
Second 0.350 - 0.550 mm (standard)
0.670 mm <service limit)
Oil 0.200 - 0.700 mm (standard)
0.84 mm <service limit)
Gudgeon Pin Bore Diameter in Piston 19.010 - 19.015 mm (standard)
19.043 mm (service limit)
Gudgeon Pin Diameter 19.000 - 19.005 mm <standard)
18.985 mm (service limit)

Connecting Rods

Connecting Rod Small End Diameter 19.035 - 19.048 mm <standard)

19.058 mm <service limit)
Connecting Rod Big End Side Clearance 0.150 - 0.300 mm (standard)
0.500 mm (service limit)

Crankshaft

Crankshaft Big End Journal Diameter 38.020 - 38.036 mm <standard)

37.996 mm (service limit)
Crankshaft Big End Bearing Clearance 0.030 - 0.056 mm (standard)
0.061 mm (service limit)
Crankshaft Main Bearing Journal Diameter 37.960 - 37.976 mm (standard)
37.936 mm (service limit)
Crankshaft End Float 0.075 - 0.175 mm (standard)
0.375 mm (service limit)
Crankshaft Run-out 0.020 mm or less (standard)
0.050 mm (service limit)

Service Manual - Tiger Explorer 1.33

General Information

Full Specification Tiger Explorer

Transmission

Type 6 Speed, Constant Mesh

Gear Ratios 1st 2.846: 1 (13/37)
2nd 2.056 :1 (18/37)
3rd 1.583 : 1 (24/38)
4th 1.2916:1 (24/31)
5th 1.138: 1 (29/33)
6th 1.037:1 (27/28)
Gear Selector Fork Thickness Input shaft 5.8 - 5.9 mm (standard)
5.7 mm (service limit>
Output shaft 6.3 - 6.4 mm (standard>
6.2 mm (service limit>
Gear Selector Groove Width Input shaft 6.0 - 6.1 mm <standard)
6.2 mm (service limit>
Output shaft 6.5 - 6.6 mm (standard)
6.7 mm (service limit)
Gear Selector Fork to Groove Clearance 0.500 mm max.

Final Drive

Final Drive Shaft drive

Front Bevel Box Bevel geared crown wheel and pinion
Rear Bevel Box Bevel geared crown wheel and pinion
Final Drive Ratio 2.557:1
Front Bevel Box Ratio 1.042: 1
Rear Bevel Box Ratio 2.455 :1
Drive System Universal-jointed shaft with torsional damper
Final Drive Oil Castrol SAF-XO Fully Synthetic Hypoid Oil
Final Drive Oil Capacity 0.17 litres

Lubrication

Type Pressure Lubrication, Wet Sump

Oil Capacity (dry fill) 4.5 litres
Oil Capacity (wet fill including filter) 4.0 litres
Oil Capacity (wet fill excluding filter) 3.85 litres
Oil pressure (in main gallery) 40.0 lb/in2 min. @ 80°C oil temperature
@ 5,000 rpm
Oil Pump Rotor Tip Clearance 0.050 - 0.150 mm (standard)
0.200 mm (service limit>
Oil Pump Body Clearance 0.050 - 0.139 mm (standard>
0.35 mm <service limit)
Oil Pump Rotor End Float 0.040 - 0.090 mm (standard)
0.170 mm (service limit)

1.34 Seivice Manual - Tiger Explorer

 General Information

Full Specification Tiger Explorer

Ignition System

Type Digital Inductive

Electronic Rev Limiter 9,500 rpm
Pick-up Coil Resistance 0.56 KW ±10%@ 20°c
Ignition Coil Type Plug-top
Spark Plug Type NGK CRSEK
Spark Plug Gap 0.7mm
Gap Tolerance +0.05/-0.1 mm

Fuel System

Fuel Type Unleaded, 91 RON CU.S. 87 CLC/AKD

Fuel Tank Capacity 20.0 litres (motorcycle upright)
Low Level Warning Lamp 4 litres remaining
Fuel Pump Type Submerged
Fuel Pressure (nominal> 3.5 bar
'
Purge Control System Electronic, via fuel system ECM

Fuel Injection System

Type Electronic, sequential

Idle Speed 1,000 rpm
Injector Type Twin jet, solenoid operated plate valve
Throttle Butterfly, electronically controlled
Control Sensors Barometric pressure, throttle position, twist
grip position, coolant temperature, crankshaft
position, oxygen sensor, induction air
temperature, manifold absolute pressure
CMAPl, gear position, road speed (from
ABS system)

Emissions Controls

Catalysts 1 in down pipe

Oxygen Sensor Heated, in down pipe
Secondary Air Injection Solenoid controlled, reed valve type
Evaporative Control Activated carbon canister <certain markets
only)

Service Manual - Tiger Explorer 1.35

General Information

Full Specification Tiger Explorer

Coolant System

Coolant Mixture Pre-mixed

Anti-Freeze Type Triumph HD4X Hybrid OAT coolant
Cooling System Capacity 2.4 litres
Radiator Cap Opening Pressure 1.1 Bar
Thermostat Opening Temperature 71°C <nominal>
Cooling Fan Switch On Temperature 103°C
Temperature Gauge Sensor Resistance 2.9 - 3.3 KW @ 15°C

Suspension

Front Fork Travel 120 mm

Recommended Fork Oil Grade KHL 15-10
Oil Level (fork fully compressed spring removed) 117mm
Oil Volume (dry fill) 664 cc
Front Fork Pull Through Groove on the outer tube is 5 mm below the
lower surface of the top yoke
Rear Wheel Travel 130 mm

Brakes

Front Type Two four piston calipers acting on twin discs

Front Caliper Piston Diameter 34.0 mm
Front Disc Diameter 305.0 mm
Front Disc Thickness 4.5 mm (standard)
4.0 mm (service limit)
Front Disc Run-out Max. 0.3 mm
Recommended Fluid DOT 4 brake and clutch
Rear Type Twin piston sliding caliper acting on single
disc
Rear Caliper Piston Diameter 27.0 mm
Rear Disc Dia. 255.0 mm
Rear Disc Thickness 6.0 mm (standard)
5.0 mm (service limit>
Rear Disc Run-out Max. 0.25 mm
Rear Master Cylinder Diameter 14.0mm
Recommended Fluid DOT 4 brake and clutch

1.36 Service Manual - Tiger Explorer

 General Information

Full Specification Tiger Explorer

Wheels and Tyres

Front Wheel Size MT 2.5 x 19

Front Tyre Size 110/80 - R19
Front Tyre Pressure 2.48 bar <36 lb/in2)
Recommended Front Tyre Option 1 Metzler Tourance EXP
Option 2 Pirelli Scorpion Trail
Option 3 Bridgestone BW501
Front Wheel Rim Axial Run-out 0.5 mm
Front Wheel Rim Radial Run-out 0.5 mm
Rear Wheel Size MT 4.0 x 17
Rear Tyre Size 150/70 - R17
Rear Tyre Pressure 2.90 bar (42 lb/in2)
Recommended Rear Tyres Option 1 Metzler Tourance EXP - M specification
Option 2 Pirelli Scorpion Trail
Option 3 Bridgestone BW502
Rear Wheel Rim Axial Run-out 0.5 mm
Rear Wheel Rim Radial Run-out 0.5 mm

Frame

Frame Type Steel trellis

Overall Length 2,248 mm C88.5 in)
Overall Width 885 mm (34.8 in)
Overall Height 1,410 mm (55.5 in)
Wheelbase 1,530 mm (60.2 in)
Seat Height 837 mm <32.9 in)
Rake 23.9°
Trail 105.5 mm
Wet Weight 259 kg
Max. Payload Crider, passenger, luggage &. accessories) 222 kg

Electrical Equipment

Battery Type YTX20L-BS

Battery Rating 12V - 18 Amp. Hour
Alternator Rating 70Amp
Tail/Brake Light LED
Fuses See page 18-11

Service Manual - Tiger Explorer 1.37

General Information

Torque Wrench Settings

Cylinder Head Area

Application Torque <Nm) Notes

Camshaft cover to cylinder head 14 Fit new sealing washer(s). Apply
engine oil to seals
Secondary air injection valve covers to camshaft cover 8
Camshaft drive chain tensioner to crankcase 9
Camshaft bearing ladder to head 10 Lubricate threads with engine oil
Camshaft sprocket to camshaft 22 Replace fixing(s) if removed
Camshaft drive chain top pad to cylinder head 10 Replace fixing(s) if removed
Cylinder head to crankcase CM6 screws) 10 Replace fixing(s) if removed
Cylinder head to crankcase bolts * Refer to section 3
Cylinder head dry seal plug 22 Apply Three Bond 13 60 to threads
Spark plugs 12
Cylinder head exhaust stud 10 Replace fixing(s) if removed
Wire guide 20

Clutch

Application Torque <Nm> Notes

Clutch cover to crankcase 11 See text
Clutch centre nut 160 Replace fixing(s) if removed
Clutch pressure plate to centre drum 10
Clutch master cylinder clamp bolts 12
Clutch lever nut 6
Clutch lever pivot bolt 1
Clutch slave cylinder to clutch cover 10
Clutch slave cylinder bleed screw 8
Clutch hose union to master cylinder and slave cylinder 25 Fit new sealing washer(s)
Clutch master cylinder cover 1.5

1.38 Seivice Manual - Tiger Explorer

 General Information

Crankshaft and Crankcases

Application Torque <Nm> Notes

Crankcase upper to lower CMS fixings) * Refer to section 5

Crankcase upper to lower (M6 fixings) * Refer to section 5

Connecting rod big end nut * Refer to section 5

Balancer gear to crankshaft 35

Big end bearings * Refer to section 5

Crankcase coolant drain plug 8 Fit new sealing washer(s)

Breather plate to crankcase 12 Replace fixing(s) if removed

Flywheel to crankshaft * Refer to section 5

Crankcase dry seal plug 22 Apply ThreeBond 1305 to threads

Engine Covers

Application Torque <Nm> Notes

Clutch cover to crankcase 11 See text

Clutch slave cylinder cover 4 Replace fixing(s) it'removed

Selector cover to crankcase (28 mm fixing) 11 See text

Selector cover to crankcase (90 mm fixing) 11 See text

Flywheel cover 11 See text

Crankcase cover to crankcase 11 See text

Balancer cover to crankcase 11 See text

Breather cover to crankcase 11

Crankcase harness guide left hand fixing 8 Use new fixing(s)

Crankcase harness guide right hand fixing 8 Use new fixing(s)

Sump cable tidy 3

Service Manual - Tiger Explorer 1.39

General Information

Transmission

Application Torque CNm> Notes

Transmission housing to crankcase 20 Replace fixing(sl if removed

Input shaft bearing retainer 12 Replace fixing(s) if removed
Detent wheel to selector drum 12 Replace fixing(s) if removed
Detent arm bolt 12 Replace fixing(s) if removed
Selector drum bearing retaining screw 12 Replace fixing<sl if removed
Gear position sensor 5 Replace fixing(sl if removed
Gear pedal crank pinch bolt 9
Gear change rod lock nuts 6
Gear pedal pivot bolt 9 Replace fixing(sl if removed
Bevel box front cover bolts 25 Replace fixing(sl if removed
Bevel box side cover bolts 9 Replace fixing(sl if removed

Lubrication System

Application Torque CNm> Notes

Sump to crankcase 12
Sump drain plug to sump 25 Fit new sealing washer(s)
Oil pressure relief valve 15 Apply ThreeBond 1305 to threads
Low oil pressure warning light switch to crankcase 13 Fit new sealing washer<sl
Oil filter adapter 10
Oil filter to adapter 10
Oil pump to crankcase 8 Replace fixing(s) if removed
Oil pump drive sprocket to pump shaft 12 Replace fixing<sl if removed
Oil pump drive chain guide 6 Replace fixing(sl if removed
Oil feed pipe casting 8 Replace fixing(sl if removed
Heat exchanger to oil pump 10 Replace fixing(sl if removed
Oil level sensor to sump 9
Breather drain tube 9 Replace fixing(sl if removed

1.40 Service Manual - Tiger Explorer

 General Information

Cooling System

Application Torque <Nm> Notes

Radiator upper mountings to frame 9
Radiator lower mountings to brackets 9
Radiator lower brackets to engine 18

Radiator drain plug 1.5

Hose clips 2

Thermostat housing to head 9

Crankcase coolant drain plug 8

Water temperature sensor 18

Radiator fan cowl fixings 8

Expansion tank bracket to frame 9

Expansion tank cover upper fixing 3
Expansion tank cover lower fixing 7

Service Manual - Tiger Explorer 1.41

General Information

Fuel System, Exhaust System and Airbox

Application Torque CNm> Notes

Fuel tank to frame 12

Fuel cap to fuel tank 4

Fuel pump mounting plate to fuel tank 9
Throttle body transition piece to cylinder head 9
Throttle body to transition piece clip 1.5
Throttle balance blanking screw 5
Fuel rail to throttle bodies 3.5
Throttle position sensor 3.5
Exhaust downpipe to cylinder head 19 Refer to section 10
Exhaust downpipe to frame 15
Exhaust downpipe clamp to silencer 10 Torque every service
Silencer to frame 30
Silencer front and rear end caps 5
Oxygen sensor 25
Secondary air injection solenoid 2
Air filter housing 3
Airbox bracket to throttle bodies 3
Airbox to mounting bracket 5
Air temperature sensor 4
MAP sensor 2
Barometric pressure sensor 6
Fall detection switch 3 Replace fixing(s) if removed
Crankshaft position sensor 6 Replace fixing(s) if removed
ECM security bracket 7
Immobiliser and TPMS module 2
Evaporative cannister 8
Gear position sensor 5
Sump cable tidy 3

1.42 Service Manual - Tiger Explorer

 General Information

Front Suspension

Application Torque <Nm> Notes

Upper yoke pinch bolt 25

Lower yoke pinch bolt 25

Fork top cap 30

Headstock upper nut 90

Damping cylinder bolt 22.5 Fit a new washer

Damping rod lock nut 15
Handlebar clamp base to top yoke CM 10 bolt) 35
Handlebar upper clamp to lower clamp CM8 bolt) 26
Handlebar grip, left hand side 3
Handlebar end weights 5
Headstock adjuster nut 40 Refer to section 12
Headstock lock nut 40 Refer to section 12
Throttle grip guide 3
Switch cube screws, left hand side 2.5

Switch cube screws, right hand side 2.5

Cable guide, lower yoke 6

Cable guide, upper yoke 7

Clutch switch 2
Front brake light switch 2

Rear Suspension

Application Torque <Nm> Notes

Swinging arm to frame left hand pivot pin 170 Refer to section 13
Swinging arm to frame right hand pivot pin 45 Refer to section 13
Swinging arm to frame Pivot locking ring 110 Refer to section 13
Rear suspension unit upper mounting bolt 48

Rear suspension unit lower mounting bolt to drop link 85

Remote reservoir clamp 3

Drag link to frame 85

Drop links to swinging arm 85

Torque arms to rear bevel box 48

Torque arms to frame 48

Hose guide on torque arm 5

Service Manual - Tiger Explorer 1.43

General Information

Rear Bevel Box and Drive Shaft

Application Torque CNm> Notes

Filler/level plug 25
Drain plug 25
Left hand pivot pin 100
Right hand pivot pin 48
Locking ring - right hand pivot pin 100
Back plate to bevel box housing 30
Rubber boot clip 1.5

Wheels

Application Torque CNm> Notes

Front wheel spindle/axle bolt 65
Front wheel spindle pinch bolts 22
Rear wheel to the final drive unit 70
Tyre valve - models without tyre pressure monitoring system 6
Tyre valve - models with tyre pressure monitoring system 5

Front Brakes

Application Torque CNm> Notes

Front brake caliper to fork so
Front brake caliper bolts 24
Front brake pad retaining pin 18
Front brake caliper bleed screw 5
Front brake hose to caliper 25
Front brake master cylinder to handlebar 12
Front brake hose to master cylinder 25
Front brake hose to clamp on front fork 3
Front brake disc to wheel 22 Replace fixing(s) if removed
Brake lever pivot bolt 1
Brake lever pivot bolt lock nut 6
Brake light switch 2
Front caliper hose support to front fork 3
Front brake light switch 2

1.44 Service Manual - Tiger Explorer

 General Information

Rear Brakes

Application Torque <Nm> Notes

Rear brake caliper 40 Replace fixing(s) if removed

Rear brake pad retaining pin 17
Rear brake caliper bleed screw 6
Rear brake hose to caliper 25
Rear brake master cylinder 18
Rear brake master cylinder reservoir 6
Rear brake hose to master cylinder 25
Brake pedal pivot bolt 22 Replace fixing(s) if removed
Brake hose P-clip bolt 6 Replace fixing(s) if removed
Brake line cover 6 Replace fixing(s) if removed
Rear brake disc 22 Replace fixing(s) if removed
Lock nut, master cylinder push rod 18

ABS System

Application Torque <Nm> Notes

ABS module to bracket 9

ABS bracket to frame lower fixing 9
ABS rear pulser ring 5 Replace fixing(s) if removed

ABS front and rear sensors 9 Replace fixing(s) if removed

ABS lines to modulator 25

ABS hard line to front brake hose 17
Rear brake line to crankcase tidy 8 Replace fixing(s) if removed

Service Manual - Tiger Explorer 1.45

General Information

Frame, Footrests, Control Plates and Engine Mountings

Application Torque <Nm> Notes

Upper crankcase to frame 105 Refer to section 9

Lower crankcase to frame 105 Refer to section 9

Cylinder head rear mountings to frame 85 Refer to section 9

Cylinder head front left hand mounting initial torque 24 Refer to section 9

Cylinder head front left hand mounting to frame 115 Refer to section 9

Cylinder head front right hand mounting to frame 100

Control plate to frame 18

Heel guard to control plate 7

Rear footrest hanger 27

Engine to frame adjuster - except cylinder head adjuster 5 Refer to section 9

Engine to frame adjuster - cylinder head adjuster 5 Refer to section 9

Handguard to its bracket 8

Handguard to spacer 8
'
Side stand mounting bolts 70

Side stand pivot 20

Side stand pivot bolt nut 20

Side stand switch 7 Replace fixing(s) if removed
Centre stand mounting bolts so
Centre stand spring upper mounting bracket 18

Centre stand spring lower mounting bracket 30

Centre stand bump stop 7

Seat bridge to frame 30
Seat lock barrel to frame 4 Apply ThreeBond 1360 to threads
Seat lock to frame 9

Cockpit subframe 30
Right hand heel guard 7

Pannier rail 27
Headstock brace to frame bolts 12

Headstock brace to frame lock nuts 12

Right hand engine protector bar to lower crankcase lock nut 105

Engine bar to radiator mounting bracket 18

Engine bar centre mounting 23
Engine bars link bar 5
Pannier third mount fixings 8
Pannier link bar lock nuts 8

1.46 Service Manual - Tiger Explorer

 General Information

Electrical

Application Torque <Nm> Notes

Alternator to crankcase 28
Alternator drive gear 54 Replace fixing(s) if removed

Alternator de-coupler to drive gear 3

Alternator power lead connection 10
Starter motor to crankcase 9

Starter motor power lead connection 7

Starter motor cover 4

Starter motor solenoid lead connection 5

Spark plug to cylinder head 12

Horn 18
Immobiliser ECU 2
Ignition switch 12 Replace fixing(s) if removed

Instrument pack 2
Headlight surround 3
Rear light 4

Front and rear indicator 5

ECM Security bracket 7 Replace fixing(s) if removed

Fog light subframe to chin panel 5

Fog light frame adjustment fixings 8

Fog light shroud to sub frame 6

Fog light to its shroud 3

Fog light switch bracket 5

Fog light switch to bracket 4

Front brake light switch 2

Clutch switch 2
Front auxiliary socket 2

Service Manual - Tiger Explorer 1.47

General Information

Bodywork

Application Torque <Nm> Notes

Mirror 25
Rear panel to frame 7
Front fork protectors 5
Front mudguard to front forks 7
Under seat tray 7
Rear mudguard upper fixings 7 Replace fixing(s) if removed

Rear mudguard lower fixings 5

Fuel tank front panel fixings 3
Side fairings to fuel tank 3
Radiator infill panel 3
Fuel tank infill panels 3
Badge housing to side fairing 3 Replace fixing(s) if removed

Windsceen to its frame 4

Windscreen frame to its support 4
Windscreen support 15
Cockpit infill panel 3
Cockpit side panel front fixing 5
Handguard to spacer 8
Handguard to bracket 8
Upper mudguard to chin panel 7
Upper mudguard infill panels 4
Chin panel to headlight support 5
Cockpit subframe 30
Headlight to cockpit subframe 4
Headlight support to cockpit frame 5
Upper mudguard mounting bracket 5
Seat infill panel 3
Sump guard to its mounting· brackets 6
Sump guard brackets to engine 6
Pannier rail 27
Luggage rack 27
Luggage rack cover 7
Mirror boss 25
Mirror lock nut 25

1.48 Service Manual - Tiger Explorer

 General Information

Clutch Hose Routing

Service Manual - Tiger Explorer 1.49

General Information

Main Wiring Harness Routing

1.50 Service Manual - Tiger Explorer

 General Information

ABS and Brake Hose Routing

Service Manual - Tiger Explorer 1.51

General Information

Fuel Tank Breather Hose Routing

1.52 Service Manual - Tiger Explorer

 2 Scheduled Maintena nce
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

Scheduled Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

Seivice Manual - Tiger Explorer 2.1

Scheduled Maintenance

Introduction Scheduled maintenance may be carried out by your

To maintain the motorcycle in a safe and reliable
condition, the maintenance and adjustments outlined in
this section must be carried out as specified in the
schedule of daily checks, and also in line with the
scheduled maintenance chart.
Weather, terrain and geographical location affect
maintenance. The maintenance schedule should be
adjusted to match the particular environment in which the
vehicle is used and the demands of the individual owner.
For advice on adjusting the service schedule, consult your
authorised Triumph dealer.
- -- - - - - - -
! 1
•\ ,&: ' - r !-! r !,,,,,
~ - - - -- - -
In order to correctly carry out the maintenance items
listed in the scheduled maintenance chart, special tools
and specialist knowledge will be required. As only an
authorised Triumph dealer will have this knowledge and
equipment Triumph strongly recommends that your
authorised Triumph dealer carries out all scheduled
maintenance.
A dangerous riding condition could result from incorrect
maintenance leading to loss of motorcycle control and
an accident
dealer in three ways; annual maintenance, mileage based
maintenance or a combination of both, depending on the
mileage the motorcycle travels each year.
Motorcycles travelling fewer than 10,000 miles per
year must be maintained annually. In addition to this,
mileage-based items require maintenance at their
specified intervals, as the motorcycle reaches this
mileage.
Motorcycles travelling approximately 10,000 miles
per year must have the annual maintenance and the
specified mileage-based items carried out together.
Motorcycles travelling more than 10,000 miles per
year must have the mileage-based items maintained
as the motorcycle reaches the specified mileage. In
addition to this, annual based items will require
maintenance at their specified annual intervals.
In all cases maintenance must be carried out at or before
the specified maintenance intervals shown. Consult an
authorised Triumph dealer for advice on which
maintenance schedule is most suitable for your
motorcycle.
! ~ J Ii f ;
- - ---- - - -

'.
-- -
Triumph Motorcycles cannot accept any responsibility
'.: . for damage or injury resulting from incorrect
-- - -- - - - - - - -
maintenance or improper adjustment carried out by the
All maintenance is vitally important and must not be
owner.
neglected. Incorrect maintenance or adjustment may
cause one or more parts of the motorcycle to Since incorrect or neglected maintenance can lead to a
malfunction. A malfunctioning motorcycle is dangerous dangerous riding condition, always have an authorised
and may lead to an accident. Triumph dealer carry out the scheduled maintenance of
this motorcycle.

2.2 Service Manual - Tiger Explorer

 Scheduled Maintenance

Scheduled Maintenance Chart

Odometer Reading in Miles CKmsl or time period,

whichever comes first
First Annual Mileage based service
Service Service
Operation Description Every 500 year 10,000 and 20,000 40,000
(800) 30,000 (32,000l (64,000l
1 month (16,000 and
48,000l
Engine- check for leaks Day . • • • .
Engine oil - renew - • • • • •
Engine and oil filter - renew - . . • • .
Valve clearances - check/adjust - •
Camshaft timing - adjust - only first
10,000 mile (16,000 km> seivice
- .
Air cleaner - renew - . . •
Autoscan - carry out a full Autoscan using
the Triumph Diagnostic tool (print a
-
. . . . ' •
customer copy)
ABS and immobiliser ECMs - check for
stored DTCs
- • • . • •
Spark plugs - check - •
Spark plugs - renew - . •
Throttle bodies - balance - • • •
Throttle body plate (butterfly) -
check/clean
- . • .
Cooling system - check for leaks Day • . • • •
Coolant level - check/adjust Day . • • • •
Coolant - renew Every 3 years regardless of mileage
Fuel system - check for leaks, chafing etc. Day • . • • •
Lights, instruments and electrical systems Day
• • . • •
- check
Steering - check for free operation Day • • • . .
Headstock bearings - check/adjust - • . • • •
Headstock bearings - lubricate - • •
Forks - check for leaks/smooth operation Day • . • . .
Fork oil - renew - •
Brake fluid levels - check Day • . . . •
Brake fluid - renew Every 2 years regardless of mileage
Brake pad - check wear levels Day • . • • •
Brake master cylinders - check for fluid
leaks
Day
• . • • .
Brake calipers - check for fluid leaks and
seized pistons
Day . . • • .
Rear suspension linkage - check/lubricate - • •
Fasteners - inspect visually for security Day • . . • •

Service Manual - Tiger Explorer 2.3

Scheduled Maintenance

Odometer Reading in Miles <Kms) or time period,

whichever comes first
First Annual Mileage based service
Service Service
Operation Description Every 500 year 10,000 and 20,000 40,000
(800) 30,000 (32,000) (64,000)
1 month (16,000 and
48,000)
Wheels - inspect for damage Day . • • • .
Wheel bearings - check for wear/smooth
operation
- . • • . •
Tyre wear/tyre damage - check Day • • • • .
Tyre pressures - check/adjust Day . . . . •
Clutch - check operation Day . • • • •
Clutch master cylinder - check for leaks - . • • • •
Clutch fluid levels - check Day • • • • .
Clutch fluid - renew Every 2 years regardless of mileage
Final drive - check for oil leaks Day . . . • •
Final drive oil - renew - only first seivice - •
Stands - check operation Day . . . • •
Exhaust clamp bolts - check/adjust - • • • . .
Accessory rack sliding carriage - check for -
correct operation::t:
• • • •
Accessory pannier link bar - check for
correct operation and adjustment::t:
-
. . . • •
Secondary air injection system - check • •
Fuel and evaporative loss* hoses - renew Every 4 years regardless of mileage
*Evaporative system fitted to models for certain markets only.
::t:Only if fitted.

2.4 Service Manual - Tiger Explorer

 3 Cylinder Head
Table of Contents
Exploded View - Cylinder Head and Valves.. . . . ........ ...... . ....... ........ .. .. . ... . ... . .... 3.2
Exploded View - Camshaft Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Exploded View - Camshaft, Camshaft Drive and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Cylinder Head Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Camshaft Cover.. ... . ...... . .......... ......... .... ....... .......... . .. ...... . .. ....... . .. 3.5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Installation ..... . .. ........... ......... . . ...... ..... .... . . . ...... ..... .. .... . '. . . . . . . . . . 3.7
Camshaft Drive Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Camshafts and Camshaft Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Camshaft and Sprocket Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Camshaft and Bearing Cap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Camshaft Installation and Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Valve Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
Valve Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Camshaft Drive Chain, Tensioner Blade and Rubbing Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Inspection - Camshaft Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Inspection - Camshaft Drive Chain Tensioner and Rubbing Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Disassembly - Camshaft Drive Chain Tensioner Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
Valves and Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
Removal from the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
Valve to Valve Guide Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
Valve Face Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

Seivice Manual - Tiger Explorer 3.1

Cylinder Head

Exploded View - Cylinder Head and Valves

~ ...,

See text

Refer to
section 9

3.2 Seivice Manual - Tiger Explorer

 Cylinder Head

Exploded View - Camshaft Cover

14Nm
u
w ~
u
~
Apply engine
~w

~
~
u ~

oil to seals

Service Manual - Tiger Explorer 3.3

Cylinder Head

Exploded View - Camshaft, Camshaft Drive and Valves

9Nm

27Nm

3.4 Service Manual - Tiger Explorer

 Cylinder Head

Cylinder Head Description Camshaft Cover

The engine is fitted with an aluminium alloy cylinder head,
which carries the camshafts, valves and spark plugs. The Removal
cylinder head is cast as a single entity and various
components are permanently added after machining. 1. Remove the rider's seat <see page 17-16).
The camshafts run directly in · the head without separate 2. Disconnect the battery, negative (black> lead first.
bearings. Valve clearances are adjusted by changing 3. Remove the fuel tank <see page 10-117J.
variable thickness shims which sit between the valve
4. Remove the airbox <see page 10-126).
tappet bucket and the valves.
5. Drain the coolant <see page 11.fJJ.
The camshafts are driven by a silent-type drive chain, via a
sprocket bolted to each of the camshafts, using slotted 6. Disconnect the right hand coolant hose at the
holes. The use of slotted holes allows the camshaft timing radiator and position aside.
to be adjusted very accurately, to compensate for Z Disconnect the electrical connections to the ignition
manufacturing tolerances in the camshaft drive system. coils and remove the coils.
The chain is guided by two blades and is tensioned by a
hydraulic tensioner.
The hydraulic tensioner is fed oil via a gallery in the
cylinder head. The combination of oil pressure and spring
pressure pushes the plunger against the tensioner blade
which tensions the camshaft drive chain. The hydraulic
tensioner has an oil pressure relief valve located in the
plunger that is set to open between 12 - 16 bar and when
open sprays oil through a drilling in the tensioner blade
onto the camshaft drive chain.
Oil is supplied to the head by a gallery in the crankcase.
Once supplied to the head, the oil is distributed along
internal drillings within the head casting and camshaft.
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 1. Electrical connectors
prevention of valve bounce at high engine speed and to 2. Ignition coils
give a smooth valve actuation. When assembling the
cylinder head it is important that the close wound, colour 8. Detach the secondary air injection hose from the
coded ends of the springs are fitted downwards (towards reed valves on top of the camshaft cover.
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.

A..Caution
In any of the following operations which necessitate the
removal or disconnection of the camshaft drive chain,
NEVER turn the engine without the camshaft drive
chain and tensioner correctly fitted and adjusted. In the
disassembled condition, the pistons will contact the
valves if the crankshaft is turned, causing severe engine
damage.

1. Spring-close clip
2. Secondary air injection hose
3. Reed valve assemblies

Service Manual - Tiger Explorer 3.5

Cylinder Head

9. Note the position of the connector bracket and 12. Noting its position, remove the air deflector towards
release the fixings securing the valve covers to the the rear of the motorcycle. Discard the fir-tree clip.
camshaft cover.

chok

1. Air deflector
1. Connector bracket 13. Progressively release the camshaft cover bolts in the
2. Fixings sequence shown below.
3. Reed valve assemblies
Note:
10. Ease the valve covers from the valves.
• Two shorter bolts are fitted at the end adjacent
11. Remove the air deflector fir-tree clip.
to the camshaft drive chain.

Cam oover
1. Fir-tree clip
Camshaft Cover Bolt Release Sequence
14. Carefully manoeuvre the camshaft cover towards the
front of the motorcycle, clear of the throttle bodies.
Then manoeuvre the cover to the right to remove it
from the motorcycle.

Never use a lever to remove the camshaft cover from

the cylinder head.
Using a lever will cause damage to the head and
camshaft cover which could lead to an oil leak.

3.6 Service Manual - Tiger Explorer

 Cylinder Head

15. Remove the camshaft cover gasket and plug tower 3. Fit a new camshaft cover seal to the groove in the
seals. If necessary, recover the dowels from the camshaft cover.
secondary air injection holes in the head (these may
come away in the cover or gasket).
16. Discard the camshaft cover seal, bolt seals and the
spark plug tower seals.
17. Remove any residual oil from the front of the
cylinder head using a syringe or lint free cloth.

Installation

1. Fit new plug tower seals to the camshaft cap ladder.

chdk

1. Camshaft cover seal groove

4. Apply silicone sealer to the areas arrowed in the
diagram below (at the factory, ThreeBond 1215 is
used).

1. Plug tower seals

2. Refit the dowels to the cylinder head.

chdk

1. Silicone sealer areas

5. Fit the camshaft cover, ensuring that the dowels,
gasket and seals remain in the correct positions.
6. Apply a thin film of engine oil to both sides of the
new washers for the camshaft cover bolts.
7. Fit the camshaft cover screws and screw seals, then
tighten until finger tight.

1. Dowels

Service Manual - Tiger Explorer 3.7

Cylinder Head .
. hten the cams haft cover bolts to 14 Nm in 11. . . coils and reconnect.
Fit the ignition
8. Finally, t1gnce shown below.
the seque

\
1· Coils
""' . ht hand coolant hose, refit the hose
ct the ng
12 Reconne to 2 Nm.
. clip and tighten (see page 11-ll.
r g system
13. Refill the coo
. b in <see pa ge 10-127l. '
Refit the air ox age 10-119).
valves.
14. R ft1 the fuel tank (see P . . ( edl lead first.
15. e battery pos1t1ve r
Reconnect the 17-16>.
16.
lZ Refit the seats <see page

cdqy hose clip

1. Spring-close. . ·ection hose
2 Secon dary air '"I bl
3.• Reed va 1ve assem Y

3.8 Service Manual - T 19er Explorer

 Cylinder Head

Camshaft Drive Chain Tensioner 5. Turn the engine clockwise until the pin can be
inserted fully in to the crankshaft.

Removal

1. Remove the camshaft cover (see page 3-S>.

2. Remove the right hand crankshaft cover, noting the
position of the patch-locked bolt. Discard the
patch-locked bolt.

1. Crankshaft Timing Pin T3880601

2. Timing hole in crankcase
Note:

In addition to the Crankshaft Timing Pin

T3880601 being installed in to the crankshaft
at me, the alignment marks on the camshaft
1. Right hand crankshaft cover bosses will point inwards at a point level with
2. Patch-locked bolt
the joint face.

3. Rotate the crankshaft clockwise (the normal direction

of rotation) using the bolt fitted to the end of the 1
cranksha~ Stop rotation just before the marks on
the camshaft bosses point inwards at a point level
with the joint face.

gaaa_2

1. Alignment marks
6. Place a suitable wedge between the camshaft drive
chain tensioner blade and crankcase, to hold the
camshaft drive chain taut during removal of the
gaaa_2
tensioner.
- - .

1. Alignment marks
! '.' f: ' r ' ! • ~
4. Insert the Crankshaft Timing Pin T3880601 in to the . -

timing hole in the crankcase. The hydraulic tensioner is under spring tension. Always
wear hand, eye, and face protection when withdrawing
the tensioner mounting bolts and take great care to
minimise the risk of injury and loss of components.

Service Manual - Tiger Explorer 3.9

Cylinder Head

Note: bl Remove the spring.

Note the orientation of the tensioner before
removal.
7. Evenly release the camshaft drive chain tensioner
mounting bolts until the plunger spring tension has
been released.
8. Remove the camshaft drive chain tensioner and
discard the 0 -ring and gasket

Inspection

1. Inspect the spring for damage and deformation.

Renew as necessary.
2. Inspect the tip of the plunger for wear and damage.
Renew as necessary. cfll>

1. Spring
Installation c) While holding the resister ring in place, pour
out the engine oil into a suitable container.
1. To set the camshaft drive chain tensioner onto the dl Ensure the resister ring is correctly located as
first tooth of the ratchet (i.e. minimum extension) shown in the illustration below.
carry out the following :
Note:
If installing a new camshaft drive chain
tensioner, do not release the plunger before
fitting.
If installing the original camshaft drive chain
tensioner, the engine oil must be drained out
of the tensioner to enable the plunger to be set
onto the first tooth of the ratchet.
al Hold the resister ring ends together and pull
out the plunger.

cfho

1. Resister ring
el Refit the spring.

cfei_2

1. Resister ring ends

2. Plunger

3.10 Seivice Manual - Tiger Explorer

 Cylinder Head

fl Hold the resister ends together and push the D To release the hydraulic tensioner, rotate the
plunger through the resister ring until the crankshaft 90° (1/4 turn) anti-clockwise using the
groove for the snap ring aligns with the snap bolt fitted to the end of the crankshaft. Then
ring. rotate the crankshaft clockwise until the
Crankshaft Timing Pin T3880601 can be
inserted into the crankshaft.
m) Check that there is tension in the camshaft
drive chain and the timing marks on the
camshaft bosses are correctly aligned.
Note:
• After fitting to the engine, the hydraulic
tensioner will be empty of engine oil. After
starting the engine, the camshaft drive chain
and tensioner blade will be noisy until full oil
pressure is felt at the tensioner plunger. This
could take up to 5 seconds.
cfei_2 n) Check that the tensioner plunger is correctly
located in the middle of the tensioner blade
when viewed from above.
1. Resister ring
o) Rotate the engine through 4 full revolutions,
2. Plunger
and reset number 1 cylinder to TDC. Ensure
3. Groove for snap ring
that the Crankshaft Timing Pin T3880601 can
4. Snap ring
be inserted fully into the timing hole in the
g) When the groove aligns with the snap ring, crankcase and crankshaft.
release the resister ring and move one end of
the snap ring into the groove. Slowly release
the plunger to ensure that it is held in place.

1. Crankshaft Timing Pin T3880601

2. Timing hole in crankcase
cfej

1. Groove for snap ring

2. Snap ring
h) Fit a new 0 -ring and gasket to the camshaft
drive chain tensioner.
i) Fit the camshaft drive chain tensioner to the
cylinder head as noted for removal. Tighten the
bolts to 9 Nm.
j) Remove the wedge, taking care not to move or
damage the tensioner blade.
k) Remove the Crankshaft Timing Pin T3880601 .

Seivice Manual - Tiger Explorer 3.11

Cylinder Head

p) Check that the camshaft boss timing marks Camshafts and Camshaft Timing
align as illustrated below.

Removal
1
1. Remove the camshaft cover (see page 3-5>.
2. Remove the crankshaft cover <see page 5-22).
3. Remove the spark plugs to reduce compression
resistance when turning the engine.
4. Rotate the engine using the 24 mm hexagon on the
end of the crankshaft so any two camshaft sprocket
fixings are accessible.

Note:
• The camshaft sprocket fixings need only be
loosened sufficiently to allow the sprockets to
gaaa_2 rotate on the camshafts.
Camshaft Boss to • The camshaft sprocket fixings are patch locked
and must never be re-used if loosened or
Cylinder Head Alignment Marks
removed; however new fixings should only be
1. Alignment marks installed during final tightening after the timing
q) Re-check the tensioner plunger location against procedure has been completed.
the tensioner blade. If the sprockets are to be removed from the
r) Remove the Crankshaft Timing Pin T3880601 . camshafts, temporarily refit the sprockets for
s) Refit the camshaft cover (see page 3-TJ. timing adjustment using the old fixings, and
only install new fixings during final tightening.
t) Refit the crankshaft cover (see page 5-22).
5. Loosen the two camshaft sprocket fixings. Do not
remove the fixings at this stage.

1. Fixings
6. Rotate engine until the remaining two fixings are
accessible.

4 Caution
Do not rotate the engine further once the four camshaft
sprocket bolts have been loosened. Rotation of the
engine with the four sprocket bolts loose will result in
valve to piston contact and serious engine damage.

7. Loosen the two remaining camshaft sprocket fixings.

Do not remove the fixings at this stage.

3.12 Seivice Manual - Tiger Explorer

 Cylinder Head

Note: 14. Lift the camshaft drive chain from the exhaust
camshaft sprocket and remove the exhaust camshaft.
• Note the orientation of the tensioner before
removal.
8. Evenly release the camshaft drive chain tensioner
mounting bolts until the plunger spring tension has
been released.
9. Remove the tensioner and discard the 0-ring and
gasket
10. Note the orientation of the camshaft ladder in
relation to the head.
11. Progressively release the bolts securing the camshaft
ladder to the head in the sequence shown below.

1. Camshaft drive chain

2. Inlet camshaft

15. Remove the camshaft drive chain and if necessary

the tensioner blade and rubbing strip (see
page 3-20>. '
16. Rotate the crankshaft and insert the Crankshaft
Timing Pin T3880601 . Ensure the crankshaft can no
longer rotate.

chec

Camshaft Ladder Bolt Release Sequence

12. Remove the camshaft ladder and top pad, and
collect the dowels <if loose) and spark plug tower
0-rings.
Note:
Each camshaft and sprocket is removed as an
assembly.
13. Lift the camshaft drive chain from the inlet camshaft
sprocket and remove the inlet camshaft.

1. Crankshaft Timing Pin T3880601

2. Timing hole in crankcase

lZ At this stage the camshafts and sprockets can be

separated if required.

Service Manual - Tiger Explorer 3.13

Cylinder Head
Camshaft and Sprocket Identification
Note:
• The inlet and exhaust camshafts are different.
They can be identified by a raised section in
the centre of the exhaust camshaft and a plain
section in the same place on the inlet camshaft.
In addition, the thrust faces on each camshaft
are offset from each other, which prevents the
camshafts being fitted incorrectly.
1. Exhaust camshaft
2. Plain section
3. Inlet camshaft
4. Raised section
5. Thrust faces
6. Offset
Never fit a camshaft sprocket to a camshaft using
incorrectly identified bolt holes. Severe engine damage
will result from incorrect attachment.
The same sprocket is used for both inlet and exhaust
camshafts, and is attached to the camshaft using slotted
bolt holes. The same holes are used when fitting the
sprocket to either camshaft.
Note that the mark on the camshaft boss is not a timing
mark, it is used as a visual aid during the timing
adjustment procedure.
Accurate camshaft timing can only be obtained using the
correct timing method and service tools as described on
page 3-75 in this chapter.
3.14 Seivice Manual - Tiger Explorer
Camshaft and Bearing Cap Inspection
1. Inspect the camshaft sprockets for damaged and
worn teeth. Replace as necessary.
2. Measure the camshaft journals with a micrometer. If
any journal is outside the specified tolerance, replace
the camshaft.
Camshaft Journal Diameters
I Standard: I 23.93 - 23 .96 mm
cheg
1. Camshaft journal
3. Examine all camshaft and camshaft bearing caps for
excessive wear and damage.
4. Check the journal-to-head clearances, using
'Plastigauge' ITriumph part number 3880150-T0301)
as follows :
Wipe the exposed areas of both the camshaft
journal and a single cap or cap area of the
ladder.
Apply a thin smear of grease to the journal and
a small quantity of silicone release agent to the
cap.
Size a length of the Plastigauge to fit across the
camshaft journal. Fit the Plastigauge to the
camshaft journal using the grease to hold the
strip in place.
Ensuring that the camshaft sprocket alignment
marking is located as for removal, refit the
camshaft cap ladder then evenly and
progressively tighten the ladder bolts to 10 Nm
in the correct sequence (see camshaft
installation).

Release the bolts and remove the ladder. Using
the gauge provided with the Plastigauge kit,
measure the width of the now compressed
Plastigauge.
Measuring the Compressed Plastigauge
Note:
The camshaft ladder is unique to each cylinder
head and is, therefore, not available separately.
If the camshaft ladder is worn or damaged, the
complete cylinder head must be replaced.
5. Calculate the journal clearance using the Plastigauge
chart supplied with the Plastigauge kit.
Camshaft Journal Clearance, Standard
Standard: 0.040 - 0.091 mm
Service Limit: 0.13 mm
6. If the clearance measured is within the specified
tolerance, remove the cap/ladder and clean off all
traces of Plastigauge. Assemble the camshafts (see
page 3-15>.
Note:
• If the measured clearance is outside the
tolerance, and the camshaft journals are within
tolerance, the cylinder head must be replaced.
A Caution
Although Plastigauge is oil soluble, all traces of the
material must be removed to prevent blockage of the oil
drillings and resultant engine damage.
Seivice Manual - Tiger Explorer
Cylinder Head
Camshaft Installation and Timing
A Caution
The camshaft sprockets are attached to the camshafts
using slotted bolt holes. This allows for very accurate
valve timing and therefore improved performance and
fuel economy.
Never fit the camshaft sprockets without correctly setting
the camshaft timing using the service tools and timing
procedure described below. Severe engine damage will
result from incorrect valve timing adjustment.
1. Check that the Crankshaft Timing Pin T3880601 is
installed. Ensure the crankshaft cannot rotate.
2. Thoroughly clean the camshafts and journals. Inspect
the ends of the camshafts for correct fitment of the
sealing plugs. Lubricate the camshafts with clean
engine oil before fitting to the cylinder head.
3. If removed, refit the camshaft sprockets noting their
orientation, and secure using the original bolts. DO
NOT tighten the fixings at this stpge, the sprockets
must be free to rotate.
4. Refit the camshaft drive chain and if removed the
tensioner blade and rubbing strip (see page 3-20).
Note:
Locate each camshaft to the head ensuring the
camshafts are correctly identified (inlet and
exhaust> and are also correctly located over
their respective valve banks.
5. Refit the exhaust camshaft to the cylinder head,
hooking the camshaft drive chain over the sprocket
as you do so.
6. Ensure there is no slack between the crankshaft and
exhaust sprocket when the sprocket fixings are
centrally located within the slotted holes.
Z Refit the inlet camshaft to the cylinder head, hooking
the chain over the sprocket as you do so.
8. Ensure the fixings on the inlet sprocket are also
centrally located within the slotted holes when there
is no slack between the exhaust and inlet sprockets.
9. Check that the chain is correctly located around the
crankshaft, and both camshaft sprockets.
3.15
Cylinder Head

10. Rotate the camshafts until the alignment marks on 13. Fit and evenly tighten the camshaft ladder fixings to
the end of the camshaft journals are pointing 10 Nm, in the sequence shown below, ensuring that
towards one another. the Camshaft Timing Plate T3880600 remains
centrally located between the camshafts.

gaaal

Camshaft Boss to
Cylinder Head Alignment Marks Camshaft Ladder Fixing Tightening Sequence
14. Refit the top pad and tighten the fixing~ to 10 Nm.
"4_~' Caution -,.
The Camshaft Timing Plate T3880600 must be located
centrally between the camshafts. Incorrect positioning of
the tool may prevent the camshaft ladder locating
correctly to the cylinder head during fixing tightening,
resulting in incorrect valve timing being set Severe
engine damage will result from incorrect valve timing
adjustment.

11. Insert the Camshaft Timing Plate T3880600 into the

camshaft slots, ensuring the removal screw is
unscrewed fully, as shown below. Ensure that the
tool is centrally located between the camshafts.

2
1. Camshaft drive chain top pad

1. Camshaft Timing Plate T3880600

2. Camshaft slots
3. Removal screw

12. Assemble the camshaft ladder in the same location

and orientation as prior to removal. Do not fit the top
pad at this stage.

3.16 Service Manual - Tiger Explorer