Triumph Tiger Motorcycle Service Manual 3850775 Issue 3 – PDF Download

Description

Triumph Tiger Motorcycle Service Manual — Part 3850775 Issue 3

This Triumph Tiger Motorcycle Service Manual is the workshop-level reference for the Triumph Tiger, published under Part Number 3850775 as Issue 3 and dated 08.99. It covers the complete machine across sixteen chapters — engine, clutch, balancers, crankshaft and pistons, transmission, lubrication, fuel injection and engine management, cooling, suspension, final drive, brakes, wheels, bodywork and the electrical system. Each chapter opens with its own contents page, then works through procedures step by step, in the order they should be carried out.

File Details

• Manual type: Motorcycle Service Manual
• Brand: Triumph
• Model: Tiger
• Part number: 3850775
• Issue: 3
• Date: 08.99
• Language: English
• File format: PDF
• Page count: 377 pages

Chapters Covered

• 1. General Information — how to use the manual, safety precautions (ignition, dangerous substances, fluoroelastomers, engine oils, brakes, fuel handling, electrical), repairs and replacements, service tools and garage equipment, full Tiger specification, torque wrench settings.
• 2. Maintenance — introduction, service check sheets, and the full scheduled maintenance routine from lights and battery through to valve clearances, drive chain and road test.
• 3. Cylinder Head & Camshaft — cam cover, cam chain tensioner, camshafts, camshaft and bearing cap inspection, valve clearances, cam chain, cylinder head removal/inspection/installation, valves and valve stem seals, valve-to-guide clearance, valve guides, valve face inspection.
• 4. Clutch — clutch cable, clutch removal, disassembly and assembly, friction plate inspection, friction plate thickness and bend/warp checks.
• 5. Balancers — balancer alignment inspection, balancer plug fitting, balancer shaft removal, disassembly, examination, assembly and installation.
• 6. Crankshaft, Rods and Pistons — engine removal/refit, crankcases, crankshaft removal and installation, connecting rods, big end bearing selection and crankpin wear, crankshaft main bearing/journal wear, crankshaft end float, pistons, piston rings and ring grooves, cylinder wear, cylinder liners, left hand crankshaft cover.
• 7. Transmission — description, auxiliary gears, alternator spindle, sprag clutch, starter idler gear, selectors, selector shaft and drum, input and output shaft assemblies, input shaft disassembly/assembly, output shaft disassembly/assembly.
• 8. Lubrication System — engine oil specification, engine oil circuit, oil level inspection, engine oil and filter change, oil pump and gears, low oil pressure warning light switch, sump, oil cooler.
• 9. Fuel System / Engine Management — fuel requirements, glossary, system description, sensors and actuators, wiring circuit diagrams (to VIN 89736 and from VIN 89737), system diagnostics, Triumph service diagnostic tool, electrical connectors, ECM MC 2000 and MC 1000, pinpoint tests for every DTC, fuel delivery system, fuel tank, fuel pump, fuel pressure regulator, airbox, air filter element, barometric pressure sensor, intake air temperature sensor, crankshaft position sensor, throttle cable, throttle bodies, throttle body balancing, injectors, throttle position sensor, idle air control valve, exhaust system, evaporative loss control system.
• 10. Cooling System — coolant, radiator hoses, radiator and cooling fan, coolant level inspection, coolant replacement, coolant pressure cap, water pump, radiator, thermostat.
• 11. Rear Suspension / Final Drive — rear suspension unit removal and installation, swinging arm removal, inspection and installation, drive chain slack inspection, adjustment, wear inspection, lubrication, drive chain (split link type) removal and replacement.
• 12. Front Suspension / Steering — fork inspection, headstock adjustment, fork oil change, fork oil level setting, fork oil level chart, forks removal/installation, disassembly, assembly.
• 13. Brakes — braking system maintenance safety precautions, fluid level inspection, changing brake fluid, brake pads, brake wear inspection, brake lights, bleeding the front and rear brakes, front brake pads, front brake caliper, front brake master cylinder, front brake discs, rear master cylinder, rear brake disc.
• 14. Wheels / Tyres — tyres, tyre pressures, tyre wear/wheel inspection, minimum recommended tread depth, important tyre information, front wheel removal/installation, rear wheel removal/installation, wheel bearings removal/installation, bearing tool selection chart.
• 15. Bodywork & Frame — seats, right hand and left hand in-fill panels, right hand and left hand side panels, rear panel and rack, cockpit, frame, footrests and fixings.
• 16. Electrical System — battery removal/refit/charging/maintenance, headlights, headlight bulb replacement, position lamp bulb replacement, rear light bulb replacement, indicator bulb replacement, alternator, starter motor, relay packs, instrument pack, full lighting and starting/charging circuit diagrams with key to wiring colour codes.

Where the model changed during production, the manual splits procedures accordingly — the engine management system is covered separately to VIN 89736 and from VIN 89737, the MC 2000 and MC 1000 ECM types each have their own wiring key, connector pin numbering and pinpoint test tables, and the barometric pressure sensor is treated as a separate component up to VIN 89736 and as an integral part of the ECM from VIN 89737. The fork oil level chart notes the Tiger (VIN 71699 on) fill.

What This Manual Gives You

This is not a generic overview. It is the Triumph Tiger Motorcycle Service Manual — the same reference a workshop technician uses to strip and rebuild the engine, set valve clearances with shims, select crankshaft and big end bearings by plastigauge, time the camshafts, balance the throttle bodies, bleed the brakes, rebuild the forks, adjust the drive chain and diagnose every stored fault code the engine management system can log. It contains the torque figures, wear limits, service limits, clearances, capacities and fluid specifications needed to do the job properly.

The torque wrench settings chapter alone lists values by assembly — cylinder head area, clutch, balancer/crankshaft/crankcase, engine covers, transmission, lubrication system, final drive, cooling system, fuel system and airbox, wheels, rear suspension, front suspension, brakes, footrests and control plates, electrical, bodywork — so every fastener goes back to the correct tension.

The engine management chapter includes pinpoint tests for every diagnostic trouble code the system can store, covering crankshaft sensor, idle air control, fuel injectors, barometric pressure sensor, throttle position sensor, purge valve, ignition coils, coolant temperature sensor, inlet air temperature sensor, fuel pump relay, sensor supply voltage, system voltage, MIL, low fuel warning lamp, fuel gauge, cooling fan relay, coolant temperature gauge, lambda sensor, and tachometer. The wiring circuit diagrams are reproduced in full.

Who It’s For

Triumph designed this manual primarily for trained technicians in a properly equipped workshop. It also contains enough detail and basic information to be useful to the owner who wants to perform their own basic maintenance and repair work — provided they have the necessary hand tools, special service tools and a basic knowledge of mechanics. The manual names the special service tools required for specific procedures, from the valve shim removal tool through to the angular torque gauge, and illustrates them where usage is not obvious.

Buy With Confidence

Every procedure in this Triumph Tiger service manual is written to be followed in the sequence it appears, with warnings, cautions and notes placed where they matter. Torque figures are given for every listed fastener. Service limits are stated so you know when a part is worn beyond safe use. Where a locking device is specified, the manual tells you to fit it. Where encapsulated bolts must be replaced, the manual says so.

This is the reference that lets you keep a Triumph Tiger running to specification — whether you are servicing the machine at the scheduled interval, chasing a fault code, rebuilding the top end, replacing the clutch, adjusting valve clearances, or stripping the crankcases.

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Instant PDF Delivery

The manual is delivered as an instant PDF download after payment. No shipping, no waiting. Read it on any device — laptop, tablet or phone — and print the pages you need for the workshop. Keep a full copy on your hard drive, your phone and a USB stick so it is always on hand when the bike is on the lift.