Motorcycle engine repair Triumph Tiger 800 XC (2010-2019)

Exploded View — Cylinder Head and Valves
Exploded View - Cylinder Head and Valves

Exploded View — Camshaft Cover
Exploded View - Camshaft Cover

Exploded View — Camshaft and Camshaft Drive
Exploded View - Camshaft and Camshaft Drive

Cylinder Head Description
The engine is fitted with an aluminium alloy cylinder head, which carries the camshafts, valves and spark plugs. The cylinder head is cast as a single entity and various components are permanently added after machining. The camshafts run directly in...

Camshaft Cover — removal and installation
Removal 1. Remove the rider's seat (see page 16-13 ). 2. Disconnect the battery, negative (black) lead first. 3. Remove the fuel tank (see page 10-91 ). 4. Remove the airbox (see page 10-98 ). 5. Remove the ignition coils from the camshaft cover. 1....

Camshaft Drive Chain Tensioner — all Models
Removal 1. Remove the camshaft cover (see page 3-6 ). 2. Remove the right hand crank cover. Discard the gasket. Note the positions of the two different bolt lengths. Discard the 3.5 mm bolts. 1. Right hand crank cover 3. Rotate the crankshaft...

Camshaft Drive Chain Tensioner Blade — disassembly and assembly
Disassembly Note: For the purpose of this instruction, the top of the tensioner blade is where the pad is located. 1. Release the clips and remove the pad. 1. Pad; 2. Clip (one side shown) 2. Detach the top hook from the tensioner blade. 3. Release...

Installation and Removal Camshafts
Removal 1. Remove the camshaft drive chain tensioner (see page 3-8 ). Note: It is not necessary to remove the camshaft drive chain completely. Each camshaft and sprocket is removed as an assembly. Before commencing work, ensure the crankshaft 'dot'...

Valve Clearances
Camshaft, valve, valve shim and valve seat wear affects the valve clearances. The effect of this wear is to change the gap between the camshaft and tappet bucket, causing engine noise and improper running. If the valve clearances become too small,...

Camshaft Drive Chain — removal, installation and inspection
Removal 1. Remove the camshafts (see page 3-13 ). 2. Remove the bolt from the centre of the camshaft drive chain housing in the cylinder head. 1. Centre bolt 3. Remove the fixing and raise the front camshaft drive chain rubbing blade and detach the...

Cylinder Head — removal, installation and inspection
Removal Note: Removal of the cylinder head is not possible with the engine in the frame. 1. Remove the engine from the frame (see page 9-3 ). 2. Remove the camshafts (see page 3-13 ). 3. Remove the camshaft drive chain (see page 3-18 ). 4. Remove...

Valves and Valve Stem Seals — installation
Removal from the Cylinder Head 1. Remove each valve from the head using a valve spring compressor. The compressor must act on the top cup to allow removal of the valve collets. Valve removal 2. Once the collets are released, remove the following...

Exploded View — Crankshaft, Connecting Rod, Piston and Liner
Exploded View - Crankshaft, Connecting Rod, Piston and Liner

Exploded View — Crankcase
Exploded View - Crankcase

Disassembly and Assembly Crankcases
Caution: The upper and lower crankcases are machined as a matched set and must never be assembled to nonmatching halves. Doing so may cause seizure of the engine. 1. Remove the engine from the frame (see page 9-3 ). 2. Remove the sump (see page 8-15...

Removal and Installation Crankshaft
Removal 1. Remove the alternator rotor from the crankshaft (see page 17-19 ). 2. Separate the two halves of the crankcase (see page 5-4 ). 3. Remove the connecting rods (see page 5-8 ). 4. Remove the camshaft drive chain (see page 3-18 ). 5. Release...

Connecting Rods — removal and installation
Removal Connecting rods may be removed from the engine after first removing it from the frame. The cylinder head must be removed and the crankcase halves separated. 1. Mark each big end cap and connecting rod to identify both items as a matched pair...

Connecting Rod Big End Bearing Selection/Crankshaft Journal Wear Check
1. Measure the bearing and crankshaft journal clearance as follows. Note: The crankshaft journal clearances are measured using 'Piastigage' (Triumph part number 3880150-T0301). Do not turn the connecting rod and crankshaft during the clearance...

Disassembly Pistons
Disassembly Note: lt is not necessary to remove the connecting rods from the crankshaft. 1. Remove the cylinder head (see page 3-20 ) 2. Remove the liner, using the frame from tool T3880315, and tool T3880101 (see page 5-17 ). 3. Remove and discard...

Cylinder Liners — removal and installation
Removal 1. Assemble the frame from tool T3880315 to tool T3880101 as shown below. 1. Frame from tool T388031S; 2. Tool T3880101 1. Paint mark 2. Mark each liner to identify correct orientation and the cylinder number from which it has been removed....

Exploded View — Balancer Shaft
Exploded View - Balancer Shaft

Removal, Inspection and Assembly/Installation Balancer
The balancer is fitted to control 'pulsing' within the engine. Without any form of balancer, the engine would 'pulse' each time the crankshaft rotated. This 'pulsing' would be felt as a vibration which would amplify as the engine speed was...

Exploded View — Frame Fixings
Exploded View - Frame Fixings

Engine Removal/Refit
Removal Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Raise and support the motorcycle. 2....