Guide to triumph tiger 800 DIY and maintenance

Triumph Tiger 800 2014 - 2020

There are 3 generations of tiger 800 released in India.

Timelines

1st gen

2011- early 2015

tiger 800

tiger 800 xc9

2nd gen

2015 - 2017

tiger 800 XR/ XRx/ XCx/ XCA

3rd gen

2018- early 2020

tiger 800 XR/ XRx/ XCx/ XCA

How to identify if my bike a BS3 or a BS4 model?

Bikes manufactured between 2014 Jun -2017 March are classified asBS3 bikes

Bikes manufactured between 2017 April - 2020 March are Bs4 bikes.

Alternative Spare parts that can be used apart from OEM

Tiger oem parts alternatives. can you guys pls contribute in filling it up. Will help one another somewhere down the line .

1.Seat lock mechanism - pulsar 135

2.Bulb wala indicators - aprilia scooter rs150 /125 . 

3.Front disc brake Caliper rubber - pulsar 

4. Battery - Yuasa , Motobatt, FLY, Amaron

SF SONIC 48S-TX14 - *MRP Rs.3000*

(Battery fits for Tiger 800 xr/ XRx/ xc/ XCx/ xca (first gen & second gen)

EXIDE 12XL14L - A2 -

(A little taller battery fits for Tiger 800 xc/ XCx/ xca (first gen & second gen)

5. Chain sprocket - DID - JT  

6 . Brake pads - EBC, gold fern, rear pads CBR 250R C ABS 

7.  Clutch plates - Barnett, EBC 

8.  Starter motor carbon brushes -- Contact Manju for refurbishment. 

Apache 200 starter motor brushes match tiger motor. The wire needs to be re-soldered to match the tiger motor slot. Brush is a bit larger than tiger's and needs some filing. 

9.  Spark plugs - ngk cr9eix iridium 

10. Air filter - bmc / kn 

11. Pre filter - uni 

12. Front / rear wheel removal tools 17 mm hex / 27 mm rear

13. Cam chain tensioner can be rebuilt just by changing the tensioner spring instead of buying the whole unit

15. Radiator Mount cushion rubber - Rx135 side panel rubber

16. Engine mount rubber T2307247 - car radiator mount rubber (will confirm car model soon)

17. Engine oil cap oaring - Pulsar oaring

18. Fork oil seal . Ktm 390.

19. Top box rubber cusioning - Activa seat cushions

20. Oil filter.  Versys - r3 - worst case.. if nothing available...car.. santro uses the same. 

21. Rear light Reflectors - RE reflectors - 20rs each

22. Center stand rubber stop bush - RE (needs to be confirmed)

23. Sump guard two side threaded bush - Honda Genset mounting rs. 80. Original rs. 749

24. Wheel Bearings - SKF bearings work brilliantly well. Model number 6204, rubber seal type (Make sure you get the one with seal on both sides as there is a model with one side seal).

25. Wheel bearing rubber seals. Get 35x47x7 size oil seal from any spare shop.

26. Sprocket bearings - SKF 6205D

Dealer Contacts across India

• Bhubaneswar Triumph Dev :+918599011304
• Goutham Keerthi Service Manager Triumph : +917353779520
• Vishnu Keerti Triumph New Manager : +91 99809 77788
• Triumph Spares Hyderabad : 07337333030
• Triumph Kochi Showroom : 04844151911
• Triumph Chandigarh : +91 82880 37321
• Vinod Keerthi Triumph : +91 99809 77722
• Triumph Gurgaon Manish : 8527060901
• Atul Kamath Triumph Mumbai +91 96190 23452
• Pune Triumph : +919850066633
• Goa Triumph Raj : 74474 20644
• Chennai Triumph Sudarshan : 863 749 9030
• Vijayawada triumph: Prasad +917337502424

Tiger most common tools that one would need for DIY / Regular maintenance

• Rear axle nut - 27 mm socket
• Front axle - 17 mm allen
• Pinch Bolt - 6mm
• brake caliper 12mm F&R
• Sprocket - 36mm
• Handle Bar - 6mm lower 8mm upper

OTR Tiger tool kit:

• 27mm rear axle wrench, & extension bar
• 5mm Allen key
• Philips/straight slot combo screwdriver & handle
• 10mm/12mm box end combo wrench
• 13mm box end wrench
• 17mm Allen key (Front axle)
• 8mm Allen (handlebar pinch bolts)
• 6mm Allen (fork pinch bolts and handlebar pinch bolts)
• 7,8,10,12,13,14mm sockets and ratchet. (A cursory check showed that some of the bolts can't be accessed with the stock combo wrench)
• T-30 Torx bit (Fork guard covers)
• T-40 Torx bit (Front brake rotor)
• 4 fuse sizes:(Mini blade fuses) 5A, 10A, 15A, 20A + 30A main fuse(blade fuse not mini)
• Fuses alternatives - KTM 390 uses the same size.
• Handle bar Top Nut - 38 mm Socket. Check this periodically. on the tiger- it has a tendency to get loose.

Key Differences between Tiger generations

Battery 

1st and 2nd Generation  tigers have a 14AH Yuasa YTX-16BS  battery.

Costs : 6021 INR

Third generation has TFT display and a smaller 11.8Ah Yuasa YTZ14S

Costs : 8900

Exhausts

Arrow exhausts for BS3 and BS4.

Smaller size for the BS4

LCD display vs a TFT Display

the 1st and 2nd gen tigers had a Small LCD display and an analogue rev counter .

the 3rd generation tiger has a 5 inch TFT display with a digital rev counter.

Where do i buy spares from?

Most of the consumables can either be bought from the links below

example : chain sprocket kit , Crash bars, Disc pads, Charging sockets

1. Motousher.com

2. Customelements.in

3. Bikenbiker.com

4. Bikegear.in

5. Highnoteperformancegear.com

6. Bigbadbikes.com

7. Viaterra.com

8. Dirtsack.in

9. Pathpavers.in

10. Lazyassbikers.com

11. MotoNerdz.in

12. Bikingspirit.in

13. Orionmotorsindia.com

14. bandidospitstop.com

15) Scott.sportnetwork.in

16) performanceracing.in

17)6kiom

18)www.boonstraparts.com/en

Estimates Service Bills

These are just a very high level estimates . may vary on what your bike needs changes. The consumables like disc pads etc are not a periodic change.

1st Service: 1000 kms Estimated cost : 7-8k INR

2nd Service : 10000 kms estimated cost : 13k INR

3rd Service :20k kms: 32k INR 

4th Service : 30k kms :

5th Service :40k kms

Battery Maintenance tips: Link to Youtube Video

Cruise control Reset procedure if the light pops up on the dashboard- .ie CC disabled.

1. Put bike in Neutral
   
2. Sit on bike, kickstand up.
   
3. Make sure the CC off/on button is off (Extended out, not depressed in, again, this was on the 15)
   
4. Turn on Key
   
5. Turn on Ignition (Red lever down)
   
6. Green light for CC should be blinking (Mine was anyway)
   

Start the reset sequence:

1. Activate the Front Brake Switch by pulling and releasing the font brake
   
2. Activate the Rear Brake Switch by pressing and releasing the rear brake pedal
   
3. Activate the Clutch Switch by pulling and releasing the Clutch
   
4. Activate the Twist Grip Cruise Control cancel switch by operating and holding the throttle grip in the fully closed position
   
5. Press the Cruise Control On/Off switch to ON (on the ’15)
   
6. Press the Cruise Control +/Accelerate/Resume Switch
   
7. Press the Cruise Control -/ Decelerate/Set Switch
   
8. CC light should stop blinking

Sena 10s battery replacement purchase link

https://www.amazon.com/gp/aw/d/B08SJJHNWP?psc=1&ref=ppx_pop_mob_b_asin_title

Sena 20s

50s 30k battery link

AOLIKES 952540 3.7V 950mAh Replacement Battery for Sena 50S, Sena 30K / 20S / 20S EVO Motorcycle Bluetooth Headset https://a.co/d/cw3Zswk

2024 January.. indicative price list 

*Tiger 800 spares * 2014-2017

And some for 2018-2019

(Cost may differs for third gen tiger 800)

1. clutch kit (full kit) - *Rs.76,920*

2. clutch plates (friction plates - *Rs. 14,475* and pressure plates - *Rs. 12,871*

3) Clutch springs (5 springs) - *Rs. 1,379*

4) center clutch - *Rs.10,816*

5) clutch out comp (clutch bell or clutch basket) - *Rs. 66,754*

6) Timing chain - *Rs.8247*

7) blade rubbing cam chain - *Rs.1090*

8) (a) facing aluminium blade tensioner - *Rs. 7875*

8(b) aluminium blade tensioner - *Rs.7209*

9) cam chain tensioner - *Rs.10,546*

10) (a) Cam shaft inlet - *Rs. 28,307*

  (b) Cam shaft outlet - *Rs. 28,307*

11) clutch cable - *Rs. 4,229*

12) (a) Rear brake caliper piston with O ring - 

*Rs.2,768*

(b) Nissin Rear Caliper - *Rs.33,213* 

13) Front brake caliper 4 pistons with O ring - 

*Rs.11,070*

(b) Front Nissin Caliper - *Rs.36,905* for one side

(c) Front BREMBO caliper - *Rs. 56,075* for one side 

14) Radiator hose (6 big hoses 3 small hoses) - *Rs.11,600*& *Rs.6090*

15) Fuel hose - *Rs.8,124*

16) (a) Front wheel bearing (2 bearings) - *Rs.5,932*

 (b) Rear wheel bearing (2 bearings) - *Rs. 5,932*

 (c) sprocket bearing - *Rs. 1,046*

17) (a) Cone set bearing - *Rs.4,352*

 (b) Dust seal coneset - *Rs.1,060*

18) Swing arm needle bearing (2 bearings) - *Rs. 1866*

19) Rear wheel cushion rubber (single piece unit) - *Rs. 5,847*

20) chain slider & damper *Rs. 2,846* & *Rs. 5692* 

- *Rs. 8,538*

21) chain and Sprockets - *Rs. 17,625*

22) headlight bulb - *Rs. 2292*

23) Oil Filter - *Rs. 1064*

24) Air Filter - *Rs. 2,938*

25) Front Nissin brake pads 2 pair cost - Rs.5036+ 5036

*Rs.10,072*

26) Rear Nissin brake pads pair cost - *Rs.4,620*

27) Tiger 800/900 - Front & Rear ABS wire with sensor - *Rs. 9440* and *Rs.12,434*

28) cam chain tensioner - *Rs.7,289*

29) Fork outer tube XRx - *Rs.48,064* per tube

30) Fork Inner Tube XRx 

LHS - *Rs.41,384*

RHS - *Rs.44,058*

31) Fork oil seal - *Rs.2,936*

32) Fork dust seal - *Rs. 2,628*

32) Front disc rotor both - *Rs. 45,552*

33) Rear Disc rotor - *Rs. 12,993*

34) (a) Yuvasa 12v 14AH battery - *Rs.10,020*

(b) Yuvasa 12v 11.8AH battery - *Rs. 11,713*

(c) Yuvasa 12v 10 AH battery - *Rs. 11,714*

35) tiger 800 engine service kit -*₹ 25,583*

36) Tiger 900 engine service kit - *₹17,960*