2001 Triumph Tiger 955cc Factory Service Manual (P/N 3857017)

• Covers the Triumph Tiger fitted with the 955cc fuel-injected, three-cylinder 12-valve DOHC engine; Triumph publication P/N 3857017, Issue 1, February 2001.
• Documents engine removal and refit, camshaft and cam-chain service, valve-clearance inspection and adjustment, crankcase separation, crankshaft/rod/piston inspection, cylinder-liner work, and balancer timing.
• Details clutch cable adjustment, clutch-pack disassembly and inspection, six-speed transmission shafts, selector forks and drum, gear-change components, starter gears, and the sprag clutch.
• Includes engine-management diagnostics with sensor and actuator locations, ECM connector data, live and freeze-frame readings, function tests, tune-download procedures, DTC charts, and electrical/non-electrical fault isolation.
• Covers cooling-system service, rear suspension and drive-chain work, fork and headstock service, front and rear brake repair, wheel bearings, bodywork/frame removal, and battery, charging, starting, lighting, and instrument systems.
• Provides 12 engine, clutch, and transmission exploded views, along with oil-circuit, cooling-system, engine-management, lighting, starting/charging, auxiliary, and full wiring diagrams.

Engine and Drivetrain Documentation

This factory service manual is written for the Tiger’s liquid-cooled 955cc transverse triple. The general-information section establishes the engine, clutch, six-speed constant-mesh transmission, chain final drive, fuel-injection, cooling, suspension, brake, wheel, and electrical specifications, followed by system-specific torque tables and a scheduled maintenance chart.

Engine repair coverage starts with the cam cover, cam-chain tensioner, camshafts, bearing-cap inspection, valve-clearance measurement, shim selection, and cam-chain removal and installation. It then moves into engine removal/refit, crankcase separation and resealing, crankshaft and connecting-rod work, bearing-shell selection, crankpin and journal wear checks, piston and ring inspection, cylinder-bore measurement, cylinder-liner extraction and installation, and balancer removal, inspection, and alignment.

The clutch chapter covers cable removal, routing, preliminary and final adjustment, clutch-cover removal, pack disassembly, friction and steel plate inspection, and reassembly. Transmission repair sections address the selector shaft, forks and drum, input and output shafts, individual gears, bushes, bearings and thrust washers, the external gear-change mechanism, and starter drive gears/sprag clutch.

Several warnings are specific to costly repair mistakes. Camshaft bearing caps are numbered and machined with the cylinder head; mixing positions or releasing them unevenly can crack the caps and damage valves. The balancer and crankshaft timing marks must be aligned, or severe vibration can damage engine components. During transmission assembly, the oil holes in the shafts, bushes, and gears must line up, because a blocked oil feed can lead to major gear damage.

Fuel Injection, Chassis, and Electrical Coverage

The fuel-system/engine-management chapter explains the ECM-controlled sensors and actuators, their locations, and the complete engine-management circuit. Diagnostic coverage includes the T3880250 Engine Management Diagnostics tool, stored DTCs, live and freeze-frame data, actuator function tests, ECM adjustments, tune-download restart procedures, connector pin numbering, electrical test charts, and non-electrical fault finding.

Fuel delivery procedures cover the tank, pump, pressure regulator, pressure checking, airbox, intake and barometric sensors, crankshaft-position sensor, throttle cable, throttle-body balancing, injectors, throttle-position sensor, idle-air-control valve, exhaust, and evaporative-loss-control system. The publication distinguishes U.S. fuel requirements and California evaporative-control equipment.

Cooling-system repair includes coolant draining and filling, pressure-cap inspection, water-pump service, radiator removal and inspection, and thermostat testing. Rear suspension/final-drive coverage includes the rear suspension unit, swinging arm, drive-chain slack and wear checks, adjustment, lubrication, and split-link chain replacement. The front-end section adds fork inspection, headstock adjustment, fork-oil changing and level setting, fork removal, disassembly, assembly, and installation.

Brake coverage goes beyond routine pad replacement. It includes fluid renewal, front and rear bleeding, front-caliper overhaul, front and rear master-cylinder service, front-disc wear and run-out checks, and disc removal and installation. The wheel chapter covers tire inspection, front and rear wheel removal, wheel-bearing replacement, and a bearing-tool selection chart. Bodywork/frame procedures address the seats, infill and side panels, rear panel and rack, cockpit, frame, footrests, and related fixings.

Electrical repair information covers battery removal and charging, headlight adjustment and bulb service, rear light and indicators, alternator removal/refit, starter-motor service, and instrument-pack removal. Separate lighting, starting/charging, auxiliary, and full-machine wiring diagrams are supplied with component keys and wire-color codes.

Specification Highlights and Technical Data

The 334-page PDF includes torque tables, fluid and fuel requirements, maintenance intervals, bearing-selection charts, inspection limits, wear specifications, adjustment data, and electrical/diagnostic test values for the covered assemblies. Listed specialist tools include T3880048 Fuel Pressure Gauge, T3880305 Clutch Anti-Rotation Tool, T3880017 Sprag Clutch Holder, T3880315 Cylinder Liner Extractor, T3880016 Balancer Gear Holder, and T3880371 Oil Pump Drive Gear Holder.

Representative drawings include the camshaft and camshaft-drive exploded view, clutch assembly, crankshaft/connecting rod/piston/liner assembly, gear selectors and drum, engine oil circuit, and engine-management circuit diagram.

Fuel-system repair, brake bleeding, fork disassembly, hot cooling-system work, and engine removal involve pressurized fluids, spring-loaded parts, hot components, and a securely supported motorcycle. The manual’s warning and caution blocks should be followed during shop work.