Tiger Explorer A9838000, A9838018, A9838027 and A9638086
Contents
1. 4 off 19 Flangedsleeve 4off 10 Screw M5x12mm 4 off 20 Cabletie Toff 2 of 11 This accessory kit is designed for use on Triumph Tiger Explorer motorcycles only and should not be fitted to any other Triumph model or to any other manufacturer s motorcycle Fitting this accessory kit to any other Triumph model or to any other manufacturer s motorcycle will affect the performance stability and handling of the motorcycle This may affect the rider s ability to control the motorcycle and could cause an accident Always have Triumph approved parts accessories and conversions fitted by a trained technician of an authorised Triumph dealer The fitment of parts accessories and conversions by a technician who is not of an authorised Triumph dealer may affect the handling stability or other aspects of the motorcycle s operation which may result in loss of motorcycle control and an accident Always ensure that the newly installed wiring does not chafe against other parts of the motorcycle such that it may be rubbed through and cause an electrical problem In addition always ensure that the newly installed wiring will not restrict steering movement Both conditions are hazardous and could give rise to a dangerous riding condition resulting in a fire loss of motorcycle control and an accident Throughout this operation ensure that the motorcycle is stabilised and adequately suppor2. TRIUMPH English Fitting Instructions Tiger Explorer A9838000 A9838018 A9838027 and A9638086 Thank you for choosing this Triumph genuine accessory kit This accessory kit is the product of Triumph s use of proven engineering exhaustive testing and continuous striving for superior reliability safety and performance Completely read all of these instructions before commencing the installation of the accessory kit in order to become thoroughly familiar with the kit s features and the installation process These instructions should be considered a permanent part of your accessory kit and should remain with it even if your accessory equipped motorcycle is subsequently sold Parts Supplied A9638086 1 Clamp clutch master cylinder 1 off 2 Screw M6 x 25 mm 2 off Publication part number A9900625 issue 4 DC 66761 1 of 11 Triumph Designs Ltd 2014 20 Parts Supplied A9838000 A9838018 and A9838027 1 Support bracket right hand 1 off 11 Washer M5 A off 2 Support bracket left hand 1 off 12 Rubber band A off 3 Saddle washer 1 off 13 Screw M6 x 12 mm 1 off 4 Fog light 2 off 14 Switch fog lights 1 off 5 Shroud fog light left hand 1 off 15 Bracket switch 1 off 6 Shroud fog light right hand 1 off 16 Screw M4 x 5 mm 2 off Z Sub harness fog lights off 1 Screw M4x8mm aio 8 Reay Toff 18 Screw M5x20mm 4off 9 Screw M5x14mm
3. ect the corresponding sub harness connector to the main harness connector CU Za TA 1 Main harness connector 2 Sub harness connector 5 of 11 4 Connect the switch harness to the corresponding 6 Recover the relay from the kit and fit to the rearmost connector on the sub harness connector in the battery box 1 Sub harness connector 2 Switch harness connector 5 Route the sub harness light switch connector and the two fog light connectors through the hole in the frame area at the rear of the headstock 1 Main harness connector 2 Switch harness connector 3 Fog light connectors 6 of 11 Fog Light Bracket Fitment 4 Slide the right hand support bracket over the left bracket as shown below 1 Remove the four screws from the cockpit to allow fitment of the bracket and flanged sleeves Retain the screws if the motorcycle is to be returned to its original condition and retain the lock nuts for reuse 1 Support bracket left hand 2 Support bracket right hand 5 Attach the right hand bracket and flanged sleeves using two M5 x 20 mm screws from the kit and the lock nuts removed previously 1 Cockpit panel left hand shown 2 Screws Note Lock nuts can be reused providing resistance can be felt when the locking portion passes over the thread of the bolt or stud e Always use the correct replacement lock nut as recommended in the Triumph catalogue 2 Position the left ha
4. he fog light switch has two operating modes and will change colour as described below e OFF white e ON green 2 The switch will automatically reset to the OFF position whenever the engine is started or stopped Bulb Replacement A9838000 only The bulbs become hot during use Always allow sufficient time for the bulb to cool before handling Avoid touching the glass part of the bulb If the glass is touched or gets dirty clean with alcohol before reuse Do not allow the fog light to hang unsupported from the harness during bulb replacement Allowing the fog light to hang from the harness will cause damage to the fog light 1 Remove the fog light unit from the shroud 2 Remove the two screws from the rear of the light unit 1 Fog light 2 Screws 3 Pull the lens out of the case 4 Disconnect the bullet connector inside the light unit 10 of 11 5 Remove the two screws securing the bulb retainer and remove the bulb Se lt W 1 X I 3 ta 1 Connector 2 Bulb retainer 3 Screws 6 Installation is the reverse of the removal process Use a genuine Triumph supplied bulb as specified in the Triumph Parts Catalogue Always have replacement bulbs installed by an authorised Triumph dealer If after fitment of this accessory kit you have any doubt about the performance of any aspect of the motorcycle contact an authorised Triumph dealer and do not ride the motorcycle until
5. nd fog light bracket and flanged sleeves from the kit to the cockpit 3 Secure using two M5 x 20 mm screws from the kit and the lock nuts removed previously 1 Screw M5 x 20 m 2 Flanged sleeve 3 Bracket m 6 Tighten the four screws to 5 Nm 1 Screw M5 x 20 mm 2 Flanged sleeve 3 Bracket 7 of 11 7 Fit the saddle washer and screw M6 x 12 mm from 9 Adjust the shroud so that its lower edge is positioned the kit Tighten the screw to 8 Nm equally with the lower edge of the bracket Tighten the screws to 6 Nm Py 1E 1 Saddle washer 2 Screw M6 x 12 mm 1 Shroud 2 Screw M5 x 14 mm Fog Light Fitment 3 Support bracket 10 Fit the right hand fog light to the shroud using two M5 x 12 mm screws and M5 washers from the kit Do not allow the fog light to hang unsupported from Do not tighten the fixings at this stage the harness during installation Allowing the fog light to hang from the harness will cause damage to the fog light 8 Attach the shroud to the right hand fog light bracket using the M5 x 14 mm screws Do not tighten the fixings at this stage N A o J tN i Q 3 1 Screw M5 x 12 mm N a 2 Shroud Tr 3 Fog light 1 1 Shroud 2 Screw M5 x 14mm 3 Support bracket 8 of 11 11 Route the fog light harness following the support bracket and secure using the rubber straps from the kit 1 Rubber straps 2 Harness 12 Follo
6. om the frame tighten the clamp screws upper first to 12 Nm 10 Remove the grub screw from the upper face of the clutch lever clamp Retain the grub screw if the motorcycle is to be returned to its original condition 1 Infill panel left hand shown 2 Scrivet 13 Following the clutch hose route the switch harness through the wire guide Secure the harness to the 1 Clutch lever clamp clutch hose using the rubber strap as shown below 2 Grub screw 11 Fit the switch bracket to the clamp and secure with the M4 x 8mm screw from the kit Tighten the screw to 3 Nm 1 Rubber strap 2 Wire guide 3 Clutch hose 1 Fog light switch bracket 4 Switch harness 2 Fog light switch 3 Screw M4 x 8 mm 4 of 11 14 Route the switch harness to the left of the headstock through the hole in the frame to the area at the rear of the headstock as shown below 1 Switch harness 2 Switch harness connector Move the handlebars to the left and right full lock while checking that the cables and harness do not bind A cable or harness that binds will restrict the steering and may cause loss of control and an accident Sub Harness Fitment 1 Identify the connector on the main wiring harness and remove the blanking plug Retain the blanking plug if the motorcycle is to be returned to its original condition 1 Connector Blanking plug 2 2 Recover the sub harness from the kit 3 Conn
7. ted to prevent risk of injury from the motorcycle falling A torque wrench of known accurate calibration must be used when fitting this accessory kit Failure to tighten any of the fasteners to the correct torque specification may affect motorcycle performance handling and stability This may result in loss of motorcycle control and an accident Switch Fitment Remove the rider s seat as described in the owner s handbook Remove the windscreen as described in the service manual Disconnect the battery negative black lead first Remove the fuel tank as described in the service manual Align the fog light switch to the switch bracket and secure with the two M4 x 5 mm screws Tighten to 3 Nm Xn wna Switch Switch bracket Screw M4 x 5 mm Support the clutch lever assembly and remove the two screws Retain the clamp and two bolts if the motorcycle is to be returned to its original condition Place the fog light switch harness between the clutch master cylinder and the switch cube Fit the clutch lever clamp from the switch mounting kit with the protrusion on the side of the clamp towards the switch cube Secure with the M6 x 25 mm screws from the kit 1 Clutch lever clamp 2 Screw M6 x 25 mm 3 of 11 9 Align the split line of the clutch lever with the 12 Remove the scrivets from both sides of the mark on the upper surface of the handlebar then headstock infill panel and remove it fr
8. the authorised dealer has declared it fit for use Riding a motorcycle when there is any doubt as to any aspect of the performance of the motorcycle may result in loss of control of the motorcycle leading to an accident Never ride an accessory equipped motorcycle at speeds above 80 mph 130 km h The presence of accessories will cause changes in the stability and handling of the motorcycle Failure to allow for changes in motorcycle stability may lead to loss of control or an accident Remember that the 80 mph 130 km h limit will be reduced by the fitting of non approved accessories incorrect loading worn tyres overall motorcycle condition and poor road or weather conditions The motorcycle must not be operated above the legal road speed limit except in closed course conditions Only operate this Triumph motorcycle at high speed in closed course on road competition or on closed course racetracks High speed operation should only be attempted by riders who have been instructed in the techniques necessary for high speed riding and are familiar with the motorcycle s characteristics in all conditions High speed operation in any other circumstances is dangerous and will lead to loss of motorcycle control and an accident 11 of 11
9. w steps 8 to 11 for the left hand side 13 Route the left and right hand fog light harnesses upwards so they will exit to the front of the cockpit WY Oi A 3 JOUR A 1 Fog light connector 2 Sub harness connector 3 Cockpit frame 14 Connect the fog lights to the corresponding sub harness connectors 15 Secure the sub harness to the main harness using the cable tie from the kit as shown below 1 Main harness 2 Cable tie 3 Headlight sub frame 4 Sub harness connector 16 Refit the headstock infill panel making sure the harnesses are located into the openings as shown below o O A 1 Infill panel left hand shown 2 Switch harness 17 Refit the fuel tank as described in the service manual 18 Refit the windscreen as described in the service manual 19 Reconnect the battery positive red lead first 20 Refit the riders seat as described in the owner s handbook 9 of 11 Fog Light System Testing Note e Fuse number 6 of the right hand fuse box protects the fog light circuit Refer to the label in the fuse box lid for fuse amperage 1 Run the engine to avoid draining the battery 2 Operate the switch and check that the fog lamps come on when the switch is illuminated 3 Adjust fog lamps to the required position and torque the fixings to 3 Nm Ensure that the fog light is adjusted so that it does not contact the shroud during operation Operation 1 T
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