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English

Publication part number A9900625 issue 4, DC 66761© Triumph Designs Ltd. 2014

Fitting Instructions:Tiger ExplorerA9838000, A9838018, A9838027 and A9638086Thank you for choosing this Triumph genuine accessory kit. This accessory kit is the product of Triumph's use of provenengineering, 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 becomethoroughly 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 youraccessory-equipped motorcycle is subsequently sold.

Parts Supplied A9638086:

1. Clamp, clutch master cylinder 1 off 2. Screw M6 x 25 mm 2 off

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Parts Supplied A9838000, A9838018 and A9838027:

1. Support bracket, right-hand 1 off 11. Washer, M5 4 off

2. Support bracket, left-hand 1 off 12. Rubber band 4 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

7. Sub-harness, fog lights 1 off 17. Screw, M4 x 8 mm 1 off

8. Relay 1 off 18. Screw, M5 x 20 mm 4 off

9. Screw, M5 x 14 mm 4 off 19. Flanged sleeve 4 off

10. Screw, M5 x 12 mm 4 off 20. Cable tie 1 off

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Switch Fitment

1. Remove the rider’s seat as described in the owner’shandbook.

2. Remove the windscreen as described in the servicemanual.

3. Disconnect the battery, negative (black) lead first.

4. Remove the fuel tank as described in the servicemanual.

5. Align the fog light switch to the switch bracket andsecure with the two M4 x 5 mm screws. Tighten to3 Nm.

1. Switch2. Switch bracket3. Screw M4 x 5 mm

6. Support the clutch lever assembly and remove thetwo screws. Retain the clamp and two bolts if themotorcycle is to be returned to its original condition.

7. Place the fog light switch harness between the clutchmaster cylinder and the switch cube.

8. Fit the clutch lever clamp from the switch mountingkit with the protrusion on the side of the clamptowards the switch cube. Secure with theM6 x 25 mm screws from the kit.

1. Clutch lever clamp2. Screw M6 x 25 mm

WarningThis accessory kit is designed for use on TriumphTiger Explorer motorcycles only and should not be fittedto any other Triumph model or to any othermanufacturer’s motorcycle. Fitting this accessory kit toany other Triumph model or to any othermanufacturer’s motorcycle will affect the performance,stability and handling of the motorcycle. This may affectthe rider’s ability to control the motorcycle and couldcause an accident.

WarningAlways have Triumph approved parts, accessories andconversions fitted by a trained technician of anauthorised Triumph dealer. The fitment of parts,accessories and conversions by a technician who is notof an authorised Triumph dealer may affect thehandling, stability or other aspects of the motorcycle’soperation, which may result in loss of motorcycle controland an accident.

WarningAlways ensure that the newly installed wiring does notchafe against other parts of the motorcycle such that itmay be rubbed through and cause an electricalproblem. In addition, always ensure that the newlyinstalled wiring will not restrict steering movement. Bothconditions are hazardous and could give rise to adangerous riding condition resulting in a fire, loss ofmotorcycle control and an accident.

WarningThroughout this operation, ensure that the motorcycle isstabilised and adequately supported to prevent risk ofinjury from the motorcycle falling.

WarningA torque wrench of known accurate calibration must beused when fitting this accessory kit. Failure to tightenany of the fasteners to the correct torque specificationmay affect motorcycle performance, handling andstability. This may result in loss of motorcycle control andan accident.

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9. Align the split line of the clutch lever with the '+'mark on the upper surface of the handlebar, thentighten the clamp screws, upper first, to 12 Nm.

10. Remove the grub screw from the upper face of theclutch lever clamp. Retain the grub screw if themotorcycle is to be returned to its original condition.

1. Clutch lever clamp2. Grub screw

11. Fit the switch bracket to the clamp and secure withthe M4 x 8 mm screw from the kit. Tighten thescrew to 3 Nm.

1. Fog light switch bracket2. Fog light switch 3. Screw M4 x 8 mm

12. Remove the scrivets from both sides of theheadstock infill panel and remove it from the frame.

1. Infill panel (left-hand shown)2. Scrivet

13. Following the clutch hose, route the switch harnessthrough the wire guide. Secure the harness to theclutch hose using the rubber strap as shown below:

1. Rubber strap2. Wire guide3. Clutch hose4. Switch harness

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14. Route the switch harness to the left of the headstock,through the hole in the frame, to the area at the rearof the headstock as shown below:

1. Switch harness2. Switch harness connector

Sub-Harness Fitment

1. Identify the connector on the main wiring harnessand remove the blanking plug. Retain the blankingplug if the motorcycle is to be returned to its originalcondition.

1. Connector2. Blanking plug

2. Recover the sub-harness from the kit.

3. Connect the corresponding sub-harness connectorto the main harness connector.

1. Main harness connector2. Sub-harness connector

WarningMove the handlebars to the left and right full lock whilechecking that the cables and harness do not bind. Acable or harness that binds will restrict the steering andmay cause loss of control and an accident.

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4. Connect the switch harness to the correspondingconnector on the sub-harness.

1. Sub-harness connector2. Switch harness connector

5. Route the sub-harness, light switch connector andthe two fog light connectors through the hole in theframe area at the rear of the headstock.

1. Main harness connector2. Switch harness connector3. Fog light connectors

6. Recover the relay from the kit and fit to the rearmostconnector in the battery box.

1. Fog light relay

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Fog Light Bracket Fitment

1. Remove the four screws from the cockpit to allowfitment of the bracket and flanged sleeves. Retain thescrews if the motorcycle is to be returned to itsoriginal condition and retain the lock nuts for reuse.

1. Cockpit panel (left-hand shown)2. Screws

Note:

• Lock nuts can be reused, providing resistancecan be felt when the locking portion passesover the thread of the bolt or stud.

• Always use the correct replacement lock nut asrecommended in the Triumph catalogue.

2. Position the left-hand fog light bracket and flangedsleeves from the kit to the cockpit.

3. Secure using two M5 x 20 mm screws from the kitand the lock nuts removed previously.

1. Screw M5 x 20 mm2. Flanged sleeve3. Bracket

4. Slide the right-hand support bracket over the leftbracket as shown below.

1. Support bracket (left-hand)2. Support bracket (right-hand)

5. Attach the right-hand bracket and flanged sleevesusing two M5 x 20 mm screws from the kit and thelock nuts removed previously.

1. Screw M5 x 20 mm2. Flanged sleeve3. Bracket

6. Tighten the four screws to 5 Nm.

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7. Fit the saddle washer and screw M6 x 12 mm fromthe kit. Tighten the screw to 8 Nm.

1. Saddle washer2. Screw M6 x 12 mm

Fog Light Fitment

8. Attach the shroud to the right-hand fog light bracketusing the M5 x 14 mm screws. Do not tighten thefixings at this stage.

1. Shroud2. Screw M5 x 14 mm 3. Support bracket

9. Adjust the shroud so that its lower edge is positionedequally with the lower edge of the bracket. Tightenthe screws to 6 Nm.

1. Shroud2. Screw M5 x 14 mm3. Support bracket

10. Fit the right-hand fog light to the shroud using twoM5 x 12 mm screws and M5 washers from the kit.Do not tighten the fixings at this stage.

1. Screw M5 x 12 mm2. Shroud3. Fog light

CautionDo not allow the fog light to hang unsupported fromthe harness during installation. Allowing the fog light tohang from the harness will cause damage to the foglight.

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11. Route the fog light harness following the supportbracket and secure using the rubber straps from thekit.

1. Rubber straps2. Harness

12. Follow steps 8 to 11 for the left-hand side.

13. Route the left and right-hand fog light harnessesupwards, so they will exit to the front of the cockpitframe.

1. Fog light connector2. Sub-harness connector3. Cockpit frame

14. Connect the fog lights to the correspondingsub-harness connectors.

15. Secure the sub-harness to the main harness usingthe cable tie from the kit, as shown below.

1. Main harness2. Cable tie3. Headlight sub frame4. Sub-harness connector

16. Refit the headstock infill panel, making sure theharnesses are located into the openings, as shownbelow.

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 servicemanual.

19. Reconnect the battery, positive (red) lead first.

20. Refit the rider’s seat as described in the owner’shandbook.

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Fog Light System Testing

Note:

• Fuse number 6 of the right-hand fuse boxprotects the fog light circuit. Refer to the labelin 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 lampscome on when the switch is illuminated.

3. Adjust fog lamps to the required position and torquethe fixings to 3 Nm. Ensure that the fog light isadjusted so that it does not contact the shroudduring operation.

Operation

1. The fog light switch has two operating modes andwill change colour as described below:

• OFF - white;

• ON - green.

2. The switch will automatically reset to the OFFposition whenever the engine is started or stopped.

Bulb Replacement (A9838000 only)

1. Remove the fog light unit from the shroud.

2. Remove the two screws from the rear of the lightunit.

1. Fog light2. Screws

3. Pull the lens out of the case.

4. Disconnect the bullet connector inside the light unit.

WarningThe bulbs become hot during use. Always allowsufficient time for the bulb to cool before handling.Avoid touching the glass part of the bulb. If the glass istouched or gets dirty, clean with alcohol before reuse.

CautionDo not allow the fog light to hang unsupported fromthe harness during bulb replacement. Allowing the foglight to hang from the harness will cause damage to thefog light.

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5. Remove the two screws securing the bulb retainerand remove the bulb.

1. Connector2. Bulb retainer3. Screws

6. Installation is the reverse of the removal process.

CautionUse a genuine Triumph supplied bulb as specified in theTriumph Parts Catalogue.

Always have replacement bulbs installed by anauthorised Triumph dealer.

WarningIf, after fitment of this accessory kit, you have any doubtabout the performance of any aspect of the motorcycle,contact an authorised Triumph dealer and do not ridethe motorcycle until the authorised dealer has declaredit fit for use. Riding a motorcycle when there is anydoubt as to any aspect of the performance of themotorcycle may result in loss of control of themotorcycle leading to an accident.

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WarningNever ride an accessory-equipped motorcycle at speedsabove 80 mph (130 km/h).

The presence of accessories will cause changes in thestability and handling of the motorcycle. Failure to allowfor changes in motorcycle stability may lead to loss ofcontrol or an accident.

Remember that the 80 mph (130 km/h) limit will bereduced by the fitting of non-approved accessories,incorrect loading, worn tyres, overall motorcyclecondition and poor road or weather conditions.

WarningThe motorcycle must not be operated above the legalroad speed limit except in closed course conditions.

WarningOnly operate this Triumph motorcycle at high speed inclosed course, on-road competition or on closed courseracetracks. High speed operation should only beattempted by riders who have been instructed in thetechniques necessary for high speed riding and arefamiliar with the motorcycle’s characteristics in allconditions.

High speed operation in any other circumstances isdangerous and will lead to loss of motorcycle controland an accident.