TRIUMPH TIGER 800 Rear Tank v1

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NOTE : BEFORE COMMENCING WORK ON THE CONVERSION, TAKE TIME TO READ THE INSTRUCTIONS CAREFULLY. ALL WORK CAN BE CARRIED OUT BY A COMPETENT MECHANIC, BUT IF YOU ARE UNSURE PLEASE CONTACT US OR A MECHANICAL PROFESSIONAL. KEEP ALL PARTS THAT ARE REMOVED, AS IT IS POSSIBLE TO REMOVE OUR KITS AND RETURN THE BIKE TO STANDARD, IF REQUIRED Tools needed to complete conversion: 5mm Allen key 6mm Allen key 13mm socket 10mm socket Small screwdriver

NO SMOKING WHEN DOING THIS WORK! Try and do this operation with as little fuel in the tank as possible, as it will make removing the OEM tank easier, and less chance of spillage.

TRIUMPH TIGER 800 Rear Tank v1

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Remove both rider & passenger seats. Use a 10mm socket and disconnect positive terminal on battery, then move terminal away from battery and refit screw.

Using a 5mm hex Allen key, remove screws from around cowling on top of tank, both sides. Then remove screws in front radiator cowling and 1 screw in each side and slide cowling backwards to remove from bike.

TRIUMPH TIGER 800 Rear Tank v1

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1328 Remove screw from rear of plastic tank trim (this one is M6 whereas all the others are M5 screws) and then lift vertically and outwards to detach from tank. There are 2 plastic tags that locate into slots in the tank, so be very careful not to break these off when trying to remove the cover

1336 There is a single screw, from the inside face, that secures the side panel, and flashers, to the bike. Remove this screw and disconnect flasher wiring connectors and remove panel from bike.

TRIUMPH TIGER 800 Rear Tank v1

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1332 Remove screw at rear of side trim panel and then slide back trim to remove. Be careful not to break the plastic tags that locate into the frame.

1335 Use 13mm socket to remove single tank fixing bolt from each side, this is hidden under the rubber flap on each side.

TRIUMPH TIGER 800 Rear Tank v1

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1339 Lift up rear of tank and preferably prop up with a block of wood, or similar, whilst accessing the fuel pump area.

Push back orange safety clip, then remove fuel pipe connector by pushing in both clips on side of connector then pull off connector from fuel pump outlet.

Remove BOTH electrical connector plugs from fuel pump by pushing in single tag on connector before removing. Remove BOTH vent pipes from underside of tank.

TRIUMPH TIGER 800 Rear Tank v1

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1347 Frame area with tank removed

1348 Before removing fuel pump, mark tank (with marker pen or similar) where radiussed area on flange is to aid re-assembly.

Using 8mm socket, remove all M6x20 screws from flange then slide off flange from fuel pump.

TRIUMPH TIGER 800 Rear Tank v1

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1356 Slide out fuel pump from tank, then bend back plastic tag to free wiring. Disconnect wiring plug by using a small screwdriver to push clip back, before pulling connector out of pump.

Remove whole pump assembly, along with O Ring seal.

1364 Clean seal face of pump body, then replace OEM O Ring and slide on new Flange Adaptor, making sure the flat face goes toward O Ring(as shown).

TRIUMPH TIGER 800 Rear Tank v1

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1365 Fit new O Ring over pump assembly then partially insert into tank and re-connect switch and bend plastic tag to hold wiring back in place in slot.

1373 Fit whole assembly into tank and fit OEM flange over assembly, and then line up radius areas on both flanges with the marked area on tank, this will give correct orientation for screw fixing.

TRIUMPH TIGER 800 Rear Tank v1

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1376 Secure pump with new M6x35 screws provided and check O rings are sealing by turning tank over and filling with a few litres of fuel, then leave to check for leaks before fitting to bike.

1382 Refit tank to bike, as shown, then feed new fuel line down the side, between frame and airbox, leaving enough of a loop at the top to prevent kinking

TRIUMPH TIGER 800 Rear Tank v1

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1386 Then feed pipe, and dry-break connector, behind airbox. Undo rubber flap from both pegs in front of battery and feed pipework through hole in flap, then re-attach flap to plastic tray.

1390 Re-attach fuel connector to tank, then slide orange cover back over connector. Re-attach both electrical connectors in original position.

TRIUMPH TIGER 800 Rear Tank v1

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1392 Re-connect both vent pipes, be careful not to get them mixed-up, as they are slightly different diameters, and need to be installed on their correct pipes.

1416/18 Slide new Rear Tank into position, ensuring dry-break and pipework is threaded under frame brace, then connect dry-breaks. If, with new Rear Tank in position, the pipework is too tight, lift the front tank, then pull through more slack from the front until there is no tension on pipework when connected. This is very important to get correct before the front tank is bolted back in position and trims re-fitted.

TRIUMPH TIGER 800 Rear Tank v1

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1394 Screw in both tank bolts and then check all rubber grommets that are in tank, as they can become dislodged when removing covers. If they are, then use a small screwdriver to push them back into place.

1397 Refit side trims by making sure tags on trim go into rubber grommets in tank, then screw in M6 side screw and front M5 screw and tighten.

1406 Refit rad scoops by sliding onto “tag” from rear, as shown.

TRIUMPH TIGER 800 Rear Tank v1

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1407 & 1321 Refit with single screw in side & both screws in front, from inside.

1410/11 Refit both side trims by sliding upwards to locate tags in slots on frame, then secure with screw.

TRIUMPH TIGER 800 Rear Tank v1

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1419/20 Pull Rear Tank back a few inches then slide in riders seat and attach.

It should now be possible to slide Rear Tank into position and lock into frame using locking pin. Depending on each bike it is sometimes required to move the pin that is attached to the Rear Tank slightly, to achieve a good locking fit. This can be done simply be removing tank and undoing both M5 button screws in plate that pin is attached to. Gently move pin forward, or back, then retry into locking mechanism until the correct fit is achieved, once happy with fit, then re-tighten both M5 screws. Once the new Rear Tank is connected to the bike it is preferable to run it with the tap fully open so that both front & rear tanks drain down equally, under gravity. The fuel gauge will still read correctly, so that half-empty on the gauge means both tanks are half empty, which would leave 13.5 litres left, as when both tanks are filled then the total combined capacity is 27 litres. There is no need to turn the tap off on the Rear Tank when filling up, but it is not possible to fill the Rear tank through the front tank, or vice-versa, as the flow of fuel through the 6mm bore pipe makes this extremely slow.

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TRIUMPH TIGER 800 Rear Tank v1

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