Maintenance and Repair Log – up to date as of 15th April 2018


Total cost of maintenance and repair up to 15/04/2018 and 38,697 miles = £4,205.86.

 

We started this journey with 12,200 miles on the bike. On this page I’m going to log any maintenance and repairs completed since we left home. Latest “event” will be at the top. Mundane things like adjusting/lubricating the chain, adjusting tyre pressures etc. will go unrecorded. Routine maintenance will be highlighted in GREEN, minor repairs in ORANGE and more major/expensive repairs in RED. Anything in GREY is just an observation possibly to be actioned later and BLUE stuff is for any modifications. Excluding fitting new tyres I do all the work myself unless specified otherwise. Click photos for larger view.

 

Mileage Date Work completed or issues noted
50,152 27/02/2018 Maintenance – changed engine oil. Used Motul 15W/50 semi-synthetic.

 

Mileage Date Work completed or issues noted
49,800 17/02/2018 Repair – horn stopped working. Stripped left hand handlebar switchgear to find “insect nests” and horn button contacts with signs of shorting. Cleaned everything out, cleaned horn electric contacts and everything back to normal.

 

Maintenance Triumph Tiger 800xc RTW

Left hand switchgear disassembled.

 

Maintenance Triumph Tiger 800xc RTW

Some kind of insect/critter nest found lurking in the left hand side switchgear.

 

 

 

Mileage Date Work completed or issues noted
49,579 08/02/2018 Repair – stepper motor failure. This is a common fault with the early Tiger 800’s. Mine failed in a strange way in that the plastic piece which fits under the “fork” broke in two. The symptoms were absolutely no idle at all and having to start the bike with throttle and then focusing on not letting the bike stall after that. Stepper motor replaced with a manual adjustment setup and original stepper motor cable tied out of the way. Need to keep it connected electronically otherwise will get fault codes in the ECU and the engine management light will come on.

 

Mileage Date Work completed or issues noted
49,448 02/02/2018 Maintenance – replaced front and rear tyres with new Heidenau K60 Scouts in Ibarra, Ecuador. I purchased these tyres whilst in the UK for the equivalent of $210 USD and flew them to Ecuador as checked baggage and avoided any import charges. Here in Ecuador the same tyres are $265 USD for the front and $400 USD for the rear!!! Interestingly I only got 8,697 miles from the rear and 10,777 from the front this time as opposed to 15,051 and 12,971 respectively last time. No idea why the differences are so great, maybe just “road” surfaces.
49,448 02/02/2018 Repair – replaced camchain tensioner. For a while now when starting the bike the camchain is very noisy. Revving the engine does not always eliminate the noise but stopping and starting the engine does. I figured that the tensioner is maybe a little tired so decided to replace it. A 15 minute job.
49,448 02/02/2018 Repair – replaced 3 indicator stems. The indicator stems are prone to breaking due to fatigue. Triumph will happily relieve you of about £35 GBP each for a new indicator. It is, however, possible to buy just the stems for £16 GBP for four and disassemble and reassemble the indicator. Much more economical and somewhat satisfying knowing you saved some money.
49,448 02/02/2018 Repair – replaced front mudguard support moulding. A small plastic part that succumbed to the bad roads around here.

 

Mileage Date Work completed or issues noted
47,131 22/08/2017 Maintenence – 48,000 mile service. Carried out a little early so as to take advantage of the location at the Steel Horse in Filandia, Colombia i.e. able to work under cover.
47,131 22/08/2017 Modification – replaced clutch with a Barnett unit from the USA. Replaced more as a precaution. The original clutches on Tiger 800’s are not the strongest and we’ll soon be doing far more mountain roads with steep switch backs on dirt so the clutch is going to take a beating.
47,131 22/08/2017 Repair – replaced lost screw in chainguard.
47,131 22/08/2017 Maintenance – replaced rear wheel spindle nut. According to Triumph this should be replaced on a regular basis. I’m on the original after 47,000 miles so it didn’t hurt to replace it. Don’t want to risk a stripped thread in the nut.
47,131 22/08/2017 Repair – replaced rubbing strip flanged sleeve which I somehow managed to misplace – oops.
47,131 22/08/2017 Repair – replaced radiator cap. Design seems to be slightly different than before!!
47,131 22/08/2017 Repair – replaced gear linkage assembly. The old one was becoming rather sloppy with wear. Being in the UK I took advantage of ebay and managed to buy an almost new assembly for just £6 GBP including postage 🙂

 

Click to read the full account of replacing the clutch in Colombia

Maintenance Triumph Tiger 800xc RTW

New Barnett Clutch – lubbly jubbly

 

Mileage Date Work completed or issues noted
46,616 08/03/2017 Repair – new MBTX16U Motobatt battery. Replaced original Yuasa battery (June 2011) so almost 6 years from the original.

 

Read about my battery woes in Colombia by clicking here.

Maintenance Triumph Tiger 800xc RTW

New MBTX16U Motobatt battery

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
46,508 03/03/17 Maintenance – new chain rubbing strip fitted. Routine scheduled maintenance. The Triumph maintenance schedule calls for replacement of the rubbing strip every 12,000 miles. This is the first replacement rubbing strip that’s been fitted since the bike was new! I could probably have run it a bit longer but I took the opportunity to source a new one in the UK and bring it to Colombia. The design has changed and the new strip is supposed to reduce the amount of chain “slap” and accompanying noise. We’ll see. UPDATE 05/04/18 It does indeed reduce chain slap noise.
46,508 03/03/17 Maintenance – new UniFilter prefilter fitted. After 34,000 miles our UniFilter was starting to look a bit secondhand with tears and splits. Delivered to my sister in law in Sydney, collected by my in-laws whilst visiting Australia and finally taken from the UK to Colombia by me!!! What a journey.

 

Maintenance Triumph Tiger 800xc RTW

New Tiger 800XC rubbing strip (below)

Maintenance Triumph Tiger 800xc RTW

Not too bad after 46,500 miles

 

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
45,853 14/12/16 Repair – rear left hand side indicator has broken again despite 3 efforts to epoxy resin it back together. New indicator fitted and old lens transferred to the front RHS to replace lens broken on the Stahlratte crossing from Panama to Colombia.

 

Mileage Date Work completed or issues noted
44,500 28/10/16 Major repair – new Nitron Adventure R2 shock absorber fitted. Cost including shipping to Colombia, import duties and taxes was £1,090

 

Maintenance Triumph Tiger 800xc RTW Nitron suspension

First ever after market shock absorber for me on any bike. Expectations are high for this new Nitron rear shock 🙂

Maintenance Triumph Tiger 800xc RTW Nitron suspension

Colourful Nitron spring. Black was an option but would have been a bit dull 🙂

Maintenance Triumph Tiger 800xc RTW Nitron suspension

Remote adjusters for damping and preload with the sexy new turquoise spring just showing at the bottom.

 

 

 

 

Mileage Date Work completed or issues noted
43,335 17/08/16 Observation – the rear shock is really not behaving itself. I’ve not seen any more oil leak since first noticing it on 09/08/16 about 500 miles ago. However, there is definitely less damping which doesn’t improve with adjustment and the bike just “crashes” over the smallest of stones when riding dirt roads. Decision has been made to order a new Nitron shock absorber from the UK and try to avoid dirt roads for the time being.

 

Mileage Date Work completed or issues noted
43,207 15/08/16 Maintenance – balance throttle bodies. Used DealerTool and the laptop to perform the balance which was quite a long way off having not been performed for a while. Part of the 42,000 mile service. Also cleaned stepper motor.

 

Maintenance Triumph Tiger 800xc RTW DealerTool

Tigger with perfectly balanced throttle bodies. Work completed by me using DealerTool software and my laptop.

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
42,851 09/08/16 Maintenance – cleaned and re-oiled the UniFilter and K&N air filter. Did this myself at A1 Motorcycles in San Jose, Costa Rica. They kindly provided the cleaner, oil, cloths and workshop space. UniFilter prefilter was filthy and the K&N filter spotlessly clean on inspection. Part of the 42,000 mile service. Also cleaned stepper motor.
42,851 09/08/16 Observation – noted some oil leaking from the rear shock absorber. Will need to keep an eye on this one.

 

Maintenance Triumph Tiger 800xc RTW K&N

K&N air filter is kept pretty clean and requires very little maintenance. Reason is fitment of the UniFilter pre-filter, a great addition to the bike

 

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
42,550 07/08/16 Maintenance – after just over two years, change brake fluid. The guys at Triumph San Jose, Costa Rica, did this for free. Brake fluid change is due every two years so about one month overdue, I’m not worried :-).

 

Mileage Date Work completed or issues noted
42,500 03/08/16 Repair – previous glue repair to rear LHS indicator has failed after less than 300 miles. Cleaned everything up. Repaired broken indicator stem with JB Weld epoxy resin. Should be a lot stronger.
42,500 03/08/16 Observation – just an observation following the installation of the updated ECU map about 800 miles ago. Fuel consumption is definitely worse. I don’t keep accurate fuel consumption records but the on-board fuel gauge is indicating about a 3-4 miles per gallon (UK) less than before. However, there is an upside. Slow speed running in technical dirt sections is definitely better. The bike pulls far more cleanly from very low revs when needed and I can generally get away with less clutch slipping when pulling out of slow hairpin turns. Much better 🙂

 

Mileage Date Work completed or issues noted
42,008 08/07/16 Maintenance – after “cleaning” by the Triumph guys in Managua the front brakes have been pretty inefficient. Decided to throw away the EBC pads that still had life in them and swap back to the originals that I’m carrying as spares. Swap complete and normal braking service has been resumed 🙂 No idea what they cleaned the pads with but they had clearly been contaminated with something.

 

Mileage Date Work completed or issues noted
41,700 28/06/16 Maintenance – 42,000 mile service. Just routine stuff that also included clean and lubricate swingarm and headstock bearings. Noted that all bearing surfaces had nothing other than what I would call polish marks on them. Did all the work myself at Triumph Managua in Nicaragua. Engine oil was Castrol 10W-50 fully synthetic. Some items left until later due to running out of time at the workshop in Managua. See above for details. Also cleaned stepper motor.
41,700 28/06/16 Repair – front LHS indicator has broken again, less than 400 miles since I glued it back together :-(. One of the mechanics at Triumph Managua has repaired it with “epoxy resin”. No idea what he used but there was no charge.
41,700 28/06/16 Observation – whilst I had the front end apart in the Triumph dealer the mechanic offered to clean up the front brake pads. I agreed as he was pretty keen. Not sure what he used but with everything back together I’d lost quite a bit of braking efficiency. Need to see if the pads “bed in” again.
41,700 28/06/16 Modification – in order to connect the official Triumph diagnostics tool the ECU map had to be updated. I’d been running with whatever the map number was from June 2012. Map installed was 20769 which is the latest as of 28/06/16 and not likely to be updated by the factory again. For reference, I use DealerTool and my laptop to connect to the ECU and perform maintenance which works great and doesn’t require any particular version of the ECU map as does the Triumph software.

 

Meet the team at Triumph Managua and read the full account of my work at their dealership by clicking here.

Maintenance Triumph Tiger 800xc RTW

Tigger fork removal in order to clean and re-grease the steering head bearings.

Maintenance Triumph Tiger 800xc RTW

First time removal, for me, of the swingarm. Determined not to neglect for so long in the future.

 

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
41,288 12/06/16 Repair – front LHS and rear LHS indicators have broken. This is a common fault on this bike and there was even a recall by Triumph at one stage which I obviously missed. Up until now the indicators have been held in place with every motorcycle travellers friend; Duct Tape :-). Glued with Superglue and black silicone.

 

Maintenance Triumph Tiger 800xc RTW

Gluing, and after using silicone, fix didn’t last very long.

 

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
40,751 28/05/16 Maintenance – fitted new rear Heidenau K60 scout tyre in Santa Tecla, El Salvador. 15,051 miles on the last rear K60. Can’t complain. $214USD for the tyre and $10USD fitting at a local car/bike tyre place.

 

Maintenance Triumph Tiger 800xc RTW Heidenau

New Heidenau K60 Scout rear tyre.

Heidenau

Heidenau K60 Scout rear tyres are as tough as old boots. This one did 15,051 miles.

 

 

 

 

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
38,671 14/03/16 Repair – coolant and radiator cap changed. When really hot the bike has been prone to “lose” some coolant. 99% of the time there’s no sign of it but on one day in Guatemala with tight uphill hairpins out of a valley a load of coolant was lost. Change was performed free of charge by British Motors in Guatemala City, Nicaragua. They didn’t do a great job on changing the coolant and I was later able to add another 1/2 litre.
38,671 14/03/16 Maintenance – new front Heidenau K60 Scout tyre. 12,971 miles out of the old K60 front tyre. £79 GBP total supply and fit.

 

Mileage Date Work completed or issues noted
36,502 26/12/15 Maintenance – 36,000 mile service and clean stepper motor. Valvoline 10W-40 fully synthetic motorcycle oil.

 

Maintenance Triumph Tiger 800xc RTW

36,000 mile service conducted under a banana tree in Chiapa De Corzo, Mexico

 

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
33,450 07/08/15 Maintenance – check valve clearances and clean stepper motor. All valve clearances in spec. Only did a go/no go check with the smallest and largest feeler gauges rather specifically measure each clearance. If it’s in spec. I’m happy. Not too worried if the gaps close up over time, I’ll just adjust the clearances when necessary :-). Note, this check was completed 2,500 miles early due to the fact that I had a garage to work in at the apartment we rented in San Cristobal De Las Casas, Mexico.
33,450 07/08/15 Maintenance – changed engine oil (no filter). Valvoline 10W-40 fully synthetic motorcycle oil.

 

Maintenance Triumph Tiger 800xc RTW Stepper Motor

Essential to keep the stepper motor clean

 

 

 

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
30,000 02/05/15 Major repair – new rear wheel fitted after finding 14 small cracks in the rim of the old one. Decision was to err on the side of caution and I ordered a new wheel from the USA as it could be supplied more quickly and more cheaply than in Mexico. Total cost incl. shipping and taxes etc. was £722GBP. Ouch.

 

Maintenance Triumph Tiger 800xc RTW Rear wheel crack

One of 14 cracks in the rear wheel rim

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
29,811 25/04/15 Maintenance – 30,000 mile service including cleaning the stepper motor. Valvoline 10W-40 fully synthetic motorcycle oil.

 

Maintenance Triumph Tiger 800xc RTW

Christmas comes early for Tigger

Maintenance Triumph Tiger 800xc RTW

A laptop is an essential piece of kit when servicing a modern motorcycle.

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
25,700 10/12/14 Maintenance – fitted new front and rear Heidenau K60 Scout tyres in Tucson. 13,500 miles from both front and rear. $326USD supplied and fitted.
25,700 10/12/14 Maintenance – new D.I.D. gold chain and sprockets front and rear replacing the originals supplied with the bike from new. Chain and sprockets fitted by BMW dealer in Tucson.

 

Maintenance Triumph Tiger 800xc RTW

New chain, sprockets and tyres

Maintenance Triumph Tiger 800xc RTW

New chain being fitted at BMW dealer, Tucson. Nice for them to have a quality bike to work on. Just kidding, good job guys.

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
24,037 05/11/14 Maintenance – 24,000 mile service including cleaning stepper motor. 10 out of 12 valve clearances were tight. Castrol 10W-50 fully synthetic oil.
24,037 05/11/14 Observation – noted that two mounting points, one each side, have cracked through on the front mudguard. I fitted larger washers in an attempt to spread the load on these as they seem to be a weak point but to no avail. For now I’ll just keep the bolts tight and see how it goes. UPDATE 27/08/16: Front mudguard is still cracked through and held on with original bolts and larger washers. No need for a repair/replacement as yet. FURTHER UPDATE 10/04/18: Eventually the mounting points gave way completely. Solution for now is to use duct tape 🙂

 

More details of the valve clearance changes here.

Maintenance Triumph Tiger 800xc RTW

Where does this go! Not a difficult task to adjust valve clearances, just time consuming first time

Maintenance Triumph Tiger 800xc RTW

Part of the process to adjust valve clearances

Maintenance Triumph Tiger 800xc RTW

Top of the cylinder head with camshafts removed. Shims are under the buckets for valve clearance adjustment.

 

 

 

 

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
20,769 25/09/14 Repair – when it’s really hot, like in Utah, the bike tends to “boil off” some coolant. Needed to buy some coolant and top it up again. I can see no sign of a leak that would explain a drop in coolant level. All hose clamps are tight but you can see the coolant bubbling in the expansion tank when coming to a stop. The temperature gauge never moves from its normal position of 5 bars.

 

Mileage Date Work completed or issues noted
18,326 30/08/14 Maintenance – 18,000 mile service including cleaning the stepper motor. Seattle Triumph changed oil and filter and did not charge labour. Rest of the work performed by me. Castrol 10W-50 fully synthetic oil.

 

Maintenance Triumph Tiger 800xc RTW

Daniel from Seattle Triumph with Tigger in their workshop

 

 

 

 

 

 

 

 

 

 

Mileage Date Work completed or issues noted
14884 27/07/14 Maintenance – fitted new front and rear EBC HH brake pads. Kept the old original front pads as spares. Wanted to try the EBC’s on the front.