Triumph A9508184 - User Manual

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Summary

Pannier Third Mount and Cable Installation

Preparation and Component Removal

Motorcycle prep, seat removal, and component disassembly for third mount and cable installation.

Moulding Modification and Cable Routing

Using templates to drill battery tray moulding and routing the pannier cable through the motorcycle.

Securing Mounts and Final Connections

Attaching pannier third mounts, applying protective film, and connecting the cable to the rocker arm.

Upper Pannier Mount Installation

Rear Rack and Mounting Plate Removal

Removing existing components to prepare for fitting the upper pannier mounts.

Attaching Upper Pannier Mounts

Assembling and securing the front and rear upper pannier mounting brackets.

Pannier Cable Adjustment

Preparing for Adjustment

Positioning the motorcycle and accessing the cable adjuster for pannier cable setup.

Setting Cable Tension and Operation

Adjusting pannier cable tension, checking operation, and fitting the cable cover.

Rear Side Reflector Fitting

Reflector Preparation and Application

Cleaning pannier surfaces and applying self-adhesive rear side reflectors.

Pannier Lock Barrel Fitment and Mounting

Lock Barrel Installation

Inserting and securing the lock barrels into the panniers.

Pannier Mounting and Operation

Mounting panniers, securing them, and understanding their lock/unlock mechanism.

Summary

Pannier Third Mount and Cable Installation

Preparation and Component Removal

Motorcycle prep, seat removal, and component disassembly for third mount and cable installation.

Moulding Modification and Cable Routing

Using templates to drill battery tray moulding and routing the pannier cable through the motorcycle.

Securing Mounts and Final Connections

Attaching pannier third mounts, applying protective film, and connecting the cable to the rocker arm.

Upper Pannier Mount Installation

Rear Rack and Mounting Plate Removal

Removing existing components to prepare for fitting the upper pannier mounts.

Attaching Upper Pannier Mounts

Assembling and securing the front and rear upper pannier mounting brackets.

Pannier Cable Adjustment

Preparing for Adjustment

Positioning the motorcycle and accessing the cable adjuster for pannier cable setup.

Setting Cable Tension and Operation

Adjusting pannier cable tension, checking operation, and fitting the cable cover.

Rear Side Reflector Fitting

Reflector Preparation and Application

Cleaning pannier surfaces and applying self-adhesive rear side reflectors.

Pannier Lock Barrel Fitment and Mounting

Lock Barrel Installation

Inserting and securing the lock barrels into the panniers.

Pannier Mounting and Operation

Mounting panniers, securing them, and understanding their lock/unlock mechanism.

This document outlines the installation and operation of a genuine Triumph accessory kit, specifically a Pannier Kit and its associated Mounting Kits, designed for various Triumph Tiger 800 and Tiger XR series motorcycles.

Function Description:

The Pannier Kit provides additional storage capacity for the motorcycle, enhancing its touring capabilities. It consists of left and right-hand pannier assemblies, which attach to the motorcycle's rear subframe via dedicated mounting points. A key feature is the cable link mechanism that connects the two panniers, designed to enhance stability by allowing a small amount of sideways pannier movement, independently of the motorcycle. The panniers are equipped with lock barrels for security and carrying handles for easy removal and transport. The installation process involves modifying the battery tray moulding to accommodate the pannier cable and third mounts, as well as fitting upper mounting plates to the rear subframe.

Important Technical Specifications:

Pannier Kit (A9508184, A9500747): Includes left and right-hand pannier assemblies, red reflectors, and a cleaning wipe.
Pannier Mounting Kit (A9508186, A9508178): Includes various mounting hardware such as pannier upper mounts (front and rear), M8x80mm bolts and nuts, M6x50mm bolts, M6 washers, M6x20mm screws, a pannier cable, left and right-hand pannier third mounts, pivot bolts, moulded caps, a template, protective film, and a cleaning wipe.
Fastener Torque Specifications:
- M6x20mm screws securing battery tray moulding and air intake duct: 6 Nm
- Shouldered bolts and M6x20mm screws securing seat hook mouldings: 5 Nm
- M6x50mm bolts securing left-hand pannier third mount to subframe: 12 Nm
- M8 nut securing rocker arm to clevis of third mount: 20 Nm
- M8 nut securing front pannier upper mount to side panel: 20 Nm
- Rear rack moulding fixings: 3 Nm
- Pannier cable lock nut: 2.5 Nm
Maximum Safe Load per Pannier: 5 kg (11 lbs). Exceeding this limit may cause instability.
Speed Restriction with Accessories: Never ride an accessory-equipped motorcycle at speeds above 80 mph (130 km/h). This limit may be further reduced by non-approved accessories, incorrect loading, worn tyres, or poor road/weather conditions.
Reflector Adhesion: Initial bonding is instant, full bonding achieved after 72 hours.

Usage Features:

Compatibility: Designed for Triumph Tiger XR, XRT, XRx, XC, XCA, XCx, and Tiger 800, 800XC, 800 XR, 800 XRx, 800 XCX, 800 XRT, 800 XCA, 800 XRX LRH models. Specific installation steps vary slightly depending on the motorcycle's VIN (e.g., up to VIN 583614 vs. from VIN 583615).
Pannier Mounting: Panniers engage with fixed hooks on the motorcycle's mounting points and are secured by the third mount rocker arm fitting into a locating cup.
Locking Mechanism: The panniers feature a lock barrel that operates in three positions: LOCK, UNLOCK, and RELEASE. The key slot must align with the corresponding symbols for each function. Keys are supplied with the motorcycle.
Pannier Operation: To unlock and open, insert the key, turn to UNLOCK, and press the latch plate. The lid has two latch positions; the second latch position ensures a full seal against water/dust ingress.
Pannier Removal: To unlock and remove, turn the key to RELEASE, lift the carrying handle to its fully raised position, and lift the pannier free.
Cable Adjustment: The pannier cable, which links the two panniers for stability, can be adjusted using a cable adjuster and lock nut located inside the battery tray moulding. This adjustment must be performed with empty panniers.
Reflectors: Red reflectors are provided for enhanced visibility and compliance with local regulations (except in Japan, where they may contravene local law).

Maintenance Features:

Installation Instructions: The manual provides detailed, step-by-step instructions for installing both the pannier kit and mounting kits, including diagrams and torque specifications for fasteners.
Cleaning: A cleaning wipe is supplied for preparing surfaces (e.g., rear subframe for protective film, panniers for reflector adhesion) to ensure proper adhesion and fitment.
Protective Film: Self-adhesive protective film is applied to the rear subframe to prevent damage from the pannier mounts.
Cable Adjustment Check: The pannier cable adjustment and operation should be re-checked at each service, as recommended in the Owner's Handbook.
Fastener Reuse: Certain original fasteners (washers, shouldered bolts, M6x20mm screws, rear rack fixings, pannier mounting plates) are retained for reuse, while others (nuts for pannier mounting plates, M6x20mm screws for battery tray moulding) are replaced with kit components. Lock nuts can be reused if resistance is felt when passing over the thread.
Burr Removal: After drilling/cutting holes in the battery tray moulding, any burrs must be removed to ensure a clean finish and proper fitment.
Load Distribution: Users are instructed to evenly distribute loads within and between panniers, pack heavy items at the bottom and inboard side, and regularly check load security.
Suspension Settings: For models with adjustable suspension, settings should be adjusted to suit the loaded condition of the motorcycle.
Handling Familiarization: After fitting, riders are advised to operate the motorcycle in a safe area to become familiar with new handling characteristics.