Service Bulletin SB629
Issue 1 - 01.2025
Subject: Front Brake Hose Alignment
Bulletin Number
629

Models Affected
Tiger Sport 800

VIN Range

Markets Affected

From CE7729 to CG6198

Canada,
North
America,
Japan
Markets Only

Background Information
Dealers are requested to check and, if necessary, reroute the front brake master cylinder hose and front
brake caliper hose at the ABS modulator as described in the procedure below.

Customer Contact Instructions
Motorcycles in the affected VIN range must have this Service Bulletin completed prior to delivery to the
customer.

Identification of Affected Motorcycles
Tiger Sport 800 motorcycles in the above VIN range.

NOTICE
Some affected motorcycles listed in the VIN range will have been reworked by Triumph prior to their
release from the factory.
Unmodified motorcycles can be identified by checking the ‘VIN Enquiry’ on www.triumphonline.net.

Warranty Claim Instructions
Bulletin Number

Fault Code

Repair Code

Description

Repair
Allowance

629

020295929

996291

Check ABS Hose
Routing

0.10 Hrs

629

020295929

996292

Adjust ABS Hose
Routing

0.40 Hrs

Time

Genuine Parts Information
Bulletin Number

Part Number

629

T3550229

Parts Ordering Instructions

Service Bulletin SB629 Issue 1

Description
Washer, 15.2 x 10 x 1,
Plated

Quantity
4, required for repair
code 996292 only

For Triumph Subsidiary and Overseas Distributor
dealers using Triumph Warranty On-Line with Parts
Auto Ordering Flag switched on: Order all repair parts
by submitting a New Prior through the Warranty On-

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Line system. Entering the above repair code in a New
Prior will automatically add the parts required and
labour times for this Service Bulletin.
For Overseas Distributor dealers NOT using Triumph
Warranty On-Line or for Overseas Distributor dealers
using Triumph Warranty On-Line with Parts Auto
Ordering Flag switched off: Orders should be placed
using the normal parts ordering procedure.
Genuine Parts Return

Dealer to retain parts for 90 days. All parts must be
stored in a secure, non-public accessed area and
correctly identified with a completed warranty label.
Thereafter, the parts must be rendered unusable
prior to scrapping.

Other Instructions
Once completed, please mark the Service Record Book that the requirements of this bulletin have been
complied with.
Before returning the motorcycle to the customer, download the latest calibration using the current version
of the Triumph diagnostic software to the following:
• Engine electronic control module
• Chassis electronic control module (if fitted)
• Keyless electronic control module (if fitted)
• Suspension electronic control module (if fitted)
• Connectivity module (if fitted)
• Instruments (if applicable).

Front Brake Hose Alignment Check

WARNING
Make sure the motorcycle is stabilised and adequately supported.
Do not support the motorcycle on any ancillary component, the exhaust system or any other nonstructural parts of the motorcycle frame.
A correctly supported motorcycle will help prevent it from falling.
Failure to follow the advice above could result in serious injury or death.
1.

Remove the seat, refer to the Service Manual.

NOTICE
The brake hoses are coloured in the images for visual purposes only,
Green - front brake caliper to ABS modulator hose.
Yellow - front brake master cylinder to ABS modulator hose.
If in doubt contact Triumph Service for clarification.
1.

Visually inspect the brake hoses for correct fitment to the ABS modulator.

Service Bulletin SB629 Issue 1

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3

2

1

1

• Figure 1
1.
2.
3.

Brake hose swaged joints
Visible gap between front brake master cylinder to ABS modulator hose and locating feature
No visible gap between front brake caliper to ABS modulator hose

Correct or incorrect fitment of the front brake hoses can be confirmed by comparing brake hose alignment
images above.
Correct front brake hose fitment:
• Both swaged brake hose joints (1) are visibly misaligned.
• An air gap is visibly present between the front brake caliper to ABS modulator hose (2) and the locating
feature.
Incorrect front brake hose fitment:
• Both swaged brake hose joints (1) appear approximately aligned.
• No air gap is visibly present between the front brake master cylinder to ABS modulator hose (3) and the
locating feature.

Correct Brake Hose Alignment
1.
2.

1.

If the two front brake hoses are correct to the visual inspection, as shown in Figure 1, mark the front
brake hoses as described below. Adjustment of the ABS hose routing is not required.
Using a paint pen, apply three alignment marks to the front caliper hoses and the corresponding area
of the locating feature as shown below.

Paint pen marks

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3.
4.

Fit the seat, refer to the Service Manual.
Submit a warranty claim for Check ABS Hose Routing using repair code 996291.

Adjust ABS Hose Routing Only
• If the front brake master cylinder to ABS modulator hose and front brake caliper to ABS modulator hose
are incorrect and transposed, as shown in Figure 1 continue with Adjust ABS routing.

NOTICE
To prevent paint damage, do not spill brake fluid onto any area of the bodywork.
Spilled brake fluid will damage paintwork.
1.
2.

1.
2.

Disconnect the battery terminals, refer to the Service Manual.
Remove the fixings from one of the front calipers and slide the brake caliper off the brake disc.

Brake caliper
Brake caliper fixings

NOTICE
Do not operate the brake lever with the brake caliper removed unless a brake pad spacer is positioned
between the brake pads.

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3.

1.
2.
3.

4.

Using a 2 millimetre disc brake pad spacer between the brake pads, operate the front brake lever slowly
until the brake pad spacer pad is held by the brake pads.

Caliper pistons
Brake pads
2 millimetre disc brake pad spacer

Pull the front brake lever towards the handlebar until a small amount of pressure is felt. Cable tie the
brake lever to this position.

2
1
B02429_2

1.
2.

Brake lever
Cable tie

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1.

Remove the front brake master cylinder hose union and front brake caliper hose union from the ABS
modulator, collecting any brake fluid. Discard the sealing washers.

2

1

1.
2.
3.

2.
3.

1.
2.

4.

3

Front brake master cylinder to ABS modulator
Front brake caliper to ABS modulator
Locating feature

Install a new sealing washer to each side of the unions and connect the brake hoses to the ABS
modulator in the orientation shown.
Tighten the front brake caliper (1) and front brake master cylinder (2) brake hose unions to 25 Nm.

Front brake caliper to ABS modulator
Front brake master cylinder to ABS modulator

Remove the plastic push rivet from the left fuel tank side panel.

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5.

1.
2.

6.

1.
2.
3.

Pull the right hand fuel tank side panel away from the fuel tank to release the two retaining clips and
two spigots from the rubber grommets. Note the position of the locking clips for installation.

Plastic push rivet
Fuel tank side panel

Check and if necessary clip the hoses into the clip.

Clip
Front brake caliper to ABS modulator
Front brake master cylinder to ABS modulator

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7.

1.

8.
9.

1.
2.

10.

Using a paint pen or suitable permanent marker, apply three alignment marks to the front caliper
hoses and the corresponding area of the locating feature as shown below.

Paint pen marks

Align the fuel tank side panel spigots and locking clips to the fuel tank. Push firmly to engage the panel
into the fuel tank.
Fit the plastic push rivet.

Plastic push rivet
Fuel tank side panel

Fit the front brake caliper, refer to the Service Manual

WARNING
Use only DOT 4 specification brake fluid as listed in the General Information section of this manual.
The use of brake fluids other than those DOT 4 fluids listed in the General Information section may reduce
the efficiency of the braking system.
Failure to follow the advice above may lead to loss of motorcycle control which could result in serious
injury or death.
Observe the brake fluid handling warnings given earlier in this section of the manual.
11.
12.
13.
14.
15.

Back bleed the front brake master cylinder, refer to the Service Manual.
Bleed the front brakes, refer to the Service Manual.
Check the front brake caliper unions for any brake fluid leaks. Rectify if necessary.
Connect the battery terminals, refer to the Service Manual.
Fit the seat, refer to the Service Manual.

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WARNING
When riding the motorcycle the rider must always wear a safety helmet, eye protection, gloves, boots,
trousers (close fitting around the knee and ankle) and a brightly coloured jacket.
Brightly coloured clothing will considerably increase a rider's visibility to other operators of road vehicles.
Although full protection is not possible, wearing correct protective clothing can reduce the risk of serious
injury or death when riding.
16.

17.
18.

Carry out a road test. When applying the brakes observe the following:
• The brakes should have a firm, responsive feel.
• The brakes should act smoothly and silently without judder.
• Upon activation of the brakes, the motorcycle should come to rest without deviating from a straight
line.
If required, rectify any faults discovered after the brake test.
Submit a warranty claim for Adjust ABS Hose Routing using repair code 992692.

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