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Build report on a Tiger 900 for Rally Racing

275 Views 3 Replies 3 Participants Last post by  eRider
Hi all! I wanted to share my custom build of my Tiger over the last 18 months. I first started riding in 2013, and these forums are what supported me in learning how to work on my bike and set my eyes on exploring the world on two wheels. I have been very appreciative of the community on here! From an '05 Bonnie up to a Tiger 900, its been a beautiful adventure with Triumph.


So, my focus was to prepare it for true Rally Racing. The bike is exceptional, but it needed more for Rally Racing. Since the build, I have raced it in the Baja 6-day Rally, the Sonora Rally, Hare and Hound's, and multiple other little races. The bike is a blast. Here are some of the key things I did to it:
Deeper details (The why / how):
  • High Fender Kit - From multiple experiences, I have come to understand that mud accumulation can tear off low fenders, which in turn poses a severe risk of entanglement with the wheel's brake line. This can lead to catastrophic consequences for both the motorcycle and the rider. By integrating a high fender, the motorcycle can negotiate any terrain with ease, while simultaneously mitigating potential hazards associated with low fenders.
  • Tail Tidy - The primary focus was to reduce weight and increase durability in the event of an inevitable crash. Added desire was something that would make it easier to mount saddle bags for offroad trips.
  • Pre Filter - Added layer of defense against the elements (Dust, Sand, Nature) to prolong the life of the air filter, and bike as a whole. Prefilters are easier to swap out and carry spares, vs multiple bulky air filters.
  • Rally Roadbook Tower - I didn’t want a handlebar-mounted roadbook, which required me to design my own tower to replace the front subframe. The design incorporated the OEM headlight and TFT screen with a roadbook placed compactly above. This also required a few more custom parts and redesigns to incorporate hand controls and any potential interference in full lock of the handlebars.
  • Custom Wheels - I wanted to maximize traction and field repair, so I worked with Woody Wheel Works to design custom wheels for the 900. There was a little bit of weight savings, but the biggest advantage was tire options for the rear that are now 18” vs the OEM 17”.
  • New Suspension - Offroad focused and built to my weight, I opted to use TracTive suspension for the front and rear. These were easier to adjust on the fly and brought the right response for my riding style.
  • Aftermarket Header and exhaust - Weight savings and a little power gain. Primary focus for me was reducing weight.
  • Miscellaneous Modifications
    • Replaced the pillion seat lock with a pull chain. Sand gets in the key hole and prevents access.
    • Bypassed the clutch safety switch (Sand can clog the switch, preventing the bike from starting)
    • Bypassed the kickstand safety switch (One less thing to worry about failing)
    • Aftermarket skid plate and lower engine guards
    • Barkbusters
    • Antigravity lithium battery for reliability and weight savings.
Rally Racing the Tiger with all of these modifications was an absolute blast. While the Tiger might not be the perfect bike to race, it is certainly not the wrong one.
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Has bypassing the clutch switch caused any issues?
My dealer was adamant that I shouldn't even change the lever because it cause havoc if the switch didn't work.

He sent me this list of things the switch controlled or has an effect on.
The Clutch switch has an effect on the following items:
1 Decel rate control using the idle speed stepper - Additional steps are used to soften the decels – when the clutch is pulled in these
steps must be dumped which will normally result in a closed throttle decel stall.
2 Fuel gauge – will not update while the clutch is in – this is to stop updating of the sensor when the fuel could be sloshing (i.e.
during gear changes)
3 Vehicle speed limiter – This will not work with the clutch switch bypassed.
4 Gear position judgment – The air cooled twins and 1050’s, with no gear position sensor, derives an idea of gear postion from RPM vs
Vehicle Speed. This function will not work so the wrong ignition maps are applied.
5 Gear position judgement other models – The clutch switch will force a ‘NO LOAD’ condition and use the neutral ignition maps. This
overrides the gear position info and the wrong ignition, second throttle and exhaust butterfly maps will be used!
6 Ignition smoothing strategy is disabled.
7 Pressure based fuel merging to Throttle based fuel is not merged– its switched which can cause a jump in fuelling (twitchy throttle).
8 Deceleration fuel reduction multiplier is not applied – causing rich decels – potentially damaging to the CAT.
9 Deceleration fuel cut-off & CAT protection fuel cut is not applied– this will definitely impact on CAT performance.
10 On some models closed loop will not work when riding.
11 D6 airflap will always be closed
12 D6 exhaust valve will remain partly closed.
13 Starter lock out switch
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You have a pretty wise dealer! So yes, the clutch bypass has shown some of these concerns. If you are not building it as a dedicated racing bike, I would recommend against it. Sand jams the safety switch, which would leave me stranded in a dune mid race. That is why I bypassed it.

The only issues from that list that I have noticed is Fuel Gage doesn't report and cruise control does not work. Some of the others might be true too, but for my racing needs I have not really noticed it.

Again, for a race bike I am happy with this trade off. Normal use, I would recommend against it.
Hi all! I wanted to share my custom build of my Tiger over the last 18 months. I first started riding in 2013, and these forums are what supported me in learning how to work on my bike and set my eyes on exploring the world on two wheels. I have been very appreciative of the community on here! From an '05 Bonnie up to a Tiger 900, its been a beautiful adventure with Triumph.
View attachment 812871

So, my focus was to prepare it for true Rally Racing. The bike is exceptional, but it needed more for Rally Racing. Since the build, I have raced it in the Baja 6-day Rally, the Sonora Rally, Hare and Hound's, and multiple other little races. The bike is a blast. Here are some of the key things I did to it:
Deeper details (The why / how):
  • High Fender Kit - From multiple experiences, I have come to understand that mud accumulation can tear off low fenders, which in turn poses a severe risk of entanglement with the wheel's brake line. This can lead to catastrophic consequences for both the motorcycle and the rider. By integrating a high fender, the motorcycle can negotiate any terrain with ease, while simultaneously mitigating potential hazards associated with low fenders.
  • Tail Tidy - The primary focus was to reduce weight and increase durability in the event of an inevitable crash. Added desire was something that would make it easier to mount saddle bags for offroad trips.
  • Pre Filter - Added layer of defense against the elements (Dust, Sand, Nature) to prolong the life of the air filter, and bike as a whole. Prefilters are easier to swap out and carry spares, vs multiple bulky air filters.
  • Rally Roadbook Tower - I didn’t want a handlebar-mounted roadbook, which required me to design my own tower to replace the front subframe. The design incorporated the OEM headlight and TFT screen with a roadbook placed compactly above. This also required a few more custom parts and redesigns to incorporate hand controls and any potential interference in full lock of the handlebars.
  • Custom Wheels - I wanted to maximize traction and field repair, so I worked with Woody Wheel Works to design custom wheels for the 900. There was a little bit of weight savings, but the biggest advantage was tire options for the rear that are now 18” vs the OEM 17”.
  • New Suspension - Offroad focused and built to my weight, I opted to use TracTive suspension for the front and rear. These were easier to adjust on the fly and brought the right response for my riding style.
  • Aftermarket Header and exhaust - Weight savings and a little power gain. Primary focus for me was reducing weight.
  • Miscellaneous Modifications
    • Replaced the pillion seat lock with a pull chain. Sand gets in the key hole and prevents access.
    • Bypassed the clutch safety switch (Sand can clog the switch, preventing the bike from starting)
    • Bypassed the kickstand safety switch (One less thing to worry about failing)
    • Aftermarket skid plate and lower engine guards
    • Barkbusters
    • Antigravity lithium battery for reliability and weight savings.
Rally Racing the Tiger with all of these modifications was an absolute blast. While the Tiger might not be the perfect bike to race, it is certainly not the wrong one.
Nice to see you here too, I am following you on Insta. Now, how much weight have you saved so far with all those changes? Or maybe a better question what is the current weight of your bike?
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