Triumph Tigress TW2, Service Sheet

Page: 21 / 75

two tabs which are opposite each other on to the cap of the connecting rod. Tighten the nuts down with a
torque wrench which has been set to 15 lb./ft., finally turning up the single tab on to one of the flats on the
nut and repeat this operation for the other cylinder.
Smear the base of the crankcase with good quality jointing compound and place a new paper washer in
position. Apply compound to the washer and then fit the baffle plate with the lips of the cross slits
inwards towards the cylinder. Place the oil filter over the dip tube or feed pipe, apply compound to the
base of the sump cover, place the cover in position over the crankcase and insert the 12 Phillips head screws.
(Each screw should have a shakeproof washer underneath the head). Tighten all the screws down finger tight
then finally secure with a screwdriver working diagonally across the cover. Do not completely tighten one
screw at a time but increase pressure gradually. Make sure that the sump plug and fibre washer are in
position in the base of the sump.
It is now advisable to assemble the
gear cluster and the simplest method of
carrying this out is to assemble the
cluster on to the cover plate.
Pick up the plate and insert the
cam plate through the
slot in
the cover
plate so that the larger portion with
the cam tracks is towards the inside of
the gearbox, insert the pivot pin so that
the hole in the pin lines up
-, with the
hole in the cam plate and insert a new
split pin, opening out the ends.
Now take the 29 tooth ratchet
pinion, `A' (Fig. 16), place the thin steel
washer 'B' inside and then fit the kick
starter spindle complete with its pawl
into the ratchet pinion. Slide the kick
starter spindle through the cover,
engaging the pawl under the stop plate
with the stop against the plate.
If, for any reason, the stop plate has been removed from the cover make sure that it is re-fitted the
correct way round, which is with the leading edge which is slightly chamfered against the stop on the
spindle. If it is fitted the wrong way round it is liable to prevent the spindle from going right home in the
case.
Fit the main shaft 'C' complete with the fixed 16 tooth pinion and the free 25 tooth pinion but leaving off
the sliding 20 tooth pinion and the selector fork. Pick up the 20 tooth sliding lay shaft pinion 'D', and fit
the selector fork to it so that in its final position the boss will point towards the change lever side of the
box. Place the pair in position over the ratchet pinion and engage the fork roller in the small cam track on
the cam plate, that is the track nearest to the cover. Slide the main shaft sliding pinion 'E', complete with
fork over the shaft and engage the roller in the longer cam track on the cam plate, which in this case is the
track away from the cover. Slide the layshaft `F', through the 20 tooth pinion twisting slightly to engage
the splines and press right home. Now pick up the selector fork shaft 'G', pass it through the two selector
forks and engage in the hole in the gearbox cover.
3
Fig. 16. Gear
cluster.