Triumph 2010 Tiger 800, Service Manual

Page: 140 / 508

Transmission
Z
Refit the output shaft to the crankcase ensuring the
snap-ring locates in the corresponding groove in the
crankcase, and the dowel locates in the slot in the
upper crankcase.
8. Ensure the output shaft seal aligns with its recess in
the crankcase.
�
1. Groove in crankcase
2. Snap ring
3. Dowel
4. Seal
9. Ensure the hole in the output shaft needle roller
bearing outer race is positioned to locate onto the
dowel provided in the upper crankcase.
cdqj
Ensure the selector forks are located in the grooves
in the output gears.
1. Roller bearing
2. Dowel
10.
Assemble the two halves of the crankcase <see
page
5-4>.
1 1 .
Refit the engine to the frame (see page
9-5>.
Input Shaft
Disassembly
Note:
•
The numbers in brackets in the following
text refer to the exploded view on
page
7-14.
Working from the opposite . end to where the clutch
assembly is fitted, dismantle the input shaft as follows:
1 .
Slide off the plain thrust washer
( 1 > .
2 .
Mark one side of second gear to denote its correct
orientation. Remove second gear
(2).
3 .
Remove the splined lock washers
(3
and 4), noting
their position.
4. Mark one side of sixth gear to denote its correct
orientation. Remove sixth gear (6), complete with the
splined bush (5) which runs inside the gear.
5. Remove the splined thrust washer (7) from in front
of the circlip between sixth and third/fourth gear.
6. Remove and discard the circlip <8> from the shaft.
Z
Mark one side of the combined third/fourth gear to
denote its correct orientation. Remove the combined
third/fourth gear (9).
8. Remove and discard the circlip
( 1 0)
from in front of
fifth gear.
9. Remove the splined thrust washer
( 1 1 )
adjacent to
fifth gear.
10.
Mark one side of fifth gear to denote its correct
orientation. Remove fifth gear
( 1 2),
complete with
the plain bush
( 1 3 )
which runs inside the gear.
Note:
•
Unless the bearing at the clutch end of the
input shaft is damaged or worn, it is not
normally necessary to remove it from the
shaft. The bearing is pressed onto the shaft
and is also pressed into its housing. The
bearing and housing are removed from the
shaft together and are then separated.
When using a press, always wear overalls, eye face and
hand protection. Objects such as bearings frequently
break-up under load and the debris caused during
break-up may cause damage and injury to unprotected
parts of the body.
Never wear loose clothing, which could become trapped
in the press and cause crushing injuries to the hand,
arms or other parts of the anatomy.
7.12
SetVice Manual
-
Tiger 800 and Tiger 800XC