Triumph 2010 Tiger 800, Service Manual

Page: 145 / 508

Output Shaft
Note:
• The numbers in brackets in the following
text refer to the exploded view on
page
7-18.
·
Working from the opposite end to the drive sprocket,
dismantle the output shaft as follows.
Disassembly
1.
Remove the output shaft bearing ( 1 ) and plain thrust
washer <2>.
2. Mark one side of first gear to denote its correct
orientation. Remove first gear (3) from the shaft,
complete with the plain bush (4) which runs inside
the gear.
3. Remove the plain thrust washer (5).
4. Mark one side of fifth gear to denote its correct
orientation. Remove fifth gear (6) from the shaft.
5. Remove the circlip (7) and splined thrust washer (8)
from in front of fourth gear.
6. Mark one side of fourth gear to denote its correct
orientation. Remove fourth gear (9) complete with
the splined bush which runs inside the gear (10>.
Z
Remove the splined lock washers ( 1 1 and 1 2) noting
their positions.
8. Mark one side of third gear to denote its correct
orientation. Remove third gear ( 14) off the shaft
complete with the splined bush ( 1 3) which runs
inside the gear.
9. Remove the splined thrust washer (15).
10. Remove the circlip ( 1 6) from in front of sixth gear.
1 1. Mark one side of sixth gear to denote its correct
orientation. Remove sixth gear (17) from the shaft.
12. Remove the circlip (18) from in front of second gear.
Transmission
13. Remove the splined thrust washer ( 19).
14. Mark one side of second gear to denote its correct
orientation. Remove second gear (21 > from the shaft,
complete with the plain bush (20> which runs inside
the gear.
15. Position the output shaft (22) in a vice with soft jaws
fitted. Tighten the vice to prevent the shaft from
turning and release the tab washer (28) from the
output sprocket nut (29), then release the nut.
16. Remove the output sprocket nut (29), tab
washer (28) and sprocket (27).
1 Z Collect the output shaft seal (26).
1 8. If it is found necessary to replace the large
bearing (24) at the end of the shaft, use a press to
remove both the bearing and output shaft sprocket
spacer (25) together.
When removing the output shaft bearing, always wear
overalls, eye, face and hand protection. The bearing
races are hardened and are liable to splinter if broken.
Debris from broken bearings could cause injury to eyes,
face and any unprotected parts of the body.
Inspection
1.
Examine all gears, bearings and bushes and thrust
washers for damage, distortion, chipped teeth and
wear beyond the service limits. Replace all defective
components and always use new circlips, a new
output shaft seal and a new sprocket tab washel" to
assemble the shaft.
Service Manual
-
Tiger 800 and Tiger 800XC
7.17