Triumph Tiger Explorer XR 2016, Service Manual

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Note
Lubricate each gear and bush with clean engine oil during assembly.
Examine all gears, bearings and sleeves for damage, chipped teeth and wear beyond the service
limits. Replace all suspect components and always use new circlips to assemble the shaft.
The splined thrust washer fitted next to second gear is different to the two other splined thrust
washers fitted elsewhere on the output shaft. It can be identified by three sets of missing splines,
equally spaced around the inner circumference.
Locate second gear to the shaft with the dog slots facing away from the bevel box. Fit the splined thrust
washer (see note above for thrust washer identification) and retain with a new circlip. 1.
1
2
3
chfg
Second gear 1.
Thrust washer 2.
Circlip 3.
Fit sixth gear with the selector fork groove facing away from the bevel box. Ensure that the oil holes in the
gear DO NOT align with the corresponding oil hole in the output shaft. 2.
WARNING
If the oil holes in the sixth gear are aligned with the corresponding hole in the output shaft, engine oil
pressure and gear lubrication will be reduced.
Reduced oil pressure and gear lubrication will cause engine damage and could also lead to engine seizure
resulting in loss of motorcycle control and an accident.
Fit a new circlip. 3.
1
2
hfj 1
Tiger Explorer XR Series
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