Input Shaft; Disassembly - Triumph 2012 Tiger 800 Service Manual

Transmission
Refit the output shaft to the crankcase ensuring the
Z
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.
Ensure the selector forks are located in the grooves
in the output gears.
cdqj
1. Roller bearing
2. Dowel
Assemble the two halves of the crankcase <see
10.
page
5-4>.
Refit the engine to the frame (see page
1 1 .
7.12
9-5>.
SetVice Manual Tiger 800 and Tiger 800XC
-

Input Shaft

Disassembly

Note:
The numbers in brackets in the following
•
text refer to
7-14.
page
Working from the opposite . end to where the clutch
assembly is fitted, dismantle the input shaft as follows:
Slide off the plain thrust washer
1 .
Mark one side of second gear to denote its correct
2 .
orientation. Remove second gear
Remove the splined lock washers
3 .
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 ru ns inside the gear.
5 . Remove the splined thrust washer (7) from in front
of the circl ip between sixth and third/fou rth gear.
6. Remove and discard the circlip <8> from the shaft.
Mark one side of the combined third/fourth gear to
Z
denote its correct orientation. Remove the combined
third/fourth gear (9).
8. Remove and discard the circl ip
fifth gear.
9. Remove the splined thrust washer
fifth gear.
Mark one side of fifth gear to denote its correct
10.
orientation. Remove fifth gear
the plain bush which runs inside the gear.
( 1 3 )
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 wea r 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.
the exploded view on
( 1 > .
(2).
a n d 4), noting
(3
from in front of
( 1 0)
adjacent to
( 1 1 )
complete with
( 1 2),