Triumph 2012 Tiger 800 Service Manual page 144

Transmission
7.
Fit a new circlip ( 10> to the input shaft ensuring that
the clip is located in the circlip groove as shown
below.
cdmo
1. F"lfth gear
2. Thrust washer
3. Circlip
8. Fit the combined third/fourth gear (9) as noted
during disassembly, with the larger gear facing
toward fifth gear. Ensure that the oil hole in the input
shaft DO ES N OT align with the oil hole in the gear.
If the oil hole in the third/fourth gear is aligned with the
corresponding hole in the input 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
9. Fit a new circlip (8) to the input shaft ensuring that
the circlip is located in the circlip groove as shown
below.
cdmp
1. Sixth gear .
2. Thrust washer
3. Circlip
7.16
SeiVice Manual Tiger 800 and Tiger 800XC
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10. Fit the splined thrust washer (7) to the input shaft
and slide up the shaft until in contact with the circlip.
1 1. Fit the splined bush (5) from sixth gear. Ensure that
the oil hole in the input shaft DOES N OT align with
the oil hole in the bush.
1 2 . Fit sixth gear (6) a s noted during disassembly, with
the dog teeth facing third/fourth gear.
1 3 . Fit the splined a n d lock washers (4 a n d 3), ensuring
the tabs in the smaller washer (3) locate in the slots
in the larger (4) washer.
cdmq
1. Second gear
2. Large splined lock washer
3. Small splined lock washer
14. Fit second gear (2) to the shaft as noted during
disassembly.
1 5 . Fit the plain thrust washer ( 1 > adjacent to second
gear.
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