Assembly - Triumph 2012 Tiger 800 Service Manual

Assembly

Note:
The numbers in brackets in the following
•
text refer to
7-18.
page
Lubricate each gear and bush with clean
•
engine oil during assembly.
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.
Bushes and gears with oil holes must always be
M I SALI G N ED with the corresponding oil holes in the
output shaft. Reduced oil pressure and gear lubrication
may result from alignment of the oil holes, which would
cause premature wear of engine and transm ission
components.
Removing the output shaft bearing from the shaft will
damage the bearing and snap ring. Never re-use
removed bearings or snap rings as use of damaged or
weakened components could lead to engine and
transmission damage.
Press only on the bearing inner race to prevent bearing
damage.
the exploded view on
-
Service Manual Tiger 800 and Tiger 800XC
1. If removed, working from the output sprocket end of
the shaft, fit a new bearing (24) and a new sprocket
spacer (25) to the shaft using a press and press bars.
Fit the sleeve with the large chamfer facing outwards.
1 . Output shaft
2. Bearing
3. Press bars
2. Lubricate and fit a new output shaft seal (2 6).
3 . If removed, transfer the shaft t o the vice a n d secure
between soft jaws. Fit the output sprocket (2 7), new
tab washer (28) and nut (29). Tighten the nut to
Close the tab washer.
85 Nm.
4. Withdraw the shaft from the vice and continue to
assemble from the opposite end to the output
sprocket.
5 . Fit the plain bush (20> t o t h e shaft.
Locate second gear <21 ) to the shaft as noted during
6.
disassembly, with the large step side facing towards
the output sprocket end. Fit the splined thrust
\
washer ( 1 9) and retain with a new circlip ( 1 8) as
shown below.
1. Second gear
2. Thrust washer
3. Circlip
Transmission
7.19