Triumph 2012 Tiger 800 Service Manual page 148

Transmission
Z Fit sixth gear ( 1 7) as noted during disassembly, with
the selector fork groove facing away from the output
sprocket end. Ensure that the oil holes in the gear
DO NOT align with the corresponding oil hole in the
output shaft.
8. Fit a new circlip ( 1 6) to retain third gear. Fit the
splined thrust washer ( 1 5) to the rear of th ird gear as
shown below.
1. Third gear
2. Splined thrust washer
3. Circlip
9. Fit the splined bush ( 1 3 ) for third gear. Ensure that
the oil holes in the gea r DO N OT align with the
corresponding oil hole in the output shaft. Fit third
gear ( 14) to the shaft with the large step side facing
away from the output sprocket.
10. Fit the splined lock washers ( 1 2 and 1 1 ), ensuring the
tabs in the smaller washer ( 1 1 ) locate in the slots in
the larger washer ( 1 2) as shown below.
1. Third gear
2. Large splined lock washer
3. Small splined lock washer
1 1. Fit the splined bush ( 1 0> from fourth gear. Ensure
that the oil holes in the gear DO N OT align with the
corresponding oil hole in the output shaft.
7.20
SeiVice Manual Tiger 800 and Tiger 800XC
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1 2 . Fit fourth gear (9) a s noted during disassembly, with
the larger step side facing towards the output
sprocket.
1 3 . Fit the splined thrust washer (8) a n d retain with a
new circlip (7) as shown below.
1. Fourth gear
2. Splined thrust washer
3. Circlip
14. Fit the fifth gear (6) to the shaft with the groove
facing towards the output sprocket. Ensure that the
oil holes in the gear DO N OT align with the
corresponding oil hole in the output shaft.
1 5 . Fit the first gear thrust washer ( 5 ) and plain bush (4).
16. Fit first gear (3) to the shaft as marked during
disassembly as shown below.
1. First gear
2. Thrust washer
3. Thrust washer
4. Needle roller bearing
1 Z
Finally fit the th rust washer ( 2 ) a n d needle roller
bearing ( 1 ) to the end of the shaft.