Crankcases; Disassembly; Assembly - Triumph 2012 Tiger 800 Service Manual

Crankshaft, Connecting Rods and Pistons

Crankcases

The upper and lower crankcases are machined as a
matched set and must never be assembled to non­
matching halves. Doing so may cause seizure of the
engine.
1. Remove the engine from the frame (see page
2. Remove the sump <see page
3.
Remove the engine covers (see pages
7-21}.
4. Remove the clutch <see page 4-6>.
5. Remove the oil pump (see page

Disassembly

Failure to follow the correct screw release sequence may
result in permanent crankcase damage.
1. Invert the engine to give access to the lower
crankcase bolts.
2. Release the lower crankcase bolts in the sequence
shown in the diagram below. Note the position of
the hardened washers under bolts 19 to 26.
5 7
Crankcase Bolt Release Sequence
3 . Separate the lower a n d upper crankcases ensuring
that the 3 locating dowels remain in the upper
crankcase.
Do not use. levers to separate the upper and lower
sections of the crankcase or damage to the cran kcases
could result.
5.4
9-3).
8-15>.
- , 4-6 and
3 8
8-8>.
10
6 1 3
Service Manual Tiger 800 and Tiger 800XC
-
Note:
At this point
•
balancer, crankshaft, bearings etc. can be
removed.
Note:
The position of each individual bearing shell
•
prior to removal.
Collect the piston cooling jets from below
•
the upper main bearings, noting that the
piston cooling jet for number 3 cylinder is
longer and has a larger diameter drilling
than the piston cooling jets for number 1
and 2 cylinders. lt can also be identified by
its smaller outside diameter and a groove
around its circumference.

Assembly

1. Use high flash-point solvent to clean the cra nkcase
mating faces. Wipe the surfaces clea n with a lint-free
cloth.
2. Fit the gearbox shafts (if removed), ensuring the
locating ring and dowels on the output shaft
bearings are positioned correctly in the crankcase.
3 . Ensure that the transmission i s in neutral.
4. Ensure that the 3 locating dowels are in position in
the upper crankcase.
1
cdmx
1. Locating dowels
the transmission shafts,