Gearbox problem - 3rd to neutral..

[CaptainTrips]

Originally Posted by D.M.

I fixed mine last week, start to finish took 45 mins and was dead easy. Done several hundred miles and not a single issue, so much easier to ride now.

For those of you looking to do the fix this is what I found.

1: You should only need to order 3 parts, T1194444 Shaft Assy, Pivot Gear Change (£109.31), T1261426 Gasket, Gear Change Cover (£5.35), T3550542 Washer, Cu, Od12.5 x Id6.4 (£0.58).
2: Don't bother ordering the detent wheel, springs or anything else, you "shouldn't" need them.
3: The spring does NOT go in the hole.......

I ordered basically everything just to be on the safe side since I had a shift return spring snap on my Spring 1050GT a few weeks back but, after having done the repair I would say just do the 3 parts.
My old Detent Wheel was exactly as the new one, no wear at all, the springs are much heavier then the one that snapped on my 1050 GT so don't expect them to be an issue.
There is a noticeable difference with the size of the lugs on the new Shaft Assy so I suspect this will be a permanent fix but, if not £115 and 45 mins work every few years ain't that bad....

Local Dealer said they had never heard of the issue and wanted £90 to do a diagnostic test ride so a DIY fix makes a lot of sense given how easy it is to do.

Hope this helps.

Cheers D.M.

I tend to agree. The original parts list came from the list of parts that one user received from Triumph to perform his own repair (in a country that had no Triumph dealer). I suspect that Triumph sent everything just in case. That was years ago.

I recently changed my selector shaft. I found it convenient to use the parts to build a complete shaft while having the old one in front of me to provide a model on how to assemble it. Like you, I did not end up changing the detent wheel, because the OEM service manual states that you need to remove the clutch and the gearbox in order to lock the drum to allow you to remove the bolt that holds the detent wheel. I have some pics, so I really should post them in the How-To section. I used a piece of flexible plastic to cover the holes into the gearbox, to prevent loss of the inner washer.

My opinion is that gear damage results from gears clashing that is caused by the worn selector shaft claw ends. My shaft had minor wear at 58k km when I changed it out. I am very gently on my bike when it comes to gear shifting. Always have been. I had the occasional missed or clunky shift. Seems better now. I did the change proactively to hopefully prevent future problems.

I noticed that the new shaft has claws that are rounded at one side rather than blunt. I think that Triumph has revised the part number for the selector shaft three or four times over the years.

[jures]

My conclusion - dogs between 2nd and 6th are worn out.....so this thing
https://www.tiger-explorer.com/index.php?topic=17129.0

It is unbeliavebly easy to repair it, the service manual, this forum - 2hours and gearbox is out. Awaiting now 2nd and 6th output gear. Not so much expensive 120€ for both + all the clips, washers, seals needed

[D.M.]

Good work Jures

Can you do us a favor? When you get the new 2nd and 6th gears can you please try to post Side by Side photos of the old and new parts showing the degree of damage along with anything else you find, this would help assess how much damage is actually being done and how likely others would be to need the same repair with similar symptoms to yours.
Post in them in the supernac thread you linked. https://www.tiger-explorer.com/index.php?topic=17129.0

Cheers

D.M.

[Crazy Kev]

Originally Posted by D.M.

Good work Jures

Can you do us a favor? When you get the new 2nd and 6th gears can you please try to post Side by Side photos of the old and new parts showing the degree of damage along with anything else you find, this would help assess how much damage is actually being done and how likely others would be to need the same repair with similar symptoms to yours.
Post in them in the supernac thread you linked. https://www.tiger-explorer.com/index.php?topic=17129.0

Cheers

D.M.

Great suggestion 

[jures]

Sure will do

[jures]

Done in other topic

[Speed_Racer]

Originally Posted by jures

My conclusion - dogs between 2nd and 6th are worn out.....so this thing
https://www.tiger-explorer.com/index.php?topic=17129.0

It is unbeliavebly easy to repair it, the service manual, this forum - 2hours and gearbox is out. Awaiting now 2nd and 6th output gear. Not so much expensive 120€ for both + all the clips, washers, seals needed

Would you mind sharing your parts order list for the 2nd/6th output gear repair? I get the "pleasure" of doing the same fix after the riding season ends - mine is exhibiting the 2nd gear pop-out issue (46k miles).

I'm going to [proactively?] replace the gearchange assembly as well but I have the parts list for that job already.

[jures]

https://www.worldoftriumph.com/collections/100090455-0-2?type=tiger-1200-xca
New parts:
1 x 14
1 x 17
also you need to replace some clips and seals
3 x 16
1 x 12
1 x 32
1 x 7

Seal for clutch cover
https://www.worldoftriumph.com/collections/100090464-0-2?type=tiger-1200-xca
1 x 3

https://www.worldoftriumph.com/collections/100090452-0-2?type=tiger-1200-xca
Tool to remove clutch
1 x 40

https://www.worldoftriumph.com/collections/100090452-0-2?type=tiger-1200-xca
Tool to remove safety bolt on drive shaft
Its either number 11 or 13 - I cant remember, but it is described in shaft removal topic, I think its 13

Thats it, 2 gears and all the one time to be used parts, and qas mentioned its for 1200 Tiger 2018.

[CaptainTrips]

Originally Posted by jures

https://www.worldoftriumph.com/collections/100090455-0-2?type=tiger-1200-xca
New parts:
1 x 14
1 x 17
also you need to replace some clips and seals
3 x 16
1 x 12
1 x 32
1 x 7

Seal for clutch cover
https://www.worldoftriumph.com/collections/100090464-0-2?type=tiger-1200-xca
1 x 3

https://www.worldoftriumph.com/collections/100090452-0-2?type=tiger-1200-xca
Tool to remove clutch
1 x 40

https://www.worldoftriumph.com/collections/100090452-0-2?type=tiger-1200-xca
Tool to remove safety bolt on drive shaft
Its either number 11 or 13 - I cant remember, but it is described in shaft removal topic, I think its 13

Thats it, 2 gears and all the one time to be used parts, and qas mentioned its for 1200 Tiger 2018.

I need to pull the clutch on mine this winter. I have one of the earlier TEXs that developed a surging clutch engagement when the engine is cold. It pretty much disappears when the engine warms up, but it is very annoying. I think some replaced the clutch basket.

[Speed_Racer]

Originally Posted by jures

https://www.worldoftriumph.com/collections/100090455-0-2?type=tiger-1200-xca
New parts:
1 x 14
1 x 17
also you need to replace some clips and seals
3 x 16
1 x 12
1 x 32
1 x 7

Seal for clutch cover
https://www.worldoftriumph.com/collections/100090464-0-2?type=tiger-1200-xca
1 x 3

https://www.worldoftriumph.com/collections/100090452-0-2?type=tiger-1200-xca
Tool to remove clutch
1 x 40

https://www.worldoftriumph.com/collections/100090452-0-2?type=tiger-1200-xca
Tool to remove safety bolt on drive shaft
Its either number 11 or 13 - I cant remember, but it is described in shaft removal topic, I think its 13

Thats it, 2 gears and all the one time to be used parts, and qas mentioned its for 1200 Tiger 2018.

Absolute boss, thank you so much! I'll double check all part numbers against my 2013