Triumph Tiger 800 Forum

Tiger 800 - Main Discussion Section => Misc Technical Help Required => Topic started by: ghulst on October 23, 2019, 08:00:05 PM

Title: Shifter dropped
Post by: ghulst on October 23, 2019, 08:00:05 PM
Hey guys, I rode to work today and as I was riding through town, my shifter dropped. Well, not off the bike, but as I shifted down it got stuck in the downward position and didnít go up anymore. Really annoying as you need to tap it back up with your foot so you can do another downshift. Really annoying when you get off a highway at 130 in 6th and then need to basically shift 12 times to get back to 2nd including tapping it a bit too hard once or twice so you need to shift back down again. :(

It is probably some kind of spring, but is there a description on this fix with pics somewhere?
Title: Re: Shifter dropped
Post by: Londonglide on October 23, 2019, 08:57:46 PM
Hey my fellow TigerTriple refugee

Start here.

https://www.tiger800.co.uk/index.php/topic,26731.0.html

or

https://www.tiger800.co.uk/index.php/topic,26931.0.html

And this

/>
I'm doing the shifter upgrade as a winter job, sounds more like a bloody nuisance than a terminal problem, hopefully.
Title: Re: Shifter dropped
Post by: ghulst on October 26, 2019, 08:21:00 AM
Thanks... That looks like a heap of work cut out for me...
Title: Re: Shifter dropped
Post by: KildareMan on October 26, 2019, 10:41:52 AM
It's an easy repair is you have some basic skills or have help that does. Check photos for before and after.
Title: Re: Shifter dropped
Post by: ghulst on October 26, 2019, 09:28:39 PM
The basic skills are not the problem. The time is. ;)

But itíll happen. Need to try to get my Ducati project out of the way first though. Because that is in pieces.
Title: Re: Shifter dropped
Post by: ghulst on October 30, 2019, 06:48:08 PM
When removing the clutch cover there seem to be two dowels that are more or less Ďstuckí to the clutch cover. I donít see those in the German video. Are those supposed to be there? I would guess they do as they are in the position of the longer bolts.
Title: Re: Shifter dropped
Post by: KildareMan on October 30, 2019, 06:59:38 PM
Leave the Fields where they are and you won't lose them
Title: Re: Shifter dropped
Post by: ghulst on October 30, 2019, 08:05:14 PM
Another question. In the video the guy says to put the bike in 2nd gear and push the brake to loosen the nut on the inner basket. For whatever reason, my inner basket is still spinning. I am also not sure whether I have actually gotten it into second gear, but cannot seem to be getting it in whatever I try.

Any other suggestions? (Besides buying the special tool at Ä150...)
Title: Re: Shifter dropped
Post by: Rtwo on October 30, 2019, 08:56:26 PM
*Originally Posted by ghulst [+]


Any other suggestions? (Besides buying the special tool at Ä150...)

a Ä20 special tool?

https://www.ebay.co.uk/itm/Triumph-Tiger-800-Clutch-Holding-Tool/112186509490
Title: Re: Shifter dropped
Post by: Londonglide on October 30, 2019, 09:16:20 PM
Just ordered one, got all the Triumph bits now, just need some time...
Title: Re: Shifter dropped
Post by: ghulst on October 31, 2019, 08:33:45 AM
By the way, I was reading the service manual, but that says you need to put the bike in 2nd gear anyway, even with the tool. Does anyone have a trick to make that happen? I cannot push the lever up further than I did and that does not make it go into gear. :(
Title: Re: Shifter dropped
Post by: Rtwo on October 31, 2019, 03:23:56 PM
Don't worry about getting it into gear

Title: Re: Shifter dropped
Post by: ghulst on November 01, 2019, 06:27:20 AM
Ok, great. :)
Title: Re: Shifter dropped
Post by: Londonglide on November 02, 2019, 07:04:10 PM
Couple of observations on mine.

Cover was very hard to remove, both dowels were showing signs of surface corrosion, and I needed to use the lever points cast onto the case to free it.

When removing the hub nut (30mm) it had already been staked, so i had to try to relieve it a but, but on loosening, using the £18 tool from ebay to hold the clutch basket, the nut split in the flat  the area around the stake, rendering the nut useless.
I had ordered a new nut anyway, but worth keeping in mind.

On dis-assembly I found mine had had a blue spring fitted already.....so it must have been done as a recall before I got it??
I'm changing the selector pawl and reinforcing the spring stud anyway, so no harm..

I also noted on mine the clutch operating arm was dirty, and looks like the dust shield is worn.
Surprising for a bike with 14K on it...
Title: Re: Shifter dropped
Post by: ghulst on November 03, 2019, 01:34:55 PM
Interesting. I have read that you need to replace the nut anyway, so that is on my list of things to get. I have got no clue whether I have the old or the new spring, but as it has 80K in km's on it and a service history, I am assuming that the spring has already been replaced. That means I will have to thread and bolt the selector pin. We'll see.

And yes, my clutch cover was very, very stuck as well. But it is off now. That is the good thing. Still waiting for the tool... The unfortunate part of not living in the country the seller is in. ;)
Title: Re: Shifter dropped
Post by: Londonglide on November 04, 2019, 07:30:53 PM
Just FYI, I started to drill out the spring stop shaft, and its very soft steel.
Was able to drill quite easily through it.
Going 4.2 for a 5mm tap.
Title: Re: Shifter dropped
Post by: KildareMan on November 04, 2019, 09:19:25 PM
Don't forget a nice Bob of picture as well.
Title: Re: Shifter dropped
Post by: Londonglide on November 04, 2019, 10:05:23 PM
First Pic
Title: Re: Shifter dropped
Post by: KildareMan on November 05, 2019, 11:11:57 AM
*Originally Posted by KildareMan [+]
Don't forget a nice Bob of picture as well.

Edit

Loctite not picture.  Bloody predictive text
Title: Re: Shifter dropped
Post by: Londonglide on November 05, 2019, 06:32:24 PM
Ahhhhh

All is clear......Predictive text can be challenging...
Title: Re: Shifter dropped
Post by: ghulst on November 08, 2019, 07:03:04 PM
Ok guys, I am at the stage where I have taken the inside basket out. Now the outside needs to come out, but I just want to be sure of something...

(https://images.weserv.nl/?url=ssl:live.staticflickr.com/65535/49034840597_f57189cb90_c.jpg)
Do I just start pulling on those two little ridges with two sets of pliers? I just want to make sure I donít need to remove something else first...
Title: Re: Shifter dropped
Post by: Londonglide on November 08, 2019, 08:55:02 PM
Yep, gentle rotation/wiggle

1 1. Slide the clutch outer drum assembly gently
backwards and forwards to dislodge the inner
bearing sleeve. Carefully remove the bearing sleeve
while supporting the clutch drum.

Probably worth ensuring a rag is protecting the lower area, just in case..
Title: Re: Shifter dropped
Post by: Londonglide on November 11, 2019, 07:25:44 PM
Hows yours Ghulst?

Mine's done.
Bit difficult to hold the shifter cam when torquing the bolt, and set the inner clutch so the flat for staking isn't opposite a spring mount, so you can get a straight strike.
Title: Re: Shifter dropped
Post by: ghulst on November 13, 2019, 09:19:13 AM
Mine is still in there. Lack of time to get the basket out...

What do you mean about holding the shifter cam? How do you align that straight strike then? I'll probably see it when I have it out though. ;)
Title: Re: Shifter dropped
Post by: ghulst on November 13, 2019, 09:26:39 PM
Lets just say that this is not a walk in the park... I'd rather ride in the park anyway, but that is not going to happen either. ;) The good news is that I have made progress.

(https://images.weserv.nl/?url=ssl:live.staticflickr.com/65535/49061456307_72bb927d62_c.jpg)
So, there is the culprit. If you look closely you can see there is something sitting there at a weird angle...

(https://images.weserv.nl/?url=ssl:live.staticflickr.com/65535/49060788623_978d1250b3_c.jpg)
There it is. The rod that holds the spring has broken and the Tiger already has the new spring.

(https://images.weserv.nl/?url=ssl:live.staticflickr.com/65535/49061456132_2b56c27bd7_c.jpg)
Time to drill out the old way the rod was fixed to the shifting mechanism. I've done the first part, now I need to drill into the rod itself and cut some thread in there. However, that requires a standing drill to make sure I go in straight and cut a nice hole. Time to find someone with a better drill. ;)
Title: Re: Shifter dropped
Post by: Londonglide on November 14, 2019, 07:10:35 AM
At least you have a definitive problem.....

Whilst in there, it might be worth fitting kit no T1194905 detent wheel and plate, which are a modified type..
Title: Re: Shifter dropped
Post by: ghulst on November 14, 2019, 03:27:50 PM
What are the advantages of that kit?
Title: Re: Shifter dropped
Post by: Londonglide on November 14, 2019, 05:02:32 PM
Improved design. No performance enhancement, but if your shifter  is worn, do it all in one go...kit was about 50 euros???
Title: Re: Shifter dropped
Post by: ghulst on November 14, 2019, 07:09:12 PM
Ok. The shifter looks ok and I only experienced good shifts so far, so I'm not sure if that is needed.

Btw. someone mentioned loctite. Nice idea. Just 243?
Title: Re: Shifter dropped
Post by: Londonglide on November 14, 2019, 09:07:53 PM
I used High strength 266 as I had some around, as Its not to likely to be removed, but I'm sure most  thread lock will do, its just to hold it in place.
Title: Re: Shifter dropped
Post by: ghulst on November 15, 2019, 08:12:31 AM
Ok. I just have some 243 sitting here, so I'll use that.

Parts ordered, including a new clutch cover as that doesn't look good on mine anymore.
Title: Re: Shifter dropped
Post by: KildareMan on November 15, 2019, 09:36:11 AM
*Originally Posted by ghulst [+]
Ok. The shifter looks ok and I only experienced good shifts so far, so I'm not sure if that is needed.

Btw. someone mentioned loctite. Nice idea. Just 243?

Just make sure it's not stud lock as opposed to thread lock
Title: Re: Shifter dropped
Post by: ghulst on November 15, 2019, 10:43:24 AM
No, it's thread lock. I'll be fine then. ;)
Title: Re: Shifter dropped
Post by: ghulst on November 20, 2019, 09:02:22 AM
Starting reassembly, though I still need to get myself a new nut and a new seal. And to get the old bl**dy seal off...

(https://images.weserv.nl/?url=ssl:live.staticflickr.com/65535/49094143171_ba60399951_c.jpg)
Title: Re: Shifter dropped
Post by: Londonglide on November 20, 2019, 01:24:39 PM
Against my own feelings, I had to use a Stanley blade on some parts. Make sure the bits can't get into the sump. Ended up having to put the clutch cover in the parts cleaner to get all the bits out of the webs, but I think your fitting a replacement? Looking good though
Title: Re: Shifter dropped
Post by: ghulst on November 20, 2019, 01:27:07 PM
I will be fitting a used replacement clutch cover as mine has some salt damage. The trouble is that that gasket is completely 'glued' on. :( So I need to work that off. That is going to be a challenge. I was actually thinking of cutting a sharp edge onto an old credit card to see if that helps. The engine side is pretty much clean, fortunately.
Title: Re: Shifter dropped
Post by: KildareMan on November 20, 2019, 01:44:46 PM
Try soaking the gasket
Title: Re: Shifter dropped
Post by: ghulst on December 03, 2019, 10:00:03 AM
I finally got the parts in and found the time to put the thing together again. It all seems to work great...  :015:

Seems.

Unfortunately, when I wanted to take it out for a test drive it turned out it had drained the battery. :138: Oh well, it is on the charger now and stashed away as we are going into a large building project the coming weeks.
Title: Re: Shifter dropped
Post by: Londonglide on December 03, 2019, 12:35:40 PM
Glad to hear it's back together. Had a similar issue to you, but not battery. I found the relocated 30A fuse extension I made for the starter solenoid had been getting hot, and had melted around one of the new fuse holder contacts. Am now waiting on a bolt in fuse assembly to have another go....
Title: Re: Shifter dropped
Post by: ghulst on December 03, 2019, 12:40:14 PM
Tiger life: when there always is something to work on.  :152:
Title: Re: Shifter dropped
Post by: Bladerunner99 on December 04, 2019, 10:39:15 AM
*Originally Posted by Londonglide [+]
Glad to hear it's back together. Had a similar issue to you, but not battery. I found the relocated 30A fuse extension I made for the starter solenoid had been getting hot, and had melted around one of the new fuse holder contacts. Am now waiting on a bolt in fuse assembly to have another go....


Any idea why it was getting hot?
Title: Re: Shifter dropped
Post by: KildareMan on December 04, 2019, 10:52:24 AM
*Originally Posted by Bladerunner99 [+]
Any idea why it was getting hot?

Probably not the best quality holder or poor manufacturer crimping of wires to fuse blades.
Title: Re: Shifter dropped
Post by: Londonglide on December 04, 2019, 07:03:07 PM
This was a NAPA fuse holder bought in Arizona.
Edit.. I think the cheap quality replacement fuse didn't help..
Title: Re: Shifter dropped
Post by: ghulst on December 09, 2019, 11:07:32 PM
Just to close this topic... Today I was able to dig out the Tiger -just to ignore the building work going on in the house- and take it for a quick spin to test all the gears. It is all working again. Pretty happy about the fix.  :152:
Title: Re: Shifter dropped
Post by: ColinXCX on December 09, 2019, 11:11:55 PM
 :493: :047:
Title: Re: Shifter dropped
Post by: Londonglide on December 10, 2019, 05:02:55 PM
Nice One Ghulst
Title: Re: Shifter dropped
Post by: ghulst on December 10, 2019, 08:19:29 PM
Thanks guys!