Tiger 800 Gear Linkage Problem

@DD that diagram appears to be from the engine side so the lever 5 needs to be pointing to 4 oclock approx. ( 90 degrees to the rod ).

Is the gear lever returning to center after selecting the gear ?

If the above doesn't work ...... I would look at 5 and mentally mark the extremes of movement up and down and set the lever to the center of that range and retest with it clamped up tight .

 

I agree with DD and Oldyam, it must be something to do with the orientation of the lever on the splined shaft.
If you have access to a similar bike you may be able to 'copy' the lever position, otherwise it will have to be trial and error until you find the exact orientation to enable all gears to be found.

 

Not sure about your bike or Triumphs in general but a lot of bikes have two centre punch marks....one on the linkage...the part where the bolt is missing....and one on the shaft where the linkage goes on the splines
Line these up (if they're there) and that should be the standard setting for your bike
I wouldn't ride it with out the bolt though as you could shear the splines off the linkage or worse the shaft splines

 

Suggestion? Hey you guys if anyone has the same bike out there post some close up photos, at least then he will be within a couple of splines either way

 

I would also advise clicking the gearbox into neutral with the linkage unattached and start with your spline positioning from neutral to ensure all gears can be engaged, then re-attach the linkage.

 

Found this on ebay and cropped it

 

I usually go for a drop of Loctite blue, but belt & braces is good too .......

 

Dont forget the 'blob' of weld DD

 

Now that's just going too far

 

Blob of weld my arse do the job right old Crispey.

Drill through the actuating arm where the splined shaft goes through.
Place actuating arm on shaft and using the newly drilled holes as a template drill the shaft and hammer in a roll pin.
Even if the bolt comes out the arm won't come off, ever

Only joking don't do it

 

Wirelock

 

Nylon nut and star washer would be good, plus a
blob of paint for a regular quick visual check.

 

Sell the bike?

 

And drill through the nut & bolt and fit an R clip just to be sure to be sure

 

Araldite.




That is all!