Triumph Tiger 800 Gear Change Mechanism Shaft Repair (T1190106)

My son's Triumph Tiger 800 XC suffered an issue which can occur on all the Tiger variants from 2010 to 2020. There is a small pin as part of the gear change mechanism which is supposed to align a spring. That spring provides centering for the shifter when between shifts. Unfortunately, the pin can shear off from the pawl which is part of the whole assembly, and then you have no spring return for your shifter.

Even worse, the expensive gear change assembly, part number T1190106, is not currently available from Triumph. So, we followed the lead of several other youtube mechanics and repaired the existing pin by drilling and tapping it for an M5 machine screw. It is a little tricky, and this video shows how we did it on this motorcycle.

►To Purchase

https://amzn.to/3U2O4NP (M5 machine screws)
https://amzn.to/3UwZw3U (11/64" drill bit)
https://amzn.to/3hinXnp (m5 x.80 tap)
https://amzn.to/3NCIpeW (Tap handle)
https://amzn.to/3WD9Tp1 (thread locker)

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