Triumphrat

spearce72 · 06-09-2008

First, let me start with a thank you to this forum for all of the valuable info available. I've already found a wealth of tips for replacing a broken kickstart spring in my '76 T140.

I was able to get the outer gearbox cover off without fully removing the right footpeg, but I don't think I'll be able to get the whole thing back together without removing the footpeg entirely. Right now, the rear brake pedal is preventing the footpeg bolt from being extracted.

Do I need to remove the rear brake pedal in order get this bolt out or maybe adjust the rear brake pedal out of the way somehow? Any info is much appreciated.

McQueen · 06-09-2008

I was able to just press down on the pedal to give enough clearance. But if that doesn't work, just take the pedal off. One 9/16 nut and you're golden.

Make sure any kids/wives/GFs/neighbors/pet parrots are out of earshot when you go to put the new spring on. You'll run though your entire repertoire of profanity getting that %$#@&* spring back on.

spearce72 · 06-09-2008

Thank you. Yeah, when I press the pedal down as far as it'll go, I'm still not getting enough clearance.

I removed the nut awhile back and started to pull the pedal but it didnt' want to give and I thought I'd consult before I put any force behind it.

So, any tips on getting that spring back in there? I'm assuming that I'll wind it back counterclockwise with the kickstart lever and then mate the cases. Do I need to really wind it up, or just enough to get the kicker at about 9 o'clock?

I think I'll try and get back together correctly once or twice to get a feel before I add the gasket and RTV.

If there was anything you remember that might be helpful, I'd love to hear from you.

Thanks again.

Scott

McQueen · 06-09-2008

Scott, you have to pry the pedal a bit for it to come off, but it does.

Spring, well, it takes some finesse and luck.

Here's what usually happens:
Get spring in position...smear your gasket sealer...start to SLOWLY and GENTLY slide the outer cover back on...then just as you think you've got it...BAM! The spring slips off just as the cases mate (and you gasket sealer touches the opposing surface). This is also where all the aforementioned profanity comes in.

It's trial and error and luck. You'll get it though.

Unless someone else here has the magic secret?

OzBloke · 06-09-2008

To get the brake lever off (it's on a square shaft), undo the nut until it's outer face is level with the outer edge of the screw thread, and then give it a medium whack with a metal hammer. The shaft will move back in a bit, and the lever will pop off the square section.

The kickstart needs to be wound up 1.25 turn counterclockwise from where it would nomally sit on the stop - about 1.75 turns from the rest position with the outer cover off. If you don't wind it up this far, the wind when riding will force it back and engage the rachet.

spearce72 · 06-10-2008

Ozbloke, I wish I had read your reply before I went about getting the pedal off. I went ahead and removed the nut and washer on the other end of the shaft and ended up pulling the pedal and shaft completely out..dropping the srping and bushing. Hopefully, that won't be too difficult to put back together.

Thank you for the tips on winding the spring up! I definitely don't want to be going back in the gearbox anytime soon after the repair.

quagmire · 06-11-2008

I'll say it agian, everyone needs to watch Hughie Hancox's video on rebuilding these engines. I followed his lead and it took all of about 2 seconds to put my kickstart spring on and mate the outer gearbox cover.

503_colville · 06-11-2008

quagmire - you're absolutely right. Those videos are both educational and entertaining. The first time I watched it I couldn't believe how many uses there are for a soft faced mallet.

panda · 06-11-2008

Just be thankfull you dont have one of those superior bikes from the far east, To replace the kick start spring on a Suzuki GT380J you have to split the crankcase in half