T509 1997 4th Gear Issue

[Topefisher]

Managed to pick up 1997 T509 Speed Triple for a autumn/winter project which has the 4th gear issue apparent.
Its done 21,500 miles and runs exceptonally well but for the "ratchetting type" of noise in 4th.
Cam chains is quiet and it starts really good. On the whole the bike is generally in excellent condition.

Although quite usable I am keen to sort it so have already started the dismantling process.

I have most stuff now disconnected and removed and expect to complete dropping the engine out next week some time.

Done my searches but cannot seem to turn up the info I require other than warnings about which models will be affected, so before I dive in splitting the engine to investigate for correcting, my two questions are as follows:

1) What actually is it causing the problem, i.e. what is it the part(s) that actually need(s) replacing because of failure?

2) When the egines split, should I be looking at doing any other serious work at this stage as I hear a lot about the high costs of sprag clutch replacement etc and wandered if this should be done as a matter of course on this model whilst its split?

Any links I have missed or information would be greatly appreciated.

[icon149]

hey check out T595.net

http://www.triumphtorque.com/

Those limey's can help you out with any questions about your T509, i'm pretty sure it is just a 4th gear made out of butter, so replace it and you should be good. but i used to ride a T509 that was out of the problem range so my knowledge is only that which i picked up on the boards.

good luck and happy motoring, i still think the T509's are the best looking speed triples!

[Topefisher]

Many thanks Icon.

If it helps anybody else I managed to find these from Icons link:

http://www.triumphtorque.com/message...d.aspx?id=3620


http://www.t595.net/album/album.asp?...pg=1&img=36394

http://www.t595.net/album/album.asp?album=9334

This on a sprag clutch:

http://stanware.digoxy.com/imageuplo.../gallery12.htm

[bigshineybike]

4th gear
the problem was with the thickness of the outer part of one of the gears. It was a few years ago I did mine so I may struggle to find the photo i took to show the difference its easy to see and even measure.

Common advice seems to be to swap the starter sprag clutch while you are in there.
that part will cost an extra £100 You do the sums whats your time worth?

I found the job easy, take care marking all the pipes and hoses that was the trickest bit.
I dont remeber why but I removed the crank position sensor and didnt note or adjust its position carefully enough, that stopped the engine running above 2000 rpm.

While you have the engine in bits check the clutch basket as well since that is a waekness on those same engines.

[Topefisher]

Thanks Bigshiney.

I have now got everything stripped down and yes the gear has an obvious weak point where two teeth were broken from.

Yes, I do intend to replace the sprag clutch even though its OK as I don,t think it makes sense not to given they can be problomatic.

The engines split at the bottom with all the shafts now out. I havn't parted any of the top end as there wasn't an intended need however I do have a significant problem in that I have found two small half rings in the sump when dismantling about Ø12mm which I cannot identify

I have been through the workshop manual and a full parts list to see if I can identify where they have come from but I cant.

I will try and suss out how to upload a photo I have shortly, to see if anybody can identify where these pieces are from.

[Topefisher]

Hi, Well last week saw the completion of my rebuild.

I managed to get the spare later model engine off Fleebay for £100.
It had the modified ( thickened ) gears and they were looking as new so I just replaced both complete gear clusters.

The clutch basket was intact in the newer engine so I have just kept it for a spare. I ground and cut out the springs from mine and had it mig welded at work as per recommendations.

Several bits that appeared in slightly better condition on the spare engine were used to replace my existings ones.

A new sprag clutch ( even though my existing one seemed perfect )and all the necessary seals and gaskets were purchased and the engine then rebuilt.

Can't believe just how many connections and hoses need sorting/routing - very time consuming, but a labour of love.

Anyways ( touch wood ) it is now running really well. The engine started without a problem.

Just a line to say thanks to those offereing their help/advice.

Malc.

Heres a picture of the completed bike:

[DEcosse]

Nice job and I'm sure very personally rewarding to have done it all yourself.

.