96 sprint alternator question

[mgt999]

After researching here, I thought my rattle noise at idle and low rpms might be my alternator. I took it apart and all appears to be well, except the housing alternator shock?? which is on the engine, is loose and does rattle. Here's a link to a schematic that shows what I'm referring too. - http://www.bikebandit.com/triumph-mo...7556sch562619\

Part #19. Is this supposed to be loose?

[sailfish]

That part should be tight. Bolt No. 25 should be holding it in. The alternator drive is one of the few weak areas on these bikes. There is an update kit that replaces some of these parts with stronger parts. I don't know much about it since my '98 came with the updated parts. My bike did have a broken bolt, No. 21, that screws into the alternator. I drilled it out and oversized the bolt to the next larger.

As you probably know, Engle Motors is your dealer there. That's were I bought my bike. They should know about the update kit.

[mgt999]

Well, looking at it some more, I can't pull the splined shaft all the way out, but most of the way. It stops, only spins one way, but dang near the whole thing will come out including part #19. I'm praying someone gives me some good news here and I'm not looking at an expensive repair.

[Roden]

mgt999,

Exercise caution! Don't pull the splined shaft out. There are parts on the shaft that if it is pulled away, may well end up in the crankcase, then you will be up for an expensive repair as it will be engine out and strip.

I believe that the updated shaft can be installed by pushing it in and using it to push out the old shaft, thereby picking up spacers etc on its way through. The clutch has to come out to do this.

Let us know your progress,

Roden

[orangem2]

Roden you are correct,
but if you can pull the spline out on the alternator side, then the bolt on the clutch side is probably fragged... the clutch basket will need to be removed to get access to the alternator drive gear. when replacing the spline just push in the updated unit and in the process push the old one out. exiting on the alternator side. the update spline has a heavier duty bolt that goes stright through the spline and connects both sides. hope this helps.

[mgt999]

Thanks guys! I am going to swing by the dealer today and see about getting the parts. I ordered a Haynes manual (I've never taken a clutch apart before) and hope it arrives today. If not, I guess I'll tackle it next week.

[The Vicar]

It is not too bad a job to do. Locking the clutch basket in place while you undo it is a bit tricky. i was lucky and managed to borow the Triumph tool from my local dealer. Only other problem I encountered was with the bolts that hold the clutch springs. One sheared off and I was no where near the torque setting! You can get away with not draining the engine oil to if you do it on the centre stand.

[mgt999]

Well the kit sure is expensive for what you get, but after reading the Haynes manual, it doesn't look all that difficult. As for holding the clutch basket, the manual suggest putting the bike in gear and have someone hold the rear brake lever down. Sounds simple enough...guess we'll find out!

Also plan to tackle fork seals in the not too distant future.

[mgt999]

Well the alternator job is done!! Wasn't too bad of a job and I think the two hardest parts were trying to get the nut off the clutch basket (the triumph tool would have really helped) and then tightening the bolt on the new spline. I was doing this alone and trying to hold them both was a little tricky. The only other frustrating part was getting the wrong clutch cover gasket from the dealer and not realizing it until it was the last thing to put on.

I think I caught this right in time because the bolt was broken on the clutch side and the gear was loose in there. Everything looked good; no banged up teeth or anything. Just glad it didn't tear anything else up.

[MotT3]

Well done ;-)