Triumphrat

tt600ryder · 05-26-2009, 06:24 AM

OK. So haven't used the bike all winter, go to start it up as I do every couple of weeks to let it tick over for a little while and decide to move it. I jump on raise stand, clutch in and stick in 1st. hear a clunkish noise and the engine cuts out.

:

Turn off, turn on again, dash says bikes in neutral, wont start (just clicks once). Tried to change gears but gear shifter completely stuck - wont do anything with clutch in or out.

_98OLVV:

Battery charge is fine, adjusted clutch cable - seems fine but gear shift will not move.

:

Questions:

1. has this ever happened to anyone (I understand this happens with GSX-R's, but never read anything similar on TT's or Triumph's).

2. any ideas how to diagnose / fix (ideally without stripping the engine and splitting the case).

3. if removing the engine is the only option any ideas on difficultly level to fix this for a relative novice who isn't afraid of getting his hands dirty (although I understand you need specialist tools).

All help gratefully received

:.

Thanks

kubbie · 05-26-2009, 08:32 AM

tt600ryder,

That is weird. My only guess without opening up the lower end would be to open the clutch cover and remove the clutch. It may be that deal where the plates dry out some and stick together. Pulling the clutch would take on possible cause out of the way.

If it turns out not to be the clutch I'd look at, in order:
1- the shift fork
2- first gear on output shaft, including the shift dogs
3- shift drum

You will need the manual cause there are too many little pieces to keep track of. But the tranny is fairly staight forward.

Good luck.

Nelli · 05-26-2009, 09:45 AM

I had that happen to my S4 during its first miles.
Turns out it was a cotter pin that had gotten loose in the gear shift mechanism, or at least thats what I was told :-) .
The shop had the clutch side cover open to fix it. A quick job, took a few days to get the gasket/seal for the cover.

tt600ryder · 05-27-2009, 12:58 PM

Cheers for the advice guys. Guess it's time to get my hands dirty - I'll check out the clutch 1st. I assume you need to drain the oil prior to opening the clutch clutch cover, and guess I will need a new gasket and sealant to close it back up?

What is a cotter pin?

tt600ryder · 05-27-2009, 01:37 PM

One further question. Do I not need the Triumph tool for removal of the clutch plates? If not what's the alternative?

tt600ryder · 06-04-2009, 10:07 AM

I managed to fix this issue now and am sharing as it has perplexed many people. Route cause was the clip on the peddle side of the gear selector moved to the left of the little grove it sits in. This resulted in the gear selector shaft slipping to the right, with the hook that locks the gears falling off the gear shaft and getting trapped behind the clutch outer drum and oil pump drive chain.

The problem is fairly easy to rectify - drain oil, open clutch cover, remove springs, remove inner clutch drum and plates (mark them to remember the order and alignment and and you don't need the £90 Triumph tool), centre nut and 2 washers, remove outer drum, re seat selector shaft and hook, replace clip on left side of selector shaft (I went for a new clip so it doesn't happen again). Test the gear selector to ensure it is changing gears.

While your there you might as well also check the depth on your friction disks. If less than 2.72mm deep or warped you need an inner drum kit (so say Triumph). Also check the plates for any warping.

To assemble re seat outer drum (align with crankshaft gear), input shaft nut and washers, inner drum and plates (make sure it is aligned based on your marks and use two of the 4 bots partially screwed in to help you keen the inner drum and plates aligned for installation as opposed to the triumph tool), springs, new gasket and seal, replace clutch cover, connect clutch cable, replace oil (Castrol GSP - nice pinky colour) and filter (up to you) and your done.

Start her up and listen to the purr.

BombFactory · 06-04-2009, 08:38 PM

Good info, and it's good to hear you fixed the issue. I bought a wrecked TT600 that the transmission was stuck in gear. The shifter lever was hit hard and popped the circlip of, pushing the shift-shaft in. I figured that the gear select fingers were slid out of place, so it sounds like your issue might be mine. I ended up getting a good deal on a used engine which is treating me well, so one day I'll have to jump into the problem engine I suppose.