Triumphrat

Vankaye · 07-21-2007, 09:12 PM

Hi Guys,
Changing the cover today. Having trouble getting the pin lined up.

Will I need to pull the starter?

Any tips or tricks to get this lined up much appreciated! Borrowed the pic
from the DIY Alternator thread. Thanks!

redl1nerpm · 07-21-2007, 10:06 PM

haha, who's bike is that?

You can actually pull that right off. The pin will pull right out and then you can get that gear out. As long as the pin is in its slot and the gear on, your stator cover will slide on, it just takes a little finesse until it pops on correctly. That rotor is magnetic so it may try to pull everything just off. If your having a lot of trouble the pin probably isn't in all the way just pull it and the gear out and look at it closely. You definitely don't need to pull the starter though. I noticed this because mine fell out the first time I pulled the stator cover off.

Vankaye · 07-22-2007, 01:36 AM

Ok, I got it. I had to turn the gear counterclockwise a bit to get
the pin lined up. Just wanted to make sure it could be flogged a little.

sdirwin · 08-11-2008, 09:12 AM

I'm having the same problem with the pin/spindle on my 2002 TT600. When I pulled the alternator cover off, the pin/spindle was sticking out of the cover (i.e., it pulled out of the idler/starter gear). Now, when I try to put it back together, the pin is keeping the cover from going back on all the way. I noticed a recessed hole in the engine case behind the idler/starter gear, but the diameter of the pin is too large to fit in the hole (at least not without the aid of a hammer!) Because the pin/spindle cam out with the alternator cover, I figured trying to hammer it into a too small hole was not the correct solution to my problem. What am I doing wrong?

themaster · 08-15-2008, 05:41 PM

Don't hammer it!

You should be able to push the gears up and left a bit, and it should push in.

It is fiddly, but it will fit in the end!

sdirwin · 08-15-2008, 06:17 PM

Even when I take the idler gear completely out of the way, it seems the pin is too large for the hole. It certainly won't slip in the hole, but I haven't tried to apply any force (even by hand). I've just been lining it up. It certainly won't slip in easily. That's what's confusing me because it came out so easily on its own (sticking out of the alternator cover). I could easily remove it from the alternator cover and put it back in the alternator cover hole, but no so with the corresponding hole on the engine case.

I'll fiddle with it some more tonight, but I'll head your advice and not attempt to persuade it with any blunt force.

Thanks-
Scott

themaster · 08-15-2008, 06:32 PM

Well, if you take out the gear out completely, you'll find its a tight fit and it does need a good shove - kind of 'clicks' into place (without clicking, if that makes sense - there's a resistance you have to push through), but no blunt force is necessary.

sdirwin · 09-02-2008, 06:30 PM

Update - I fiddled with the idler gear until it moved right into perfect position for the pin. However, there was no way that pin was going into its recess without a little persuasion. I put a wood block on it and gave the block a very light rap with a tack hammer. The pin popped right into place.

Scott