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Trophy Trophy 3 & 4 - for all 900 and 1200cc models 1991- 2004

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Old 11-05-2012, 01:18 PM   #1 (permalink)
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John F 96 1200 Motor Repair - Your Opinion Sought

Hey Everybody,
On Sunday a friend and I dropped the oil pan/sump, removed the valve cover, and also popped off the trans case cover and ignition sensor cover. The motor looks clean on the inside. Really, factory new. When we turned the motor, it advanced smoothly. When we put the bike in 6th gear and rolled the rear wheel (bike on center stand), the trans sounded like it's normal rattly self. It rolled smoothly as well.

The sump had a large number of metal shavings, some small bearings, what looked like a destroyed roller cage, and three large (inch-long) pieces of curved metal. The sump and filter look like they did their respective jobs. When we turned over the motor with the pan dropped, nothing fell out of it. Ditto with
the trans.

I posted 11 pictures in the photo album I recently set up on the other Trophy Forum on yahoo. They show all the bits I described in the paragraph immediately above. Please look at these photos and let me know what you think this stuff is. I'll post those photos here as well.

My money is still on the sprag clutch. When I try to start the bike, it sounds like there's two little bolts clattering around in a tin can that's being spun. Not a big, clunky, horrible, metal getting hammered sound. More a light, clinkity dinkity sound.

If any of you has experience with the sprag clutch, do look at the photos and let me know what you think. After I hear from all of you fine people, I will make a hypothesis and proceed accordingly. I'm expecting to drop the motor and crack her open. I guess I'm a sick person because I'm really looking forward to continuing the investigation and digging further into this motor.

I'll go load the photos onto this site right now and let you know where they can be found. Thanks for weighing in with your opinions. I'll do a photo essay as I disassemble this beast.
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Old 11-05-2012, 09:57 PM   #2 (permalink)
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I think it's the sprag clutch. Check out photos and let me know what you think!

Hey Everybody,
I uploaded four photos showing the metal bits, small ball bearings, and what appears to be a destroyed bearing cage that I found in the sump/oil pan. The photos are here:

http://www.triumphrat.net/memberalbu...y.php/cat/1836

What's your diagnosis?
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Old 11-12-2012, 05:18 PM   #3 (permalink)
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Ive never seen a sprag clutch in person on one of these engines,I would think its hard to tell for sure that all the small bits have come out,drag to take it apart but........1 little chunk on the loose could cause more mayhem.
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Old 11-13-2012, 09:14 PM   #4 (permalink)
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Well.....unfortunatly.....you're going to need to split the cases I think. The only ball bearings in the engine are in the transmission and the starter sprag clutch assembly. I would think a full tear-down woud be needed just to ensure you get all the broken pieces out.
Happy trails,
Erv
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Old 12-28-2012, 01:18 PM   #5 (permalink)
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Originally Posted by ervdrvr1 View Post
Well.....unfortunatly.....you're going to need to split the cases I think. The only ball bearings in the engine are in the transmission and the starter sprag clutch assembly. I would think a full tear-down woud be needed just to ensure you get all the broken pieces out.
Happy trails,
Erv
+1

I wouldn't bother doing anything less than this.
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Old 03-09-2013, 01:31 PM   #6 (permalink)
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any news?
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Old 03-14-2013, 11:55 PM   #7 (permalink)
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Update from John F

I have three stubborn lower crank case bolts stuck. I buggered up the heads of these bolts so I must remove the bolt heads (with a drill bit that is slightly larger than the bolt diameter) and then pry open the crank case. Once the crank case is split, I expect to find the remains of the sprag clutch bearings. I have discovered more shrapnel and ball bearings rolling around inside the motor. I'm posting pictures on the Trophy facebook group sometime in the next few days.

The bike is about 90 percent disassembled. Only the forks and nose cone are still on the frame. And since I've gone this far, I'm going to painstakingly take the rest of it apart and renew it from tip to tail. Perform all the maintenance and renewal. Might as well! I'm probably looking at a couple of years of work, going at a leisurely pace. Good thing I got my Bonneville to ride!
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Old 03-16-2013, 01:29 AM   #8 (permalink)
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Quote:
Originally Posted by FasTriumph View Post
I have three stubborn lower crank case bolts stuck. I buggered up the heads of these bolts so I must remove the bolt heads (with a drill bit that is slightly larger than the bolt diameter) and then pry open the crank case. Once the crank case is split, I expect to find the remains of the sprag clutch bearings. I have discovered more shrapnel and ball bearings rolling around inside the motor. I'm posting pictures on the Trophy facebook group sometime in the next few days.

The bike is about 90 percent disassembled. Only the forks and nose cone are still on the frame. And since I've gone this far, I'm going to painstakingly take the rest of it apart and renew it from tip to tail. Perform all the maintenance and renewal. Might as well! I'm probably looking at a couple of years of work, going at a leisurely pace. Good thing I got my Bonneville to ride!
Yikes! You will know that bike pretty well when its all over.
I did a version of that on a 76 R75/6,it was a big effort,changing frames,rebuilding what ever came up bad .

Once I finished it and rode it,I realized it was an under braked/poor shifting/slow/ill handling sort of scow.

It taught me about wrenching,good practice.
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Old 03-16-2013, 11:17 AM   #9 (permalink)
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Yes, I am getting intimate with my Trophy 1200

Quote:
Originally Posted by Flattrack loon View Post
Yikes! You will know that bike pretty well when its all over.
I did a version of that on a 76 R75/6,it was a big effort,changing frames,rebuilding what ever came up bad .

Once I finished it and rode it,I realized it was an under braked/poor shifting/slow/ill handling sort of scow.

It taught me about wrenching,good practice.
One great thing about this bike is I know it is a fabulously handling Sport Touring rig. So I know the reward will be there at the end of the work. Yes, I have come to love this creature - machine. It's a great bike.

I have dreams of an award-winning custom paint job. Still going to keep the British Racing Green base color, but there's some fun/trick things I'm going to do.

You know what's funny? My gas tank continues to be spotless. I mean no rust. Nothing. 98% of the gas I have put in her is BP 93 Octane premium. Occasionally got trapped on the road having to buy 91 or 89, but it's never sat still unless full of premium and that enzyme-laced fuel stabilizing water scavenging stuff.

Bolt extraction tonight after I drive to Iowa to pick up my oldest daughter.
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Old 03-18-2013, 05:14 AM   #10 (permalink)
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Was the extraction successful?
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