Triumphrat

d3v1c3

Primary, gear-case, transmission. Call it what you will, mine needs to be disassembled . I took a low speed spill and want to get the scrape polished out and re powder coated. I am going to be taking the cover apart myself and sending it to my dealer to have repaired and powder coated. The only issue I am having is a technical publication to do this with. I do not have a manual on hand to disassemble the cover. I am sure I can do it on my own, but I prefer to do it correctly without any incident. I have one on order but I am supposed to drop off the cover on tuesday to my dealer. Does anyone have the ability to scan a few of the steps along with the associated parts diagram into a PDF? I would be thankful. I suppose if this is against the forum rules it shall be deleted promptly. But it never hurts to ask. Thanks in advance.

Hotboppincat

Which side?

Do you want to remove the clutch cover on the left as you are sitting on the bike?

GDCobra

There's not really too much to 'disassemble' with the cover only the clutch release mechanism which going from memory pretty much just drops out, depending on what you are doing you may also have to remove the needle roller bearings for the clutch shaft and gear change lever but unless you're going to powder coat it I'd leave them alone, it's all pretty intuitive once you look at it, I didn't have a manual when I did it, take some photo's as you do it so aid re-assembly.

One thing to make very , very sure of is that the starter idler which sits on a shaft which engages at either end on the inner and outer (the one you're removing) case. When you disassemble this shaft can pull out of the engine side case and the gear shift it's position, it can look correct but if you leave it like that it will all attempt to self destruct when you try to start the engine.

Hotboppincat

http://www.worldoftriumph.com/triump...lock_03=232888

Exploded parts diagram here covers both sides.

d3v1c3

Thank you for both replies. That will help me out tremendously.

GDCobra, once the cover was removed the only loose parts that I noticed were the; wavy washer (which I did not see on the exploded parts list), and the dowel rod. everything else seems to be in its place still. I suppose once I get my manual in the mail everything should go back together fairly easily.

I noticed you said "unless you're going to powder coat it" did you mean me personally? I was going to have a professional do all of that so I suppose I can just leave the bearing in.

Hotboppincat

I just looked at the Haynes, the 4 cover dowels, the starter gear wave washer, and shaft are the only bits you are likely to lose. I can't scan the Haynes and upload it, cos of copyright.

But it goes something like this:

Drain the oil
Remember the position of the gear lever for reassembly. Undo pinch bolt and remove linkage.
Remove the clutch cable from the arm.
Remove breather hose from crankcase
Unscrew the bolts
Take the cover off.
Remove the old gasket
(Keep the 4 locating dowels safe, remembering where they go.)
Keep the wave washer safe, the shaft will pull out of the starter gear too..
I think thats it.

d3v1c3

Perfect. that will at least allow me to take care of everything until my manual arrives. Thanks for all of the help.

GDCobra

Yeah, forgot about the wavey washer but the important thing is when you put that 'dowel' back in that it engages correctly with the bore in the inner case, that's the main 'gotcha' with this cover. Your powder coaters may take the bearings (and the associated oil seals) out and chuck them away (you may be replacing them anyway), I'd check with them the best thing to do before leaving it with them.

Mvke

Gonne do the same job as you did , what manual are you talking about , would like that one.

Forchetto

Probably this one:

http://www.haynes.co.uk/webapp/wcs/s...egory_rn=10501