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Discussion Starter #1 (Edited)
Long story short, I was out on a trail and went down. In the process I broke my clutch lever and bent the gear shift selector. The bike is currently stuck in 3rd gear and working the shifter up or down does absolutely nothing...which leads me to believe that either the gear shift shaft and or the pivot plate are bent as well.

Has anyone else experienced this before? Seems like it might be a common thing. It looks like the clutch has to be removed to be able to get to the shaft. Has anyone done this before? Any tips or things I should look out for?? Thanks in advance!
 

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Discussion Starter #4
Ok, so new problem. I finally got all the parts I needed to start on this project. After pulling everything apart, I was able to remove and install the new gearshift shaft...which is a lot of work!!

The new problem is the old unit was not just bent but the part on the end of the arm that actually selects the gears is broken in about 3-4 pieces. I was able to fish out 2 of the pieces but there is definitely at least one more down in the bottom somewhere. So now the new project is to drop the oil pan and hopefully clean out the last of the pieces.

Obviously I dont want to leave any metal bits/parts in the engine. Besides cleaning out the oil pan is there anything else I should look at or do?? I'm hoping the strainer in the sump kept out any of the metal bits.
 

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Shifter damage is a real Achilles heel of Triumph's modern classic line, all of them.

Did considerable searching but couldn't find the thread about making a thick Delrin spacer that fits on the shifter shaft between the shifter lever and the engine case. I have one installed, made by Simon64ds, who also designed it. Hopefully, it'll prevent shifter mechanism damage in the event of a low energy left side fall by spreading impact forces to the left side case. The spacer is black and doesn't interfere with the shifter in any way.

I've been surprised that these are not made by some after market supplier. My theory is that they're so simple and cheap to make that it would be impossible to charge enough to recoup costs and make money.

Edit: Here ya go. Found the thread. See the photo of the spacer installed in post #54:

https://www.triumphrat.net/water-cooled-twins-technical-talk/946324-street-twin-lost-downshifting-bent-internal-shift-mechanism-diy-walk-through-6.html
 

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SoCal OG when I tore into my t120 for the same issue one of the gear shafts fell into the sump. I removed it with a strong magnet taped to a bendable wire coat hanger. Make sure it is attached to the wire really well. This saved me from having to drop the pan. Good luck!
 

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Discussion Starter #8
SoCal OG when I tore into my t120 for the same issue one of the gear shafts fell into the sump. I removed it with a strong magnet taped to a bendable wire coat hanger. Make sure it is attached to the wire really well. This saved me from having to drop the pan. Good luck!
I tried that initially but there really is not much space to get into the pan. Plus I really wanted to make sure I got everything out...dont need bits of metal floating around. I did end up dropping the pan this weekend and that was quite an adventure! The Haynes manual basically says remove the bolts and drop the pan. Its not even close to that simple...but thats for a whole different story.
 

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I tried that initially but there really is not much space to get into the pan. Plus I really wanted to make sure I got everything out...dont need bits of metal floating around. I did end up dropping the pan this weekend and that was quite an adventure! The Haynes manual basically says remove the bolts and drop the pan. Its not even close to that simple...but thats for a whole different story.
Did you manage to find all the missing bits?
Hopefully they wouldn't be small enough to fit into any oil passages:|
 

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Discussion Starter #10
Did you manage to find all the missing bits?
Hopefully they wouldn't be small enough to fit into any oil passages:|
I think I got them all. There were 3 main pieces plus some small shavings in the bottom of the pan. I'm confident I got everything and nothing got through the sump screen. Attached is a pic of 2 pieces plus whats left of the main shaft. What a crazy ordeal this whole thing has been!!
 

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Damage to the shifter internals isn't necessarily from a hit to the shift lever, but rather to the shift shaft itself. It gets displaced to the right. As a minimum the shift forks get bent, making shifting difficult. A harder hit bends or breaks other parts, and shifting becomes impossible. A spacer between the shift lever and the engine case is the only solution, but even this is probably only effective protection in a fall off of the side stand, or a really low speed left side drop. So sure, why not add a folding shift lever, but add the spacer, too.
 

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Discussion Starter #13
I'll be adding some kind of spacers for sure. This whole episode has been a serious pain. On the bright side I've become really familiar with the inner workings of this bike.
 

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I'll be adding some kind of spacers for sure. This whole episode has been a serious pain. On the bright side I've become really familiar with the inner workings of this bike.
was there any evidence that your damage was due to the shaft being pushed in towards the gearbox, was the circlip forced out of the groove on the outside of the case?
I'm just wondering if it's possible this damage could be caused by the gear lever being forced up or down by an impact beyond it's normal range of motion, and if that is the case the spacer mod won't help and a hinged lever has only a 50/50 chance depending on the angle of the impact.
Just a thought:|
 

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Discussion Starter #15
was there any evidence that your damage was due to the shaft being pushed in towards the gearbox, was the circlip forced out of the groove on the outside of the case?
I'm just wondering if it's possible this damage could be caused by the gear lever being forced up or down by an impact beyond it's normal range of motion, and if that is the case the spacer mod won't help and a hinged lever has only a 50/50 chance depending on the angle of the impact.
Just a thought:|
If I had to guess the impact came at roughly a 45 degree angle..not directly inward. All the circlips and washers were in place and not deformed or out of place. I dont think the spacer mod would have prevented any damage but maybe it would have lessened the damage. Impossible to tell.
 
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