Idler Boss Reinforcement

[unclescratch]

I have been a 'wrench/motorhead' all of my life. Always did my own maintenance and repairs. Have a good assortment of tools and familiar with their use. Not a difficult job for me. Do your homework, take your time and this is not a major event. Lots of threads about this procedure w/photos. "Do your homework". . I would not hold off on getting this done, you are gambling with a known issue that 'can' lead to serious repair costs. What is your 'risk tolerance' ?

. https://www.other forum/threads/clu...ttp-safe-start-project.985645/#post-200422500 (try this link)

 

[sikatri]

I have been a 'wrench/motorhead' all of my life. Always did my own maintenance and repairs. Have a good assortment of tools and familiar with their use. Not a difficult job for me. Do your homework, take your time and this is not a major event. Lots of threads about this procedure w/photos. "Do your homework". May I suggest: other forum (as a resource)? I would not hold off on getting this done, you are gambling with a known issue that 'can' lead to serious repair costs. What is your 'risk tolerance' ??

I do my own as well. In my younger days I worked as a mechanic in a classic car restoration shop. Been keeping my hand in and started working on everything I own again after having some mechanic mistreat my MINI JCW. I’ve been working on my motorcycle now since I bought it a few years back. Figured it was easier to get under than my cars. LoL. I decided today, I would not start it or ride it until the procedure is done. While I know I could rebuild an engine, I really would enjoy riding it rather than rebuilding and spending months off the road. Appreciate your advice and comments. I have a shop manual and a couple of other Triumph manuals to cross reference. I’m not going to press my luck. I’ll partially drain it sometime this week and slowly take off the cover. Thanks.

 

[unclescratch]

https://www.other forum/threads/clutch-gasket-repair-and-ttp-safe-start-project.985645/#post-2004225008 Try this link for more info and another source for Triumph related stuff.

Still unable to link to another triumph forum. Rats ! I wasn't born w/this computer stuff......

 

[sikatri]

https://www.other forum/threads/clutch-gasket-repair-and-ttp-safe-start-project.985645/#post-2004225008 Try this link for more info and another source for Triumph related stuff.

Still unable to link to another triumph forum. Rats ! I wasn't born w/this computer stuff......

I’m going to look and see what it looks like under the cover. Wasn’t planning on a clutch job unless something looks fishy. I have a clutch tool I bought a few years ago just in case. LoL. Yeah, your link didn’t work. I wouldn’t think there is anything tricky about this, but first time is always a first time. If you recall anything special or note worthy in the process let me know. Thanks.

 

[unclescratch]

I did mine at about 15k miles. Purchased all the seals going through the cover along with the gasket before I removed the cover. There isn't that much oil in the cases, maybe just drain it all if it is new enough to re-use it.

 

[sikatri]

I did mine at about 15k miles. Purchased all the seals going through the cover along with the gasket before I removed the cover. There isn't that much oil in the cases, maybe just drain it all if it is new enough to re-use it.

I have several cover gaskets. Need to look into seals. Didn’t realize there might be a need to replace a few. I’ll check. Going to need a new crush washer for the oil drain anyway.

 

[sikatri]

This is so far the only instructions I’m finding.
https://www.triumphtwinpower.com/pdf/Safe-Start Installation Guide.pdf

 

[unclescratch]

There are 'other' sites for discussion of Triumph motorcycles. But this site does not allow me to show them here for whatever reason. Perhaps you could google them? The instructions from TTP should get anyone through this though.

 

[sikatri]

There are 'other' sites for discussion of Triumph motorcycles. But this site does not allow me to show them here for whatever reason. Perhaps you could google them? The instructions from TTP should get anyone through this though.

I’m on another as well. I don’t go there often, but I’ll check it out. I think there’s a thread or two on the subject. What I’m trying to figure out does the small gear come out without having to remove the larger adjacent one. From what I think, the shaft comes out and the gear slips off. The adjacent gears have single use bolts, so if they needed to come off, new bolts would be needed. Doesn’t look like they need to.

 

[unclescratch]

As I recall, I did not remove the larger gear.

 

[sikatri]

As I recall, I did not remove the larger gear.

Good. Then it’s starting to seem simple enough.

 

[sikatri]

A package from the UK arrived!

I have a few other projects to finish up before I start this and the clutch job. Soon though.

 

[sikatri]

Thought I'd post a few of the idler boss reinforcement pictures in this thread.

Idler gear and shaft in place with wavy washer.

Close up.

Pulling the idler shaft out.

Note how the boss wall is thinner on the right side. This is where it most likely shears.

Underside of the idler boss reinforcement.

Top view of the idler boss reinforcement.

Covering the shaft hole from the JB Weld.

JB Weld coated reinforcement placed on idler boss. Wait 24 hours before reassembly.

Idler gear and shaft in place. Don't forget the wavy washer. Clean off gaskets, install cover, linkage, cable and fill with oil. Time to ride.

 

[Qship]

Good stuff and peace of mind for you.
Thanks for sharing.