T90 Kickstart Spring

[T90 Arrow]

Hi, I took the gearbox cover off my 1967 T90 the other day to replace the gearlever shaft oil ring. As I eased the cover of the kickstart spring shot off and unwound. I can't seem to get it back on. the spring cover plate only goes onto the shaft by about 1/8th of an inch. Sometimes it comes apart again before I can get the gearbox cover on. Other times I get the cover most of the way on and then Twang, it's off again. What exactly holds the spring and spring cover onto the shaft. If you look at
www.classicbike.biz/triumph/repair/350-500/63-74-350-500cc-repair.pdf
it might help. Page 146 Fig D9.
If you haven't got a workshop manual for a T90 or T100 you have now.
Thanks, Barry

 

[CarlS]

Hi, Barry; GrandPaul, or one of the other vintage experts will be along to answer this.

 

[Rocky]

Ah yes, I recall that frustrating wrestling match very well, but it's been many years since I was in there.
I have that factory manual and found it invaluable when I restored my T100 15 years ago.
What you see is what you get. The Haynes manual offers no additional advice when fitting the spring.
The "distance piece" has to be a good square fit over the kickstarter shaft in order for it to remain in place when you put the cover on. Nothing but a close fit between the "piece" and the shaft holds things together until you get the cover on.
If the inside edges of the "piece" are worn it will tend to slip off as you have seen. It also helps to get the mating pieces as dry of oil as you can to reduce slippage and increase friction. If your "piece" is in good condition then it comes down to patience I guess. There isn't any other way that I know of to help keep it in place.
I think I ended up buying a new "piece" with sharper edges/shoulders in order to get it to stay in place.
Anyway, I did get it back together after many attempts and I haven't removed it since.
Sorry I can't be of more help.

 

[grandpaul]

Yep, there's nothing positive that I can add. It took me 4 tries my first time, 2 the next time. Haven't had to mess with one since...

 

[T90 Arrow]

Thanks for that lads, just keep trying. What actually holds it in place once the gearbox cover is on. Surely it can't be the cover or it would wear it every time you kicked it over. Barry

 

[Rocky]

That's a very good question and I can't answer it, but some part of the mechanisms inside the cover must keep the plate in place. It wouldn't be the aluminum cover directly of course. There is lots of gearbox oil in there so there wouldn't be much wear.
It's been many years since I was inside my T100 so I don't have a good mental picture of the inside of the cover and how it looks.
Wouldn't it be nice if we could look inside once it's together and see the relationship of the parts.

 

[The Seeker]

Is it similar to newer Bonnevilles where you have to crank the kickstarter shaft a little bit in order for it to slide back on?

 

[T90 Arrow]

Don't think so unless someone knows different. Barry