Triumph bonneville gear selector fix

Triumph Bonneville Gear shaft removal and replacement

REMOVE AND INSTALL GEAR SHAFT ASSEMBLY
Removal
Remove the oil from engine and place bike on stand.
1. In a crisscross pattern loosen the clutch cover bolts with an 8mm Allen key.
2. With a rubber mallet work free the cover and remove.
3. Carefully remove the idle gear cogs and shaft being careful not to drop in oil sump.
4. Remove the clutch spring bolts with a 10mm socket.
5. Remove the pull rod.
6. Remove the pressure plate.
7. With a pointed tool flatten the flange on the clutch plate housing bolt.
8. With a special too block the clutch housing in order to remove the housing nut with a 30mm socket.
9. Pull clutch plate housing out trying to keep the clutch plates all in order.
10. Be careful there is a big washer often stuck on by oil on the back of the clutch plate housing.
11. Slide out the outer needle bearing and bearing sleeve and then let the upper chain sprocket drop in order to remove from the lower sprocket.
12. Remove the upper chain sprocket and chain with the inner needle bearing.
13. With an 8mm socket remove the two chain guide bolts and chain guide.
14. Remove the selector arm, you can leave the guide rod in place.
15. Place a rag at the bottom to cover access to the oil sump.
16. Remove the stopper arm spring with the tip of a small screwdriver.
17. Remove the stopper arm bolt with a 30 Torx head.
18. Remove the detent wheel if needed with a 6 Allen key.
Install
1. Thread lock the detent 6 Allen wheel bolt and install detent wheel @ 12nm
2. Thread lock 30 torx stopper arm bolt and tighten to 12nm.
3. Make sure stopper arm is free to pivot and not blocked and that the bearing is on the inside.
4. Install the stopper arm spring.
5. Move the detent wheel so that the stopper arm bearing is resting in the neutral groove of the detent wheel(the flatter cupped groove).
6. Remove the rubber “O” ring on the new gear shaft and install.
7. Thread lock the two chain guide bolts and install the chain guide tightening to 9nm.
8. Place oil pump chain over the lower sprocket and lift up to tighten and put the bearing sleeve and first needle bearing into the hole of the top chain sprocket.
9. Apply oil to the No1 starter idle gear sprocket and shaft and install.
10. Install the clutch housing using the locator holes on the back for alignment.
11. Oil up second needle bearing and slide in.
12. Place oil on big washer and place on inside of clutch drum.
13. Oil up the No2 starter idle sprocket and pin and install, locate hole before inserting pin.
14. Make sure that the clutch plate spring is raise off its seat below.
15. Install the friction and main plates into the housing making sure that the rounded edges are facing the inside in the following order:
1.Narrow edged Friction
2. Wide edged plain
3. Wide edged friction
4. Wide edged plain
5. Wide edged friction
6.Wide edged plain
7. Wide edged friction
8. Wide edged plain
9. Wide edged friction
10. Wide edged plain
11. Wide edged friction
12. Wide edged plain
13. Narrow friction
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14. Narrow plain
15.Narrow friction

The last two are installed in the friction plate with number 15 going in first followed by number 14.

16. Install the spring washers with the last one with “out” facing the outside.
17. Install the new clutch nut and tighten to 95nm with a 30mm socket and tool to stop clutch housing rotating.
18. Tap down the locking flange of the nut.
19. Lubricate the pull rod and install.
20. Install the pressure the plates with the remaining plates inside.
21. Install with the plates offset from the rest.
22. Install the clutch springs and tighten the three bolts evenly to 10nm making sure that the pull rod is always able to slide in and out smoothly.
23. Install the locating pins and then the clutch cover gasket.
24. Make sure that the washer is on the gearchange shaft.
25. Smear some grease on the two rubber o rings on the end of the balancer shaft.
26. Smear grease on the gearchange shaft oil seal lips, and lubricate the shaft bearing in the cover with oil.
27. Pull the pull rod as far out as you can so it seats against the bearing in the pressure plate
28. Set the release shaft arm so that it points back (aft)then fit the cover.
29. Check that the cover is located on the dowels and seated all around, then push the release arm in so it is at right angles to the cover.
30. Apply thread lock to the two shortest clutch cover bolts that fit either side of the gearchange shaft.
31. The four longest bolts fit around the front in the holes that sit further out than the rest.
32. Do not forget to install the clutch cable brackets as you are bolting up.
33. Tighten to 10nm in a crisscross pattern and tighten up in a clockwise direction.