C-Clip failure...trashed transmission.

[ransan]

This particular failure mode has nothing to do with the year, it spans 2005 up to at least 2014 for confirmed cases.

The failure mode is wear to that exact circlip during downshifts. It dislodges up onto the shaft and then at some point the gear walks and boom during a 3 to 4 upshift.

The cause is very simple, it's one of these three or a combination of them:
A) Circlip installed backwards
B) People kicking the lever downshifting or stomping on the heel plate if using a heel shifter.
C) Bottom of Groove OD at upper limit or slightly over tolerance and shaft OD being at lower limit or slightly under limit.

This IS actually a reasonable class action or at least a NTSB forced recall issue. It can definitely lead to accident/injury. I was leaned over near the edge of the tire, full throttle going 3 to 4 at 7500 RPM or so when I did it while passing traffic.

Triumph is WELL aware of the issue.

Thanks Claviger Been missing your experience and expertise in most things Rocket related.

 

[Claviger]

Thanks Claviger Been missing your experience and expertise in most things Rocket related.

Thanks Ransan, just hard-learned (expensive) lessons, nothing more.

 

[Manic_Mechanic]

I wonder what the statute of limitations is on this type of law suit.

 

[Rocket Scientist]

If I had one of mine split apart like that, I'd be sure to remove, clean, and RED loctite that pesky little bolt, that holds the shift linkage to the spool shaft........ just sayin....

When I had mine split to do the trans work, I checked that little bolt and it was only finger tight

 

[Rocket Scientist]

Had the same issue, Robinson machines a deeper or wider groove for the circlip, you should have no issues. Plus there's a right and wrong way to install the circlip, which Triumph apparently didn't realize, and installed them randomly
The stamping process of manufacturing the circlip produces a rounded edge on one side, that should not be the side pressure works against.

The circlips Robinson's used in mine appear to be surface ground, so they don't have a "rounded" side.

 

[Steff]

Same thing happened to me on my 2005. But when the rear locked up, the bike went right and crashed into a fence. I however was thrown into the air and busted up most of the left side of my body. Seven weeks later I bought an 09.
The 05 now has a 2016 engine in it. It's bobbed and th 09 is bagged.

I got the '06 model. What sort of mileage did you have on it before it went bang? Mine has done 34k, so hopefully it's a good un. Seems to be pot luck on who gets a bad un.

 

[Rocket Scientist]

Mine shatted at about 70,000 miles. Mine had the second gear repaired at the dealership before I got it. They put all the circlips on backwards. Yours may never have a problem. If you have a heel / toe shifter, I wouldn't use the heel part. I believe they cause a lot of transmission problems. They give you way to much mechanical advantage over some fairly delicate parts in the trans.

 

[Steff]

Mine shatted at about 70,000 miles. Mine had the second gear repaired at the dealership before I got it. They put all the circlips on backwards. Yours may never have a problem. If you have a heel / toe shifter, I wouldn't use the heel part. I believe they cause a lot of transmission problems. They give you way to much mechanical advantage over some fairly delicate parts in the trans.

Ta

 

[Steff]

Ta, one can get paranoid. This will be my last ride.I really don't want to spend 1000s and the ball ache of spannering.

 

[Manic_Mechanic]

I got the '06 model. What sort of mileage did you have on it before it went bang? Mine has done 34k, so hopefully it's a good un. Seems to be pot luck on who gets a bad un.

Over 62K