Clutch failure

[ozrider]

maybe double check you have got all the front cover bolts out, just saying

 

[HansO]

Still need to know how to get the front plate off. The steel rod will not let the front plate pass

if you are talking about the chrome coolant pipe that come down diagonally from top left (when facing front of motor) down to connect to water pump via a hose, it is held in with friction from the O ring on it you need to gently prise it out

 

[patrol21]

Thanks Hanso...I kinda figured as such and went to bike bandit as there layouts are generally a good reference tool. Anyhow, guess I just have to push a bit more elbow grease....its tight to get a finger behind it. My thanks

 

[warp9.9]

After you get the coolant lines and pump out. along with the cover bolts and the two cover bolts that also hold the clutch cable mount on. Two things can make it stick first being its is just the gasket and will take some persuasion. or if it is kind of loose but will not come totally off then you need to rotate the lifter shaft a little or the broken half is still hooked to the lifter piece. Some rocking and rattling to get it loose All by hand mind you.
In case it helps here is a shot of the lifter shaft in place on the cover with the OEM return spring so you can see how it captures the lifter piece head. This is why you have to rotate it to release the cover totally or rotate it to capture the lifter piece head on assembly.
hope this helps and questions as away

 

[patrol21]

Thanks warp...the plate popped right off and is loose, have the pieces of the lifter spring removed and spring dropped out..it is simply getting the downtube (chrome) that is held into the case by an o ring. Didn't want to pry last eve too much if it had some hidden set screw, flange I was missing. Just some prying without cranking on the front casing looks like its the path. only took and hour or two too get the radiator off, oil drain, coolant drain, bolts for the case, the two brackets that hold the radiator upper in place etc...easy , just time consuming with hops consumption mixed in...the manual is pretty much useless. your a way better resource...LOL!

 

[warp9.9]

Thanks warp...the plate popped right off and is loose, have the pieces of the lifter spring removed and spring dropped out..it is simply getting the downtube (chrome) that is held into the case by an o ring. Didn't want to pry last eve too much if it had some hidden set screw, flange I was missing. Just some prying without cranking on the front casing looks like its the path. only took and hour or two too get the radiator off, oil drain, coolant drain, bolts for the case, the two brackets that hold the radiator upper in place etc...easy , just time consuming with hops consumption mixed in...the manual is pretty much useless. your a way better resource...LOL!

No problem there is only one bolt going thru the coolant tube plus the cover. then its just pry till the O-ring pops out. its actually easy and a good design IMO. I followed the book and its not bad I just found a few short cuts along the way. Now I just walk out there as say "show me your clutch bastid" and it disassembles itself in front of me while piddling on the floor

 

[HansO]

Thanks Hanso...I kinda figured as such and went to bike bandit as there layouts are generally a good reference tool. Anyhow, guess I just have to push a bit more elbow grease....its tight to get a finger behind it. My thanks

I used a large flat bladed screwdriver with some padding so as not to mark the engine front cover, it takes a bit of pressure but just gradually increase pressure while trying to hold it square so it is a straight pull

 

[HansO]

No problem there is only one bolt going thru the coolant tube plus the cover. then its just pry till the O-ring pops out. its actually easy and a good design IMO. I followed the book and its not bad I just found a few short cuts along the way. Now I just walk out there as say "show me your clutch bastid" and it disassembles itself in front of me while piddling on the floor

Yeah much easier once you have done it the first time

 

[Jeff Cameron]

Poor Warp.....He seems to have photos of every common broken part. Handy guy to have around but he must have a stack of parts receipts for all the things he has had to replace. HP is not cheap!

 

[Jag]

Triumph should give @warp9.9 free parts for pushing their parts to extreme limits and seeing what they can handle. Maybe he should head up their Quality control, and he would be able the help out their R&D too.