Stuck in fifth and clunking, -after advice, hints tips and tricks TIA

[Mittzy]

I've borrowed that (and the bar that goes with it) from the dealer a couple of times. I had planned to take that schematic to a machinist along with a couple of cartons but haven't got around to it yet.

My alternative was to source a bolt that matched pitch and diameter and taper the end to fit...but haven't got around to that either...i have an 11 month old so spare time is a long forgotten luxury...

A 3rd option is order one from Triumph if you are feeling wealthy!

We will take this opportunity to summon @Mittzy and @Ishrub who might know of one on the east coast somewhere...both are resourceful fellas

I have those tools, BSA Bob had a couple made up and i bought one for $50 AUD

 

[Ishrub]

@Noir_Nikko you may find a happy sharer in Brissie then.
It helps us all if we display our location in our Avatar block.

Click on your Avatar image in TOP RH banner strip and then click on Account details and it will allow you to modify what appears.

 

[Noir_Nikko]

Will it make a difference making the alternator removal out of 1 1/2 hex
$100 vs $50

I think I'm going to buy the Clutch Basket tool
By the time postage is paid anyway

Thank you all again and again

 

[mr hunt]

Will it make a difference making it out of 1 1/2 hex
$100 vs $50

I think I'm going to buy the Clutch Basket tool
By the time postage is paid anyway

Thank you all again and again

I assume 1.5 inch is referring to the head size?

...also you can make the clutch basket tool for free if you screw a few fibres and steels together from an old set. Ask your dealer if they've got any lying around. Otherwise I think Suzuki have a couple of models with same size clutch???

 

[Noir_Nikko]

I assume 1.5 inch is referring to the head size?

...also you can make the clutch basket tool for free if you screw a few fibres and steels together from an old set. Ask your dealer if they've got any lying around. Otherwise I think Suzuki have a couple of models with same size clutch???

I am
The alternator removal tool, machinist can make it for $50 if out of 1 1/2 AF Hex
Or $100 if 35.5AF I believe from the drawing
(I think i've answered my own question after getting a chance to read the manual again, it won't matter)
It should only change what tool I use to do and undo it up ie, 1 1/2 Af vs 35.5Af?

Made a tool for the flywheel, however need to modify it now realising the purpose of the alternator puller tool
Worked to get the centre bolt out but not the rotor

Going to make (as per @mr hunt suggestion) or buy the Basket tool

Keep telling myself I will need the tools again in the hopefully distant future

Annnnd for anyone in Tassie, I have a set lol

 

[dandiego]

I’ve read thru this thread but haven’t seen what the actual issue was.

Are you certain it’s not just the detent spring? Because that’s sure what the symptoms point to.

 

[Noir_Nikko]

Update,
Finally got the case apart and is as suspected, broken circlip
photos attached

-second photo can see missing circlip groove

 

[Noir_Nikko]

This little spring fell out of the crank case bottom half,
Motor was upside down and it fell out when I turned the case back over for inspection.
Pictured beside non-return valve

Any ideas gentlemen??

 

[Gerald]

This little spring fell out of the crank case bottom half,
Motor was upside down and it fell out when I turned the case back over for inspection.
Pictured beside non-return valve

Any ideas gentlemen??

Believe it goes in engine block before you install non-return valve, same hole.

 

[Ishrub]

It is not #21 Detent Spring T1190086 or #25 Spring, Gearchange Return T1190016
So if it has no broken edges and is neatly finished at each end without protrusions it could be:
#6 Spring, Gear Indicator T1190780

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#	Part	Stock	RRP	Qty Used	Basket
1	BOLT,SPRING ABUTMENT T1190208 No Longer Available Share this part	NO LONGERAVAILABLE	$3.27excl. VAT(£2.63)	-
1	Bolt, Spring Abutment T1190054 Share this part	BACKORDERNO STOCK	$3.54excl. VAT(£2.85)	1	QuantityMinusPlus
2	Kit, Detent Arm & Spring T1190307 Share this part	BACKORDERNO STOCK	$16.26excl. VAT(£13.09)	-	QuantityMinusPlus
2	Dentent Arm Assy T1190305 Share this part	BACKORDERNO STOCK	$16.26excl. VAT(£13.09)	-	QuantityMinusPlus
3	Arm, Gearchange Actuator T1190061 Share this part	BACKORDERNO STOCK	$16.63excl. VAT(£13.39)	-	QuantityMinusPlus
4	Selector Drum T1190219 Share this part	BACKORDERNO STOCK	$209.03excl. VAT(£168.30)	-	QuantityMinusPlus
4	Kit, Selector Drum Assy T1190640 Share this part	BACKORDERNO STOCK	$242.81excl. VAT(£195.50)	-	QuantityMinusPlus
5	SHAFT GEAR POSITION T1197800 Replaces T1190267 Share this part	BACKORDERNO STOCK	$30.09excl. VAT(£24.23)	-	QuantityMinusPlus
6	Spring, Gear Indicator T1190780 Share this part	BACKORDERNO STOCK	$2.86excl. VAT(£2.30)	-	QuantityMinusPlus
7	Pin, Gear Indicator T1190777 Share this part	BACKORDERNO STOCK	$2.96excl. VAT(£2.38)	-	QuantityMinusPlus
8	SHAFT,GEARCHANGE ACTUATOR T1190212 Share this part	BACKORDERNO STOCK	$31.14excl. VAT(£25.07)	-	QuantityMinusPlus
9	Bearing Ball, Unshld, 20x42x8 T3800090 Share this part	BACKORDERNO STOCK	$4.22excl. VAT(£3.40)	1	QuantityMinusPlus
10	DETENT WHEEL T1190004 Share this part	BACKORDERNO STOCK	$21.80excl. VAT(£17.55)	-	QuantityMinusPlus
11	Screw, Pan/Hd, Tx, M6 x 25, Enc T3331041 » Eng No 127359 Share this part	BACKORDERNO STOCK	$0.58excl. VAT(£0.47)	2	QuantityMinusPlus
12	Bolt, HHF, Lghtd, M8 x 16, Enc T3201977 Replaces T3200220 Share this part	1-3IN STOCK	$2.84excl. VAT(£2.29)	-	QuantityMinusPlus
13	Keeper Plate T1190207 Share this part	BACKORDERNO STOCK	$11.45excl. VAT(£9.22)	1	QuantityMinusPlus
14	Screw, M6 x 12, Enc, Raw T3051062 Share this part	BACKORDERNO STOCK	$0.83excl. VAT(£0.67)	2	QuantityMinusPlus
15	E Circlip T3500044 Share this part	1-3IN STOCK	$0.53excl. VAT(£0.43)	1	QuantityMinusPlus
16	Selector Shaft T1190066 THIS PART IS NOW OBSOLETE Share this part	NO LONGERAVAILABLE	$17.04excl. VAT(£13.72)	-
17	SELECTOR FORK, 1ST/4TH GEAR T1190650 Share this part	BACKORDERNO STOCK	$68.62excl. VAT(£55.25)	-	QuantityMinusPlus
18	SELECTOR FORK, 5TH GEAR T1190655 Share this part	BACKORDERNO STOCK	$68.62excl. VAT(£55.25)	-	QuantityMinusPlus
19	SELECTOR FORK, 2ND/3RD GEAR T1190660 Share this part	BACKORDERNO STOCK	$68.62excl. VAT(£55.25)	-	QuantityMinusPlus
20	WASHER, THRUST,24X17X1.5 T3550116 Share this part	BACKORDERNO STOCK	$3.34excl. VAT(£2.69)	-	QuantityMinusPlus
21	Detent Spring T1190086 Share this part	BACKORDERNO STOCK	$2.74excl. VAT(£2.21)	-	QuantityMinusPlus
22	Gearchange Shaft Assy T1190028 Share this part	BACKORDERNO STOCK	$95.01excl. VAT(£76.50)	-	QuantityMinusPlus
23	E Circlip T3500044 Share this part	1-3IN STOCK	$0.53excl. VAT(£0.43)	1	QuantityMinusPlus
24	SLEEVE,SPRING,GEARCHANGE T1190053 Share this part	BACKORDERNO STOCK	$0.89excl. VAT(£0.72)	-	QuantityMinusPlus
25	Spring, Gearchange Return T1190016 Share this part	BACKORDERNO STOCK	$2.70excl. VAT(£2.17)	-	QuantityMinusPlus
26	Washer, Spring, Wavy T3600908 Share this part	BACKORDERNO STOCK	$1.64excl. VAT(£1.32)	-	QuantityMinusPlus
27	PLATE, CONTACT T1190217 No Longer Available Share this part	NO LONGERAVAILABLE	$6.37excl. VAT(£5.13)	-

Transmission - Triumph ROCKET III, CLASSIC & ROADSTER | Triumph ROCKET III, CLASSIC & ROADSTER Transmission with fast delivery to United States | Fowlers Parts

Triumph ROCKET III, CLASSIC & ROADSTER | Transmission with fast delivery to United States. Available at Fowlers Parts, the UK's No.1 Motorcycle Parts Supplier.

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Wrong type of springs

10	Spring, Belleville, 54 x 39 x 0.7 T1180052 Share this part	1-3IN STOCK	$4.01excl. VAT(£3.23)	-	QuantityMinusPlus
10	Spring, Belleville, 40.5 x 0.6 T1180288 Share this part	1-3IN STOCK	$4.01excl. VAT(£3.23)	-