Well there are two sets of what i am assuming are connectors under the tank, BUT, they are completely taped up and the tape is in pristine condition and very tight, so they haven't been damaged or come lose. They are about an inch and a half square and maybe a centimetre thick. Are we talking about the same thing?. I didn't want to take all that tape off......do i have tooo? On the positive side, the starter motor tests fine, although one of the brush tension springs came off and i can't find anything online demonstrating some trick to get the thing back on lol. Thanks for your help. si
Yes, block connectors. Vaguely T shaped, as I recall. After a full continuity check of the starter circuit and earthing I would be for substituting the relays. Take them both to a local motor factor for replacement. Seem to recall they are Bosch?
Hi All, So, dozy bugger i am. Starter motor is fine, so was putting it back in the bike, but had to get the front part that has the Or ring on it out of the crank case (I undid the two long bolts when i took it off the bike, so part remained attached to the bike.... i know, I know, but i've never done anything like this before) Now i watched a video that says that sometimes the cog / gear on the end of the starter shaft gets left in the crank housing and not to worry when removing the starter if that happens, its just a case of aligning the spigot? correctly when refitting it. As that whole end stayed on the bike, it was obviously still in there. I put my little finger in the hole that the starter spigot? goes in and couldn't feel anything. I then took the clutch casing back off and hey presto, the gear that attaches to the end of the starter motor spigot? is MISSING. Ha! must have fallen out when i first removed the clutch casing and i was too stupid to notice. I guess that everything has been working fine, but the starter had no way to engage the engine. Great! Now i know what the problem is, now i just need to replace the part. Now my problem is that the Haynes manual (oh why have they stopped producing service manuals?) does not name this part(s) so i don't know what i am looking for. Is it part of the starter idle gear assembly possibly?? Picture attached for reference. If anyone can tell me what bit or bits i have lost i would be very grateful. Shame i don't know where to send the beer! Cheers guys
Compare the photos The splined shaft of the starter motor engages with the idler gear. There is no cog...... But why is the idler gear mashed into the casting at the front?
I am guessing you reassembled the idler gear completely out of position.......you need to check the idler boss casting on the outer clutch cover and the main casting. Can you see how the idler gear has migrated North West between starter motor and sprocket until it hit the outer casing?
On this one the boss is broken.....a problematic repair. Photograph what you find...... If I am right, and you simply failed to fit the idler in its bosses you may have had a lucky escape with everything jamming up. It will need a careful clean up to remove swarf and maybe an oilstone polish of any roughened gear teeth.....
Finally! If you have a broken boss, don’t discard the fragments. This: https://www.triumphtwinpower.com/pdf/Safe-Start Installation Guide.pdf might be the best basis for a cost effective repair.
Hi, I think it is the camera angle. Nothing is touching the casing and i didn't move / remove (on purpose) any of the gears. THANK YOU for all your excellent help, but i think i have to know my limits and it is going to the local Triumph specialists tomorrow, before i do something that will cost a fortune to fix. I have learned a huge amount though and your assistance worth its weight in gold. Many thanks
Phew! I kept studying it and convinced myself from what must be gasket material that it was touching! Plugs out, can you turn the engine over? That would tend to confirm the problem remains electrical. My suspicion remains with one of the relays... https://www.linkedin.com/pulse/automotive-relays-fundamentals-testing-kiril-mucevski
