Triumph - Shaft, Assembly, Gearchange - T1190255

This was a job i would not have tackled if not for a web video, which was invaluable. i extend my sincere gratitude to whoever took the time to post it!!!!!

http://99legend.blogspot.com/2011/02/gearchange-shaft-replacement.html

This was a design flaw in my opinion. The "rat" forum is replete with complaints of broken shafts on the 885cc "Classics" Triumph series. Thunderbird, Thunderbird sport, Adventurer and Legend.

I have little to add to the above video. We did hang the bike via an engine hoist placed under the triple tree which almost brought the bike to a vertical position. Made it so much easier to access the trans. I would emphasize the need to place the middle tooth of the 5 tooth "quadrant" which is welded to the shift shaft, exactly in the center of the 6 tooth "selector gear", which is mounted to the selector drum. Don't know if this changes on the 6 speed "sport". We guessed position a couple of times and had to do some things over. Perfect shift when done right. You will probably have to rotate the shifter drum as you try to center to quadrant gears. Per the video, replacing the "stopper plate" will require a navy PHD, maybe even a doctorate, in cussing.

Sump bolts were t30 torx. Be aware of the "stop bolt" which limits movement of quadrant when assembled. This legend did not have the two flat washers shown on the shifter return spring. Fiche also does not show them. Probably an original factory spec adjustment per engine. Finally, i did use a cutoff wheel to put a pretty deep notch in the back of the new ridiculously expensive ($80.00) shift lever, in hope that any future left side drop will break it rather than the weak shaft end.

I am still curious if my dealer would have split cases or accessed thru the bottom end. Thank goodness for helpful forum posts alerting me to this procedure.

Parts used in this repair

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Total price:  $197.18

Triumph PEDAL, GEARCHANGE (T2080284) $100.77

Triumph GASKET, SUMP, 3CYL (T1230056) $15.79

This item: Triumph SHAFT, ASSEMBLY, GEARCHANGE (T1190255) $80.62