Bonneville America Forums Forums Technical Forums General Tech Help! Starter Idler Gear Shaft Washer &

I just replaced the clutch springs on my 2002 Bonneville America, a post-fire model. I watched carefully when I took the primary cover off (althought this was my first time since 40 years ago). I did not see any Starter Idler Gearshaft Washer. I looked closely beneath the bike, etc., but could not find one. The Triumph manual says there is one. The Haynes manual calls it a "wave washer".

Also, there was not a "clutch "Release Arm Return Spring". This is supposed to be below the clutch release arm (that release arm passes vertically up through the primary cover, and you attach the aft end of the clutch cable to it).

Does anyone know if perhaps my bike never had these two parts, or should I stop & try to mailorder them before reassembly???

The bike was working okay, but with the windshield, bags, & passenger, at higher speeds, I believe the clutch may have been slipping a little upon accelleration, so I just replaced the clutch springs during my regular oil change.

Thanks for any help,

--Tom

I would install the washer and spring. Obviously if they haven't been in place for however long you owned the bike, they probably aren't that critical but ... why take chances?

Thanks. If I don't hear otherwise, that's what I will have to do. BTW, I also had a 69 BSA Firebird Scrambler (red). Great bike.
--Tom

Its been a long time since I had mine apart, but I remember putting it back together wrong and the spring would pop out when I pulled clutch lever. Its a little coil spring that wraps around the bottom end of that shaft. There's a good picture of it in the factory manual (2004 edition) on page 5.10. Without it, I don't think you would have any travel in the clutch lever. Also, be careful the idler gear is properly positioned, the shaft it rides on is loose-fit between the primary cover and the block. When I pulled my cover off, the pin pulled out and gear dropped out of position. Look carefully in the bottom of the case for wavy washer and spring, you don't want them left loose in there. There are plastic oil pump gears in there that will not survive eating metal parts. Below is Bike Bandit's schematic, spring is listed as part #3. No wavy washer shown. Looks like their parts list is mixed in with alternator cover.

http://www.bikebandit.com/triumph-motorcycle-america-2002-engine-cover-s/o/m17595sch565404

EDIT: Found the wavy washer. Same site, different page.
http://www.bikebandit.com/triumph-motorc...m17595sch565421

Mine was red also. Painted it green (very similar to the Triumph Scramber). I wasn't the most mechanically inclined then. I can remember hitting the horn button and the bike quitting - ^%$*&(*%# Lucas electrics. Parts used to fall off the bike regularly. Always had a problem with the bottom barrel nuts coming loose. Replaced the stock pipes with a pair of "shorties" which often got the attention of the local police. It was a lot of fun to ride. My girlfriend wasn't so tickled when her backside was covered in gear oil flung from the rear chain.

It was also a treat to start, tickle the carbs, pull out the kickstarter lever, put your life in your hands as you jumped on that kickstarter. Ever been thrown over the handlebars?

They were there and they need to be put back... make absolutely certain they are not laying in the case somewhere and if not, get them ordered.

We all can't stress enough how important it is that you make absolutely sure that they are not laying in the engine anywhere.

I think I remember finding the wavy washer stuck to the inside of the primary cover.

I have searched extensively and can find nothing, especially in the motor. They are just gone. Still awaiting parts to reassemble.