I was riding my TLR 200 over a practice stage today for about an hour and everything was running fine as normal - although at the beginning of my ride the clutch felt to be slightly slipping and so I backed off the cable adjustment and all was good.

Eventually I stopped for a rest - maybe 10 minutes and when I went back she started first kick as usual but a terrible rattle coming from the clutch side - sounding like around the starter area but not sure.

I immediately switched off and trailered the bike home and removed the clutch cover - this is what I found however I can't see where the problems is. The engine turns over smoothly by hand - can anyone throw me an idea where to begin. Metal pieces are non-ferrous.

Edited April 8, 201214 yr by keychange

your probably best off stripping it down completely to find the problem and to be sure to get all the debris out obviously particles going around the engine could cause all kind of damage

First strip the clutch, your problem started there, but I would not be satisfied until I the thing would lay in parts on the table, You see finding the problem is one thing but the most important thing is finding the cause of the problem.

Guy

did you remove the oil trap cover or was it missing.On the end of the crank.

did you remove the oil trap cover or was it missing.On the end of the crank.

Yes I removed the oil trap cover.

Well clutch area looks fine - no sign of any damage or wear and so the motor is now on the bench. I guess I have to split the cases, funny after 40 years and lost count how many bikes, I have never had to split the cases before .... this might take a while.

Did you remove the oil pump cover behind the oil trap.

I repeat - yes I did remove the oil pump cover

Did you remove the oil pump cover behind the oil trap.

Is this something that would fit through the oil filling hole? Do you have small kids that like to play near your bike?

Is this something that would fit through the oil filling hole? Do you have small kids that like to play near your bike?

It would fit through the oil hole - but no kids - the cases are full of shrapnel so It something inside - the clutch area is intact and the cam area is fine - I am gradually dismantling as time permits

I have the flywheel cover off an no sign of violence - but I can't shift the cylinder head bolt - it is only a 10mm head and have tried ring spanner and impact driver - heated the area around the bolt and it just will not move. ..... update used socket head on impact driver and belted the bugger till it gave up

Edited April 11, 201214 yr by keychange

piston and barrel look like new - a bit of carbon on top to be expected but the rest looks new - gudgeon and big end are good - no slop at all. So it has to be gear box and I can't get the flywheel off

Finally have the engine split and sure enough here is the damage - but why did it happen, it looks like the kick start catch on the ratchet has slipped past the stopper bolt and snapped of that part of the casing - I welcome other suggestions. Good news is that on superficial inspection apart from the lump of casing missing there is no other damage . The casing looks sound, there appears no damage to gears etc . Barrel and piston look fine great is the barrel in this coated? If not it does need a hone. The bearing are all nice and firm although I have not had a chance to check all of the clearances - if ok I will reassemble and replace cam chain and adjusters - is there anything else I should do will I have it apart?

Hi Andrew,

the kickstart mechanism is a weak thing. I would check the complete kickstarter spindle with starter pinion and starter rachet. In doubt I would replace it.

For part no. have a look here:

http://www.cmsnl.com...list/E++12.html

Bernhard

Edited April 12, 201214 yr by Rollox

Hi do you still have the standaed TLR kickstarter on the bike, complete with the stop arm fixed by the rear brake lever?

TLTEL