Throttle

Throttle Cable
Lubrication
Adjustment
Housing Modification

General Comments
If you ride your motorcycle often you will get to know
the feel of your throttle and know if it is getting sloppy
or sticking. After substantial research on Internet
discussions forums and feedback from those that have
taken their throttle cables apart, the consensus seems
to be that the inside of the cable does not need
lubricating like it does on much a older bike. This
probably explains why it is not covered in the Triumph
Service Manual. However, the cables have been
known to break on some bikes due to rubbing against
the plastic inside the housing therefore it is best to
inspect the condition of these and lubricate the
exposed bit. Note, these pictures have the Oxford Hot
Grips installed, but the procedures are no different on
the OEM grips. This guide also includes how to
smooth out the sharp inner edge. Previously I assumed
that the engineers at Triumph have infinite wisdom,
but this is clear evidence that they dont. There is a
sharp edge on the inside of the back throttle housing.
Through use of the throttle cable it cuts away the
plastic and eventually into throttle cable. No matter
how much you lubricate this you cant avoid this
problem unless you modify the housing.

Lubrication
What you need before hand
Philips Screwdriver
Lubrication- e.g. ACF-50
o Long spray nozzle
Steps
1. There are two screws on the back part of the
throttle housing. Undo these using a Philips
screwdriver

2. This will reveal the throttle cable ends. There is

no need to put any lubricant down the cables
but to help improve their longevity it can be
useful to lubricate the ends. So spray a suitable
lubricate or anti-corrosion agent like ACF-50
or WD-40 on them. This is a good time to
modify the housing if you have not done so
already or check that the damage has stopped.

Spray on the cable end, plastic and ball ends of

the cable.
3. Once lubed, put the front housing back on and
put the screws back in using a Philips but no
need to tighten fully just yet.
4. Sit on the bike and rotate the throttle housing
into a position that feels comfortable. Once in
position tighten the screws sensibly.
5. To be thorough, use a spray lubricant with a
long nozzle on it and spray the other end of the
cable. This is situated in-between the throttle
bodies under the tank. Although not entirely
necessary, this will also help reduce wear over
time.
Job Done!

2 Thunderbird Storm

Adjustment
What you need before hand
Masking tape
Pen/pencil
Small ruler
Steps
1. With the engine off twist the throttle from the
open to fully open position. The turn should be
smooth, turn without excessive force and
spring back into position.
2. The tolerance for the throttle grip free play is
2-3mm. This means that when you take up the
slack in the cable there should be a minimum
of 2mm and a maximum of 3mm free play
before the throttle is engaged. To get this
accurate, mark out on a piece of tape a 0 line,
then a mark at 2mm and again at 3mm.

3. Then place the tape onto the throttle unit and

another piece on the actual handle. Mark on the
other piece of tape a line parallel with the 0
mark.

needs tightening. If it is in spec, job done. If

not, continue on.
Opening Cable Adjuster

Closing Cable Adjuster

5. Just above each cable adjuster is a lock nut.
Undo the opening cable adjuster lock nut then
turn the adjuster to tighten or loosen it
depending on the measured free play until it is
in spec. Once in position tighten the locknut.
6. Optional: For Your Information- With the
closing cable, undo the lock nut and loosen the
adjuster several turns. What you will notice is
that when the closing cable is inappropriately
adjusted the throttle will not spring back into
position smoothly or possibly at all. Readjust
the closing cable adjuster a turn at a time
checking the spring back of the throttle and
when it springs back smoothly and quickly
tighten the locknut. Then recheck that the
throttle free play is still in specification.
7. The closing cable can also be checked by
inspecting the free play at the throttle cam.
However, this is located under the tank in
between the two throttle cams and is just not
easily accessible despite what the owners
manual says. Also, even if you do remove
enough to easily access it, it is not clear how
you measure it. So I would stick with the
optional step above for making sure the close
cable is doing its job.

4. Then take up the slack in the throttle and make

sure that the line moves at least in line with the
2mm line but not past the 3mm line. Logically
if the throttle doesnt move enough the opening
cable needs loosening, if it moves too much it

8. It is not often necessary but worth knowing

that if you need further gross adjustment of the
opening cable there is another adjuster located
underneath the fuel tank towards the front of
the bike. Move the cables out of the way and
move the rubber cover back to access the lock
nut and adjuster.

Throttle 3

Adjuster

3. Slide out the closing cable ball end from its

connection point.

Closing Cable
9. After all adjustments are complete, turn the
bike on and check again that the throttle is
returning smoothly to the closed position and
still in specification. Remove the tape from the
bike.
Job Done!

Housing Modification

4. Then slide out the opening cable ball end from its
connection point. As you can see from the picture
below, this is the problem. The sharp edge makes
a mess of the plastic and gets worse each time the
throttle is sprung back into position.
Sharp Edge

Damaged Plastic

What you need before hand

A small abrasive
o Dremel Tool with grinding wheel
o Sandpaper, 240grit is sufficent
Screwdriver adapter: 4Hex, Philips
Spanner 14mm
Torque wrench 8Nm
Steps
1. As per the instructions above, use a Philips
screwdriver to separate the two halves of the
throttle housing.
2. Loosen the opening cable. Unscrew the locknut all
the way and screw the adjuster towards the
throttle.
Slacken Cable

5. To make it easier to remove the rear throttle

housing, undo the right handlebar weight using a
4Hex screwdriver adapter.
6. Unscrew the retainer holding in the opening cable
to the housing using a Philips screwdriver. Lift out
the cable.
7. Undo the closing cable retaining nut using a
14mm spanner then slide out the cable.
8. With the rear housing away from the bike use an
abrasive to smooth out the sharp edge. I suggest
using a small grinding wheel on a Dremel Tool,
which will quicken the process. But be careful,
you dont want to grind too much away. When the

4 Thunderbird Storm

edge is rounded off use some sandpaper (I used
240grit with good effect) to smooth out the edge
further.

13. Screw the throttle housing back together using a

Philips screwdriver and tighten sensibly.
14. Readjust the opening cable and check the throttle
free play as per the instructions above.
Job Done!

9. Assembly is now the reverse of disassembly. Put

the closing cable back through the relevant hole in
the rear housing cover. Tighten the retaining nut
using a 14mm spanner until sensibly tight.
10. Put the opening cable back through the hole in the
rear housing cover. Tighten the retaining fixture
using a Philips screwdriver until sensibly tight.
11. Place both cables ball ends back into their plastic
holding position. Pay particular attention to the
closing cable making sure that it sits straight. Turn
the throttle and check that it isnt sliding off to the
side because the back of it isnt in correctly. It
should sit as per the photo below.

12. Screw the end weight back in using a 4Hex

adapter and tighten to 8Nm.