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General Comments
There is lots of Internet debate around the proper care
of the clutch cable, which is not surprising given that
the Triumph Service Manual is silent on the issue of
lubrication. Some people have reported that their
clutch cable broke and after taking it apart they have
found that the break was due to lubrication attracting
dirt and becoming abrasive. Whereas others have said
that lubrication has been integral to the maintenance of
the cable. The choice is yours but given that no
lubrication is mentioned in the manual it seems
sensible to check for proper movement of the cable
and lubricate just the ends.
Disconnection/Removal
What you need before hand
A bike lift makes this job easier but it isnt
essential.
Screwdriver: T27
Socket wrench: 8mm
Screwdriver: 5Hex bit
Torque wrench:
Steps
1. Optional- the manual says remove the seat and
disconnect the batter. Im not convinced this is
necessary but feel free to discuss online.
2. Remove radiator grill by undoing the screw at
the bottom of the grill using T27 screwdriver
adaptor. Then lift the grill upwards and off the
two top lugs on the radiator.
Radiator Lugs Holes
2 Thunderbird Storm
Locknut
Adjuster
Cap
Actuating Arm
Undo
8. Undo the screw attached to the actuating arm
on the clutch shaft using a 8mm socket.
6. Slide the boot (ribbed rubber casing) on the
end of the cable. Remove the E-Clip and
replace if rusted. A small flat head screwdriver
will work.
Locknut
E-Clip
7. Remove the cap on the end of the clutch
spindle.
11. Unscrew the adjuster until it comes out from
the clutch level housing. Then maneuver the
ball end of the clutch cable out from the lever.
12. Optional- if removing the cable completely
from the bike tie a piece of string to one end of
the cable. Pull the cable out and pull the string
through the same routing placement. Untie the
string when it is all the way through
Clutch 3
Grease
13. Undo the nut on the clutch leaver using a
10mm socket Remove the clutch lever pin and
the clutch lever. If the lever pin is not coming
out give it a firm tap and it should pop out.
Unscrew this
Steps
1. Clean all parts of dirt: cable ends, clutch lever,
screw threads and area around the clutch end.
2. Visually look at both ends of the cable and
look for any fraying. If it is frayed or rusted it
is best to replace the cable to save you any
hassles when on the road.
3. Spray some ACF-50/Cable lubricant on both
ends of the exposed cable. Check that the cable
moves freely in its casing by pulling then
pushing on one end of the cable. If it doesnt
move freely replace it.
4 Thunderbird Storm
Installation
Dot
Clutch 5
10. Sent both adjusters- the one at the lever housing
and the one by the radiator so that there is equal
adjustment in both directions.
11. With the adjuster at the lever housing halfway in,
turn the adjuster by the radiator until there is 23mm of free play at the clutch lever. Measure the
gap between the clutch lever housing and the lever.
Measure gap