Clutch

Clutch Cable & Lever

Disconnection/Removal
Inspection and lubrication
Installation

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.

3. Optional- this step is only needed if you are

removing the cable completely, if not there is
no need to undo this screw. If you are, unscrew
the fixing located under the bike near the sump
using 8mm socket. If you are having trouble
finding it, follow the cable from the end of the
clutch until you see it.
Unscrew this one

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:

4. To improve access to the cable and adjuster

undo the screw attached to the frame towards
the top of the radiator using a 5Hex
screwdriver adapter.
This one

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

5. There is an adjuster on the left side of the bike

by the radiator. Move the rubber part up to
reveal the locknut. Undo the locknut using a
10mm spanner to hold the adjuster and a 12mm
spanner to undo the locknut. Undo the adjuster
to give the maximum amount of slack in the
cable.

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.

9. Disconnect the cable from the lower end by

moving the ball end out of the actuating arm.
10. Back to the clutch lever end, undo the locknut
and line it up with the adjuster. If the locknut is
stuck, just stick a flathead screwdriver in the
gap for leverage.
Adjuster

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

14. Clean all parts thoroughly.

Inspection and Lubrication

What you need before hand
Possibly a new cable T2046008
ACF-50/Cable lubricant
Multi-purpose grease

5. Apparently there are two inner cable nipples

that should be checked. If they are loose or
perished then replace the cable. However, I
cannot see what the Triumph Service Manual is
referring to here. Please feel free to enlighten
me via Facebook or an online forum.
6. Spray some ACF-50 or other appropriate cable
lubricant on the bushing in the clutch lever and
check that it too moves freely.
Bushing

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.

7. Spray some ACF-50/Cable lubricant clutch

sensor plunger and push it in and out several
times and make sure it moves freely.
Clutch Sensor Plunger

4. Smear some multipurpose grease on each of

the ball ends. This helps them swivel in their
resting places.

4 Thunderbird Storm

Installation

Dot

Line up with spit

What you need before hand

Multipurpose grease
Screwdriver: T27, 5Hex
Torque wrench 3Nm, 7Nm, 10Nm
Socket: 10mm
Spanner: 10mm, 12mm
Bike lift makes this job easier
Steps
1. Place some multipurpose grease on the clutch leaver
pin and resting place of the clutch lever. Place the
clutch leaver back into position and screw the nut on
using 10mm socket and tighten sensibly or to 3Nm if
you want to be accurate.

5. Once in place, tighten the screw in the actuating

arm to 10Nm using 8mm socket.
6. Return the E-clip to the clutch cable. Check that it
doesnt fall out again, you may need to bend the Eclip in a the sides so that it has a firm fit and wont
fall off when driving.
2. If you have removed the cable completely, tie the
cable to be installed to the string. Pull the cable
through so that it sits in the correct routing in the
bike.
3. Attach the ball end of the cable to the actuating
arm.
4. Refit the actuating arm to the clutch shaft. The split
in the arm must line up with the dot on the clutch
cover. The dot is hard to see when the actuating
arm is on. I found it easier to put a small flat ruler
in the gap and then I could see from above if it
lined up.

7. Push the boot (ribbed rubber casing) back over the

cable.
8. Optional- if you removed the cable tighten the
retainer underneath the bike to 7Nm using 8mm
socket.
9. Back at the clutch lever, put the cable back into the
lever and screw the adjuster back into the housing

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

12. Operate the clutch and re-check the amount of free

play
13. Now use the adjuster at the clutch lever housing
until there is 1-2mm of free play. Then tighten the
locknut.
14. Refit the radiator cover using T27 adapter and
tighten sensibly.
15. If you disconnected the battery reconnect it with the
Philips screwdriver. Then re-install the riders seat
to 9Nm and the pillion seat to 10Nm both using a
5Hex head.
Job Done!