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| DizzE | | Thor |  |  | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 20 Mar 2012 - 20:03 Post title : Replace Clutch Cable | | | Thanks matt1600 for these tips. I'm just coping them here for future reference.
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mat1600 says:
Not much of a problem apart from having to get under the bike for a cable clip (steel), this clip only needs undoing and swinging out of the way - do not remove it. There is another clip further towards the front of the engine - this is a 'wrap around and push in clip', it also holds anothe cable (wire). It is easier done with the rad grill removed as there are another couple of wrap around and push in clips.
The cable comes with an adjuster half way along the cable - this should be slackened right off so as to get plenty of free cable to play with at each end. You do not need to take off the clutch pull arm at the engine end , as it says in the book, its easy enough leaving it in place.
When both nipples are in place, take up the adjustment with the mid adjuster (which should now be at the toppish end of the rad grill), and then final adjustment at the lever allowing a couple of mm play in the lever.
It is better to feed the new cable in from under the bike, feeding one end up to the lever then the other to the engine end. Fasten the engine nipple first.
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| Draeger | | Set | |  | | Reg. Date | : | 28/08/2011 | | Posts | : | 63 | | Location | : | Comox, British Columbia, Canada |
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| | Posted : 15 Jun 2012 - 03:20 Post title : Re: Replace Clutch Cable (Re: DizzE) | | | Thank you - looks like I might be doing exactly this shortly. With less than 10,000 KM on the Tbird I just discovered I'm hanging on by two wires.
| If there is lead in the air, there's still hope.
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| fab | | Thor | |  | | Reg. Date | : | 12/10/2009 | | Posts | : | 2,515 | | Location | : | wyong, nsw, Australia |
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| | Posted : 15 Jun 2012 - 04:13 Post title : Re: Replace Clutch Cable (Re: Draeger) | | | that's from the clutch cover end,normally its from the clutch lever end
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Remember, soft cocks hang around all life long, hard ones come and go
ahh f**k im deep
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| davetac1 | | Thunderbird | | | Reg. Date | : | 06/09/2010 | | Posts | : | 8,379 | | Location | : | Haverhill, Ma., United States |
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| | Posted : 15 Jun 2012 - 04:48 Post title : Re: Replace Clutch Cable (Re: Draeger) | | | The clutch lever/cable assembly is probably the MOST USED control on EVER MOTORCYCLE EVER BUILT.So,if you do this simple little service procedure called "lubing BOTH ENDS of the clutch cable" periodically [I do it the first of every month] the fraying will cease.All ya need is a drop of oil on each end,work the lever a couple times so the oil finds its way into the pivot points on both ends of the cable,then wipe off the excess.Now this procedure takes all of 30 seconds to do,not to mention that inspection of the cable ends can be done at the same time.
The other thing ya wanna do every couple months or so, is remove the bolt that secures the clutch lever in place,[10MM nut] slide the lever out of the housing just enough to access the bushing,remove it and apply some grease on both sides of it,[inside and outside],then put it back in place.now this procedure takes about five minutes to do.But I think you'll discover that by doing these simple procedures,these clutch cable problems will go away.
My clutch cable is original,is still in good shape, and I am just shy 38,000 miles.However,as ya probably read in another post,I just replaced the lever and the bushing as both were worn and slopey from usage,yet the cable is still good.Do ya have any idea how many times I've used that clutch over that 38,000 miles???I don't think I could count em.lol I even carry a spare cable with me because of all the problems I've read about on here,yet haven't encountered to date because of this simple little maintenance.
So take it or leave it.Your choice! But the bottom line is "IT WORKS" and just might save ya alittle embarrassment and a lot of AGGRAVATION when you're out on the highway and or a loooooooooooooooooooooooooong ways from home. lol Dave!!!
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| mat1600 | | Thunderbird | |  | | Reg. Date | : | 06/03/2010 | | Posts | : | 8,596 | | Location | : | Bridlington, Democratic Independant State of Yorkshire, United Kingdom |
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| | Posted : 15 Jun 2012 - 07:33 Post title : Re: Replace Clutch Cable (Re: davetac1) | | | davetac1 wrote:
The other thing ya wanna do every couple months or so, is remove the bolt that secures the clutch lever in place,[10MM nut] slide the lever out of the housing just enough to access the bushing,remove it and apply some grease on both sides of it,[inside and outside],then put it back in place.now this procedure takes about five minutes to do.But I think you'll discover that by doing these simple procedures,these clutch cable problems will go away.
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This is probably the one bit of preventative maintenance that will save you stood at the side of the road trying to boot your own arse.
The little plastic bush, that Dave mentions, seizes up and goes rigid. The result is that it starts bending the cable when you work your clutch....................... then, my friends...the end is nigh.
A quick check - just see if your cable is swiveling ok and not bending - better still follow Daves advice - bloody wish I had done.
| My first natural instinct is to breathe. My second is to evade tax's.
| | Post edited by mat1600 on 15 Jun 2012 - 07:33 |
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| mjgt | | Thor | |  | | Reg. Date | : | 16/09/2011 | | Posts | : | 2,201 | | Location | : | North Somerset, United Kingdom |
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| | Posted : 15 Jun 2012 - 16:09 Post title : Re: Replace Clutch Cable (Re: mat1600) | | | Yep, as soon as I saw the first thread on this I greased mine up, it was as dry as a witches F#*#y so it's good advice 
| Mick . . .  Keep the rubber side down!!
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| davetac1 | | Thunderbird | | | Reg. Date | : | 06/09/2010 | | Posts | : | 8,379 | | Location | : | Haverhill, Ma., United States |
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| | Posted : 15 Jun 2012 - 20:56 Post title : Re: Replace Clutch Cable (Re: mat1600) | | | The bushing is brass or bronse,not plastic.If it was plastic,it wouldn't last a week.lol You could visably see the wear on my old bushing and I've been greasing it regularly,but I guess not regularly enough. Dave!!!
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| mat1600 | | Thunderbird | | | | Reg. Date | : | 06/03/2010 | | Posts | : | 8,596 | | Location | : | Bridlington, Democratic Independant State of Yorkshire, United Kingdom |
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| | Posted : 15 Jun 2012 - 21:08 Post title : Re: Replace Clutch Cable (Re: davetac1) | | | Will have to correct you there Dave. They are plastic.
| My first natural instinct is to breathe. My second is to evade tax's.
| | Post edited by mat1600 on 15 Jun 2012 - 21:09 |
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| davetac1 | | Thunderbird | | | Reg. Date | : | 06/09/2010 | | Posts | : | 8,379 | | Location | : | Haverhill, Ma., United States |
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| | Posted : 15 Jun 2012 - 21:22 Post title : Re: Replace Clutch Cable (Re: mat1600) | | | Mat:The bushing I changed is brass,not plastic, and has alittle groove carved right around the center of it.It's located in the hole in the clutch lever which the lever pivots on,and the bolt passes thru it to hold it in place in the assembly on the end of the left handle bar.I have it right here in front of me as I'm typing this.Part#T20461526 and they come two [2] in a package and are BRASS.Are we talking about the same thing here or somethin else??? Please explain!!! Dave!!!
| | Post edited by davetac1 on 15 Jun 2012 - 21:26 |
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| mat1600 | | Thunderbird | | | | Reg. Date | : | 06/03/2010 | | Posts | : | 8,596 | | Location | : | Bridlington, Democratic Independant State of Yorkshire, United Kingdom |
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| | Posted : 15 Jun 2012 - 21:32 Post title : Re: Replace Clutch Cable (Re: davetac1) | | | The ones on mine were a red plastic  . I remember thinking that it was a bit of a cheepy idea. Cant remember what the one I took off (the broken one) was. Wonder if factory and replacement are different.  Anyhow, I gave her an oil change and a good look over (for the Bloc trip) and the cables are fine - But then again I check it regularly now and dab a bit of grease on it.
| My first natural instinct is to breathe. My second is to evade tax's.
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| davetac1 | | Thunderbird | | | Reg. Date | : | 06/09/2010 | | Posts | : | 8,379 | | Location | : | Haverhill, Ma., United States |
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| | Posted : 15 Jun 2012 - 22:22 Post title : Re: Replace Clutch Cable (Re: mat1600) | | |
mat1600 wrote:
The ones on mine were a red plastic |
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Mat: You mentioned the "ONES" as in plural, or more than one.There is only one bushing used in the clutch lever.My old bushing was also brass.But maybe Triumph used a plastic bushing on the older production machines.I don't know.Is your scooter an early production model???
However,my back up replacement CLUTCH CABLE has red on one end but I didn't look to see if it was medal or plastic.So could it be that you were referring to the cable end and not the lever??? Dave!!!
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| mjgt | | Thor | | | | Reg. Date | : | 16/09/2011 | | Posts | : | 2,201 | | Location | : | North Somerset, United Kingdom |
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| | Posted : 16 Jun 2012 - 07:26 Post title : Re: Replace Clutch Cable (Re: davetac1) | | | If I understand you correctly I think you are both right, when I did mine I noticed that the lever end nipple (bushing) was brass but with a red plactic collar around it, I assume it's an attempt at an anti friction collar but having seen some of the pictures posted it just puckers up and is ineffective unless greased.
| Mick . . . Keep the rubber side down!!
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| davetac1 | | Thunderbird | | | Reg. Date | : | 06/09/2010 | | Posts | : | 8,379 | | Location | : | Haverhill, Ma., United States |
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| | Posted : 16 Jun 2012 - 17:33 Post title : Re: Replace Clutch Cable (Re: mjgt) | | | Thank you mjgt.I think you just cleared it up,as to what we were both saying [two different things] and it now makes sense. Dave!!!
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| Draeger | | Set | | | | Reg. Date | : | 28/08/2011 | | Posts | : | 63 | | Location | : | Comox, British Columbia, Canada |
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| | Posted : 16 Jun 2012 - 20:17 Post title : Re: Replace Clutch Cable (Re: davetac1) | | |
davetac1 wrote:
The clutch lever/cable assembly is probably the MOST USED control on EVER MOTORCYCLE EVER BUILT.So,if you do this simple little service procedure called "lubing BOTH ENDS of the clutch cable" periodically [I do it the first of every month] the fraying will cease.All ya need is a drop of oil on each end,work the lever a couple times so the oil finds its way into the pivot points on both ends of the cable,then wipe off the excess.Now this procedure takes all of 30 seconds to do,not to mention that inspection of the cable ends can be done at the same time.
The other thing ya wanna do every couple months or so, is remove the bolt that secures the clutch lever in place,[10MM nut] slide the lever out of the housing just enough to access the bushing,remove it and apply some grease on both sides of it,[inside and outside],then put it back in place.now this procedure takes about five minutes to do.But I think you'll discover that by doing these simple procedures,these clutch cable problems will go away.
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After seeing what I saw in that photo a couple of days ago ... I have been converted into a clutch cable maintenance advocate. I will totally do this from now on Dave!!!
Fortunately I have a great dealership - I made it there yesterday without incident after greasing the cable up and crossing my fingers.
The dealer didn't have a spare cable - so they actually stripped one off a showroom floor Tbird and installed it on mine free of charge. I drank a couple of cups of excellent free coffee ... and was back on the road in an hour.
Savage Cycles in Victoria British Columbia ... hats off. Outstanding service!!!
| If there is lead in the air, there's still hope.
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| mat1600 | | Thunderbird | | | | Reg. Date | : | 06/03/2010 | | Posts | : | 8,596 | | Location | : | Bridlington, Democratic Independant State of Yorkshire, United Kingdom |
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| | Posted : 16 Jun 2012 - 23:30 Post title : Re: Replace Clutch Cable (Re: Draeger) | | |
Thats just the sort of service you need - and when you need it.
| My first natural instinct is to breathe. My second is to evade tax's.
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| mjgt | | Thor | | | | Reg. Date | : | 16/09/2011 | | Posts | : | 2,201 | | Location | : | North Somerset, United Kingdom |
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| | Posted : 17 Jun 2012 - 18:06 Post title : Re: Replace Clutch Cable (Re: mat1600) | | | That is good service, not sure my dealer would be so accomodating.
| Mick . . . Keep the rubber side down!!
| | Post edited by mjgt on 17 Jun 2012 - 18:06 |
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