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Old 11-02-2021, 08:35 AM   #1
sikatri
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Idler Boss Reinforcement and Clutch Disk job

Going to start an idler boss reinforcement and clutch disk replacement job on a 2005 Triumph Thruxton. Itíll be my first time with either job. Looking forward to getting the experience. Itís not my first clutch job, it is my first clutch job on a motorcycle. I know, two different animals. At least with the motorcycle I donít have to remove half the front end to get the transmission out. LoL. Tips and advice appreciated before I start.
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Old 11-02-2021, 08:43 AM   #2
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The clutch parts.
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Old 11-02-2021, 08:26 PM   #3
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Should be easy compared to a car.
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Old 11-03-2021, 10:58 AM   #4
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Should be easy compared to a car.
Yes, from my service manual, it doesn't look too complicated. Pay attention to disc order and oil them first.
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Old 11-03-2021, 11:03 AM   #5
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Yes, from my service manual, it doesn't look too complicated. Pay attention to disc order and oil them first.
Yup.
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Old 11-03-2021, 05:02 PM   #6
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Started disassembly. Disconnected shift linkage, clutch cable and removed bolts. Removed breather hose clamp and hose. Tapped around the cover with a rubber mallet and eased the cover off pushing the breather connection tube at the same time.
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Old 11-03-2021, 05:07 PM   #7
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Since Iíll be also doing an idler boss reinforcement, removed the wavy washer, the idler shaft and the idler gear.
Note the idler boss wall thickness is weakest on the right side.
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Old 11-03-2021, 05:08 PM   #8
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Some cleanup now and install the boss reinforcement and then hopefully this weekend I can start on the clutch.
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Old 11-03-2021, 06:24 PM   #9
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Not a 1 day job?
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Old 11-03-2021, 06:30 PM   #10
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Not a 1 day job?
It could easily be done in a day or an afternoon. Itís not that hard. I have other misc jobs I have to do. I just donít have the time to spend a day on it. Iím also going to clean the cover and polish it a bit. Sort of just enjoying myself.
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Old 11-04-2021, 06:20 PM   #11
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I can understand that. Lol. I've been messing with the fuel cap on my rc390 for about a month now. May check if it still leaks this week.
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Old 11-04-2021, 07:02 PM   #12
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I can understand that. Lol. I've been messing with the fuel cap on my rc390 for about a month now. May check if it still leaks this week.
Things come up. I had to attend lectures all day today for my annual licensing renewal requirements. Still got more to go on those by the end of the year. LoL.
Is it a vacuum leak on the cap?
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Old 11-06-2021, 04:40 AM   #13
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Things come up. I had to attend lectures all day today for my annual licensing renewal requirements. Still got more to go on those by the end of the year. LoL.
Is it a vacuum leak on the cap?
It's just not sealing on the tank. May be a over flow hose and then wouldn't sit flush with the tank cover. Have to trim the cover back. I want some race Glass as the stock body work weights alot.
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Old 11-06-2021, 01:11 PM   #14
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Hit a snag! Interesting problem. The Barnett High Performance Clutch kit has seven friction discs and seven steel discs. It should have had only six. Two of the seven steel plates are thicker and then there are five thinner discs. Question is which six do I use?
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Old 11-06-2021, 02:05 PM   #15
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I suspect I know the answer, but have sent out an inquiry. Not in a hurry, I can afford to wait for an answer.
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Old 11-08-2021, 08:37 AM   #16
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Took the clutch apart Friday and waited for a response. Had a ďsick dayĒ weekend anyway.
Iím going to soak the new discs today and install the idler boss reinforcement. If I donít get a response, Iíll install the two thicker steel plates and four thinner ones. All friction plates look the same.
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Old 11-16-2021, 10:00 AM   #17
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Boss reinforcement installed. Clutch discs replaced. Center bolt clutch torqued to 105Nm, bearing assembly torqued to 9Nm, gaskets cleaned off, new gaskets and seals installed, cover torqued to 9Nm, gear shifter linkage bolt torqued to 9Nm and motorcycle filled with oil. Ready to ride!
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Old 11-16-2021, 10:01 AM   #18
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The idler boss reinforcement.
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Old 11-16-2021, 10:02 AM   #19
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This job done. Final cable adjustments and checks.
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Old 11-16-2021, 10:24 AM   #20
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In case anyone is interested, this job should take about 25 to 26 hours. There is a 24 hour waiting period for the idler boss reinforcement to set. The other clutch related work is easily done during the wait period. The old discs looked like the pics attached below. Some wear noticeable.
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