Idler Boss Reinforcement and Clutch Disk job

sikatri · 11-02-2021, 07:35 AM

Going to start an idler boss reinforcement and clutch disk replacement job on a 2005 Triumph Thruxton. It’ll be my first time with either job. Looking forward to getting the experience. It’s 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 don’t have to remove half the front end to get the transmission out. LoL. Tips and advice appreciated before I start.

sikatri · 11-02-2021, 07:43 AM

The clutch parts.

GABRIEL · 11-02-2021, 07:26 PM

Should be easy compared to a car.

sikatri · 11-03-2021, 09:58 AM

Quote:

Originally Posted by GABRIEL

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.

less_than_coop · 11-03-2021, 10:03 AM

Quote:

Originally Posted by sikatri

Yes, from my service manual, it doesn't look too complicated. Pay attention to disc order and oil them first.

Yup.

sikatri · 11-03-2021, 04:02 PM

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.

sikatri · 11-03-2021, 04:07 PM

Since I’ll 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.

sikatri · 11-03-2021, 04:08 PM

Some cleanup now and install the boss reinforcement and then hopefully this weekend I can start on the clutch.

GABRIEL · 11-03-2021, 05:24 PM

Not a 1 day job?

sikatri · 11-03-2021, 05:30 PM

Quote:

Originally Posted by GABRIEL

Not a 1 day job?

It could easily be done in a day or an afternoon. It’s not that hard. I have other misc jobs I have to do. I just don’t have the time to spend a day on it. I’m also going to clean the cover and polish it a bit. Sort of just enjoying myself.

GABRIEL · 11-04-2021, 05:20 PM

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.

sikatri · 11-04-2021, 06:02 PM

Quote:

Originally Posted by GABRIEL

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?

GABRIEL · 11-06-2021, 03:40 AM

Quote:

Originally Posted by sikatri

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.

sikatri · 11-06-2021, 12:11 PM

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?

sikatri · 11-06-2021, 01:05 PM

I suspect I know the answer, but have sent out an inquiry. Not in a hurry, I can afford to wait for an answer.

sikatri · 11-08-2021, 08:37 AM

Took the clutch apart Friday and waited for a response. Had a “sick day” weekend anyway.
I’m going to soak the new discs today and install the idler boss reinforcement. If I don’t get a response, I’ll install the two thicker steel plates and four thinner ones. All friction plates look the same.

sikatri · 11-16-2021, 10:00 AM

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!

sikatri · 11-16-2021, 10:01 AM

The idler boss reinforcement.

sikatri · 11-16-2021, 10:02 AM

This job done. Final cable adjustments and checks.

sikatri · 11-16-2021, 10:24 AM

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.

11-02-2021, 07:35 AM	#1
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	Idler Boss Reinforcement and Clutch Disk job Going to start an idler boss reinforcement and clutch disk replacement job on a 2005 Triumph Thruxton. It’ll be my first time with either job. Looking forward to getting the experience. It’s 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 don’t have to remove half the front end to get the transmission out. LoL. Tips and advice appreciated before I start. Attached Thumbnails

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11-02-2021, 07:43 AM	#2
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	The clutch parts. Attached Thumbnails

11-03-2021, 04:02 PM	#6
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	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. Attached Thumbnails

11-03-2021, 04:07 PM	#7
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	Since I’ll 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. Attached Thumbnails

11-02-2021, 07:26 PM	#3
GABRIEL Senior Member Join Date: Jan 2007 Location: SW/SE Houston Feedback Rating: (14) Posts: 7,677 Experience: 1-3 months	Should be easy compared to a car.

11-03-2021, 04:08 PM	#8
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	Some cleanup now and install the boss reinforcement and then hopefully this weekend I can start on the clutch.

11-03-2021, 05:24 PM	#9
GABRIEL Senior Member Join Date: Jan 2007 Location: SW/SE Houston Feedback Rating: (14) Posts: 7,677 Experience: 1-3 months	Not a 1 day job?

11-04-2021, 05:20 PM	#11
GABRIEL Senior Member Join Date: Jan 2007 Location: SW/SE Houston Feedback Rating: (14) Posts: 7,677 Experience: 1-3 months	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.

11-06-2021, 12:11 PM	#14
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	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? Attached Thumbnails

11-06-2021, 01:05 PM	#15
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	I suspect I know the answer, but have sent out an inquiry. Not in a hurry, I can afford to wait for an answer.

11-08-2021, 08:37 AM	#16
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	Took the clutch apart Friday and waited for a response. Had a “sick day” weekend anyway. I’m going to soak the new discs today and install the idler boss reinforcement. If I don’t get a response, I’ll install the two thicker steel plates and four thinner ones. All friction plates look the same. Attached Thumbnails

11-16-2021, 10:00 AM	#17
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	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! Attached Thumbnails

11-16-2021, 10:01 AM	#18
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	The idler boss reinforcement. Attached Thumbnails

11-16-2021, 10:02 AM	#19
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	This job done. Final cable adjustments and checks.

11-16-2021, 10:24 AM	#20
sikatri Senior Member Join Date: May 2014 Location: Houston Feedback Rating: (0) Posts: 112 Bike(s): 2005 Triumph Thruxton	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. Attached Thumbnails