26

Thunderbird Storm



Allen key) to 12Nm. I started with 5Nm, then
9Nm and then 12Nm. It maybe useful to know
that the original manual stated the same tightening
sequence as releasing. However in the updated
manual for 2012 it has different numbers
whereby; 1=5, 2=6, 3=6, 4= 8. 5=3, 6=2, 7=4, 8=
1. In either case the theory is the same; tighten in
progressive opposites. Number 2 as picture below
is very awkward to get to. None of my angled
adapters would fit and I didnt have a torque
wrench skinny enough to fit in. So I made an
adapter to fit over an Allen key which gave me
some distance. Maybe experienced mechanics
tighten by feel but Id be interested to hear what
others use to get in there.

1 5 8 4
118. Reinstall the coolant pipe. Place a smear of
grease around the inside of the pipe to make it
easier to slide on. Once in place tighten the
clamps using a Philips screwdriver.

2 6 7 3
119. Move the thermostat/coolant entry pipe back into
position. Put a little grease on the inside of the
117. Reinstall the 4 ignition coils with the connectors
hose to make it easier to slip onto the coolant pipe.
facing the rear of the engine. Smear a bit of silicone
grease on the rubber part before inserting to
increase water resistance and reduce the risk of
corrosion.

120. Reconnect the overflow hose to the thermostat.

Make sure it routes down the side of the frame.
Using adjustable pliers to get the clip into
position.
 Valve Clearance 27

Reinstalling The Cables

121. Untie the cables from the frame (if you tied them
out of the way previously. Overall follow the steps
you recorded in your pictures for reassembly. But if
they fail you then these pictures should help. Begin
with the far left injector and reconnect it. 124. Connect the white connector.

125. Move the left map sensor connector back under

the frame and into position.

122. Reconnect the two black connectors, one of

which should have tape on it so you know which
one goes with which.

No tape Tape

126. Reconnect the hose to the thermostat/Radiator

filler.

123. Reconnect the white connectors, one should

have red tape on it.
 28 Thunderbird Storm

127. Reinstall the screw securing the radiator filler using 132. Tighten the hose clamps for the coolant hose
8mm socket (9Nm if you want to be exact). and radiator filler.

128. Move the cable holder back into position using

5Hex bit and tighten sensibly.

133. Screw in the coolant tube fixing using T30 and

tighten sensibly (or to 7Nm).

129. Reconnect the horn and refit the bracket using 8

or10mm socket and tighten sensibly. Make sure the
cables are neatly behind the bracket.

134. Screw in the left map sensor to the frame fixing

using T30 and tighten sensibly (or to 7Nm).

130. If your model has them refit the secondary air

injection hoses.

131. Reinstall the right hand side cable guard using

8 or 10mm socket if removed and tighten sensibly.

135. Reconnect the other ignition cables that you

labeled on disassembly.
 Valve Clearance 29

136. Move the leads tied up on the right side of the

engine back into position.
140. Loosely replace cable ties as seems necessary.
Dont tie them completely yet as things may need a
shuffle later but it helps to keep them in place.

141. Move the male orange connectors back under

the throttle cables and reconnect them. Again a
small smear of silicone might help them slide
together, stay sealed and help with the next
disassembly.

137. Move any extra cables like heated grips and

satnav back into place along the frame.

142. Return the pink wire with the U-clip under the
138. Move the main harness into place and bend the throttle cables but over the larger two connectors
nearby and reconnect with the female.
tag back over it.

139. Reinstall the left hand injector body if you

143. Wiggle the plastic central wiring holder back into
removed it and tighten sensibly.
place and pop the two brown lugs on the connectors
back into their holes. You may need to bend the
brown lugs back so that they remain in the holder.
30 Thunderbird Storm

144. Slide the connector with the U-clip back into Tighten this screw
the side of the plastic central wiring holder.
147. Tighten the screw towards the top right of the
145. Pop the throttle cables back into place on the wiring with a T30 head to a sensible degree. Note
holder and note that the left one goes over the top the bracket is on the bottom, the plastic bracket in
and the right one goes underneath- see pictures the middle and the bracket with the metal insert is
below. on the top.

148. Put the brown and pink wire connector back

together

146. Screw back in the screw at the base of the plastic

frame to a sensible level, no need to torque.
 Valve Clearance 31



149. Reconnect the white to white plug (a MAP
sensor I think) on the right side of the area.

152. Move the expansion tank overflow pipe into

position. It clips into the back of the tank and also
150. The final wiring re-assembly should look like into a clip under the bike behind the right exhaust.
this. Note- this bike has a sat-nav and heated
handle grip cabling on the right that may not be on
your bike. But you get the idea- this is how the
cable should sit.

153. Reinstall the expansion tank and tighten

sensibly (3nm to be exact) using a 10mm socket.

Replace Cooling System and Refill Coolant

151. Replace the cooling expansion tank bracket.

Tighten sensibly (3nm to be exact) using a 10mm
socket for all 3 fixings.
154. Push the hose back on the expansion tank and
using adjustable pliers pinch the hose clamp back
into position.
32 Thunderbird Storm

155. Reconnect the coolant fan.

Lower pipe

158. Reinstall the upper radiator fixing using a 8mm

socket and tighten sensibly (6Nm to be exact).

156. Reposition the radiator and move it into

connection with the upper and lower hoses.

159. Tighten and check all clamps connecting the

157. Once the hoses are connected, make sure that radiator and coolant hoses are securely fixed.
the radiator is sitting on the lugs and the rubber
mounts are not contorted or overly squished. This
took a bit of fiddling but it got there.

Lower mounting lug

 Valve Clearance 33



160. Replace the radiator cover. It sits on two rubber
lugs at the top of the radiator and is held in place
by a screw at the bottom, do it up using a T27
screw bit.

Bleed Nipple

162. Replace the bleed nipple and copper washer,

tighten to 9Nm using a 8mm socket.

163. Fill up the expansion tank to the MAX line.

161. Now undo the bleed nipple screw using an

8mm socket. There is a small copper washer under
the bleed nipple screw, replace it. Place a funnel
into the radiator cap/filler and slowly poor in the
HD4X Hybrid OAT coolant. Dont do it too fast
otherwise it may shoot out the hole instead of
draining down. When coolant comes gently out of
the bleed nipple stop pouring coolant.

Replace The Tank

164. Place the tank back into position

165. Put the bolt and sheath at the rear of the tank
back into the hole and screw the nut on finger
tight but do not torque yet.
 34 Thunderbird Storm

169. Now you need to make sure all the air is out of
166. Once the rear bolt is in, lift the tank from the front
and put in the tank brace.
the system. Remove the radiator cap. Reconnect
the instrument panel and battery. Turn the ignition
on and start the bike. You will probably see the
coolant drop and air come out the opening. Blip
the throttle to further encourage a change in
coolant pressure. Then turn the bike off. If the
coolant level went down then poor some more in.
I found the easiest way to do this was with a long
syringe but you may have other methods; remove
the tank again or have an L-shaped pipe. Repeat
this process as needed until there appears to be no
more air in the system and the coolant is full.
Syringe

167. Reconnect the fuel hose and clip the blue bit back
into the lock position. If it isnt all the way in and
locked, fuel will leak out which will be dangerous.
168. Reconnect the breather hose, fuel pump connector
and fuel sensor connector.
Fuel pump connector Fuel level sensor
170. Once fully bleed and burped, put the radiator
cap on. Keep turning it until it is fully tight, as
just one turn will lead to a leak. Also check that
the right type of radiator cap is in place- it needs
to be 1.2Bar.
171. Optional- This is a good time to double check
for leaks and the operation of the cooling, before
you put everything back. Connect up DealerTool
or equivalent to the ECU (see ECU guide for
further details). Turn on the bike and monitor it.
When the temperature of the bike gets to 1040C
then the cooling fan should come on. The
thermostat opens at 820C, you can remove and
check this but it isnt standard maintenance
unless you suspect and issue. If everything
works as it should with no leaks carry on.

Breather hose Fuel hose

 Valve Clearance 35



the edge of the seal can help with this. Dont push
this into position, arrange the cable so that it sits
nicely before screwing it in. Tighten the three
screws on the instrument panel using a 5-Hex
sensibly.

177. Reconnect the instrument panel wires then

using a 5-Hex secure the panel to the tank.

178. Reconnect/reinstall the battery connecting the

positive and then the negative terminal.

172. Remove the tank brace and lower the tank into 179. Install the rider and pillion seat using a 5Hex
position making sure that none of the hoses head.
become kinked or trapped.
180. Fire up the bike and pray you have done it all
173. Tighten the front tank fixing sensibly using the correct. Let her warm up and see if the coolant in
4-Hex head (8Nm to be precise, but you may strip the expansion tank needs topping up. Once at the
it if not careful). correct level replace the expansion tank cover using
8mm socket and tighten sensibly.

174. Now tighten the rear tank bolt to 9Nm using a

8mm socket and torque wrench on one end and a
10mm spanner on the other.

175. Reconnect the main cable to the rear of the If all okay, give yourself a pat on the back, this is a
instrument panel and slide the rubber seal into monster of a job.
place to prevent water and/or dirt getting in.
Replace any cable ties needed in the area. Job Done!

176. Place the instrument panel into position

making sure the rubber seal around its edge is in
place. Running a small a small plastic spatula along