yerbluez
XS650 Member
Is there a way I can make up for the lack of travel on the worm drive at the perch? I will likely order the new assembly but would like to take it out in the meantime.
Your install appears to be correct. There are four splines or "swirls" on the male part of the worm. That means you can start it threading into the female part in one of four positions. Only one will result in the worm arm being angled as it should be when fully turned into the female part. The other three starting points would place the worm arm 90° or 180° away from that 7 or 8 o'clock fully seated position. It's pretty easy to see and realize you have it wrong. It wouldn't be possible to hook the cable to it in the other three positions.
Not really. Many of us set the worm screw a bit tighter than the spec, backing it off maybe 1/8 of a turn instead of the specified 1/4 turn. When you set the worm screw, have the adjuster at the hand lever turned fully in, at it's loosest setting. Put as much slack in your cable as possible. Now you're going to try to remove, adjust out, as much of that freeplay as you can with the worm adjusting screw. Work the clutch lever in and out as you turn the worm screw in. Don't pull the lever all the way in and disengage the clutch, just enough so you take up the freeplay and start to feel resistance. What you're trying to do here is push all the pushrod parts together, the series of balls and rods that run over to the clutch from the worm. You should find that the worm adjusting screw will turn in a bit more as you work the hand lever and get all the parts stacked tightly together.
Do you mean like this?
It's also possible there could be something stopping it from going in all the way, like old hardened grease packed into the bottom of the seal cup. Fully inserted, the seal cup or holder should sit about 1mm above the mounting screws
I mentioned the adjustment thing back in post #11. That is what's responsible for the more than 90° angle between his cable and worm arm once adjusted. Probably too much adjustment at the perch and not enough at the worm screw. You get your best mechanical advantage when the cable is at 90° to the arm. We strive to set our adjustments so the arm will begin at slightly less than that angle and sweep through it as you pull the lever in.