Zero Freeplay at Wormgear Adjuster

Uhlaf

XS650 Addict
Messages
174
Reaction score
24
Points
18
Location
Toronto
Afternoon,

I had to replace my pushrod, pushrod oil seal, and a spring on the clutch side. Everything went well until I went to install the left case cover. I was missing the ball bearing in the worm gear so I cleaned and lubed up the wormgear and gave it the bearing which I was running with out for a long time.

Here's the problem, I adjust the clutch level at the perch for 0 free play and then switch to the worm gear adjuster where I find out that I cannot turn the screw in at all, it hits the pushrod immediately. The adjuster screw is so far out that I can't even put the cover plate back on the worm gear adjuster.

Here's the order from clutch to worm gear that I have installed;

Pressure plate--->mushroom plunger plug---->ball bearing---->pushrod---->ball bearing---->worm gear.

I did switch from a 2 rod to a single rod solution.

Any ideas?
 
First off, you're doing the clutch adjustment sort of backwards. You should set the adjuster screw on the worm gear first, then finish with a small amount of adjustment up at the handlebar. So, loosen the handlebar adjuster all the way up (turn it all the way into the perch) and then see if the worm adjuster screw will adjust as it should.
 
Lever perch is set to give full slack, still no dice.

I double check to see if the worm is set to 7 o'clock which it is at rest but when I attached the clutch cable it gets pulled to 9 o'clock just through the length of cable coming through the elbow. What I don't understand is that my cable worked perfectly well before. The cable itself is free to move as well as the cable shroud. This is driving me nuts.

Anyone know how much the cable should be protruding into the engine case so I can compare?
 
Maybe you weren't missing the ball in the worm after all, and now you've added another? If the ball is missing and you remove the adjuster screw, you can look and see right through the worm. I'd remove the ball you added, remove the adjuster screw, and have a look-see through the worm.
 
Yeah something's goofy the cable shouldn't put much stretch on the spring.

worm-001-jpg.28143
 
Last edited:
Going out on a limb here, but you originally mention replacing the pushrod. Did you upgrade from a two piece to a one piece? Did you remove the inner ball bearing on the clutch side when you pulled the pushrod out? Just wondering the possibilities of having an extra ball bearing in there somewhere.
 
Yup, I’d bet on an assembly error - either an extra ballbearing in there somewhere or the push rod in bass-acwards.
 
Extra ball bearing is what I thought to. I double checked today and I can confirm that the assembly goes Pressure plate/mushroom thingy/ball bearing/rod/ball bearing/worm. The stepped down end of the pushrod is what is coming out of the engine and pushing against the worm.

5Twins, is it possible to seat 2 ball bearings? Where are the bearing supposed to be seated in the worm?
 
Back
Top