3 screw worm

Are you talking about the clutch actuation worm assembly? I've only seen them held on with two screws.
Leo
 
Finally found MarkSteedSpeed's album pic showing XS1 vs later worm body mounting.

full
 
hmmmm....wonder if a later cover would fit so the worm could be replaced? Might have to drill that lower mounting boss. The earl rotor cover do fit on the later covers, would look same, except the squared off part over the output sprocket. I wont tell.
 
my automotive experience has been that clutch linkages should be fully slack when clutch is engaged. if i use the worm as is, the cable will be holding the worm slightly rotated and not slack. any thoughts are truely appreciated.
 
The worm actuator doesn't fully bottom when everything's properly adjusted. If you go into the Tech section, and read the clutch worm actuator experiment thread, you find many more clues...
 
update: this xs1 has a 256 cover, the worm mounting boss is large but drilled for the small later worm assy. it had an early worm assy drilled to fit a late cover. WTF! the mikesxs worm assy adjust screw is too long so i cut it about 10mm shorter and used the rest of the assy. it looks like the clearence at the drive sprocket may be a little tight. i did not ride it today, its too late, too hot and too humid and i'm not as young as i was when i originally got this bike in the early 1970s.
 
I wonder if your early cover has a raised worm mount surface.
On my later XS1B cover, measured the amount of recess of the worm mount surface, 14mm.
 

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ok, that did work kinda. but... 2many's clutch tidbits thread is really a must read (beginning to end), at post 185, 5twins covers all the lever options pretty daggone well. i tried mikes easy squeezy thing although it worked, i wasn't comfortable with the geometry in this application so I ebayed for the stock and the Il9. for the Il9 to work in this application I cut the seal holder off (as the original had none), the offset difference lined the pull up and feels better than the mikes part. Oh yeah, these parts cost less, it's just too bad that I had to buy all to get this right.
 
While I don't have the Engine number of the change over I have found the 3 lobe worm only on early production 1970 bikes, a 3 worm cover will also have a screw on aluminum cap, the 4 lobe worm covers have the push in chrome cap like all later bikes. As wrenchjohns bike was later production it would have come with the "later 256 cover" but an early worm was modified and used, for unknown reasons. Maybe a dealer replacement 3 lobe worm was shipped in error???
some pics of an early cover here; http://www.xs650.com/threads/listen...ing-to-tell-me-xs1-wake-up.43086/#post-430111
this bike is serial # 450 ish
 
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