grooved push rod

[the red baron]

Hi guys, I'm new to the yamaha 650, i have a 73 TX650 and have the stiff clutch issue, i took the side cover off today and removed clutch push rod, firstly the ball was on the outer end as opposed to what is shown in my parts diagram where its at the clutch end.

Secondly the rod is grooved at the outer end as if its been wearing on something, can anyone enlighten me.

cheers Ray

 

[I am Carbon]

The push rod or rods there is a single piece that has a ball on the inside that sits between the rod and the clutch.and a two piece push rod setup that has two balls one sits between the inside rod and clutch and the second ball between the two rods. there is also a ball inside the worm gear assembly.
the end of the rods do have a recess area guess ya could call it a groove.
http://www.mikesxs.net/product/39-6510.html
http://www.mikesxs.net/product/39-6511.html

 

[TwoManyXS1Bs]

Here's a cross-sectional pic of the XS650 clutch system, using the 1-piece pushrod.

The actuator end of the pushrod is a smaller diameter so it can fit into the actuator.

Here's an exagerated example of the wear groove, about 50-60mm from the end, that can form on the clutch pushrod when it's old/worn and the guide bushing/seal needs replacement. Most left side oil leaks come from this.

View attachment 41701

More info can be found in this thread:

http://www.xs650.com/forum/showthread.php?t=32267

 

[the red baron]

Thanks Twomany for the pics, the wear on that rod is not exagerated compared to mine, in the diagram whats between the adjuster and the rod is that the ball fitted into worm gear.

cheers Ray

 

[gggGary]

There are two balls, one each end. the one in the worm is not listed because it is "supposed" to be captive in the worm but often isn't. Hardware or bicycle shop 5/16" ball bearings work fine. No biggie on the groove, they "all" have it, dirt from the chain and the rod spinning grind it into the rod. Chuck the rod in a drill, use fine paper and smooth the groove edges then polish and install. A coat of grease on the rod may help slow the groove re-forming. I do this on nearly every bike I get while I'm replacing the seal.