New clutch worm issue

[MartinNC]

Hello everyone, I've been hanging around for a while and learning. Finally started rebuilding my xs and was going to post my tale of woe when it was done but have come across this and it might help someone out. The new clutch worm I bought from Heiden (I'm sure Mikes and others sell the same product) had a problem, where the end had been crimped over to stop the ball from falling out, it had not been deburred sufficiently for the push rod (smaller diameter) to enter it. I did notice this when putting back on the cover, the cover sat proud by about 1/16, but I tightened it up anyway and was rewarded with a kick start that slipped!
Solution drill out the burr, but be careful as the hole isn't very circular and the drill will grab

 

[Brian902]

Small bit in a dremel would work good for this.

Not much room for filing, but if you had a small round file, bust it in half, chuck it into a common drill and you have a de-burring tool.

If used a large cotter pin and small strip of sand paper to make a de-burring too as well.

Good luck.

 

[TwoManyXS1Bs]

That certainly is a problem. Have a look at this post:

http://www.xs650.com/forum/showpost.php?p=325458&postcount=112

And for more info on that MikesXS worm, have a look at posts #112 - #120 in this thread:

http://www.xs650.com/forum/showthread.php?t=31554

 

[Brian902]

Very professional TwoMany! Great job.

MikesXs designer must have missed a few steps. hahaha

Poor fellow can't even copy things correctly.

He needs help. (out the door)

 

[TwoManyXS1Bs]

Poor fellow can't even copy things correctly.

He needs help. (out the door)

If he finds his way to Trojan, I'd avoid that product as well...

 

[5twins]

That's probably why there's about a billion people in China, lol.