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XS650 Clutch Worm Actuator experiment & tidbits

Discussion in 'The Garage' started by TwoManyXS1Bs, Oct 27, 2013.

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  1. ReycleBill

    ReycleBill Part Time Tyrannicide XS650.com Supporter

    Can't say, I only rode about 200 miles before I blew the engine. But the clutch is fine.
     
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  2. Team Junk

    Team Junk XS650 Guru XS650.com Supporter Top Contributor

    I can tell you I tested 2m's clutch pull a few months back and it was amazing light so I assume the push rod is still cranking along.
     
    ReycleBill, Jim, TwoManyXS1Bs and 2 others like this.
  3. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Hey, guyz.
    Yeah, the XS1B's clutch action and pushrod are still working fine.

    To answer questions about the clutch cables and aluminum pushrod, have a look into these.

    http://www.xs650.com/threads/32945

    http://www.xs650.com/threads/32267

    For those with a lathe, there should be enuff info in there to make your own pushrod from 8mm or 5/16" round rod. Lookup Alexandria Precision to source some high-quality 7075AL rods.

    And, yeah, I didn't want to slight or insult any cable suppliers, but if you study the cable experiments thread, you should see that the Motion Pro cable has the best performance...
     
    gggGary, GLJ, ReycleBill and 2 others like this.
  4. Paul Sutton

    Paul Sutton Still Looking Good Top Contributor

    On my XS SH I found that 8mm would not fit down the shaft whereas 5/16" fitted nicely. Consequently I had to use the lathe to turn the 8mm down slightly. I am not sure if this tight fit is common to all XS models.
     
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  5. ReycleBill

    ReycleBill Part Time Tyrannicide XS650.com Supporter

    Now if someone would develop a thread-in pushrod seal.......
     
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  6. yamahama

    yamahama '72 XS in Restoration XS650.com Supporter

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    Interesting...the cable I have is black, slightly curved short metal tube at case and only says Made in Japan TSK 6. Needs to be removed as I can not even put pressure on clutch lever. Silver/ grey is original...ok.
     
  7. rusto

    rusto XS650 Member

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    Hello. Just swapped in a royal enfield ball and ramp mechanism. Only done about 30 miles but feels really good so far.

    View attachment 169650
     

    Attached Files:

  8. ReycleBill

    ReycleBill Part Time Tyrannicide XS650.com Supporter

    Can you give us model and year on that Royal Enfield ball and ramp mechanism? My local Triump/ Royal Enfield dealer is a great guy but I doubt he has a crossover reference to XS650s. And I won't set foot in the local Honda/Yamaha dealer's shop anymore.
     
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  9. rusto

    rusto XS650 Member

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    The eBay listing just said 5 speed, part number 550512 but googling that seems to confirm it. It's on an adaptor plate as i didn't want to mod any xs parts. The cable arm cracked when I tried to bend it a small amount - the case hardening goes deep, hence my ugly version. And I added a short tube to support the push rod and hold the ball bearing. I'll make it tidy when I've done a few more miles.
     
  10. 5twins

    5twins XS650 Guru Top Contributor

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    Do you think it gives more "thrust" and hence, plate separation vs. stock? If so then a more detailed "how to" would be nice. You mentioned needing to make an adapter plate?
     
  11. rusto

    rusto XS650 Member

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    I'd tried a hard to make the clutch work better but still had the usual stickiness and mushiness at the lever and loss of travel with a warm engine. The ball mech has little flex so I guess more lever movement makes it to the pushrod plus it works smooth giving very good modulation. And with the engine hot, no loss of travel so clicks into neutral with no effort. I'd say the old mech was pushing the plates far enough in ideal conditions but lost too much travel, say when the engine is hot - the Enfield one works more consistently. I've only done a few miles so far (did get the engine pretty hot tweaking the carbs) but I'm hopeful! I'll pop the cover off in a minute to take some pics. ​
     
  12. Rusto, you have peaked my interest. I second the post a "how to" request.
    john
     
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  13. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Are the balls protected from the junk the chain throws around?
     
  14. rusto

    rusto XS650 Member

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    Cool, I'll do some more miles and try to confirm it's good.
    Adaptor is just a thick 45mm washer with holes for the original mechanism screws. 50mm washer would be better as the 2 holes are right on the edge but would need grinding to clear the generator case. Then 3 tapped holes for the countersunk screws, the screws cut so they don't bottom out. The new mech needs countersunk screws for clearance.

    IMG_0899.JPG IMG_0900.JPG
    The 3 screws seat the ramp plate onto the washer and 2 screw heads pretty equally. Like I said, I had to bodge a new arm on and add a stubby tube to support the pushrod and hold its ball.
    IMG_0896.JPG
    New adjuster screw was too long so swapped it.
    Next time I'd weld the cable arm on where it gives more cable slack - my adjuster is nearly in all the way. And I'd fit a longer arm with more cable holes to experiment with. Also, the layout means there's not a stack of adjustment at the pushrod. Glad I didn't have to shorten it but I could have.
     
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  15. rusto

    rusto XS650 Member

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    Jim, no, none! And the grease might attract dirt but the steel is pretty hard. I'll chance chance it and add an item to the maintenance diary...
     
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  16. rusto

    rusto XS650 Member

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    Just to say, I didn't look into this much, just picked a part and wanted to try it. I'm certain a more scientific approach would work better!
     
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  17. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Does it look like there's room for a cover? Maybe a rubber boot... or a tin cup type affair?
     
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  18. rusto

    rusto XS650 Member

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    There's not much space between the mech and generator case but yes, a tin cover with a gap there for clearance could work. I haven't cleaned inside the case yet but this seems the cleanest area so that'll probably help.
     
  19. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    The original just uses a "tin cup" with a rubber seal. Looks like something like that could be adapted. Just found a new one on Ebay for 18 bucks. Before I pull the trigger, you think the pull is enough easier to make it worthwhile?

    IMG_20200611_165822.jpg
     
  20. rusto

    rusto XS650 Member

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    Yes the original is well protected. Actually pull effort seems similar but maybe more of the energy gets where it's supposed to go and more consistently. I'm cautious about saying to go for it until I've done more miles under more conditions but it looks good so far. And sure you know, everyone seems to get varying results with what they do so there's that!
     
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