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Zero Freeplay at Wormgear Adjuster

Discussion in 'The Garage' started by Uhlaf, Jan 7, 2019.

  1. Uhlaf

    Uhlaf XS650 Addict

    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?
     
    gggGary likes this.
  2. 5twins

    5twins XS650 Guru Top Contributor

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    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.
     
  3. Uhlaf

    Uhlaf XS650 Addict

    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?
     
  4. 5twins

    5twins XS650 Guru Top Contributor

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    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.
     
    gggGary and Superjet like this.
  5. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    Yeah something's goofy the cable shouldn't put much stretch on the spring.

    [​IMG]
     
    Last edited: Jan 8, 2019
  6. willis

    willis xsive compulsive disorder Top Contributor XS650.com Supporter

    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.
     
    gggGary likes this.
  7. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    Is the rod installed with the necked down end into the worm?
    81 clutch.png
     
    MaxPete likes this.
  8. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    Yup, I’d bet on an assembly error - either an extra ballbearing in there somewhere or the push rod in bass-acwards.
     
  9. Uhlaf

    Uhlaf XS650 Addict

    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?
     
    gggGary likes this.
  10. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Check the protrusion of the pushrod from the seal, should be 1-15/16". Any more or less means too many or not enuff 5/16" balls.

    Also, the single pushrod is 243mm in length...
     
    gggGary and mrtwowheel like this.
  11. Uhlaf

    Uhlaf XS650 Addict

    I'll check today, Thanks 2many that's awesome info.
     
    gggGary likes this.
  12. Uhlaf

    Uhlaf XS650 Addict

    Double bearings in worm gear.

    Thank you all for your time, especially 5twin.
     
    mrtwowheel, gggGary and MaxPete like this.
  13. Uhlaf

    Uhlaf XS650 Addict

    Double bearings in worm gear.

    Thank you all for your time, especially 5twin.
     
    Superjet and TwoManyXS1Bs like this.
  14. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    Very good - that does happen occasionally. Nonetheless, it is good to have found the problem.

    Cheers,

    Pete
     
    TwoManyXS1Bs likes this.

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