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selling my nearly stock red and white 1972 xs 650 or the xs-2. Please take a look at the eBay ad: http://m.ebay.com/itm/152281834975?_mwBanner=1 Get in touch if you have any questions ! Thanks

Thanks for this description, it helps clarify the process of adjustment for those of us who are new to it. Removing the left side cover and replacing the pushrod seal etc., really helps to get a visual of how everything works together as well.

I got it to work alright after all. Thank you all for your help! Think I may need a new assembly at some point , but for the meantime the new clutch cable helped, as well as all the tips you guys provided. it's definitely smoother, not a single finger pull but better. Clutch engages now when...

Is there a way I can make up for the lack of travel on the worm drive at the perch? I will likely order the new assembly but would like to take it out in the meantime.

Yeah after looking at it a bit more and putting it in different positions I can see what you mean. If it's installed wrong, the drive isn't seated completely.

peanut you are right, it starts at 8 with the cable attached, and ends at 9. Doesn't seem like enough pull there

Do you mean like this?

I just pulled the male end of the drive out and inspected the nylon female end, it all looks okay and moves smoothly and without issue by hand when the cable is off. So I'm guessing something else is up. Gonna reassemble everything and give it another shot. Maybe the new cable fixed the issue .

Okay well thanks a lot guys for the quick responses. Don't get too many days to work on this and want to get her back on the road! I'll look at the nylon and see if I have to order that.. Or perhaps just order a new assembly. The original problem was that the clutch lever wasn't really...

I didn't disassemble the worm gear to check the nylon part, but perhaps that could be what's happening. I'll look into that. The ball bearing is inside, just kind of stuck towards the back with grease. Should it move more freely?

See if this works, sorry -

Clutch lever

The clutch feels tight when I pull it, very tough to get it back to the handle bar. I'll get a video in a minute once I put the case back on. I backed the worm drive screw out pretty far then screwed back in until I felt a little resistance then back a 1/4 turn. Then tightened then nut. I have...

Here is another Video with the case off, does this look normal?

Right now I don't feel that the resistance on the cable is the issue, I think it's the lack of pull on the worm drive once the case is on. I just don't know how to fix this. If that is indeed the problem

Thanks for those routing instructions, your handlebars look just like mine. I just installed the motion pro cable it seems to work okay, until I put the cover back on and then it's stiff as ever. I think something is wrong with the actuator- I feel like it is not extending enough once I have...

Thanks I'll go through all of this again. As for the spring, is that something you can likely find at any hardware store or should I go through Mikes? I'm gonna try out my motion pro cable today, does anyone know the correct aprox length of the wire for a 72? I do not have the stock handlebars...

I took the cable out and with the spring still attached this is what the position looks like. I really don't know how to replicate your photo peanut without removing the spring?