I've been working on the 79 survivor. With only 9400 miles the PO's were having clutch issues, there was a new cable, what looks like a new factory worm assembly. And they still had it fuggled up, First I backed off the cable adjuster all the way, then reset the worm screw, that got it back to a working clutch. Straightened the elbow in the aftermarket cable a bit, rerouted it to the factory position. Lubed the cable, that probably had never been done... but the lever was still a bit stiff (and wobbly). Pulled the lever off off to grease the pivot and found this.
Not good, less than 10K and all wallered out. the bolt wear was minimal, the aluminum lever took the hit.
The bottom o-ring was MIA and just hard dry remains of a bit of grease. I happened to have some sintered bronze bushings of the right size, 8mm ID x 10mm OD x 8mm L, so I bushed the lever. Drilled it out with a 25/64" bit. Reamed to 10mm. Used a home made tool and got rid of the tiny lip left from the inside of the o-ring recess. then pressed in the new bushing, filed and sanded it just a touch so it's length is flush with the lever thickness, greased it, put in an o-ring and reassembled. Wobble gone and I thought the pull was noticeably reduced.
Did this again on Madness in 2018, used a 3/8" end mill in the drill press which let me center the hole quite easily, the end mill's flat bottom cutting edge doesn't follow the old, now off center, oval hole like a drill bit will. I hacksawed the bushing "join joint" wider, filed off the rough edges, tapped it into the hole and the lever is snug again.
Often the bolt IS quite worn, the number has superseded to
Bolt
90109-06798-00 list $3.50, boats.net 10-2018 $1.94
edit (02-25-2018) years later 5t noted I had mistyped 25/32 when the bit should be 25/64", now corrected!
MikesXS sells a replacement pivot bolt.
https://www.mikesxs.net/yamaha-xs650-clutch-lever-holder-bolt-409-650-81.html
Not good, less than 10K and all wallered out. the bolt wear was minimal, the aluminum lever took the hit.
The bottom o-ring was MIA and just hard dry remains of a bit of grease. I happened to have some sintered bronze bushings of the right size, 8mm ID x 10mm OD x 8mm L, so I bushed the lever. Drilled it out with a 25/64" bit. Reamed to 10mm. Used a home made tool and got rid of the tiny lip left from the inside of the o-ring recess. then pressed in the new bushing, filed and sanded it just a touch so it's length is flush with the lever thickness, greased it, put in an o-ring and reassembled. Wobble gone and I thought the pull was noticeably reduced.
Did this again on Madness in 2018, used a 3/8" end mill in the drill press which let me center the hole quite easily, the end mill's flat bottom cutting edge doesn't follow the old, now off center, oval hole like a drill bit will. I hacksawed the bushing "join joint" wider, filed off the rough edges, tapped it into the hole and the lever is snug again.
Often the bolt IS quite worn, the number has superseded to
Bolt
90109-06798-00 list $3.50, boats.net 10-2018 $1.94
edit (02-25-2018) years later 5t noted I had mistyped 25/32 when the bit should be 25/64", now corrected!
MikesXS sells a replacement pivot bolt.
https://www.mikesxs.net/yamaha-xs650-clutch-lever-holder-bolt-409-650-81.html
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