Mysterious ball bearings

[Aidanmiller]

Hey guys, I took my crank case over off (actually to track my stator wire) when I re connected it the pin that connects to my clutch seems to off loosened and I’d lost all tension in my clutch. I pulled it out to inspect and found some ball bearings with it.

Totally lost. Have I fucked up?

 

[Kevin Kruse]

Got any pictures? How many bearings do you see? When you say pin are you referring to the pushrod?



That’s the only place I can see where ball bearings would come out. If so there should be 2 ball bearings in between the pushrods.



That would make sense if you’re clutch is totally loose all of a sudden.

 

[gggGary]

A ball bearing is held captive in the worm gear but often manages to get free.

 

[gggGary]

You can see the ball and stake marks that're SUPPOSED to keep it in place.

 

[Aidanmiller]

Got any pictures? How many bearings do you see? When you say pin are you referring to the pushrod?

View attachment 355483

That’s the only place I can see where ball bearings would come out. If so there should be 2 ball bearings in between the pushrods.

View attachment 355484

That would make sense if you’re clutch is totally loose all of a sudden.

This is what I was thinking upon some inspection but I didn’t notice any breaks or obvious damage, how would I reconnect them and to what?

 

[Aidanmiller]

 

[Kevin Kruse]

Hmm, I think the bearings should all be the same size, not sure about that smaller one. Double check the actuator to see if the bearing hasn’t fallen out of it like @gggGary said, maybe take a picture of that?

And there’s 2 pushrods going through the case, the one you’re holding and another one behind it, with 2 bearings located as in the diagram posted above.

It might be a good idea to take the other pushrod out and check to see if you have a bearing behind that one. You’ll need a magnetic screwdriver or one of those telescoping magnets.

Was this bike running before?

 

[gggGary]

necked down end of that rod faces out into the worm gear, there should be a ball at the inner end between that rod and the one further in and one where the inner rod pushes on the clutch.

 

[gggGary]

all three are 5/16" or 8mm

 

[Aidanmiller]

But why were those balls both behind the pin originally though? Just a old bodge job maybe?

 

[Aidanmiller]

Hmm, I think the bearings should all be the same size, not sure about that smaller one. Double check the actuator to see if the bearing hasn’t fallen out of it like @gggGary said, maybe take a picture of that?

And there’s 2 pushrods going through the case, the one you’re holding and another one behind it, with 2 bearings located as in the diagram posted above.

It might be a good idea to take the other pushrod out and check to see if you have a bearing behind that one. You’ll need a magnetic screwdriver or one of those telescoping magnets.

Was this bike running before?

Bike was running before, I didn’t wanna water it untill I figured out this problem, sorry clear me up what’s the actuator

 

[gggGary]

what’s the actuator

#22

aka the worm gear.
Was just working on an XS1B this morning the ball was missing from the worm gear and the adjuster screw #24 was run in an extra 8mm to compensate.

 

[5twins]

To confirm whether or not the ball has fallen out of the worm gear, remove the adjuster screw. If the ball is missing, you'll be able to look right through the worm. This ball isn't shown on the parts drawing because it's considered part of the worm assembly. But as mentioned, when the crimps wear away, it can (and does) fall out. Pack it with grease to hold it in there .......

 

[5twins]

And yes, they are 5/16", don't know why what with this being a "metric" bike, lol. 5/16" is slightly smaller than 8mm (7.94mm), so an 8mm ball may not fit.