Xs650 clutch worm gear Anybody know which way this is Forums. I changed the engine oil, lashed the clutch lever (which really wouldn’t move) to the handlebar with a bungee cord, put some rock ‘n roll on the Disaster Central Workshop sound Start by confirming that the ball bearings are in place. Messages 235 Reaction score 1,045 Points 143 Adjusting your clutch is a two part affair. Clutch worm over adjusted to minimise any cable play Friction plates appear to be contaminated by use of the wrong oil Plain plates worn concentrically but not axialy warped Clutch springs overly heavy for street use. If you don't have one, get a 12mm offset box wrench. The clutch is together correctly, holes lined up and with new plates. 5 mills per The worm, worm adjuster screw, and it's lock nut are all just plain steel and can rust together. thanks please help - is the clutch rod supposed to fit in the top of the worm gear ? Bought a new clutch rod lever assembly from Mike's. Latest activity New posts New media New media Haven't tested it yet, but I just left the worm gear screw setting where it was; it's a bit snug cold, but I'll test it 78 xs650 clutch cable for 1" bars needed? Flash1977; Aug 26, 2024; The Garage; Replies XS650. Mar 25, 2013 #1 ‘m rebuilding a 78 xs650 and I’m having a difficult time with the clutch disengaging correctly. Without the clutch plates and springs on, if I move the hub in gear it will rotate the wheel. 2" clevis hole. was wondering if anyone was trying to make one now. 4. quiets cam chain noise. Now the clutch will not disengage. It controls the freeplay between the worm and the clutch XS650 Hydraulic Clutch Conversion – Install Instructions March 14, 2012 / in Uncategorized / by Hugh Owings. It seems easier to modify the case or the clutch mechanism with this design. I am game for a new DIY bimetallic push rod too. Placed the end in housing at engine and routed up to lever. 1 KB · Views: 492 Reply. On mine, I even drilled another hole on the worm gear operating arm which is closer to the centre of 1973 xs650 clutch/kickstarter problem. but put it into first expansion taking place in the first fews minutes of starting an XS650. 5mm thick and the (5) metal plates measure 1. The (6) fiber clutch plates measure 3. com? A ball bearing also goes in the worm gear. ive looked through the forums but most of the threads are pretty old. Thread starter ejnogaski; Start date Dec 26, 2010; Hello I picked back up today where I left off last august or so on my xs650. Best to put it in neutral. If you drop the gear out of neutral into first it just stalls. Just feels like it's barely engaging now. com Forum to help you do that little job. XS650 Clutch Pushrod experiment & tidbits. I've read a lot of different posts on clutch adjustment problems and experimenting with different push-rods etc. Also, on another note, which clutch cable mount hole are people using? Mikes has two options. the bike runs good. Pull is just fine to me. I have replaced the standard clutch with Hugh's hydro clutch, one piece clutch rod, replaced the friction pads, and made sure my worm gear is clean and greased. Steven Simpson XS650 Addict. tons of grease on the ball in the worm gear and grease on the push rod. 25 x 100mm threaded rod The clutch lever and perch Forums. RayWhitt; Nov 1, 2021; The Garage; Replies 3 Views 1K. It was never the strongest but it never slipped. I had the pushrods out and thought it fell out of the engine (past the seal) so threw it in and pushed in the clutch pushrod. Fully release the perch adjuster then back the worm screw out just a little bit, or about 1/8 turn, now turn the perch adjuster out for about 1/2" free movement at the clutch lever tip, check action cold and hot, see if that helps. Messages 118 Reaction score 37 Points 28 Location Tacoma, WA. I have a well lubed cable, a new well lubed worm. On the downside, the left engine cover has a long crack at the rear on the top side and the Thanks man. I took the bike for a short little ride this evening in order to do two things. I never did buy a whole new worm gear but have tried 4 or 5 different used ones and all XS650 Clutch Worm Actuator Rotation Guage (degree wheel) TwoManyXS1Bs; Feb So when I adjust the clutch, I end up with 1 of 2 scenarios no matter where I adjust the worm gear (and yes I'm slacking the lever adjustment first and then setting cable free play after adjusting the worm gear). Check that the worm's arm is still pulled all the way down by it's return spring. I backed off worm gear bolt to place in lever to set adjustment and ensure clutch performs correctly. It has a nice smooth start as I slowly release it while giving it some throttle and then just stalls as soon as it’s fully let out. I shifted clutchless all the way home, and I was wondering what kind of Functions fine at speed. Adamc XS650 MEDDLER. Clutch worm adjustment nut Thread starter Evilclone13; Start date Jun 2, 2013; Tags clutch Evilclone13 XS650 Enthusiast Depending on type of clutch worm and stock/aftermarket clutch levers, total leverage multiplier at clutch lever is about 30-50. make sure the "captive" ball bearing is still inside the worm gear. If you have 0. 1st Scenario: If I set the worm gear to where the clutch plates grab correctly when I release the clutch lever, I end up having a I have been trying to trace the cause of the inability to select neutral. Messages 276 Reaction score 62 Points 28 Location Northwest Missouri XS650. let it idle wheel spins in the air. Messages 60 Reaction score 57 Points 18 Location Calgary, AB. My stock XS1B has a factory clutch worm in excellent shape, replaced 16 years ago, kept clean, lubed and adjusted. I'd bet the one in the worm gear is missing. Take off the filter screen. problems after new cable Replace your worm gear assembly or at least the female plastic part that mounts in the case. Take up as much slack as you can with that worm gear adjuster, then finish with the adjuster at the lever to get the last little bit of freeplay out. Conformed the working spring, and rod placement, set clutch adjuster etc. Wanted - New worm gear assembly. Hello all, I am having trouble with my clutch and would like to know where to start. 4mm? Dannyh82; Oct 6, 2024; The Garage; Replies 2 Views 110. If the grooves are not too deep they can be The free length of the clutch cable (difference between cable housing and cable) has influence how far the “worm gear screw” is out of the “worm gear nut” in closed position. Both bikes operate just like before. And when installing the lock nut, it doesn't need to be super tight, just a little bit past snug. Sstandard gear fitted to a clutch basket with kit installed. I now have no clutch and when I crank the motor with the electric starter I hear a Forums. This will make it much easier for you to do the conversion at home without the need for The XS650 clutch is adjusted via a worm gear located on the left side of the engine. 057" (modified cable-elbow entry base) Not much of an improvement to the clutch action, but a serious improvement to my pickyness hi guys, does anyone know if there is a kit i can buy for a foot clutch. There is barely enough push rod motion to get full plate separation. -Your clutch worm gear out of the cover-M8x1. livingdeadmc XS650 Junkie. -Brand new worm gear assembly lubed well with bearing grease. The new clutch plain plates have a micro- dimpled appearance which the suppliers claim is for oil retention. Ccanady XS650 Addict. Thread starter Jack Dunneisen; With bike in gear, rotate kick lever, rear wheel turns. The clutch push rod has to be installed with the necked down end facing out at the worm gear. com receives a small share of sales from some links on this page, These clutches need as much stroke of the worm gear as possible. Tried the old 2 piece pushrod too. That visual helped a ton. But each is different and you will find the adjustment you like best. I'm using 15/40 ROTELLA T. IIRC the 79 has the 2 piece push rod, there should be a bearing between the two sections A standard hardware store 5/16" bearing works for both those. I readjust the free play once the engine warms up. If it's not moving out enough (2-3mm) then you'll have to look at your worm gear, cable, or lever. Got it all together and have an extra part. com receives a small share of sales from some links on this page, After riding the bike for a while when I come to a stop in first gear with the clutch lever pulled in the bike wants to creep forward. The friction plates are new, steel clutch plates are good, the one piece 9 1/2 inch shaft is straight and smooth, I replaced the worm gear, clutch cable, the 6 clutch holding springs are good and I’ve replaced the 6 spring holds with aluminum ones you sell. so there Enjoy XS650. 0035" per degree of rotation (about 0. 3. Last edited: Oct 9, 2014. Sometimes clips and doohickeys in an XS650 clutch assembly and missing any of them will result in a dead clutch. 073" movement. The worm is made of plastic, it's old and can crack. Check that the cable is still attached to the multi-start plastic worm's arm. Are you sure you haven't lost the ball out of the worm gear? Reply. Thread starter jimmybrown78; Start date Oct 9, 2014; J. If the clutch is to tight that is difficult or impossible to do then I adjust at the worm gear . com receives a small share of sales from some links on this page, Id start at the top and work back,,,,double check the settings at the clutch lever first and work back to the worm gear and so on. Bike runs great but suffers from the typical clutch adjustment issues. The cracked worm can make the lever hard to pull to. 1. The bushing is not a big deal with the one piece rod. When the worm gear is adjusted improperly, the pressure plate is prevented from expanding People have also had success on the hydraulic clutch conversion kits for pit bikes. Messages 8,055 greased everything and its a completely new bike. Part of why the proper free play adjustment is so important on both this and the XS650. The bike had been in a barn for many years and was really in rough shape. The pit bike conversion is under $50, but it still uses the stock worm gear. Any ideas? Reply. Thread starter TwoManyXS1Bs; Start date Dec 6, 2013; been there through a new cable, through a new lever, through filing on the lever to smooth it on the cable, through a worm gear disassembly and regreasing, through a bushing change and a seal change, through many cover removals, Hey everyone I'm just on the very last leg of my build and need some help with the clutch push rod. These are all over Ebay and Vid#1 is to make sure my clutch washers and bearings are in the correct sequence. Clamp the drain plug in a vice. With these springs, the new plates, new actuator worm in the side cover, the almost new Motion pro cable, everthing well lubed I can pull the clutch with two fingers. Reply Reactions: timbeck , TwoManyXS1Bs and Gator xs2 Enjoy XS650. Just search for “clutch adjustments” or “clutch worm” and you will find it. I don’t have big hands but think it will be manageable. Not enough to actually move me, but if I strattle the bike it will actually pull away. The worm gear actuator can be installed in 4 different positions. 781 " from the centre of the worm gear. from a stop the bike pulls good through 1st 2nd and most of the way through 3rd untill i get to around 5000 rpms. Remove the casting to check the cable and clutch operating system. I don't have those problems. 079". I've been kind of rough on them. The old one is intact but has cracks in the plastic housing and the screws are loose (are they supposed to be)? With this older one I can stick the thinner head of the push rod through the hole. Reply Reactions: timbeck , TwoManyXS1Bs and Gator xs2 XS650 Clutch Assembly Sequence. Clutch adjustment xs2. All the clutch mechanisms (worm gear, push rods, clutch cable) have now been cleaned, Xs650 clutch assembly. Thank you! The clutch is definitely not disengaging properly - I've attached a video of the plates moving in and out. Vonturd XS650 Addict. Takes afew hours to do but I get double the throw from factory, takes 1 finger to pull the clutch and no wiring, or huge clutch cable!! XS650. Worm gear / pushrod travel 1. Thread starter ejnogaski; Start date Dec 26, 2010; Tags clutch Clutch Drag. Aftermarket clutch lever, Hugh's PMA, PAMCO. Jun 11, 2021 #5 You should probably inspect your worm in the left cover. Thread starter Irish_prick; Start date Mar 25, 2013; Irish_prick master of the cut'n wheel. Doing it again. When these bikes warm up, the free play gap at the clutch lever can become larger, and that prevents good plate separation in the clutch. 003" for the different pitch MikesXS worm mechanism). It all seems to be separating fine now although I still can't kick the bike in first without the back wheel moving. . com receives a small share of sales from some links on this page, You can also drill a second hole in the clutch worm gear operating arm. I still have a hard clutch pull but have made it worse for myself with a longer pull Magura clutch lever and a short arm on the worm gear. 650s up until the late '70s used a white plastic or nylon insert. Apr 20, 2021. maybe even point me in the right direction on how to make one. Or you can do the angle gauge, and derive the plunge depths at 3. (I installed thicker palmswell handgrips awhile back, and these reduced the clutch lever pull, producing only 0. Yet Another Clutch Mod. I have decided to change the kit to include button head bolts and half nuts instead of rivets. I bought the bike in boxes with the motor Forums. Reactions: timbeck. Clutch works. com? Consider making a Well, the twist clutch is going to have to wait. L. Messages 946 Also, at this point there’s a chance it’s not the clutch itself, it could be the oil, or maybe it could be the adjustment? I was really taking shots in the dark with the worm gear, rather than fine-tuning, and the clutch cable was adjusted all the way out when I got it, so maybe the worm gear is still the problem at this point? So here's my specs: 1981 xs650 special 650central clutch cable Brand new mikesxs worm gear using inner cable mount- mikes worm gear has 2 cable attachment points to choose from 650central perch Adjusted lever and cable using advice from tech section. V. 65" travel max - Wanted - New worm gear assembly. I also removed the clutch shaft, cleaned it, checked it for straightness (OK) or wear (none), lubed it with clean motor oil and reinserted it. Click to expand I just ordered this kit. Oct 6, 2024. Crashedkiwi; Jan 12, 2023; The Garage You may want to take clutch worm plunge depth readings, too. It is kinda common for strands to break inside the clutch cable due to rust and age. My next steps are to pull the worm gear and clean and grease XS650 Addict. Remove the LH footpeg, shift lever. 7", Lever force = 14 lbs, Worm travel = 0. 097", which makes for about 0. Messages 22 Reaction score 0 Points 1 Tried adjusting the clutch at the worm gear and it either goes to far out and just spins the kickstarter or it grabs and then again jams the kickstarter. Now you need to clean up the clutch worm gear mechanism Check it for being overly worn, but most are in Hey guys, I know people have posted in the past on clutches that won't disengage (stuck plates, cracked worm gear, etc). com receives a small share of sales from some links on this page, Oft times referred to as the Worm or clutch Worm gear. The cable operation is smooth that I know. com receives a small share of sales from some links on this page, I don't think it is a problem with the clutch basket, as I don't think the worm gear could bend the rod before breaking the clutch cable and I would feel significant resistance on the clutch lever. The XS650 clutch worm actuator rotates to create the lateral movement that pushes the clutch pushrod, about 0. Yes, I know the clutch have been covered, but I couldn't find any solution in all threads I read. The tool works great, but we saw no gains. That way you can get scoring values, mills-per-pound. ) with little to no improvement. I also couldn't get it into neutral at that point. i drilled a new hole, so that it now measures 1. If you physically can't move the gear selector then there must be something more serious wrong. if the clutch is easy to pull in there is no problem leaving the bike in first for the 2 minute wait for the signal change to occur. If I This causes the inner part of the worm to rotate inside to outer part. Here's the problems: 1 Neutral light XS650. By that, I mean pump the lever in and out through the available freeplay. Using the stock mechanical worm gear, the movement is only about 0. What's new. One sharp bend can fuggle your clutch action. As long as the bike doesn't lurch forward and stall when you drop it in 1st with the clutch pulled in, I'd say you're fine. I've been fighting the same issue for months now. The best way is then to remove the clutch basket and dismount the #4gear from the bike. Here are two more videos. 78 This improved the push rod motion from 0. Messages 45 Reaction score 56 Points 18 Location Sherwood. Going to try 20/50 motorcycle oil next time. Manually turn crankshaft with a wrench, clutch basket rotates, and timing advance weights rotate Clutch lever pulled in, rotate kick lever, inner clutch hub and steel plate rotate easily. Has anyone come up with a reasonable solution? When it's cold outside or the bike isn't too hot the 1/8" free play at the . That is the distance from centre of the arm out to the hole that pulls on the arm. The pressure plate engages in the boss, but not more than 1. All seem to cover slipping, neutral problem, gear problem etc. Some of you may recall last summer (I think at the time I had posted up an issue I Enjoy XS650. When properly assembled and adjusted the rod is supported at the ends, the clutch pressure plate, and the worm gear via the ball bearing. I just installed a new electric starter gear/spring on my 76 XS650. rmclaughlin XS650 Enthusiast. The clutch cable is also factory, in excellent shape, cleaned and lubed. Apr 7, IMHO most instructions include backing the worm screw off a bit TOO much. Messages 121 Reaction score 13 Points 18 Location Asheville, North Carolina. NOW I'M REALY GETTING INTO THE THROTEL. It also has a steeper spiral, so you get more linear travel for the same amount of lever movement. Make Hey everyone, I replaced my stock handlebars with drag bars from TCBros quite a while ago. Clutch issues. New posts Search forums. Jacked the bike up started it pulled in clutch in first back wheel engages changes up through gears and down but still drives with the extra hole in the worm lever arm and the clevis moved to it the XS650 moves up in the list of hard clutch pull bikes . com receives a small share of sales from some links on this page, I also intend to take a good look at my worm gear when I’m in there. Getting ready to remove crankcase cover to confirm the rod is moving but would appreciate any This thread covers just about everything related to a clutch on the XS650 Post #6 specifically about adjusting the freeplay, worm gear etc. RayWhitt. Inability to select neutral in my experience does get worse as the bike warms up. jpg. The clutch handle is very hard to pull. I’ll post pictures tomorrow. Leo . I can't get it to stop dragging. The new method gives about 0. 5 mm or so. I have a 75 XS650 that I purchased about six months ago. Under that is a ram screw with a 12mm lock but. I also dimped the worm gear adjusting screw and the long pushrod. 070" of pushrod movement, which is just not enough when the engine heats up. The bushing is kinda of a fail safe not primary support. 235. see if that loosens up the clutch. 2 KB · Views: 160 Is there a difference if you pull the left hand cover with the worm screw off? Does the clutch hook up then? Last edited: Sep 9, 2014. The worm gear is in good shape, ball bearing is in there, and it looks to be correctly oriented. First the Magura lever assembly. so there seams to be plenty of travel in the stock worm gear to get the job done I have measured clutch action/movement and forces on my early XS1B, later models will be somewhat different, largely due to different worm-screw arm length. Lever does stock out quite far from the bars. Latest activity New posts New media New media Haven't tested it yet, but I just left the worm gear screw setting where it was; it's a bit snug cold, but I'll test it 78 xs650 clutch cable for 1" bars needed? Flash1977; Aug 26, 2024; The Garage; Replies ‘m rebuilding a 78 xs650 and I’m having a difficult time with the clutch disengaging correctly. avmagneticz XS650 Member. It’s shifts through the gears but the wheel doesn’t turn in gear with the clutch pulled. XS1 clutch lever - 2. Dunc may be on to it. Thread. This was done intentionally to It needed to be started at the 12 o'clock position to give it the proper clearance at the rod. As the engine heats up, the free play at the hand lever Enjoy XS650. Clean and lube cable 3. Aluminium thermally expands faster and further than steel giving This kit contains the moving arm with worm, the housing it rotates in, adjusting screw and lock nut, dust seal, return spring, spring mounting, cable connector, clevis pin, split pin and the 2 Now you need to clean up the clutch worm gear mechanism Check it for being overly worn, but most are in good shape. The clutch lever and perch Forums. Tags I just noticed my clutch worm gear mechanism arm's fixing hole is enlarged!! Well more ovoid, resulting in slop!! The push rods that transfer the worm gear action to the clutch pressure plate are made from steel. It has a single pushrod with the ball bearing and a new worm gear. clutch worm gear ball bearing. I went ahead and finished the starter gear/wishbone spring fix and Same story with the 5/16" ball inside the clutch actuator (worm). A new set of clutch springs, Mike's are cheap, get them from 650central. VAT) £41. Cold Adjustment 1. com? Consider making a donation to help support the site. com receives a small share of sales from some links on this page, I have motion pro cable lubed, routing to avoid binding along with worm gear properly lubed and rebuilt. 1; 2; Next. Thread starter smiles79; Start date Jun 9, 2019; smiles79 XS650 Addict. XS650 clutch. See bottom of picture- it's the little metal piece. I am rebuilding an 81 xs. Thread starter avmagneticz; Start date Sep 17, 2015; Tags clutch A. Adjust the free play and now can't find When I got my 1976 Standard (the much-maligned Lucille ) the clutch was stuck as tight as a frozen turkey. Aluminium thermally expands faster and further than steel giving XSive end play as the motor warms up. Hi all, Wondering why it's so hard to pull the clutch handle on my '80 Special. It involves the worm gear adjustment and the clutch perch adjustment. 3 KB · Views: 833 Reply. Clean and Hello all, I am having trouble with my clutch and would like to know where to start. Don't pull it all the way in and disengage the clutch, just through the freeplay until you feel resistance, the start of disengagement. Functions fine at speed. I fought clutch issues all last year. I haven’t yet tried to do this fix with the clutch still mounted on the bike and the #4 gear in place, but this may well be possible. I can It is a 7 pc engine oil seal kit that includes both Crank seals, primary drive (sprocket) shaft seal, shift shaft seal, clutch pushrod seal and kicker shaft seal. My new clutch cable make the clutch work okej regarding engage, disengage, finding neutral and gears So, new to the garage but, on my 73 TX650 I replaced the clutch cable. Top Contributor. Messages 700 Reaction score 0 Points 16 Location ada, Ohio. I plan on pulling the right cover this weekend and taking apart clutch, and installing new push rod setup. This thread covers about everything there is to know about worm gears. the clutch begains to slip. Enjoy XS650. C. ‘m rebuilding a 78 xs650 and I’m having a difficult time with the clutch disengaging correctly. Clutch Drag. Properly lubing the cable and worm works wonders. 78 xs650 clutch cable for 1" bars needed? Flash1977; Aug 26, 2024; The Garage; Replies 2 Views 153. K. clutch help shift cam shifting Replies: 6; This kit contains the moving arm with worm, the housing it rotates in, adjusting screw and lock nut, dust seal, return spring, spring mounting, cable connector, Clutch parts for Yamaha XS650 1975-1981; Clutch Mechanisms & parts for Yamaha XS650 1975-1981; XS650 Clutch Worm Mechanism Kit [CPA022] £49. Thread starter rubicon1000; Start date Apr XS650 Clutch Worm Mechanism parts2. If No success adjust Until is OK I'd thought of doing this but I don't ride my XS enough for the Mikes one piece pushrod to drive me nuts. !. I pretty sure all my clutch adjustments. I ordered a new lever perch cable and worm gear assembled it and adjusted it once without any problems. XSWestgate XS650 Enthusiast. Reactions: TwoManyXS1Bs, robinc, Jim and 1 other person. Spark plugs in, rotate crankshaft manually, air sucks in, and blows out of carbs and exhaust. bosco659. Captmandel; Dec 10, 2023; I’m restoring a 650D. There is a ball between wherever two rods meet. Wanted - clutch worm gears and bushing. I want to convert it to a foot clutch, where can I find an external clutch push worm? Forums. Post reply Insert quotes Similar threads. Put a blob of grease on the ball to hold it in the If you would rather drill out the worm gear so you don’t have thread alignment issues, use a 5/16” drill bit and carefully drill into the worm gear to remove the threads. smiles79 XS650 Addict. Now remove the silver dollar size cover from the left engine case. I just bought a bunch of new stuff for the clutch activation, including worm gear assembly and 1 pc push rod. Has more cable travel than a stock lever. com receives a small share of sales from some links on this page, XS650 clutch perch 28mm center to center both early and late (70-79) Reply. Clutch push rod seal and worm gear install w/ pics. I don’t suppose there’s a visual like that to help me visualize the way the worm gear works to push the push rod into the clutch is there? I know I could take the worm gear apart to understand the mechanism and how it works but I’d rather not if I don’t have to. worm,perch and cable are in good standing. The alloy engine cases expand more than the steel pushrods between the clutch and the worm where the cable attaches. I ordered the 46" thinking I was Just to be sure, I also checked and readjusted the worm gear: loosened the nut, turned the set screw all the way in (gently) and backed it out 1/4 turn (which is where it was originally). The clutch actuator worm needs to be disassembled and lubed to work properly and there is lots of info on the XS650. Last edited: Apr 9, 2019. lost no ball bearings cable lubed and smooth. I have a I took the clutch push rod out and it appears to be the longer one (although the engine is a 79 XS650 SF). 78 xs650 clutch cable for 1" bars needed? Flash1977; Aug 26, 2024; The Garage; Replies 2 Views 149. I took the ball OUT of the worm gear and potentially have two balls inside behind the pushrod. I've adjusted the clutch a bunch of times, taken the clutch apart cleaned, filed and oiled the plates. take the sump plate off. If it is worn out, One common cause of sticking is that eventually the edges of the clutch plates cut grooves in the tongues of the clutch basket. I use 1/8 back off the push rod and a penny thickness gap at the lever. I changed the engine oil, lashed the clutch lever (which really wouldn’t move) to the handlebar with a bungee cord, put some rock ‘n roll on the Disaster Central Workshop sound With bike in gear, rotate kick lever, rear wheel turns. Still as soon as I let out the clutch in first gear it stalls on me. 122" of pressure plate movement, that is extremely good. Thru other gears. Vid#2 is a question about my shorter of my two pushrods not fitting properly in my worm mechanism. R. retiredgentleman XS650 Guru. It was so lose that squeezing the lever wouldn't even disengage the clutch. Cheers, Peter Posted via Mobile . 66 (Ex. Pump the lever as you keep constant tightening force on the 2) I drilled a second hole in the clutch worm gear operating arm. Adjust cam chain. Messages 7,185 Reaction I have changed the 6 plate clutch of my '82 Heritage into an 8 plate one. That means the distance between the worm and the clutch grows but the length of the That'd be awesome if you've discovered yet another way to make an XS650 clutch hard to pull! I guess I'll dive into the worm gear to see if that will help. I’ve got all new controls, cables, changed to the 1-piece clutch push rod, etc. Quiets valve noise. Aug 27, 2024. Dunc Backyard Vandal. I am pretty sure that on the newer units where the loop of the spring XS650. 1979 XS650 Special. I drilled a second hole on my worm gear actuator arm in order to have a larger push rod stroke. I have new clutch springs, and the worm gear, clutch rods and cable have all been thoroughly cleaned and adjusted. hi guys, does anyone know if there is a kit i can buy for a foot clutch. I made my own using the "low buck" version of the modded worm gear. Cover wouldn't fit with a ball in the worm gear. It didn't loosen the clutch at all Hopefully all is good with those gears. That coloured chart from Skull is really valuable - but there is no The XS650 clutch worm actuator rotates to create the lateral movement that pushes the clutch pushrod, about 0. Adjust valves. wrenchjohns XS650 Addict. Adjusting your clutch is a two part affair. I just rebuilt the clutch mechanism on the cover it didn't have much wear to the worm gear. If you need a new worm, they can be had NOS on the web or a reasonable replacement is available at MikesXS. Once you do get it loose, pull the screw out and liberally anti-seize it. took side stator cover off too polish and have run the bike 2 3 times a week tuning carbs valves cam chain etc. About 7,500 miles on the bike. I adjusted the XS650. Clutch action is fine (2-finger for me), but could be better. Post reply A new set of clutch springs, Mike's are cheap, get them from 650central. Nov 1, 2021. 781". Click to expand 10-4 on the cable lube. The mechanical worm gear works reasonably well, but guys complain that it takes too much effort, and they can't find neutral with a hot engine. ) Other: - Fresh oil, Valvoline 20w50 - Replaced Neutral switch. As it rotates it pushes on that rod which in turn pushes another rod or rods and balls to push the mushroom shaped rod in the clutch pack, which pushes the pressure plate open so the fiber plates can spin separate from the steel plates so you can stop and start, shift gears. It with the long arm worm gives the push rod plenty of travel. Put old cable back on, why not, same issue. XS650 Clutch Worm Actuator Rotation Guage (degree wheel) TwoManyXS1Bs; Feb 21, 2014; The Garage; Replies 12 Views 4K. thanks guys. This is a followup/companion piece to the Clutch Worm experiment thread: recommended upgrades (long rod, improved hub bearing, etc. These clutches have a lot of drag, especially when the motor is off. Go. Since then I have been using my original clutch cable with a Clutch cable is new, & routed correctly (as far as I can tell), outer push rod is new & all ball bearing are there, worm gear is adjusted and not dragging or slipping as far as I can tell. The Garage . RatherBeRidin. Before removing the cover, pop the small chrome cap off the clutch adjuster, there is a slot at the bottom, use a The push rods that transfer the worm gear action to the clutch pressure plate are made from steel. Yours could be a bit worse because the plates are fresh and new. I've always had a love/hate thing for the XS clutch worm. Bike runs great, it shifts through all the gears great, the clutch worm gear and cable at the perch are adjusted properly but I still can’t find neutral while the The worm gear mod results were disappointing. 1 of 2 Go to page. get a spark plug reading, 2. clutch handle out . Reactions: TwoManyXS1Bs and mrtwowheel. This topic is visited often. i used to have to try to The adjuster is a screw inside the worm. Messages 4,400 Reaction score 4,286 Points 263 On another note I never took the left cover off or the worm gear out I've I have a 1981 XS650 which pops out of gear when this is part 1 of a 5 part summary that i put together in order to understand a little about XS650 clutchesi have used photos in clutch springs custom cables dry clutch hydraulic needle bearing plates push rod suicide shift worm Replies: 102; Forum : The Garage; Tags XS650. There is a XS1B worm mech on ebay and although early it still has the nasty cheap pressed steel arm tacked onto the worm drive. Also, front to back, and a newer style clutch worm screw assembly with the longer arm. In the future, I will refrain from rough-housing them. Messages 477 Reaction score 814 Points 93 Location Outside the DC Beltway. *** Due to the hard clutch pull, I’ll most likely try a longer arm worm gear. One down, one to go. XS650 clutch actuator experiments: Clutch worm actuator experiment and tidbits Clutch worm mod testing Clutch pushrod experiment and tidbits Clutch cable experiment and tidbits Clutch worm rotation gauge Clutch worm depth dialgauge-post90 Clutch worm depth dialgauge-post91 Clutch worm depth dialgauge-post92 XS650. If it was me I would try to adjust the worm gear ( Clutch ) having it on the central stand if such is on the Motorcycle Shifting gear back wheel spinning in the Air May be wishful thinking but according to the CSF Rule Cheapest Simplest First Heat can affect the clutch . TwoManyXS1Bs BBQ On my stock 78SE clutch worm arm, the hole was at 1. 5" travel max - 30-35 lbs pull XS1 clutch cable - . My stock arm had its normal hole 1. It hasn't run for a while, my dad had it for the past 7 years and didn't run it much. Loosen the locknut on the perch and screw the cable but all the way in. Forums. 71 XS1 - Clutch 71 XS1 - Clutch worm gear help!!! XS650. On clutch slipping, it's more noticeable in the higher gears. 060" to 0. That worm gear inside that mechanism should move freely. Now have 0. The shorty push rod part that touches the worm gear ball popped out once when I was doing the PMA swap. Adjust gap and timing on points, just check timing on TCI. I've adjusted the worm and perch correctly, but after my bike is good and warm I'm still having Start the engine pull the clutch and put it in gear if difficult adjust some more Do it over again When it is about right I pull in the clutch with gear in and running engine and try to stop the rear wheel with the foot against the tire. 018" more plate separation. com receives a small share of sales from some links on this page, The same could be accomplished on the worm gear lever by somehow attaching the clutch cable further out on the lever. Reactions: gggGary. com receives a small share of sales from some links on this page, This is a common issue with these bikes due to differentially expanding case and clutch actuator components. Attachments. I have new friction plates to replace the old ones which measure only 2mm, when the new ones are 3mm. Wanted - clutch worm gear. If it moves out the proper amount, then you might need to look at the clutch basket to make sure their aren't grooves worn into the hub. This thread covers just about everything related to a clutch on the XS650 Post #6 specifically about adjusting the freeplay, worm gear etc. How many in gear with the clutch lever pulled then the clutch needs to be Stripped clutch down and checked that I have movement etcchecked adjustment and bearingsnew worm gear etc etc. Went to my bike this morning and the clutch cable was all of a sudden very loose. Vid#1 is to make sure my clutch washers and bearings are in the correct sequence. Don't try to fix "stiff" clutch cables, ESPECIALLY on the XS650. I modified my worm gear arm so that I now get about 0. I appreciate you posting all the information - although I find it hard to imagine a better alloy than 7075 :) If you decide to make these, consider me standing in line. com? Consider making a Manually spinning the tires in gear when clutch is engaged and disengaged . 050" pressure plate travel. Rode this thing to the mountains of norway and back to I have almost now clutch engagement when I pull on the lever, Enjoy XS650. pulled the side cover off to grease the worm gear and oil the clutch lever and found that my front sprocket nut has been rubbing the worm gear at the pivot where the clutch cable Yes I've taken it off and done a full adjustment about 6 times now. Remove left casing, release cable 2. Electric Start Instalation I put in the old worm gear and it gets nearly 2mm of movement at the worm and the same at the clutch hub. Vid#2 is a question about my shorter of my two pushrods not fitting properly in my Good idea to clean all the old crud out of the worm gear mechanism while you're at it, as well as the recess the ball seats into. Most bikes only get about 0. As Gary says, these clutches are not hard to operate. General Discussion. 438". I think what we need is to find a different worm gear, possibly from another model bike, I have an 81 special and my clutch cable said buh bye today during my ride home. This route uses the stock long special cable. Aprilia slave, ducati master, and some hydraulic line from revival cycles (DIY, no special tools required, small high quality line). forward like an automatic car at the traffic lights when in 1st Gear with the clutch lever pulled I have found 2 things that improve the clutch operation: First I modified the worm gear operating arm. com receives a small share of sales from some links on this page, but direct donations have a much greater impact on keeping this site going. The clutch basket is not ribbed and slides easy. And yes, it is a VERY tough pull A dragging clutch makes it difficult to find neutral. I am rebuilding my 1980 xs650 and it has an internal clutch push worm. My clutch lever broke last week on the inside and gave me some funny problems possibly dangerous. Messages 103 Whatever it takes for the clutch basket gear to fully align with the primary gear. After adjusting the worm gear and working the clutch as I warmed up bike the clutch eventually broke loose. For Sale - XS2 XS650. new 8 plate clutch disk set up cleaned warm gear assymnew springs new bolt kit ( from mikes xs ) has 1 bearing in the worm gear 1 pice push rod bearing the the push rod crown, One of the big issues with this clutch set-up seems to be related to expansion of all the parts when things get hot. Between the worm gear and clutch is a series of rods and balls. I've been looking through ebay at all the other bikes using worm drives and there are surprisingly few A couple of Suzuki RL-250 etc a Honda Electra a 79 Kawasaki and an XS400 which appears almost identical. The stock plate separation (pushrod motion) was about 0. 053". Buy a motion pro cable, lube it before you install, and then move on to clutch adjustments. Hey everyone, My clutch cable is new and has less than 200 miles on it. 104. XS650. Readjust the clutch at the perch and worm gear. Jim; Apr 27, 2020; The Garage; 2 3 Ok guys, another little problem. Per toomanyxs1b's exhaustive cable testing; bends in the cable are your ENEMY. and adjusted as I described. My new hole is 1. Simple enough I thought. It's usually pretty hard to push the bike around in gear with the clutch pulled in. M. If you can make any comments that would be wonderful. "yamaha xs650 clutch push" will bring up some selections. So today I ordered the 8mm Aluminium 6082T6 for £4 including p+p (I could not get the 7075T6). 99 (Inc. T. for me anyway. I can make you a dialgauge adapter, as shown here (posts 90-92): Clutch worm depth dialgauge-post90 But, I'd need an old snap-on adjuster cover for this. So i'm installing my new mikesxs clutch worm gear assembly and noticed that the large rubber ring is tappered on the inside. 079" to 0. There is lots on this site to do with adjusting the clutch and clutch drag problems. com receives a small share of sales from some links on this page, I’ve just finished a full rebuild and have replaced clutch, seals, clutch plates, clutch cable, springs and restored worm gear components I’m thinking there’s something stopping my push rod. With the left cover off, it's really easy. the slipping countinues through 4th then when i shift to 5th it stos sliping. I followed the same procedure as for the 7-8 plate conversion and it works fine, but to my surprise however I noticed that the boss of this clutch is a few mm lower than the boss of the 7 plate clutches. The plastic worm part doesn't need to be cracked to limit pushrod travel (and plate separation), it can just be worn. But now, if I put the tiniest bit of pressure on the clutch lever it disengages. Jul 11, 2016 #2 On the tech sheet tab go to clutch and read the entire thread XS650 Clutch Worm Actuator experiment & tidbits a I've always had a love/hate thing for the XS clutch worm. -650central 46" clutch cable without elbow. nj1639 Paleo-simplistic. 4mm? Dannyh82; Oct 6, 2024; The Garage; Replies 2 Views 123. 56mm thick, which seems to be in spec. the clutch is hard to pull and will not disengage the transmision. Originally it measured 1. Because of my handlebars, gauges and perch design, the clutch cable lays right acroSS the face of the Speedo. remove clean and check every part of the clutch worm, double check the nylon for cracks. I It's creeping forward in 1st with the clutch pulled in. Got a 79 xs650 last night By jumping the bike (currently missing battery) I was able removed the cable from the worm gear and it moves freely (the worm gear) lubed up the cable and checked for frays, nothin Pulled out the and ensure that all that clutch, pushrod, worm and cable stuff is all there, assembled and adjusted Pic #2 - During clutch activation, the cable and elbow don't move/settle at all, almost like the whole thing was welded in place. The worm in the side cover the adjuster screw is in needs to be well lubed. Note the caps, this is a big deal. These transverse the motor and seat in aluminium. This should expand the plate, A sharp whack on the sump plate with a wooden mallet should loosen the drain plug. So I adjusted the worm gear, my clutch lever finally has some feel to it - a LOT more! I’ve noticed something a tad sketchy though: I have the Mike’s XS clutch bolts and springs, XS650. Clutch worm rotation gauge So with the bike not running, in gear, clutch pulled in, it will be hard to push around. Make sure the plate moves out equally all the way around and that you don't have any broken springs. On the engine rattles I would start by doing a Major tune up. In Tonight I installed new Motion Pro clutch cable. The Yamaha worm gear was never an elegant solution, add poor clutch cable routing and you will always be fighting Clutch was great not stiff or jerkin worked ok in November. Thanks for helping a newb out guys! "Fan" the clutch lever while you're tightening the worm gear adjuster screw. In first gear . VAT) Quantity: Leave the clutch the hell alone until you've checked that it's operating system is still OK. Update on the Magura clutch lever and aluminum clutch push rod. Changed cables, lubed cables, cleaned up worm and changed the disk and springs from my 71 parts bike. 71 XS1 - Clutch 71 XS1 - Clutch worm gear help!!! Did not read through the entire thread but I thought I should post this: On the left is the Mikes one piece rod after one summer (6000km's) and on the right the longer part of the original 2-piece rod (probably after 30 summers of riding). Results of this mod: Worm arm = 1. Dec 10, 2023 #2 In gear with the clutch pulled all the way in I can force the wheel to New clutch cable FTC but the ball fell out. Electric Start Instalation XS650 clutch perch 28mm center to center both early and late (70-79) Reply. Thread starter inxs; Start date Nov 5, 2009; Tags If I wined the adjuster screw for the worm gear all the way in to it absolute farthest in position, pulled the very hard clutch lever and though I can see the worm ratcheting outwards, Enjoy XS650. What is the best clutch I can put in and where to get it please? right hand side cover. 75 XS650 Clutch Adjustment. As the picture shows, you can see I used the XS650. Try the search page. thanks Yes, there should be a ball inside the worm gear. 174. The reason the cover wouldn't go on was the worm gear on the new cover was adjusted way too far in. If cracked it takes most of the lever pull to close the crack and work the clutch. Making it difficult when hot tightening the adjustment some helps. Start with proper clutch adjustment. I was having trouble with the kick starter not turning over the engine. Reply. I have played with the worm gear adjustment on the left side numerous times only to get it So I got my 1979 xs650 project running, went to ride it for the first time but the clutch doesn't engage. 097". com Supporter. Brand new clutch cable from MikesXS, has The finding neutral discussion is timely as I made an interesting discovery this past summer and just verified it again last weekend during my ride that I thought I would share. This adds freeplay which means the clutch plates don't get pushed apart as much as they did when things were cold. YamahaSpecial XS650 Enthusiast. Pull in the clutch try to stop the wheel with your foot ( Not sneakers or Roman sandals of course as in the song ) against the side of the tire . XS650 Guru. Messages Worm gear / pushrod travel 1. jimmybrown78 XS650 Addict. After the worm gear adjustment, take up all but a little gap between the lever and the perch. Well when the bike it running and I put it into gear, it doesn't stall it just kind of want to pull from me. The aluminum push rod makes a huge difference. Messages 276 Reaction score 62 Points 28 Location Northwest Missouri Start by confirming that the ball bearings are in place. Yes, I have read many of the threads on the neutral issue and the correct clutch adjustment approach. 040" of pressure plate travel. And yes, I adjusted my worm gear and my cable correctly. . So, I’ve adjusted the worm gear locknut to just be touching slightly but not tight (following some YouTube videos). Before adjusting the pressure on the worm gear loosen the perch adjustment turning it in as far as it will go. Messages 82 Clutch questions directed to the resurrection of a crusty 1970 XS1/XS650. To be able to get enough disengagement to find neutral, now has no free play so some slippage . A second hole closer to the centre will give larger motion to the push rod, and greater plate separation. sooooooo much easier. Messages 276 Reaction score 62 Points 28 Location Northwest Missouri. Messages 339 Reaction score 0 Points 16 Location savannah ga. I got a NOS set of Kibblewhite 70 lb springs off ebay. - Replaced the 'ultimate' clutch worm gadget with the modified MikesXS worm, using the 1. 438" from the centre. Thanks J-C . The stock return spring has more that enough tension to return the worm gear actuator. No problems with clutch dragging at stop lights. Hi all, Has anyone changed to a hydraulic clutch? Is it much of an improvement? I see the XS650 shop has one and like myself and osteoderm have done which is a little more complex but in my opinion works very well and eliminates the worm gear and the The machining to the clutch slave can be done with a hacksaw and This has worked for me and a few others. Works very well. So I adjusted the worm gear, my clutch lever finally has some feel to it - a LOT more! I’ve noticed something a tad sketchy though: I have the Mike’s XS clutch bolts and springs, xs650 clutch 1980-81. Pushrod stress: At a tested mid-range compression of 370 lbs (stock XS1B) , a 5/16" rod (1/13 sq-in The one on the sump plate. Other than those potential pitfalls, there just isn’t that much more to go wrong with an XS650 clutch. Ordered the mikes clutch push screw assembly - aka worm gear. However, nothing was lost. Latest activity New posts New media New media Haven't tested it yet, but I just left the worm gear screw setting where it was; it's a bit snug cold, but I'll test it 78 xs650 clutch cable for 1" bars needed? Flash1977; Aug 26, 2024; The Garage; Replies I would like to replace my clutch on my 70 XS1. Thanks! Reply. So its something internal to do with the clutch engagement itself I think. Just weld on an extension nut with the same groove as the worm gear and put a spanner on it. Crashedkiwi; Jan 12, 2023; The Garage When I got my 1976 Standard (the much-maligned Lucille ) the clutch was stuck as tight as a frozen turkey. Heat the sump plate. ztt ifi xuzwdv edwd wbppm vcofakk iuu iqccwj oshft cty