Hi,
me again with my clutch adjustment issues. I'm going to order the brass worm gear from KDI. Having looked at the plastic one in the push lever assembly I am not quite sure how to remove it. I don't want to force things and cause damage. Can anyone please shed light on the easiest way to remove the plastic worm gear?
Many thanks in advance.

I’ve got the same problem, I think it’s just a nylon gear pressed on real tight.

.

They're not pressed on . . .they're molded onto an irregular surface.
Sorry, the only way to remove it, is to destroy it.

I've attached a picture showing the inner side of a broken gear . . .


 

.

.

.

Most people don't have a problem removing the original gear because it's already split/broken before they replace it.  If the original gear looks good still, no harm in continuing to use it that I can think of?

Assuming you've turned it out of the housing. Revolve clockwise looking at it from the inside. Then [says me not having done it] you'll need to accurately time where the brass spiral presses on or your adjustment will be 'all up the creek' in relation to where the arm sits at rest.