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Clutch worm gear install

  • Hawksip
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Clutch worm gear install was created by Hawksip

Boy I have a good one for you all.  I bought a worm gear assembly and in the process of installing it it turned out the arm that holds the cable isn't attached to the worm gear.   It appears that it needs to be pressed / peened and expanded.  Either that or maybe a spot weld.  Has anyone else ever had this problem ?

below shows the new and old assembly.
18 Jan 2022 17:22 #1

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Replied by MarkT on topic Clutch worm gear install

That's the way some of them come.  Wouldn't call it a "problem"...  maybe a "challenge"? 

There are a few posts in the forum with methods...  RT325 had some good ones if I remember right. 
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
18 Jan 2022 18:59 #2

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Replied by Hawksip on topic Clutch worm gear install

Thanks, did some searching but with nothing specific to this worm gear assy.  I did however see one that mentioned Tig welding.  I think I will go the Tig route if I can't figure out how to fabricate a mandrel that squeezes it together.  Tig tack is probably the best, just need to make sure it is installed correctly first.  The part was expensive and shipped from England.
19 Jan 2022 02:09 #3

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Replied by MarkT on topic Clutch worm gear install

I just searched "clutch peen" and the thread below was the second result.  Shows exactly how Schu did his. 

I can't recall anyone mentioning welding...  I would not want to risk heat ruining the plastic or rubber but it's your part...  there are other threads on this topic here but not sure you'll find anything better or more specific than the one below. 

yamaha-enduros.com/index.php/forums/mini...emble-from-arm#75916
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
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19 Jan 2022 04:42 #4

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Replied by Hawksip on topic Clutch worm gear install

Mark, 
it is good to know that the peening is a viable option.  I was concerned that hammering would break the worm.  It appears the metal is soft enough based on the pictures on the thread you provided.   I agree Tig could damage the worm gear as well if not carefully tacked.  I am going to visit my welder and see if he thinks there will be much heat soak with tacking.   If that is too risky it is good to know someone else peened it.  I could make a mandrel on the lathe that could make the peening a cleaner operation if I need to go that route. Thanks for taking the time to find that thread.  It makes me feel much better knowing it isn't unusual.   
22 Jan 2022 04:52 #5

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Replied by MarkT on topic Clutch worm gear install

Peening wasn’t just done by “someone”… it’s the way Yamaha did it.

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Several other models were built that way as well.  It’s a tried and true system.   

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1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
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22 Jan 2022 08:36 #6

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Replied by RT325 on topic Clutch worm gear install

Must be steel in the center of the nylon worm to rest on the vice to then peen the other bit over, so worn won't be directly touched,-i think.
Can you get it in & out when peened up, not like some bigger 125 175 early models where it needs to be assembled & peened in place as can't turn it full circle while in place.
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Last edit: 22 Jan 2022 14:09 by RT325.
22 Jan 2022 14:06 #7

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Replied by Hawksip on topic Clutch worm gear install

So Against factory process and better judgement I decided to try the Tig weld instead of peening.  As it turns out tack welds with the Tig don't generate much heat even though it was immersed in water afterwards just to be safe.    I do see a possible issue difference with how the  ball bearing. I think I will is captured.  I will have to grease it up good so it won't fall out when I install it.  I think the peening method captures the bearing.   Anyway... more than one way to skin a cat.  Thanks to all for your help..
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24 Jan 2022 11:49 #8

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Replied by RT325 on topic Clutch worm gear install

Wish i had a tig. Hope it hangs together. Looks like 4 spots would be better if heat can be avoided 4 times. JT1? by the looks. Had two myself in the "70's for the kids. Have a third one i'd forgotten about my grand son has [& outgrown]. That one's a rolling wreck but still does the job.
24 Jan 2022 13:36 #9

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Replied by Hawksip on topic Clutch worm gear install

We shall see how it holds up.  Could easily add a couple more tacks.   It is a 1972 JT2 it is a fun project. Not perfect but I want a runner for a pit bike.  Great to hear from you. 
24 Jan 2022 13:46 #10

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