550 clutch push rod ball size

Yeah mate its clear.
Cheak my previous post with my 65mm measurement

So now it seems it's back to the clutch actuator. I have several covers with actuators I can measure etc. So we should be able to get to the bottom of this... I hope .

Here is a blow up of the parts I expect you should have.

loudhvx wrote: So now it seems it's back to the clutch actuator. I have several covers with actuators I can measure etc. So we should be able to get to the bottom of this... I hope .

Thanks for confirming i havnt stuffed that side up Lou, I'm pretty happy I don't have to rip the basket back off.

Now with the ball fitted there's no way the sprocket cover will go on lol. I think the h1 cover positions the adjuster 9-10mm closer to the case / pushrod

Edit just reading through your post

I'll be here for a few hours, so I can check in periodically. We know the motor cases are the same Kz550D1 cases, so all we have to do is measure offsets from the sprocket cover mounting surfaces to the actuator core well. We might use a straight edge to bridge across from mounting points, then measure the depth from the straight edge to the bottom of the well (where the adjuster screw would be located).

Lou you bloody legend.
I just grabbed the actuator arm to measure it . yes spot on . then noticed mine didnt quite look the same as the photo.
I found the missing ball .
Stupid previous owner has jammed it into the actuator. I've never seen one before and thought it was ment to look like that. Will post a pic when I can. The other actuator I tried has had the same thing done to it. Wot the hell?

Now I need to get a 9.5mm ball out of a hole made for 8mm rod . thinking of drilling a very small hole from the other side and punching it out?

Nice one. Will have to put that one down in the books under "things you may never ever consider that someone might do".

I dont know exactly how the bell crank is constructed. I think I might try to sacrifice a super sharp center punch to get the ball out first. It cant have gone in all the way, could it?

Also, if you do get it out, can you confirm the ball is exactly 3/8". I've always wondered if it might be metric and a little off from 3/8.

Never under estimate a determined man! Its below the surface. So I'm guessing he got it all the way in

Without using micrometers the new ball I bought from partzilla measured 9.52mm on my vernier's . if I don't mangle the original I'll give that a measure to.

I am so glad the A Model doesn't use this clutch actuator set up.

CoreyClough wrote: I am so glad the A Model doesn't use this clutch actuator set up.

I am glad for you too, Corey.

loudhvx wrote:

CoreyClough wrote: I am so glad the A Model doesn't use this clutch actuator set up.

I am glad for you too, Corey.

me too

After cleaning out the grease the ball came loose but refused to come out, even with a large magnet. so i stacked some weld tacks and removed them with some pliers.
they measured the same as my new one..

glad thats sorted

Wow. I wonder how that thought press went? Maybe like ....

Hmmm. I have this little ball left over, I wonder where it goes?
The book says at the end of the pushrod. I really don't want to take the clutch apart again.
Surely it doesn't really matter which end of the rod the ball touches.
Hmm. Here is a nice round hole. Looks like the right size.
Ahhh, nice and tight, only needed my small hammer.
Crap! The cover has shrunk. Cheap Jap crap!
If I put a 1/2 inch bead of sillycone over the gasket, nobody will know.
Why the *#€¥! Won't the bolts thread in?
Aha! I have an assortment of wood screws that should work.
Only broke off three. There are enough to do the job without them.
Dang, there is a leak.
Another tube of sillycone around the outside should fix it.
Stupid bike shifts like crap!
Cheap Jap crap.
I'll put it on CL for $6,500. That is cheap for a custom hard tail chopper.
With the profits I can buy a real motorcycle.
Hmm, I see a 1961 Hardly Ableson for only $2,000. All it needs is a carb ajustment to run like new.
I am brilliant.