Tach Drive Worm Gear

Oh crap... upon removing my tachometer drive attached to the engine head to inspect the seals, I accidently yanked what I think is the tach drive worm gear? Its a twisted gear thing on a short rod that connects to the tach cable. How do I put this back in?? Please, Help:(

Thanks

If it is the same as the 650, all you need to do is push it back in. The wormgear will turn on the cam as it goes back in.

I tried pushing it back in and I didn't want to push too hard, not knowjing what problems I would cause. Is there any turning involved or just a solid push. Can I break anything if pushed to hard.

What is it fitting into? The cam chain?

The tach drive holder just pushes in and out, and the worm gear rides in the seal. Just make sure you clean and lubricate all the parts well so that the O-ring on the tach drive holder does not get torn when you push it back into place. There are two pinion holder stops retained with an allen bolt to retain the holder in place, and prevent it from turning. The assembly is shown in the Kawasaki drawings in the cam cover section.

I have seen the diagram and it doesn't answer my question. The tach gear, 10 tooth, indicated as part 41060 on the diagram came out along with the unit. I just push that back in? With it greased of course.

I understand the assmbly and how everything is supposed to be attached, I just can't see inside the cylinder to the matching gear. Does it just take a little wiggling?

Thanks all

Hi Folks,

I'm having the same issue/concerns. I pulled the tach housing out to replace the seal and got the gear with it. I'm trying to get the gear back in there but it kind-of goes in and then sits down loosely (if that makes any sense). When I took it out it felt like it was definitely threaded in something, as it would come out a bit and then re-seat if I let go... it doesnt feel like that now. I cant find a diagram of what its going into and am worried I'm not going to get it seated right and jam something up when I start the bike next time. Do I need to set the timing at TDC? Any tips/tricks?

Did I hert my motocicle? :blush:

You just have to wiggle and twist it until the tach drive gear meshes back up with the cam gear.

Then it will all slide into place.

Alright, thanks.

Once I re-assembled everything it seemed to seat nicely when I muscled with it for a minute. Hopefully its seated properly, but it sounds like as long as it goes all the way in it pretty much has to be in right. We'll see if it explodes or not when I fire it up...

Improper insertion of the tach drive worm gear can cause massive damage to the valve train and possibly explosion!

:laugh: NOT! :laugh: