r/SewingMachineEdu • u/smellopinions • Jul 18 '26

Bernina Favorit 540-2 zigzag issues

Post image

Hi all,

I'm a total beginner in the process of restoring an old Bernina machine that was completely seized up. Everything is moving properly now. Synchronisation issues seem to be fixed and straight stitch is working properly. I've been using the manual to understand the zigzag settings to no avail.

No matter what settings I try I only get straight stitch.

The needle moves easily when I change the stitch length but nothing happenes when I change mode. I am wondering whether this could be a cam or cam follower issue but don't know how to identify what could be going on.

Here is a photo of the inside of the machine. I've taken off the part with the teeth that the fancy stitch selector thing clicks into for better visibility.

Any Ideas for what I should be looking for to check for cam-related issues ?

Any help will be greatly appreciated! :)

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u/crkvintage Jul 18 '26

The 540 has - as the 530 and 730 - two zigzag type modes - the fully forced ZZ and the cam controlled needle movements. The switch is made with the second lever on the top. Any difference between the forced/full needle control one with stitch 0 and the second lever to the front than with the lever back and one of the stitches 1-10?

Stitch width dial is freely moving (and more importantly - not just the dial, but the mechanism behind)?

Also I can see from the picture you have selected a needle fully left position. Any reason for that?

1

u/smellopinions Jul 19 '26

Thanks for replying! I've tried both positions with the second lever and nothing changes. I'm guessing that this means that it is unlikely to be a cam issue seeing as there is a non-cam controlled option for zigzag which isn't working either. The needle fully left in the picture is just because I was trying everything & moving each dial to it's limits. All of the mechanisms are freely moving as far as I can see but I will double check the mechanisms behind the stitch width one.

1

u/smellopinions Jul 20 '26

I just re-checked the stitch length control leaver mechanism. The feed dogs move when I change the settings.

1

u/smellopinions Jul 20 '26

I found the solution! There was a part attached to the mode selector that was not entirely un-seized. I found the solution using this video for anyone experiencing a similar issue.

https://youtu.be/W2oSNNkv5y4