Anybody else have their clutch "push lever assembly" break on them? - Star Motorcycle Forums: Star Raider, V-Max, V-Star, Road-Star Forum
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post #1 of 11 (permalink) Old 05-04-2016, 09:12 PM Thread Starter
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Anybody else have their clutch "push lever assembly" break on them?

Hey all,
On my way home from work today I went to down shift, pulled the lever and felt a "pop"...then it was obvious I no longer was able to engage the clutch.
I coasted to the curb and killed the engine. Put it in neutral and pushed it down to a parking lot. I thought I snapped my clutch cable, and since I have a cable repair kit in my bag, I started removing covers to access the clutch push lever assembly.

Surprisingly, what I found was this.

Anyone else have your push lever assembly break on you?
Bike only has a little over 20K miles on it.
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post #2 of 11 (permalink) Old 05-04-2016, 10:00 PM
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yes, way back in the days of my 82 virago 750. had to slam shift that sucker home. shifting like that still sounded better than the starter 'clutch'
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post #3 of 11 (permalink) Old 05-04-2016, 10:17 PM
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post #4 of 11 (permalink) Old 05-05-2016, 05:47 PM
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Quote:
Originally Posted by Cvett67 View Post
Hey all,
On my way home from work today I went to down shift, pulled the lever and felt a "pop"...then it was obvious I no longer was able to engage the clutch.
I coasted to the curb and killed the engine. Put it in neutral and pushed it down to a parking lot. I thought I snapped my clutch cable, and since I have a cable repair kit in my bag, I started removing covers to access the clutch push lever assembly.

Surprisingly, what I found was this.

Anyone else have your push lever assembly break on you?
Bike only has a little over 20K miles on it.
did you buy the bike used if so the previous owner might have installed heavier clutch springs that stressed the lever.
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post #5 of 11 (permalink) Old 05-05-2016, 09:41 PM
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Originally Posted by bevo1981 View Post
I replaced it. never had an issue after that
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post #6 of 11 (permalink) Old 05-06-2016, 04:40 AM Thread Starter
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Originally Posted by pauli466 View Post
did you buy the bike used if so the previous owner might have installed heavier clutch springs that stressed the lever.
Yes, I'm the 3rd owner. I bought it from a friend of mine whom had owned it since 2006. I know he didn't change anything in the clutch, and the bike had only 2200 mile on it when he bought it. He says as far as he knows, it was bone stock when he got it.


All I can guess is there were defects in the stamped piece. After removing it, other than the break, you don't see any issues with it. On the back side is another story. You can see several stress/ fatigue cracks in the metal.

I was going to suggest that other owners inspect theirs for cracks, as to possibly avoid getting stranded by a $15 part. Maybe mine was a isolated case, who knows. Obviously it's not currently a common issue, which is a good thing.

I've already ordered a new one, but I think I'll order a second one to keep as a back up.....just in case.
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post #7 of 11 (permalink) Old 05-06-2016, 09:45 AM
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Yup pretty isolated. I've never seen it one single time in the 10+ years I've been around the 1100's...even with bikes approaching 200,000 miles.
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post #8 of 11 (permalink) Old 05-06-2016, 12:03 PM
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Originally Posted by Sick Mick View Post
Yup pretty isolated. I've never seen it one single time in the 10+ years I've been around the 1100's...even with bikes approaching 200,000 miles.
slick, what's the highest milage 650 you'v seen to date, the highest i'v ever found online was a 94,000 mile engine on ebay. the highest i'v seen at rallies and such were in the high 70s i was trying to find out how long the rings last in the 650 i bet the rest of the engine could make 200,000 easy, but i'm not sure on the rings because no coatings are used on the bore of a 650.
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post #9 of 11 (permalink) Old 05-06-2016, 09:53 PM
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Originally Posted by pauli466 View Post
but i'm not sure on the rings because no coatings are used on the bore of a 650.
I believe the cylinders are ceramic coated.

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post #10 of 11 (permalink) Old 05-06-2016, 11:08 PM Thread Starter
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I fabricated a new lever out of a piece of scrap 1" X 1/8th" stainless flat stock today at work. It actually works great, but the button head screw I had to use to attach the piece for the cable to hook into, hits the cover. If not for that, I'd probably just leave it on and be done with it.
So for now I'm just leaving the push lever cover off so I can ride until the new one comes in.



Where there is a will..there's a way.
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Last edited by Cvett67; 05-07-2016 at 08:03 AM.
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