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Discussion Starter #1
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. :confused:
 

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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. :confused:
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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Discussion Starter #6
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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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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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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Discussion Starter #10 (Edited)
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. :grin:
 

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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. :grin:
Years ago a friend of mine had a similar situation. He broke a metal lever and went to a friend who worked in a machine shop. He presented the broken part and asked his friend, "Can you make one of these?" after looking it over the friend assured him that it was no problem and would have it done by the end of the day. Later that afternoon the guy showed up to get his part. The friend handed him the original part and the new duplicate. Everything was identical, including the break. :smile: After a few minutes savoring the reaction the friend produced a another new unbroken part. :smile: Just thought that I would share that. Augie
 
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