Results 1 to 10 of 10

Thread: ST1100 - Clutch Handle Assembly rebuild with pics

  1. #1
    smunderdog's Avatar
    Bike
    1996 ST1100
    Join Date
    Aug 2008
    Location
    IN, Indianapolis
    Posts
    475
    My Gallery

    ST1100 - Clutch Handle Assembly rebuild with pics

    Let this bit of maintenance go a little too long so I thought I'd share what things look like when you rebuild the rod/bushing/boot components in the ST1100 clutch lever assembly.

    I had noticed that the point in the lever pull at which the clutch was activating had slowly been changing and then recently it got to the point where clutch activation didn't occur until the very last bit of travel before the lever was pulled all the way to the grip. Yikes! And then when I would release it the clutch handle wouldn't spring all the way back open...

    So I pulled up the collective wisdom here on the forum by searching "1100 clutch lever" and found this thread that sounded pretty much like what was happening to me.

    Before I even opened up the assembly off to Partzilla I went and ordered the handle, bushing, rod & boot.

    22884-MB0-006 ROD, PUSH $12.46
    22885-MB0-006 BUSH $7.82
    45504-410-003 BOOT $7.34
    53178-KE8-006 LEVER, L. HANDLE $13.55

    Total including $7.95 shipping was $49.12

    So let's take a peek at what I was dealing with. Inspection before I took it apart showed me this...see anything that doesn't match your handle? Is the rod supposed to be visible?



    The rod had worn all the way through not only the bushing...but also the handle itself! Double Yikes!

    Comparison shot of the handles:





    Comparison shot of the bushings:





    Comparison shot of the rods. The rubber "washer" on the old rod is actually a piece of the boot that had disintegrated inside the assembly:



    It is a simple assembly to inspect and repair if needed...takes 10 minutes and a flat head screwdriver. Very easy "first thing" to check if you think the feel of your clutch pull is changing.


    26 States & Counting!
    STOC #8309
    IBA #45735

  2. The Following User Likes This Post:


  3. #2
    lomita's Avatar
    Bike
    2001 ST1100
    Join Date
    Sep 2013
    Location
    southern california by the sea
    Posts
    73
    My Gallery

    Re: ST1100 - Clutch Handle Assembly rebuild w pics

    Thanks for the great write up with pics. I just finished my rebuild overhaul of the assembly couple weeks ago and with your listing of parts can now replace the bushing, that is, as soon as it arrives. My current bushing was beginning to wear on one side.

    Thanks again.

  4. #3
    lomita's Avatar
    Bike
    2001 ST1100
    Join Date
    Sep 2013
    Location
    southern california by the sea
    Posts
    73
    My Gallery

    Re: ST1100 - Clutch Handle Assembly rebuild w pics

    Got my new bushing today and installed it tonite. Thanks again for the part number. Smooth as silk now and nice warm feeling equipment is just like new again.

  5. #4
    (Threadstarter)
    smunderdog's Avatar
    Bike
    1996 ST1100
    Join Date
    Aug 2008
    Location
    IN, Indianapolis
    Posts
    475
    My Gallery

    Re: ST1100 - Clutch Handle Assembly rebuild w pics

    Glad the part list and photos were helpful.

    The bushing (and maybe the rubber boot) definitely appear to be the parts that wear the most. Had I taken mine apart before I ordered parts I probably wouldn't have replaced the rod...and had I addressed things much earlier I'm guessing I wouldn't have needed to replace the handle either.

  6. #5
    STRIDER ESB's Avatar
    Bike
    '07 ST 1300
    Join Date
    Aug 2008
    Location
    Oklahoma
    Posts
    227
    2017 Miles
    012000

    My Gallery

    Re: ST1100 - Clutch Handle Assembly rebuild w pics

    Nice Pics & Repair proceds. Good article. How many miles ??
    YEA - That pushrod will wear right thru the lever if NOT caught in time !!
    I let it go, the first time, ALMOST as far as yours, & had to make a spacer to shove in that pocket just to get home.
    My clutch wouldn't disengage, if the bushing wore thru ! After that, I ordered about 2 at a time, to keep in stock.
    Never needed a new Lever.
    STU Bernard - '91 SSMST (250K Mi.) & '07 ST13 (141 K Mi.) -- S.B. --

  7. #6
    Gotta make tracks Mark's Avatar
    Bike
    '04 ST1300, BLUE
    Join Date
    Jan 2005
    Location
    Tempe AZ
    Age
    64
    Posts
    14,733
    2017 Miles
    000088

    My Gallery

    Re: ST1100 - Clutch Handle Assembly rebuild w pics

    Nicely done.
    (well except for the waiting too long bit! )

    Thanks!
    Mark

    If you love your bike, let it go.
    If it comes back, you high sided.....

  8. #7
    Old Glory's Avatar
    Bike
    ST1300
    Join Date
    May 2007
    Location
    Huntsville, Alabama
    Posts
    619
    Tip Overs
    3
    My SPOT
    My Gallery

    Re: ST1100 - Clutch Handle Assembly rebuild w pics

    Wow, your post came at a great time for me. I noticed the same issue the last time I went for a ride. Ordered the parts. Thanks for the post.

    John-

  9. #8
    Old Glory's Avatar
    Bike
    ST1300
    Join Date
    May 2007
    Location
    Huntsville, Alabama
    Posts
    619
    Tip Overs
    3
    My SPOT
    My Gallery

    Re: ST1100 - Clutch Handle Assembly rebuild w pics

    Oops - anyone know how much different the ST100 assembly is from the 1300?

    The parts catalog gives a different part number for just a lever. Anyone need a
    ST100 left lever?

    John-
    Last edited by Old Glory; 11-05-2016 at 11:43 AM.

  10. #9

    Re: ST1100 - Clutch Handle Assembly rebuild with pics

    Thanks for this. Just checked mine and the bushing looks just like yours,"boot" and all.
    Lever is fine so ordered the bushing and a new boot.
    Cheers
    Ian

  11. #10
    ST-Cat77's Avatar
    Bike
    97 ST1100
    Join Date
    May 2017
    Location
    Fort Washington MD
    Age
    53
    Posts
    32
    My Gallery

    Re: ST1100 - Clutch Handle Assembly rebuild with pics

    Excellent write up..I'll take a look at mine, as well. This looks like something simple enough for me. Tnx!

+ New Posts

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •