Clutch Shudder and push pin mod.

[Robert May]

Had an issue with clutch shudder when I first got my bike back in June 2008. After putting 1300 miles on it the tube nut backed off so had to repair that. Shudder disappeared for about 8000 miles then would show up every once in a while in stop and go traffic. So fast forward to 20000 miles later and every 2nd light I stop at results in an embarrassing shudder and a Cager up my A$$ blowing the horn while I try to idle away to get rolling.

So I had been reading about the Clutch Push Piece or Pin mod and I decided to pull it out machine it flat on opposing sides and reassemble it and do nothing else. Went for a ride and the shudder has vanished. I road back and forth through town and it never did it again. I have one light that is 2 mins and 15 secs long. This one is the one that gets me every time. No problem. Even went to the park and did several 2 min idles and was able to pull away under power every time.

This is a great mod. The fun is back!!!

[BigpapaM109]

Did you take pics of how much you machined?

[bwl60]

That is great! I am hoping to get mine torn apart this weekend again and do that too. I am also going to check the tube nut, maybe take it off and red loctite it just to make sure. Caught a cold an havn't been able to get to the bike. lol The sucky part is weather has been great! haha. I will post pics of how mine goes too. Thanks for all the info.

[meba109]

Did this mods about 30'000 klms ago THIS IS THE ONLY MOD TO STOP CLUTCH SHUDDER !

[CanadianM109R]

Had an issue with clutch shudder when I first got my bike back in June 2008. After putting 1300 miles on it the tube nut backed off so had to repair that. Shudder disappeared for about 8000 miles then would show up every once in a while in stop and go traffic. So fast forward to 20000 miles later and every 2nd light I stop at results in an embarrassing shudder and a Cager up my A$$ blowing the horn while I try to idle away to get rolling.

So I had been reading about the Clutch Push Piece or Pin mod and I decided to pull it out machine it flat on opposing sides and reassemble it and do nothing else. Went for a ride and the shudder has vanished. I road back and forth through town and it never did it again. I have one light that is 2 mins and 15 secs long. This one is the one that gets me every time. No problem. Even went to the park and did several 2 min idles and was able to pull away under power every time.

This is a great mod. The fun is back!!!

How long ago did you do this mod? Keep us posted. Mine is apart right now at FutuR 's place, so it might be a good time to do this mod!

Any pics or details on what you did?

[Robert May]

Guys I did not take any pics I looked at stepink104's pic in this attachment and then machined a flat on the pushpin on opposing sides.
http://www.m109riders.com/forums/att...4&d=1331238585

I rode 212 miles this weekend did about 60 miles of stop and go up and down the MS Gulf Coast. I got stuck behind a St.Patricks day Parade but never once had any shudder issues. What a nice ride. This mod has made me fall in love with my bike all over again.

[MATT'sADDICTION]

Did this mods about 30'000 klms ago THIS IS THE ONLY MOD TO STOP CLUTCH SHUDDER !

I don't know if that is a completely accurate statement. I can verify that I had clutch shudder very regularly and could certainly do it on demand with just a little extra throttle on take off. I put off changing the wave washer and (the other washer) way too long, cause as soon as I did, NO MORE SHUDDER! I have put a good 1500 miles since the replacement with no apparent shudder returning. I did not file the push pin at that time. If the shudder returns, I will. And I will report how many miles I got on just the washer replacement. But until then, the pin mod and the wave washer replacement both seem to fix the shudder issue. I have not heard any reports of the shudder returning with the wave washer replacement. If that is not correct, please enlighten.

MT

[MATT'sADDICTION]

[QUOTE=Robert May;1598562]Had an issue with clutch shudder when I first got my bike back in June 2008. After putting 1300 miles on it the tube nut backed off so had to repair that. Shudder disappeared for about 8000 miles then would show up every once in a while in stop and go traffic.

Robert,

You state that the shudder went away the first time for 8000 miles, and then started returning. Will you keep us posted if your shudder starts returning again?

Thanks,

MT

[stepink104]

Guys I did not take any pics I looked at stepink104's pic in this attachment and then machined a flat on the pushpin on opposing sides.
http://www.m109riders.com/forums/att...4&d=1331238585

I rode 212 miles this weekend did about 60 miles of stop and go up and down the MS Gulf Coast. I got stuck behind a St.Patricks day Parade but never once had any shudder issues. What a nice ride. This mod has made me fall in love with my bike all over again.

Robert,
nice to hear it work out for you,east rider and myself did this mod and we never had another issuse ever.
the clutch plate and wave washer no diffrence,i was going to measure it with a mic but never had the reason to.
i have put hundreds of miles on along with Craig and no issuse yet,
ENJOY THE RIDE........its like a new bike.

kenny

[stepink104]

this was done on bench grinder.........

[Robert May]

Kenny I really do appreciate the info and pic you posted. Like I said I have fell in love with my bike all over again.

[CanadianM109R]

So you used a grinder to make a flat spot on the entire length of that pin. You did this on 2 sides. Is this correct?

What was the idea behind this? How did you know it would work?

[Dommy]

Thanks guys all for this precious info

I have the gut feeling that I could be in the need to do this mod sooner or later ... this morning I had a first sign of clutch shudder upon pulling off from stand still just after switching on the bike and let the motor idle for a few minutes.

[REDSTORM]

So you used a grinder to make a flat spot on the entire length of that pin. You did this on 2 sides. Is this correct?

What was the idea behind this? How did you know it would work?

I would also like to know.

[DEADLYCHEEZE]

Rumor has it that it is better to put 3 flats, as opposed to 2, on the adjustment pin.

[Blackey]

Rumor has it that it is better to put 3 flats, as opposed to 2, on the adjustment pin.

3 flats = Good. Been Shudder free for two days now.

[Chops]

Did you guys reset the adjustment on the pin as per the manual.

CLUTCH COVER
Loosen the lock nut 1 and turn in the release screw 2 to feel resistance.
From that position, turn out the release screw 2 1 turn and tighten the lock nut 1 securely by holding the release screw 2.

Or did you just fit it back with same adjustment it had when you removed it.

[stevem109r]

Adjust as per the manual


Sent via electronic carrier pigeon

[Chops]

Thanks Steve

[GODRA]

Hi guys ive been keen on doing this mod but, does anyone know if this mod and installing the smoother shifting pack, will work ok together? Im thinking it should be ok, but just double checking? Thanks

[futurR]

Hi guys ive been keen on doing this mod but, does anyone know if this mod and installing the smoother shifting pack, will work ok together? Im thinking it should be ok, but just double checking? Thanks

Your post #81 and my reply #83---already answered that for you.

http://www.m109riders.com/forums/sho...73#post1712273

[Torque Junkie]

Adjust as per the manual


Sent via electronic carrier pigeon

Was just at my local dealership last weekend talking to the owner about the clutch shudder issued I had been having on my C109R. Took .3mm off the pin in three areas as instructed by Listen1's posting. This leaves a flat spot approximately 1/8" wide (or slightly less) on the pin. More is not better!!! This will allow the center your clutch to become pressure fed with oil. Remove too much from the pin (like I did) and you run the risk of allowing too much oil flow to the clutch, thus possibly starving the top end. I bought a new pin and took less off before I put things back together. Anyway, the owner went and made me a copy of a service bulletin Suzuki had sent him dated 3/8/2007. It contains additional service manual information concerning clutch cable play adjustment for the VZR1800, starting by removing the secondary gear case cover, the clutch cable holder along with the clutch cable. Inspect the clutch release arm play. STD: play is 8.0mm with limit: play being 4.0mm. If this isn't correct it instructs you to drain the oil, remove the mufflers, remove the clutch cover and then adjust the pin in the center of the clutch by feeling for resistance, backing the release screw out 1 turn and tightening the locknut. Then reinstall everything!! May be something you want to consult your dealer about??

[Kazimodo]

Anyway, the owner went and made me a copy of a service bulletin Suzuki had sent him dated 3/8/2007. It contains additional service manual information concerning clutch cable play adjustment for the VZR1800, .....May be something you want to consult your dealer about??

..
Thanks Torque Junkie , that service bulletin has been posted here already in many threads
it explains step by step the adjustment pin proper install .
I would put a link to one of them threads but too lazy tonight , maybe later .

[Chops]

This one the one I need ?

http://www.mym109r.com/howtos/m109-c...adjustment.pdf

[GODRA]

@ FutureR. Cool thanks I did t see the reply. Thanks

[Kazimodo]

This one the one I need ?

http://www.mym109r.com/howtos/m109-c...adjustment.pdf

..
Yeah , that's the Suzuki Bulletin posted in a few threads
, step by step pin adjustment , and then clutch lever adjustment to be done too.

[Too Tough]

So is it best to go 2mm or 2.5 mm wide. Gonna get mine done but need to know how deep also..

Was just at my local dealership last weekend talking to the owner about the clutch shudder issued I had been having on my C109R. Took .3mm off the pin in three areas as instructed by Listen1's posting. This leaves a flat spot approximately 1/8" wide (or slightly less) on the pin. More is not better!!! This will allow the center your clutch to become pressure fed with oil. Remove too much from the pin (like I did) and you run the risk of allowing too much oil flow to the clutch, thus possibly starving the top end. I bought a new pin and took less off before I put things back together. Anyway, the owner went and made me a copy of a service bulletin Suzuki had sent him dated 3/8/2007. It contains additional service manual information concerning clutch cable play adjustment for the VZR1800, starting by removing the secondary gear case cover, the clutch cable holder along with the clutch cable. Inspect the clutch release arm play. STD: play is 8.0mm with limit: play being 4.0mm. If this isn't correct it instructs you to drain the oil, remove the mufflers, remove the clutch cover and then adjust the pin in the center of the clutch by feeling for resistance, backing the release screw out 1 turn and tightening the locknut. Then reinstall everything!! May be something you want to consult your dealer about??

[bwl60]

So is it best to go 2mm or 2.5 mm wide. Gonna get mine done but need to know how deep also..

Since the pin is round, the wider you go, the deeper it will get. It just needs to be flat and 2 to 2.5 mm wide. I did mine on 3 sides at about 2mm. Now it is smooth as butter.

[Blackey]

Since the pin is round, the wider you go, the deeper it will get. It just needs to be flat and 2 to 2.5 mm wide. I did mine on 3 sides at about 2mm. Now it is smooth as butter.

Did you do the wave washer and plates at the same time? Or did the butteryness come from the pin mod alone?

[Deacon]

I did the mod and everthing turned out fine. But I didn't adjust the clutch nut afterwards, so after I got everything back together the clutch was very tight. I had the nut on the cluthch lever adjusted out so I screwed it back flush, and have the "2 quarter" spacing that is required. My question is do I need to go back in and readjust the cluth pin screw/nut?