Upgrade your Clutch System
Page 1 of 3 123 LastLast
Results 1 to 30 of 68

Thread: Upgrade your Clutch System

  1. #1
    Supporting Vendor Rainey5230's Avatar
    Join Date
    Sep 2007
    Location
    Taiwan
    Posts
    667

    Default Upgrade your Clutch System

    We can referred the 06-09 M109 as the first generation 109, and the 10-on as the second. What's difference between the two gens is not only in the redesigned tachometer but most importantly, the clutch system. We have learned that when entering first gear the impact of gears collision deteriorate significantly with the 10-on models. The inconvenience of shifting from first to second gear on the 06-09 models has been improved. The root of the problem lies on the five clutch plates in the old gens that when in motion, the friction between the plates are not enough without the bigger kg/m clutch spring, which is also the reason why we have to pull pretty hard when reaching the clutch lever. What's worse is that this clutch spring will experience elastic fatigue after consistent usage for two years. The second gens clutch system altered into six clutch plates to increase its friction and lower the kg/m of the spring. The result is easier and more comfortable when reaching the lever and longer lifespan for the clutch spring as well. Revo-cycles has successfully help many of our riders to upgrade their 06-09 models' clutch system into 10-on's.

    Click image for larger version. 

Name:	1304150016e03adb675bede1ba.jpg 
Views:	2328 
Size:	51.6 KB 
ID:	297529
    2012 on the left, 2008 on the right

    Click image for larger version. 

Name:	13041500163552bcdcc871398d.jpg 
Views:	2339 
Size:	58.9 KB 
ID:	297537

    Although the OEM part number is different, both of them shares the same sizes.
    Click image for larger version. 

Name:	13041500160a13b2dd1318a23f.jpg 
Views:	2993 
Size:	71.9 KB 
ID:	297545

    2012 has become lighter
    Click image for larger version. 

Name:	13041500165a433d486c6edf1d.jpg 
Views:	2314 
Size:	53.0 KB 
ID:	297553
    The clutch pressure disk on the outside is the same, so all you need to do is change the clutch plates, clutch driven plate and springs to finish the upgrade.
    Click image for larger version. 

Name:	1304150016607fdbc277cd094e.jpg 
Views:	2268 
Size:	41.7 KB 
ID:	297561
    2012 on the left, with softer handling that is more comfortable for longer ride.




  2. Remove Advertisements
    M109Riders.com
    Advertisements
     

  3. #2
    Co-Sponsor ducks517's Avatar
    Join Date
    Nov 2007
    Location
    Clay NY
    Posts
    3,521

    Default

    That's some great information.

    For More information check out my WEBSITE HERE!!!

  4. #3
    Very Active Member Andy33's Avatar
    Join Date
    Jan 2010
    Location
    Calgary, Alberta
    Posts
    720

    Default

    So am I understanding this right?
    You are saying the guts of an 06-09 clutch can be directly swapped for an 10-current model and this "should" greatly improve the shift from 1-2?
    If all I need to do is upgrade the plates and springs to have the better functioning clutch this could be a great mod for us older model guys.

    I take it you have done this swap?
    2009 M109 LE
    ISO grips, Swing Wing pegs, Shifter/Brake pedal MOD, Rivco 2" Risers, V-Stream Windshield, Cobra Sissy Bar/Rack, Tach Relocated, Mini Bullet Signals, Scythe 2 Mirrors, Debadged, DeBeaved,
    RaceTech fork Springs, Progressive 465, LA Choppers 2" bones, Cycle House Kickstand, Chrome Stock Wheels, Freedom Exhaust, Goldwing Intake MOD + K&N filters, Cobra Power Pro


  5. Remove Advertisements
    M109Riders.com
    Advertisements
     

  6. #4
    Very Active Member thevili's Avatar
    Join Date
    Jan 2009
    Location
    Fergus, Ontario, Canada
    Posts
    3,349

    Default

    Quote Originally Posted by Andy33 View Post
    So am I understanding this right?
    You are saying the guts of an 06-09 clutch can be directly swapped for an 10-current model and this "should" greatly improve the shift from 1-2?
    If all I need to do is upgrade the plates and springs to have the better functioning clutch this could be a great mod for us older model guys.

    I take it you have done this swap?
    That is what he is saying, also that he had done it several times...
    M109R 2011 Black, 2" lowering bones, air horn, flash to pass garage door opener, Brakeaway Cruise Control, V-stream windshield, Back Off Brake hold, OEM engine guards, Cobra One Piece rear luggage carrier, Cobra Tri Pro 2 in 1 Black exhaust, Cobra FI 2000 AT fuel processor.

  7. #5
    Very Active Member cbxer55's Avatar
    Join Date
    Feb 2009
    Location
    Oklahoma City
    Posts
    5,456

    Default

    First off, I have never for one moment thought the clutch pull of my 06 is hard. NOT EVEN CLOSE! Ever ridden a bike with a really stout Barnett racing clutch? That's hard. My 2006 M109R has a super easy clutch pull.

    As for duration, mine's now going on ten years old and still works like a charm. Not one problem with the clutch since I bought the bike new in July 2006. Every once-in-a-blue-moon, I get the shudder. Haven't had it for months now. If I warm the bike up good, and pull the clutch in and give it a few brisk revs, I never get the shudder at all. All I have to do is remember to do those, and it's all good. I've had bikes before where that was necessary, or the clutch plates would stick together.

    I have no intention of ever having the clutch cover off my bike, as long as it keeps functioning as it does now. Which is to say: PERFECTLY!

    I know others have had problems. Those have always been hit-or-miss. I've read of others besides myself, who have never has one problem with their early models. You got to do what you got to do. If swapping out the internals fixes those bad ones, GREAT! I myself, do not feel the need to waste my time (or money) doing that since mine functions so well.
    SILVER 2006 M109R.
    BLACK 2008 B-KING


  8. #6
    Very Active Member
    Join Date
    Oct 2011
    Location
    Breslau, Ontario, Canada
    Posts
    357

    Default

    I'm in a similar boat. I have a 2009 and have not had any clutch issues. Have not had any issues going from 1-2 either - in fact, I think the shift is pretty smooth. Occasionally, I've gotten the RPM's wrong and the shift was like a Mack truck but that is rare. That said, I don't know if the previous owner did an y upgrades (shift star or plates) but I don't think so. I've been told my clutch pull is hard but I manage.
    2009 M109R LE
    2015 Boss tins, Custom speedo and tach faces and LEDs. ISO Grips. Brake Away Cruise control. Cobra Swepts. Debeavered, Fi200R Fuel management, polished risers and trees, SS Brake lines, ATRE, Custom forward controls. HID kit. Ultimate seat and backrest. Dunlop E3s, 250 rear, Plastidipped rims, cobra solo rack

  9. #7
    Very Active Member cbxer55's Avatar
    Join Date
    Feb 2009
    Location
    Oklahoma City
    Posts
    5,456

    Default

    I agree on the first-to-second as well. Once in a while, less than once a year, I blow it somehow. And get a gnarly rough shift. Usually I can shift from first-to-second at any rpm I desire with no hysterics. It was pretty bad when I first got the bike, but it's just kept getting better and better the longer I've owned it. I'm not out there putting around either. Riding it pretty hard and getting the rpm's up near red line in first and second gear. If I thought there was a problem, I'd address it. I would not sell the bike because of it, I love this bike way too much to get rid of it over something that can be fixed.
    SILVER 2006 M109R.
    BLACK 2008 B-KING


  10. #8
    Very Active Member edwilk55's Avatar
    Join Date
    Apr 2011
    Location
    Jonesboro, GA
    Posts
    503

    Default

    Bringing this thread as I'm about to do this upgrade on my 08. I'll report back after I'm done. I've done the pin mod to elim the shudder already, but now, I'm slipping at above 4k RPM under load. I can't wait to see if there's a big diff here and I'll let y'all know.

  11. #9
    Very Active Member Andy33's Avatar
    Join Date
    Jan 2010
    Location
    Calgary, Alberta
    Posts
    720

    Default

    Quote Originally Posted by edwilk55 View Post
    Bringing this thread as I'm about to do this upgrade on my 08. I'll report back after I'm done. I've done the pin mod to elim the shudder already, but now, I'm slipping at above 4k RPM under load. I can't wait to see if there's a big diff here and I'll let y'all know.

    Nice, would really like to hear how it goes for you. This is high on my list of Mods to do.
    I cant say I've experienced the "shudder" all that much. Maybe once. But I am very interested in having my bike run as good as it can.

    Good luck. Report back soon.
    2009 M109 LE
    ISO grips, Swing Wing pegs, Shifter/Brake pedal MOD, Rivco 2" Risers, V-Stream Windshield, Cobra Sissy Bar/Rack, Tach Relocated, Mini Bullet Signals, Scythe 2 Mirrors, Debadged, DeBeaved,
    RaceTech fork Springs, Progressive 465, LA Choppers 2" bones, Cycle House Kickstand, Chrome Stock Wheels, Freedom Exhaust, Goldwing Intake MOD + K&N filters, Cobra Power Pro


  12. #10
    Very Active Member MainEvent's Avatar
    Join Date
    Apr 2012
    Location
    Northern Virginia
    Posts
    588

    Default

    Quote Originally Posted by edwilk55 View Post
    Bringing this thread as I'm about to do this upgrade on my 08. I'll report back after I'm done. I've done the pin mod to elim the shudder already, but now, I'm slipping at above 4k RPM under load. I can't wait to see if there's a big diff here and I'll let y'all know.
    Any updates on the new mod? Any noticeable changes in shifting? I'm planning on checking my plates. I bought a shift star kit which I plan on installing once I get my bike back.


  13. #11
    Very Active Member edwilk55's Avatar
    Join Date
    Apr 2011
    Location
    Jonesboro, GA
    Posts
    503

    Default

    Quote Originally Posted by MainEvent View Post
    Any updates on the new mod? Any noticeable changes in shifting? I'm planning on checking my plates. I bought a shift star kit which I plan on installing once I get my bike back.
    I was slack in spending the $400, but just ordered all a couple days ago. Will install asap when the parts arrive. EOM was target for delivery.


    Sent from my Apple brain boiler tapped by the NSA!

  14. #12
    Very Active Member MainEvent's Avatar
    Join Date
    Apr 2012
    Location
    Northern Virginia
    Posts
    588

    Default

    Quote Originally Posted by edwilk55 View Post
    I was slack in spending the $400, but just ordered all a couple days ago. Will install asap when the parts arrive. EOM was target for delivery.


    Sent from my Apple brain boiler tapped by the NSA!
    Wow, $400 is pretty steep. I remember paying around $240 for all the plates for my 07', about 3+ years back.

    Keep us posted on your results. Intrigued to see the results. I had no ideas there were changes to the clutch from 2010 up. If I had know, I might have gone with the new plates as opposed to the old stack.


  15. #13
    Very Active Member edwilk55's Avatar
    Join Date
    Apr 2011
    Location
    Jonesboro, GA
    Posts
    503

    Default

    Quote Originally Posted by MainEvent View Post
    Wow, $400 is pretty steep. I remember paying around $240 for all the plates for my 07', about 3+ years back.

    Keep us posted on your results. Intrigued to see the results. I had no ideas there were changes to the clutch from 2010 up. If I had know, I might have gone with the new plates as opposed to the old stack.
    Yeah, wasn't thrilled about the cost, but figured I needed a clutch anyway, so what the hell.


    Sent from my Apple brain boiler tapped by the NSA!

  16. #14
    Very Active Member edwilk55's Avatar
    Join Date
    Apr 2011
    Location
    Jonesboro, GA
    Posts
    503

    Default

    Quote Originally Posted by edwilk55 View Post
    Yeah, wasn't thrilled about the cost, but figured I needed a clutch anyway, so what the hell.


    Sent from my Apple brain boiler tapped by the NSA!
    And you could get buy for under $300, but I'm replacing everything in there.


    Sent from my Apple brain boiler tapped by the NSA!

  17. #15
    Very Active Member M109Dreamer's Avatar
    Join Date
    Jul 2008
    Location
    Forney, TX
    Posts
    6,783

    Default

    I paid just under $400 with shipping for all the fibers, steels, wave, seat, #6 drive plate. And also the gasket. That was 2 years ago.

    Sent from my SAMSUNG-SM-G920A using Tapatalk

  18. #16
    Very Active Member edwilk55's Avatar
    Join Date
    Apr 2011
    Location
    Jonesboro, GA
    Posts
    503

    Default

    Quote Originally Posted by M109Dreamer View Post
    I paid just under $400 with shipping for all the fibers, steels, wave, seat, #6 drive plate. And also the gasket. That was 2 years ago.

    Sent from my SAMSUNG-SM-G920A using Tapatalk
    Yup


    Sent from my Apple brain boiler tapped by the NSA!

  19. #17
    Very Active Member MainEvent's Avatar
    Join Date
    Apr 2012
    Location
    Northern Virginia
    Posts
    588

    Default

    Yea Clutch problems are a pain in the a$$. Mines failed on me during MAM 2012 when we were right in the middle of that ride from Tazwell VA to Marion VA. (Rt 16 aka Back of the Dragon). Couldn't ride the bike in any gear past 2nd and could only go 25mph. I was scared as hell, didn't think I was gonna make it through. Luckily I have BigPapa a stone's throw away, so we ordered the plates and he helped install after the meet.

    Haven't had any issues since, but seeing sometimes this is a reoccurring thing, plus I didn't do the pushpin mod or check the tubular nut, I figure to check it out this season while my bike is down.


  20. #18
    Member
    Join Date
    Mar 2015
    Location
    United States
    Posts
    17

    Default

    OK, so does this work on the C109rt? Can I use an M109 clutch in my bike? Do I purchase a 2010 M109 clutch kit? I know, so many questions. One more, does a bike's clutch have a throw out bearing like a car and if so why doesn't it come in the clutch kit? OK, I lied, one more question. What should I buy, when replacing the clutch, that doesn't come in the kit and is there a preferred after market kit? Now I'm done.

  21. #19
    Member Leather's Avatar
    Join Date
    Mar 2016
    Location
    Alberta, Canada
    Posts
    13

    Default

    Quote Originally Posted by cbxer55 View Post
    Every once-in-a-blue-moon, I get the shudder. Haven't had it for months now. If I warm the bike up good, and pull the clutch in and give it a few brisk revs, I never get the shudder at all. All I have to do is remember to do those, and it's all good.
    My 06 is new to me and I have had the shudder a few times...Just trying to figure out what I'm doing wrong if my revs are too low or I am too slow to release the clutch. Any other tips you guys have to help prevent this?
    Last edited by Leather; 03-22-2016 at 12:23 AM. Reason: Spelling error

    2006 M109R

  22. #20
    Very Active Member cbxer55's Avatar
    Join Date
    Feb 2009
    Location
    Oklahoma City
    Posts
    5,456

    Default

    Quote Originally Posted by Leather View Post
    My 06 is new to me and I have had the shudder a few times...Just trying to figure out what I'm doing wrong if my revs are too low or I am too slow to release the clutch. Any other tips you guys have to help prevent this?
    Riding season is approaching. If the damn wind would go away. We'll see what transpires on mine this year. Been lucky so far. Got a new battery today, and am off Friday, so putting it in and riding starting then. Also have new oil and filter to go in this weekend, four quarts of Suzuki 20W-50 petroleum oil (and every ounce is going in).

    The only time I've ever experienced the shudder was when the engine was still cold, never happened to me fully warmed up. What I said before has worked well for me. Can't guarantee that for anyone else. I'm anal about warming my vehicles up before splitting. I've gotten the shudder only a handful of times, and every one of them I was in a hurry and bypassed my usual long warm up. I hope that continues, as I am not in a big hurry to tear into the internals anytime soon.
    SILVER 2006 M109R.
    BLACK 2008 B-KING


  23. #21
    Member Leather's Avatar
    Join Date
    Mar 2016
    Location
    Alberta, Canada
    Posts
    13

    Default

    Quote Originally Posted by cbxer55 View Post
    The only time I've ever experienced the shudder was when the engine was still cold, never happened to me fully warmed up. What I said before has worked well for me. Can't guarantee that for anyone else. I'm anal about warming my vehicles up before splitting. I've gotten the shudder only a handful of times, and every one of them I was in a hurry and bypassed my usual long warm up. I hope that continues, as I am not in a big hurry to tear into the internals anytime soon.
    It has happened to me after my bike has been running and is warmed up. Must be something else for me.

    2006 M109R

  24. #22
    Very Active Member edwilk55's Avatar
    Join Date
    Apr 2011
    Location
    Jonesboro, GA
    Posts
    503

    Default

    Quote Originally Posted by MainEvent View Post
    Any updates on the new mod? Any noticeable changes in shifting? I'm planning on checking my plates. I bought a shift star kit which I plan on installing once I get my bike back.
    Clutch is in. Fits perfectly.

    Initial impressions with the 8 miles I was able to ride is it's great. Clutch pull is easier. 1-2 shifts aren't as notchy.

    I'll give another update after I put some miles on this coming Sunday.

  25. #23
    Very Active Member thevili's Avatar
    Join Date
    Jan 2009
    Location
    Fergus, Ontario, Canada
    Posts
    3,349

    Default

    Quote Originally Posted by edwilk55 View Post
    Clutch is in. Fits perfectly.

    Initial impressions with the 8 miles I was able to ride is it's great. Clutch pull is easier. 1-2 shifts aren't as notchy.

    I'll give another update after I put some miles on this coming Sunday.

    Looking forward to hear from you, not that I don't trust Rainey's opinion!!!
    I have friends overseas who needs reassurance....
    M109R 2011 Black, 2" lowering bones, air horn, flash to pass garage door opener, Brakeaway Cruise Control, V-stream windshield, Back Off Brake hold, OEM engine guards, Cobra One Piece rear luggage carrier, Cobra Tri Pro 2 in 1 Black exhaust, Cobra FI 2000 AT fuel processor.

  26. #24
    Very Active Member mark95621's Avatar
    Join Date
    May 2008
    Location
    Roseville, CA
    Posts
    108

    Default

    Hey guys,

    So I am interested in this mod for my 08 shudder machine. Actually I did the pin mod a few years ago and the shudder is gone but ever since then I have had issues with the bike pulling in first gear with the clutch pulled in. Now its getting to the point that it can hardly shift down when coasting or coming to a stop and have to match the engine speed to the transmission to shift (like shifting without the clutch) It seems that the clutch really isn't working at all except when at a stop it does generally disengage the engine. Also its been darn near impossible to get into neutral at a stop light with the engine running. As soon as the engine is off it goes right into neutral no problem.

    So long story but now I'm thinking I'll just replace the clutch all together and wonder what parts I must buy. I'd like to replace the pin (modded) as well and am hoping there is a good replacement that fixes the shudder issue out of the box.

    In this mod do I need to change the basket? Can I just order the clutch fibers and plates and springs and new pin and be done with it? Is there a list of required parts somewhere?

    If anyone has other clutch advice for me I'd gladly take it.

    Thanks!!!
    '08 Orange (More LE then LE), 250 club, De-Beavered, Arlen Ness Rad II Teardrop Mirrors, Custom JSD, Custom GPS mount and 12V adapter, Custom License plate mount, Custom License plate LED lights, De-baffled stock exhaust.

  27. #25
    Very Active Member edwilk55's Avatar
    Join Date
    Apr 2011
    Location
    Jonesboro, GA
    Posts
    503

    Default

    Quote Originally Posted by mark95621 View Post
    In this mod do I need to change the basket? Can I just order the clutch fibers and plates and springs and new pin and be done with it? Is there a list of required parts somewhere?

    If anyone has other clutch advice for me I'd gladly take it.
    No on the basket. Stock works perfectly. New plates are thinner, so fit right in.

    Plates #5,9 and 10 are a must as well as springs. But since you're in there and have spent that much, might as well replace the other 3 components. You can get away without replacing #6.

    I wouldn't replace the pin. No need unless you think you didn't mod it correctly the first time.

    No advice needed really. It's just a clutch swap. Make sure to torque properly.

    Now did you tighten/lock tight the Nut holding on the primary drive gear when you went in the first time? That's the nut that loosens itself over time. If not, you'll want to do that requiring a special tool, good 6pt socket and torque wrench / quality impact gun.

    For reference on all mentioned above:

    http://poisnus.com/M109RFiles/M109R%...eplacement.pdf

  28. #26
    Member
    Join Date
    Mar 2016
    Location
    Grand Rapids, MI
    Posts
    7

    Default

    Quote Originally Posted by edwilk55 View Post
    Bringing this thread as I'm about to do this upgrade on my 08. I'll report back after I'm done. I've done the pin mod to elim the shudder already, but now, I'm slipping at above 4k RPM under load. I can't wait to see if there's a big diff here and I'll let y'all know.
    Hey, wondering if the clutch upgrade fixed the slipping under load? When you say slipping, is it specifically in 2nd gear or any gear at 4K RPM?

  29. #27
    Very Active Member edwilk55's Avatar
    Join Date
    Apr 2011
    Location
    Jonesboro, GA
    Posts
    503

    Default

    Quote Originally Posted by Jpaulson12 View Post
    Hey, wondering if the clutch upgrade fixed the slipping under load? When you say slipping, is it specifically in 2nd gear or any gear at 4K RPM?
    It's was in any gear and yes, it fixed it, buuuuuut... I didn't need the upgrade to fix the slipping. I found I installed the inner plate 10 backwards when I did the pin mod last year, so while it worked for a season, it ate up two plates causing my slipping.

  30. #28
    Very Active Member mlrman's Avatar
    Join Date
    May 2011
    Location
    central IL
    Posts
    157

    Default

    Quote Originally Posted by edwilk55 View Post
    It's was in any gear and yes, it fixed it, buuuuuut... I didn't need the upgrade to fix the slipping. I found I installed the inner plate 10 backwards when I did the pin mod last year, so while it worked for a season, it ate up two plates causing my slipping.
    I wonder if that's what I did too, as my new clutch fried after a season and a half. I' going to do this upgrade since I've got it apart anyway. Thanks for the info.

  31. #29
    Very Active Member mlrman's Avatar
    Join Date
    May 2011
    Location
    central IL
    Posts
    157

    Default

    Can anyone explain why there are alternate clutch drive plates to #6? (7,8 in diagram?) Thanks.

  32. #30
    Very Active Member edwilk55's Avatar
    Join Date
    Apr 2011
    Location
    Jonesboro, GA
    Posts
    503

    Default Upgrade your Clutch System

    Quote Originally Posted by mlrman View Post
    Can anyone explain why there are alternate clutch drive plates to #6? (7,8 in diagram?) Thanks.
    It was asked / answered in a separate post I found when researching. The word was just stick with 6 (std part # when ordering), but I can't recall why.


    Sent from my Apple brain boiler...tapped by the NSA, hacked by the FBI!

Posting Permissions

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