Listan1 M109R - M109Riders.com

Suzuki M109R Clutch
Created: April 28, 2007 6:31 AM By: Listan1
Last updated: 11/18/10 10:18:01 PM You are visitor # Hit Counter

I went to up the road and suddenly I had no clutch
No clutch, will not change gear; stop the engine and fight it into neutral, start the engine fine; hold the clutch lever kick it into 1st. gear and the bike takes off with the clutch lever depress fully…
Road it back home 2 miles in 2nd. gear, had to start it in first gear like if you are push starting and keep going, fight it into 2nd. gear
Feel like the pressure plate is stock

Call local dealers and none of them ever came across his issue
Talk to Suzuki and they said that they don’t have any reports of this happening at all….
Here is the phone number to Suzuki 1-714-572-1490
Something isn’t right about this picture… I forget to tell you all that I was coming to a red light at the time when it first happen, luckily I was making a right turn and there was not that much vehicles on the road at that time… this could have been bad had it been earlier
Remember the gears stayed engaged at all times even with the clutch lever depress all the way and it will not into neutral..
Guys keep the phone number and start reporting these issues directly to Suzuki

place bike on jack or side-stand you will be working on the right side jack is recommended to be able to spin the back wheel... this will be prove useful later
remove the exhaust system for this you will need a socket drive alien key with 8" or longer 3/8 drive extension to remove the header pipes bolts 12 mm socket and wretch Hard Khrome Sideburner clean/polish exhaust before starting engine after reinstallation
remove the side-cover bolts there is 3 bolts with washer 2 at the top and 1 at the bottom... be sure to put these back in the right place; if not you will have oil leak when retighten, go easy on these bolts (about 10-14 ft lbs max) you don't want to strip the aluminum treads or break any bolts polish cover after installing it
bottom side-cover bolt with the washer
note that there is 2 long bolts in this set that also need to be install in the right place (upper left side cover) clean and inspect
remove the side-cover... there is 2 dowels on the cover. use a rubber mallet to lightly tap the side cover loose try not to rip the gasket by carefully removing the cover I was able to re-use my gasket if damage replace gasket must be oil free and clean when reinstalling or you may have oil leak clean and inspect
dowels on the side-cover must be oil free and clean when reinstalling or you may have an oil leak clean and inspect
PRIMARY DRIVE GEAR with the transmission in gear hold the clutch lever and spin the rear wheel... the PRIMARY DRIVE GEAR should spin freely if not move on to the next step
CLUTCH PRESSURE DISC press clutch lever, the disc should move out slightly and the rear wheel should be able to spin freely if not, remove the 6 bolts (10 mm socket) and springs remove CLUTCH PRESSURE DISC and inspect for damage when retighten, go easy on these bolts (about *6 to 8* ft lbs) you don't want to strip the aluminum treads or break any bolts
spin rear wheel to see if the PRIMARY DRIVE GEAR spins freely push the CLUTCH PUSH PIECE in and then press the clutch lever the piece should move out about 1/4 inch if so then move on to nest step
remove the CLUTCH PUSH PIECE by pulling it out there is washers and a bearing here inspect
remove CLUTCH DRIVE PLATES clean and inspect each plates and set them down in the order and position they are remove will also be a good time to order any damage or worn clutch drive plates
spin rear wheel to see if the PRIMARY DRIVE GEAR spins freely CLUTCH SLEEVE HUB NUT stop here if you are only replacing the clutch	stop here if you are only replacing the clutch
CLUTCH SLEEVE HUB NUT pry or tap the locking bend back to its original shape on the hub nut when reinstalling: this nut has to be retighten at about 80 ft lbs.... I just use the impact gun and get it nice and tight... you must re-bend the nut to lock the nut back in place
remove clean and inspect nut use an impact gun with a 30 mm socket (6 point socket preferable) and remove the hub nut an electric impact gun works good... as it is not too powerful to cause damage
remove clean and inspect washer
CLUTCH HUB remove clean and inspect clutch hub
CLUTCH HUB
now spin rear wheel to see if the PRIMARY DRIVE GEAR spins freely if it does spin freely at this point... you are there clean and inspect
Tubular Nut there is a nut that look like a gear in the center of the PRIMARY DRIVE GEAR... check to see if it is loose if you can turn it by hand, you found your problem remove the nut and inspect
the nut in question is call a Tubular Nut clean and inspect


Tubular Nut the nut in question I made my own tool that I use on an impact gun to run it down 100-105 ft lbs read that Honda Socket / Spanner for the VTX works. Part Number: 07910-4630100 Cost: $55.75 get it nice and tight clean and inspect
clean Tubular Nut with electrical contact cleaner or a solvent that those not leave any residue apply lock-tite when installing nut 100-105 ft lbs
remove washer and PRIMARY DRIVE GEAR clean and inspect
clean and inspect
clean, inspect and apply lock-tite when installing the gear is not listed separately in the parts manual and may be sold as part of the PRIMARY DRIVE GEAR clean and inspect
clean and inspect gear, washers and bearings
clean and inspect PRIMARY DRIVE GEAR SPACER
clean and inspect
now you have everything clean inspected order all necessary parts reverse disassemble process to install clean everything before installing... after a short test drive I will recommend a oil & filter change too... your engine was exposed to dust and lint... my test drive was done on the jack... be very cautious doing this... good luck Listan1

Download M109R Service Manual here -Thanks Orange Dragon for the PDF file

Clutch parts name & part Number

1. 21151-48G00 SPACER, PRIMARY DRIVE GEAR 1

2. 21100-48G00 GEAR ASSY, PRIMARY DRIVE 1

3. 21410-48G00 HUB, CLUTCH 1

4. 21413-48G00 SPRING, CLUTCH 6

5. 21441-48G00 PLATE, CLUTCH DRIVE NO.1

6. 21441-48G10 PLATE, CLUTCH DRIVE NO.2

7. 21441-48G20 PLATE, CLUTCH DRIVE NO.3

8. 21441-48G30 PLATE, CLUTCH DRIVE NO.4

9. 21451-48G00 PLATE, CLUTCH DRIVEN NO.1

10. 21451-48G10 PLATE, CLUTCH DRIVEN NO.2

11. 21462-48G00 DISC, CLUTCH PRESSURE 1

12. 21471-48G00 SEAT, WAVE WASHER 1 109X124X1.6

13. 21472-48G00 WASHER, CLUTCH PLATE 1

14. 21482-41G00 BOLT, CLUTCH SPRING 6

15. 09159-24010 NUT, CLUTCH SLEEVE HUB 1

16. 09160-25056 WASHER, CLUTCH SLEEVE HUB THR 1 25X50X2.50

17. 09160-25056 WASHER, PRIMARY DRIVE 1 25X50X2.50

18. 09164-24006 WASHER, CLUTCH SLEEVE HUB WAV 1

19. 09263-32020 BEARING, PRIMARY DRIVE 1 32X37X38.3

20. 23110-24F00 ROD, CLUTCH 1

21. 23111-48G00 ROD, CLUTCH PUSH, L 1

22. 23121-41G00 PIECE, CLUTCH PUSH 1

23. 23122-02FR0 BALL, CLUTCH PUSH 1

24. 23122-48G00-A05 CAMSHAFT, CLUTCH RELEASE 1

25. 23123-41G00-A05 CAP, CLUTCH PUSH ROD 1

26. 23125-48G00-A05 SPRING, CLUTCH RELEASE RETURN 1

27. 23271-48G00-A05 ARM, CLUTCH RELEASE 1

28. 09134-06015-A05 SCREW, CLUTCH PUSH ROD 1

29. 09160-10020-A05 WASHER, CLUTCH RELEASE 1 10.5X24X1.0

30. 09160-15045 WASHER, CLUTCH PUSH PIECE 1 15.5X28X1.0

31. 09263-10014 BEARING, CL RLSE CAM LOWER 1 10X14X10

32. 09263-12027 BEARING, CL RLSE CAM UPPER 1 12X18X12

33. 09263-15003 BEARING, CLUTCH PUSH PIECE 1 15X28X2.0

34. 09282-10012 SEAL, CL RLSE CAMSHAFT OIL 1

35. 09283-06010 SEAL, CLUTCH PUSH ROD OIL 1

36. 09285-10004 SEAL, CLUTCH PUSH ROD CAP 1

37. 01550-0620A BOLT, CL RELEASE ARM 1

38. 08310-0006A NUT, CLUTCH RELEASE ADJ 1

By: Listan1

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