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

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 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

  Tool Picture

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

Service Manual

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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