Suzuki M109R Replacement

Suzuki M109R Replacement

Clutch replacement

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Suzuki M109R Clutch Replacement
Special thanks to Listan1 from
M109RIDERS
forums for this info.
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Summary of Contents for Suzuki M109R

  • Page 1 Suzuki M109R Clutch Replacement Special thanks to Listan1 from M109RIDERS forums for this info. Disclaimer: The information contained in this website is for general information purposes only. The information is provided by mym109r.com and while I endeavor to keep the information up to...
  • Page 2 Begin: 1. Place bike on jack or kickstand (you will be working on the right side) NOTE: Oil will leak out if bike is vertical and not if it’s on the kickstand) 2. A jack will allow you to spin the back wheel which may prove useful later | MYM109R.COM...
  • Page 3 Remove the Exhaust System: 1. Instructions for this can be found under link for the Scorpion exhaust. (http://mym109.homestead.com/files/HOWTOS/M109R_Scorpion_Tips_Instalation.pdf) | MYM109R.COM...
  • Page 4 Remove the side-cover bolts: 1. Make note of each bolt that comes out: 2. There are 3 bolts with washers (2 at the top and 1 at the bottom) Be sure to put these back in the right place or you will have an oil leak. 3.
  • Page 5 | MYM109R.COM...
  • Page 6 Remove the side-cover:  Use a rubber mallet to lightly tap the side cover loose  Try not to rip the gasket by carefully removing the cover (NOTE: The gasket will probably stick to the block and cover. Carefully use a small screwdriver, et bike.
  • Page 7  Must be oil free and clean when reinstalling or you may have an oil leak  Clean and inspect Dowels on the side-cover Figure 3 | MYM109R.COM...
  • Page 8 PRIMARY DRIVE GEAR 1. With the transmission in gear hold the clutch lever and spin the rear wheel... the PRIMARY DRIVE GEAR should spin freely 2. If not, move on to the next step | MYM109R.COM...
  • Page 9 CLUTCH PRESSURE DISC 1. Remove the 6 bolts (10 mm socket) and springs 2. Remove CLUTCH PRESSURE DISC and inspect for damage NOTE: When retightening, go easy on these bolts (about 6 to 8 ft lbs) you don't want to strip the alum | MYM109R.COM...
  • Page 10 1. For testing for other issues:  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 2.
  • Page 11 1. Remove the CLUTCH PUSH PIECE by pulling it out 2. There is washers and a bearing here 3. Inspect | MYM109R.COM...
  • Page 12 Remove CLUTCH DRIVE PLATES: 1. Clean and inspect each plates and set them down in the order and position they are remove 2. Will also be a good time to order any damage or worn clutch drive plates | MYM109R.COM...
  • Page 13 1. Spin rear wheel to see if the PRIMARY DRIVE GEAR spins freely stop here if you are only replacing the clutch | MYM109R.COM...
  • Page 14 CLUTCH SLEEVE HUB NUT 1. To remove, you can either pry / tap the notch on the nut back to its original shape or simply hit it with the impact gun. It will come off w/out much effort. 2. 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.
  • Page 15 1. Remove clean and inspect nut 2. Use an impact gun with a 30 mm socket (6 point socket preferable) and remove the hub nut 3. An electric impact gun works good as it is not too powerful to cause damage | MYM109R.COM...
  • Page 16  remove clean and inspect washer | MYM109R.COM...
  • Page 17 CLUTCH HUB: 1. Remove clean and inspect clutch hub | MYM109R.COM...
  • Page 18 The CLUTCH HUB | MYM109R.COM...
  • Page 19 Now spin rear wheel to see if the PRIMARY DRIVE GEAR spins freely Clean and inspect Tubular Nut: 1. 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 a BIG problem 3.
  • Page 20 1. Clean and inspect | MYM109R.COM...
  • Page 21 Tubular Nut Tool: Honda Socket / Spanner for the VTX works. Part Number: 07910-4630100 Cost: $90.00 | MYM109R.COM...
  • Page 22 1. Clean and inspect 1. Clean Tubular Nut with electrical contact cleaner or a solvent that those not leave any residue 2. Apply Loctite when installing nut 3. Tighten to 100-105 ft lbs | MYM109R.COM...
  • Page 23 1. Remove washer and PRIMARY DRIVE GEAR clean and inspect 1. Clean and inspect | MYM109R.COM...
  • Page 24 1. Clean, inspect and apply loctite when installing 2. The gear is not listed separately in the parts manual and may be sold as part of the PRIMARY DRIVE GEAR 3. Clean and inspect | MYM109R.COM...
  • Page 25 1. Clean and inspect gear, washers and bearings | MYM109R.COM...
  • Page 26 1. Clean and inspect PRIMARY DRIVE GEAR SPACER | MYM109R.COM...
  • Page 27 1. Yow you have everything clean inspected 2. Order all necessary parts 1. Clean everything before installing. 2. Reverse to install everything following torque specs included. 3. After a short test drive, it’s recommend you perform an oil & filter change as your engine was exposed to dust, dirt and lint.
  • Page 28 Figure 4 Factory Diagram | MYM109R.COM...
  • Page 29 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.
  • Page 30 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.
  • Page 31 Clutch Plate Install Order: Figure 5 Install 1 (direction doesn’t matter) Plate #6 21441-48G10 | MYM109R.COM...
  • Page 32 Figure 6 Install 2 (direction doesn’t matter) #13 - WASHER, CLUTCH PLATE 21472-48G00 (new) | MYM109R.COM...
  • Page 33 Figure 7 Install 3 (much debate if direction matters, but general consensus is wide side toward bike..this pic shows the opposite of that) #12, SEAT, WAVE WASHER 21471-48G00 (new) | MYM109R.COM...
  • Page 34 Figure 8 Install 4 Plate #10 21441-48G00 | MYM109R.COM...
  • Page 35 Figure 9 Install 5 Plate #5 21451-48G00 | MYM109R.COM...
  • Page 36 Figure 10 Install 6 Plate #9 21441-48G00 | MYM109R.COM...
  • Page 37 Figure 11 Install 7 Plate #5 21451-48G00 | MYM109R.COM...
  • Page 38 Figure 12 Install 8 Plate #9 21441-48G00 | MYM109R.COM...
  • Page 39 Figure 13 Install 9 Plate #5 21451-48G00 | MYM109R.COM...
  • Page 40 Figure 14 Install 10 Plate #9 21441-48G00 | MYM109R.COM...
  • Page 41 Figure 15 Install 11 Plate #5 21451-48G00 | MYM109R.COM...
  • Page 42 Figure 16 Install 12 Plate #9 21441-48G00 | MYM109R.COM...
  • Page 43 Figure 17 Install 13 Plate #5 21451-48G00 | MYM109R.COM...
  • Page 44 Figure 18 Install Last Plate: (make sure it’s facing away from the bike) Plate #10 21451-48G10 | MYM109R.COM...

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