You are visitor - Happy Paws - Home Pagehappypaws-pet.com/m109/listan1_tubular_nut.pdfSuzuki M109R Clutch You are visitor # I ride my bike every day and today road to work came home

Suzuki M109R Clutch You are visitor #

I ride my bike every day and today road to work came home all’s wellJust a few ago I went to up the road and suddenly I had no clutchNo 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 andthe 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. gearFeel like the pressure plate is stock

Call local dealers and none of them ever came across his issueTalk to Suzuki and they said that they don’t have any reports of this happening at all….Here is the phone number to Suzuki 1-714-572-1490Something 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 Iwas 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 earlierRemember 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 mainly working on theright side

jack is recommended to be able tospin the back wheel... this will beprove useful later

remove the exhaust system

for this you will need a socketdrive alien key with 8" or longer3/8 drive extension to remove theheader pipes bolts

12 mm socket and wretch

Hard Khrome Sideburner

clean/polish exhaust beforestarting engine

Listan1 M109R - M109Riders.com http://pagreaves.com/109/clutch/clutch.htm

1 of 16 10/23/2008 2:55 PM

remove the side-cover bolts

there is 3 bolts with washer 2 atthe top and 1 at the bottom... besure to put these back in the rightplace; if not you will have oil leak

when retighten, go easy on thesebolts (about 16 ft lbs) you don'twant to strip the aluminum treadsor break any bolts

polish cover after installing it

bottom side-cover bolt with thewasher

note that there is 2 long bolts inthis set that also need to be installin the right place (upper left sidecover)

clean and inspect


2 of 16 10/23/2008 2:55 PM

remove the side-cover... there is 2dowels on the cover.

use a rubber mallet to lightly tapthe side cover loose

try not to rip the gasket bycarefully removing the cover

I was able to re-use my gasket

if damage replace gasket

this are must be oil free and cleanwhen reinstalling or you may havean oil leak

clean and inspect

dowels on the side-cover

must be oil free and clean whenreinstalling or you may have anoil leak

clean and inspect

PRIMARY DRIVE GEAR

with the transmission in neutralhold the clutch lever and spin therear wheel... the PRIMARYDRIVE GEAR should spin freely

if not

move on to the next step


3 of 16 10/23/2008 2:55 PM

CLUTCH PRESSURE DISC

press clutch lever the disc shouldmove out slightly out and the rearwheel should be able to spinfreely

if not, remove the 6 bolts (10 mmsocket) and springs

remove CLUTCH PRESSUREDISC and inspect for damage

when retighten, go easy on thesebolts (about 22 ft lbs) you don'twant to strip the aluminum treadsor break any bolts

spin rear wheel to see if thePRIMARY DRIVE GEAR spinsfreely

push the CLUTCH PUSH PIECEin and then press the clutch lever

the piece should move out about1/4 inch

if so then move on to nest step

remove the CLUTCH PUSHPIECE by pulling it out

there is washers and a bearinghere

inspect


4 of 16 10/23/2008 2:55 PM

remove CLUTCH DRIVEPLATES

clean and inspect each plates andset them down in the order andposition they are remove

will also be a good time to orderany damage or worn clutch driveplates

spin rear wheel to see if thePRIMARY DRIVE GEAR spinsfreely

CLUTCH SLEEVE HUB NUT

CLUTCH SLEEVE HUB NUT

pry or tap the locking bend backto its original shape on the hubnut

when reinstalling:

this nut has to be retighten atabout 80 ft lbs.... I just use theimpact gun and get it nice andtight...

you must re-bend the nut to lockthe nut back in place


5 of 16 10/23/2008 2:55 PM

remove clean and inspect nut

use an impact gun with a 30 mmsocket (6 point socket preferable)and remove the hub nut

an electric impact gun worksgood... as it is not too powerful tocause damage

remove clean and inspect washer

CLUTCH HUB

remove clean and inspect clutchhub


6 of 16 10/23/2008 2:55 PM

CLUTCH HUB

now spin rear wheel to see if thePRIMARY DRIVE GEAR spinsfreely

if it does spin freely at thispoint... you are there

clean and inspect

Tubular Nut

there is a nut that look like a gearin the center of the PRIMARYDRIVE GEAR... check to see ifit is loose

if you can turn it by hand,you found your problem

remove the nut and inspect


7 of 16 10/23/2008 2:55 PM

the nut in question is call aTubular Nut

clean and inspect

Tubular Nut

the nut in question

when installing this nut, use ahammer and blunt aluminum rodor brass rod as a punch to tightenit up

get it nice and tight

clean and inspect

clean Tubular Nut with electricalcontact cleaner or a solvent thatthose not leave any residue

apply lock-tite when installing nut


8 of 16 10/23/2008 2:55 PM

remove washer and PRIMARYDRIVE GEAR clean and inspect

clean and inspect

clean, inspect and apply lock-titewhen installing

the gear is not listed separately inthe parts manual and may be soldas part of the PRIMARY DRIVEGEAR

clean and inspect


9 of 16 10/23/2008 2:55 PM

clean and inspect gear, washersand bearings

clean and inspect PRIMARYDRIVE GEAR SPACER

clean and inspect


10 of 16 10/23/2008 2:55 PM

now you have everything cleaninspected

order all necessary parts

reverse disassemble proclean everything beforeinstalling...

after a short test drive I willrecommend a oil & filter changetoo... your engine was exposed todust and lint...

my test drive was done on thejack... be very cautious doingthis...

good luck

Listan1


11 of 16 10/23/2008 2:55 PM

Clutch parts name& part Number

1. 21151-48G00SPACER,PRIMARY DRIVEGEAR 1

2. 21100-48G00GEAR ASSY,PRIMARY DRIVE1

3. 21410-48G00HUB, CLUTCH 1

4. 21413-48G00SPRING,CLUTCH 6

5. 21441-48G00PLATE, CLUTCHDRIVE NO.1




9. 21451-48G00PLATE, CLUTCHDRIVEN NO.1

10. 21451-48G10PLATE, CLUTCHDRIVEN NO.2

11. 21462-48G00DISC, CLUTCHPRESSURE 1

12. 21471-48G00SEAT, WAVEWASHER 1109X124X1.6

13. 21472-48G00WASHER,CLUTCH PLATE1

14. 21482-41G00BOLT, CLUTCHSPRING 6

15. 09159-24010NUT, CLUTCHSLEEVE HUB 1

16. 09160-25056WASHER,CLUTCH SLEEVEHUB THR 125X50X2.50


12 of 16 10/23/2008 2:55 PM

17. 09160-25056WASHER,PRIMARY DRIVE1 25X50X2.50

18. 09164-24006WASHER,CLUTCH SLEEVEHUB WAV 1

19. 09263-32020BEARING,PRIMARY DRIVE1 32X37X38.3

20. 23110-24F00ROD, CLUTCH 1

21. 23111-48G00ROD, CLUTCHPUSH, L 1

22. 23121-41G00PIECE, CLUTCHPUSH 1

23. 23122-02FR0BALL, CLUTCHPUSH 1

24. 23122-48G00-A05CAMSHAFT,CLUTCHRELEASE 1

25. 23123-41G00-A05CAP, CLUTCHPUSH ROD 1

26. 23125-48G00-A05SPRING,CLUTCHRELEASERETURN 1

27. 23271-48G00-A05ARM, CLUTCHRELEASE 1

28. 09134-06015-A05SCREW,CLUTCH PUSHROD 1

29. 09160-10020-A05WASHER,CLUTCHRELEASE 110.5X24X1.0

30. 09160-15045WASHER,CLUTCH PUSHPIECE 115.5X28X1.0


13 of 16 10/23/2008 2:55 PM

31. 09263-10014BEARING, CLRLSE CAMLOWER 110X14X10

32. 09263-12027BEARING, CLRLSE CAMUPPER 112X18X12

33. 09263-15003BEARING,CLUTCH PUSHPIECE 115X28X2.0

34. 09282-10012SEAL, CL RLSECAMSHAFT OIL1

35. 09283-06010SEAL, CLUTCHPUSH ROD OIL 1

36. 09285-10004SEAL, CLUTCHPUSH ROD CAP1

37. 01550-0620ABOLT, CLRELEASE ARM 1

38. 08310-0006ANUT, CLUTCHRELEASE ADJ 1


14 of 16 10/23/2008 2:55 PM

http://www.m109riders.com/forum/index.php/topic,13045.new.html#new


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You are visitor - Happy Paws - Home Pagehappypaws-pet.com/m109/listan1_tubular_nut.pdfSuzuki M109R Clutch You are visitor # I ride my bike every day and today road to work came home