Suzuki M109R Replacement Download Page 13 | Manualshive

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13

| MYM109R.COM

1.

Spin rear wheel to see if the PRIMARY DRIVE GEAR spins freely

stop here if you are only replacing the clutch

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Summary of Contents for M109R

Page 1: ...ation is therefore strictly at your own risk In no event will I be liable for any loss or damage including without limitation indirect or consequential loss or damage or any loss or damage whatsoever...

Page 2: ...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 m...

Page 3: ...3 MYM109R COM 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...

Page 4: ...he top and 1 at the bottom Be sure to put these back in the right place or you will have an oil leak 3 There are two long bolts in the top left NOTE When retighten go easy on these bolts about 10 14 f...

Page 5: ...5 MYM109R COM...

Page 6: ...arefully removing the cover NOTE The gasket will probably stick to the block and cover Carefully use a small screwdriver et bike Slow and steady You should be able to re use your gasket if damaged rep...

Page 7: ...7 MYM109R COM Must be oil free and clean when reinstalling or you may have an oil leak Clean and inspect Figure 3 Dowels on the side cover...

Page 8: ...8 MYM109R COM 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...

Page 9: ...UTCH 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 t...

Page 10: ...esting 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 If so the...

Page 11: ...11 MYM109R COM 1 Remove the CLUTCH PUSH PIECE by pulling it out 2 There is washers and a bearing here 3 Inspect...

Page 12: ...YM109R COM 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 pl...

Page 13: ...13 MYM109R COM 1 Spin rear wheel to see if the PRIMARY DRIVE GEAR spins freely stop here if you are only replacing the clutch...

Page 14: ...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 NOTE Yo...

Page 15: ...109R COM 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...

Page 16: ...16 MYM109R COM remove clean and inspect washer...

Page 17: ...17 MYM109R COM CLUTCH HUB 1 Remove clean and inspect clutch hub...

Page 18: ...18 MYM109R COM The CLUTCH HUB...

Page 19: ...RIMARY DRIVE GEAR spins freely 2 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 2 if you can turn it by hand y...

Page 20: ...20 MYM109R COM 1 Clean and inspect...

Page 21: ...21 MYM109R COM Tubular Nut Tool Honda Socket Spanner for the VTX works Part Number 07910 4630100 Cost 90 00...

Page 22: ...22 MYM109R COM 1 Clean and inspect 1 Clean Tubular Nut with electrical contact cleaner or a solvent that those not leave any residue 2 Apply RED Loctite when installing nut 3 Tighten to 100 105 ft lbs...

Page 23: ...23 MYM109R COM 1 Remove washer and PRIMARY DRIVE GEAR clean and inspect 1 Clean and inspect...

Page 24: ...24 MYM109R COM 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...

Page 25: ...25 MYM109R COM 1 Clean and inspect gear washers and bearings...

Page 26: ...26 MYM109R COM 1 Clean and inspect PRIMARY DRIVE GEAR SPACER...

Page 27: ...d 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 c...

Page 28: ...28 MYM109R COM Figure 4 Factory Diagram...

Page 29: ...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...

Page 30: ...9 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...

Page 31: ...31 MYM109R COM Clutch Plate Install Order Figure 5 Install 1st direction doesn t matter Plate 6 21441 48G10...

Page 32: ...32 MYM109R COM Figure 6 Install 2nd direction doesn t matter 13 WASHER CLUTCH PLATE 21472 48G00 new...

Page 33: ...33 MYM109R COM Figure 7 Install 3rd 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...

Page 34: ...34 MYM109R COM Figure 8 Install 4th Plate 10 21441 48G00...

Page 35: ...35 MYM109R COM Figure 9 Install 5th Plate 5 21451 48G00...

Page 36: ...36 MYM109R COM Figure 10 Install 6th Plate 9 21441 48G00...

Page 37: ...37 MYM109R COM Figure 11 Install 7th Plate 5 21451 48G00...

Page 38: ...38 MYM109R COM Figure 12 Install 8th Plate 9 21441 48G00...

Page 39: ...39 MYM109R COM Figure 13 Install 9th Plate 5 21451 48G00...

Page 40: ...40 MYM109R COM Figure 14 Install 10th Plate 9 21441 48G00...

Page 41: ...41 MYM109R COM Figure 15 Install 11th Plate 5 21451 48G00...

Page 42: ...42 MYM109R COM Figure 16 Install 12th Plate 9 21441 48G00...

Page 43: ...43 MYM109R COM Figure 17 Install 13th Plate 5 21451 48G00...

Page 44: ...44 MYM109R COM Figure 18 Install Last Plate make sure it s facing away from the bike Plate 10 21451 48G10...

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