Suzuki M109R Use and care manual

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

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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)

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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. There are two long bolts in the top left.
NOTE: 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.
Figure 1 Bottom side-cover bolt with the washer

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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, etc. to pull the gasket away from
bike. Slow and steady)
You should be able to re-use your gasket (if damaged, replace gasket)
Must be oil free and clean when reinstalling or you may have oil leak
Figure 2 There are 2 dowels on the cover

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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

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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

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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 aluminum treads or break any bolts!

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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. If so then move on to nest step

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

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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

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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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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.
NOTE: You must re-bend the nut to lock the nut back in place. (hit the notch with a center punch
and brass hammer to re-notch it)

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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

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remove clean and inspect washer

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CLUTCH HUB:
1. Remove clean and inspect clutch hub

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The CLUTCH HUB

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1. Now spin rear wheel to see if the PRIMARY 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, you found a BIG problem
3. Remove the nut and inspect

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1. Clean and inspect