Front suspension and handlebars of motorcycle Suzuki Boulevard M109R (2006-2025)

Front fork construction
1. O-ring; 2. Spacer; 3. Outer tube; 4. Oil seal retainer; 5. Oil seal; 6. Oil seal stopper ring; 7. Dust seal; 8. Spring; 9. Inner rod/Damper rod (cartridge); 10. Inner tube; A. Front fork cap bolt; B. Inner rod lock nut; C. Damper rod bolt; D....

Removal and disassembly front fork
Remove the front wheel. ( 9-9 ) Remove the bolts, left and right and front fender. Remove the fasteners 1 and bolts 2. Remove the head light assembly and disconnect the couplers. Loosen the front fork upper clamp bolt 3. Note: Slightly loosen the...

Inspection front fork
Inner and outer tubes Inspect the inner tube outer surface and outer tube inner surface for scratches. Inspect the "ANTI-FRICTION" metal surfaces for scratches. If any defects are found, replace them with a new one. Caution: Do not remove the...

Reassembly front fork
Reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: Oil seal and dust seal Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. 1. Dust seal; 2. Oil seal...

Installation front fork
Install the front fork in the reverse order of removal. Pay attention to the following points: Install the front fork to the steering stem and steering stem upper bracket. Install the top of outer tube 5 mm (0.2 in) higher than the upper surface of...

Steering construction
1. Handlebar clamp; 2. Handlebar clamp holder; 3. Handlebar holder bracket; 4. Steering stem upper bracket; 5. Steering stem nut; 6. Dust seal; 7. Steering stem upper bearing; 8. Steering stem lower bearing; 9. Steering stem; A. Handlebar clamp...

Steering removal
Remove the front forks. ( 9-15 ) Remove the handlebar. ( 9-30 ) Remove the tachometer. ( 10-32 ) Remove the turn signal mounting bolts 1, brake hose guide bolts 2 and brake hose mounting bolt 3. Remove the steering stem head nut 4 and washer. Remove...

Inspection and disassembly steering
Inspect the removed parts for the following abnormalities. Handlebars distortion Distortion of the steering stem. Bearing wear or damage Abnormal noise of bearing If any abnormal points are found, replace defective parts with the new ones. Remove...

Reassembly steering
Reassemble the steering stem in the reverse order of disassembly. Pay attention to the following points: Outer race Press in the upper and lower bearing outer races with the special tools. 09941-34513: Steering outer race installer set Inner race...

Installation steering
Install the steering stem in the reverse order of removal. Pay attention to the following points: Bearing Apply SUZUKI SUPER GREASE "A" to the bearings. 99000-25010: SUZUKI SUPER GREASE "A" or equivalent Install the upper bearing 1 to the steering...

Steering tension adjustment
Check the steering movement in the following procedure. By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 - 30 mm (0.8 - 1.2 in). Check to make sure that the cables and wire harnesses are properly routed....

Construction, removal and installation handlebars
Construction 1. Handlebars; 2. Grip end cap; 3. Left handlebar grip; 4. Left handlebar switch; 5. Right handlebar grip; 6. Right handlebar switch Removal Remove the right rear view mirror 1. Remove the brake master cylinder 2. Remove the throttle...