Engine fuel supply and exhaust systems of motorcycle Suzuki Boulevard M109R (2006-2025)

Fuel delivery system
The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel...

Fuel tank and fuel pump
Fuel tank removal Remove the left and right frame side covers. ( 9-5 ) Remove the fuel tank mounting bolt. Lift and support the fuel tank about 10 cm (3.94 in) with the proper stay. Note: Be careful not to lift the fuel more than about 10 cm (3.94...

Throttle body construction
1. TP sensor; 2. STP sensor; 3. STVA; 4. Fuel delivery pipe; 5. IAP sensor; 6. O-ring; 7. Fuel injector; 8. Cushion seal; 9. Air screw; 10. ISC valve; 11. Vacuum hose; А. Fuel delivery pipe mounting screw; В. STP sensor mounting screw; С. TP sensor...

Air cleaner box removal
Remove the fuel tank. ( 6-3 ) Remove the bolts. Disconnect the drain hose 1. Loosen the clamp screw 2. Remove the right air cleaner box. Remove the bolts. Disconnect the drain hose 3. Loosen the clamp screw 4. Remove the left air cleaner box. Air...

Throttle body disassembly, cleaning and inspection
Disconnect the IAP sensor vacuum hoses 1, ISC valve hoses 2 and fuel feed hoses 3. Remove the fuel delivery pipes and hose assembly 4. Remove the fuel injectors 5. Remove the TP sensor 6 and STP sensor 7 with the special tool. 09930-11950: Torx...

ISC valve inspection, removal and installation
The ISC valve can be checked without removing it from the throttle body. Refer to the ISC VALVE INSPECTION for details. ( 5-70 ) If the resistance is not within the standard range, replace the ISC valve motor assembly with a new one. ISC Valve...

Throttle body reassembly
Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points: With the STV fully closed, install the STP sensor 1 and tighten the STP sensor mounting screw to the specified torque. Note: Apply thin coat of...

Air cleaner chamber and throttle body installation
Installation is in the reverse order of removal. Pay attention to the following points: Connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead wire refers to...

STP sensor adjustment
If the STP sensor adjustment is necessary, measure the sensor out put voltage and adjust the STP sensor position as follows: Remove the air cleaner chamber. ( 6-13 ) Disconnect the STVA coupler. ( 6-14 ) Insert the needle pointed probes to the STP...

Fuel injector removal, inspection and installation
Fuel injector removal Remove the fuel tank. ( 6-3 ) Remove the air cleaner chamber. ( 6-13 ) With battery negative cable disconnected, disconnect the injector couplers. Remove the fuel delivery pipes. ( 6-15 ) Remove the fuel injectors. ( 6-16 )...

Throttle valve synchronization
Check and adjust the throttle valve synchronization among two cylinders. Step 1 Remove the fuel tank. ( 6-3 ) Remove the ISC valve. ( 6-18 ) Connect the ISC valve coupler 1 and hoses 2. Connect the special tool (Mode select switch) to the dealer...

Throttle position sensor (TPS) setting
After all adjustments are completed, check or adjust the TPS setting condition. (Refer to page 5-20 for TPS setting procedure.)

EXCVA (exhaust control valve actuator) and EXCV (exhaust control valve)
EXCVA and EXCV removal Turn the ignition switch OFF. Remove the left frame side cover. ( 9-5 ) Connect the special tool (Mode select switch) to the dealer mode coupler. ( 5-18 ) After turning the special tool's switch ON, turn the ignition switch...

Exhaust pipe and muffler removal
Remove the right frame cover. ( 9-5 ) Remove the lower frame cover 1. Disconnect the EXCVA lead wire couplers 2. Disconnect the front and rear HO2 sensor lead wire couplers. (For E-02, 19, 24) Remove the muffler cover 3. Remove the No. 1 muffler 4....

Throttle body hose routing
Throttle body hose routing 1. ISC valve hose (R); 2. ISC valve hose (L); 3. Throttle body; 4. Boost hose; 5. Purge hose (For E-33); 6. ECT sensor; 7. Air cleaner; 8. Breather hose; 9. Oxygen senser (For E-02,19,24); *1. Yellow mark; *2. Face the tip...

Pair (air supply) system hose routing (for Е-03, 28, 33)
Pair (air supply) system hose routing (for Е-03, 28, 33) 1. PAIR control solenoid valve; 2. PAIR reed valve

Pair (air supply) system hose routing (for the others)
Pair (air supply) system hose routing (for the others) 1. PAIR control solenoid valve; 2. PAIR reed valve

Fuel tank installation
Fuel tank installation 1. Heat shield; 2. Fuel pump; 3. Clamp; 4. Face the tip of clamp to the backward; 5. Face the arrow mark to the forward, when installing the fuel tank cap; 6. Fuel tank cushion; 7. Rear fender cover cushion; 8. Apply instant...