Motorcycle engine repair Suzuki M109R (Boulevard, 2006-2025)

Engine components removable with engine in place
The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. Engine center ITEM REMOVAL INSPECTION INSTALLATION PAIR control...

Engine removal and installation engine removal
Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. Drain engine oil. ( 2-17 ) Drain engine...

Engine disassembly
Caution: Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions. Remove the front and rear spark plugs. Starter motor Remove the...

Engine components inspection and service
Caution: Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations.

Cylinder head cover — installation, disassembly and inspection
Disassembly Remove the PAIR reed valve cover 1 and PAIR reed valve 2. Inspection Inspect the PAIR reed valve for the carbon deposit. If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. Installation Install...

Camshaft wear and runout
Camshaft identification The camshafts can be identified by the engraved letter. "A" Front intake camshaft "B" Front exhaust camshaft "C" Rear intake camshaft "D" Rear exhaust camshaft Cam wear Check the camshaft for wear or damage. Measure the cam...

Cam chain tension adjuster
Inspection The cam chain tension adjusters are maintained at the proper cam chain tension automatically. Unlock the ratchet А, and move the push rod in place to see if it slides smoothly. If any stickiness is noted or ratchet mechanism is faulty,...

Cylinder head and valve
Cam chain tensioner Remove the cam chain tensioner 1. Cylinder head distortion Decarbonize the combustion chambers. Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at...

Cylinder repair
Cylinder distortion Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the...

Piston and piston ring
Piston diameter Using a micrometer, measure the piston diameter at 10 mm (0.4 in) А from the piston skirt end. If the measurement is less than the limit, replace the piston. Piston diameter: Service Limit: 111.880 mm (4.4047 in) at 10 mm (0.4 in)...

Starter clutch — disassembly
Starter driven gear inspection Turn the starter driven gear by hand. Inspect the starter clutch for a smooth movement. Check that the gear turns only in one direction. Inspect the starter driven gear bushing for any damage. If necessary, replace it...

Starter torque limiter
Starter torque limiter inspection Caution: Do not attempt to disassemble the starter torque limiter. The starter torque limiter is available only as an assembly. Check the slip torque with the special tools. Slip torque Standard: 31 - 51 Nm (3.1 -...

Generator cover
Generator inspection ( 10-10 ). Reassembly Apply a small quantity of THREAD LOCK to the startor bolt. Tighten the generator stator bolts 1, clamp bolt 2 and CKP sensor bolts 3. 99000-32050: THREAD LOCK "1342" or equivalent Generator stator bolt 1:...

Crankcase — removal and installation
Gearshift fork and gearshift cam Removal Remove the gearshift cam bearing retainer screws 1 and gearshift fork shaft retainer plug 2 from the lower crankcase. Remove the gearshift fork shafts 3 and gearshift forks 4 from the lower crankcase. Remove...

Balancer driven gear
Balancer driven gear inspection Visually inspect the gear teeth for wear and damage. If they are worn, replace the gear with a new one. Balancer driven gear disassembly Remove the balancer shaft with the special tool. 09913-70210: Bearing installer...

Crankshaft and conrod — installation
Conrod small end I.D. Using a small bore gauge, measure the inside diameter of the conrod small end. Conrod small end I.D.: Service Limit: 23.040 mm (0.9071 in) 09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22403: Small bore gauge (18 - 35 mm) If...

Crankshaft journal and thrust bearing — installation and inspection
Inspection Inspect each bearing of upper and lower crankcases for any damage. Selection Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown. 09900-22301: Plastigauge Caution: Never rotate the crankshaft when a...

Engine reassembly
Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. Note: Apply engine oil to each running and sliding part before reassembling. Crankshaft Install the...

Balancer shaft
Install the balancer shaft on the upper crankcase. Note: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing. Set the balancer shaft so that its punch mark А is aligned with the punch mark В on the...

Front cam chain tension adjuster
After unlocking the ratchet, push the cam chain tension adjuster rod. Insert the special tool between the ratchet and the adjuster body. 09918-53810: Chain tensioner lock tool Install the front cam chain tension adjuster No. 1 with the bolts and...

Generator — reassembly
Degrease the tapered portion of the generator rotor assembly and also the crankshaft. Use nonflammable cleaning solvent to wipe off the oily or greasy matter to make these surfaces completely dry. Install the key 1. Install the generator rotor...

Rear cam chain drive sprocket
Install the rear cam chain drive sprocket 1 onto the crankshaft. Note: When installing the cam chain drive sprocket, align the wide spline teeth А and В. Install the rear cam chain drive sprocket bolt with the washer. Hold the generator rotor and...

Starter torque limiter/starter idle gear
Install the starter idle gear 1 and shaft 2. Install the bushings 3 into the crankcase and generator cover. Note: Apply molybdenum oil solution to the inside of the bushings. Molybdenum oil solution Fit the washers 4 onto the starter torque limiter...

Rear cam chain idler sprocket
Engage the cam chain No. 1 onto the cam drive idler sprocket and it to the upper crankcase. Align the groove А on the cam idler sprocket with the embossed line В on the upper crankcase. ( 3-94 ) Apply SUZUKI MOLY PASTE to the idler shaft 3 and...

Piston ring — reassembly
Install the piston rings in the order of oil ring, 2nd ring and 1st ring. The first member to go into the oil ring groove is a spacer 1. After placing the spacer, fit the two side rails 2. Note: Side designations, top and bottom, are not applied to...

Cylinder — reassembly
Fit the dowel pins and new gaskets 1 to the crankcase front and rear. Caution: Use the new gaskets to prevent oil leakage. Apply a small quantity of MOLYBDENUM OIL SOLUTION to the sliding surface of the pistons and cylinder walls. Molybdenum oil...

Front camshafts
Turn the crankshaft counterclockwise approx. 1-1/3 turns (486°) with the box wrench and align "F I T" line А on the crankshaft with the index marks В of the upper crankcase hole while keeping the camshaft drive chain pulled upward. Caution: Pull the...

Rear camshafts
From the position where the front camshafts have now been installed, rotate the generator rotor approx. 2/3 turn (234°) and align the "R I T" line А on the crankshaft with the index marks В of the upper crankcase hole. Caution: Pull the cam chain...

Front cam chain tension adjuster of engine reassembly
The cam chain tension adjuster are identified by the embossed letters (F-UP). Retract the push rod by pushing the stopper 1. Install a new gasket 2. Caution: Use a new gasket to prevent oil leakage. Install the cam chain tension adjuster 3 and...

Front and rear cylinder head cover
Pour engine oil in each oil pocket in the cylinder heads. Note: Be sure to check the valve clearance. ( 2-8 ) Install the new gaskets to the cylinder head covers. Apply SUZUKI BOND to the cam end caps of the gaskets as shown. 99104-31140: SUZUKI...

Installing generator cover
Install the dowel pins and gasket 1. Caution: Use the new gasket to prevent oil leakage. Install the generator cover and tighten its bolts. Note: Fit the new gasket washers to the bolts А. Caution: Use the new gasket to prevent oil leakage. Apply...

Intake pipe
Apply SUZUKI SUPER GREASE "A" to the O-ring. 99000-25010: SUZUKI SUPER GREASE "A" or equivalent Install the intake pipes. Caution: Use the new O-ring to prevent air from scking through the joint. Note: Face the "UP" mark on the intake pipe to the...

Starter motor
Apply SUZUKI SUPER GREASE "A" to the O-ring. 99000-25010: SUZUKI SUPER GREASE "A" or equivalent Tighten the starter motor 1 bolts to the specified torque. Starter motor bolt: 6 Nm (0.6 kgf·m, 4.5 lb·ft) Install the spark plugs. ( 2-16 )