M109R Clutch Removal and Install - All Years

This video will help you remove and install a new clutch to your M109R with all the proper adjustments.
To order a clutch - • M109R OEM Clutch Kits ...
To upgrade to the 2011-Present clutch here are the part numbers. This works on all years. The stack height is the same even though it is one more fiber and one more steel plate. The plates have their thickness reduced to keep the same stack height.
Here is what you need
qty (6) Part # - 21413-35F10 SPRINGS
qty (6) Part # - 21441-22H00 PLATE,CLUTCH DR
qty (5) Part # - 21451-22H00 PLATE,CLUTCH DR
qty (2) Part # - 21451-48G10 PLATE,CLUTCH DR
qty (1) Part # - 21441-48G40 PLATE,CLUTCH DR
qty (1) Part # - 21471-48G00 SEAT,WAVE WASHER
qty (1) Part # - 21472-48G10 WASHER,CLUTCH
Clutch cover gasket - qty 1 - 11482-48G00
If you need a pressure - plate - #11 DISC PRESSURE 21462-48G00

[@zato6226]

The only Clutch replacement video that covers the pressure plate adjustment screw that I've found. Very thorough , clear explanation, and simplified . Thank you.

[@bigpapam109]

Glad we could help and thanks for watching. We will be having a bunch more videos coming.

[@stephenmackinnon7328]

Excellent video, right on point with out any BS,

[@daveralph5830]

Simply the best clutch replacement video I've seen for the M1800 - I'm a novice and I changed the lot with no issues. Well done chaps!

[@lhcycles1301]

Thank Dave! Glad it helped you.

[@sternjam]

Great instructional video, I was able to replace my clutch cause of this vid and I’m not a mechanic but I am good with tools 😊 👍🏽 👍🏽👍🏽👍🏽

[@lhcycles1301]

That is awesome! Very glad we could help you do it yourself. Thanks for watching.

[@brandonchamp6322]

This video was such a huge help. There aren't any other videos about the 109 with this much detail. A perfect instructional.

[@lhcycles1301]

Thanks so much for watching! I am glad that we could do this and help fellow riders do the job and save money.

[@robertwilson6793]

Gentlemen ; I can't thank you enough for sharing your experience with all who love this beast of a bike . Very informative and appreciated. Thanks again.

[@lhcycles1301]

You’re welcome. Glad we can help and save you from having to put it in a shop.

[@paulpepi1047]

A very well explained step by step video, you have done well grasshopper 👍

[@lhcycles1301]

Thank you!

[@SKIDMARK507]

Brilliantly done my friend, thank you for looking after us with your skills. Skid.

[@lhcycles1301]

Thanks!!

[@bradasmith]

Amazing video, very informative and will be extremely helpful when I do my tube nut and new clutch plates.... Thank you !!

[@lhcycles1301]

Glad to help! Thanks for the kind words.

[@user-sk4nk7ko6c]

Vidoes soo lovely

[@derekknoblock3104]

Spectacular thank you so much!!!

[@lhcycles1301]

Glad we could help!

[@allwelike]

Thank you very helpfull

[@lhcycles1301]

Thank you. Glad it helps.

[@petehira1594]

Because torque settings are for new bolts & thread, Im a bolt torque tuner as well Snug is the word I also use supa glue over Loctite if needed. Great Vid good job!

[@lhcycles1301]

Thanks! You can torque older bolts with no issues. The only ones you don't want to do is torque to yield bolts, like in heads etc... Those stretch when you torque them so you will see a failure if you reuse them. I torque just about everything, but small bolts I trust my "feel" more than a torque setting.

[@petehira1594]

so if the "pin" is too tight the clutch will not be fully released? Thus, it slips?

[@stevewirch1247]

Great video! One question for you. While replacing the clutch, is it worth taking the basket off and checking the tube nut? I'm about to do the clutch on my 07 and wanted your opinion. I have no symptoms of tube nut being loose... Thanks

[@ahmadalgarny7434]

Thank you for the interest, but how many discs are there inside the clutch without the two rings?

[@N0b00st]

Can you change the clutch on the bike or do you have to take it out

[@kylemisiolek4801]

Those 2 small ones in the right way

[@lhcycles1301]

Not sure I understand your comment.

[@jed-uq4yz]

I've had to release the pin twice & have found the best adjustment is 1 full turn.

[@lhcycles1301]

1 full turn is what the manual calls for. I prefer 3/4 as it keeps the engagement closer to the grip. Either one works fine.

[@jaydot1987]

Thank you for the video. It was very informative. How long should the plates soak for before we begin the installation?

[@lhcycles1301]

Thanks! I usually soak overnight and have never had an issue.

[@alejandroleynes]

Thanks for the video, could you give me the link where to buy the cloch? I bought one. The motorcycle data is correct, but I received one that was a little smaller in size. Even the teeth are different. Thanks.

[@leonardolares9314]

excellent. Sr. I have a question for you. How can I know if my clutch M109R is working porpely ?

[@lhcycles1301]

If the bike feels like the rpm’s are going up under throttle, but it isn’t increasing speed like it should.

[@bigsi924]

Just done my new clutch in a 2016 Boss Intruder.The set of plates that I was sent has 6 double sided ones? Not 5.?I got my kit from Mean Cycles .When I put them in they filled the basket to the same place as on your video .I'm guessing not all 1800 Suzuki clutches are the same?

[@lhcycles1301]

2006-2009 have a 5 disk setup. 2011-present have a six disk. They end up at the same stack height. Earlier models can upgrade to your setup with no issues.

[@twistedmetriccycles]

always torque your bolts!!!! it will cause a leak

[@ScottMiller-tu3gg]

Sorry to bother you about this again, I did the mod on the pushrod (ground 3 flats) and it still chatters. I did not ride it very long, does it take a while for the oil to work through? I am going to try to lean the bike to the right (with my son`s help) to see if that helps. Thanks!

[@lhcycles1301]

Did you replace the wave washer and inspect the main drive plate? The oiling is immediate but if you didn't replace the wave washer and inspect the main drive plate, that could be your issue. Sometimes it gets grooved. Also, the wave washer is a spring and we believe that due to lack of oil, it gets hot and also contributes to the issue, which is why we always replace that.

[@twistedmetriccycles]

the cover is 7-8 foot pounds like 90% of metric aluminum motors

[@lhcycles1301]

Have seen them snap at 8 ft/lbs. It won't leak when snugging up good. Never had one leak in over 100 clutch jobs. Also, if the torque wrench is not calibrated well, and is reading low, it will snap those bolts. Have seen this a few times now.

[@GG-xs8vt]

Very interesting video. Thanks. Question, I just picked up a M109R. What does the M and R stand for. Thanks again.

[@lhcycles1301]

Thanks for watching! The M stands for muscle. In the Boulevard line there is a C for cruiser as well. I am not sure what the R is for.

[@GG-xs8vt]

Super , thanks for that.

[@lhcycles1301]

@@GG-xs8vt glad to help.

[@oliverbeck622]

Great! One question.: The allready known issue with the loose tube nut, happens on my clutch. Do you know the exact dimensions of that nut? I ask, because I'll buy me a matching tool for it. THX in advance

[@lhcycles1301]

real sorry, never saw this. I do not know the dimensions of it but I can measure it the next time i have one apart.

[@michaelweathers2267]

Is this the same way for a C109r? Are the clutch kits the same as well?

[@lhcycles1301]

Same premise for the clutch. I have never checked the part numbers to see if it is the same clutch.

[@ScottMiller-tu3gg]

I have a feeling this is what is wrong with my recently purchased bike. I just started getting bad clutch chatter at times when pulling out from a stop in 1st gear - not all of the time though. I`m thinking the clutch was never adjusted and now it may have burned clutch plates? I have read about doing a pushrod mod (grinding the sides to allow more oil to pass), are you familiar with this?

[@lhcycles1301]

Actually your issue is from lack of oil. Look up the clutch pin mod where it is ground on 3 sides to allow more oil.

[@ScottMiller-tu3gg]

Thank you! Is this something I can do or does it have to be sent to a machine shop? I tried to look it up and couldn`t find any clear info. I get the gist of what needs to be done. @@lhcycles1301

[@lhcycles1301]

@@ScottMiller-tu3gg here is a thread. You can do it yourself but the picture is wrong. We do 3mm wide, not deep. If you don't want to do it, let me know and I can put you in touch with someone that does them. Send yours and it is $30 shipped back. I do some myself and send some to him. www.m109riders.com/threads/clutch-pin-mod-step-by-step.327818/

[@sternjam]

I’m not a motorcycle mechanic but this was pretty straightforward!!! Great video Now I’m kinda thinking about doing it my self, thanks for the tips which gain my confidence!!! 🫡

[@lhcycles1301]

Glad we could help.

[@PrimoGixxer]

Does the bike need to be on neutral to change the clutch?

[@lhcycles1301]

It makes no difference.

[@michaelnewman68]

Can you post or add how far the clutch should be moving after the install? I just changed mine but once I get everything back together and pull the clutch it still doesn’t work? Think I need a new clutch cable? I just replaced it though with the motion pro armor coat clutch cable from parts giant.

[@lhcycles1301]

In the beginning of the video, you can see it where I talk about the pressure plate. After you have it all back together, and have it adjusted, is the arm moving up and down? If the cable is new, then that should not be the problem. Did you do the internal adjustment when doing the clutch?

[@michaelnewman68]

@@lhcycles1301 thank you for your help. I did do the adjustments like you showed, and I followed the video step by step, I watched it 20 times. Lol. I ended up leaving the cover off the clutch after the third time of having to take it off to make sure that it was working correctly. And I found that after doing all my adjustments the screw is tight and when I pull my clutch it only separates about a cm. Is that right?

[@lhcycles1301]

@@michaelnewman68 give me a call when you are free. 240-671-4410. If I don't answer I am working on a bike, leave me a message and I will call you back.

[@michaelnewman68]

I can’t thank you enough for all of your help and advice. Thank you so much.

[@lhcycles1301]

@@michaelnewman68 you're welcome. Hopefully we can get this figured out.

[@donaldwayne4219]

So, at how many miles should the clutch require replacing then?

[@lhcycles1301]

all depends on how you ride it and if it is adjusted correctly. Friend had 105k on his 109 clutch before he blew the motor up.

[@user-sk4nk7ko6c]

Please I want vidoe in yahama fi bicke

[@maxamus01]

I just followed this and when adjusting the set screw to get a little tension on it now there is not enough room to get the lock/jam nut on. What could cause that. The arm is all the way up. Do i need to adjust the arm.

[@lhcycles1301]

When the screw bottoms out, you back on 3/4 to 1 turn and you will be fine. When you do that the nut isn’t able to be in the threads? If so then something is wrong with the clutch or install. What year bike and what clutch did you put in?

[@maxamus01]

@@lhcycles1301 2008. EBC Clutch

[@maxamus01]

I was trying to add a picture but can't for some reason

[@lhcycles1301]

@@maxamus01 Ok, I have no luck with those and we won't install them. Most of our customers that come in with burnt up clutches tend to be EBC. There is a measurement called "stack height" and that is the measurement of the full clutch pack. if the stack height is off and is too high, your pin needs to go in further and that could be your issue.

[@lhcycles1301]

@@maxamus01 message me the image on FB if you want. Harris Horwtiz.

[@kevinshack2004]

What if u have a hydraulic clutch how would u adjust it

[@lhcycles1301]

Sorry for the delay. You would need to remove the slave cylinder from the clutch arm, do the adjustment and put it back. It is a pain but that is what needs to be done.

[@kevinshack2004]

Sounds good preciate it

[@kevinshack2004]

Ur video help 1000%

[@lhcycles1301]

@@kevinshack2004 that is awesome. Glad we could help.

[@dmable7969]

Where can I order link

[@lhcycles1301]

OneidaSuzuki.com

[@mrbroadway226]

​@lhcycles1301 Is there a key word to search? I put in clutch plate and nothing shows

[@lhcycles1301]

@@mrbroadway226 where are you located. I am now selling the full kit. Cheaper than you will find anywhere. Text me at 240-671-4410. I ordered 6 and they are should be here in the next few days. I have 5 sold and one left.