Suzuki M109R Boulevard Step by Step Engine Removal

This is a full step by step (per Suzuki service manual) how to on removing the engine from the flagship of the Suzuki cruiser lineup... The M109R. This bike hasn't changed since it came to market so this tutorial will be the same for any year from 2006 to current.
This is a very big job and I must stress the importance of having the proper tools, space, and general mechanical knowhow.
Happy to answer any questions so leave a comment and subscribe!
Thanks for watching!

[@paulhernandez21]

Wow, that looks like a pain in the ass. Great job. I just got my hands on a 2007 M109 and this video will definitely come in handy one day. My first cruiser, coming off a 1000cc R1. Amazing sport cruiser for anyone wanting to switch from a super sport to cruiser. This bike is smooth, comfortable and powerful as hell.

[@MotoMedic]

The biggest pain is the sheer size of the engine. Probably weighs in around 200lbs. It's actually a relatively easy engine to disassemble an put together.

[@paulhernandez21]

With your experience with this bike, are parts hard to come by?

[@russelltimmerman3771]

man i love my 109 but frankly they are so cheap used, it nearly makes sense to get a new bike than to fix the second gear problem in an old one.

[@Cadavissr31]

Thank you for showing that video. I figure it is very much the same process for the M90?

[@MotoMedic]

@@Cadavissr31 I would imagine it's fairly similar, yes.

[@joelrivera5368]

Good job bro

[@user-ot9jj3rf5t]

i need mine done!

[@owenrichardson3026]

Thanks for that knowledge ,great vid :)

[@WaitAMinute1989]

Ps. Don't lose any bolts. Geez, better you than me. Great Job!

[@MotoMedic]

🤣🤣 Definitely DON'T lose any bolts lmao!

[@sumitkkanungo5423]

when I start the my 2012 model m109r, the sound of rattling sound comes from the side of the clutch and as soon as you press the clutch lever, the sound stops what is the problem of the thing please help me

[@ericthered9655]

Manual says to put the secondary drive on before putting the engine back in. If you can make that come together you are one bad man.

[@MotoMedic]

I'm not that bad lol... Had to pull the secondary when I shoved the thing back in 😂

[@ericthered9655]

@@MotoMedic Like catching flies with chop sticks.

[@tsrwakemaster]

great video

[@suntzuwarsword1964]

Very cool...thank you...

[@lalib74]

Sir do you have crankshaft 2013 boulevard m109r. 1800 cc

[@MotoMedic]

No... I'm not a parts house or a dismantler lol

[@tyrone5066]

Why are there so many m109r 2nd gear problems and is it expensive to fix.?

[@MotoMedic]

I think they just didn't sell enough of them to consider a recall on the design. It is an expensive job to do. About 12 hours labor plus parts.

[@gilbertocanez8998]

i have Suzuky 109r boulevard 2007 ...... I have problems with my motorcycle the rear head gets too hot and has no compression and the front head doesn't heat up and comes out with pressure on the muffler what could it be and what do I have to do to fix it

[@MotoMedic]

From your description I honestly have no idea what's wrong with your bike. I'd have to have my hands on it and that's not easy so I'd recommend taking it to a mechanic.

[@k.bellingham8335]

As always thanks to you KZbinrs for providing this indispensable knowledge. So why are you pulling this engine? I have an M109r and wondering what the issue is. Comments below lead to think there is a transmission problem. Thanks MotoMedic for .... just being you lol.

[@MotoMedic]

Thanks for the comment! Yes it's a pretty common issue with this bike. 2nd gear shift forks go and they'll start slipping out of 2nd gear.

[@Kalanioccc]

i had my bike in to get the 2nd gear slipping fixed. long story short, i got the bike back 2.5 years later and now it's down on power, seems like only one cylinder is firing. I replaced all spark plugs and got fuel injectors cleaned, replaced fuel filter (it was completely missing when i got the bike back). anyway, it starts and runs, it idles weird (every 2-3 seconds it does a weird hiccup type thing) but it will go with throttle and not stumble. it's just really down on power. could they have messed up the timing? ps - im in northern utah.

[@MotoMedic]

Sounds like timing to me. Not hard to get it a little off. 2.5 years?? That's insane!

[@Kalanioccc]

@@MotoMedic that's what i was afraid of. yeah, young powersports down here in utah really botched the whole thing. they fixed the transmission alright but when they got it back together it wasn't running right, and then they gave me the runaround for a couple years trying to "figure it out." i think they only set the timing on one of the cylinders and not both.

[@Kalanioccc]

@@MotoMedic i posted a short on my channel of it idling. i also let it run for a while and used a laser temp gun, noticed the rear cylinder was running hotter than the front.

[@MotoMedic]

@@Kalanioccc yeah man... That sure sounds like it's off a tooth or something. It could be a very simple fix but you'd have to get the head covers off and re-time it. Cam chain has to get loose enough to move. Probably just tensioner out could slack it enough, then just have to get it to TDC and start going through the steps.

[@Kalanioccc]

@MotoMedic possible to do without pulling engine you think?

[@davejones5160]

Is this much different that swapping out a c50? I have one with a broken rod bearing. Was thinking of switching it out but can't find a video on it.Great job by the way!

[@MotoMedic]

Not sure how closely it'll be to the C50 but it's probably similar. Do whatever you can to find a service manual! They're the best reference and exactly how I do every job. I'm willing to bet you can find a pdf copy of your service manual with some googling and a little snooping around. 👍

[@RamonGarcia-py9hp]

Necesito la máquina completa de esa moto

[@MotoMedic]

donde vives? Vivo en Quintana Roo, MX

[@coenwooldrik]

Nice clear video. But I have a question tho regarding the engine lift. I will be swapping an engine on an Intruder 800, from 92. Do you think this would be possible without any lift at all? Or do you recommend me to purchase one, because its too much of a hassle without it? Thanks in advance

[@MotoMedic]

Find one to borrow at least... It'll make life so much easier. These things are awkward and heavy, and never just slip right out.

[@coenwooldrik]

@@MotoMedic already ordering one, thanks

[@MotoMedic]

@@coenwooldrik good call 👍 lol

[@MichaelWilliams-mt4hu]

I sure hope that my 2nd gear holds up. I'm sure that a shop would change thousands.

[@MichaelWilliams-mt4hu]

Sorry...would charge thousands.

[@MotoMedic]

The repairs with parts in my shop totaled just under $2000. Any dealership will be significantly more.

[@ericw.2726]

shift into 2nd firmly, and never roll on hard while you're there. depending on your year that'll help keep 2nd operating properly. also avoid the pin mod.

[@NOPHATCHIX777]

Where u located and whats a motor and trana rebuild cost?

[@MotoMedic]

I'm in northern Idaho. And for this particular job you're looking at 12 hours at $100 an hour. Plus parts... Where are you from? It's probably cheaper to take it to your local shop unless you're within a few hours drive of me.

[@mikeyy1011]

I have to do this on my 2009. Engine blew front rod not sure if can fix it or just replace engine with a used one. Bike only has about 25000kms

[@MotoMedic]

Oh man that sucks! Personally... I think I'd try finding another engine to stuff in it. Probably cost less overall and get ya back on the road sooner.

[@mikeyy1011]

@@MotoMedic Thanks for the quick response. I'm in canada so not many salvage yards here that have these. But I'm going to try and reach out to a few places in the US for it

[@TheWilldee]

About to drop mine also to due to slipping out of second all the time; being Suzuki original parts should I go to an after market dealer to get new replacement parts?

[@MotoMedic]

If you never want it happening again I'd get the OEM parts and take them to a machine shop and get them back cut. Unless you're able to find the exact gear already back cut that's aftermarket. I'd think that would be a tough find myself. Or just replace it and ride it until you decide to sell lol. Unless you plan on keeping it around a long time.

[@TheWilldee]

@@MotoMedic Thanks a bunch for info. The bikes are awesome and with such high end compared to 2019 chieftain I test drove. I just love the response and thrill of it as a cross between cruiser and sport bike: not many can miss with it. Best of both worlds.

[@MotoMedic]

@@TheWilldee I'd most definitely agree with that!

[@visionsoundelectronics9615]

Where are you located at I have a M109 I'm trying to get a second gear replaced

[@MotoMedic]

Coeur d'Alene Idaho. And I don't have my shop back up and running.

[@rafaramirez7756]

Hi Moto Medic i do need a rebuild engine for my suzuki m109 2007 what can i do or where are you located, need information please!!

[@MotoMedic]

I'm in north Idaho, Rafa... I'm not sure it's worth shipping an engine for me to do it, but I thank you for wanting me to do it 🤙 I'm sure there are very good mechanics that are a lot closer to you than I am!

[@coolkatz9012]

Makes Harley's look like a dream to work on..except the vrods fkn nightmare.

[@MotoMedic]

I'd rather work on anything metric than bother with fixing my Harley. I don't even own SAE tools lol. Engineering just isn't even close to the Japanese or even most euro brands IMHO.

[@coolkatz9012]

@@MotoMedic Good call )

[@ericthered9655]

@@MotoMedic Heretic! Bring on the butt-hurt Harley only guys.

[@keithsuiter6741]

I have a M109 need the number to your shop if I have any problems like that

[@MotoMedic]

Keith when I did this video my shop was in the central valley of California. I'm in northern Idaho now and will be getting back to working on bikes again in the near future. At the moment though I'm working 50 hours a week as a commercial HVAC installer while I get ready to get the shop going again. I'm happy to answer any questions though and you can always reach me directly through email [e-mail]

[@duanerobertson5515]

Do you have time for one more m109?

[@MotoMedic]

No longer have a shop so I'm not able to do much. But if you're near Coeur d'Alene Idaho let's see what we can do lol

[@travespepple1877]

How long did the removal actually take?

[@MotoMedic]

You can get it done in 5 hours. But give yourself 8.

[@Thermool]

@@MotoMedicso not 15 minutes? Lol You make it look easy, and the manual helps a lot

[@MotoMedic]

@@Thermool lol... Nope. A bit longer

[@carlgar2007]

I would have taken the radiator down, drive unit out, Why fight the thing?

[@MotoMedic]

Did it by the service manual. Didn't have to fight it really. It's just a massive engine.

[@dontefoster2927]

How much does that engine weigh?

[@MotoMedic]

Getting up close to about 150lbs or more.

[@nextup2212]

Where are you located

[@MotoMedic]

When this video went up I had a shop in Bakersfield, CA. I'm no longer in business and only do work on the side and I'm in Eastern Washington.

[@GG-xs8vt]

Hell No… Thanks for the video.

[@MotoMedic]

🤣

[@dealviindeproductions1687]

This freaked me out😬

[@MichaelWilliams-mt4hu]

Sorry....charge thousand

[@reece8355]

Sale me them pips

[@MotoMedic]

Wish I could... not my bike :D