M109R problem

P

Planet earth

New member
A coworkers '07 M109R has a problem, it lost the clutch! There is action with the cable & arm. After doing some "other" forum searching I found that there have been some people with the same problem. The problem seems to be that the nut for the primary gear has come loose. Has anyone had this problem? It's just out of the 1 year warranty so we are going to fix it. The only thing I may have a problem with is the exhaust, seems there is some kind of valve & sensor that needs to be removed/instaled a special way. Has anybody removed and reinstalled their exhaust without any problems? There is a poker run next weekend so there is no time to find a repair manual. Here's a link:

http://pagreaves.com/109/clutch/clutch.htm
 
The fix seems pretty straight forward, good link!! As far as the exhaust I removed my sideburners yesterday to install new crush gaskets. I had a nasty high speed backfire. Found the my front gasket was leaking, my culprit. As far as removing the exhaust here is my procedure. First but a blanket, piece of cardboard, whatever on the ground under the exhaust. Remove any rings.

1] Loosen rear can to header clamps, 5mm allen.
2] Remove rear can 3/8-16 bracket bolts, behind and slightly underneath rear can, 9/16 box end wrench.
3] Remove rear can.
4] Loosen and remove header studs, 12mm socket or 12mm box/open end combo.
5] Carefully remove pipes, one at a time.
6] Inspect crush gaskets, it usually is better just to order new gaskets since they are a one time use. Reinstall clamp studs is 18 ft/lbs
7] Do your clutch thing.
8] Install new crush gaskets
9] Carefully install header pipes, finger tight only
10] Install the PITA can making sure the pipe clamps are in position and start the 3/8-16 bracket bolts
11] Uniformly tighten the header studs to 18 ft/lbs
12] Tighten can to header pipe clamps with 5mm allen
13] Tighten 3/8-16 bracket bolts
14] Test drive and check for exhaust leaks
15] Reighten everything after 100 mi.
 
You are speaking about the SET valve. Head back over to the M109 owners forum and pose that question.

FYI, I would try to get the dealer to do it still. It is a known issue that Suzuki is trying to hide. Play hardball and you should be able to get the dealer to roll over and do it as it is a quality issue that has been growing recently.
 
:DProblem fixed!:D The SET valve took 2 tries to get it right. We went on the poker run, me on my GT750 and my buddy on his M109R & had no problems at all. The round trip was 150 miles and the M shifted better then new!:bluethum:
 
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