Couple of things I found when rebuilding mine. You can get the cases apart if you cut down an alan key to remove the part that stops the cases coming apart and leave the flywheel/generator in place, or buy the correct puller. I ordered the puller but while it was in transit, I cut down an alan key and got the cases apart. The rod that holds the fork gets bent ever so slightly. Whilst this is hardly noticeable, it does make a difference to where the fork engages the dogs. I changed mine to a solid rather than hollow tube. Going to take a lot of force to bend the solid bar. The dogs that engage 3rd gear are back cut from the factory. As I wanted to make sure I didn't have to go inside again, I had the dogs for 2nd gear back cut. Replaced all the forks with stronger items too. I think a lot of the stronger parts come the support that the Busa gearbox gets as that bike gets seriously abused in drag racing. Some 30K miles since the rebuild and not only does the gearbox still work, it works better now than it ever did from the factory. Never had any clutch judder and bike is currently on 67K miles. It's a 2013 bike so maybe Suzuki changed something? Love the bike but Suzuki, what went wrong with 2nd gear?
Hey Brian, great video. I'm curious if the seal that's next to the oil jet can be replaced without splitting the case. As mine is leaking oil from that seal. Thanks!
Be interesting to know what year this motor and others are that you have done and whether Suzuki modified it themselves in later engines, and how many km's before this shows as a problem.
Très intéressant et instructif ce tuto. Je vois que point de vu conception c'est du sérieux ce moteur (aucune courroie) mais qu'est ce qu'il s'est donc passé pour que cette boite de vitesse ait autant morflée ? serait -ce dû au gicleur qui était bouché ? (impressionnant cette fourchette cassée ainsi que ces dent d'engrenages) Ce "bouilleur" est relativement simple à démonter. Thank you Brian, friendship from France !
I'm about to buy a 2006 or 2007 M109R from a dealer and wondering if I should ask them to do this b4 I buy? Also, when this gets done, does this mean it wont happen again or did Suzuki do a recall to have it fixed permanently?
hey, i am interested in is m109 and c109 using same crancshaft covers? my c109 has damaged crancshaft cover(right side) and cant find used part. does cm109 cover fits c109 ?
I bought a 2012 M109r 2 months ago. It had 15500km on it. I have only done 1000km now I'm having this same problem. Very pissed off. I'm taking it back to the dealer to try and get them to do it under statutory warranty but I doubt they'll do it. We'll see
Hi Brian! Right now I'm thinking about getting an m109r and doing some research about potential problems. Your video was very helpful. I have to warn you though. It seems like you are somewhat mistaken about the gearbox lubrication system. The countershaft and driveshaft are not used as oil passages. They are lubricated through two separate jets and the oil channels lead to their needle bearing sides - the left one on the countershaft and the right one on the driveshaft. After that the oil just splashes around and drips down to the oil pan. At 50:40 you can see where the second channel starts and passes in the roller bearing seat to the driveshaft. The oil jet modification you have done allows more oil to pass to the countershaft and clutch but not the driveshaft. Although it may be that the cams on 2nd and 3rd driven gears will be lubricated better anyway - with the oil splatter from the countershaft. I wonder if all those problems happen with the unmodified clutch pull pin.
Hey how you doing I was trying to see where you located at I have an M109 and I have the same problem trying to see how much you charge to fix that with the second gear doing the same thing
Hi I have 09 1800 intruder 8,000 miles on it,bit concerned about the heavy clunk when putting into first gear it always done it from I got it.Have no issues with gears r clutch have check drive shaft all good if you put it in n e gear can rock the wheel about 2 inch you can hear the clunk inside engine put you in mine key way worn r clutch springs slack,your advice would be much appreciated thanks William
Can I get to my transmission without dropping the whole motor out of the bike? I know the clutch can be changed but what about the shifting forks and gears?
How do you know the cam, piston wrist pen and crank still get sufficient oil flow? how about thinner oil, better oil pump or different pressure control valve? Do you know if 2019/ 2020 models have made changes to improve this?
не так страшен как малюют . ну да шестеренок дохера , но зато электрики мало . ну не харли конечно , но соотносимо с хондой втх . минус один шестерни если полетят встанут в копейку. (хотя это маловероятно) nice job mexanicum respekto !
Jesus don't leave me now I'm going to do this next winter in OZ You must do the re-assembly for me I love this mate It is the best I've seen I can do this mod because of this vid I'm sure I'll be able to double the hole sizes as well as in the jet I'd just feel more confident having you do the re-assembly Please David
@@briandouglas1401 great to hear from you I will have no difficulty fixing this 2nd gear issue with your very good vid I need to feel 100% by having you do the reassembly I will set up a big screen in my workshop and just buckle up and do it Wonderful Brian David in Ballarat
@David Scott, I too am looking at doing this job, except I believe I have a big end bearing issue in my spare motor, and I’d like to mod a few things while I’m in the motor and box, like back cut the gears and have them re-hardened, polish inlet, outlet manifolds and crank shaft, oil jet mod, and anything else I can get done while I’m in there! Like you I’m confident doing the removal and tear down and documenting, but the rebuild worries me greatly... having a pro like @Brian. Douglas with a really helpful vid would really help, along with the manual I believe I could fix mine... The last motor I had fixed cost me over $6000...! Time to learn and save some valuable $$$ Thank you @Brian Douglas for the vids they are fantastic...
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
You should have used straps. We used them on our hoist. They are rated 2500 lbs each. This looks complicated. I really like this bike but seen this makes me worried. I have a 2015 Gxsr750R I was hoping to trade for this. Due to the return being too low from the dealers, I will just keep it and hopefully tried to get this. I’ll just sell mine privately. Any advice. Iam trying to transition from sports to cruiser bikes.
In reference to the second gear issue, I see what happens, the damage and potential damage… but I dont see WHY it happens… and more specifically, what is done to fix it? I am interested in getting an M109r and am able to do a rebuild on my own… I just need the info on why it happens and how to fix it. I cant imagine that second gear just pops back into the fork on its own. Are the dogs made incorrectly? Is the shift fork too wide or positioned incorrectly on the shift fork shaft?
In a nutshell it is insufficient oil to the clutch causing clunky gear change coupled with a hugely powerful engine that means something has to give. That is usually the gear engagement cutouts and selector forks. More oil at the clutch reduces the clunky gear change and it doesn’t happen again. I am still running the first engine I modified and don’t expect I will need my spare engine I have also modified.
if the transmission went into multiple gears wouldn't it lockup causing the wheel to lock and the bike to crash, or do the teeth always shear off before that can happen
On a smaller and lighter bike yes but this is a heavy bike and has a big fat rear tyre with heaps of traction. The bike I am repairing in the video did lock up but only after gears had broken and jammed up the other gears. The engine is just too big and powerful for the gearbox. I have heard of this happening at slow speed and the box locked up without shearing the gears but that poor bloke was on a roundabout in the rain so slow speed and reduced traction.
Good day, my name is Alexey. I am from Kazakhstan, the city of Almaty. I have an M109r in stock. The other day, oil flowed from the gearbox oil seal. I removed the gearbox and found two problems. I cannot twist the washer that closes it, this is the first problem. The second problem was detected by the backlash and noise of the bearing which is located on the motor housing. I have two questions for you: How to unscrew the washer? How to remove the sprocket and bearing to replace the bearing. Is it possible to do this without disassembling the engine?
@@bradh3292 Thanks for the answer. As a result, I had to disassemble the entire engine, this is the first time in my life. To disassemble this is half the battle, but now I don't even know how to assemble it! You don't have a video of how to assemble it correctly in what order!
Just got to get some disposable income to buy the parts. two gears plus a selector fork going to set me back $400 and as i have a running engine that i have already modified its pretty low on the priority at the moment.
