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BigPapaM109
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« on: February 20, 2008, 12:17:59 PM » |
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This thread, and the pdf, have been updated 5/5/2008 to reflect changes. Users have given great feedback that made things easier or problems they encountered so I have incorporated those into this thread. The order of the detent arm, washer and spring was reversed by someone and it was binding so I put that in here. Putting the detent arm on first, per the manual, and then the star made it easier so I reflected that as well.Thanks to CBR1000Dude for his right up on the spring fix and I ended up borrowing one of his pictures as mine came out blurry. UPDATE: I had an issue this past weekend where as we left the bike in neutral and because of that it would not allow us to torque down the star bolt as the star was trying to turn. So, I suggest you leave the bike in first gear when starting this mod.If your Factory Pro box says “M109” on it then you have the right gasket. If not, you may not have the correct gasket and you would need to order one from your dealer. The part # should be 11485-48GOO This install doc is here as a pdf so you can print and walk it out to your bike. First thing....DRAIN YOUR OIL.  This is the only chrome cover that you will need to remove. There are 5 bolts that need to be removed.  You need to remove this 10mm bolt and then gently separate with a screw driver. You just need to rock this back and forth and push in the center and it will easily come off. Remember, if you pry this apart, you may need to use a big plier and gently squeeze back together when you reinstall it later on so the bolt can go through.  After this comes off the shaft, just set it down and out of the way. You will notice that the shift lever is loose so you can put this where you want to be out of your way. The blue arrow points to another 10mm bolt. We first took that bolt out but realized shortly after that it can stay in as that whole bracket comes loose when you remove the 5 bolts to the cover.  Don't freak out by all the colored arrows but I felt the need to point a few things out to make life easier. These all use a 8mm socket. 2 yellow arrows, just normally take those bolts out. 1 green arrow, has a cable with a connector that the bolt goes through. Remember to put that back on when you reinstall cover. 2 red arrows, remove both bolts and take the whole bracket and slide it out of the way towards the left. 1 blue arrow, this is the shaft that will come out and stays attached to the cover.  Use a 10mm socket and remove the screw. The spring and the arm will slide right off. Be careful as there is a washer on the bottom of the arm where the bolt goes through.  At this point, use a 5mm hex bit socket or an allen wrench and unscrew the bolt in the center of the star. Eventually the star will just come off with the bolt still in it.  If the bolt is in the star when you pull it off, simply tap this bolt out of the star and put it in the new star.  First, put lock tight on the bolt. Assemble the spring to the arm as you can see in the picture. Just in case you are not sure, bolt goes through the detent arm, then the washer and then the spring goes on. Go ahead and bolt this back on the bike with the star out. Torque the bolt to 10 Nm or 7 ft/lb. Check the play in the arm and if moves freely then you are ok, if it feels hard and will not move, back off the bolt just a little until it is not binding.  Take a screw driver and pry the detent arm to the right and put the star back on, There is a hole on the back of the star. Make sure you put that on so that it sets in on the pin. Put the bolt in until the star is firmly on and then you can release the detent arm. Use lock tight and also torque the bolt to 13nm or 9 ft/lb.  The cover is now ready to go on. I found the easiest way is to just remove the shaft and put that in first as you can see in the next picture. Now, when you remove the shaft from the cover, be VERY careful as there is a washer on the inside where the shaft goes through the cover. Don't lose it and you have to look for it as it can be covered in oil.   At this time, you should clean the cover with a razor blade and brake cleaner to make sure there is no residue of the gasket on both surfaces. I then use a gasket sealer and brush it on. I brush it on the cover, place the gasket on, then brush on the sealer on the gasket and then mount it up to the bike. When you put the cover on, remember to bolt the bracket and the wire connector back in place. The manual did not give torque specs that we could find so we put the cover back on, tightened very snug but not over doing it.
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« Last Edit: May 05, 2008, 11:55:24 AM by BigPapaM109 »
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 07 Pearl White 9 A & R Motorsports 6K HID GI-PRO Blue OEM crash gaurds, thanks Ryan Stebel Air Horn Shift Kit -EVO-S93 XP brake light module Kuryakyn Zombie™ Pegs ISO Grips Custom Dynamics Hyper Light Kits Custom Dynamics Chrome LED License Plate Eagle Eye LED Large Turn Signal in front & rear Chrome Brake Reservoir 1.5" bones DeBeavered DeBadged Accessory Fuse Block Regular Cut Gel Seat K&N Filters |
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Delmustator
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« Reply #1 on: February 20, 2008, 12:38:45 PM » |
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Did you have to replace the gasket? I noticed some material was still stuck near some of the bolts.
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-Del
06 VB Suzuki Boulevard M109R -Lowered 2.5- -Polished BIG AIR- -Kury ISO Grips w/TB- -Stealth Rack- -Dunny Elite 250- -6K HID- -Barnett Stainless Cables- -LE Clear Taillight- -Suzuki Engine Guards- - FP Shift Kit-
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BigPapaM109
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« Reply #2 on: February 20, 2008, 12:48:10 PM » |
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Did you have to replace the gasket? I noticed some material was still stuck near some of the bolts.
Used the stock gasket. It came right off, and all I did was wipe it down before putting the cover on. There was no left over gasket near the bolts, that was just oil residual basically and wiped right off. Gasket looked brand new when we pulled it off. |
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07 Pearl White 9 A & R Motorsports 6K HID GI-PRO Blue OEM crash gaurds, thanks Ryan Stebel Air Horn Shift Kit -EVO-S93 XP brake light module Kuryakyn Zombie™ Pegs ISO Grips Custom Dynamics Hyper Light Kits Custom Dynamics Chrome LED License Plate Eagle Eye LED Large Turn Signal in front & rear Chrome Brake Reservoir 1.5" bones DeBeavered DeBadged Accessory Fuse Block Regular Cut Gel Seat K&N Filters |
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CBR1000DUDE
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« Reply #3 on: February 20, 2008, 01:02:58 PM » |
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I was hoping you would have taken a photo of the 2 stars side by side so we could see the differences. It looks very similar, maybe a hair deeper in the valleys. It also is smaller in diameter, the OEM goes all the way to the edge of the big bearing. Actually, the more I look at the photos, the more I see. Did you look at them side by side?
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« Last Edit: February 20, 2008, 01:09:01 PM by CBR1000DUDE »
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A man must know his limitations... Harry Callahan
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BigPapaM109
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« Reply #4 on: February 20, 2008, 01:07:36 PM » |
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I was hoping you would have taken a photo of the 2 stars side by side so we could see the differences. It looks very similar, maybe a hair deeper in the valleys. Did you look at them side by side?
I did my friend....I put them in the review thread but will put them here too. http://www.m109riders.com/forum/index.php/topic,26315.0.html"First thing that we noticed was the size of the star. It is a lot smaller which possibly could shorten the shift. Second, if you look at the springs, you will notice that the spring on the right is the new one from Factory Pro and it appears to have a slight curve in its design. This makes it appear identical to the fix that CBR1000dude did to his bike."   |
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07 Pearl White 9 A & R Motorsports 6K HID GI-PRO Blue OEM crash gaurds, thanks Ryan Stebel Air Horn Shift Kit -EVO-S93 XP brake light module Kuryakyn Zombie™ Pegs ISO Grips Custom Dynamics Hyper Light Kits Custom Dynamics Chrome LED License Plate Eagle Eye LED Large Turn Signal in front & rear Chrome Brake Reservoir 1.5" bones DeBeavered DeBadged Accessory Fuse Block Regular Cut Gel Seat K&N Filters |
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rcj_houston
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« Reply #5 on: February 20, 2008, 01:09:23 PM » |
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Awesome write up bro!  Excellent work! |
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White 07' M109R:
"A motorcycle is a spiritual object...When I ride...I'm exactly in the moment...it's like meditation...I'm in the flow." ~Indian Larry~ R.I.P.
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JUtah
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« Reply #6 on: February 20, 2008, 01:36:30 PM » |
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Not really seeing the difference in the spring...
Have you put any miles on it yet? Any noticeable difference?
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BigPapaM109
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« Reply #7 on: February 20, 2008, 01:46:02 PM » |
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Not really seeing the difference in the spring...
Have you put any miles on it yet? Any noticeable difference?
It is very suttle but if you look at the spring, it come out and curves like a mm or 2 more. When it is on the bike, it didn't lay flat like stock but was off the wall like a mm or 2 which is like CBR1000Dude's fix. As far as noticeable difference, there is a review in the general area but I noticed a huge difference. As far as miles, not really but in the mile I drove it I went up and down the gears considerably and it is enough to completely notice the difference. As far as I was concerned, Factory Pro has been doing this for a long time and is very good at what they do so the difference I noticed in the shifting in the mile or so I tested it was enough for me to believe. |
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07 Pearl White 9 A & R Motorsports 6K HID GI-PRO Blue OEM crash gaurds, thanks Ryan Stebel Air Horn Shift Kit -EVO-S93 XP brake light module Kuryakyn Zombie™ Pegs ISO Grips Custom Dynamics Hyper Light Kits Custom Dynamics Chrome LED License Plate Eagle Eye LED Large Turn Signal in front & rear Chrome Brake Reservoir 1.5" bones DeBeavered DeBadged Accessory Fuse Block Regular Cut Gel Seat K&N Filters |
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seapup
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« Reply #8 on: February 20, 2008, 02:20:41 PM » |
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1 wheel peel
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« Reply #10 on: February 20, 2008, 03:51:46 PM » |
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IN4RNO-M109R
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« Reply #11 on: February 20, 2008, 05:32:02 PM » |
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2008 M109R Orange Mods: Engine Guards, Laminar Lip Windshield, Kuryakyn ISO Pegs and Grips & throttle boss, M109 Engine Cover, Tank bra, JS Quick change seat knobs, Battery Tender, Boulevard MC Cover, Gregg's SS side covers, Temp Gauge dip stick, Suzuki rack and backrest. Amsoil user. Member - Oregon Chapter.
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BigPapaM109
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« Reply #12 on: February 20, 2008, 05:36:36 PM » |
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Thanks. I also posted this above in the start of the thread, after the fact but... This install doc is here as a pdf so you can print and walk it out to your bike. |
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07 Pearl White 9 A & R Motorsports 6K HID GI-PRO Blue OEM crash gaurds, thanks Ryan Stebel Air Horn Shift Kit -EVO-S93 XP brake light module Kuryakyn Zombie™ Pegs ISO Grips Custom Dynamics Hyper Light Kits Custom Dynamics Chrome LED License Plate Eagle Eye LED Large Turn Signal in front & rear Chrome Brake Reservoir 1.5" bones DeBeavered DeBadged Accessory Fuse Block Regular Cut Gel Seat K&N Filters |
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Big6'9
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« Reply #13 on: February 20, 2008, 05:40:32 PM » |
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Don't freak out by all the colored arrows but I felt the need to point a few things out to make life easier. These all use a 8mm socket. 2 yellow arrows, 1 green arrow, 2 red arrows, 1 blue arrow, [/quote] Next time Turn off Dance Dance revolution to post without the arrows  Hey it was a good post thanks for the info |
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Quote That shift to second is easy to miss if you don't shift it like you mean it. by Jutah 90 GT Telara The last year Datsun Bluebird import    http://media.putfile.com/M109--ME |
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rynosback
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« Reply #14 on: February 20, 2008, 06:14:11 PM » |
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Great write up. |
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06 Black 9 A & R 6K HID GI-PRO Blue Gel seats Billet Derby cover OEM crash gaurds Stebel air Horn SS Clutch cable SS front and rear brake lines Shift Kit -EVO-S93 XP brake light module ISO wing pegs KewlMetal Kewlocks BEST MODS FOR THE MONEY, BANG FOR THE BUCKhttp://www.m109riders.com/forum/index.php/topic,29852.0.html |
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dealien
Semi Active Member
 Offline
Posts: 64
BAU BAU
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« Reply #15 on: February 20, 2008, 06:15:56 PM » |
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really nice post ...Thanks guys for the work...i`ll do mine but i have warranty and that will be a problem ...so i guess i hate to wait until the warranty expires... Thanks for the pics....Really nice job...congrats!!!  |
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If u want something done right u`ve got to do it urself!!!
I would rather die of thirst than drink from the pocal of mediocrity!!!
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Local Boully
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« Reply #16 on: February 20, 2008, 06:23:23 PM » |
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excellent "how-to" BigPapa. I look forward to getting mine!
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« Last Edit: February 20, 2008, 06:25:22 PM by Local Boully »
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Local Boully
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« Reply #18 on: February 20, 2008, 06:27:37 PM » |
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really nice post ...Thanks guys for the work...i`ll do mine but i have warranty and that will be a problem ...so i guess i hate to wait until the warranty expires... Mine is under warranty also, but by what I've been reading lately, even if something breaks in there, Suzuki is doing their best to wash their hands of it anyway. I'm not waiting for the warranty to run out. Might as well fix it before Zuk tells me I broke it anyway  |
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BigPapaM109
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« Reply #19 on: February 20, 2008, 06:36:02 PM » |
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really nice post ...Thanks guys for the work...i`ll do mine but i have warranty and that will be a problem ...so i guess i hate to wait until the warranty expires... Thanks for the pics....Really nice job...congrats!!! WHY?  The whole process is 1 hour and you can take the same hour and convert back to stock star and spring before putting the bike in for a warranty claim. I have a 3 year on mine and will convert it back if something happens. Chances are, you may prevent your tranny from going and being denied coverage of the same exact warranty you are worried about. |
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07 Pearl White 9 A & R Motorsports 6K HID GI-PRO Blue OEM crash gaurds, thanks Ryan Stebel Air Horn Shift Kit -EVO-S93 XP brake light module Kuryakyn Zombie™ Pegs ISO Grips Custom Dynamics Hyper Light Kits Custom Dynamics Chrome LED License Plate Eagle Eye LED Large Turn Signal in front & rear Chrome Brake Reservoir 1.5" bones DeBeavered DeBadged Accessory Fuse Block Regular Cut Gel Seat K&N Filters |
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Shock
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« Reply #20 on: February 20, 2008, 08:18:08 PM » |
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wylu
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« Reply #21 on: February 20, 2008, 08:52:46 PM » |
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Great job |
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The Iceman
Semi Active Member
Offline
Posts: 74
"DOUBLE TROUBLE"
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« Reply #22 on: February 20, 2008, 09:02:45 PM » |
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FANTABULUS Great job
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07 LE-- MOD'S to date: Zuki Gel seats, engine guard, back rest, lugage rack, Power Com III, V/H pipes, Holly Intakes, JSD-3, chrome drive shaft, swing arm and brake covers, Cycle House levers, Carbon Fiber kit. More in the mail and much more to come.
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BirdMan
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« Reply #23 on: February 21, 2008, 12:26:33 AM » |
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: I will be doing this mod soon and thanks for the info it should be a breeeeeeze
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Ken(BirdMan)  |
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Zoom
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« Reply #24 on: February 21, 2008, 01:52:04 AM » |
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2007 RED M109R
Gel Seats, chrome shaft cover, rear caliper cover, ISO grips and TB, Iso Dually foot pegs, 2" lowering bones, custom exhaust, Factory Pro Shift Kit, Dunlop E3 130/250, V-Stream Light Tint Touring shield.
De-badged & De-beavered, hard bags, GIPro, 2" polished risers, Suzuki engine guards, K&N filters, Barnett cables, Stebel horn, FI200R, Amsoil in engine and rear.
1980 Sportster XLH 1000, original paint, engine never apart, had since 1986.
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