Can any tell me what happened here
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Thread: Can any tell me what happened here

  1. #1

    Default Can any tell me what happened here

    I recently just did a large Preventive Maintenance job myself and was conducting a test drive. On my drive I heard what I thought possibly a loose bolt fall off the bike. It wasn’t until i came home and saw I was leaking oils when I found this.(see pictures attached). It Is a 2007 and has about 48,000 miles. The work I did was replace the clutch disks and springs, new K&M air filters, fuel filter, spark plugs and oil change. Any help is appreciated, I’m taking her to the shop Tuesday. Just want to know if there is something I messed up?
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  3. #2
    Radio Active Member rynosback's Avatar
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    Quote Originally Posted by Ambuttrey View Post
    I recently just did a large Preventive Maintenance job myself and was conducting a test drive. On my drive I heard what I thought possibly a loose bolt fall off the bike. It wasnt until i came home and saw I was leaking oils when I found this.(see pictures attached). It Is a 2007 and has about 48,000 miles. The work I did was replace the clutch disks and springs, new K&M air filters, fuel filter, spark plugs and oil change. Any help is appreciated, Im taking her to the shop Tuesday. Just want to know if there is something I messed up?
    Looks like something let loose in your secondary.
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  4. #3
    Radio Active Member rynosback's Avatar
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    I thought I remember this happening once. Here is a thread on it, https://www.m109riders.com/forums/sh...Hole+secondary

    The hole in the housing even looks to be in same spot.
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  6. #4
    Very Active Member Frotosride's Avatar
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    I hate that this happened and it really is disappointing but I'm never getting rid of my 9! Mostly replying to bookmark and remind myself to just rebuild the secondary before I put the fresh engine through its paces. Hope your primary gear on the output shaft isn't trashed... I couldn't imagine paying a dealer to take my engine out much less splitting the case and tearing apart the whole output shaft.
    "Beat it like a red-headed Ford":
    '19 M9 '06 M9
    '09 commander
    '87 silverado on35's'87 c10 lwb(LS twin turbo sleeper project)'83 k20'83 k5 cucv 6.2 Detroit

  7. #5
    Very Active Member NoSetFine's Avatar
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    Ok.... now you guys are just freakin me out.
    People taking immaculate care of their 9's, just 'sploding for no reason.
    dafuq?!
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  8. #6
    Very Active Member blacklightning's Avatar
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    I am not mechanical at all. But I can tell you, there should not be a hole there. Sorry to hear that this happened to you. Hopefully you can get it back together without too much hassle, or money.

  9. #7
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    Something failed in the secondary drive. That's not that hard to remove. I'm sure you would see the problem. Obviously you need a new secondary drive.

  10. #8
    Very Active Member Dommy's Avatar
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    Quote Originally Posted by blacklightning View Post
    I am not mechanical at all. But I can tell you, there should not be a hole there
    Woe to You Oh Earth and Sea for the Devil sends the beast with wrath because he knows the time is short Let him who hath understanding reckon the number of the beast for it is a human number its number is M109R.

  11. #9

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    Just wanted to keep everyone updated, I went ahead and upgraded, the shop gave me an insane quote but I don’t think they even opened the secondary drive case. I’m going to see what I can and already get it running again. Any tips or video links will help. Here is some pictures of my new bike.Click image for larger version.

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  12. #10
    Radio Active Member rynosback's Avatar
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    Quote Originally Posted by Ambuttrey View Post
    Just wanted to keep everyone updated, I went ahead and upgraded, the shop gave me an insane quote but I dont think they even opened the secondary drive case. Im going to see what I can and already get it running again. Any tips or video links will help. Here is some pictures of my new bike.Click image for larger version.

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    I hope you get her back up and running right.
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  13. #11
    Very Active Member Frotosride's Avatar
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    Congrats on the new B.O.S.S.... That's the one I'm hoping to get. I've decided to keep my 06 and just use it as a test platform.

    For the other 9 I will look through the service manual and see if it shows disassembly and post up the pics and articles. You will definitely need to get another one and probably just put in the parts they already upgraded. Just know they aren't cheap. I know that Suzuki has updated PN for the bevel gears and I'm not sure that is absolutely needed unless your primary out put gear is messed up. The other part is I think the output gear is pressed into the bearing and onto the shaft. I will look to verify when I get a chance. Good luck..
    Last edited by Frotosride; 02-09-2020 at 08:25 PM.
    "Beat it like a red-headed Ford":
    '19 M9 '06 M9
    '09 commander
    '87 silverado on35's'87 c10 lwb(LS twin turbo sleeper project)'83 k20'83 k5 cucv 6.2 Detroit

  14. #12
    Very Active Member Frotosride's Avatar
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    Oh and you can completely remove the secondary drive unit from the engine and driveshaft without taking the engine out or removing the rear swing arm. Keep the the piece that looks like a metal gasket. It is actually a shim for setting back lash between the two bevel gears just like any normal differential.
    "Beat it like a red-headed Ford":
    '19 M9 '06 M9
    '09 commander
    '87 silverado on35's'87 c10 lwb(LS twin turbo sleeper project)'83 k20'83 k5 cucv 6.2 Detroit

  15. #13
    Very Active Member Frotosride's Avatar
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    So I just looked it up and the output/drive bevel gear is actually pressed on. You will need a special puller or just a lot of ingenuity to get it off the splines.

    In this pic are all the parts. Upgraded ones are circled.
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    "Beat it like a red-headed Ford":
    '19 M9 '06 M9
    '09 commander
    '87 silverado on35's'87 c10 lwb(LS twin turbo sleeper project)'83 k20'83 k5 cucv 6.2 Detroit

  16. #14
    Very Active Member Frotosride's Avatar
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    Here are the parts on rebuilding the secondary drive unit and setting back lash.
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    Last edited by Frotosride; 02-09-2020 at 09:21 PM.
    "Beat it like a red-headed Ford":
    '19 M9 '06 M9
    '09 commander
    '87 silverado on35's'87 c10 lwb(LS twin turbo sleeper project)'83 k20'83 k5 cucv 6.2 Detroit

  17. #15
    Very Active Member Frotosride's Avatar
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    Continued..
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    "Beat it like a red-headed Ford":
    '19 M9 '06 M9
    '09 commander
    '87 silverado on35's'87 c10 lwb(LS twin turbo sleeper project)'83 k20'83 k5 cucv 6.2 Detroit

  18. #16
    Very Active Member Frotosride's Avatar
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    And you're done.
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    "Beat it like a red-headed Ford":
    '19 M9 '06 M9
    '09 commander
    '87 silverado on35's'87 c10 lwb(LS twin turbo sleeper project)'83 k20'83 k5 cucv 6.2 Detroit

  19. #17

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    Thank you Frotosride! I appreciate it a lot I’ll let you guys know how it turns out on the repairs!

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