Suzuki Boulevard M109R engine repair and overhaul


Symptoms of engine repair on a Suzuki Boulevard M109R are:

  • Extraneous noise in the engine
  • High oil consumption
  • Coolant flow
  • Low compression in the engine or large difference between cylinders
  • Excessively high compression associated with carbon deposits in the combustion chamber
  • Blue smoke from the muffler
  • Obvious oil leak from the engine
  • Transmission problems
  • Stages of repair work on the Suzuki Boulevard M109R engine:

  • Disassembly of Suzuki Boulevard M109R for engine removal
  • Removing the Suzuki Boulevard M109R engine
  • Cleaning the engine before disassembly
  • Disassembling the motor
  • Complete engine troubleshooting
  • Cleaning the engine from metal shavings and other contaminants
  • Diagnosis of all engine bearings and gears
  • Replacement of worn/broken/bent parts
  • Engine assembly
  • Checking valve clearances
  • Engine installation on Suzuki Boulevard M109R
  • Final assembly of Suzuki Boulevard M109R, launch
  • All engine repair work is carried out by a highly qualified mechanic with extensive experience. A 1 year guarantee is provided for all work performed.

Suzuki Boulevard M109R valve adjustment

Check the thermal clearances of the valves according to the service manual for your Suzuki Boulevard M109R, as well as after disassembling the head or replacing the timing chain or when a characteristic “clunking noise” appears from the cylinder head.

Increased valve clearances lead to increased noise when the engine is running, and if the clearances are too small, the valves will not close, and the engine will not develop rated power, and sometimes it will be difficult to start.

Our service center provides:

  • Adjusting valves using a rocker mechanism
  • Adjusting valves with washers (Washers are available for adjusting valves with a diameter of 7.48 mm and 9.48 mm)
  • Please note that after adjusting the valves, in some cases it is necessary to synchronize the carburetors.

    Motorcycle service Suzuki Intruder / Boulevard.

    MOTOR SERVICES.

    We provide professional services for repair, tuning and optimization of Suzuki Intruder / Boulevard motorcycles with a guarantee of quality work and WITHOUT USE of spare parts and tuning made in China! Being an official dealer of the Suzuki factory, as well as all famous Japanese, Spanish, Taiwanese, American and Italian custom studios that produce unique tuning and spare parts for the Suzuki Intruder / Boulevard, we also produce more than 250 items of exclusive tuning for these motorcycles and have various production capacities for individual projects!

    SERVICE IN OUR SERVICE. FULL DIAGNOSTICS AND PRE-SALE INSPECTION OF YOUR MOTORCYCLE IN OUR SERVICE IS ALWAYS FREE! WE DO NOT PROVIDE DIAGNOSTICS, SELECTION, OR ON-SITE MOTORCYCLE REPAIR SERVICES!
    ATTENTION!
    We do not accept motorcycles with consumables and spare parts purchased externally for service, because... We cannot guarantee their performance, and therefore cannot take responsibility for the consequences of their use! As a last resort, if we do not have the necessary parts in stock, we can direct you to trusted stores or offer to purchase original parts to order, at a big discount, through us... We accept for service only water-injected motorcycles of the following Suzuki models:

    • VZR1800 / M1800R / M109R;
    • VLR1800/C109R;
    • VZ1500/M90;
    • VL1500/C90;
    • VZ800 / M800 / M50;
    • VL800/C50.

    The cost of work is calculated based on the totality and volume of services:

    Please note that the cost of services in aggregate is lower than the same services separately - the more services are provided at one time, the lower their cost!
    Painting work:
    Only complete motorcycles are accepted for painting, both with and without restoration of painted parts, taking into account the disassembly and assembly of the motorcycle by our own forces.
    Painting and restoration of individual spare parts is carried out only in conjunction with other work on this motorcycle. Spare parts brought separately for painting and repair, as separate works, are not accepted. Motor slipway - repair of a motorcycle frame:
    Correction (restoration) of a motorcycle frame is carried out on a turnkey basis and includes: disassembling and assembling the motorcycle, correcting the geometry of the frame, restoring the appearance of the frame (painting).
    Motorcycles are accepted only assembled! The price of a set of services, for example, for M109R / VZR1800 / M1800R is 130,000 rubles. Motorcycle service hours:

    • 24 hours a day, by appointment, from mid-April to October 1st!
    • From October 1 to mid-April, the motorcycle service works only for the maintenance of motorcycles in winter storage!
    • from September 15 of each year, registration for service is carried out at the beginning of the next season;
    • information regarding winter storage is here...

    POPULAR PRODUCTS ON OUR SITE:

    Repair and replacement of clutch Suzuki Boulevard M109R

    One of the most important mechanisms of the Suzuki Boulevard M109R is the clutch. Although this is a fairly simple structural element, it has an important task. The operation of the clutch is based on the frictional force between its discs. The torque of the motor is transmitted to the driven parts, which in turn transmit the torque of the gearbox.

    The need for clutch repair in Moscow is dictated by various factors, among which are intensive operating conditions. In addition, repair of the Suzuki Boulevard M109R clutch is in demand in case of planned wear of its individual elements.

    Common clutch faults Suzuki Boulevard M109R

  • Wear of friction linings.
  • Deformation of damper springs.
  • Malfunction of the clutch basket splines.
  • Clutch repair or maintenance involves the following work:

  • Replacement of friction discs of the Suzuki Boulevard M109R clutch;
  • Repair or replacement of the clutch machine;
  • Replacing or servicing the clutch cable;
  • Replacing and adjusting the clutch lever.
  • Diagnostics and replacement of timing chain, repair of timing chain tensioner Suzuki Boulevard M109R

    Quite often, a malfunction of the Suzuki Boulevard M109R timing chain is caused by an increase in the pitch between the links. As a result, the engine begins to idle incorrectly. Therefore, it is not at all surprising that the chain begins to jump several teeth at the same time. What does this mean? Firstly, the engine will stall. Secondly, the valves may be jammed. This, in turn, may require expensive engine repairs. Therefore, when the first signs of malfunction are detected, it is recommended to replace the timing chain on the Suzuki Boulevard M109R.

    Suzuki Intruder M1800R (VZR1800, Boulevard M109R)

    There is still a virus of chopperism in me and it activates from time to time. I’m sitting here, thinking to myself: “I should take something for the season. Without hesitation, I would take a used GS in good condition to replace a stolen one, but it turns out to be a bit expensive. And those that we can afford look too tired. But you can try something alternative!” And then there is old age, inevitable, like the tide of the sea. In your fifth decade, your reaction weakens, your joints creak, and you increasingly want to roll rather than fly. This is where you start looking at choppers, cruisers and other bobbers.

    It was at that moment that I saw the Suzuki Intruder and realized that if I ever owned a chopper, this would be it. Moreover, precisely , and not , and precisely R, and not . Perhaps even in a version with a racing stripe across the entire device.

    I really like its appearance, and since for choppers appearance is the most important operational parameter, the matter can be considered resolved. However, innate paranoia forced me to delve into the thickets of the Internet to understand how this device is doing with such little things as comfort, reliability and technical equipment. If you ask me, a person far from the chopper topic, about the legends in this area, I will immediately name HD and Vulcan from Kawasaki. I admit that real chopperologists will not agree with me, nevertheless, for me personally, these two brands are the most recognizable. Of course, HD's leadership is undeniable, despite all the efforts of Japanese manufacturers. But for our life we ​​still want something more suitable and, most importantly, cheaper. So we can’t do without the Japanese. You will say that they do not have a “soul” or whatever else you can call that special charm that Harleys exude even from photographs on the Internet. I will answer - some have. The Intruder family, in my opinion, was just one of many faceless families with the help of which the Japanese tried to bite off at least a piece of the Harley pie. This impression dissipated as soon as I saw the M1800R or, translated into American language, Boulevard M109R.

    So, Intruder. The name means something like “one who intrudes,” a sort of uninvited guest. Invaded


    entered the motor market back in 1985 and at that time was just one of many choppers - V2, water-cooled, 750 cc, 63 horsepower, one brake disc, chrome everywhere and a saddle quilted in the fashion of that time. Since then, the family has branched and expanded, there were even octams with 13 forces per 140 kilograms of dry weight, and, perhaps, the first success was Volusia, which had a completely classic appearance. Our hero entered the market in 2006.

    So, appearance is, in my opinion, the main characteristic of a chopper/cruiser. And here the Suzuki designers distinguished themselves; in my opinion, the big Intruder is the most beautiful of its Japanese classmates. Yamaha's Road Star looks homemade, especially the headlight and passenger seat spoil the look. The Raider, which appeared on the market in 2008, is still from the same opera as Honda's Fury, but, in my opinion, much scarier. The Honda VTX 1800 looks better than the Yamaha, but everything is spoiled by the smudge of the passenger seat, ridiculous shock absorbers and unclear exhaust pipes. Whether it's our handsome man or not.

    The device looks like a single unit. The line of the headlight through the tachometer on the steering wheel smoothly flows into the tank, the passenger seat is replaced with a lid and does not destroy the silhouette, the device looks fast even in static conditions. The detailing is also good - turbine wheels, excellent optics, chic bend of exhaust pipes, beautifully cut at the ends, wide 240 mm rear wheel. You can’t even tell that the motorcycle entered the market in 2006; it still looks futuristic.

    He can also amuse my old megalomania. The fact is that the Intruder engine boasts a piston with a diameter of 112 millimeters - this is the largest piston among all internal combustion engines installed on land vehicles. It doesn't catch your eye, but it warms your soul.

    Now let's see what foreign testers write about the M1800R.

    The first article that I came across described the author’s rides with Kevin Schwantz, world champion in the royal class of MotoGP and owner of a racing school. The article contained the phrase “When was the last time Suzuki could boast of a cruiser that starts grinding the asphalt from the start, then catches traction and stands on its rear wheel?” To be honest, I was sure that no cruiser could stand on its rear wheel due to the peculiarities of weight distribution and relatively low specific power, so I considered the phrase a journalistic exaggeration. No such luck, he really stands up in the candle! It must be said that quite often the authors of articles considered the motorcycle as a cruiser for a retired sports biker. The dynamic parameters are really excellent (of course, with such and such characteristics), and the device in the corporate promotional photo against the backdrop of drag racing lights does not look alien.

    In technical terms, the motorcycle is made without compromise. The 46mm inverted front fork provides more than enough rigidity even for such a heavy and powerful bike. The brakes with radial calipers are borrowed from the GSX-R, and they are also plenty to spare. The engine, despite its volume, runs very smoothly, vibrations are killed by balancer shafts and mounting to the frame through rubber cushions. Testers especially note the precise operation of the gearbox, with a smooth gear change accompanied by the correct chopper clatter.

    The large Intruder also has disadvantages:

    - Tru-bikers from motorcyclecruiser.com believe that it is better to admire a motorcycle from afar. If you get closer, many parts of the body kit will reveal their true – plastic – essence, which incredibly crushes the guys who grew up on no-silicon Harleys.

    — the knob in first and second gear must be turned very smoothly, otherwise the device behaves nervously. It’s not surprising - the driveshaft, the injector, the huge volume of cylinders, it’s hard to expect anything else.

    - either the passenger seat or the cover - you will have to decide in the garage. Pay for style, nothing can be done.

    — the rear brake is rather weak by chopper standards. However, thanks to the compression of the huge cylinders, for effective braking it is often enough just to close the throttle.

    — the suspension, with the only adjustment of the rear spring preload, is tuned rigidly, which has a beneficial effect on handling, but I suspect that on our asphalt we will have to forget about the softness of the ride.

    — the clutch is a little tight, the handle is located far away, the hand in a traffic jam quickly goes numb even for a person with large palms.

    - ergonomics are controversial - the saddle is uncomfortable for tall people, the footpegs are too far for short people.

    So what happens? The Intruder is a beautiful motorcycle with enormous power, excellent handling, excellent brakes and no comfort. It’s not suitable for long-range travel, especially in the eastern direction, and this is the most interesting scenario for me now. Well, we’ll look further, but for those who are not drawn to either the track or Siberia, I advise you to take a closer look at the device.

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