Engine Mechanical:
Complete overhaul, disassembly, assembly, inspection, repair of all engine components including pistons, rings, valves, camshafts, crankshaft, lubrication system.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, lines, pressure testing, cleaning and adjustment.
Ignition System:
Spark plugs, ignition coils, ECU control, timing adjustments, troubleshooting.
Transmission Drivetrain:
Clutch system, transmission gears, shafts, bearings, final drive, shaft drive maintenance and repair.
Cooling System:
Radiator, fan, thermostat, water pump, coolant flow, bleeding procedures, capacity.
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier, battery), starting system (starter motor, solenoid), lighting system, instrumentation, horn, sensors.
Brake System:
Hydraulic system, calipers, master cylinders, brake lines, pads, discs, bleeding, fluid specifications, ABS (if applicable).
Suspension System:
Front forks (telescopic, inverted), rear shock absorber, linkages, adjustment, rebuild, oil change.
Steering System:
Handlebars, steering stem, bearings, lubrication, adjustment.
Chassis Frame:
Frame integrity, sub-frame, structural components, inspection.
Bodywork Trim:
Fenders, fuel tank, seat, fairings, side covers, removal, installation, detailing.
Scheduled Maintenance:
Oil changes, filter replacements, spark plug checks, valve clearance adjustments, lubrication points, drive shaft maintenance.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon issues, error code interpretation (if applicable), wiring harness testing.
Engine Rebuild:
Detailed instructions for complete engine disassembly, cleaning, inspection, measurement, component replacement, and reassembly.
Suspension Fork Rebuild:
Comprehensive guide to servicing front forks, including oil replacement, seal replacement, and spring inspection.
Brake System Service:
Pad replacement, caliper service, line flushing, bleeding, master cylinder repair.
Electrical Component Replacement:
Stator, regulator/rectifier, starter motor, battery, sensors, switches, and controls replacement.
Fuel System Cleaning And Adjustment:
Throttle body cleaning, injector testing, fuel pressure checks.
Torque Specifications:
Precise torque values for all critical fasteners and components.
Depth Of Coverage:
Comprehensive: Covers everything from basic fluid changes and checks to complete engine, transmission, and electrical system overhauls.
Diagnostic Tools Required:
Information on specialized tools and diagnostic equipment required for advanced repairs.
Engine Type:
Liquid-cooled, 4-stroke, V-twin
Displacement:
1783 cc (109 cubic inches)
Bore X Stroke:
112.0 mm x 90.5 mm
Compression Ratio:
11.5:1
Valve Train:
SOHC, 4 valves per cylinder, SRAD (Suzuki Ram Air Direct) intake
Horsepower:
Approx. 125 hp @ 6200 rpm (at crankshaft)
Torque:
Approx. 118 lb-ft @ 3200 rpm (at crankshaft)
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle valves
Fuel Type:
Unleaded gasoline, 91 octane (AKI) or higher recommended
Oil Type:
SAE 10W-40 API SG, SF or SH
Oil Capacity With Filter:
4.8 L (5.1 US qt)
Coolant Type:
Suzuki Super Coolant (or equivalent ethylene glycol-based coolant with distilled water, 50/50 mix)
Engine Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Replacement Interval:
Every 12,000 km (7,400 miles) or 12 months.
Spark Plug Inspection Interval:
Every 12,000 km (7,400 miles).
Valve Clearance Inspection Interval:
Every 24,000 km (14,900 miles).
Air Filter Cleaning Interval:
Every 6,000 km (3,700 miles) or as needed depending on conditions.
Fork Oil Type:
Telescopic fork oil, ISO VG 10 (SAE 5W)
Fork Oil Capacity:
Approximately 511 ml (17.0 US fl oz) per fork leg.
Common Wear Items:
Tires, brake pads, clutch plates, fork seals (due to weight and performance).
Potential Issues Covered In Manual:
Wiring harness durability, regulator/rectifier cooling, fuel injection sensor calibration, shaft drive spline lubrication.
Suzuki History Highlights:
Suzuki Motor Corporation, founded in 1909, has a long history in manufacturing motorcycles, known for innovation and performance across various segments.
M109R Introduction:
The VZR1800/M109R was introduced in 2006 as a flagship cruiser, featuring a powerful 1783cc V-twin engine derived from Suzuki's GSX-R sportbike technology.
Key Updates Across Years:
Minor styling updates, color variations, and special edition models (e.g., M109R Limited, M109R Boss) were introduced throughout its production run. Performance remained largely consistent.
Manufacturing Location:
Japan
Production Period:
2006 - 2014 (for the specific generation covered by this manual)
