Motorcycle engine cooling and lube systems Suzuki Boulevard M109R (2006-2025)
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Oil pump — removal, installation, disassembly and inspection
Removal Remove the oil pump assembly 1 with oil return pump. Disassembly Remove the oil return pump outer rotor 1, inner rotor 2 and pin 3. Inspection Rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly,...
Removal Remove the oil pump assembly 1 with oil return pump. Disassembly Remove the oil return pump outer rotor 1, inner rotor 2 and pin 3. Inspection Rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly,...
Oil pressure regulator
Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. If the piston does not operate, replace the oil pressure regulator with a new one. Oil strainer Clean the oil strainer if necessary. Inspect the oil...
Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. If the piston does not operate, replace the oil pressure regulator with a new one. Oil strainer Clean the oil strainer if necessary. Inspect the oil...
Oil strainer
Clean the oil strainer using compressed air. Install the oil strainers 1. Note: Align the boss A with the groove B of crankcase. Apply SUZUKI SUPER GREASE "A" to the O-rings. 99000-25010: SUZUKI SUPER GREASE "A" or equivalent Caution: Use a new...
Clean the oil strainer using compressed air. Install the oil strainers 1. Note: Align the boss A with the groove B of crankcase. Apply SUZUKI SUPER GREASE "A" to the O-rings. 99000-25010: SUZUKI SUPER GREASE "A" or equivalent Caution: Use a new...
Water pump
Apply SUZUKI SUPER GREASE "A" to the O-ring. Caution: Use a new O-ring to prevent oil leakage. 99000-25010: SUZUKI SUPER GREASE "A" or equivalent Install the water pump. Note: When install the water pump, fit the convex part A of the oil pump shaft...
Apply SUZUKI SUPER GREASE "A" to the O-ring. Caution: Use a new O-ring to prevent oil leakage. 99000-25010: SUZUKI SUPER GREASE "A" or equivalent Install the water pump. Note: When install the water pump, fit the convex part A of the oil pump shaft...
Oil pressure switch
Apply SUZUKI BOND to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. 99000-31110: SUZUKI BOND "1215" or equivalent Oil pressure switch: 14 Nm (1.4 kgf·m, 10.0 lb·ft) Note: Be careful not to apply...
Apply SUZUKI BOND to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. 99000-31110: SUZUKI BOND "1215" or equivalent Oil pressure switch: 14 Nm (1.4 kgf·m, 10.0 lb·ft) Note: Be careful not to apply...
Thermostat — reassembly
Apply engine coolant to the O-ring. Caution: Use a new O-ring to prevent engine coolant leakage. Install the thermostat assembly 1 and connect the water hoses 2. Tighten the thermostat assembly bolt.
Apply engine coolant to the O-ring. Caution: Use a new O-ring to prevent engine coolant leakage. Install the thermostat assembly 1 and connect the water hoses 2. Tighten the thermostat assembly bolt.
Engine coolant
At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the...
At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the...
Cooling circuit
Cooling circuit inspection Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. Remove the fuel tank. (6-3) Remove the left frame head cover. (9-6) Remove the radiator cap 1 and connect the tester...
Cooling circuit inspection Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. Remove the fuel tank. (6-3) Remove the left frame head cover. (9-6) Remove the radiator cap 1 and connect the tester...
Radiator and water hose
Radiator removal and disassembly Remove the fuel tank. (6-3) Remove the frame head covers and radiator covers. (9-6) Drain the engine coolant. (2-20) Disconnect the reservoir hose 1 and cooling fan lead wire coupler 2. Disconnect the oil cooler...
Radiator removal and disassembly Remove the fuel tank. (6-3) Remove the frame head covers and radiator covers. (9-6) Drain the engine coolant. (2-20) Disconnect the reservoir hose 1 and cooling fan lead wire coupler 2. Disconnect the oil cooler...
Cooling fan — inspection
Inspection Remove the right frame head cover and right radiator cover. (9-6) Disconnect the cooling fan coupler 1. Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. The voltmeter is for making sure...
Inspection Remove the right frame head cover and right radiator cover. (9-6) Disconnect the cooling fan coupler 1. Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. The voltmeter is for making sure...
ECT sensor — removal, installation and inspection
Removal Drain the engine coolant. (2-20) Remove the air cleaner chamber and throttle body. (6-13) Disconnect the ECT sensor coupler 1. Remove the rear intake pipe and thermostat assembly. (3-13) Remove the ECT sensor 2. Inspection Check the ECT...
Removal Drain the engine coolant. (2-20) Remove the air cleaner chamber and throttle body. (6-13) Disconnect the ECT sensor coupler 1. Remove the rear intake pipe and thermostat assembly. (3-13) Remove the ECT sensor 2. Inspection Check the ECT...
Removal, inspection and installation thermostat
Removal Remove the left air cleaner box. (6-13) Place a rag under the thermostat cover. Remove the thermostat cover 1. Remove the thermostat 2. Inspection Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for...
Removal Remove the left air cleaner box. (6-13) Place a rag under the thermostat cover. Remove the thermostat cover 1. Remove the thermostat 2. Inspection Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for...
Removal and disassembly water pump
Removal and disassembly Note: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is...
Removal and disassembly Note: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is...
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