2009 DL650 Suzuki V-Strom (E3) Full Clutch Rebuild

jayhawknavy02 · 2025-09-26T19:34:18-0400

Not right "now" but in the future I plan to do a full clutch rebuild based on the age and miles of my 2009 Suzuki V-Strom DL650 (E3) non-ABS bike. I know they're mostly and typically pretty bullet proof, sheesh....mine is clearly plugging along since I bought it with a couple miles on it. That said, at some point I'm going to re-baseline the clutch back to new, so any possible wear / worn parts will be pulled, if they're good, I'll keep them as spares / backups.

Below is what I "think" I need for a full clutch rebuild along with special tools (only tracking two), but correct me if I'm wrong please. I'd rather do this right, and one time, than do it twice. Planning on grabbing the special tools from GB Motorcycle as they make some other items I want to purchase.

Clutch Diagram from RevZilla

https://www.revzilla.com/oem/suzuki/2009-suzuki-v-strom-650/clutch?submodel=dl650

https://www.partzilla.com/catalog/suzuki/motorcycle/2009/v-strom-dl650/crankcase-cover

PARTS

Clutch Spring
- QTY: 6
- P/N: 21413-17G01
Drive Plate (No. 2)
- QTY: 1
- P/N: 21441-29F00
Clutch Drive Plate (No. 1)
- QTY: 6
- P/N: 21441-29F20
Clutch Driven Plate
- QTY: 6
- P/N: 21451-28C31
Lock Washer
- QTY: 1
- P/N: 09617-20009
Oil Seal (6x34x5)
- QTY: 1
- P/N: 09285-06015
Clutch Release Arm Spring
- QTY: 1
- P/N: 09443-08001
Magneto Gasket
- QTY: 1
- P/N: 11483-19F00
Clutch Cover Gasket
- QTY: 1
- P/N: 11482-44H00
Bearing (15x28x2)
- QTY: 1
- P/N: 09263-15003
Plug Gasket (13.8X18.8X0.4)
- QTY: 1
- P/N: 09168-16002
Plug O-RIng
- QTY: 1
- P/N: 09280-22008
Bolt Gasket
- QTY: 2
- P/N: 09168-06023
Oil Filler Plug O-Ring
- QTY: 1
- P/N: 09280-17003

SPECIAL TOOLS

Suzuki Special Tool (Rotor Holder)
- QTY: 1
- P/N: 09930-44530
- GB Motorcycle Suzuki Holder Generator Rotor Tool Hyperlink
Suzuki Clutch Holding Tool
- QTY: 1
- GB Motorcycle Clutch Holding Tool Hyperlink

Rolex · 2025-09-26T22:33:18-0400

If you want a like new clutch you will need to replace or smooth out the highs and lows on the clutch basket

PeteW · 2025-09-27T04:49:24-0400

Clutch thrust washer is a maybe as well.

You don't need the rotor holder if you have a welder. Tack several of the metal plates to a length of steel rod and you have a clutch holder.

Also a comment, the clearance on assembly for the plates is a bit generous. I had t go from half a turn to 1/4 turn on my 2012. You may have to finesse your 2009 as well. I did the clutch on my 2006 but after all this time

, can't remember details. 2012 was a bit more recent and I know the 'by the book' settings didn't result in a usable clutch.

jayhawknavy02 · 2025-09-27T16:54:47-0400

Rolex said:
If you want a like new clutch you will need to replace or smooth out the highs and lows on the clutch basket

As always thank you. I’ll replace it, and do the work to keep the original as a spare.

If I have this right the P/N is

Primary Driven Gear Assembly (ASSY)
21200-17860

PeteW said:
Clutch thrust washer is a maybe as well.

Will do!
Thank you for confirming, but I think the correct washer being referenced is

Washer (Thrust)
09160-15045

Should I replace the other washer as well?

Washer
09160-20067

PeteW said:
Also a comment, the clearance on assembly for the plates is a bit generous. I had to go from half a turn to 1/4 turn on my 2012. You may have to finesse your 2009 as well. I did the clutch on my 2006 but after all this time , can't remember details. 2012 was a bit more recent and I know the 'by the book' settings didn't result in a usable clutch.

Will do, thank you!

Brockie · 2025-09-27T20:23:11-0400

Curious to know why you feel the clutch needs replacement.
Has the take up point become especially abrupt due to wear and fibre plate hardening, or does it slip under load?
Just wondering if suspension work might be more beneficial.

2009 DL650 Suzuki V-Strom (E3) Full Clutch Rebuild

Top Contributors this Month

Recommended Communities