Suzuki 57100-05881 User manual

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GENUINE SUZUKI ACCESSORIES
99021-26J01
INSTALLATION INSTRUCTIONS
Description: GRIP HEATER Part Number: 57100-05881
Applications: AN650L3 Installation Time: 1.5 Hours
Ref. Description QTY
1Left grip heater 1
2Right Grip Heater 1
3Clamp 5
4Grip Heater Lead Wire 1
5Grip Heater Switch 1
6Switch Bracket 1
7Screw 2
8Spacer 1
9Installation Instructions 1
Ref. Description
(1) +Driver
(2) -Driver
(3) Cutting pliers
(4) Hexagon wrench (5 mm)
(5) Hexagon socket (5 mm)
(6) Degreasing Agent
[Available at stores]
(7) Grip Cement
(8) SUZUKI Super Grease A or
equivalent [Recommended
99000-25011]
(9) Torque wrench
Contents
Tools
Required
(1) (2) (3)
(4) (5) (6)
(7) (8) (9)

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WARNING / CAUTION / NOTICE / NOTE
Please read this manual and follow its instructions carefully. To empha-
size special information, the symbol and the words WARNING, CAU-
TION, NOTICE and NOTE have special meanings. Pay particular
attention to messages highlighted by these signal words:
NOTE: Indicates special information to make maintenance easier or
instructions clearer.
1. Check that the kit includes all the parts listed in the first page.
2. Check each part in the kit for scratches or any form of damage.
3. Park the vehicle on a level ground.
4. Remove the ignition key from the switch and store it in a safe place.
5. Protect any items removed or to be installed from scratches by plac-
ing them on a soft cloth first before putting them on the ground.
6. Use care not to cause any damage to the body of the vehicle during
installation of the accessory.
Tighten bolts to the torque indi-
cated in the right table as standard
value unless otherwise explicitly
specified.
The value shows conventional or
“4” marked bolt tightening torque.
For other bolts not listed in the
table, refer to the service manual.
Important
WARNING
Indicates a potential hazard that could result in death or serious
injury.
CAUTION
Indicates a potential hazard that could result in minor or moder-
ate injury.
NOTICE
Indicates a potential hazard that could result in vehicle or equip-
ment damage.
Precautions
for
Installation
Tightening
Torque
Diameter
(mm)
Tightening Torque
N·m kgf-m lbf-ft
5 3.0 0.3 2.0
6 5.5 0.55 4.0
813.01.39.5
10 29.0 2.9 21.0

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Removal of Vehicle Parts
1. Remove the handle front/rear
cover, front panel, front leg
shield cover, wind screen,
meter front upper/lower panel
and combination meter panel
assembly.
Installation of Right Grip Heater
1. Loosen the screw and remove
the right side end cap.
NOTE: Try not to loosen the screw
excessively. If it is loos-
ened excessively, the right
side end cap may be bro-
ken and fallen down into
the handlebar.
2. Slide the boot, loosen the lock-
nut of the throttle cable, and
tighten fully the adjuster. Then,
loosen the throttle cable.
Installation
Handle front/rear coverHandle front/rear coverHandle front/rear cover Combination
meter panel
Combination
meter panel
Combination
meter panel
Front panelFront panelFront panel
Wind screenWind screen
Meter front
upper/lower
panel
Meter front
upper/lower
panel
Front leg
shield cover
Front leg
shield cover
Right side grip
Screw
Right side end cap
Boot
Lock-nut
AdjusterAdjuster

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3. Remove screws from the switch
box. First disconnect throttle
cable No.2, then No.1 with care,
and pull out the right side grip.
NOTE: Removed right side grip
will not be reused.
4. Apply thinly grease to the han-
dlebar.
5. Apply grease to the end of the
throttle cables and cable pulley.
6. Insert the right side grip heater
into the handlebar. Then, install
the throttle cable No.1 first, then
No.2.
7. Set the stopper peg of the
switch box to the hole in the
handlebar and tighten screws.
NOTE: After tightening screws of
the switch box, check to
make sure that the switch
box does not rattle.
WARNING
Do not try to wrench off the
throttle cable No.1 and No.2
forcibly by using pliers or other
tools. The throttle cable may
be bent, causing improper
return of the throttle.
Switch box
Throttle cable No.1
Throttle cable No.2
Right side grip
FWD
FWD Switch box
Throttle cable No.1
Throttle cable No.2
Right side
grip heater
Grease
Grease
Hole
Stopper
peg

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8. Reinstall the existing right side
end cap that was removed step 1.
9. Pass the grip heater lead wire
between the switch box and the
front brake master cylinder
holder. Align the white tape part
of the grip heater lead wire with
the contact surface of the front
brake master cylinder holder,
and fix them by using a clamp.
NOTE: Cut off the excess clamp.
10.Pass the grip heater lead wire
into the cable guide from the
bottom side of the handlebar
along the handle switch lead
wire.
WARNING
Check for smooth opening
and closing operations of the
throttle. See if there is any
catch in the throttle operation.
CAUTION
Fix the grip heater lead wire
securely by using a clamp so
that no tension should be felt
in the throttle grip lead wire
when operating the throttle.
Clamp
Grip heater lead wire
Grip heater
lead wire
Guide
Guide

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11.Fix the grip heater lead wire by
using the handle switch lead
wire and the clamp.
NOTE: Cut off the excess clamp.
Installation of Left Grip Heater
1. Loosen the screw and remove
the left side end cap.
NOTE: Try not to loosen the screw
excessively. If it is loos-
ened excessively, the left
side end cap may be bro-
ken and fallen down into
the handlebar.
2. Open the gap between the grip
and the handle with a -driver,
then inject degreasing agent to
pull out the grip.
NOTE: Removed left side grip will
not be reused.
Handle switch
lead wire
Grip heater
lead wire
Clamp
Screw
Left side end cap
Left side grip
NOTICE
Use the -screwdriver with
care so as not to scratch the
surface of the handlebar.
Driver
Left side grip
Degreasing agent

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3. Wipe off the rest of adhesive
adhered to the handlebar by
using a degreasing agent and a
waste cloth.
4. Pass the switch bracket to the
handlebar.
5. Remove the screw from the
lower side of switch box and
pass the spacer and the switch
bracket through the screw.
Then, tighten the screw.
Waste cloth Handlebar
Degreasing agent
Switch bracket
SpacerSpacer
ScrewScrew
Switch bracketSwitch bracket

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6. Apply cement evenly and rather
abundantly to the inside of the
left side grip heater.
7. Before cement is dried, spray
the degreasing agent to the
inner surface of the left side grip
heater and that of the handle-
bar, then insert the left side grip
heater into the handlebar at a
stroke.
Grip cement
Left side grip heater
Left side grip heater
Handlebar
Degreasing agent

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8. Reinstall the existing left side end
cap that was removed step 1.
NOTICE
• When the grip is inserted,
do not stop in midway but
insert it at a stroke.
• When inserting it, do not hit
the grip end with a hammer
or twist it forcibly, the grip
heater may be cut off.
• When the grip cannot be
inserted in midway, pull out
the grip by pouring the
degreasing agent into a gap
between the grip heater and
the handlebar. At this time,
do not twist forcibly the
heater wire with a screw-
driver or such similar tool,
the heater wire inside the
grip heater may be cut off.
WARNING
Use the designated grip
cement, and dry well the
applied part, then check if it is
securely adhered.
If the cement other than those
designated is used, or drying
is not enough, there would be
a risk of the grip slipping off
during the riding.
Left side grip heater
Left side grip heater
FWD
Lead wire
Handlebar

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Installation of Grip Heater Switch
1. Install the grip heater switch to
the switch bracket and tighten
the screws.
2. Pass the grip heater switch lead
wire into the cable guide by the
lower side of the handlebar
passing along the handle switch
lead wire.
3. Fix the grip heater switch lead
wire to the switch bracket by
using a clamp.
4. Fix the grip heater switch lead
wire and the grip heater lead
wire to the handle switch lead
wire by using a clamp.
NOTE: Cut off the excess clamps.
Switch
bracket
Screw
Grip heater
switch
Grip heater
switch
Grip heater switch
lead wire
Cable guide
Cable guide
Clamp
Grip heater
lead wire
Grip heater
lead wire
Handle switch
lead wire
Handle switch
lead wire
Grip heater switch
lead wire
Grip heater switch
lead wire
Switch bracket
ClampClamp