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)

GENUINE SUZUKI ACCESSORIES
2/15
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

GENUINE SUZUKI ACCESSORIES
3/15
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

GENUINE SUZUKI ACCESSORIES
4/15
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

GENUINE SUZUKI ACCESSORIES
5/15
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

GENUINE SUZUKI ACCESSORIES
6/15
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

GENUINE SUZUKI ACCESSORIES
7/15
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

GENUINE SUZUKI ACCESSORIES
8/15
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

GENUINE SUZUKI ACCESSORIES
9/15
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

GENUINE SUZUKI ACCESSORIES
10/15
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

GENUINE SUZUKI ACCESSORIES
11/15
Connection of Lead Wire
1. Connect the left and right sides grip heater coupler and grip heater
switch coupler to the lead wire coupler.
Left side grip heater Right side grip heater
Grip heater switch
Lead wire
Orange
/Yellow White
/Black
Orange Orange
/Yelllow

GENUINE SUZUKI ACCESSORIES
12/15
2. Pass the lead wire between the
ECM and the leg shield brace
and connect the lead wire to the
vehicle harness coupler located
in front of ECM.
3. Pass the grip heaters of right
and left sides and grip heater
switch lead wire (left side clamp
only) to the clamps of the vehi-
cle and fix the clamps securely.
Installation of Vehicle Parts
1. Install the vehicle parts in the
reverse order of removal.
NOTE: Install carefully the handle
front cover and the rear
cover so as not to pinch
the lead wire.
ECM
Leg shield
brace Coupler
Lead wire
CAUTION
Fix the clamps securely so
that there should be no ten-
sion in the lead wire when the
handlebar is turned to the
right and/or left.
Clamp
Handle
rear cover
Handle
rear cover
Handle
front cover
Handle
front cover

GENUINE SUZUKI ACCESSORIES
13/15
To adjust the cable play:
1. Loosen the lock-nut 2.
2. Turn the adjuster 3so that the
throttle grip has 2.0 – 4.0 mm
(0.08 – 0.16 in) play.
3. Tighten the lock-nut 2.
4. Reinstall the boot 1.
Function Checking and Inspection
1. Check if the lead wire is not under an undue force when the throttle
grip is fully open, or when the handlebar is turned fully to the right
and to the right.
2. Check if the left side grip heater is securely adhered.
After Engine Is Started
1. Check if the engine idle speed is not changed when the handlebar is
fully turned to the right and the left.
2. Check if the lighting devices as the headlamp operate correctly.
3. Check if the heater gets warm by changing the position of the switch.
Handling Method
Grip heater warms right and left
grips when the grip heater switch is
turned on with the engine running.
The grip heater switch will be
turned off when the ignition switch
is turned off.
2.0 – 4.0 mm
(0.08 – 0.16 in)
Grip heater switch
Switch

GENUINE SUZUKI ACCESSORIES
14/15
The grip heater temperature can be adjusted in five steps by pushing the
switch. Pushing the switch changes temperature as follows:
NOTE:
• The grip heater has a built-in automatic switch to avoid unnecessary battery
power consumption. The automatic switch turns off grip heater when the
engine speed becomes lower at engine idling speed. When the engine speed
increases, the automatic switch turns on grip heater.
• Pushing the switch will not turn on the grip heater when the engine speed is
low. Increase the engine speed and push the switch again to turn on the grip
heater.
CAUTION
Improperly using the grip heater can be hazardous. Rider can suffer
burns even if the heating temperature is fairly low when the rider is
wearing no gloves and leaves the heater on for long periods. Dam-
aged grip can suffer burns or get an electrical shock.
• Be sure to wear gloves to avoid burns.
• Replace the damaged grips to avoid burns or electrical shock.
OFF 5 : MAX
: Full light
: Half light
: Turn off
431: MIN
2

GENUINE SUZUKI ACCESSORIES
15/15
When the grip heater does not operate normally, check the following
items, and consult your SUZUKI Dealer from whom you bought the prod-
uct.
• Grip heater does not operate. Or it can not be adjusted.
1. Has the engine started?
2. Is the grip heater switch set on the position between LO ⇔HI?
• Grip heater temperature is too low or too high.
1. Have you adjusted the grip heater switch to be set between LO ⇔
HI?
2. When the temperature is too high, set the switch on LO or OFF, or
wear a thick pair of gloves.
• Whole surface of the grip heater is not warmed.
1. This is no failure.
In order that the fingertips may be warmed, the heat distribution is
made to concentrate mostly to the position where the fingertips come
to contact.
• Grip heater switch indicator light up.
1. Too low battery voltage.
Recharge the battery fully.

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GENUINE SUZUKI ACCESSORIES
99021-26J01
INSTRUCTIONS DE MONTAGE
Description: CHAUFFE-POIGNÉE Code: 57100-05881
Modèle: AN650L3 Temps d’installation: 1,5 hr(s)
Réf. Description Q.té
1Chauffe-poignée gauche 1
2Chauffe-poignée droit 1
3Serre-câble 5
4Conducteur de chauffe-poignée 1
5Contacteur de chauffe-poignée 1
6Support de contacteur 1
7Vis 2
8Entretoise 1
9Instructions de montage 1
Réf. Description
(1) Tournevis +
(2) Tournevis -
(3) Pinces coupantes
(4) Clé à six pans (5 mm)
(5) Douille à six pans (5 mm)
(6) Agent de dégraissage
[Disponible dans le commerce]
(7) Ciment pour poignée
(8) SUZUKI Super Grease A ou
équivalent
[Conseillé 99000-25011]
(9) Clé dynamométrique
Contenu
Outils
nécessaires
(1) (2) (3)
(4) (5) (6)
(7) (8) (9)

GENUINE SUZUKI ACCESSORIES
2/15
AVERTISSEMENT / ATTENTION / AV I S / NOTE
Lire attentivement ce manuel et se conformer soigneusement aux ins-
tructions données. Pour souligner des informations spéciales, on utilise
le symbole et les mots AVERTISSEMENT, ATTENTION, AV IS et
NOTE. Lire avec soin les messages précédés par ces mots:
NOTE: Signale des informations spéciales pour faciliter l’entretien ou
clarifier des instructions importantes.
1. Vérifier que le kit inclut toutes les pièces énumérées en première page.
2. Vérifier que les pièces du kit ne sont pas rayées ou détériorées d’une
manière quelconque.
3. Garer le véhicule sur une surface plane.
4. Enlever la clé de contact du contacteur et la ranger dans un endroit sûr.
5. Protéger des rayures toutes les pièces déposées ou à installer en les
plaçant sur un chiffon plutôt qu’à même le sol.
6. Éviter d’endommager le véhicule pendant l’installation de l’acces-
soire.
Serrer les boulons au couple spé-
cifié dans le tableau des valeurs
standards ci-contre sauf spécifica-
tion contraire.
Les valeurs données dans ce
tableau correspondent aux cou-
ples de serrage des boulons con-
ventionnels ou des boulons
marqués “4”. Pour les boulons non
listés dans ce tableau, voir le
manuel d’entretien.
Important
AVERTISSEMENT
Indique un danger potentiel pouvant résulter en blessures graves
ou mortelles.
ATTENTION
Indique un danger potentiel pouvant résulter en blessures légè-
res ou modérées.
AVIS
Indique un danger potentiel pouvant résulter en détérioration du
véhicule ou des équipements.
Précautions
à
l’installation
Couple de
serrage
Diamètre
(mm)
Couple de serrage
N·m kgf-m
53,00,3
6 5,5 0,55
813,01,3
10 29,0 2,9

GENUINE SUZUKI ACCESSORIES
3/15
Dépose des pièces du véhicule
1. Déposer les couvercles avant/
arrière de la poignée, le pan-
neau avant, le couvercle du
protège-jambe avant, le pare-
brise, les panneaux avant supé-
rieur/inférieur du tableau de
bord et l’ensemble panneau du
combiné d’instruments.
Installation du chauffe-poignée droit
1. Desserrer la vis et déposer le cha-
peau d’extrémité de côté droit.
NOTE:
Attention à ne pas trop desser-
rer la vis. Si cette vis est des-
serrée de manière excessive,
le chapeau d’extrémité de côté
droit risque de se briser et de
tomber dans le guidon.
2. Faire glisser le soufflet, desser-
rer le contre-écrou du câble des
gaz et serrer à fond la molette
de réglage. Desserrer ensuite
le câble des gaz.
Montage
Couverclesavant/arrière
duguidon
Couverclesavant/arrière
duguidon
Couverclesavant/arrière
duguidon Panneau ducombiné
d’instruments
Panneau ducombiné
d’instruments
Panneau ducombiné
d’instruments
Panneau
avant
Panneau
avant
Panneau
avant
Pare-brisePare-brise
Panneaux avant
supérieur/inférieur
dutableau de bord
Panneaux avant
supérieur/inférieur
dutableau de bord
Couvercle du
protège-jambe
avant
Couvercle du
protège-jambe
avant
Poignée de côté droit
Vis
Chapeau d’extrémité de
côté droit
Soufflet
Contre-écrou
Pièce de réglagePièce de réglage

GENUINE SUZUKI ACCESSORIES
4/15
3. Déposer les vis du boîtier de com-
mande. Débrancher d’abord soi-
gneusement le câble des gaz n°1,
puis le câble n°2 et extraire la poi-
gnée de côté droit.
NOTE:
La poignée de côté droit dépo-
sée ne sera pas réutilisée.
4. Enduire le guidon d’une fine
couche de graisse.
5. Enduire l’extrémité des câbles
des gaz et la poulie des câbles
de graisse.
6. Insérer le chauffe-poignée droit
dans le guidon. Reconnecter
ensuite les câbles des gaz n°1
et n°2 dans cet ordre.
7. Placer le goujon de butée du
boîtier de commande dans le
trou du guidon et serrer les vis.
NOTE: Après avoir serré les vis
du boîtier de commande,
vérifier que celui-ci ne
vibre pas.
AVERTISSEMENT
Ne pas forcer la dépose des
câbles n°1 et n°2 à l’aide de
pinces ou de tout autre outil.
Les câbles risquent de se cin-
trer et de gêner le retour en
position du papillon.
Boîtier de commande
Câble desgaz n°1
Câble desgaz n°2
Poignée de
côté droit
AVANT
AVANT Boîtier de commande
Câble desgaz n°1
Câble desgaz n°2
Chauffe-poignée
droit
Graisse
Graisse
Trou
Goujon
de butée