Suzuki 57100-0682 Series User manual

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GENUINE SUZUKI ACCESSORIES
99021-06L30
I N S T A L L A T I O N I N S T R U C T I O N S
Description: HEATER SET, GRIP Part Number: 57100-0682
Applications: DL1050RQ/RC M0- Installation Time: 1.6 Hours
Ref. Description QTY
1Grip Heater (L) 1
2Grip Heater (R) 1
3Grip Heater Lead Wire 1
4Grip Heater Controller 1
5Controller Bracket 1
6Clamp 6
(3 pc is spare)
7Clamp 2
8Installation Instructions 1
Contents
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Ref. Description
(1) +Driver
(2) -Driver
(3) Open end wrench (17 mm)
(4) T wrench (10, 12 mm)
(5) Cutting pliers
(6) Socket (10, 12 mm)
(7) Ratchet handle
(8) Hexagon socket (3, 4 mm)
(9) Extension
(10) Torque wrench
Ref. Description
(1) SUPER GREASE (A) or
equivalent
[Recommended 99000-25480]
(2) Grip cement
(3) Degreasing Agent
[Available at stores]
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.
Tools
Required
(1) (2) (3)
(4) (5) (6)
(7) (8) (9)
(10)
Items Pro-
vided by
the Cus-
tomer
(1) (2) (3)
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
8 13.0 1.3 9.5
10 29.0 2.9 21.0
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8WARNING / 8CAUTION / NOTICE / NOTE
Please read this manual and follow its instructions carefully. To empha-
size special information, the symbol 8and 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. Disconnect the negative (–) cable from the battery.
6. 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.
7. Use care not to cause any damage to the body of the vehicle during
installation of the accessory.
Important
8WARNING
Indicates a potential hazard that could result in death or serious
injury.
8CAUTION
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
NOTICE
Refer to the DL1050 service manual, when removing or installing
the STD part.
STD part = Part which is equipped with the vehicle as standard
part.
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Removal of Vehicle Parts
1. Remove the pillion seat (A),
front seat (B), center cover (C)
and right and left side cover (D).
2. Remove the rear carrier (E),
rear frame cover center (F) and
frame cover (G).
Installation of Grip Heater (R) 2
1. Remove the knuckle cover.
(if equipped)
2. Loosen the screw of the han-
dlebar balancer and remove the
balancer assembly out of the
handlebars.
Installation
(A) (B)
(D)
(C)
(E)
(F)
(G)
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3. Remove the STD rubber clamp
of right handlebar.
4. Remove the STD clamps in 2
points.
5. Remove the fasteners in 3
points to make space for the
right-side cover.
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6. Remove the right switch box.
7. Make sure the handlebar is
completely turned to the right
and then remove the throttle
grip.
NOTE: STD throttle grip will not
be reused.
8WARNING
Never touch the screws in the
switch holder.
8CAUTION
Never pull the switch holder
forcibly.
It may cause cutting the wir-
ing.
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8. Install the Grip Heater (R) 2
with its lead wire facing upward,
so that the boss is inserted into
the groove.
9. Align the switch box stopper
with the positioning hole in the
handlebar and then tighten the
screw.
NOTE: After tightening screws of
the switch box, make sure
that the switch box does
not rattle.
10.Install the cover that was
removed in step 5.
11.Reinstall the knuckle cover (if
equipped) and handlebar bal-
ancer that was removed step 1
and 2.
Installation of Grip Heater (L) 1
1. Remove the knuckle cover.
(if equipped)
2. Loosen the screw of the han-
dlebar balancer and remove the
balancer assembly out of the
handlebars.
8WARNING
Open and close the throttle,
and make sure if there is any
catch in the throttle operation.
Grip heater
lead wire
Boss
Recess
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3. Open the gap between the left
handlebar grip and the handle-
bar with a -driver, then inject
degreasing agent to pull out the
left handlebar grip.
NOTE: Removed left handlebar
grip will not be reused.
4. Wipe off the rest of adhesive
adhered to the handlebar by
using a degreasing agent and a
waste cloth.
5. Apply grip cement evenly and
rather abundantly to the inside
of the Grip Heater (L) 1.
NOTICE
Use the -driver with care so
as not to scratch the surface
of the handlebar.
Handlebar
Clean cloth
Degreasing
agent
Grip cement
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6. Apply grip cement to the han-
dlebar surface. Insert the Grip
Heater (L) 1into the handlebar
at a stroke before the grip
cement dries.
As shown in the illustration,
align the line on the Grip Heater
(L) 1with the arrow on the TC
selector switch. Handlebar
Grip cement
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.
Line
Line
Left handlebar switch box
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7. Reinstall the knuckle cover (if equipped) and handlebar balancer that
was removed step 1 and 2.
Installation of left and right grip
heater lead wires
1. Pass the right grip heater lead
wire between the right handle-
bar switch box and the front
brake master cylinder holder.
Align the white tape on the Grip
Heater (R) 2lead wire
between the front brake master
cylinder holder bolts and secure
it with the Clamp 6.
NOTE: Cut off the excess part of the Clamp 6.
8WARNING
Use an appropriate grip cement, and dry well the applied part,
then check if it is securely adhered.
If it has not completely dried or if a different cement is used, there
is a risk that the grip may slip off while riding. Verify that the grip is
securely mounted to the handlebars before operating the vehicle.
8CAUTION
• 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 the wire so that the throttle grip lead wire does not come
into contact with other parts when the throttle is opened/
closed.
Right grip heater
lead wire
Bolt
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