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
B'/B0B*ULSBKHDWHUB(1*IP࣮࣌ࢪ㸰㸮㸯㸷ᖺ㸯㸮᭶㸱㸯᪥ࠉᮌ᭙᪥ࠉ༗๓㸷󰪍㸲㸷ศ

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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
B'/B0B*ULSBKHDWHUB(1*IP࣮࣌ࢪ㸰㸮㸯㸷ᖺ㸯㸮᭶㸱㸯᪥ࠉᮌ᭙᪥ࠉ༗๓㸷󰪍㸲㸷ศ

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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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2. Remove the upper-right bolt
from the radiator and route the
Grip Heater (L) 1/(R) 2lead
wires.
3. Install the upper-right bolt into
the radiator.
"Bolt:
10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Grip heater
lead wire
Bolt
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4. Pass the Grip Heater (L) 1/(R) 2lead wires along the handlebar
switch lead wires and fix them using the Clamps 6as shown in the
illustration.
NOTE:
• Be sure there should be no excessive tension nor remarkable slack in
the left and right grip heater lead wires.
• Cut off the excess Clamp 6.
a
c
d
f
be
da
a
1
2
4
3
d
"A"
"A"
2
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Wiring
a. Grip Heater (R) 2lead wire
b. Right handlebar switch lead wire
c. Front brake hose
d. Grip Heater (L) 1lead wire
e. Clutch hose
f. Left handlebar switch lead wire
Installation
. Secure the Grip Heater (R) 2lead wire, the right handlebar switch lead wire, and the
accelerator position sensor lead wire to the front break hose with STD clamp.
. Secure the Grip Heater (L) 1and (R) 2lead wires, the right handlebar switch lead wire, the
accelerator position sensor lead wire, the ignition switch lead wire, and the immobilizer
antenna switch lead wire with the Clamp 6.
. Secure the Grip Heater (L) 1lead wire, the left handlebar switch lead wire, and clutch hose
with STD clamp.
. Secure the Grip Heater (L) 1and (R) 2lead wires and main harness with the Clamp 7.
Clearance
“A”: 20 – 30 mm (0.8 – 1.2 in)
1
2
3
4
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Installation of Grip Heater Lead Wire
1. Pass the Grip Hater Lead Wire 3and fix them using the Clamp 7
and STD clamp as shown in the illustration.
DL1050RQ DL1050RC
a
12
a
34
5
7
6
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Wiring
a. Grip Heater Switch 3lead wire
Installation
. Route the Grip Heater Lead Wire 3along the outside of the tank bracket.
. Route the Grip Heater Lead Wire 3through the inside of the frame.
. Secure the Grip Heater Lead Wire 3and frame with the Clamp 7.
. Route the Grip Heater Lead Wire 3above the battery holder.
. Secure the Grip Heater Lead Wire 3, starter motor lead wire, and main harness with STD
clamp.
. DL1050RQ
Route the Grip Heater Lead Wire 3along the right side of the ABS pipe.
. DL1050RC
Route the Grip Heater Lead Wire 3below the ABS pipe.
1
2
3
4
5
6
7
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Connection of left and right grip heater coupler
1. Connect the Grip Heater (L) 1and Grip Heater (R) 2couplers to the
Grip Heater Lead Wire 3couplers.
2. Connect the Grip Heater Lead Wire 3to the vehicle harness coupler
which is at the back of the radiator in the right side of the vehicle.
Yellow
Black
/Blue
YellowBlack
Blue
White
Green
To vehicle harness
coupler
Right grip heater coupler
Left grip heater
couplers
Vehicle harness
coupler
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Installation of Grip Heater Control-
ler
1. Install the Controller Bracket 5
to the Grip Heater Controller 4.
2. Connect the coupler of the Grip
Heater Lead Wire 3to the Grip
Heater Controller 4.
3. Install the boot after making a
connection.
4. Install the Grip Heater Control-
ler 4to the vehicle boss.
5. Install the vehicle parts in the
reverse order of removal.
8CAUTION
After installation, make sure
that the boot is securely
attached.
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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.
Handling Method
Start engine, turn on the switch of
the grip heater then grip heater
start running and get warm.
According to the air temperature,
the grip heater temperature can be
adjusted in 3 levels from LEVEL3 to
LEVEL 1.
After Engine Is Started
1. Check if the lighting devices such as the headlamp operate correctly.
2. Check if the grip heater temperature changes by pushing the witch
and changing the indicator from LEVEL 3 to LEVEL 1.
Switch
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The grip heater temperature can be adjusted in three 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 and the battery voltage increases,
the automatic switch turns on grip heater and the indicator comes
back.
• 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.
8CAUTION
Do not use the grip heater, when air temperature is above 20 degrees
to avoid burns due to overheating.
• Be sure to wear gloves to avoid burns.
• Replace the damaged grips to avoid burns or electrical shock.
OFF LEVEL3
MAX
LEVEL2 LEVEL1
MIN
3 times blink
7 times repeat
Lighting
2 times blink
7 times repeat
Lighting
1 time blink
7 times repeat
Lighting
B'/B0B*ULSBKHDWHUB(1*IP࣮࣌ࢪ㸰㸮㸯㸷ᖺ㸯㸮᭶㸱㸯᪥ࠉᮌ᭙᪥ࠉ༗๓㸷󰪍㸲㸷ศ

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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
LEVEL1 LEVEL3?
• Grip heater temperature is too low or too high.
1. Have you adjusted the grip heater switch to be set between LEVEL1
LEVEL3?
2. When the temperature is too high, set the switch on LEVEL1 or OFF,
or wear a thick pair of gloves.
• The grip heater may perform/feel differently depending on the location.
1. This is no failure.
• Grip heater switch indicator blinking.
1. Too low battery voltage.
Recharge the battery fully or replace the battery with new one.
Even if the grip heater switch is turned off, when battery voltage
becomes low, the indicator blinks.
B'/B0B*ULSBKHDWHUB(1*IP࣮࣌ࢪ㸰㸮㸯㸷ᖺ㸯㸮᭶㸱㸯᪥ࠉᮌ᭙᪥ࠉ༗๓㸷󰪍㸲㸷ศ