Suzuki 57100-2181 Series User manual

1/20
GENUINE SUZUKI ACCESSORIES
99021-21K60
I
INSTALLATION INSTRUCTIONS
Description: HEATER SET, GRIP Part Number: 57100-2181
Applications: DL250L8 Installation Time: 1.1 Hours
Ref. Description QTY
(1) Grip heater (L) 1
(2) Grip heater (R) 1
(3) Grip heater lead wire 1
(4) Grip heater switch 1
(5) Switch bracket 1
(6) Screw 2
(7) Clamp 9
(8) Installation instructions 1
Contents
(1) (2) (3)
(4)
(5) (6) (7)
(8)

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Ref. Description
(A) Driver
(B) Driver
(C) Open end wrench (14 mm)
(D) Hexagon socket (10 mm)
(E) Hexagon socket (5 mm)
(F) Ratchet handle
(G) Cutting pliers
(H) Torque wrench
Ref. Description
“A” SUZUKI SUPER GREASE A
or equivalent
[Recommended 99000-25011]
“B” Grip cement
“C” Degreasing agent
[Available at stores]
Tools
Required (A) (B) (C)
(D) (E) (F)
(G) (H)
Items Pro-
vided by
the Cus-
tomer
“A”“B”“C”

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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 fuel tank.
(Refer to the DL250 service
manual)
Installation of Grip Heater (R)
1. Loosen the bolt of balancer sev-
eral turns and pull the balancer
assembly out of the handlebars.
NOTE: Loosen the bolt only
enough to remove the bal-
ancer. Otherwise, the bal-
ancer may disassemble
and some components
may remain in the handle-
bar.
2. Slide the boot, loosen the lock-
nut of the throttle cable, and
tighten fully the adjuster. Then,
loosen the throttle cable.
Installation
Fuel tank
Handleba
r
balancer
Bolt
Boot Lock-nut
Adjuster

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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.
: 99000-25011
SUZUKI SUPER GREASE A or
equivalent
6. Insert the grip heater (R) (2)
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.
Right switch box
Throttle cable
No.1
Throttle cable
No.2
Right side grip
Right switch box
Throttle cable No.1
Throttle cable
No.2
Hole
Stopper
peg
Grip heater (R)
(2)

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8. Reinstall the balancer assembly
that was removed step 1, and
tighten the bolt to fix the han-
dlebar balancer.
Tightening torque
Bolt: 5.5 N·m (0.55 kgf-m, 4.0
lbf-ft)
9. Adjust the cable play:
1) Loosen the lock-nut.
2) Turn the adjuster so that the
throttle grip has 2.0 – 4.0
mm (0.079 – 0.157 in) play.
3) Tighten the lock-nut.
4) Reinstall the boot.
10.Pass the grip heater lead wire
between the switch box and
front brake master cylinder
holder. Align the white tape on
the grip heater lead wire with
the position between the front
brake master cylinder holder
bolts and fix the wire by using a
clamp (7).
NOTE: Cut off the excess clamp.
WARNING
Check for smooth opening
and closing operations of the
throttle. See if there is any
catch in the throttle operation.
Handlebar
balancer
Bolt
Boot
Lock-nut
Adjuster
CAUTION
Using a clamp, fix the grip
heater lead wire leaving the
slack so that the wire is not
pulled when the throttle is
operated.
Front brake
master cylinder
holder bolt
Grip heater
lead wire
Clamp (7) White tape

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Installation of Grip Heater (L)
1. Loosen the bolt of balancer
several turns and pull the bal-
ancer assembly out of the han-
dlebars.
NOTE: Loosen the bolt only
enough to remove the bal-
ancer. Otherwise, the bal-
ancer may disassemble
and some components
may remain in the handle-
bar.
2. Open the gap between the grip
and the handlebar with a
driver, then inject degreasing
agent to pull out the grip.
NOTE: Removed left side grip will
not be reused.
Handlebar
balancer
Bolt
NOTICE
Use the driver with care so
as not to scratch the surface
of the handlebar.

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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. Apply cement evenly and rather
abundantly to the inside of the
grip heater (L) (1).
Clean cloth
Degreasing
agent
Handlebar
Grip cement
Grip heater (L) (1)

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5. Before cement is dried, spray
the degreasing detergent to the
inside of the grip heater (L) (1)
and to the handlebars, then,
insert the grip. Slide grip heater
(L) (1) onto handlebar with the
lead wire pointing down.
NOTE: Install the grip heater (L)
(1) to the position shown
in the illustration.
Grip cement
Grip heater (L) (1)
Handlebar
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 grip
heater with a screwdriver or
such similar tool, the heater
wire inside the grip heater
may be cut off.
Grip heater (L) (1)
FRONT
UP
Left switch box
Grip heater (L) (1)

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6. Reinstall the balancer assembly
that was removed step 1, and
tighten the bolt to fix the han-
dlebar balancer.
Tightening torque
Bolt: 5.5 N·m (0.55 kgf-m, 4.0
lbf-ft)
WARNING
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 would be a risk of the
grip slipping off during the rid-
ing. Verify that the grip is
securely mounted to the han-
dlebars before operating the
vehicle.
Handlebar
balancer
Bolt

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Installation of Grip Heater Switch
1. Install the switch bracket (5) to
the grip heater switch (4).
2. Remove the left rear view mir-
ror.
3. Position the grip heater switch
(4) so that the opening between
the end face of the switch
bracket (5) and left switch box is
set equally, and install the left
rear view mirror.
4. Reinstall the boot.
Grip heater
switch (4)
Switch bracket (5)
Screw (6)
Rear view mirrorSwitch bracket
end face
Left switch box Grip heater switch

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Connection of Grip Heater Lead Wire
1. Pass the left and right grip heater lead wires and grip heater switch
lead wire along the wiring harness, and fix them using the clamps (7)
as shown in the illustration.
NOTE:
• Be sure there should be no excessive tension nor remarkable slack in
the left and right grip heater lead wire and grip heater switch lead
wire.
• Cut off the excess clamps.
11
1
3
14
15
16
14
15
17
19
18
19
1117
2

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1. Cut off the original clamp on the vehicle.
Clamp the right grip heater lead wire and right handle switch lead wire.
Face the locked part of clamp forward.
2. Pass the right grip heater lead wire, ignition switch lead wire and right handle switch lead
wire through the guide.
3. Cut off the original clamp on the vehicle.
Clamp the right grip heater lead wire, ignition switch lead wire and right handle switch lead
wire.
4. Cut off the original clamp on the vehicle.
Clamp the left grip heater lead wire and left handle switch lead wire.
Face the locked part of clamp forward.
5. Cut off the original clamp on the vehicle.
Clamp the left grip heater lead wire, grip heater switch lead wire and left handle switch lead
wire.
Face the locked part of clamp forward.
6. Cut off the original clamp on the vehicle.
Clamp the left grip heater lead wire, grip heater switch lead wire, ignition switch lead wire
and left handle switch lead wire at the red tape.
7. Right grip heater lead wire
8. Left grip heater lead wire
9. Grip heater switch lead wire

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14
11
12
13
14
15
[A]
[B]

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[A]: With ABS
[B]: Without ABS
1. Cut off the original clamp on the vehicle.
Using a clamp, fix the right grip heater lead wire, right handle switch lead wire at the red
tape, ignition switch lead wire at the white tape and throttle cables to the brake hose metal
part.
Face the locked part of clamp upward.
2. Cut off the original clamp on the vehicle.
Using a clamp, fix the right grip heater lead wire, right handle switch lead wire at the red
tape, ignition switch lead wire at the white tape and throttle cables to an upper hole in the
frame.
Face the locked part of clamp upward.
3. Cut off the original clamp on the vehicle.
Using a clamp, fix the left grip heater lead wire, grip heater switch lead wire and left handle
switch lead wire to a hole in the frame.
4. Right grip heater lead wire
5. Left grip heater lead wire and grip heater switch lead wire

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2. Connect the coupler of the grip
heater lead wire (3) to the vehi-
cle side harness coupler.
3. Using the original clamp on the vehicle, fix the grip heater switch lead
wire.
4. Connect the right and left grip heater lead wire couplers and grip
heater switch lead wire coupler to the couplers of grip heater lead
wire (3).
NOTICE
After connecting the couplers, tuck the couplers and lead wires
into a space between the frame pipes and avoid interference with
the fuel tank.
Grip heater
lead wire (3)
Wiring harness
coupler

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5. Install the vehicle parts in the reverse order of removal.
Grip heater switch (4)
Grip heater lead wire (3)
Orange
/Yellow White
/Black
Orange Orange
/Yelllow
Grip heater (LH) (1) Grip heater (RH) (2)
Grip heater
lead wire
Original
clamp
Grip heater switch
lead wire
Grip heater
lead wire (3)

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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 the left.
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
turned fully to the right and the left.
2. Check if the lighting devices as the headlight 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.
Switch
Grip heater switch

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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

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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 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 2 seconds.
1. Too low battery voltage.
Recharge the battery fully.