Suzuki 57100-2181 Series User manual

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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