Suzuki 57100-27830 User manual

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GENUINE SUZUKI ACCESSORIES
99021-11J20
Description: HEATER SET, GRIP Part Number: 57100-27830
Applications: DL650L2/AL2 Installation Time: 2.0 Hours
INSTALLATION INSTRUCTIONS
Ref. Description QTY
AGrip Heater Lead Wire 1
BGrip Heater Switch 1
CSwitch Bracket 1
DGrip Heater (R) 1
EGrip Heater (L) 1
FClamp 6
GScrew 2
HInstallation Instructions 1
Ref. Description
(1) +Driver
(2) -Driver
(3) Open end wrench (17 mm)
(4) Hexagon wrench (4, 5 mm)
(5) T wrench (10 mm)
(6) Cutting pliers
(7) SUZUKI Super Grease “A” or equivalent [Recommended 99000-25010]
(8) Grip cement [Recommended 39442-09D00]
(9) Degreasing Agent [Available at stores]
Contents
Tools
Required
(1) (2) (3) (4)
(9)
(7)
(5) (6) (8)

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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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Remove cowling.
1. To remove the seat, insert the
ignition key into the lock and
turn it clockwise.
Raise the rear end of the seat
and slide it backward.
2. Remove the right and left screws.
Unhook the right and left hooks and pull the side frame cover 1.
Installation
RIGHT
LEFT

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3. Remove the screws and fasten-
ers.
4. Pull off the front tank cover
hooks.
Covers have hooks at the cir-
cled places.
5. Raise the fairings 2with a
hand to separate it from the
front tank cover 3.

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6. Unhook the hooks and remove
the front tank cover 3.
Covers have hooks at the cir-
cled places.
7. Remove the fuel tank side
cover screws.
RIGHT
LEFT

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8. Loosen the instrument panel
screws.
Push down the instrument
panel at around the circled
place to unhook the hooks.
9. Push the fairing 2at around
the circled place with thumbs
and roll up the fairing to unhook
the hooks.
RIGHT
LEFT

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10.The fuel tank cover has fasten-
ers behind the cover at the rect-
angle mark places.
Pull up the fuel tank side covers
4to unfasten the fasteners.
11.The fuel tank side cover has a fastener behind the cover at the circled
place.
Move the fuel tank side cover 4backward to slip off the hook.
RIGHT
LEFT
RIGHT
LEFT

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12.Remove the right and left fairing
screws.
13.Remove the bolts and fasten-
ers.
14.Push the instrument panel
cover at the circled place with
thumb and roll up the cover to
unhook the hook.
RIGHT
LEFT

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15.Move the instrument panel to
the arrowed direction to unhook
the hooks.
16.Disconnect the meter coupler
5and remove the instrument
panel assembly.

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17.Remove the right and left
screws.
18.Remove the cowling brace bolts
and unhook the hooks.
19.Remove the couplers 6and
release the wiring harness from
the clamp 7.
Remove the cowling assembly.

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Connect Grip Heater (R) D, Grip
Heater (L) Eand Grip Heater
Switch Bto Grip Heater Lead
Wire A.
1. Move the radiator forward by
removing the bolts.
2. Pass the wire of Grip Heater
(R) Dand (L) Einto the guides
(LH and RH).
3. Connect Grip Heater Lead Wire
Ato the main harness.
Bolt
Bolt
Bolt Radiator
Radiator
Radiator
Guide
Guide
Guide

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4. Connect the coupler of Grip
Heater (R) Dto the coupler
(Orange/Yellow and White/
Black) of Grip Heater Lead Wire
A.
5. Connect the coupler of Grip
Heater (L) Eto the coupler
(Orange/Yellow and Orange) of
Grip Heater Lead Wire A.
6. Connect the coupler of Grip
Heater Switch Bto the coupler
of Grip Heater Lead Wire A.
7. Clamp the Grip Heater Lead
Wire Aand brake pipe with
Clamp F.
Install Grip Heater (R) D.
1. Loosen the screw of balancer
with a +driver several turns
and pull the balancer assembly
out of the handlebars.
NOTE: Loosen the screw only
enough to remove the bal-
ancer. Otherwise, the bal-
ancer may disassemble
and some components
may remain in the handle-
bar.
2. Remove the two screws of the
switch box. Loosen the throttle
pulling cable and disconnect
throttle cables carefully from
the right grip. Pull out the right
grip from the handlebars.
NOTE: Do not force to remove the
throttle cables when dis-
connecting the throttle
cables.
Balancer
Balancer
Balancer
Screw
Screw
Screw
Screw
Throtlle pulling cable

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3. Pass the Grip Heater (R) D
lead wire to front of the handle-
bars.
4. Install the Grip Heater (R) Din
the order of removal.
• Apply thinly grease to the
handlebars.
• Apply grease to the end of the
throttle cables and cable pul-
ley.
99000-25010:
SUZUKI SUPER GREASE
“A” or equivalent
• Connect throttle cables to the
throttle cable pulley of Grip
Heater (R) D.
• When installing the switch
assembly to the handlebars,
set the stopper peg of the
switch box to the hole on the
handlebars.
NOTE: Check that the switch
housing is fitted securely
and throttle grip moves
smoothly after tightening
the screws.
5. Reinstall the existing balancer
and screw that was removed
step 1.
Throttle cable No.1
Throttle cable No.2
Grip Heater (R)
Grip Heater (R)
Grip Heater (R)
Grip Heater (R)
Stopper peg
Stopper peg
Stopper peg

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Install Grip Heater (L) E.
1. Loosen the screw of balancer
with a +driver several turns
and pull the balancer assembly
out of the handlebars.
NOTE: Loosen the screw 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 handle with a -driver,
then inject degreasing agent to
pull out the grip.
NOTE: Use the -screwdriver
with care so as not to
scratch the surface of the
handlebar.
3. Spray the degreasing agent to
the outside of the handlebars
and wipe off the rest of adhe-
sive with a clean cloth.
4. Apply abundant grip cement
evenly inside Grip Heater (L) E
and handlebars.
Handlebar
Degreasing
agent
Clean cloth
Grip cement
Grip Heater (L)

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5. Before cement is dried, spray
the degreasing detergent to the
inside of the Grip Heater (L) E
and to the handlebars, then,
insert the grip. Slide Grip
Heater (L) Eonto handlebars
with the lead wire pointing
down.
NOTE:
Perform installation quickly,
before the cement dries.
NOTE: 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. Verify that the grip is securely mounted to the handle-
bars before operating the vehicle.
Handlebar
Grip Heater (L)
NOTICE
Hitting the grip end with a
hammer or twisting the grip
can damage the grip heater
due to heater wire cut.
• Do not hit the grip end with a
hammer or twist it forcibly.
• When the grip cannot be
inserted in midway, pull out
the grip by pouring the
degreasing detergent 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.
Grip Heater (L)
UP
Grip Heater (L)
Lead Wire
FRONT

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6. Install the balancer assembly
by sliding it in and tightening
with the existing screw.
Install Grip Heater Switch B.
1. Pass the Grip Heater Switch B
lead wire under the handlebars.
2. Install the Switch Bracket Cto
the Grip Heater Switch Bby
using the two Screws G.
3. Fix the Grip Heater Switch B
assembly with the left view mir-
ror.
Balancer
assembly
Screw
Left view mirror
Left view mirror
Left view mirror

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Set two Clamps F.
1. Pass the Grip Heater (R) D
lead wire between the brake
lever holder and switch box.
Match holder joint section and
white tape point. Clamp Fthe
Grip Heater (R) Dlead wire at
the white taping point.
2. Clamp the Grip Heater (R) D
lead wire, right switch box lead
wire and brake hose with
Clamp F.
NOTE: Cut off the excess clamp.
3. Re-clamp the Grip Heater (R)
Dlead wire and switch box
lead wires (RH) with guide
plate.
4. Re-clamp the Grip Heater (L) E
lead wire, Grip Heater Switch B
lead wire, left switch box lead
wire and clutch cable with clamp
and Clamp F.
White taping point
White taping point
White taping point
Clamp
Clamp
Clamp
Guide plate
Guide plate
Guide plate
Clamp
Clamp
Clamp

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5. Reinstall the removed parts.
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 Grip Heater (L) E
is securely adhered.
After Engine Is Started
3. Check if the engine idle speed
is not changed when the han-
dlebar is fully turned to the right
and the left.
4. Check if the lighting devices as
the headlamp operate correctly.
5. Check if the heater gets warm
by changing the position of the
switch.
WARNING
Inadequate throttle cable play
can cause engine speed to
rise suddenly when you turn
the handlebars. This can lead
to loss of control and an acci-
dent.
Adjust the throttle cable play
so that engine idle speed does
not rise due to handlebar
movement.

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Handling Method
Grip heater warms right and left
grips when the Grip Heater Switch
Bis turned on with the engine run-
ning. The Grip Heater Switch B
will be turned off when the ignition
switch is turned off.
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.
Switch
WARNING
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 Bindicator light up.
1. Too low battery voltage.
Recharge the battery fully.