Suzuki 57100-2884 Series User manual

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GENUINE SUZUKI ACCESSORIES
99021-28K50
INSTALLATION INSTRUCTIONS
Description: HEATER SET, GRIP Part Number: 57100-2884
Applications: DL650AL7/XAL7 Installation Time: 2.0 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 10
7Installation Instructions 1
Contents

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Ref. Description
(1) +Driver
(2) -Driver
(3) Open end wrench (10 mm)
(4) T wrench (10 mm, 12 mm)
(5) Cutting pliers
(6) Hexagon socket
(3 mm, 4 mm, 5 mm)
(7) Extension
(8) Torque wrench
Ref. Description
(1) SUZUKI Super Grease “A”
or equivalent
[Recommended 99000-25011]
(2) Grip cement
(3) Degreasing Agent
[Available at stores]
Tools
Required
(1) (2) (3)
(4) (5) (6)
(7) (8)
Items Pro-
vided by
the Cus-
tomer
(1) (2) (3)

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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

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Removal of Vehicle Parts
1. Remove the air cleaner box.
(Refer to the DL650 service
manual)
Installation of Grip Heater (R)
1. Remove the knuckle cover.
(if equipped)
(Refer to the DL650 service
manual)
2. 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.
3. Slide the boot, loosen the lock-
nut of the throttle cable, and
tighten fully the adjuster. Then,
loosen the throttle cable.
Installation
Air cleaner box
Air cleaner box
Knuckle cover
Knuckle cover
Handlebar balancer Screw
Handlebar balancer Screw
Boot
Boot
Lock-nut
Lock-nut
Adjuster
Adjuster

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4. 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.
5. Apply thinly grease to the han-
dlebar.
6. Apply grease to the end of the
throttle cables and cable pulley.
X99000-25011:
SUZUKI SUPER GREASE
“A” or equivalent
7. Insert the Grip Heater (R) 2
into the handlebar. Then, install
the throttle cable No.1 first, then
No.2.
8. 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.
8WARNING
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.
Switch box Throttle cable No.1
Throttle cable No.2
Right side grip
FWD
FWD
Switch box
Throttle cable No.1
Throttle cable No.2
Hole
Hole
Stopper
peg
Grip Heater (R)

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9. Reinstall the existing knuckle
cover (if equipped) and handle-
bar balancer that was removed
step 1 and 2.
10.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.
11.Pass the grip heater lead wire
between the switch box and the
front brake master cylinder
holder. Align the white tape part
of the grip heater lead wire with
the contact surface of the front
brake master cylinder holder,
and fix it by using a Clamp 6.
NOTE: Cut off the excess clamp.
8WARNING
Check for smooth opening
and closing operations of the
throttle. See if there is any
catch in the throttle operation.
Boot
Boot
Lock-nut
Lock-nut
Adjuster
Adjuster
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.
Grip heater
lead wire
Grip heater
lead wire
Clamp
Clamp

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Installation of Grip Heater (L)
1. Remove the knuckle cover.
(if equipped)
(Refer to the DL650 service
manual)
2. 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.
3. 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.
Knuckle cover
Knuckle cover
Handlebar balancer
Screw
Handlebar balancer
Screw
NOTICE
Use the -driver with care so
as not to scratch the surface
of the handlebar.

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4. Wipe off the rest of adhesive
adhered to the handlebar by
using a degreasing agent and a
waste cloth.
5. Apply cement evenly and rather
abundantly to the inside of the
Grip Heater (L) 1.
Handlebar
Degreasing
agent
Clean cloth
Grip cement
Grip Heater (L)

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6. Apply cement to the handle-
bars. Before cement is dried,
spray the degreasing detergent
to the inside of the Grip Heater
(L) 1and to the handlebars,
then, insert the grip. Slide Grip
Heater (L) 1onto handlebar
with the lead wire pointing
down.
NOTE: Align the line of Grip
Heater (L) 1and left
switch line as shown in the
illustration.
Handlebar
Grip Heater (L)
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.
Grip Heater (L)
Line
Line
Line
Line
Grip Heater (L)
Grip Heater (L)
Left switch
Left switch

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7. Reinstall the existing knuckle
cover (if equipped) and handle-
bar balancer that was removed
step 1 and 2.
Installation of Grip Heater Control-
ler
1. Install the Controller Bracket 5
to the Grip Heater Controller 4.
2. Fix the Grip Heater Controller
4assembly to the battery
box.
3. Connect the Grip Heater Lead
Wire 3coupler to the Grip
Heater Controller 4.
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.
Grip Heater Controller
Controller Bracket
Grip Heater Controller
Controller Bracket
Grip Heater Controller
Grip Heater Controller
Grip Heater Lead Wire
Grip Heater Lead Wire