Suzuki DL250L8 User manual

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GENUINE SUZUKI ACCESSORIES
99021-21K20
I
INSTALLATION INSTRUCTIONS
Description: SIDE CASE
Applications: DL250L8 Part Number: Right and left: 95400-2181*
Right side: 95400-2182*
Left side: 95500-2181*
Installation Time: 0.2 H each side
Ref. Description QTY
(1) *1 Side case (L) 1
(2) *1 Side case (R) 1
(3) *1 Label 2 (1)
(4) Installation instructions 1
(5) *2 Key set 1
*1 If either right or left side case is purchased, a label (3) is included in the accessory parts
set.
*2 The key set is not included in the accessory parts set. Please purchase the key set sep-
arately.
Ref. Description
(A) Hexagon socket (10 mm)
(B) Ratchet handle
(C) Torque wrench
Contents
(4) (5)
(1) (2) (3)
Tools
Required (A)
(C)
(B)

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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 on the first page.
2. Check each part in the kit for scratches or any form of damage.
3. Park the vehicle on 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.
7. When operate the key, align it with “LOCK” or “OPEN” position on the
lock lever surely.
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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NOTE: The following steps are for
the right side of the motor-
cycle. Follow the same
steps for the left side.
1. Remove the nut and the plate.
NOTE: Use the key cylinder
marked with “R” to the right
case and with “L” to the left
case.
2. Insert the key cylinder into the
hole of the side case.
3. Install the plate and tighten the
nut to the specified torque.
NOTE: When fitting the plate to
the key cylinder, face the
marked side toward the
key insertion side.
Tightening torque
Nut: 2.5 N·m (0.25 kgf-m, 1.8
lbf-ft)
Installation
of
Key Cylinder
Washer
Nut
Plate
Mark
Key cylinder Hole
Washer
Nut
Plate
Mark

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4. Insert the key into the key cylin-
der and turn it counterclockwise
90 degrees, and push down the
lock lever into the lock position.
NOTE: For the left side case, turn
the key clockwise 90
degrees.
NOTE: The following steps are for
the right side of the motor-
cycle. Follow the same
steps for the left side.
1. Insert the key into the key cylin-
der of the side case and turn it
counterclockwise 90 degrees.
NOTE: For the left side case, turn
the key clockwise 90
degrees.
2. Lift up the lock lever and open
the side case lid.
Lock lever
Installation
of Side Case
Key
NOTICE
Do not hold the key when lift-
ing up the lock lever. The key
could become deformed or
damaged.
Lock lever

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3. Stick the label (3) aligning it
with the marking off line.
4. Close the side case lid.
5. Lift up the handle and down the
locking bar.
6. Install the side case (2) onto the
brackets as shown.
Label (3)Marking off line
Handle
Locking bar
Side case (2)

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7. Fold the handle down and make
sure that the locking bar is fitted
into the slot of the side case
upper bracket.
8. With the handle and lock lever
folded down completely, lock
the case by turning the key.
WARNING
Make sure that the side case
is surely installed. Otherwise,
the case could come off while
riding, resulting in an acci-
dent.
Handle
Locking
bar
WARNING
Make sure that the handle is
completely folded down and
that the mark is not visible
before locking the case. If the
handle is not completely
folded down before locking,
the case could come off while
riding, resulting in an acci-
dent.
Mark

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NOTE: The following steps are for
the right side of the motor-
cycle. Follow the same
steps for the left side.
1. Insert the key into the key cylin-
der of the side case and turn it
counterclockwise 90 degrees.
NOTE: For the left side case, turn
the key clockwise 90
degrees.
2. Lift up the handle and remove
the side case.
NOTE: The following steps are for
the right side of the motor-
cycle. Follow the same
steps for the left side.
1. Insert the key into the key cylin-
der of the side case and turn it
counterclockwise 90 degrees.
NOTE: For the left side case, turn
the key clockwise 90
degrees.
Removal of
Side Case
Key
Handle
Opening
Side Case
Key

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2. Lift up the lock lever and open
the side case lid.
Close the side case by reversing
the opening procedure.
NOTICE
Do not hold the key when lift-
ing up the lock lever. The key
could become deformed or
damaged.
Lock lever
Closing
Side Case
WARNING
Make sure that the handle is
completely folded down and
that the mark is not visible
before locking the case. If the
handle is not completely
folded down before locking,
the case could come off while
riding, resulting in an acci-
dent.
Mark

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• The cases are not completely waterproof. Always store luggage in a
plastic bag or the like.
• Make sure the handles, lock levers and cases are securely locked
before riding.
• Do not store valuables or fragile luggage in the case. If they are kept
in the case, there is a risk of theft or breakage.
Handling
Precautions
WARNING
• To avoid damage or deformation of the case, observe the fol-
lowing precautions.
- When close the lid, do not catch the luggage or stopper rope.
- When set the center stand upright or move the motorcycle, do
not apply force through the case.
- If fitting, removal or operation of the case does not work well,
consult your Suzuki dealer.
• If the stopper rope is removed, the case hinge could be dam-
aged. Do not remove the stopper rope.
• If the case is not installed correctly, or it is not locked in place,
it may come off. Therefore, make sure that it is properly
installed and locked before riding.
• A mounted case is highly susceptible to crosswinds. Always be
careful when riding in strong winds.
• When the side cases are mounted, always ride carefully as they
affect the stability and maneuverability of the motorcycle.
• Maximum loading capacity:
3 kg (6.6 lbs) per case
• Maximum motorcycle speed when case is mounted:
130 km/h (81 mph)
• Reduce luggage weight if the combined weight of luggage and
cases exceeds the maximum loading weight limit of the carrier
or motorcycle. Maximum side case
loading capacity is 3 kg
(6.6 lbs) per case.
• Store the luggage in both sides of the cases equally. Loading
imbalance between right and left may affect the stability and
maneuverability of the motorcycle.