Suzuki Burgman MiniTrike Installation Manual

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Filed Under (Suzuki) by admin on 17-02-2012

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installation Checklist Review entire installation manual Remove side/rear cover Modify side cover Install MiniTrike and double check all bolts Replace side/rear cover Align MiniTrike wheels Double check all bolts for tightness Test ride MiniTrike slowly in an open area to familiarize yourself with handling characteristics MiniTrike Installation NOTE: Install all bolts loosely until all brackets are in place. Tighten bolts only after all brackets and bolts are in place Refer to diagram for bracket identification 1. Place scooter on side stand on a firm level surface 2. Remove rear/side panel Refer to motorcycles service manual for questions regarding panel removal. 3. Remove center stand. 4. Drill two frame holes. See figure 1 5. Attach bracket A to the center stand mounting brackets. Place bushings inside of center stand mounting brackets. See figure 2 6. Attach bracket F ( left side ) and bracket G ( right side ) to frame holes drilled in step 4. Be certain to insert bushing into drilled holes and insert bolt through bushing. 7. Attach axels and wheels to MiniTrike and position in proper relation to scooter. 8. Attach bottom of brackets F (left) and G (right) to mounting point on MiniTrike frame 9. Attach bracket D ( left side ) and bracket E ( right side ) to BOTTOM of forward mounting point on MiniTrike frame. 10. Attach bracket B (left side) C (right side) to brackets D/E and to rear of crossbar on bracket A . 11. Tighten all bolts ensuring MiniTrike is square with scooter

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SUZUKI BOULEVARD M109R Fuel Injected Models INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 16-02-2012

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1. Remove seat, right and left side covers, and fuel tank. 2. Remove airbox. We highly recommend you consult the factory service manual for proper removal of airbox. 3. Route wiring harness as shown in the picture. (Fig 1) 4. Unplug stock wiring harness from injectors and plug in the connectors from Fuelpak as shown. (Fig 2) 5. Unplug the TPS connector (grey) and attach T-tap connectors to the two outside wires. (Fig 3) 6. Route Fuelpak green wire to T-tap on the factory black wire with brown stripe. Routh the Fuelpak violet wire to T-tap on the factory pink wire with black stripe as shown (Fig 3) 7. Reattach the TPS connector. 8. Route red wire to the front of engine and down to the horn. (Fig 4) 9. Disconnect the two position connector from horn and snip connector in half so you have two one-wire connections. 10. Reattach factory grey wire to horn. Attach Fuelpak red wire to the other horn connection. Plug the factory horn orange wire to the male connection on the Fuelpak red wire. 11. Route black wire to battery negative connection as shown. (Fig 5) 12. Attach Fuelpak to Fuelpak harness and mount to bracket under the left side cover as shown. (Fig 6) 13. Before reassembling the bike, make sure handlebar switch is in the engine-not-running position and turn the key on. Fuelpak should light up. Sound the horn. If Fuelpak turns off when the horn is sounded, recheck the red wire connection on the horn and that it is connected to the orange wire from the factory harness. 14. Follow the service manual to reinstall the airbox and gas tank.

SUZUKI GSX-R1300 / HAYABUSA Fuelpak Connectors INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 15-02-2012

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Remove the main seat and passenger seat. 2. Use a prop to hold the tank up in the trunk area. 3. Disconnect the main wiring harness from each of the lower injectors. (Fig 1) 4. Lay the Fuelpak unit in the tail section and route the wire harness down the left side of the motorcycle toward the throttle bodies. 5. Plug the Fuelpak wiring harness in line of the stock wiring harness and injectors. (Fig 2) 6. Locate the throttle position sensor connector on the right hand side of the throttle body. 7. Install the Fuelpak wiring harness TPS connectors in line of the stock wiring harness. (Fig 3) 8. Attach ground wire to the negative side of the battery. 9. Install Fuelpak in the tail section using the supplied velcro. (Fig 4) 10. Bolt the fuel tank back into place. INSTALLATION INSTRUCTIONS FOR P/N 62009 READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION FUEL INJECTION

Suzuki GSF 1200S Bandit Upgrade INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 15-02-2012

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Holeshot Steering Damper 12 Then he attached a wire to the damper rod, to prevent it from getting lost in the fork tube, and pulled out the stock spacer and spring. 11 The Bandit has an internal damper that’s connected to the top and bottom of the fork tube. Kevin loosened the nut to detach it from the fork cap. 5 Rich loosened the damper body clamp and slid it onto the damper. 6 Next, he mounted the damper, front and rear, using a flat washer and a locking nut as a safety precaution. Then he began the final adjustments (see sidebar for details). When finished, he tightened the bolts in the fairing bracket. 7 To install the fork brace, Rich had to first carefully cut off the plastic fork protectors. 8 He placed the body of the brace between the forks and loosely bolted each end of the brace in place. He finished by tightening all the bolts to spec. 9 The Works Performance spring kit comes with everything needed for installation. 10 With the bike on the lift, Kevin jacked up the front end to reduce the spring load. He removed the bars, loosened the pinch bolts, and removed the fork cap. Holeshot Fork Brace Works Dual-Rate Spring Kit February/March 2006 RoadBike 87 www. RoadBikeMag.com February/March 2006 RoadBike 88 16 The Muzzys kit comes with the canister, a midsection pipe, and a centerstand stop plate and bolt. 17 I removed the stock muffler, starting from where the midsection pipe joins the header. If the gasket is in good condition, you can reuse it. 18 Since the stock pipe included a centerstand stopper, Muzzys provides a new one. With the muffler removed, I mounted the stop plate to the centerstand pivot bolt. 19 I carefully eased the Muzzys midsection pipe into the stock gasket, and then slid the muffler on and rotated it until the mounting brackets were aligned. 13 Kevin compared the stock spring assembly (bottom) to the Works one (top) to see if he needed to cut the provided spacer. There’s a difference of about .25″, but the instructions account for this discrepancy (years of the stock spring carrying a load), so no cutting was required.

2001-2008 Suzuki V-Strom DL650 And DL1000 Adapter Installation Manual

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Filed Under (Suzuki) by admin on 15-02-2012

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Adapter Parts List Item Desc. Quantity A. Front Adapter 1 B. Rear Adapter 1 C. Frame Grabber, Front 2 D. Frame Grabber 1 E. 5/16 x ½” Button Head Screws 4 F. M8 x 50mm Bolts 2 G. Washers (Not shown) 6 2. Assembly Instructions Familiarize yourself with all of the parts in the Main Arm and Motorcycle Adapter assemblies. Follow these installation instructions FIRST . The following instructions include our recommended torque values for all fasteners used to assemble the Johnny Rack™. Do not exceed those torque values when installing the rack, otherwise damage to the Main Arm may occur. When stock mounting points are used to mount the rack to the motorcycle, refer to the motorcycle user’s manual for recommended torque values. 1. Remove the seat, the rubber rack cover on the rear rack or if you have a Givi Top Case mounting plate remove it too. Remove the 4 bolts shown (A and B). 2. Align front frame grabbers over front grab bar mounting holes (A). 3. Reinstall original bolts that you removed. Torque to 150in.lbs. 4. Place rear frame grabber over holes on rear rack (B). 5. If you do not have side luggage racks installed on the motorcycle, you will need to place 3 stacked washers (3/4 ” OD) over each hole and under the frame grabber to take up the extra space.

SUZUKI SV650 REAR SET POWERLET Installation Manual

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Filed Under (Suzuki) by admin on 15-02-2012

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STEP #1 – Remove the seat. See the Suzuki service manual. STEP #2 – Stretch out the wiring harness. Run the harness down the LEFT side of the battery cover, between the frame and the plastic water protectors/inner fender. There is a hole through which the harness may pass, visible when looking down to the left side of the battery cover, and toward the rear [B]. Insert a tie wrap, upward, though the black ring behind the silver footpeg bracket [A]. Let the wire hang down by the rearset for now. Next remove the negative battery connection, followed by the positive battery connection. Route the red lead forward toward the battery through the “notch” on the left side of the battery cover. Connect the red & black wire as follows: RED WIRE = BATTERY POSITIVE BLACK WIRE = CHASSIS GROUND Chassis bolt [D]. Tuck the fuse holder into a cavity in front of the plus terminal of the battery [C] under the battery cover. Ty-wrap the fuse-holder to the nearby wiring. STEP #3 – Apply either dielectric grease or Vaseline to the terminals. The center terminal is plus and the outer ring is negative (see dwg below). Install the fuse in the fuse holder. Connect the red wire to the positive terminal & the black wire to the negative terminal. Use a voltmeter to check if the polarity is correc

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Suzuki SV 650s OXFORD "Hot Grips" INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 14-02-2012

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Installation of heated grips on motorcycles is popular in the UK since it’s not unheard of for even the “fair weather biker” to be caught out by a cold snap. Add to this the fact that many operations on a bike are performed by the hands and fingers, which will not perform well when frozen! 1) Before fitting the grips to the SV, a position must be chosen for the controller. The grips, needless to say, have their mounting places predetermined. I chose to make a small bracket for mounting on the top yoke. This allows the control box to sit level with the top surface for an integrated look whilst remaining accessible for operation. First of all- The mounting bracket in place: Picture shows a strip of rubber on either side of the bracket to stop rubbing / vibrations. Using the flat base and sticky pad supplied, mount the controller on the bracket. 2) With the easy bit done, we need to turn attention to the installation of the power feed cable. It would be too easy to leave the grips switched on with the bike parked up, or for kids to switch them on draining the battery and leaving you stranded. With this in mind, we really want to use a suitably rated power feed that is only “on” when the ignition key is turned on. Fortunately enough, the “pointy” SV has a couple of spare contacts in the fuse box which can be tapped for this purpose

SUZUKI PUTS THE 'STYLE' IN LIFESTYLE WITH CUSTOM ACCESSORIES INSTALLATION

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Filed Under (Suzuki) by admin on 14-02-2012

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Suzuki Genuine Accessories are available for the all-new Equator midsize pickup truck, four-door SX4 Sport, five-door SX4 Crossover, XL7 midsize crossover and rugged Grand Vitara. The accessories can be purchased through local Suzuki dealers. Suzuki Equator  All-weather floor mats – Rubberized all-weather mats, ideal for keeping dirt, moisture and harsh debris from coming in contact with the vehicle’s carpet interior.  Bluetooth® module – The Suzuki-integrated hands-free Bluetooth phone system features a clean installation, fresh look and works with most Bluetooth-enabled mobile phones. Quality sound plays through the vehicle’s factory stereo and speakers, and the phone system automatically mutes the radio during phone calls. (Also available for SX4 Sport, SX4 Crossover, Grand Vitara and XL7.)  Body side moldings – Durable polyurethane molding set helps protect exterior paint from door dings and road rash.  Hood mask – Durable vinyl, custom-fit mask helps protect the front end of the vehicle from damage caused by minor road debris.  iPod® interface kit – Provides a seamless connection from an iPod to the vehicle’s radio and/or steering-wheel audio controls. (Also available for SX4 Sport, SX4 Crossover, Grand Vitara and XL7.)

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Suzuki GSXR600/ 750 2006-2007 Frame Slider Installation Manual

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Filed Under (Suzuki) by admin on 13-02-2012

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There is an existing 1 inch hole in the right body panel, remove right side bolt. Mount right side puck (shorter slider) with (99-HB-SH10125080) Socket Cap 10 X 1.25 X 80 Main Engine Stud and torque down. 2. Remove left side panel. 3. Locate the left side engine stud and remove bolt. (arrow below is pointing to bolt location) 4. Some photos in this section are used for illustration examples only. It is up to you how you decide to cut your motorcycles bodywork to accept the frame slider there are many different ways customers go through this process. Shogun is not responsible for any part of your motorcycle for any reason. Precisely measure location of cut and if in doubt at any point please call us before the install process has begun. Professional installation is recommended. Always use proper safety measures during the install of this product. Do not try to install this product without proper tools, recently calibrated torque wrench, correct torque specifications from factory service manual, safety goggles and gloves. 5. Body Prep. Use masking tape to completely mask off the area on the body where you will be working. We usually will tape off approximately 6 to 8 inches around the though hole area and any other edges that could get bumped or scratched while working. Tip: In some locations you may want to double up the thickness of the masking take to give extra protection.

Suzuki DRZ 400E & Kawasaki KLX400E Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 13-02-2012

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1. Remove the seat, side panels, and fuel tank. Kill switch connector Photo 1 2. Unplug and remove the stock headlight. 3. Unplug and remove the stock kill button. See Photo 1. 4. Unplug and remove the stock taillight. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. 5. Taillight Installation: Attach the provided LED taillight to the under side of the rear fender using the provided countersunk mounting hardware as shown in Photo 2. Route the taillight wires forward to the area on top of the airbox along the right side of the fender. Secure the taillight wires to the taillight plastic with zip-ties so the tire cannot make contact. Photo 2 6. Rear Turn Signal Installation: Attach the rear turn signals to the flat portions on the sides of the LED taillight. Position them so they are out of the path of the exhaust. Route the wires forward securing with zip-ties. Route the right turn signal wires and the taillight wires around the front of the muffler mount and between the fender and the black plastic splashguard as shown in Photo 3. Route Right Turn Signal & Taillight wires here Photo 3 Page 3 of 10
7. Brake Light Switch Installation: This step requires bleeding the rear brake. If you do not feel comfortable performing this step please refer it to a qualified mechanic. Installation: Remove the guard that protects the rear master cylinder and reservoir. Temporarily remove the bolt that secures the brake reservoir to the frame. Remove the bolt that holds the banjo fitting to the top of the rear master cylinder. Replace this bolt with the provided hydraulic switch retaining the upper and lower crush washers as shown in Photo 4. Bleeding the Brakes: Do not begin this process without a fresh bottle of brake fluid. Remove the lid from the brake fluid reservoir. Put the box end of 8mm wrench over the brake bleed nipple and install the bleed hose (supplied) tightly over the nipple. Position the loop on the hose above the nipple as shown in Photo 5 with the other end of the hose in a container to catch the fluid. Crack the bleed nipple open about 1/8 to a quarter turn keeping the loop in the hose vertical. Slowly depress the brake pedal to fill the hose with fluid. Pump slowly until you have brake fluid extending up into the loop, then you can pump the pedal fairly aggressively to drive air out of the system – The fluid above the bleed nipple will prevent air from re-entering the system. DO NOT LET THE RESERVOIR GO DRY – ADD FLUID AS NEEDED. Pump the pedal until there are no more bubbles, and then close the nipple with the wrench. Double check that the pedal is firm and the brake works properly.

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