2003-2006 Suzuki SV1000S Heli Installation Instructions
Heli Bars are designed to safely increase your riding comfort, however it is imperative that these instructions be followed to ensure correct installation. Failure to follow these instructions could result in improper installation and create a dangerous control situation.
Installation is simply a reversal of the disassembly process.
* We recommend changing one bar at a time. *
1.) Remove both left and right damper weights. Note the locations of all cables, hydraulic lines and wire looms. On the right bar, the throttle cables run under the front brake reservoir. Make a note of this, as is can be confusing during reassembly. Take a digital photo or video for reference.
2.) Remove top triple clamp. (the steering stem nut is 32 mm)
3.) Remove the front brake reservoir from the right handlebar. Leave the bracket attached to the reservoir, as it will be used to remount to the Heli Bar in the same location.
4.) On the right side, assemble the controls onto the Heli Bar and slide down on the fork tube low enough so they don’t interfere with the top triple clamp when it’s reinstalled. Tighten the clamp screws enough so the bar does not move.
5.) Assemble the left side controls on the left Heli Bar and slide down on left fork tube as per above.
6.) Reassemble the top triple clamp. To make this easier, put the machine in 1st gear. Standing in front of the machine, put one of your shins against the front wheel and apply a bit of rearward force to the front end. This will help take the bind out of the front end and help the triple clamp slide down over the steering stem. Torque the steering stem nut and the two fork tube pinch bolts to the factory specs.
Get pdf 2003-2006 Suzuki SV1000S Heli Installation Instructions
