SUZUKI 800 VOLUSIA Adaptor Kit Installation Instructions
Congratulations on your purchase of the SUZUKI 800 VOLUSIA Adaptor Kit. We’re sure you’ll be pleased with the new level of performance you’ll experience. This kit should be installed on bikes with After Market Exhaust Pipes only and jetted, (not included). We recommend that an experienced mechanic perform this conversion. Use the appropriate Suzuki service manual for reference to complete jetting of carbs. Remember, gasoline is extremely flammable and can be explosive under certain conditions. Work in a well- ventilated area and clean up any spills immediately. Check for leaks before riding.
1) Remove Seat – 6mm allen head
2) Remove Dash 1 - 3mm allen and 2 - 4mm allen heads.
3) Remove Tank 1 - 12mm socket at the rear of the tank.
4) Remove the chrome cosmetic cover on the left side of the bike – 2 8mm socket heads. Disconnect the 2 vacuum lines from the tank and fuel line.
5) Pop the idle adjustment out of the bracket and lift at the rear of the tank. Unplug the one white electrical plug.
6) Remove the stock air box 2 – 4mm allen heads at the top of the air box. Loosen the hose clamp and pull out from the bottom of the air box and remove.
7) Remove the stock air box hanger bracket 3 – 10mm bolts.
8 )Jetting can now be done.
9) Plug the pair valve hose with the supplied red plug – It is the large 5/8 hose going to the vacuum canister on the left hand side of the bike.
10) Place the provided O-Ring in the grove at the top oval opening.
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