Automotive Manual PDF

The tools you needs:
A drill with a smaller bit such as a 1/4″
A dremel or similar to cut a hole in plastic
T27 Torx bit and driver with 4” extension
Extendable magnet
Pliers

1. Take the kit out of the box and lay everything out. You can install either the ballasts or bulbs first but typically it is easier to install the bulbs first.
2. There are 3 T27 torx screws holding the headlight on. The 2 on top are visible in this picture.
3. with the 2 screws removed…
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Rear:
1. Raise and properly support back of car. I used a long metal bar that I had which reached across from one of the lower A-arms to the other and jacked up in the middle. I then put jack stands under the rear jacking points using jacking pucks.
2. Remove wheels
3. On the passenger’s side of the car you will need to remove the brake pipe bracket so that the suspension can be lowered. It is attached by 2 10mm nuts.
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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.
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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.
(more…)

[Read more →]