Before starting, make sure the motorcycle is securely tied into a bike hoist or lift.
Remove the seat, fuel tank, left and right-side covers, maxi fuse, rear fender, frame cross-over bracket and rear shock.
Route the wiring harness in from the left-hand side.
Connect the red wire to the positive on the battery.
Connect the black wire to the earth point on the left-hand frame rail.
Ensure the relay sits in the position shown in the photos below.
The SAS-18 Kit reuses the OE shock bushing from the bottom of the OE shock.
Remove this from the OE shock before fitting it to the new SAS-18 Suspension.
Ensure you pack the bottom bearing with high temperate bearing grease before fitting the bottom bushing and the 2 x O-Rings supplied. (See pictures below.)
The top Suspension bearing requires 2 spacers to be installed.
Note: Tapered side must face in, flat side must face out.
Fit the Suspension into position, route the wiring down towards the left side of the bike and connect to the wiring harness, ensuring it does not come close to the exhaust.
Before fitting the top OE shock bolt, apply grease to the shaft of the bolt and medium strength Loctite to the threads. Fit the top OE shock bolt and tighten to 55ft pounds.
Before fitting the bottom OE shock bolt, make sure the Suspension has vertical movement and horizontal roll on the top spherical bearing (i.e. the Suspension moves freely on the bearing). Before fitting the bottom OE shock bolt, apply grease to the shaft of the bolt and medium strength Loctite to the threads. Fit the bottom OE shock bolt and tighten to 55 ft pounds. Tighten the pinch bolt to 15 ft pounds (FXDR 10 ft pounds).
Remove the old OE clutch clamp.
Install your SAS Handlebar Switch using OE bolts as shown in the image below.
You can route the wiring in one of two ways –
1. Either down the inside of the handlebars with OE wiring, if your hand control wiring is already inside the bars. (To do this, you will need to unpick the electrical plug.)
OR
2. You can run the wiring down your handlebars and cable tie the wiring to the bars.
Route the rest of the wiring down under the gas/petrol tank towards the left-hand-side cover.
Note: Handlebar wiring is long enough for up to 20” bars. Depending on your bar size, you may have excess wiring. This wiring can be secured safely behind the left-hand-side cover.
Tech Tip: Running wire through frame
Using a thin rod, gently slide the rod up the backbone of the frame until it sticks out the wiring hole at the neck.
Tape the Handlebar Switch wiring to the rod and gently pull it back through the frame. Route the wiring down to the left-side cover and connect the handlebar wiring to the wiring harness.
To do this, the gray clutch connector will need to be removed and re-fitted.
Re-fit fuel tank, frame cross-over bracket, rear fender, maxi fuse, left and right-hand-side cover and seat.
Remove 2 x 5/16th Allen key head bolts from the side stand and remove the complete side stand.
Fit the wedge plate to the back of the side stand and re-fit the side stand to frame using RED Loctite on the Allen key head bolts and tighten to 45 ft pounds.
Before riding the bike, please check that when the bike is either fully lowered or raised to maximum height, there are no clearance issues and nothing rubs anywhere – i.e. wheel to guard or frame.
SAS Air Ride Suspension is designed with the ability to be ridden at any height, at any time, if installed correctly. That is, you can ride completely aired out or at full height for extra ground clearance. This can also be adjusted while riding to suit the riding conditions.
Every rider will have their own set height they prefer. This is generally something you will discover for yourself while riding.
When first getting used to your Air Ride Suspension, we recommend raising the bike to full height before riding, then sit on the bike and the Suspension should sag down about ¾ – 1” with your weight on the bike. If it doesn’t go down, you have too much pressure in the Suspension. Simply press the bottom button to release some pressure to find your “sweet spot”.
If the bike sags down too much, you simply don’t have enough pressure. In this case, press and hold the top button for another 5-10 seconds until you find a pressure that’s good for you.
Depending on the road conditions, adjust your suspension while riding to find your preference. Keep in mind, the lower it is, the harder the Suspension may feel and the easier your footpegs and exhaust may scrape.
If you’re riding through twisty roads and around the mountains, raise your Suspension to gain maximum clearance.
Note: Just make sure you don’t over-pressurize the kit – don’t worry it will not hurt the Suspension in any way, but it may feel a little rigid. We recommend raising the Suspension to full height and having a little bounce on the seat to feel how the Suspension rebounds with your weight.
Remember to take photos of your bike with your SAS Air Ride Suspension fitted and tag us on Facebook and Instagram using:
#SASAirSuspension @SASAirSuspension
We love to be able to share your bike!
For any further questions or concerns please call or email us: info@sasairsuspension.com
02 4954 4436 (Australian Eastern Standard Time)
