Before starting work, ensure the motorcycle is securely tied into a bike hoist or lift.
Raise the motorcycle so the back wheel is off the bench.
Place a second jack under the back wheel to support the wheel (see photo below).
Remove the OE shocks, keeping OE rear shoulder bolts and washers.
SAS-99 + SAS-99XL
Before fitting the Suspension, inspect the 4 OE rear shoulder bolts and front shock bushes.
SAS-00
Before fitting the Suspension, inspect the 2 OE rear shoulder bolts and front shock bushes.
Thoroughly clean the OE rear shoulder bolts and washers, then coat the bolts and Suspension ends with anti-seize or grease.
Apply Loctite to threads. (See photo below. Cleaned OE rear shoulder bolts shown.)
Install your SAS Air Ride Suspension Kit with the flat side facing down towards the ground.
Fit the rear Suspension bolts first, allowing the Suspension to hang down.
Do not fully tighten the bolts just yet.
Route your wiring loom over the frame rail to the outside of the bike.
Note: Do not go over and in front of the cross-member. Keep the wiring on the rear side of the cross-member. (See photos below.)
Raise the front of the Suspension up and fit the 2 supplied M12 bolts. Apply Loctite to the threads.
SAS-99 + SAS-99XL
Tighten all four OE shoulder bolts to 121-136 ft-lbs.
SAS-00
Tighten rear OE shoulder bolts to 121-136 ft-lbs.
Tighten front M12 bolts to 50-55 ft-lbs.
Route the wiring loom along the frame rail and up to the battery location at back right-hand side of the battery area. You will find a small hole to route the wiring through to secure the wiring loom to the frame. (See photos below.)
The OE shoulder bolts will have a gap between the head of the bolt and the Suspension end.
Do not shim this gap. This is designed to stop shock bind.
Securely tie the wiring loom to the oil tank line or OE wiring loom using a cable tie.
Ensure the wiring harness is clear of all moving parts and will not get crimped, pinched or caught in any location.
Position the filter/breather just in front of the battery where the filter won’t get wet or suck in dirty air.
Remove the old OE clutch clamp.
Install your SAS Handlebar Switch using the 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 of the bars (to do this you will need to unpick the electrical plug).
OR
2. 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 battery location.
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 under the gas/petrol tank – see image below.
Step 5. Wiring Harness
Remove the fuse from the fuse holder
Connect the red positive wire to the positive terminal on the battery.
Connect the negative terminal to the frame ground.
Connect the male bar switch plug to the female wiring harness plug.
Connect the female plug from the Air Ride Suspension unit to the male wiring harness plug.
Reinstall the fuse and check the handlebar switch and Suspension are working correctly.
Push the top button to raise the bike.
Push the bottom button to lower the bike.
Before riding the bike:
Please check, when the bike is both fully lowered and raised, 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 use 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 1-1.5” 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 can 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 Suspension fitted & tag us on Facebook & Instagram using:
#SASAirSuspension @SASAirSuspension
For any further questions or concerns please call or email us: info@sasairsuspension.com
02 4954 4436 (Australian Eastern Standard Time)
