Suzuki Burgman 650 AM/FM CD Radio Do it yourself Modification

The following booklet has been reposted as a Blog.

This booklet includes pictures and instructions purchased from online and locally. Although this manual is written for the average user, there is some assumption that you are technically/Mechanically inclined, handy with wiring (and it’s theories), and know what components that you will be using. The following instructions and components were used for this DIY manual and not necessary your choices too. You may substitute your own parts such as bigger speakers, etc. It is also suggested that you read through this manual before you begin.
Parts needed:

1. 1  Pyle Marine Radio (Model: PLCD16MRWB ) from Pyle with remote it can be purchased from Links above and below this Blog (Affiliated link, please consider your purchase from here)
2. 2  4” speakers from Wal-mart (or anywhere)
   
3. 3  About 20’ of Speaker wire
   
4. 4  A pack of quick ties
   
5. 5  About 5 foot long sold copper wire
   
6. 6  3/4 inch Aluminum Angle cut to 5 inches from your local hardware store.
   
7. 7  One Red wire about 10’(ignition wire)
   

Tools needed:

1. 1  Electrical tape
   
2. 2  Wire cutter/stripper
   
3. 3  Two each of: 5/16 Nut, machine thread bolt (1/4” long), &
   Washers.
   
4. 4  Hacksaw
   
5. 5  Metal File
   
6. 6  One 5/16 size hole drill bit (obviously you’ll need a drill)
   
7. 7  One 5/32 size hole drill bit
   

Preparing and making the needed parts

1. First thing we need to do is cut the ! inch Aluminum Angle to about 5 inchs
   
   
   
   
2. Then file the edges
   
3. Using a 5/32 size drill bit, drill a hole about 8.5mm from the edge of the Angle
   and 56.65mm apart. You might also use the two screws on top of the left hydraulic fluid reservoir to make sure you have correctly measured it correctly.
   
   
   
   
4. Center the holes as best as you can.
   
5. Using the 5/16 size drill bit, drill on top of the 5/32 inch hole, but do not go all the
   way through. Stop when you notice that the 5/16 hole is almost though the AL angle. This will allow the tapered screw to be flush.
   
   
   
   

6. This step is optional, but recommended. Take the Plastic remote clip that came with your Pyle Radio and cut the top “half Moon” off one side of the plastic clip as shown.

Burgman 650 disassembly

1. There are 8 screws holding the top of your dash down. Please remove all eight of these screws. There are 4 on each side of the Burgman 650 and repeat on left side. Note: Red arrow. It is fine thread and silver color.
   
   
2. Remove Engine compartment cover (one screw).

Fishing the wires and cables

1. Using the 2’ copper wire make a small hook on one end.
   
2. From the left side of the Burgman, under the CVT fuse area push the pointed end
   (not the end where you made the small hook) down towards the open engine compartment. You might have to reach in behind the panel to pull the rest of the copper wire through.
   
   
   
   
3. Cut the speaker wire into two 10’ length (for right and left speakers)
   
4. Wrap the two speaker wires, remote control cable, and ignition wire onto the
   hooked end of the copper wire. Be careful that you are pulling the correct remote control cable end. Afterwards Wrap some electrical tape (or duct tape) around the wires on the hook. Also, make the left and right speaker wire so that you’ll know which speaker left or right.
   
   
   
   

5. Pull the wires thru to the engine compartment. You might have to keep trying because it’s a tight fit. You might have to tug out on the plastic panel to give it some room to pull through.
   
6. Route all the wires behind the outer frame and push it out towards the up front of the Burgman including the remote control cable. (Red arrow) Pay no attention to the extra red wires in this picture as I have other accessories on my bike.
   
   
   
   

7. Reach down thru the left side of the scooter and grab your speaker wires and remote cable.
   
   
   
   
8. Using wire wraps, fasten the left speaker to the Burgman frame. The top is strapped to the horizontal frame (pipe). I find that it works best to insert tie wrap thru the hole as shown on upper arrow. Bottom is pulled against the Vertical pipe frame.
   
   
   
   
   
   
   
   
   
   
   

The theory behind placing the speaker like that is that when traveling, the wind will help carry the sound waves up thru the vents.
9. Cut any access wires. Strip the wires and crimp on the wire terminals.

10. Attach the speaker wires to the left and right speakers. For the right speaker wire, make sure you route the wire away from the front wheel fork so that it will not get caught up while turning. Push the remote wire down inside the left side handlebar plastic covering and connect with the cable that you pull up.

11. Push the remote control cable down the steering column and attach to cable. Be sure that you keep it away from getting caught up in the front wheel fork.
    
12. Remove the two screws from the left brake reservoir
    
13. Screw in the angle bracket using the two screws.
    
14. Attached the plastic remote clip using the Nut & Bolts. You may slide the remote
    along the bracket as you see fit.
    
15. Clip on the remote.
    
    
    
    

16. Wire the Yellow wire directly to the 12v+ battery under the seat. Black wire to negative ground. Connect the Red wire to the ignition wire of the radio. The wire that you pulled from the front(fused Cig ignition).
    
17. Pull the ignition wire up through the fuse box, and since I did not want to modify the bike, I just folded the wire back and tucked it into the orange fuse wire(this is the cig outlet and is tied to the ignition). After a few months of testing this, I permanently spliced in the wire.
    
    
    
    

18. Connect the remote cable to the radio.
    
19. Connect the right and left speaker wires to the radio. You will not need the
    left/right rear speaker wires, so you can tie them back... Although, I’m actually thinking that we can actually put rear speakers on the Burgman! Just not sure where to put it yet.
    
20. Remember the copper wire that we used to fish the wires through? Well, since I did not want to modify my Burgman permanently by drilling a hole through the outer panel, I used that copper wire as an antenna. I stuck the wire into the antenna socket, used electrical tape to hold it together, then I ran the antenna along the outer inside panel of the Burgman. Works for me! I can hear my favorite station loud and clear. You might have to judge for yourself if this will work for you if you have a weak station that you want to pull in.
    
21. I had to play with the placement of the radio a few times to get my favorite spot. You might just want to leave it sitting flat along the bottom of the trunk. I ended up strapping it to the side of the trunk.
    
    
    
    
22. Strap & secure any loose wiring with the quick ties.
    
23. Replace the front dash panel with 8 screws, and middle engine cover.
    
24. I believe you’re done! Push the power button and start jamming down the street!
    
    
    
    

I hope you’ve enjoyed installing this system as much as I have. The Burgman is a great machine and having this radio installed makes it that much better! Remember, please drive carefully! At first you’ll be tempted to look at the remote controls while driving, but I think with practice you’ll learn how to operate the remote without looking. I especially like the placement of the power and mute switch... All you have to do is flip you thumb right over.
Please send me pictures of any modifications that you’ve done. I’ve love to see them!

Ride safe, Mike.