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Wipe broken heat wire and its surrounding area clean with a cloth dampened in alcohol.

Fig 1: Measuring Break Area
Courtesy of SUZUKI OF AMERICA CORP.
Apply a small amount of conductive silver composition to tip of drawing pen. Shake silver composition container before use.
Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly overlap existing heat wire on both sides [preferably 5 mm (0.20 in)] of the break.
After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver composition is deposited.

Fig 2: Checking Continuity Between Wires
Courtesy of SUZUKI OF AMERICA CORP.

Do not touch repaired area while test is being conducted.
Apply a constant stream of hot air directly to the repaired area for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area and hot air outlet.

Fig 3: Applying Stream Of Hot Air To Repaired Area With Heat Gun
Courtesy of SUZUKI OF AMERICA CORP.

If a heat gun is not available, let the repaired area dry for 24 hours.

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.

• Brakes feel soft, pull hard to one side, or make grinding noises.

• The engine overheats, stalls repeatedly, or misfires under load.

• You are missing required tools, torque specs, or safe lifting equipment.

• You are not confident in the next step or safety outcome.

Safety Warning

Repairing Procedure