Suzuki RM-Z450 Manual Download Page 21

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3-4

Rear suspension rebound damping force adjuster

Rear suspension compression damping adjuster

Kick starter lever

ECM tuning map coupler

Rear brake fluid reservoir

Engine oil filler cap

Rear brake pedal

Engine oil filter

Radiator cap

Summary of Contents for RM-Z450

Page 1: ...enger vehicle or off road vehicle can expose you to chemicals including engine exhaust carbon monoxide phthalates and lead which are known to the State of California to cause cancer and birth defects...

Page 2: ...All information illustrations pho tographs and specifications con tained in the manual are based on the latest product information available at the time of publica tion Due to improvements or other ch...

Page 3: ...information The mean ing of each symbol is also included in the table SYMBOL DEFINITION Torque control required Data beside it indicates specified torque Apply oil Use engine oil or transmission oil...

Page 4: ...ORCYCLING FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS CONTROLS EQUIPMENT AND ADJUSTMENTS BREAK IN RUNNING IN AND INSPECTION BEFORE RIDING RIDING TIPS INSPECTION AND MAINTENANCE STORAGE PROCEDURE AND M...

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Page 6: ...1 1 1 THE SPORT OF MOTOCROSS MOTORCYCLING GENERAL CONSIDERATIONS 1 2 INSPECT YOUR MACHINE BEFORE RIDING 1 4 LABELS 1 4...

Page 7: ...eye protection every time you ride Wear protective gear Wear proper clothing when you ride Avoid loose clothes or scarves which could get caught in moving parts Abrasion injuries can be minimized by...

Page 8: ...rescription and over the counter drugs and cause drowsi ness loss of coordination loss of balance and loss of good judge ment If you are tired or under the influence of alcohol or other drugs PLEASE D...

Page 9: ...n entire pre ride inspection before you head out on the trail Spend ing a few minutes preparing your machine for a ride can help pre vent accidents due to mechanical failure or costly LABELS Read and...

Page 10: ...2 1 2 FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL 2 2 ENGINE OIL 2 4 ENGINE COOLANT SOLUTION 2 6...

Page 11: ...y changing to a different gas station If the situation is not improved by changing consult your Suzuki dealer Oxygenated fuels which meet the minimum octane requirement and the requirements described...

Page 12: ...these requirements check with the service station operator or the fuel supplier NOTE To help minimize air pollution Suzuki recommends that you use oxygenated fuels Be sure that any oxygenated fuel you...

Page 13: ...ion of SG SH SJ SL SM or SN with a JASO classifica tion of MA API American Petroleum Institute JASO Japanese Automobile Standards Organization NOTE SUZUKI highly recom mends the use of ECSTAR brand en...

Page 14: ...r of oil sales company 2 Oil classification Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING or RESOURCE CONSERVING oils Some engine oils which have an API classification of SH...

Page 15: ...freeze solution Therefore engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to the freezing point WARNING Engine coolant is harmful or f...

Page 16: ...er only Water other than distilled water can cor rode and clog the aluminum radia tor Required amount of engine cool ant water solution capacity total 1100 ml 1 2 US qt NOTE This 50 mixture will pro t...

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Page 18: ...TMENTS LOCATION OF PARTS 3 2 LEFT HANDLEBAR 3 5 RIGHT HANDLEBAR 3 6 FUEL TANK CAP 3 7 STARTER KNOB 3 8 KICK STARTER LEVER 3 8 GEARSHIFT LEVER 3 9 REAR BRAKE PEDAL 3 9 SIDE STAND 3 10 SUSPENSION ADJUST...

Page 19: ...3 2 CONTROLS EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS 1Clutch lever 2S HAC switch 3Front brake fluid reservoir 4Front brake lever 5Engine stop switch 6Fuel tank cap 7Throttle grip...

Page 20: ...3 3 8Front fork compression damping force adjuster 9Starter knob 0Idle screw AFront fork rebound damping force adjuster BGearshift lever CFootrests...

Page 21: ...ebound damping force adjuster ERear suspension compression damping adjuster FKick starter lever GECM tuning map coupler HRear brake fluid reservoir IEngine oil filler cap JRear brake pedal KEngine oil...

Page 22: ...nsmission gears Squeez ing the lever disengages the clutch Engine Stop Switch 2 To stop the engine push the engine stop switch S HAC SUZUKI HOLESHOT ASSIST CONTROL switch 3 This is a system that assis...

Page 23: ...rease engine speed Turn it away from you to decrease engine speed Front Brake Lever Adjustment Adjust the front brake lever posi tion as follows 1 Loosen the lock nut 1 2 Turn the adjuster 2 in or out...

Page 24: ...tank when refueling 1 Fuel level 2 Filler neck WARNING If you overfill the fuel tank fuel may overflow when it expands due to engine heat or heating by the sun Fuel that overflows can catch fire Stop...

Page 25: ...e kick starter lever with the transmission in neutral will start the engine If the clutch lever is squeezed you can also start the engine with the transmis sion in any gear other than neu tral Kick do...

Page 26: ...ttle at the same time you operate the gearshift lever Lift the gearshift lever to upshift and depress the lever to downshift Neutral is located between 1st and 2nd gear When neutral is desired depress...

Page 27: ...ork compression and rebound damping force and oil capacity are adjustable for rider s preference rider s weight and course condition NOTE Break in new front forks before attempting adjustment Be sure...

Page 28: ...95 lbf ft Compression Damping Force Adjustment To set the adjuster you must gently turn the adjust screw 1 clockwise until it stops then back it out the recommended number of clicks Do not force the...

Page 29: ...r equivalent grease Front fork air bleeder valve 1 3 N m 0 13 kgf m 0 95 lbf ft Reducing the fork oil 1 Remove the front forks Refer to Service Manual 2 Remove the air bleeder valve 3 Leaning the fron...

Page 30: ...nd damping force to a softer setting 2 Decrease fork oil capacity 3 Change the spring with an optional softer one Feels too soft overall and bottoms Jump Large bump When braking 1 Adjust the compressi...

Page 31: ...s for spare parts only The spring assembled at the factory does not have identification slit mark Spring Part No Spring rate Identifica tion Slit mark on the spring end Standard Oil quantity Oil quant...

Page 32: ...3 15 Fig 1 Standard Part No 51171 37K00 Fig 2 Hard Part No 51171 37K20 Slit End of roll Grinding end 90 Slit Slit Slit 45 45 45 End of roll Grinding end...

Page 33: ...re are any suspension abnor malities Rear shock absorber damage and oil leakage 6 42 Swingarm and links tightness 6 42 Tire pressure 6 39 Tire and wheel damages 6 39 Spoke nipple tension and rim lock...

Page 34: ...to 5 5 mm 0 22 in from spring free length Standard 234 5 mm 9 232 in Spring set length adjustable range 226 237 mm 8 90 9 33 in at spring free length 240 mm 9 45 in 5 After adjusting the spring pre lo...

Page 35: ...stopped posi tion or you may damage the adjuster Standard setting counterclockwise 1 1 2 turns Rebound Damping Force Adjustment To set the adjuster you must gen tly turn the adjust screw 2 clock wise...

Page 36: ...4 Measure the distance L1 from the seat bolt to the chain adjuster lock nut with the motorcycle on the stand and the rear wheel lifted off the ground Spring Part No Spring rate Marking paint Set lengt...

Page 37: ...rcycle normally in full riding gear 6 Find the sag by subtracting L2 from L1 Standard sag range 105 mm 4 1 in When the sag measured is Adjustment procedure Less than 105 mm 4 1 in Reduce spring pre se...

Page 38: ...o harder settings See note below 2 Adjust the rebound damping force to a harder setting See note below 3 Change the spring with an optional stiffer one 3 19 Feels harsh and hits bumps too harshly Jump...

Page 39: ...tom where as it felt fine before the front fork adjustment was made BALANCE TEST Stand next to the motorcycle on level ground Place one foot on the foot rest closest to you Sharply push down The front...

Page 40: ...4 1 4 BREAK IN RUNNING IN AND INSPECTION BEFORE RIDING BREAK IN RUNNING IN 4 2 INSPECTION BEFORE RIDING 4 3...

Page 41: ...ng 3 Ride for 60 minutes using less than 3 4 throttle opening NOTE The break in running in period is the period of greatest wear The bolts and nuts of the new machine can loosen quickly Be sure to ret...

Page 42: ...motor cycle before riding and to prop erly maintain your motorcycle increases the chances of an accident or equipment dam age Always inspect your motorcy cle each time you use it to make sure it is in...

Page 43: ...hose Breather hose clogging and bend Engine idle speed Revolution speed Brake fluid Fluid level Brakes Brake lever position Brake pedal height Operation Wear pads Drive chain and engine sprocket Slac...

Page 44: ...4 5 Exhaust pipe and muffler Exhaust gas leakage Tightening torque Damage Bolts and nuts Tightening torque WHAT TO CHECK BEFORE RIDE BEFORE PRACTICE BEFORE RACE REMARKS...

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Page 46: ...TRUCTIONS 5 2 INSPECTION BEFORE ENGINE OIL LEVEL CHECK 5 2 STARTING THE ENGINE 5 3 SELECTION OF S HAC SUZUKI HOLESHOT ASSIST CONTROL MODE 5 6 SELECTING A MODE 5 8 SELECTION OF ECM TUNING MAP 5 12 STOP...

Page 47: ...dling speed after riding will cause engine overheat as this compe tition motorcycle does not have the radiator cooling fan and coolant reservoir Riding the motorcycle under severe con ditions such as...

Page 48: ...olant level and air cleaner condition before starting the engine 6 18 6 32 6 14 Check that the fuel tank has enough fuel for practice or race before starting the engine Shift the transmission into neu...

Page 49: ...ease the kick starter lever from this position and allow it to return to the top While keeping the throttle closed depress the kick starter lever strongly through the full stroke Never open the thrott...

Page 50: ...le during the kick start oper ation NOTE If the engine fails starting open the throttle fully and depress the kick starter lever slowly about 4 5 times to clear too rich fuel mixtures in the engine Th...

Page 51: ...ntended specifically for starts that use a starting gate Do not use S HAC for a start that does not use a starting gate The start off state of the motorcycle is defined as being from the point that th...

Page 52: ...Mode B fast flashing Normal dirt Selected mode Engine control release conditions Mode A or Mode B Control released 6 seconds after starting begins Control released when throttle is closed after start...

Page 53: ...wever that even while the indicator light is lit to indicate the engine run time holding down the S HAC switch 2 for more than 0 7 seconds will cause the indicator light 1 to switch to slow flashing m...

Page 54: ...t will be lit for 0 2 sec per 1 hour of engine run time Releasing the S HAC switch during this interval will cause mode A to be selected Time sec Normal mode Mode A Engine run time Lamp check Indicato...

Page 55: ...C switch 2 for more than 1 8 seconds will cause the indicator light 1 to switch to fast flashing mode B Releasing the S HAC switch 2 to select mode B will cause the fast flash pattern to continue NOTE...

Page 56: ...lit for 0 2 sec per 1 hour of engine run time After the indicator light starts fast flashing releasing the S HAC switch will select mode B Time sec Mode B Mode B Normal mode Mode A Engine run time La...

Page 57: ...ther injection map for slightly leaner mixture or that for slightly richer mixture depending on the selected shunt wire NOTE The changeover is exe cuted immediately after the engine has been started S...

Page 58: ...rom the bracket 2 Disconnect the mode select coupler cap 1 3 Connect the short wire 2 to the mode select coupler 4 Install the mode select coupler to the bracket 5 Start the engine NOTICE Improper mod...

Page 59: ...nt or rear brake can cause skidding and loss of control Apply both brakes evenly and at the same time WARNING Hard braking while turning may cause wheel skid and loss of control Brake before you begin...

Page 60: ...NGINE RUN TIME RESET PROCEDURE 6 8 GENERAL LUBRICATION 6 10 FUEL TANK 6 12 AIR CLEANER 6 14 SPARK PLUG 6 17 ENGINE OIL 6 18 IDLE SPEED ADJUSTMENT 6 26 THROTTLE CABLE ADJUSTMENT 6 27 FUEL HOSE 6 28 CLU...

Page 61: ...maintenance listed NOTICE Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage Use only genuine SUZUKI replacement parts or...

Page 62: ...6 3...

Page 63: ...in Engine oil filter 6 19 R Oil strainers 6 22 I Inspect after 1st initial break in Cooling system I Replace radiator hose and engine coolant every year Flushing for overhaul or storage Clutch I Repl...

Page 64: ...uide R Brakes 6 33 I Replace brake hose and fluid every year Front brake caliper axle bolt T Front fork oil R Change after 1st initial break in Front fork I Check front fork inner tube frequently for...

Page 65: ...seconds lamp check engine run time will be dis played by indicator light light ing time NOTE Lighting of lamp check and engine run time is made only at the first time and when there is DTC available t...

Page 66: ...6 7 1 0 1 0 2 0 3 0 2 4 EXAMPLE In the case that the engine run time is 12 hours Indicator light ON OFF Lamp check Engine run time Repeat DTC will be displayed Time sec...

Page 67: ...attery wire 3 After connecting the battery wire turn the throttle grip to full open within 2 seconds then maintain this state for 5 to 10 seconds 4 Fully close the throttle grip for more than 5 second...

Page 68: ...6 9 2 0 5 0 5 0 10 0 Time sec Disconnect the battery wire Throttle grip Full open Full close...

Page 69: ...ecessary to lubricate many components is in itself valuable preventative maintenance It allows you to inspect for wear fatigue adjustment and fastener tight ness and it allows you to clean out the gri...

Page 70: ...onditions Clean and pack the bearings Keep seals fresh Grease the seals 7 Rear suspension pivots Every 1 race More often according to conditions Clean and pack the bearings Keep seals fresh Grease the...

Page 71: ...olts 1 and the seat 2 2 Remove the bolts 3 and the right and left radiator covers 4 3 Disconnect the fuel pump cou pler 5 4 Remove the fuel tank bolt 6 and rubber band 7 5 Lift and hold the fuel tank...

Page 72: ...ove the fuel tank assem bly WARNING Fuel spilled from the fuel hose can catch on fire Stop the engine before discon necting the fuel hose Keep flames sparks and heat sources away Do not smoke Catch fu...

Page 73: ...place can be hazardous A flame can spit back from the engine to the air intake box without the air cleaner element to stop it Severe engine damage can also occur if dirt enters the engine due to runni...

Page 74: ...to remove excess oil 6 Clean any dirt or debris from inside the air cleaner case NOTE Recycle or properly dis pose of used oil and solvent NOTICE A torn air cleaner element will allow dirt to enter th...

Page 75: ...of the element 2 2 Install them in the air cleaner box by engaging the projection A of the element holder with the hole B of the air cleaner box NOTICE Failure to position the air cleaner element prop...

Page 76: ...he spark plug gap A with a wire type feeler gauge The standard spark plug gap is 0 9 1 0 mm 0 035 0 039 in If the measured spark plug gap is out of standard range replace the spark plug with a new one...

Page 77: ...le on level ground on the side stand Remove the bolts Remove the under guard 2 Start the engine and run it for a few minutes 3 Stop the engine and wait three minutes 4 Hold the motorcycle vertically N...

Page 78: ...GINE OIL AND FILTER CHANGE Change the engine oil and oil filter at the scheduled times The oil should be changed when the engine is warm so that the oil will drain thoroughly from the engine The proce...

Page 79: ...ipes can burn you Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil WARNING Children and pets may be harmed by swallowing new or used oil Rep...

Page 80: ...f m 8 5 lbf ft 8 Remove the bolts 6 holding the filter cap 7 in place 9 Replace the oil filter 8 and the O ring 9 with a new one Oil filter cap bolt 11 N m 1 1 kgf m 8 5 lbf ft NOTICE Failure to use a...

Page 81: ...f the oil strainer is damaged replace the oil strainer If the oil strainer is clogging clean the oil strainer in the following pro cedures NOTE Clean the oil strainer thor oughly up to first 2 to 3 ti...

Page 82: ...he magnet and oil strainer 15 Insert the magnet and clip into the oil strainer Hook the clip C to the groove D WARNING The strainer has a strong mag net Magnetic force may affect pacemaker operation D...

Page 83: ...18 Remove the bolts Remove the oil pump No 2 cover G Remove the snap ring H and oil strainer No 2 I 09930 06108 Snap ring pliers Close type 19 Check the oil strainers for any damage or clogging If th...

Page 84: ...ft 23 Install the gear shift lever and protector under the engine 24 Pour fresh oil through the filler hole Approximately 1100 ml 1 2 US qt will be required NOTE About 1050 ml 1 1 US qt of oil will b...

Page 85: ...ustment when the engine is hot 3 Connect the special tool to the high tension cord 09900 26010 Digital tachometer 09900 26006 Engine tachometer 4 Turn the idling adjust screw 1 and set the engine idle...

Page 86: ...correct limits 6 Replace the boot 1 Throttle cable play 2 0 4 0 mm 0 08 0 16 in WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars This can lea...

Page 87: ...efects are found the fuel hose must be replaced Replace the fuel hose every four years CLUTCH ADJUSTMENT Adjust the clutch cable play as fol lows Minor Adjustment Quick Adjuster Turn adjuster 1 so the...

Page 88: ...motorcycle to an authorized Suzuki dealer if the drive chain needs to be replaced The condition and adjustment of the drive chain should be checked before each use of the motorcy cle Always follow th...

Page 89: ...ed if necessary If you find any of these problems with your sprocket consult your Suzuki dealer Drive Chain Cleaning and Oiling Clean and oil the chain as follows 1 Remove dirt and dust from the drive...

Page 90: ...that the right and left adjuster washers 4 are at the same position on scales 5 3 With the adjusters 3 held in position tighten the lock nuts 2 4 Push the adjuster washers 4 to the adjusters 3 and ti...

Page 91: ...trol center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fresh air If coolant gets in eyes flush eyes with water and seek medical attention Wash thoroughly after handling Keep...

Page 92: ...r disk brakes NOTE Operating in mud water sand or other extreme conditions can cause accelerated brake wear If you operate your motorcy cle under these conditions the brakes must be inspected more oft...

Page 93: ...lowers the boiling point and can cause brake system malfunction due to corrosion of brake compo nents Boiling brake fluid or brake system malfunction could result in an accident Replace the brake flu...

Page 94: ...t with skin or eyes Solution can be poison ous to animals If brake fluid is swallowed do not induce vomiting Immedi ately contact a poison control center or a physician If brake fluid gets in eyes flu...

Page 95: ...with new ones After replacing either the front or rear brake pads the brake lever or pedal must be pumped several times This will extend the pads to their proper position WARNING Failure to inspect an...

Page 96: ...ake lever pedal you may get poor braking per formance which could result in an accident After brake system repair or brake pad replacement pump the brake lever pedal several times until brake pads are...

Page 97: ...djuster 2 to locate the pedal 0 10 mm 0 0 39 in below the top face of the footrest 3 While holding the yoke 3 tighten the lock nut to the specified torque Rear brake master cylinder rod lock nut 6 0 N...

Page 98: ...torcycle form the crucial link between your motorcycle and the road Failure to take the precautions below may result in an accident due to tire failure Check tire condition and pressure before each ri...

Page 99: ...r tires each time before you ride Replace tires if tires show visual evidence of damage such as cracks or cuts When you replace a tire be sure to replace it with a tire of the size and type listed bel...

Page 100: ...pples with a spoke nipple wrench so as all spokes have same tension Spoke nipple front wheel 5 5 N m 0 56 kgf m 4 05 lbf ft Spoke nipple rear wheel 6 0 N m 0 61 kgf m 4 45 lbf ft Inspect the bead stop...

Page 101: ...are found replace the front fork with a new one REAR SUSPENSION Move the rear suspension up and down several times and inspect for smooth movement Inspect for damage and oil leaks Inspect the bolts an...

Page 102: ...6 43 STEERING Inspect the steering by moving the front forks up and down and back and forward If the steering has play or binds inspect steering stem head nut tightness and steering bearings...

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Page 104: ...7 1 7 STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE 7 2 PROCEDURE FOR RETURNING TO SERVICE 7 3 CORROSION PREVENTION 7 4 MOTORCYCLE CLEANING 7 5 INSPECTION AFTER CLEANING 7 7...

Page 105: ...nk to the top with fuel mixed with the amount of gasoline stabilizer recom mended by the stabilizer man ufacturer 2 Run the engine for a few min utes until the stabilized gaso line fills the fuel inje...

Page 106: ...fficult to start until the deteriorated stale fuel is discharged from the fuel line Repeated kick operation is required for flushing the fuel line with fresh fuel 1 Fill the fuel tank more than half f...

Page 107: ...ff an addi tional cleaner may be required Follow the manufacturer s directions when using these special cleaners Repair finish damage as soon as possible Carefully exam ine your motorcycle for dam age...

Page 108: ...box Washing the Motorcycle When washing the motorcycle follow the instructions below 1 Remove dirt and mud from the motorcycle with cool running water You may use a soft sponge or brush Do not use har...

Page 109: ...r washing the motorcycle Waxing the Motorcycle After washing the motorcycle waxing and polishing are recom mended to further protect and beautify the paint Only use waxes and polishes of good quality...

Page 110: ...ck your motorcycle for any problems that may have arisen during your last ride WARNING Operating the motorcycle with wet brakes can be hazardous Wet brakes may not provide as much stopping power as dr...

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Page 112: ...8 1 8 CONSUMER INFORMATION SERIAL NUMBER LOCATION 8 2 LOCATION OF LABELS 8 3...

Page 113: ...t title documents for your motorcycle You also need these numbers to help your dealer when you order parts The frame number 1 is stamped on the steering head tube The engine serial number 2 is stamped...

Page 114: ...or highways Motorcycle does not meet federal and state safety and other standards for street use or off road use Single rider only Slow down on slippery surfaces unfamiliar terrain or when visibility...

Page 115: ...system Primary kick Lubrication system Semi Dry sump DRIVE TRAIN Clutch Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern 1 down 4 up Primary reduction ratio 2 625 63 24 Gear r...

Page 116: ...Electronic ignition CDI Spark plug NGK DIMR8C10 Generator Single phase A C generator CAPACITIES Fuel tank 6 3 L 1 7 US gal Engine oil oil change 1050 ml 1 1 US qt With filter change 1100 ml 1 2 US qt...

Page 117: ...RUN TIME INDICATION PROCEDURE 6 6 ENGINE RUN TIME RESET PROCEDURE 6 8 F FRONT FORK 6 42 FUEL 2 2 FUEL HOSE 6 28 FUEL TANK 6 12 FUEL TANK CAP 3 7 G GEARSHIFT LEVER 3 9 GENERAL CONSIDERATIONS 1 2 GENER...

Page 118: ...42 REPLACEMENT PARTS 6 2 RIGHT HANDLEBAR 3 6 S SELECTING A MODE 5 8 SELECTION OF ECM TUNING MAP 5 12 SELECTION OF S HAC SUZUKI HOLESHOT ASSIST CONTROL MODE 5 6 SERIAL NUMBER LOCATION 8 2 SIDE STAND 3...

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