Suzuki RM-Z450 Anwendungshandbuch

Part No. 99011-28H50-01A

October, 2007 EN

RM-Z450

OWNER’S SERVICE MANUAL

FOREWORD

This manual is presented as a means whereby you

can maintain your RM-Z450 in top working condi-

tion at all times. Your riding skill and the mainte-

nance steps outlined in this manual will assure you

of top performance from your machine under any

type of competition.

We sincerely wish you and your Suzuki motorcycle

a successful partnership for many years of happy

riding.

All information, illustrations, photographs and speci-

fications contained in the manual are based on the

latest product information available at the time of

publication. Due to improvements or other changes,

there may be some discrepancies in this manual.

Suzuki reserves the right to make production

changes at any time, without notice and without

incurring any obligation to make the same or similar

changes to motorcycle previous built or sold.

Suzuki Motor Corporation believes in conservation

and protection of Earth’s natural resources. To that

end, we encourage every motorcycle owner to recy-

cle, trade in, or properly dispose of, as appropriate,

used motor oil, engine coolant, and other fluid, and

tires.

GENERAL CONSIDERATIONS

• Wear a helmet and goggles

A helmet is the most important piece of gear to

wear. Helmets do not reduce essential vision or

hearing. Generally, helmets do not cause or

intensify injury if you crash. Helmets simply help

your skull protect your intelligence, your memory,

your personality, and your life.

Your eyesight is equally valuable. Wearing suit-

able eye protection can help keep your vision

unblurred by the wind and help shield your eyes

from branches and airborne matter like bugs, dirt,

or pebbles kicked up by tires. Wear a helmet and

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 wearing protective clothing including gloves,

strong boots that fit over the ankle, long pants,

and a long sleeve shirt or jackets. Experienced

riders often wear a kidney belt and chest or back

protector for additional comfort and protection.

• Inspect your machine before riding

Before each use, perform an inspection per “Peri-

odic Inspection” section starting on page 2-3.

• No Passengers

Suzuki RMs are designed for the rider only.

cCOPYRIGHT SUZUKI MOTOR CORPORATION 2007

• Practice on level ground

Before you begin riding, you should find a good

place to practice the skills you need to ride

safely. Find a flat, open area with enough space

to maneuver. Check with your Suzuki dealer or

call police department if you do not know where

you can ride.

Review the controls on your motorcycle before

riding.

•Knowyourlimits

Always ride within the boundaries of your own

skills. Knowing these limits and staying within

them will help you avoid accidents. Ride only in

events appropriate for your experience.

Safely competing on a motorcycle requires that

your mental and physical skills are fully part of

the experience. You should not attempt to oper-

ate a motorcycle, especially one with two wheels,

if you are tired or under the influence of alcohol

or other drugs. Alcohol, illegal drugs, and even

some prescription and over-the-counter drugs

and cause drowsiness, loss of coordination, loss

of balance, and loss of good judgement. If you

are tired or under the influence of alcohol or other

drugs, PLEASE DO NOT RIDE your motorcycle.

• Conclusion

The actions of other riders are unpredictable.

Your motorcycle’s condition can change. These

factors can best be dealt with by giving every ride

your full attention.

Circumstances beyond your control could lead to

an accident. You need to prepare for the unex-

pected by wearing a helmet and other protective

gear, and practicing safe riding techniques to

minimize the damage to you and your machine.

May all of your rides on your new Suzuki be winning

rides!

SERIAL NUMBER LOCATION

The frame number



1is stamped on the steering

head as shown in the illustration. The engine serial

number



2is stamped on the right side of the crank-

case assembly.

Write down the serial numbers here for your future

reference.

Frame No.

Engine No.

WARNINGS FOR SERVICING

!WARNING

Never run the engine indoors or in a

garage. Exhaust gas contains carbon mon-

oxide, a gas that is colorless and odorless

and can cause death or severe injury.

Only run the engine outdoors where there

is fresh air.

!WARNING

Hot engine and muffler can burn you.

Wait until the engine and muffler cools

before servicing.

!WARNING

Fuel can catch on fire if you do not handle

it properly. Gasoline vapors can catch fire

easily.

Do not smoke when servicing the machine.

Do not service the machine in an area

where there are open flames or sparks.

!WARNING

Brake fluids and engine coolant can be

hazardous to humans and pets. Brake fluid

and engine coolant are harmful or fatal if

swallowed, and harmful if it comes in con-

tact with your skin or eyes.

Keep brake fluid and engine coolant away

from children. Call your doctor immedi-

ately if swallowed, and induce vomiting.

Flush eyes or skin with water if either

brake fluid or engine coolant gets in eyes

or comes in contact with skin.

PRECAUTIONS FOR

SERVICING

• Replace gaskets, snap rings, circlips, O-rings

and cotter pins with new ones.

• Take care not to expand the end gap larger than

required to slip the circlip over the shaft when

installing a circlip.

• Use special tools where specified.

• Use genuine SUZUKI parts and recommended

oil.

• When two or more persons work together, pay

attention to the safety of each other.

• After reassembly, inspect parts for tightness and

operation.

REPLACEMENT PARTS

Use only genuine SUZUKI replacement parts or

their equivalent. Genuine SUZUKI parts are high

quality parts which are designed and built specially

for SUZUKI motorcycle.

NOTE:

Use of replacement parts which are not equivalent

in quality to genuine SUZUKI parts can lead to per-

formance problems and damage.

!WARNING

Servicing the machine with engine running

can be hazardous. You can be caught in

the moving parts such as the drive chain,

sprockets etc.

Be sure to stop the engine when servicing

the machine.

!WARNING

Servicing the machine without proper

clothes and protective gear can be hazard-

ous. You can be injured if you do not wear

proper clothes and protective gear.

Be sure to wear proper clothes and shoes

for servicing and wear protective glasses,

mask or gloves as necessary.

SYMBOL MARKS AND MATERIALS

Listed in the table below are the symbols indicating instructions and other information. The meaning of each

symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK SUPER “1360”

or equivalent.

99000-32130

Apply oil. Use engine oil or transmission

oil unless otherwise specified.

Use SUZUKI FORK OIL SS-05

or equivalent.

99000-99001-SS5

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1:1)

Use SUZUKI REAR SUSPENSION OIL

SS-25 or equivalent.

99000-99001-S25

Apply SUZUKI SUPER GREASE “A”

or equivalent.

99000-25010

Use engine coolant or equivalent.

Apply SUZUKI SILICONE GREASE

or equivalent.

99000-25100

Apply or use brake fluid. (DOT 4)

Apply SUZUKI MOLY PASTE

or equivalent.

99000-25140

Measure in voltage range.

Apply SUZUKI BOND “1215”

or equivalent.

99000-31110

Measure in resistance range.

Apply SUZUKI BOND “1207B”

or equivalent.

99000-31140

Measure in diode test range.

Apply THREAD LOCK SUPER “1303”

or equivalent.

99000-32030

Use special tool.

Apply THREAD LOCK SUPER “1322”

or equivalent.

99000-32110

Indication of service data.

Apply THREAD LOCK “1342”

or equivalent.

99000-32050

Replace a part with a new one when

reassembling.

ABBREVIATIONS USED IN THIS

MANUAL

AC : Alternating Current

API : American Petroleum Institute

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

CKP Sensor : Crankshaft Position Sensor

(CKPS)

DC : Direct Current

DTC : Diagnostic Trouble Code

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FP Relay : Fuel Pump Relay

GND : Ground

GP Switch : Gear Position Switch

IAP Sensor : Intake Air Pressure Sensor (IAPS)

(MAP Sensor)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

JASO : Japanese Automobile Standards

Organization

LH: Left Hand

Max : Maximum

Min : Minimum

RH : Right Hand

SAE : Society of Automotive Engineers

TO Sensor : Tip-Over Sensor (TOS)

TP Sensor : Throttle Position Sensor (TPS)

WIRE COLOR

B : Black Lg : Light green

Bl : Blue O : Orange

Br : Brown P : Pink

Dg : Dark green R : Red

G : Green Y : Yellow

Gr : Gray

B/Bl : Black with Blue tracer

B/Br : Black with Brown tracer

B/R : Black with Red tracer

B/W : Black with White tracer

B/Y : Black with Yellow tracer

Bl/B : Blue with Black tracer

Bl/G : Blue with Green tracer

Bl/R : Blue with Red tracer

Bl/W : Blue with White tracer

Bl/Y : Blue with Yellow tracer

Br/W : Brown with White tracer

G/B : Green with Black tracer

G/W : Green with White tracer

Gr/W : Gray with White tracer

R/B : Red with Black tracer

R/Bl : Red with Blue tracer

R/W : Red with White tracer

W/Bl : White with Blue tracer

W/R : White with Red tracer

Y/R : Yellow with Red tracer

GROUP INDEX

GENERAL INFORMATION 1

PERIODIC MAINTENANCE 2

TROUBLESHOOTING 3

MACHINE TUNING 4

ENGINE REMOVAL AND INSTALLATION 5

CYLINDER HEAD, CYLINDER AND PISTON 6

CLUTCH 7

KICK STARTER 8

GEARSHIFTING 9

TRANSMISSION AND CRANKSHAFT 10

LUBRICATION SYSTEM 11

FI SYSTEM DIAGNOSIS 12

FUEL SYSTEM AND THROTTLE BODY 13

COOLING SYSTEM 14

ELECTRICAL SYSTEM 15

FRONT AND REAR WHEELS 16

FRONT AND REAR BRAKES 17

FRONT FORK AND STEERING 18

REAR SUSPENSION 19

SERVICING INFORMATION 20

CONTENTS

GENERAL INFORMATION

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

000

E-03

E-19

E-28

Japan

U. S. A.

E.U.

Canada

JS1RL 42A000 500001 –

JS1RL 42C 82 100001 –

JS1RL 42A000 500001 –

JS1RL 42C 82 100001 –

1-1 GENERAL INFORMATION

LOCATION OF PARTS ............................................................................... 1- 2

ACCESSORY ............................................................................................... 1- 3

SIDE STAND ......................................................................................... 1- 3

FUEL AND OIL RECOMMENDATION ........................................................ 1- 3

OPERATING INSTRUCTIONS .................................................................... 1- 4

STARTING THE ENGINE ...................................................................... 1- 4

STOPPING THE ENGINE ..................................................................... 1- 5

TRANSMISSION ................................................................................... 1- 5

BREAK-IN (RUNNING-IN) ........................................................................... 1- 6

WHEN THE MOTORCYCLE IS NEW ................................................... 1- 6

WHEN ENGINE PARTS ARE REPLACED ........................................... 1- 6

EXTERIOR PARTS ...................................................................................... 1- 7

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