2009-2014 Suzuki RM-Z450 Service & Repair Manual

FOREWORD This manual is presented as a means whereby you can maintain your RM-Z450 in top working condition at all times. Your riding skill and the maintenance 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 RM-Zs are designed for the rider only.

• 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. • Know your limits 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 1 is stamped on the steering head as shown in the illustration. The engine serial number 2 is 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 contact 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 performance 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 hazardous. 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 A AC : Alternating Current API : American Petroleum Institute B BTDC : Before Top Dead Center B+ : Battery Positive Voltage C CKP Sensor : Crankshaft Position Sensor (CKPS) D DC : Direct Current DTC : Diagnostic Trouble Code E ECM : Engine Control Module Engine Control Unit (ECU) (FI Control Unit) ECT Sensor : Engine Coolant Temperature Sensor (ECTS), Water Temp. Sensor (WTS) F FI : Fuel Injection, Fuel Injector FP : Fuel Pump FP Relay : Fuel Pump Relay G GND : Ground GP Switch : Gear Position Switch I IAP Sensor : Intake Air Pressure Sensor (IAPS) (MAP Sensor) IAT Sensor : Intake Air Temperature Sensor (IATS) J JASO : Japanese Automobile Standards Organization L LH: Left Hand M Max : Maximum Min : Minimum R RH : Right Hand S SAE : Society of Automotive Engineers T 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 JS1RL42A000 503103 – JS1RL42C 92 100035 – JS1RL42A000 503098 – JS1RL42C 92 100037 – 1-1 GENERAL INFORMATION LOCATION OF PARTS ............................................................................... 1- 2 ACCESSORY .............................................................................................. 1- 4 SIDE STAND ......................................................................................... 1- 4 FUEL AND OIL RECOMMENDATION ........................................................ 1- 4 OPERATING INSTRUCTIONS .................................................................... 1- 5 STARTING THE ENGINE ..................................................................... 1- 5 STOPPING THE ENGINE ..................................................................... 1- 6 TRANSMISSION ................................................................................... 1- 6 BREAK-IN (RUNNING-IN) .......................................................................... 1- 7 WHEN THE MOTORCYCLE IS NEW ................................................... 1- 7 WHEN ENGINE PARTS ARE REPLACED .......................................... 1- 7 EXTERIOR PARTS ..................................................................................... 1- 8

GENERAL INFORMATION 1-2 1 LOCATION OF PARTS Read and follow all of the warnings labeled on your motorcycle. Make sure you understand all of the labels. Keep the labels on your motorcycle. Do not remove them for any reason. 2 1 3 WARNING Failure to follow these safety precautions may increase your risk of injury; Wear a helmet, eye protection, and bright, protective clothing. Don’t ride after consuming alcohol or other drugs. Closed course competition use only – do not use on public streets, roads, 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 is reduced. Read owner’s manual carefully. • • • • • • • The owner’s manual contains important safety information and instructions. If the motorcycle has been resold, obtain the owner’s manual from the previous owner or contact your local Suzuki dealer for assistance. • This motorcycle is sold “AS IS” with NO WARRANTY OF ANY KIND. The purchaser assumes all responsibilities concerning quality, performance, maintenance, and repair. THIS MOTORCYCLE IS DESIGNED FOR CLOSED COURSE COMPETITION USE ONLY. IT DOES NOT CONFORM TO U.S. EPA NOISE STANDARDS. MFD BY : SUZUKI MOTOR CORPORATION MADE IN JAPAN

1-3 GENERAL INFORMATION 1 Clutch lever 2 Hot starter lever 3 Engine stop switch 4 Front brake lever 5 Throttle grip 6 Fuel tank cap 7 Starter knob/Idle screw 8 Gearshift lever 9 Front suspension compression damping adjuster 0 Front suspension rebound damping adjuster A Kick starter lever B Rear brake pedal C Rear suspension compression damping adjuster D Rear suspension rebound damping adjuster

2009-2014 Suzuki RM-Z450 Service & Repair Manual

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