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Manuals and User Guides for Suzuki RM-Z450. We have 3 Suzuki RM-Z450 manuals available for free PDF download: Owner’s Service Manual, Manual
Suzuki RM-Z450 Owner’s Service Manual (373 pages)
Brand: Suzuki
|
Category: Motorcycle
|
Size: 36.23 MB
Table of Contents
-
Group Index
9
-
Serial Number Location
4
-
Replacement Parts
6
-
Abbreviations Used in this Manual
8
-
Table of Contents
9
-
Location of Parts
11
-
Accessory
12
-
Side Stand
12
-
-
Fuel and Oil Recommendation
12
-
Operating Instructions
13
-
Starting the Engine
13
-
Stopping the Engine
14
-
Transmission
14
-
-
Break-In (Running-In)
15
-
When the Motorcycle Is New
15
-
When Engine Parts Are Replaced
15
-
-
Exterior Parts
16
-
-
Periodic Maintenance
17
-
Periodic Maintenance
19
-
Inspection before Practice
19
-
Inspection before Race
20
-
(All Items of Inspection before Practice on Previous
20
-
Periodic Maintenance Chart
21
-
-
Spark Plug
23
-
Air Cleaner
24
-
Air Cleaner Element Removal
24
-
Washing
24
-
Installation
24
-
-
Engine Oil and Oil Filter
25
-
Inspection before Engine Oil Level Check
26
-
Engine Oil Level Inspection
26
-
Engine Oil Change
27
-
Engine Oil Filter Change
28
-
-
Oil Strainers
29
-
OIL STRAINER (No.1) REMOVAL
29
-
OIL STRAINER (No.2) REMOVAL
29
-
Inspection
29
-
OIL STRAINER (No.2) INSTALLATION
29
-
OIL STRAINER (No.1) INSTALLATION
29
-
-
Engine Coolant
30
-
Engine Coolant Level Check
30
-
Engine Coolant Replenishment
31
-
Cooling System Inspection
31
-
-
Clutch Cable
32
-
Major Adjustment
32
-
Minor Adjustment
32
-
-
Throttle Cable
33
-
Throttle Cable Adjustment
33
-
Throttle Cable Oil Supply
33
-
-
Hot Starter
34
-
Crankcase Breather Hose
35
-
Engine Idle Speed
35
-
Fuel Hose
35
-
Valve Clearance
36
-
Valve Clearance Adjustment
37
-
-
Cylinder Head, Cylinder and Piston
40
-
Cylinder Head Inspection
40
-
Cylinder Inspection
40
-
Piston Inspection
40
-
-
Muffler Silencer
41
-
Silencer Inspection and Replacement
41
-
-
Drive Chain and Sprockets
42
-
Drive Chain Slack
42
-
Crankcase Driveshaft Oil Seal
42
-
Drive Chain Adjustment
43
-
Drive Chain Plate Wear
43
-
Drive Chain Lubrication
44
-
Sprocket Inspection
44
-
-
Drive Chain Guide, Buffer and Tensioner Roller
45
-
Drive Chain Guide Inspection
45
-
Drive Chain Buffer and Roller Inspection
45
-
-
Brakes
46
-
Brake Fluid Level
46
-
Brake Pad
47
-
Front Brake Lever Adjustment
47
-
Brake Pedal Height Adjustment
47
-
-
Front Fork
48
-
Rear Suspension
48
-
Wheels and Tires
48
-
Wheel Rim and Tires Inspection
48
-
Spoke Nipple and Rim Lock Inspection
49
-
Tire Pressure
49
-
-
Steering
49
-
Lubrication
50
-
Compression Pressure Check
51
-
Compression Test Procedure
51
-
-
Oil Pressure Check
52
-
Oil Pressure Test Procedure
52
-
-
-
Troubleshooting
53
-
Engine
54
-
Radiator (Cooling System)
60
-
Chassis
61
-
Brakes
62
-
Electrical
63
-
-
Machine Tuning
64
-
Front Fork Tuning
65
-
Compression Damping Force Adjustment
65
-
Rebound Damping Force Adjustment
65
-
Oil Quantity Minor Adjustment
66
-
OIL CHANGE (Only for Outer Tube Oil Chamber)
67
-
Spring Change
69
-
Front Fork Tuning Procedure
71
-
-
Rear Suspension Tuning
72
-
Compression Damping Force Adjustment
72
-
Rebound Damping Force Adjustment
73
-
Spring Pre-Load Adjustment
73
-
Rear Suspension Tuning Procedure
74
-
-
Suspension Balance
76
-
Balance Test
76
-
Balancing Tips
76
-
Engine Removal and Installation
77
-
-
Engine Removal and Installation
78
-
-
Cylinder Head, Cylinder and Piston
86
-
Construction
87
-
Cylinder Head, Cylinder and Piston
87
-
-
Engine Top Side Disassembly
88
-
Cylinder Head Cover Removal
88
-
Camshafts (Automatic Decomp.) and Cam Chain Tension Adjuster Removal
88
-
Cylinder Head Removal
89
-
Cylinder Removal
91
-
Piston and Piston Ring Removal
91
-
-
Engine Top Components Inspection and Service
92
-
Automatic Decomp. Inspection
92
-
Camshaft Inspection
92
-
Cam Chain Tension Adjuster Inspection
94
-
CAM CHAIN No.2 GUIDE INSPECTION
94
-
Cylinder Head and Valve Inspection
95
-
Intake Pipe Removal
103
-
Intake Pipe Installation
103
-
Ect Sensor Removal
103
-
Ect Sensor Inspection
103
-
Ect Sensor Installation
103
-
Cylinder Inspection
104
-
Piston and Piston Ring Inspection
105
-
Piston Diameter
105
-
Piston Ring Groove Width
106
-
Piston Ring Thickness
106
-
Piston Ring End Gap
106
-
-
Crankshaft and Conrod Inspection
107
-
-
Engine Top Side Assembly
108
-
Piston and Piston Ring Installation
108
-
Cylinder and Cylinder Head Installation
110
-
Camshaft (Automatic Decomp.) and Cam Chain Tension Adjuster Installation
112
-
Cylinder Head Cover Installation
116
-
-
Cam Chain, Cam Chain Tensioner and Cam Chain
117
-
No.1 GUIDE
117
-
Removal
117
-
Inspection
117
-
Installation
118
-
-
-
Clutch
119
-
Construction
120
-
Clutch
120
-
-
Clutch Plate
121
-
Removal
121
-
Inspection
123
-
Installation
124
-
-
Primary Driven Gear and Clutch Sleeve Hub
126
-
Removal
126
-
Inspection
127
-
Installation
127
-
-
Clutch Release Camshaft
129
-
Removal
129
-
Inspection
129
-
Installation
130
-
-
-
Kick Starter
131
-
Construction
132
-
Kick Starter
132
-
Removal
133
-
-
Kick Starter
133
-
Inspection
134
-
Installation
135
-
-
-
-
Gearshifting
138
-
Construction
139
-
Gearshift Linkage
140
-
Removal
140
-
Inspection
142
-
Installation
142
-
-
Gear Position (Gp) Switch
145
-
Removal
145
-
Inspection
145
-
Installation
145
-
-
-
Transmission and Crankshaft
146
-
Construction
147
-
Transmission and Crankshaft
147
-
-
Engine Bottom Side
148
-
Primary Drive Gear Removal
148
-
Crankcase Separation
149
-
Transmission Removal
149
-
Crankshaft Removal
150
-
Transmission Inspection
151
-
Conrod Inspection
152
-
Crankshaft Inspcection
152
-
Oil Reed Valve Inspection
152
-
Crankshaft Runout
152
-
Oil Seal Inspection
153
-
Oil Seal Removal and Installation
153
-
Bearing Inspection
154
-
Bearing Removal and Installation
154
-
Crankshaft Installation
157
-
Transmission Installation
158
-
Crankcase Installation
160
-
Primary Drive Gear Installation
161
-
-
-
Lubrication System
162
-
Engine Lubrication System
163
-
Engine Lubrication System Chart
163
-
Engine Oil Change
164
-
Engine Oil Filter Change
164
-
Engine Oil Level Inspection
164
-
Oil Pressure Check
164
-
Oil Reed Valve Inspection
164
-
Oil Reed Valve Installation
164
-
Oil Reed Valve Removal
164
-
Oil Strainer Installation
164
-
Oil Strainer Removal
164
-
Oil Strainers Inspection
164
-
Oil Relief Valve Inspection
165
-
Oil Relief Valve Installation
165
-
Oil Seal Inspection
165
-
Oil Seal Removal
165
-
OIL PUMP No.1 and No.2 REMOVAL
166
-
Oil Seal Installation
166
-
OIL PUMP No.1 and No.2 INSPECTION
167
-
OIL PUMP No.1 and No.2 INSTALLATION
168
-
-
Fi System Diagnosis
170
-
Precautions in Servicing
172
-
Electrical Parts
172
-
Ecm/Various Sensors
173
-
Electrical Circuit Inspection Procedure
175
-
Using the Multi-Circuit Tester
178
-
-
Fi System Technical Features
179
-
Injection Time (Injection Volume)
179
-
Compensation of Injection Time (Volume)
180
-
Injection Stop Control
180
-
Fi System Parts Location
181
-
Fi System Wiring Diagram
183
-
-
Ecm Terminal
184
-
Self-Diagnosis Function
185
-
Dealer Mode
185
-
Diagnostic Trouble Code Table
186
-
Tp Sensor Adjustment
187
-
-
Fail-Safe Function
188
-
Fi System Troubleshooting
189
-
Customer Complaint Analysis
189
-
Visual Inspection
190
-
Self-Diagnostic Procedures
191
-
Self-Diagnosis Reset Procedure
191
-
Dtc and Defective Condition
192
-
12″ Ckp Sensor Circuit Malfunction
194
-
14″ Tp Sensor Circuit Malfunction
196
-
15″ Ect Sensor Circuit Malfunction
198
-
17″ Iap Sensor Circuit Malfunction
200
-
21″ Iat Sensor Circuit Malfunction
203
-
23″ to Sensor Circuit Malfunction
205
-
24″ Ignition System Malfunction
206
-
31″ Gp Switch Circuit Malfunction
207
-
32″ Fuel Injector Circuit Malfunction
209
-
41″ Fp Relay Circuit Malfunction
211
-
63″ Crankshaft Rotation Signal Circuit Malfunction
213
-
Iap Sensor Inspection
215
-
Iap Sensor Removal and Installation
215
-
Tp Sensor Inspection
215
-
Tp Sensor Removal and Installation
215
-
Ect Sensor Removal and Installation
216
-
Iat Sensor Inspection
217
-
Iat Sensor Removal and Installation
217
-
To Sensor Inspection
217
-
To Sensor Removal and Installation
217
-
-
-
-
Fuel System and Throttle Body
218
-
Fuel System
219
-
Construction
219
-
Fuel Tank and Fuel Pump Removal
219
-
Fuel Tank and Fuel Pump Installation
220
-
Fuel Pressure Inspection
221
-
Fuel Pump Inspection
222
-
Fuel Discharge Amount Inspection
223
-
-
Throttle Body
224
-
Construction
224
-
Removal
225
-
Disassembly
226
-
Cleaning
229
-
Inspection
229
-
Reassembly
229
-
Installation
232
-
Fuel Injector Removal
233
-
Fuel Injector Inspection
233
-
Fuel Injector Installation
233
-
-
-
Cooling System
234
-
Construction
235
-
Engine Coolant
236
-
Replacement
236
-
-
Cooling Circuit
237
-
Inspection
237
-
-
Radiator
238
-
Inspection
238
-
Removal
239
-
Installation
239
-
-
Water Pump
240
-
Removal
240
-
Inspection
241
-
Installation
242
-
-
-
Electrical System
244
-
Cautions in Servicing
245
-
Connector
245
-
Coupler
245
-
Clamp
245
-
Switch
245
-
Semi-Conductor Equipped Part
246
-
Connecting the Battery
246
-
Wiring Procedure
246
-
Using the Multi-Circuit Tester
247
-
-
Location of Electrical Components
248
-
Construction
250
-
Generating System
251
-
Inspection
251
-
-
Ignition System
254
-
Troubleshooting
254
-
Inspection
256
-
-
Magneto Rotor
260
-
Removal
260
-
Installation
261
-
-
Stator
262
-
Removal
262
-
Installation
262
-
-
-
Front and Rear Wheels
263
-
Construction
264
-
Front Wheel
265
-
Removal
265
-
Inspection
265
-
Dust Seal and Bearing Replacement
266
-
Disc Plate Replacement
267
-
Installation
268
-
-
Rear Wheel
269
-
Removal
269
-
Inspection
270
-
Dust Seal and Bearing Replacement
270
-
Disc Plate Replacement
272
-
Rear Sprocket Replacement
272
-
Installation
273
-
Rear Wheel Spokes Replacement
273
-
-
-
Front and Rear Brakes
274
-
Construction
275
-
Brake Fluid Air Bleeding
276
-
Brake Fluid Replacement
277
-
Brake Pads Replacement
278
-
Front Brake Pads
278
-
Rear Brake Pads
278
-
-
Brake Disc Inspection
279
-
Caliper
279
-
Front Caliper Removal and Disassembly
280
-
Caliper Inspection
281
-
Caliper Cleaning
281
-
Front Caliper Reassembly and Installation
281
-
Rear Caliper Removal and Disassembly
282
-
Rear Caliper Reassembly and Installation
283
-
-
Master Cylinder
285
-
Front Master Cylinder Removal and Disassembly
285
-
Master Cylinder Inspection
286
-
Master Cylinder Cleaning
286
-
Front Master Cylinder Reassembly and Installation
287
-
Rear Master Cylinder Removal and Disassembly
288
-
Master Cylinder Inspection
289
-
Rear Master Cylinder Reassembly and Installation
289
-
-
Brake Lever
290
-
Removal
290
-
Installation
290
-
-
Brake Pedal
291
-
Removal
291
-
Installation
291
-
-
-
Front Fork and Steering
292
-
Construction
293
-
Front Fork, Steering
293
-
Handlebar Controls
294
-
Removal
295
-
Disassembly
296
-
Inspection
300
-
Reassembly
302
-
Installation
308
-
-
Steering
309
-
Removal
309
-
Inspection
311
-
Bearing Replacement
312
-
Installation
313
-
-
-
Rear Suspension
318
-
Construction
319
-
Rear Suspension
319
-
-
Rear Shock Absorber
320
-
Removal
320
-
Spring Replacement
321
-
Inspection
322
-
Bearing Replacement
323
-
Oil Replacement
324
-
Disassembly and Inspection
327
-
Reassembly
328
-
Installation
329
-
Disposal
329
-
-
Swingarm
330
-
Removal
330
-
Inspection
332
-
Bearing Replacement
333
-
Installation
334
-
-
Rear Suspension Linkage
335
-
Removal
335
-
Inspection
336
-
Bearing Replacement
337
-
Installation
338
-
-
-
Servicing Information
341
-
Service Data
342
-
Oil Pump
344
-
-
Tightening Torque
351
-
Fi System and Intake Air System
352
-
Cooling System
352
-
-
Special Tools
355
-
Wiring Diagram
358
-
Wiring Harness Routing
359
-
Cable Routing
361
-
Fuel Hose Routing
362
-
Radiator Hose Routing
363
-
Rear Brake Pedal Set-Up
363
-
Clutch Cable Adjuster
364
-
Hot Starter Lever Installation
364
-
Front Brake Hose Routing
365
-
Rear Brake Hose Routing
366
-
Handlebar Set-Up
367
-
Chain Roller Installation
368
-
Rear Wheel Spokes Installation
368
-
Specifications
369
-
Dimensions and Dry Mass
369
-
Drive Train
369
-
-
Optional Parts
371
-
Spare Parts List
371
-
Setting Data
372
-
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Suzuki RM-Z450 Owner’s Service Manual (342 pages)
Brand: Suzuki
|
Category: Motorcycle
|
Size: 34.35 MB
Table of Contents
-
Group Index 1
9
-
Serial Number Location
5
-
Replacement Parts
7
-
Table of Contents
9
-
Location of Parts
11
-
Accessory
12
-
Side Stand
12
-
-
Fuel and Oil Recommendation
12
-
Operating Instructions
13
-
Starting the Engine
13
-
Stopping the Engine
14
-
Transmission
14
-
-
Break-In (Running-In)
15
-
When the Motorcycle Is New
15
-
When Engine Parts Are Replaced
15
-
-
Exterior Parts
16
-
-
Periodic Maintenance 2
18
-
Periodic Maintenance
20
-
Inspection before Practice
20
-
Inspection before Race
21
-
(All Items of Inspection before Practice on Previous
21
-
Periodic Maintenance Chart
22
-
-
Spark Plug
24
-
Air Cleaner
25
-
Air Cleaner Element Removal
25
-
Washing
25
-
Installation
25
-
Engine Oil and Oil Filter
26
-
Inspection before Engine Oil Level Check
27
-
Engine Oil Level Inspection
28
-
Engine Oil Change
28
-
Engine Oil Filter Change
29
-
Oil Strainers
30
-
-
Engine Coolant
31
-
Engine Coolant Level Check
31
-
Engine Coolant Replenishment
32
-
Cooling System Inspection
32
-
-
Clutch Cable
33
-
Major Adjustment
33
-
Minor Adjustment
33
-
-
Throttle Cable
34
-
Throttle Cable Adjustment
34
-
Throttle Cable Oil Supply
34
-
-
Hot Starter
35
-
Crankcase Breather Hose
36
-
Engine Idle Speed
36
-
Fuel Filter
37
-
Fuel Hose
37
-
Valve Clearance
38
-
Valve Clearance Adjustment
39
-
-
Cylinder Head, Cylinder and Piston
42
-
Cylinder Head Inspection
42
-
Cylinder Inspection
42
-
Piston Inspection
42
-
-
Exhaust Silencer
43
-
Silencer Inspection and Replacement
43
-
Silencer Reassembly
44
-
-
Drive Chain and Sprockets
44
-
Drive Chain Slack
44
-
Drive Chain Adjustment
45
-
Drive Chain Plate Wear
45
-
Drive Chain Lubrication
46
-
Sprocket Inspection
46
-
-
Drive Chain Guide, Buffer and Tensioner Roller
47
-
Drive Chain Guide Inspection
47
-
Drive Chain Buffer and Roller Inspection
47
-
-
Brakes
48
-
Brake Fluid Level
48
-
Brake Pad
49
-
Front Brake Lever Adjustment
49
-
Brake Pedal Height Adjustment
49
-
-
Front Fork
50
-
Rear Suspension
50
-
Wheels and Tires
50
-
Wheel Rim and Tires Inspection
50
-
Spoke Nipple and Rim Lock Inspection
51
-
Tire Pressure
51
-
-
Steering
51
-
Lubrication
52
-
Compression Pressure Check
53
-
Compression Test Procedure
53
-
-
Oil Pressure Check
54
-
Oil Pressure Test Procedure
54
-
-
-
Troubleshooting
56
-
Engine
57
-
Carburetor
61
-
Radiator (Cooling System)
61
-
Chassis
62
-
Brakes
63
-
Electrical
64
-
-
Machine Tuning
66
-
Carburetor Tuning
67
-
Principles of Carburetor Tuning
67
-
Slow System
68
-
Main System
70
-
Intermediate System
70
-
Carburetor Tuning in Practice
72
-
-
Front Fork Tuning
75
-
Compression Damping Force Adjustment
75
-
Rebound Damping Force Adjustment
75
-
Oil Quantity Minor Adjustment
76
-
OIL CHANGE (Only for Outer Tube Oil Chamber)
77
-
Spring Change
79
-
Front Fork Tuning Procedure
81
-
-
Rear Suspension Tuning
82
-
Compression Damping Force Adjustment
82
-
Rebound Damping Force Adjustment
83
-
Spring Pre-Load Adjustment
83
-
Rear Suspension Tuning Procedure
84
-
-
Suspension Balance
86
-
Balance Test
86
-
Balancing Tips
86
-
Engine Removal and Installation
88
-
-
Engine Removal and Installation
89
-
-
Cylinder Head, Cylinder and Piston
98
-
Construction
99
-
Cylinder Head, Cylinder and Piston
99
-
-
Engine Top Side
100
-
Cylinder Head Cover Removal
100
-
Camshafts (Automatic Decomp.) and Cam Chain Tension Adjuster Removal
100
-
Cylinder Head Removal
101
-
Cylinder Removal
102
-
Piston and Piston Ring Removal
103
-
Cam Chain, Cam Chain Tensioner and Cam Chain Guide Removal
104
-
-
Engine Top Components Inspection and Service
105
-
Automatic Decomp. Inspection
105
-
Camshaft Inspection
105
-
Cam Chain Tension Adjuster Inspection
107
-
Cam Chain Tensioner Inspection
108
-
Cylinder Head and Valve Inspection
108
-
Oil Seal Inspection
116
-
Cylinder Inspection
117
-
Piston and Piston Ring Inspection
118
-
Piston Ring Groove Width
119
-
Piston Ring Thickness
119
-
Piston Ring End Gap
119
-
-
Crankshaft and Conrod Inspection
120
-
Cam Chain, Cam Chain Tensioner and Cam Chain Guide Installation
121
-
Piston and Piston Ring Installation
122
-
Cylinder and Cylinder Head Installation
124
-
Camshaft (Automatic Decomp.) and Cam Chain Tension Adjuster Installation
126
-
Clutch
129
-
Cylinder Head Cover Installation
129
-
-
-
Clutch
130
-
Construction
131
-
Clutch
131
-
-
Clutch Plate
132
-
Removal
132
-
Inspection
134
-
Release Bearing Replacement
135
-
Installation
136
-
-
Primary Driven Gear and Clutch Sleeve Hub
138
-
Removal
138
-
Inspection
139
-
Installation
139
-
-
Clutch Release Camshaft
141
-
Removal
141
-
Inspection
141
-
Installation
142
-
-
-
Kick Starter
144
-
Construction
145
-
Kick Starter
145
-
Removal
146
-
-
Kick Starter
146
-
Inspection
147
-
Installation
148
-
-
-
-
Gearshifting
152
-
Construction
153
-
Gearshift Linkage
153
-
Removal
154
-
Gearshift Linkage
154
-
Inspection
155
-
Installation
156
-
-
-
Transmission and Crankshaft
160
-
Construction
161
-
Transmission and Crankshaft
161
-
-
Engine Bottom Side
162
-
Primary Drive Gear Removal
162
-
Crankcase Separation
163
-
Transmission Removal
163
-
Crankshaft Removal
164
-
Transmission Inspection
165
-
Conrod Inspection
166
-
Crankshaft Inspcection
166
-
Oil Seal Inspection
167
-
Oil Seal Removal and Installation
167
-
Bearing Inspection
168
-
Bearing Removal and Installation
168
-
Crankshaft Installation
171
-
Transmission Installation
172
-
Crankcase Installation
174
-
Primary Drive Gear Installation
175
-
-
-
Lubrication System
178
-
Engine Lubrication System
179
-
Engine Lubrication System Chart
179
-
Engine Oil Change
180
-
Engine Oil Filter Change
180
-
Engine Oil Level Inspection
180
-
Oil Pressure Check
180
-
Oil Seal Inspection
180
-
Oil Seal Removal
180
-
Oil Strainers Inspection
180
-
Oil Strainers Installation
180
-
Oil Strainers Removal
180
-
OIL PUMP No.1 and No.2 REMOVAL
181
-
Oil Seal Installation
181
-
OIL PUMP No.1 and No.2 INSPECTION
182
-
OIL PUMP No.1 and No.2 INSTALLATION
183
-
-
Fuel System
186
-
Fuel Tank and Fuel Valve
187
-
Construction
187
-
Removal
187
-
Cleaning and Inspection
188
-
Installation
188
-
-
Carburetor
189
-
Construction
189
-
Removal
190
-
Disassembly
191
-
Cleaning
195
-
Inspection
195
-
Reassembly
197
-
Installation
201
-
-
Throttle Position Sensor
202
-
Inspection
202
-
Removal
203
-
Installation
203
-
-
-
Cooling System
204
-
Construction
205
-
Engine Coolant
206
-
Replacement
206
-
-
Cooling Circuit
207
-
Inspection
207
-
-
Radiator
208
-
Inspection
208
-
Removal
209
-
Installation
209
-
-
Water Pump
210
-
Removal
210
-
Inspection
211
-
Installation
211
-
-
-
Electrical System
214
-
Cautions in Servicing
215
-
Connector
215
-
Coupler
215
-
Semi-Conductor Equipped Part
215
-
Using the Multi-Circuit Tester
215
-
Switch
215
-
-
Location of Electrical Components
216
-
Construction
217
-
Electrical System
217
-
Electrical Circuit
217
-
Troubleshooting
218
-
-
Ignition System
220
-
Ignition System Peak Voltage Inspection
220
-
Ignition System Coil Inspection
221
-
Ignition Coil Primary Peak Voltage Inspection
221
-
Ignition Coil Inspection
222
-
Engine Stop Switch Inspection
222
-
-
Magneto Rotor
223
-
Removal
223
-
Installation
225
-
-
Stator
226
-
Removal
226
-
Installation
226
-
-
-
Front and Rear Wheels
228
-
Construction
229
-
Front Wheel
230
-
Removal
230
-
Inspection
231
-
Dust Seal and Bearing Replacement
232
-
Disc Plate Replacement
234
-
Installation
234
-
-
Rear Wheel
235
-
Removal
235
-
Inspection
236
-
Dust Seal and Bearing Replacement
236
-
Disc Plate Replacement
238
-
Rear Sprocket Replacement
239
-
Installation
239
-
Rear Wheel Spokes Replacement
239
-
-
-
Front and Rear Brakes
240
-
Construction
241
-
Brake Fluid Air Bleeding
242
-
Brake Fluid Replacement
243
-
Brake Pads Replacement
244
-
Front Brake Pads
244
-
Rear Brake Pads
244
-
-
Brake Disc Inspection
245
-
Caliper
245
-
Front Caliper Removal and Disassembly
246
-
Caliper Inspection
247
-
Caliper Cleaning
247
-
Front Caliper Reassembly and Installation
247
-
Rear Caliper Removal and Disassembly
248
-
Rear Caliper Reassembly and Installation
249
-
-
Master Cylinder
251
-
Front Master Cylinder Removal and Disassembly
251
-
Master Cylinder Inspection
252
-
Master Cylinder Cleaning
252
-
Front Master Cylinder Reassembly and Installation
253
-
Rear Master Cylinder Removal and Disassembly
254
-
Master Cylinder Inspection
255
-
Rear Master Cylinder Reassembly and Installation
255
-
-
Brake Lever
256
-
Removal
256
-
Installation
256
-
-
Brake Pedal
256
-
Installation
257
-
-
-
Front Fork and Steering
258
-
Construction
259
-
Front Fork, Steering
259
-
Handlebar Controls
260
-
Removal
261
-
Disassembly
262
-
Inspection
266
-
Reassembly
268
-
Installation
274
-
-
Steering
275
-
Removal
275
-
Inspection
278
-
Bearing Replacement
279
-
Installation
280
-
-
-
Rear Suspension
284
-
Construction
285
-
Rear Suspension
285
-
-
Rear Shock Absorber
286
-
Removal
286
-
Spring Replacement
287
-
Inspection
288
-
Bearing Replacement
289
-
Oil Replacement
290
-
Disassembly and Inspection
293
-
Reassembly
294
-
Installation
295
-
Disposal
295
-
-
Swingarm
296
-
Removal
296
-
Inspection
298
-
Bearing Replacement
299
-
Installation
300
-
-
Rear Suspension Linkage
301
-
Removal
301
-
Inspection
302
-
Bearing Replacement
303
-
Installation
304
-
-
-
Servicing Information
308
-
Service Data
309
-
Oil Pump
311
-
-
Tightening Torque
317
-
Special Tools
321
-
Wiring Diagram
324
-
Cable Routing
325
-
Wire Harness Routing
327
-
Fuel Hose Routing
328
-
Radiator Hose and Carburetor Hose Routing
329
-
Rear Brake Pedal Set-Up
330
-
Magneto Installation
331
-
Clutch Cable Adjuster
332
-
Front Brake Hose Routing
333
-
Rear Brake Hose Routing
334
-
Handlebar Set-Up
335
-
Rear Wheel Spokes Installation
336
-
Front Number Plate Installation
337
-
Ignition Coil Installation
337
-
Specifications
338
-
Optional Parts
340
-
Spare Parts List
340
-
Setting Data
341
-
Suzuki RM-Z450 Manual (121 pages)
Brand: Suzuki
|
Category: Motorcycle
|
Size: 2.57 MB
Table of Contents
-
Table of Contents
4
-
The Sport of Motocross Motorcycling
6
-
Fuel, Engine Oil and Coolant Recommendations
10
-
-
Controls, Equipment and Adjustments
18
-
Location of Parts
19
-
Left Handlebar
22
-
Right Handlebar
23
-
Fuel Tank Cap
24
-
Kick Starter Lever
25
-
Starter Knob
25
-
Gearshift Lever
26
-
Rear Brake Pedal
26
-
Side Stand
27
-
Suspension Adjustment
27
-
Suspension Balance
39
-
Break-In (Running-In) and Inspection before Riding
40
-
-
Riding Tips
46
-
Inspection before Engine Oil Level Check
47
-
Instructions
47
-
Starting the Engine
48
-
Selection of S-Hac (Suzuki Holeshot Assist Control) Mode
51
-
Selecting a Mode
53
-
Selection of Ecm Tuning Map
57
-
Stopping and Parking
59
-
-
Inspection and Maintenance
60
-
Maintenance Schedule
61
-
Precautions for Maintenance and Setting
61
-
Replacement Parts
61
-
Engine Run Time Indication Procedure
65
-
Engine Run Time Reset Procedure
67
-
General Lubrication
69
-
Fuel Tank
71
-
Air Cleaner
73
-
Spark Plug
76
-
Engine Oil
77
-
Idle Speed Adjustment
85
-
Throttle Cable Adjustment
86
-
Clutch Adjustment
87
-
Fuel Hose
87
-
Drive Chain
88
-
Engine Coolant
91
-
Brakes
92
-
Tires
98
-
Spoke Nipple and Bead Stopper
100
-
Front Fork
101
-
Rear Suspension
101
-
Steering
102
-
-
Storage Procedure and Motorcycle Cleaning
104
-
Storage Procedure
105
-
Procedure for Returning to Service
106
-
Corrosion Prevention
107
-
Motorcycle Cleaning
108
-
Inspection after Cleaning
110
-
Consumer Information
112
-
Specifications
115
-
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Suzuki RM-Z450
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Для Suzuki RM-Z450
- Руководство по использованию и ремонту (Owners Service Manual) для Suzuki RM-Z450 (2007)
- Сервисный мануал (Service Manual) на Suzuki RM-Z450 (2005-2007)
- Мануал по ремонту (Repair & Service Manual) на Suzuki RM-Z450 (2009)
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- Suzuki RM-Z450
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- Сервисная документация
This manual should be considered a permanent part of the
motorcycle and should remain with the motorcycle when resold
or otherwise transferred to a new owner or operator. The
manual contains important safety information and instructions
which should be read carefully before operating the motorcycle.
California Proposition 65 Warning
Operating, servicing and maintaining a passenger
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 or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the
engine except as necessary, service your vehicle in
a well-ventilated area and wear gloves or wash your
hands frequently when servicing your vehicle. For
more information go to www.P65Warnings.ca.gov/
passenger-vehicle.
WARNING
|
Detail Specifications: 1053/1053918-rmz450.pdf file (13 Nov 2022) |
Accompanying Data:
Suzuki RM-Z450 Motorcycle PDF Owner’s Service Manual (Updated: Sunday 13th of November 2022 04:58:01 PM)
Rating: 4.4 (rated by 37 users)
Compatible devices: drz 400 2000, LS650 Savage, VZR1800 2007, GSX-R150, GS1100L 1980, 1987 GSX-R150, GT 380, VL800.
Recommended Documentation:
Text Version of Owner’s Service Manual
(Ocr-Read Summary of Contents, UPD: 13 November 2022)
-
349, Suzuki RM-Z450 SERVICING INFORMATION 20-9 SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke 310 (12.2) — Front fork inner tube O.D. 47 (18.5) — Front fork spring free length 495 ± 2.5 (19.49 ± 0.10) 488 (19.21) Front fork damping force adjuster Rebound MAX – 11 clicks turn back — Compres- sion MAX – 11 clicks turn back — Front fork air pressure 0 kPa (0 …
-
182, 12-13 FI SYSTEM DIAGNOSIS A ECM J CKP sensor H IAT Sensor K Crankshaft rotation signal sensor I TP Sensor L GP switch
… -
151, TRANSMISSION AND CRANKSHAFT 10-6 TRANSMISSION INSPECTION • Inspect the gear teeth, dogs, and gearshift grooves for abnor- mal wear and damage. • Inspect the bushings and splines for abnormal wear and dis- coloration. • If necessary, replace defective parts with a new one. • Inspect the gearshift cam groove for abnormal wear and dam- age. • If any defects are found, repl…
-
277, FRONT AND REAR BRAKES 17-4 • Connect a transparent tube to the bleeder valve and set the other end into a receptacle. • Pump the brake lever/pedal until air bubbles stop coming out from the reservoir. • Hold the brake lever/pedal in the squeezed position. • Open the bleeder valve and tighten the bleeder valve. • Release the brake lever/pedal. • Re…
-
180, 12-11 FI SYSTEM DIAGNOSIS COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). INJECTION STOP CONTROL SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- SOR SIGNAL When engine coolant temperature is low, injection time (vol- ume) is increased. INTAK…
-
144, 9-7 GEARSHIFTING • Install the gearshift return spring D, snap ring E and washer F onto the gearshift shaft C properly. NOTE: When installing the return spring, position the stopper D of gearshift arm between the return spring ends E. » 09900-06107: Snap ring pliers • Install the gearshift shaft assembly G. NOTE: Pinch the gearshift arm stopper…
-
247, ELECTRICAL SYSTEM 15-4 USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester + and — probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. • When measuring the resistance, make sure that no voltage is applied. If voltage is…
-
30, Suzuki RM-Z450 2-14 PERIODIC MAINTENANCE ENGINE COOLANT ENGINE COOLANT LEVEL CHECK • Remove the radiator cap 1. • Check that the engine coolant level is at the bottom of the inlet hole. If not, replenish the radiator with specified engine cool- ant. • Tighten the radiator cap securely. NOTE: * This motorcycle does not have an overflow tank at the end of breather hose. Theref…
-
237, COOLING SYSTEM 14-4 COOLING CIRCUIT INSPECTION • Remove the radiator cap. • Connect the tester 1 to the filler. • Give a pressure of about 120 kPa (1.2 kgf/cm 2 , 17.0 psi) and see if the system holds this pressure for 10 seconds. • If the pressure would fall during this 10-second interval, it means that there is a leaking point in the system. In such a case, inspect the …
-
153, Suzuki RM-Z450 TRANSMISSION AND CRANKSHAFT 10-8 OIL SEAL INSPECTION • Inspect each oil seal lip for wear and damage. • If any defects are found, replace the oil seal with a new one. OIL SEAL REMOVAL AND INSTALLATION • Remove the oil seals ( 1, 2, 3, 5) with the special tool. » 09913-50121: Oil seal remover • Remove the oil seal 4 with the suitable tool. • Ap…
-
152, 10-7 TRANSMISSION AND CRANKSHAFT • Measure the gearshift fork groove width with a vernier cali- pers. # Gearshift fork groove width Standard: 5.0 – 5.1 mm (0.197 – 0.201 in) » 09900-20101: Vernier calipers CONROD INSPECTION • For conrod inspection other than the following, refer to page 6-22. • Measure the conrod deflection with the special t…
Recommended Instructions:
30518, TH47LF20U — 47″ HD LCD TV, DSR-PD150, T17T030, ER 1642 T
-
I49cc Dirt RunnerRead this manual carefully. It contains important safety information.Children under the age of 16 should be supervised by a responsible adult. Always wear a helmet; It could save your Life!Do not remove this operator’s manual from this vehicle.Please obtain, review, and follow provincial / municipal government acts and regulations pertaining …
49CC DIRT RUNNER 33
-
Piaggio would like to thank youfor choosing one of its products. We have drawn up this booklet to show you all features of our product. Please read the booklet carefully before usingyour vehicle. It includes information, suggestions and warnings regarding your vehicle. You will also be informed of features, details and devices thatwill prove the excellence of your choice. We be …
APE 50 E4 110
-
MOTORCYCLERIDE-ON®Harley-Davidson is a registered trademark and the motorcycle sound is a trademark of H-D Michigan, Inc. used under license.Fisher-Price, Power Wheels by Fisher-Price andPower Lock are U.S. trademarks of Mattel, Inc.Owner’s Manual with Assembly InstructionsFor Model 74370Product features may vary from the picture above.Please read this manual and save it with your original s …
HARLEY-DAVIDSON 74370 36
-
Table of Contents Description 1. Technical Specifications 1 2. Identification Data 3 3. Location of Parts 4 4. Steering cum Ignition lock 5 5. Fuel Tank Cap / Fuel Tap 6 6. Speedometer Details 7 7. Control Switches 9 8. Removal & Fitment of Side Covers 11 9. Battery / Tool kit 1210. Daily Safety Checks 1311. How to ride your …
160 STREET 31
Additional Information:
Popular Right Now:
Operating Impressions, Questions and Answers:
IMPORTANT
WARNING/ CAUTION/
NOTICE/NOTE
Please read this manual and fol-
low its instructions carefully. To
emphasize special information,
the symbol
WARNING, CAUTION, NOTICE
and NOTE have special mean-
ings. Pay particular attention to
messages highlighted by these
signal words:
WARNING
Indicates a potential hazard
that could result in death or
serious injury.
CAUTION
Indicates a potential hazard
that could result in minor or
moderate injury.
NOTICE
Indicates a potential hazard
that could result in vehicle or
equipment damage.
NOTE: Indicates special informa-
tion to make maintenance easier
or instructions clearer.
and the words
FOREWORD
This manual is presented as a
means whereby you can maintain
your RM-Z450 in top working con-
dition at all times. Your riding skill
and the maintenance steps out-
lined in this manual will assure
you of top performance from your
machine under any type of com-
petition.
We sincerely wish you and your
Suzuki motorcycle a successful
partnership for many years of
happy riding.
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 changes, there may be
some discrepancies in this man-
ual. 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
believes in conservation and pro-
tection
of
resources.
To
encourage
every
owner to recycle, trade in, or prop-
erly dispose of, as appropriate,
used motor oil, engine coolant,
and other fluid, and tires.
Corporation
Earth’s
natural
that
end,
motorcycle
we