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Suzuki
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RM-Z450
Suzuki RM-Z450 Service Manual
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SERV
ICI
NG INFO
RMATI
ON
20-
15
S
PEC
IAL
TO
OL
S
09900-06107
Snap ring pliers
09900-06108
Snap ring
pliers
09900-20101
V
ernier calipers
(150 mm)
09900-20202
Micrometer
(25 – 50 mm)
09900-20204
Micrometer
(75 – 100 mm)
09900-20205
Micr
ometer
(0 – 25 mm)
09900-20530
Cylinder g
auge set
09900-20513
Cylinder gaug
e r
o
d
09900-20602
Dial gaug
e
(1/1 000, 1 mm)
09900-20607
Dial gauge
(1/100, 10 mm)
09900-20701
Magnetic stand
09900-20803
Thickness gauge
09900-21304
V
-block (100 mm)
09900-22301
Plastigaug
e
09900-22302
Plastigauge
09900-22403
Small bore gaug
e
(18 – 35 mm)
09900-25008
Multi-circuit tester
09900-25009
Needle pointed
probe set
09910-20115
Conrod ho
lder
09910-32812
Crankshaft installer
09910-60611
Universal c
lamp
wrench
09911-11310
Crankshaft installer
attachment
09913-10750
Compression
gauge
adaptor
09913-50121
Oil seal rem
o
ver
09913-70210
Bearing installer set
354
356
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 Specifications
General
Brand
Suzuki
Model
RM-Z450
Category
Motorcycle
Language
English
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