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RMX450Z
Suzuki RMX450Z Service Manual
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1J-1
Charging System:
Engine
Charging System
Schematic and Routing Diagram
Charging System Diagram
BA02J21A02001
Component Location
Charging System Component
s Location
BA02J21A03001
Refer to “Electri
cal Components Location” in Se
ction 0A (Page
0A-6).
Battery
Condenser
IC
Regulator/Rectifier
Load
Generator
Ignition switch
Fuse
IA02J1
1A0018-04
281
283
Table of Contents
Section 0 General Information
13
Table of Contents
13
General Description
26
Clutch Lever Clearance Inspection and Adjustment
36
Adjustment
38
Hot Starter Lever Clearance Inspection and
38
Throttle Body Inspection
38
Crankcase Breather (PCV) Hose Inspection
38
Fuel Hose Inspection
39
Valve Clearance Inspection and Adjustment
39
Exhaust Pipe Bolt and Muffler Bolt Inspection
43
Spark Arrester Cleaning
43
Drive Chain Inspection and Adjustment
45
Drive Chain Cleaning and Lubricating
46
Crankcase Driveshaft Oil Seal Inspection
46
Sprocket Inspection
46
Drive Chain Buffer, Guide and Roller Inspection
47
Brake System Inspection
47
Wheel and Tire Inspection
49
Rear Suspension Inspection
49
Front Fork Inspection
49
Steering System Inspection
50
Kick Starter Lever Inspection and Lubrication
51
Chassis Bolt and Nut Inspection
51
Compression Pressure Check
52
Oil Pressure Check
52
SDS Check
52
Special Tool
54
Specifications
55
Service Data
55
0C-2 Service Data
56
Section 1 Engine
65
Precautions
69
Precautions for Engine
69
1A-1 Engine General Information and Diagnosis
70
General Description
70
Injection Timing Description
70
FI System Wiring Diagram
73
Schematic and Routing Diagram
73
ECM Terminal
74
Component Location
75
FI System Parts Location
75
Diagnostic Information and Procedures
76
Engine Symptom Diagnosis
76
Self-Diagnostic Procedures
79
Use of SDS Diagnosis Reset Procedures
81
Show Data When Trouble (Displaying Data at the Time of DTC)
82
SDS Check
84
DTC Table
88
Fail-Safe Function Table
89
FI System Troubleshooting
90
Malfunction Code and Defective Condition Table
91
DTC "12" (P0335): CKP Sensor Circuit Malfunction
93
DTC "14" (P0120-H/L): TP Sensor Circuit Malfunction
96
DTC "15" (P0115-H/L): ECT Sensor Circuit Malfunction
103
DTC "17" (P0105-H/L): IAP Sensor Circuit Malfunction
109
DTC "21" (P0110-H/L): IAT Sensor Circuit Malfunction
117
DTC "23" (P1651-H/L): to Sensor Circuit Malfunction
122
DTC "24" (P0351): Ignition Coil Circuit Malfunction
129
DTC "31" (P0705): GP Switch Circuit Malfunction
129
DTC "32" (P0201): Fuel Injector Circuit Malfunction
131
DTC "41" (P0230): FP Relay Circuit Malfunction
134
DTC "63" (P1771): Crankshaft Rotation Signal Circuit Malfunction
136
Service Data
139
Specifications
139
Special Tool
140
Special Tools and Equipment
140
Crankcase Breather (PCV) Hose Inspection
141
Crankcase Breather (PCV) Hose Removal and Installation
141
Emission Control Devices
141
Precautions
141
Precautions for Emission Control Devices
141
Repair Instructions
141
CKP Sensor Inspection
142
Component Location
142
Diagnostic Information and Procedures
142
ECM Removal and Installation
142
Engine Electrical Components Location
142
Engine Electrical Devices
142
Engine Symptom Diagnosis
142
Precautions
142
Precautions for Engine Electrical Device
142
Repair Instructions
142
IAP Sensor Inspection
143
IAP Sensor Removal and Installation
143
TP Sensor Inspection
143
TP Sensor Removal and Installation
143
TP Sensor Adjustment
144
IAT Sensor Inspection
145
IAT Sensor Removal and Installation
145
ECT Sensor Removal and Installation
146
ECT Sensor Inspection
147
TO Sensor Inspection
147
TO Sensor Removal and Installation
147
GP Switch Inspection
148
GP Switch Removal and Installation
148
Service Data
148
Specifications
148
Recommended Service Material
149
Special Tool
149
Special Tools and Equipment
149
Tightening Torque Specifications
149
Camshaft and Sprocket Assembly Diagram
150
Engine Mechanical
150
Schematic and Routing Diagram
150
Throttle Cable Routing Diagram
151
Compression Pressure Check
153
Diagnostic Information and Procedures
153
Engine Mechanical Symptom Diagnosis
153
Engine Components Removable with the Engine in Place
154
Repair Instructions
154
Air Cleaner Box Removal and Installation
157
Air Cleaner Element Cleaning
157
Air Cleaner Element Removal and Installation
157
Hot Starter Cable Removal and Installation
158
Throttle Cable Inspection
158
Throttle Cable Removal and Installation
158
Throttle Body Components
160
Throttle Body Construction
161
Engine Idle Speed Inspection and Adjustment
163
Hot Starter Lever Construction
163
Throttle Body Inspection
163
Throttle Body Removal and Installation
164
Throttle Body Disassembly and Assembly
166
Engine Assembly Removal
169
Throttle Body Inspection and Cleaning
169
Engine Assembly Installation
173
Engine Top Side Disassembly
176
Engine Top Side Assembly
179
Camshaft Inspection
185
Valve Clearance Inspection and Adjustment
185
Cam Chain Guide Inspection
187
Cam Chain Tension Adjuster Inspection
187
Cam Chain Tensioner Inspection
188
Cylinder Head Disassembly and Assembly
188
Cylinder Head Related Parts Inspection
192
Valve Guide Replacement
195
Valve Seat Repair
196
Cylinder Inspection
197
Piston Ring Removal and Installation
198
Piston and Piston Ring Inspection
199
Engine Bottom Side Disassembly
200
Engine Bottom Side Assembly
204
Conrod and Crankshaft Inspection
210
Gearshift Shaft Inspection
210
Oil Pump No. 1 Inspection
210
Oil Pump No. 2 Inspection
210
Oil Reed Valve Inspection
210
Oil Strainer Inspection
210
Crankshaft Oil Seal / Bearing Inspection
211
Crankshaft Oil Seal / Bearing Removal and Installation
212
Transmission Oil Seal / Bearing Inspection
214
Transmission Oil Seal / Bearing Removal and Installation
214
Clutch Release Camshaft Oil Seal / Bearing Inspection
215
Clutch Release Camshaft Oil Seal / Bearing Removal and Installation
215
Clutch Release Camshaft Removal and Installation
215
Service Data
216
Specifications
216
Recommended Service Material
219
Special Tools and Equipment
219
Special Tool
220
Engine Lubrication System
223
Engine Lubrication System Chart Diagram
223
Precautions
223
Precautions for Engine Oil
223
Schematic and Routing Diagram
223
Diagnostic Information and Procedures
224
Engine Lubrication Symptom Diagnosis
224
Oil Pressure Check
224
Engine Oil and Filter Replacement
225
Engine Oil Level Inspection
225
Oil Pump No. 1 Components
225
Oil Pump No. 1 Removal and Installation
225
Oil Pump No. 2 Strainer Removal and Installation
225
Oil Strainer Inspection and Cleaning
225
Oil Strainer No. 1 Removal and Installation
225
Repair Instructions
225
Oil Pump No. 2 Components
227
Oil Pump No. 2 Removal and Installation
227
Oil Pump Inspection
228
Oil Reed Valve Removal and Installation
229
Oil Relief Valve Inspection
229
Oil Relief Valve Removal and Installation
229
Oil Gallery Oil Seal Inspection
230
Oil Gallery Oil Seal Removal and Installation
230
Oil Reed Valve Inspection
230
Service Data
230
Specifications
230
Tightening Torque Specifications
230
Recommended Service Material
231
Special Tool
231
Special Tools and Equipment
231
Engine Cooling System
232
Precautions
232
Precautions for Engine Coolant
232
Precautions for Engine Cooling System
232
Cooling Circuit Diagram
233
Engine Coolant Description
233
General Description
233
Schematic and Routing Diagram
233
Diagnostic Information and Procedures
234
Engine Cooling Symptom Diagnosis
234
Water Hose Routing Diagram
234
Cooling Circuit Inspection
235
Radiator Cap Inspection
235
Radiator Inspection and Cleaning
235
Repair Instructions
235
Radiator Removal and Installation
236
Radiator Reservoir Tank Inspection
237
Radiator Reservoir Tank Removal and Installation
237
Water Hose Inspection
237
Water Hose Removal and Installation
237
ECT Sensor Inspection
238
ECT Sensor Removal and Installation
238
Engine Coolant Temperature Indicator Inspection
238
Water Pump Components
238
Water Pump Removal and Installation
239
Service Data
242
Specifications
242
Tightening Torque Specifications
242
Water Pump Related Parts Inspection
242
Recommended Service Material
243
Special Tools and Equipment
243
Fuel System
244
Precautions
244
Precautions for Fuel System
244
Diagnostic Information and Procedures
245
Fuel System Diagnosis
245
Fuel Pressure Inspection
246
Fuel Pump Inspection
246
Repair Instructions
246
Fuel Discharge Amount Inspection
247
Fuel Hose Inspection
247
Fuel Level Indicator Inspection
247
Fuel Pump Relay Inspection
247
Fuel Tank Components
248
Fuel Tank Removal and Installation
248
Fuel Injector / Fuel Delivery Pipe / T-Joint Removal and Installation
249
Fuel Injector Inspection and Cleaning
249
Fuel Pump Removal and Installation
249
Service Data
250
Specifications
250
Tightening Torque Specifications
250
Recommended Service Material
251
Special Tool
251
Special Tools and Equipment
251
Ignition System
252
Ignition System Components Location
252
Ignition System Diagram
252
Schematic and Routing Diagram
252
Diagnostic Information and Procedures
253
Ignition System Symptom Diagnosis
253
No Spark or Poor Spark
254
Ignition Coil and Plug Cap Inspection
255
Repair Instructions
255
Spark Plug Cap and Spark Plug Removal and Installation
255
Spark Plug Inspection and Cleaning
255
CKP Sensor Inspection
257
Crankshaft Rotation Signal Sensor Inspection
258
CKP Sensor / Crankshaft Rotation Signal Sensor Removal and Installation
259
Engine Stop Switch Inspection
259
Engine Stop Switch Removal and Installation
260
Ignition Switch Inspection
260
Ignition Switch Removal and Installation
260
Service Data
261
Special Tool
261
Special Tools and Equipment
261
Specifications
261
Tightening Torque Specifications
261
Component Location
262
Diagnostic Information and Procedures
262
Schematic and Routing Diagram
262
Starting System
262
Starting System Components Location
262
Starting System Diagram
262
Starting System Symptom Diagnosis
262
Starter Motor Runs but Does Not Crank the Engine
263
Starter Motor will Not Run
263
Repair Instructions
264
Starter Motor Components
264
Starter Motor Disassembly and Assembly
265
Starter Motor Removal and Installation
265
Starter Motor Related Parts Inspection
266
Starter Relay Removal and Installation
267
Gear Position (GP) Switch Inspection
268
Starter Relay Inspection
268
Starter Torque Limiter / Starter Idle Gear / Starter Clutch Components
270
Starter Torque Limiter / Starter Idle Gear / Starter Clutch Removal and Installation
271
Starter Torque Limiter Inspection
272
Starter Clutch Related Parts Inspection
273
Starter Driven Gear Bearing Removal and Installation
273
Starter Button Inspection
274
Kick Starter Components
275
Kick Starter Removal and Installation
276
Kick Starter Related Parts Inspection
279
Recommended Service Material
280
Service Data
280
Special Tools and Equipment
280
Specifications
280
Tightening Torque Specifications
280
Special Tool
281
Charging System
282
Charging System Components Location
282
Charging System Diagram
282
Component Location
282
Schematic and Routing Diagram
282
Charging System Symptom Diagnosis
283
Diagnostic Information and Procedures
283
Battery Current Leakage Inspection
284
Battery Runs down Quickly
284
Repair Instructions
284
Generator Inspection
285
Regulated Voltage Inspection
285
Generator Removal and Installation
286
Regulator / Rectifier Removal and Installation
288
Battery Components
289
Battery Recharging
289
Regulator / Rectifier Inspection
289
Battery / Battery Protector Removal and Installation
290
Battery Visual Inspection
291
Recommended Service Material
291
Service Data
291
Special Tools and Equipment
291
Specifications
291
Tightening Torque Specifications
291
Special Tool
292
Exhaust System
293
Exhaust System Components
293
Precautions
293
Precautions for Exhaust System
293
Repair Instructions
293
Muffler / Exhaust Pipe Removal and Installation
294
Exhaust System Inspection
295
Spark Arrester Inspection
295
Recommended Service Material
296
Special Tools and Equipment
296
Specifications
296
Tightening Torque Specifications
296
Section 2 Suspension
297
Precautions
298
Precautions for Suspension
298
Diagnostic Information and Procedures
299
Suspension and Wheel Symptom Diagnosis
299
Suspension General Diagnosis
299
Front Fork Components
300
Front Suspension
300
Repair Instructions
300
Front Fork Removal and Installation
301
Front Fork Disassembly
302
Front Fork Assembly
306
Front Fork Parts Inspection
310
Front Suspension Adjustment
311
Service Data
314
Specifications
314
Special Tool
316
Rear Shock Absorber Components
317
Rear Suspension
317
Repair Instructions
317
Cushion Rod / Cushion Lever Components
318
Swingarm Components
319
Rear Suspension Assembly Construction
320
Rear Shock Absorber Removal and Installation
321
Rear Shock Absorber Disassembly
322
Rear Shock Absorber Assembly
324
Rear Shock Absorber Inspection
326
Rear Suspension Inspection
326
Rear Suspension Oil Replacement
327
Rear Suspension Adjustment
330
Cushion Lever Removal and Installation
331
Cushion Lever Inspection
332
Cushion Lever Bearing Removal and Installation
333
Cushion Rod Inspection
334
Cushion Rod Removal and Installation
334
Cushion Rod Bearing Removal and Installation
335
Swingarm Removal and Installation
336
Swingarm Related Parts Inspection
339
Swingarm Bearing Removal and Installation
340
Service Data
341
Specifications
341
Tightening Torque Specifications
341
Recommended Service Material
342
Special Tool
342
Special Tools and Equipment
342
Precautions
344
Precautions for Wheel and Tire
344
Wheels and Tires
344
Front Wheel Components
345
Repair Instructions
345
Front Wheel Assembly Construction
346
Front Wheel Assembly Removal and Installation
346
Front Wheel Related Parts Inspection
348
Front Wheel Dust Seal / Bearing Removal and Installation
349
Rear Wheel Components
352
Rear Wheel Assembly Construction
353
Rear Wheel Assembly Removal and Installation
354
Rear Wheel Spoke Construction
354
Rear Wheel Related Parts Inspection
355
Rear Wheel Dust Seal / Bearing Removal and Installation
356
Service Data
358
Specifications
358
Recommended Service Material
359
Special Tool
359
Special Tools and Equipment
359
Tightening Torque Specifications
359
Section 3 Driveline / Axle
361
Precautions
362
Precautions for Driveline / Axle
362
Diagnostic Information and Procedures
363
Drive Chain and Sprocket Symptom Diagnosis
363
Drive Chain Related Components
364
Repair Instructions
364
Drive Chain Roller Construction
365
Engine Sprocket Removal and Installation
365
Rear Sprocket Removal and Installation
366
Drive Chain Buffer Removal and Installation
367
Drive Chain Guide Removal and Installation
367
Drive Chain Related Parts Inspection
367
Drive Chain Roller Removal and Installation
367
Drive Chain Replacement
368
Service Data
371
Specifications
371
Tightening Torque Specifications
371
Recommended Service Material
372
Special Tool
372
Special Tools and Equipment
372
Section 4 Brake
373
Brake Fluid Information
374
Precautions
374
Precautions for Brake System
374
Brake Control System and Diagnosis
375
Front Brake Hose Routing Diagram
375
Schematic and Routing Diagram
375
Rear Brake Hose Routing Diagram
376
Air Bleeding from Brake Fluid Circuit
377
Brake Fluid Level Check
377
Brake Hose Inspection
377
Brake Pedal Height Inspection and Adjustment
377
Brake Symptom Diagnosis
377
Diagnostic Information and Procedures
377
Repair Instructions
377
Brake Fluid Replacement
379
Front Brake Hose Removal and Installation
381
Rear Brake Hose Removal and Installation
381
Front Brake Master Cylinder Components
382
Front Brake Master Cylinder Assembly Removal and Installation
383
Front Brake Master Cylinder / Brake Lever Disassembly and Assembly
384
Front Brake Master Cylinder Parts Inspection
385
Rear Brake Master Cylinder Assembly Removal and Installation
386
Rear Brake Master Cylinder Components
386
Rear Brake Master Cylinder Disassembly and Assembly
387
Brake Lever Removal and Installation
388
Rear Brake Master Cylinder Parts Inspection
388
Rear Brake Pedal Construction
389
Rear Brake Pedal Removal and Installation
390
Service Data
390
Specifications
390
Special Tool
392
Front Brake Components
393
Front Brakes
393
Repair Instructions
393
Front Brake Caliper Removal and Installation
394
Front Brake Pad Inspection
394
Front Brake Pad Replacement
394
Front Brake Caliper Disassembly and Assembly
395
Front Brake Caliper Parts Inspection
397
Front Brake Disc Removal and Installation
397
Front Brake Disc Inspection
398
Service Data
398
Specifications
398
Recommended Service Material
399
Special Tool
399
Special Tools and Equipment
399
Tightening Torque Specifications
399
Rear Brake Components
400
Rear Brake Pad Inspection
400
Rear Brake Pad Replacement
400
Rear Brakes
400
Repair Instructions
400
Rear Brake Caliper Removal and Installation
401
Rear Brake Caliper Disassembly and Assembly
402
Rear Brake Caliper Parts Inspection
403
Rear Brake Disc Removal and Installation
404
Rear Brake Disc Inspection
405
Service Data
405
Specifications
405
Tightening Torque Specifications
405
Recommended Service Material
406
Special Tool
406
Special Tools and Equipment
406
Section 5 Transmission / Transaxle
407
Precautions
408
Precautions for Transmission / Transaxle
408
Diagnostic Information and Procedures
409
Manual Transmission
409
Manual Transmission Symptom Diagnosis
409
Repair Instructions
410
Transmission Components
410
Transmission Removal and Installation
411
Transmission Construction
413
Countershaft Gear / Driveshaft Gear Disassembly and Assembly
414
Transmission Related Parts Inspection
415
Transmission Oil Seal / Bearing Inspection
416
Transmission Oil Seal / Bearing Removal and Installation
416
Gear Position (GP) Switch Inspection
419
Gear Position (GP) Switch Removal and Installation
419
Gearshift Shaft / Gearshift Cam Plate Components
420
Gearshift Construction
421
Gearshift Shaft / Gearshift Cam Plate Removal and Installation
421
Gearshift Linkage Inspection
424
Gearshift Shaft Oil Seal / Removal and Installation
425
Service Data
425
Specifications
425
Recommended Service Material
426
Special Tools and Equipment
426
Tightening Torque Specifications
426
Special Tool
427
Clutch
428
Clutch Lever Position Switch Inspection
428
Clutch System Symptom Diagnosis
428
Diagnostic Information and Procedures
428
Precautions
428
Precautions for Clutch System
428
Repair Instructions
428
Clutch Cable Inspection and Adjustment
429
Clutch Cable Removal and Installation
429
Clutch Control System Components
430
Clutch Cable Adjuster Construction
431
Clutch Release Camshaft Removal and Installation
431
Clutch Release Camshaft / Oil Seal / Bearing Inspection
432
Clutch Components
433
Clutch Removal
434
Clutch Installation
435
Clutch Parts Inspection
438
Recommended Service Material
440
Service Data
440
Special Tools and Equipment
440
Specifications
440
Tightening Torque Specifications
440
Special Tool
441
Section 6 Steering
443
Precautions
444
Precautions for Steering
444
Diagnostic Information and Procedures
445
Steering General Diagnosis
445
Steering Symptom Diagnosis
445
Handlebars Components
446
Repair Instructions
446
Steering / Handlebar
446
Handlebar Construction
447
Handlebars Removal and Installation
448
Handlebars Inspection
450
Steering Components
451
Steering Removal and Installation
452
Steering Related Parts Inspection
454
Steering Stem Bearing Removal and Installation
454
Steering System Inspection
454
Recommended Service Material
456
Special Tool
456
Special Tools and Equipment
456
Specifications
456
Tightening Torque Specifications
456
Section 9 Body and Accessories
459
Component Location
460
Electrical Components Location
460
Precautions
460
Precautions for Electrical System
460
Schematic and Routing Diagram
461
Wiring Diagram
461
Wiring Systems
461
Wiring Harness Routing Diagram
462
Service Data
467
Specifications
467
Tightening Torque Specifications
467
Headlight Construction
468
Lighting Systems
468
Repair Instructions
468
Headlight Cover Construction
469
Headlight Removal and Installation
469
Headlight Beam Adjustment
470
Headlight Bulb Replacement
470
Tail Light Construction
471
Tail Light Removal and Installation
472
Reflex Reflector Construction (E-28 Only)
473
Headlight Relay Inspection
474
Service Data
474
Special Tool
474
Special Tools and Equipment
474
Specifications
474
Tightening Torque Specifications
474
Combination Meter / Fuel Meter / Horn
475
General Description
475
Speedometer System Description
475
Repair Instructions
476
Speedometer Construction
476
Speed Sensor Harness Routing Diagram
477
Speed Sensor Inspection
478
Speed Sensor Removal and Installation
478
Speedometer Inspection
478
Speedometer Removal and Installation
478
Fuel Level Indicator Light Inspection
479
Fuel Level Indicator Light Removal and Installation
479
Fuel Level Indicator Switch (Thermistor) Inspection
479
Ignition Switch Inspection
480
Ignition Switch Removal and Installation
480
Service Data
480
Special Tool
480
Special Tools and Equipment
480
Specifications
480
Tightening Torque Specifications
480
Exterior Parts
481
Exterior Parts Removal and Installation
481
Repair Instructions
481
Body Frame Construction
483
Body Structure
483
Repair Instructions
483
Seat Rail Removal and Installation
484
Footrest Bracket Construction
485
Side-Stand Construction
485
Recommended Service Material
486
Side-Stand Removal and Installation
486
Special Tools and Equipment
486
Specifications
486
Tightening Torque Specifications
486
5
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Suzuki RMX450Z Specifications
General
Brand
Suzuki
Model
RMX450Z
Category
Motorcycle
Language
English
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