Suzuki RM-Z450 Manual
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Suzuki RM-Z450 Manual

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California Proposition 65 Warning
Operating, servicing and maintaining a passenger
vehicle or off-road vehicle can expose you to
chemicals
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.
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.
WARNING
including
engine
exhaust,
carbon

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Summary of Contents for Suzuki RM-Z450

  • Page 1 California Proposition 65 Warning 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.
  • Page 2 This manual is presented as a  WARNING/ CAUTION/ means whereby you can maintain NOTICE/NOTE your RM-Z450 in top working con- dition at all times. Your riding skill Please read this manual and fol- and the maintenance steps out- low its instructions carefully. To...
  • Page 3 SYMBOL MARKS AND MATERIALS Listed in the table below are the symbols indicating instructions and other information. The mean- ing of each symbol is also included in the table. SYMBOL DEFINITION Torque control required.  Data beside it indicates specified torque.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS THE SPORT OF MOTOCROSS MOTORCYCLING FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS CONTROLS, EQUIPMENT AND ADJUSTMENTS BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING RIDING TIPS INSPECTION AND MAINTENANCE STORAGE PROCEDURE AND MOTORCYCLE CLEANING CONSUMER INFORMATION SPECIFICATIONS INDEX...

  • Page 6: The Sport Of Motocross Motorcycling

    THE SPORT OF MOTOCROSS MOTORCYCLING GENERAL CONSIDERATIONS ................1-2 INSPECT YOUR MACHINE BEFORE RIDING ........... 1-4 LABELS ....................... 1-4...
  • Page 7 No Passengers shield your eyes from branches Suzuki RM-Zs are designed for and airborne matter like bugs, the rider only. dirt, or pebbles kicked up by tires. Wear a helmet and eye protection Practice before competing every time you ride.
  • Page 8 May all of your rides on your new Alcohol, illegal drugs, and even Suzuki be winning rides! some prescription and over-the- counter drugs and cause drowsi- ness, loss of coordination, loss of balance, and loss of good judge- ment.
  • Page 9 INSPECT YOUR MACHINE LABELS BEFORE RIDING Read and follow all the labels on the motorcycle. Make sure you Review the instructions in the understand all of the labels. Do “INSPECTION BEFORE RIDING” not remove any labels from the section of this manual. Perform an motorcycle.

  • Page 10: Fuel, Engine Oil And Coolant Recommendations

    FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL ........................2-2 ENGINE OIL ......................2-4 ENGINE COOLANT SOLUTION ................. 2-6...
  • Page 11 In such case, try changing to a different gas station. If the situation is not improved by changing, consult your Suzuki dealer.
  • Page 12 NOTE: • To help minimize air pollution, Suzuki recommends that you use oxygenated fuels. • Be sure that any oxygenated fuel you use has octane rat- ings of at least 90 pump octane ((R+M)/2 method).
  • Page 13 ENGINE OIL SAE Engine Oil Viscosity Suzuki recommends the use of Suzuki recommends the use of SAE 10W-40 engine oil. If SAE SUZUKI PERFORMANCE 10W-40 engine oil is not available, MOTOR OIL or equivalent engine select an alternative according to oil.
  • Page 14 JASO T903 Energy Conserving The JASO T903 standard is an Suzuki does not recommend the index to select engine oils for 4- use of “ENERGY CONSERVING” stroke motorcycle or “RESOURCE CONSERVING” engines. Motorcycle and ATV oils. Some engine oils which have...
  • Page 15  WARNING mends the use of ECSTAR brand coolant. ECSTAR has been spe- Engine coolant is harmful or cially formulated for your SUZUKI fatal if swallowed or inhaled. product and contributes to the Solution can be poisonous to desired motorcycle performance animals.
  • Page 16 SUZUKI SUPER LONG LIFE COOLANT (Blue) “SUZUKI SUPER LONG LIFE COOLANT” is pre-mixed to the proper ratio. Add only “SUZUKI SUPER LONG LIFE COOLANT” if coolant level drops. It is not nec- essary to dilute “SUZUKI SUPER LONG LIFE COOLANT” when replacing coolant.

  • Page 18: Controls, Equipment And Adjustments

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS ..................3-2 LEFT HANDLEBAR ..................... 3-5 RIGHT HANDLEBAR ..................3-6 FUEL TANK CAP ....................3-7 STARTER KNOB ....................3-8 KICK STARTER LEVER ..................3-8 GEARSHIFT LEVER .................... 3-9 REAR BRAKE PEDAL ..................3-9 SIDE STAND ......................

  • Page 19: Location Of Parts

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS 1 Clutch lever 2 S-HAC switch 3 Front brake fluid reservoir 4 Front brake lever 5 Engine stop switch 6 Fuel tank cap 7 Throttle grip...
  • Page 20 8 Front fork compression damping force adjuster 9 Starter knob 0 Idle screw A Front fork rebound damping force adjuster B Gearshift lever C Footrests...
  • Page 21 D Rear suspension rebound damping force adjuster E Rear suspension compression damping adjuster F Kick starter lever G ECM tuning map coupler H Rear brake fluid reservoir I Engine oil filler cap J Rear brake pedal K Engine oil filter L Radiator cap...

  • Page 22: Left Handlebar

    LEFT HANDLEBAR S-HAC (SUZUKI HOLESHOT ASSIST CONTROL) switch 3 This is a system that assists oper- ation during the start of races that use a starting gate. Refer to SELECTION OF S-HAC (SUZUKI HOLESHOT ASSIST CONTROL) MODE for details. ( 5-6)

  • Page 23: Right Handlebar

    RIGHT HANDLEBAR Front Brake Lever Adjustment Adjust the front brake lever posi- tion as follows: Front Brake Lever 1 1. Loosen the lock nut 1. Apply the front brake by squeez- 2. Turn the adjuster 2 in or out to ing the front brake lever towards obtain the proper brake lever the grip.

  • Page 24: Fuel Tank Cap

    FUEL TANK CAP  WARNING If you overfill the fuel tank, fuel may overflow when it expands due to engine heat or heating by the sun. Fuel that overflows can catch fire. Stop adding fuel when the fuel level reaches the bottom of the filler neck.

  • Page 25: Starter Knob

    STARTER KNOB KICK STARTER LEVER This motorcycle has a starter sys- Depressing the kick starter lever tem to provide easy starting when with the transmission in neutral the engine is cold. When starting will start the engine. If the clutch the cold engine, pull the starter lever is squeezed, you can also knob all the way toward you.

  • Page 26: Gearshift Lever

    GEARSHIFT LEVER REAR BRAKE PEDAL This motorcycle has a 5-speed Pressing the rear brake pedal will transmission which operates as apply the rear brake. shown. To shift properly, squeeze the clutch lever and close the throttle at the same time you operate the gearshift lever.

  • Page 27: Side Stand

    SIDE STAND SUSPENSION ADJUSTMENT NOTICE Turning adjusters by force can damage the suspensions. Do not turn adjusters beyond their natural limits. FRONT FORK TUNING This motorcycle is not equipped The front fork compression and with a side stand. To support the rebound damping force, and oil motorcycle for a short period of capacity are adjustable for rider’s...
  • Page 28 3. Apply grease to the new O- ring 2 and tighten the air bleeder valve 1 to the speci- fied torque.  Grease 99000-25100 (SUZUKI SILICONE GREASE or equivalent To set the adjuster, you must gently grease) turn the adjust screw 2 clockwise ...
  • Page 29 The fork oil quantity must be fied torque. adjusted equally on both fork legs to provide equal perfor-  Grease 99000-25100 mance. (SUZUKI SILICONE GREASE or equivalent grease)  Front fork air bleeder valve: 1.3 N·m (0.13 kgf-m, 0.95 lbf-ft) 3-12...
  • Page 30 Front Fork Tuning Procedure Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression and rebound damping force following the instructions below.
  • Page 31 1. Remove the front fork. (Refer to Service Manual) 2. Remove the front fork spring. (Refer to Service Manual) 3. Adjust the front suspension according to the rider’s weight and pref- erence by referring to the table below. Identifica- tion Standard Oil quantity adjustable Spring...
  • Page 32 Fig.1 Fig.2 Slit Grinding end Grinding end 45° Slit Slit 45° Slit End of roll End of roll 90° 45° Standard (Part No.51171-37K00) Hard (Part No.51171-37K20) 3-15...
  • Page 33 • Read owner’s manual for ( 6-39) more information. • Spoke nipple tension and rim lock tightness ( 6-41) NOTE: Ask your Suzuki dealer to dispose of the rear suspension NOTE: unit. • Perform settings based on the feeling of running under stan- dard setting.
  • Page 34  Spring set length Spring Pre-load Adjustment 1. Place a block under the chas- adjustable range: sis tube. 226 – 237 mm (8.90 – 9.33 in) 2. Remove the muffler and seat [at spring free length rail assembly. 240 mm (9.45 in)] (Refer to Service Manual) Forward 54 –...
  • Page 35 Compression Damping Force Rebound Damping Force Adjustment Adjustment To set the adjuster, you must gen- To set the adjuster, you must gen- tly turn the adjust screw 1 clock- tly turn the adjust screw 2 clock- wise until it stops, then back it out wise until it stops, then back it out the recommended number of the recommended number of...
  • Page 36 Rear Suspension Tuning Procedure 1. Remove the rear shock absorber. (Refer to Service Manual) 2. Remove the rear shock absorber spring. (Refer to Service Manual) 3. Adjust the rear suspension according to the rider’s weight and pref- erence by referring to the table below. Marking Spring Part No.
  • Page 37 5. Measure the distance L2 from the seat bolt to the chain adjuster lock-nut with the motorcycle off the stand and riding the motorcycle normally in full riding gear. 6. Find the sag by subtracting L2 from L1.  Standard sag range: 105 mm (4.1 in) When the sag measured is: Adjustment procedure Less than 105 mm (4.1 in)
  • Page 38 After the sag measurement has been set 105 mm (4.1 in), test ride the motorcycle and adjust the suspension for the rider and track conditions referring to the guide below. Symptom Section Adjustment Procedure Feels too hard overall • Jump 1.

  • Page 39: Suspension Balance

    SUSPENSION BALANCE BALANCING TIPS • Check for air pressure build-up Balancing the front to rear sus- in front forks. Heat and altitude pension properly is the most criti- will increase air pressure in the cal adjustment for suspension front forks. performance.

  • Page 40: Break-In (Running-In) And Inspection Before Riding

    BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING BREAK-IN (RUNNING-IN) ................... 4-2 INSPECTION BEFORE RIDING ................4-3...
  • Page 41 When engine parts are replaced BREAK-IN (RUNNING- Follow the same procedure when IN) AND INSPECTION any of the following parts are BEFORE RIDING replaced: • Piston • Piston ring BREAK-IN (RUNNING-IN) • Cylinder • Crankshaft When the motorcycle is new •...
  • Page 42 INSPECTION BEFORE RIDING  WARNING  WARNING Checking maintenance items when the engine is running can Failure to inspect your motor- be hazardous. You could be cycle before riding and to prop- severely injured if your hands erly maintain your motorcycle or clothing get caught in mov- increases the chances of an ing engine parts.
  • Page 43 BEFORE BEFORE BEFORE WHAT TO CHECK REMARKS RIDE PRACTICE RACE • Heat range, fouled electrode,   Spark plug – tightness • Loose spark plug cap • Dust    Air cleaner element • Lubrication • Damage  Air cleaner –...
  • Page 44 BEFORE BEFORE BEFORE WHAT TO CHECK REMARKS RIDE PRACTICE RACE • Exhaust gas leakage   – • Tightening torque Exhaust pipe and muffler   – Damage    Bolts and nuts Tightening torque...

  • Page 46: Riding Tips

    INSTRUCTIONS ....................5-2 INSPECTION BEFORE ENGINE OIL LEVEL CHECK ........5-2 STARTING THE ENGINE ..................5-3 SELECTION OF S-HAC (SUZUKI HOLESHOT ASSIST CONTROL) MODE ..5-6 SELECTING A MODE ..................5-8 SELECTION OF ECM TUNING MAP ..............5-12 STOPPING AND PARKING ................5-14...

  • Page 47: Instructions

    INSPECTION BEFORE ENGINE RIDING TIPS OIL LEVEL CHECK INSTRUCTIONS NOTICE Leaving the engine at idling speed after riding will cause engine overheat as this compe- tition motorcycle does not have the radiator cooling fan and coolant reservoir. Riding the • Before starting the engine, motorcycle under severe con- check that there is sufficient oil...

  • Page 48: Starting The Engine

    NOTE: STARTING THE ENGINE • The oil level measurement • Inspect the engine oil level, become inaccurate coolant level and air cleaner unless the motorcycle is held condition before starting the upright as the motorcycle incli- engine. ( 6-18, 6-32, 6-14) nation affects the oil level.
  • Page 49 When the Engine is Cold: NOTE: When kick-starting the engine, make sure to remove the side stand. 3. Return the starter knob 1 when the engine revs at steady speed. 1. Pull out the starter knob 1. 2. Kick down the kick starter lever slowly from the top position until engine...
  • Page 50 When the Engine is already Conditions when the starter knob is used Warm or Restarts: Engine condition Starter knob Kick down the kick starter lever slowly from the top position until Warm engine Push back (OFF)* engine compression resistance is Cold engine Pull out (ON) felt, release the kick starter lever...

  • Page 51: Selection Of S-Hac (Suzuki Holeshot Assist Control) Mode

    SELECTION OF S-HAC (SUZUKI HOLESHOT ASSIST CONTROL) MODE S-HAC is a function that controls engine characteristics when starting a race using a starting gate 1. One of three different modes can be selected for engine control. NOTE: • S-HAC performs control intended specifically for starts that use a starting gate.
  • Page 52 S-HAC MODE Mode (Indicator light) Use for Normal mode (Unlit) – Mode-A (slow flashing) Hard & dry dirt, or concrete base Mode-B (fast flashing) Normal dirt Engine control release conditions Selected Engine control release conditions mode Control released 6 seconds after starting begins. Control released when throttle is closed after starting begins.

  • Page 53: Selecting A Mode

    SELECTING A MODE Start the engine and shift the gear to neutral, 1st, or 2nd. Next, adjust the engine speed so it is no greater than 3500 rpm. NOTE: The S-HAC mode setting cannot be change (to mode-A or mode-B) while a DTC (Diagnostic Trouble Code) is displayed. Mode-A The indicator light 1 will light for a lamp check (2 seconds) and •...
  • Page 54 Mode-A *1 Indicator light will be lit for 0.2 sec. per 1 hour of engine run time. Indicator light Lamp check Engine run time Mode-A Normal mode S-HAC switch Time (sec) Releasing the S-HAC switch during this interval will cause mode-A to be selected.
  • Page 55 Mode-B The indicator light 1 will light for a lamp check (2 seconds) and • then become an engine run time indicator light. Note, however, that even while the indicator light is lit to indicate the engine run time, holding down the S-HAC switch 2 for more than 0.7 seconds will cause the indicator light 1 to switch to slow flashing (mode-A).
  • Page 56 Mode-B *1 Indicator light will be lit for 0.2 sec. per 1 hour of engine run time. Indicator light Lamp check Engine run time Mode-A Mode-B Normal mode S-HAC switch Time (sec) After the indicator light starts fast flashing, releasing the S-HAC switch will select mode-B. 5-11...

  • Page 57: Selection Of Ecm Tuning Map

    SELECTION OF ECM TUNING NOTE: The changeover is exe- cuted immediately after engine has been started. • Select White short wire (map for slightly leaner mixture) when: 1. Raining 2. In highly humidity • Select Gray short wire (map slightly richer mixture) when:...
  • Page 58 Short Wire Connecting Procedure NOTICE Improper mode select coupler can damage system. Keep dry when connecting the coupler. 3. Connect the short wire 2 to the mode select coupler. 4. Install the mode select coupler to the bracket. 5. Start the engine. 1.

  • Page 59: Stopping And Parking

    STOPPING AND PARKING  WARNING 1. Twist the throttle grip away from yourself to close the Hard braking on wet, loose, throttle completely. rough, or other slippery sur- 2. Apply the front and rear brakes faces can cause wheel skid evenly and at the same time.

  • Page 60: Inspection And Maintenance

    INSPECTION AND MAINTENANCE PRECAUTIONS FOR MAINTENANCE AND SETTING ........6-2 REPLACEMENT PARTS ..................6-2 MAINTENANCE SCHEDULE ................6-2 ENGINE RUN TIME INDICATION PROCEDURE ..........6-6 ENGINE RUN TIME RESET PROCEDURE ............6-8 GENERAL LUBRICATION ................6-10 FUEL TANK ....................... 6-12 AIR CLEANER ....................

  • Page 61: Precautions For Maintenance And Setting

    Use only genuine SUZUKI little or no ventilation. replacement parts or their equivalent. NOTICE Genuine SUZUKI parts are high Poorly-made replacement parts quality parts which are designed can cause your motorcycle to and built specially for SUZUKI wear more quickly and may motorcycle.
  • Page 63 MAINTENANCE CHART It is very important to inspect and maintain the machine regularly. Fol- low the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.
  • Page 64 Interval Every Every Every races race 3 races 6 races Remarks Every Every Every hours Service Item 2 hours 6 hours 12 hours Check sprocket bolt for Engine sprocket – – looseness at each race thereafter. Check and retighten sprocket bolts at initial and Rear sprocket –...

  • Page 65: Engine Run Time Indication Procedure

    ENGINE RUN TIME INDICATION PROCEDURE 3. After indicator light will be lit for seconds (lamp check), engine run time will be dis- played by indicator light light- ing time. NOTE: • Lighting of lamp check and engine run time is made only at the first time, and when there is DTC available, this DTC will be displayed repeat-...
  • Page 66 EXAMPLE: In the case that the engine run time is 12 hours. Repeat Indicator light Lamp check Engine run time DTC will be displayed Time (sec.)

  • Page 67: Engine Run Time Reset Procedure

     36890-28H00: ENGINE RUN TIME RESET Battery wire (option) PROCEDURE NOTE: In case of TP sensor fail- ure, no engine run time reset operation is possible. 1. Disconnect the battery coupler 1 from the cap. 2. Connect a 12 volt battery to the battery coupler using the battery wire.
  • Page 68 Throttle grip Disconnect the battery wire. Full open Full close – 10.0 Time (sec.)

  • Page 69: General Lubrication

    GENERAL LUBRICATION Apply grease or oil to the moving parts to increase durability and pre- vent wear. NOTICE Lubricating electrical switches can damage the switches. Do not apply grease or oil to electrical switches. Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance.
  • Page 70 LUBRI- ITEM FREQUENCY COMMENTS CANT 1 Clutch cable Run oil through cables until it exits the Pre-race and lower end. Lube the cable ends where between every race they pivot. 2 Clutch lever pivot Throttle grip and throttle case Lightly grease the inside of throttle Pre-race cable spool.

  • Page 71: Fuel Tank

    FUEL TANK Fuel tank Removal 3. Disconnect the fuel pump cou- pler 5. 1. Remove the bolts 1 and the seat 2. 4. Remove the fuel tank bolt 6 and rubber band 7. 2. Remove the bolts 3 and the right and left radiator covers 5.
  • Page 72 6. Place a rag under the fuel 8. Put the cleaned plug and cap hose 8 and unlock the fuel to the fuel hose and fuel pump. hose connector B by pulling the retainer A. NOTICE 7. Remove the fuel hose connec- tor B from fuel pipe.

  • Page 73: Air Cleaner

    AIR CLEANER Removing the Element 1. Remove the bolts and seat. The air cleaner element must be kept clean to provide good engine power and gas mileage. Use the following procedure to remove the element and inspect it.  WARNING Operating the engine without the air cleaner element in place can be hazardous.
  • Page 74 Washing the Element NOTICE A torn air cleaner element will allow dirt to enter the engine and can damage the engine. Replace the air cleaner element with a new one if it is torn. Carefully examine cleaner element for tears dur- ing cleaning.
  • Page 75 Installing the Element 2. Install them in the air cleaner box by engaging the projection 1. Fit the element 2 onto the ele- A of the element holder with ment holder 1. the hole B of the air cleaner box. NOTE: Fit the projection A of the element holder to the hole of the element 2.

  • Page 76: Spark Plug

    SPARK PLUG Spark Plug Inspection To remove the spark plug, follow the procedure below. 1. Remove the seat. 2. Remove the radiator covers and fuel tank. Measure the spark plug gap A with a wire type feeler gauge. The standard spark plug gap is 0.9 – 1.0 mm (0.035 –...

  • Page 77: Engine Oil

    Installation ENGINE OIL Tighten the spark plug with speci- fied tightening torque after tight- ENGINE OIL LEVEL CHECK ening the spark plug temporarily Check the engine oil level accord- with fingers. ing to the following procedure, after the “INSPECTION BEFORE ...
  • Page 78 ENGINE OIL AND FILTER CHANGE Change the engine oil and oil filter at the scheduled times. The oil should be changed when the engine is warm so that the oil will drain thoroughly from the engine. The procedure is as follows: 1.
  • Page 79  WARNING Children and pets may be harmed by swallowing new or used oil. Repeated, prolonged contact with used engine oil may cause skin cancer. Brief contact with oil may irritate skin. Keep new and used oil and used oil filters away from chil- dren and pets.
  • Page 80 Failure to use an oil filter with the correct design can damage your motorcycle’s engine. Be sure to use a genuine Suzuki oil filter or an equiva- lent one designed for your motorcycle.  Oil filter cap bolt: 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
  • Page 81 Oil Strainer (No.1) Cleaning 11.Check the oil strainer for any damage or clogging. If the oil strainer is damaged, replace the oil strainer. If the oil strainer is clogging, clean the oil strainer in the following pro- cedures. NOTE: Clean the oil strainer thor- oughly up to first 2 to 3 times because steel particles will be caught when the engine is new.
  • Page 82 13.Remove the magnet B using 15.Insert the magnet and clip into the suitable steel rod. the oil strainer. Hook the clip C to the groove D.  WARNING The strainer has a strong mag- net. Magnetic force may affect pacemaker operation. Do not perform the mainte- nance if you wear a pacemaker because...
  • Page 83 Oil Strainer (No.2) Cleaning 16.Remove the bolt. Remove the gearshift lever E. 18.Remove the bolts. Remove the pump No.2 cover Remove the snap ring H and oil strainer No.2 I. 17.Remove the bolts. Remove the  09930-06108: generator cover F. Snap ring pliers (Close type) 19.Check the oil strainers for any damage or clogging.
  • Page 84 NOTICE Engine damage may occur if you use oil that does not meet Suzuki’s specifications. Be sure to use the oil specified in the FUEL, OIL AND ENGINE COOLANT RECOMMENDA- TIONS section.

  • Page 85: Idle Speed Adjustment

    IDLE SPEED ADJUSTMENT 1. Adjust the throttle cable play. ( 6-27) 2. Start the engine and warm it NOTE: Make this adjustment when the engine is hot. 4. Turn the idling adjust screw 1 and set the engine idle speed as follows.

  • Page 86: Throttle Cable Adjustment

    THROTTLE CABLE ADJUSTMENT  WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars. This can lead to loss of control and an accident. 1. Remove the boot 1. 2. Loosen the lock nut 2. Adjust the throttle cable play 3.

  • Page 87: Fuel Hose

    FUEL HOSE CLUTCH ADJUSTMENT Lift the fuel tank by referring to the FUEL TANK section. Adjust the clutch cable play as fol- lows: Inspect the fuel hose for damage Minor Adjustment and fuel leakage. If any defects (Quick Adjuster) are found, the fuel hose must be replaced.

  • Page 88: Drive Chain

    It does not use a master link. We recommend that you take your motorcycle to an authorized Suzuki dealer if the drive chain needs to be replaced. The condition and adjustment of the drive chain should be checked before each use of the motorcy- cle.
  • Page 89 If necessary, consult the drive chain. your authorized Suzuki dealer. • Do not use a volatile solvent Good Worn such as paint thinner, kero- sene and gasoline.
  • Page 90 Drive Chain Adjustment 35 – 45 mm (1.4 – 1.7 in) Inspect the drive chain slack 1. Loosen the axle nut 1. before each use of the motorcy- 2. Loosen the lock-nuts 2 and cle. The drive chain should be adjust the drive chain slack to adjusted for 35 –...

  • Page 91: Engine Coolant

    ENGINE COOLANT 1. Check that the engine coolant level is at the bottom of the inlet hole. If not, replenish the COOLANT LEVEL radiator with specified engine  WARNING coolant. Engine coolant is harmful or fatal if swallowed or inhaled. Solution can be poisonous to animals.

  • Page 92: Brakes

    INSPECTION BEFORE cracks, damage or engine coolant RIDING section. Always main- leakage. If any defects are found, ask your Suzuki dealer to replace tain your brakes according to the radiator hose with a new one. the MAINTENANCE SCHED- ULE. NOTE: Operating in mud, water,...
  • Page 93 Brake Fluid  WARNING Brake fluid will gradually absorb moisture through the brake hoses. Brake fluid with high water content lowers the boiling point and can cause brake system malfunction due to corrosion of brake compo- nents. Boiling brake fluid or FRONT brake system...
  • Page 94 NOTE: SUZUKI highly recom-  WARNING mends the use of ECSTAR brand brake fluid. ECSTAR has been Brake fluid is harmful or fatal if specially formulated your swallowed, and harmful if it SUZUKI product and contributes comes in contact with skin or to the desired motorcycle perfor- eyes.
  • Page 95 FRONT If you need to replace brake pads, have your Suzuki dealer do this work. Inspect and main- tain the brake pads as recom- mended. REAR 6-36...
  • Page 96 NOTE: Do not squeeze/depress  WARNING the brake lever/pedal when the pads are not in their positions. It is If you ride this motorcycle after difficult to push the pistons back brake system repair or brake into position. replacement without pumping the brake lever/pedal, you may get poor braking per- formance which could result in...
  • Page 97 Rear Brake Pedal Adjustment The rear brake pedal must be adjusted to set the clearance NOTICE between the pedal and the foot- rest. Adjust the brake pedal as fol- An incorrectly adjusted brake lows: pedal may force brake pads to continuously rub against the disk, causing damage to the pads and disk.

  • Page 98: Tires

    TIRES Tire Pressure and Loading Check tire pressure each time  WARNING before you ride, and adjust tire pressure according to the table The tires on your motorcycle below. Tire pressure should only form the crucial link between be checked and adjusted before your motorcycle and the road.
  • Page 99 Tire Condition and Type FRONT REAR Tire condition and tire type affect SIZE 80/100-21 51M 110/90-19 62M motorcycle performance. Cuts or cracks in the tires can lead to tire BRIDGESTONE BRIDGESTONE TYPE BATTLECROSS BATTLECROSS failure and loss of motorcycle con- X30F X30R trol.

  • Page 100: Spoke Nipple And Bead Stopper

    SPOKE NIPPLE AND NOTICE BEAD STOPPER NUT Improperly tightening spoke nipples can damage the wheel. Tighten the spoke nipples less than 1/2 turn at a time. Inspect the spoke tension and then retighten the spoke nipple. Check the tension to verify the tightness of the spoke nipples.

  • Page 101: Front Fork

    FRONT FORK REAR SUSPENSION • Move the front fork up and • Move the rear suspension up down several times and down several times and inspect for smooth movement. inspect for smooth movement. • Inspect for damage and oil • Inspect for damage and oil leaks.

  • Page 102: Steering

    STEERING Inspect the steering by moving the front forks up and down, and back and forward. If the steering has play or binds, inspect steering stem head nut tightness and steering bearings. 6-43...

  • Page 104: Storage Procedure And Motorcycle Cleaning

    STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ..................7-2 PROCEDURE FOR RETURNING TO SERVICE ..........7-3 CORROSION PREVENTION ................7-4 MOTORCYCLE CLEANING ................7-5 INSPECTION AFTER CLEANING ............... 7-7...

  • Page 105: Storage Procedure

    Suzuki recommends that you entering. trust this maintenance work to your Suzuki dealer. If you wish to TIRES service the machine for storage Inflate tires to the normal pres- yourself, follow the general guide- sure.

  • Page 106: Procedure For Returning To Service

    PROCEDURE FOR RETURNING 1. Fill the fuel tank more than half full. TO SERVICE 2. Shift the transmission into neu- 1. Clean the entire motorcycle. tral. 2. Remove the oily rags from the 3. While keeping throttle air cleaner intake and muffler approximately open, outlet.

  • Page 107: Corrosion Prevention

    Common causes of corrosion gone through to the bare • Accumulation of road salt, dirt, metal, have a Suzuki dealer moisture, or chemicals in hard- make the repair. to-reach areas. • Store your motorcycle in a dry, •...

  • Page 108: Motorcycle Cleaning

    MOTORCYCLE CLEANING Washing the Motorcycle When washing the motorcycle, follow the instructions below: 1. Remove dirt and mud from the motorcycle with cool running water. You may use a soft sponge or brush. Do not use hard materials which scratch the paint. 2.
  • Page 109 NOTE: Be sure to dry the motor- NOTICE cycle after washing the motorcy- cle. Blow off water from parts by High pressure washers such as applying air blow if it is necessary those found at coin-operated to remove parts just after washing car washes have enough pres- the motorcycle.

  • Page 110: Inspection After Cleaning

    INSPECTION AFTER CLEANING For extended life of your motorcy- cle, lubricate it according to the “LUBRICATION POINTS” section.  WARNING Operating the motorcycle with wet brakes can be hazardous. Wet brakes may not provide as much stopping power as dry brakes.

  • Page 112: Consumer Information

    CONSUMER INFORMATION SERIAL NUMBER LOCATION ................8-2 LOCATION OF LABELS ..................8-3...
  • Page 113 Write down the serial numbers CONSUMER here for your future reference. INFORMATION Frame No.: SERIAL NUMBER LOCATION You need to know the frame and Engine No.: engine serial numbers to get title documents for your motorcycle. You also need these numbers to help your dealer when you order parts.
  • Page 114 Read and follow all of the warnings labeled on your motorcycle. Make sure you understand all of the labels. Keep the labels on your motorcy- cle. Do not remove them for any reason. MFD BY : SUZUKI MOTOR CORPORATION MADE IN JAPAN WARNING Failure to follow these safety precautions may increase your risk of injury;...

  • Page 115: Specifications

    SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..........2175 mm (85.6 in) Overall width............ 835 mm (32.9 in) Overall height ..........1260 mm (49.6 in) Wheelbase ............1480 mm (58.3 in) Ground clearance..........330 mm (13.0 in) Seat height ............960 mm (37.8 in) Curb mass (weight) .........
  • Page 116 ELECTRICAL Ignition type .............Electronic ignition (CDI) Spark plug ............NGK DIMR8C10 Generator ............Single-phase A.C. generator CAPACITIES Fuel tank............6.3 L (1.7 US gal) Engine oil, oil change ........1050 ml (1.1 US qt) With filter change......1100 ml (1.2 US qt) Coolant ............1100 ml (1.2 US qt)
  • Page 117 INDEX AIR CLEANER ..... 6-14 FRONT FORK ......6-42 FUEL ........2-2 FUEL HOSE ......6-28 BRAKES....... 6-33 FUEL TANK ......6-12 BREAK-IN (RUNNING-IN) ..4-2 FUEL TANK CAP ....3-7 CLUTCH ADJUSTMENT..6-28 GEARSHIFT LEVER ....3-9 CORROSION GENERAL PREVENTION ......7-4 CONSIDERATIONS ....1-2 GENERAL LUBRICATION .....6-10 DRIVE CHAIN ......
  • Page 118 SELECTING A MODE ....5-8 SELECTION OF ECM TUNING MAP ........5-12 LABELS........1-4 SELECTION OF S-HAC LEFT HANDLEBAR....3-5 (SUZUKI HOLESHOT ASSIST LOCATION OF LABELS ..8-3 CONTROL) MODE ....5-6 LOCATION OF PARTS ..3-2 SERIAL NUMBER LOCATION ......8-2 SIDE STAND ......3-10 MAINTENANCE SPARK PLUG.......6-17...

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