Suzuki RM-Z450L5 Set-Up Manual/Parts List
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Suzuki RM-Z450L5 Set-Up Manual/Parts List

Suzuki RM-Z450L5 Set-Up Manual/Parts List

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FOREWORD
This motorcycle has been designed and produced utilizing Suzuki's most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please read this manual and follow its instructions carefully. To emphasize special
information, the symbol
and the words WARNING, CAUTION, NOTICE and
NOTE have special meanings. Pay particular attention to messages highlighted by
these signal words:
Indicates a potential hazard that could result in death or serious injury.
Indicates a potential hazard that could result in minor or moderate injury.
Indicates a potential hazard that could result in motorcycle or equipment
damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.
99505-01055-01E
L5
June '14 (TK) 19
© COPYRIGHT SUZUKI MOTOR JAPAN

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Summary of Contents for Suzuki RM-Z450L5

  • Page 1 FOREWORD This motorcycle has been designed and produced utilizing Suzuki’s most modern technology. The finest product, however, cannot perform properly unless it is cor- rectly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this motorcycle.
  • Page 2 PREPARATION WORKSHOP  CAUTION Assembling the vehicle in poor working condi- tion can be hazardous. Place the packed vehicle on a level floor where it is clean and spacious. A: Packed vehicle B: Working space SELF PROTECTION  CAUTION Assembling the vehicle without proper clothes and protective gear can be hazardous.
  • Page 3 Remove the strap. Take out the front wheel assembly from the crate base. A: Strap B: Front wheel assembly Remove the bolts of the bracket. Remove the bolts to take off the rear wheel holding bracket. A: Bolt B: Rear wheel holding bracket Remove the bolts from the crate.
  • Page 4 Lift the steel frame to separate it from the base of the crate.  CAUTION Careless steel frame separation can injure a person. Lift the steel frame with two persons. Wear proper protective clothes and gear. NOTE: Be careful not to damage the motorcycle when separating the steel frame.

  • Page 5: Spare Parts

    SPARE PARTS Check all spare parts. Item Part Name Q’ty Magneto cover gasket Clutch cover outer gasket Water pump case O-ring Sprocket spacer O-ring Engine oil filter comp Oil filter cap O-ring Exhaust pipe gasket Muffler joint connector Drive chain joint set Clutch lever Brake lever NOTE:...

  • Page 6: Location Of Parts

    • Please hand over the parts shown as Item J, K, L, M and N in the above table to your customer together with motorcycle. • S-HAC = SUZUKI holeshot assist control Parts listed above are installed respectively into the positions as follows.
  • Page 7 The photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: Front brake master cylinder B: Throttle assembly Engine stop switch Clutch cable S-HAC switch...

  • Page 8: Removing The Bracket

    Before assembling the motorcycle, thoroughly understand the “Safety Check Out” described on page 39. After completion of assembly, carefully check the motorcycle referring to the “Safety Check Out”, then deliver the motorcycle to the customer. ASSEMBLY REMOVING THE BRACKET Remove the bolt to take off the front brake master cyl- inder from the bracket.
  • Page 9 HANDLEBARS Loosen the throttle housing retaining screws. Insert the throttle assembly onto the handlebars. NOTE: Check the spacer is onto the handlebars. A: Throttle assembly B: Handlebars C: Spacer Install the handlebar assembly with the clamp and the four bolts. NOTE: •...
  • Page 10 NOTE: • The line drawings on page 37 and 38 show the proper routing of the control cables, hose and wirings. • Refer to them in addition to following the instruc- tions carefully. A: Front brake hose B: Throttle cables C: Clutch cable D: Engine stop switch wiring harness E: S-HAC switch wiring harness...
  • Page 11 THROTTLE Align the matching mark on the handlebars with mat- ing surface of the throttle housing. Install the throttle assembly with two screws after the assembly is positioned so that there is approximately 0.5–1.0 mm of clearance between the grip end and the end of the handlebars.

  • Page 12: Front Brake Master Cylinder

    FRONT BRAKE MASTER CYLINDER Install the front brake master cylinder onto the handle- bars. NOTE: • Install the holder in position according to the mark “UP”. • Align the matching mark on the handlebars with the master cylinder-to-holder fitting surface. A: Holder B: Front brake master cylinder C: 6 ×...

  • Page 13: Clutch Cable

    CLUTCH CABLE Pass the clutch cable through the adjuster cover and lever cover. A: Clutch cable B: Adjuster cover C: Lever cover Check the clutch cable end. Align the clutch cable end with the recess of clutch release arm. A: Cable end B: Recess (Clutch release arm) Turn the clutch lever adjuster in as far as possible and align the slots.
  • Page 14 ENGINE STOP SWITCH Hook the holders on the grooves of the engine stop switch. NOTE: Use the holder with an internal thread cutting at the lower side. A: Engine stop switch B: Holder (Upper) C: Holder (Lower) D: Thread cutting Install the engine stop switch to the left of handlebars.

  • Page 15: Front Fender

    CLAMP Clamp the engine stop switch wiring harness and S-HAC switch wiring harness to the handlebars with strap. A: Strap L:100 mm B: Strap L:130 mm C: Engine stop switch wiring harness D: S-HAC switch wiring harness E: Handlebars FRONT FRONT FRONT FENDER Install the front fender with four sets of mounting parts...
  • Page 16 TAKING OUT THE MOTORCYCLE Bind a hoist band around the handlebar clamps as shown in the photograph. NOTE: Lift the motorcycle a little by using a hoist to pre- vent the motorcycle from falling down. NOTICE Binding a hoist band to the handlebar or grips can damage the motorcycle parts.

  • Page 17: Front Wheel

    FRONT WHEEL Loosen the axle holder bolts. Remove the front axle from the fork legs. A: Axle holder bolt B: Front axle Mount the front wheel assembly properly. A: Right fork leg B: Left fork leg C: Front wheel spacer D: Front axle E: Axle nut (18 mm flange nut) RIGHT...
  • Page 18 Insert the front axle from the right side of fork leg and fix the front wheel assembly to the front fork. NOTICE Forcing to install the front axle can damage the motorcycle. Align the shaft line of front forks and wheel. Install the front axle by hand.
  • Page 19 Extract the stand. Move the front fork up and down hard 4 or 5 times. Tighten the axle holder bolts to the specified torque.  Front axle holder bolt: 21 N·m (2.1 kgf-m) A: Axle holder bolt Place the motorcycle on the stand.

  • Page 20: Radiator Cover

    RADIATOR LOUVER Insert the boss of radiator louver into the hole of radia- tor. Set the radiator louver as shown in the photograph. A: Radiator louver B: Boss C: Hole RADIATOR COVER Install the radiator cover with flange bolt and stepped washer.

  • Page 21: Number Plate

    NUMBER PLATE Insert the hole of the front number plate to the boss of front fender. A: Number plate B: Hole C: Boss Install the front number plate with flange bolt. NOTE: • Route the brake hose in front of the number plate.
  • Page 22 FUEL TANK VENT HOSE Install the fuel tank vent hose to the fuel tank cap. Insert the free end of fuel tank vent hose to the hole of steering shaft. NOTE: Be sure not to bend or twist the hose when install- ing.

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