Suzuki RM-Z450 Manual
  1. Manuals
  2. Brands
  3. Suzuki Manuals
  4. Motorcycle
  5. RM-Z450
  6. Manual
Suzuki RM-Z450 Manual

Suzuki RM-Z450 Manual

Hide thumbs Also See for RM-Z450:
Table of Contents

Advertisement

Quick Links

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.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the RM-Z450 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Suzuki RM-Z450

Summary of Contents for Suzuki RM-Z450

  • Page 1 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.
  • Page 2 IMPORTANT All information, illustrations, photo- graphs and specifications contained in the manual are based on the latest  WARNING/ CAUTION/ product information available at the time of publication. Due to improve- /NOTE ments or other changes, there may be Please read this manual and follow its some discrepancies in this manual.

  • Page 4: Table Of Contents

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

  • Page 6: Consumer Information

    CONSUMER INFORMATION GENERAL CONSIDERATIONS ................1-2 SYMBOL MARKS AND DEFINITION ..............1-4 LABELS ....................... 1-4 SERIAL NUMBER LOCATION ................1-4...
  • Page 7 Wear protective gear CONSUMER Wear proper clothing when you ride. INFORMATION Abrasion injuries can be minimized by wearing protective clothing including gloves, strong boots that fit over the GENERAL CONSIDERATIONS ankle, long pants, and a long sleeve shirt or jackets. In addition, wearing a Wear a helmet and goggles kidney belt and chest or back protec- A helmet is the most important piece...
  • Page 8 Ride only in events No Passengers appropriate for your experience. Suzuki RM-Zs are designed for the rider only. Safely competing on a motorcycle requires that your mental and physical Practice before competing skills are fully part of the experience.
  • Page 9 SYMBOL MARKS AND DEFINITION SERIAL NUMBER LOCATION Listed in the table below are the sym- bols indicating instructions and other information. The meaning of each symbol is also included in the table. SYMBOL DEFINITION Torque control required.  Data beside it indicates specified torque.

  • Page 10: Controls

    CONTROLS LOCATION OF PARTS ..................2-2 LEFT HANDLEBAR ..................... 2-5 RIGHT HANDLEBAR ..................2-6 FUEL TANK CAP ....................2-7 STARTER KNOB ....................2-8 KICK STARTER LEVER ..................2-8 GEARSHIFT LEVER .................... 2-9 REAR BRAKE PEDAL ..................2-9 ACCESSORY SIDE STAND ................2-10 SUSPENSION ADJUSTMENT ................

  • Page 11: Location Of Parts

    CONTROLS LOCATION OF PARTS RM-Z450 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 12 RM-Z450 8 Front fork compression damping force adjuster 9 Battery coupler 0 Spark plug A Starter knob B Idle screw C Air cleaner D Front fork rebound damping force adjuster E Oil strainer (No.2) F Generator cover bolt G Gearshift lever H Oil strainer (No.1)
  • Page 13 RM-Z450 J Rear suspension rebound damping force adjuster K Rear suspension compression damping adjuster L Kick starter lever M ECM tuning map coupler N Radiator cap O Rear brake fluid reservoir P Rear brake pedal Q Engine oil drain plug...

  • Page 14: Left Handlebar

    This is a system that assists opera- tion during the start of races that use a starting gate. Refer to SELECTION OF S-HAC (SUZUKI HOLESHOT ASSIST CON- TROL) MODE for details. ( 5-6) CLUTCH LEVER 1 The clutch lever is used for disengag-...

  • Page 15: Right Handlebar

    FRONT BRAKE LEVER 2 RIGHT HANDLEBAR Apply the front brake by squeezing the front brake lever towards the grip. Front Brake Lever Adjustment Adjust the front brake lever position as follows: THROTTLE GRIP 1 Engine speed is controlled by the position of the throttle grip.

  • Page 16: 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 17: Starter Knob

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

  • Page 18: Gearshift Lever

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

  • Page 19: Accessory Side Stand

    ACCESSORY SIDE STAND SUSPENSION ADJUSTMENT Turning adjusters by force can damage the suspensions. Do not turn adjusters beyond their natural limits. FRONT FORK SETTING The front fork compression and This motorcycle is not equipped with rebound damping force, and oil a side stand.
  • Page 20 Hard and tighten the air bleeder valve 1 to the specified torque.  Grease 99000-25100 (SUZUKI SILICONE GREASE or equivalent grease)  Front fork air bleeder valve: 1.3 N·m (0.13 kgf-m, 0.95 lbf-ft) To set the adjuster, you must gently...
  • Page 21 1 to the specified torque. can cause handling instability.  Grease 99000-25100 The fork oil quantity must be (SUZUKI SILICONE GREASE or adjusted equally on both fork legs equivalent grease) to provide equal performance.  Front fork air bleeder valve: 1.3 N·m (0.13 kgf-m, 0.95 lbf-ft)
  • Page 22 FRONT FORK SETTING PROCEDURE Test ride the motorcycle and find out how the front suspension reacts on vari- ous 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 23 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 preference by referring to the table below. Identifica- tion Standard Oil quantity adjustable Spring Part No.
  • Page 24 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) 2-15...
  • Page 25 ( 6-39) • Spoke nipple tension and bead stopper nut tightness ( 6-41) NOTE: Ask your Suzuki dealer to dis- pose of the rear shock absorber unit. NOTE: • Perform settings based on the feeling of running under standard setting.
  • Page 26  Spring set length adjustable Spring Pre-load Adjustment 1. Support the motorcycle using the range: commercially available support 227 – 239 mm (8.94 – 9.41 in) stand, etc., and lift the rear wheel [at spring free length 240 mm off the ground. (9.45 in)] 2.
  • Page 27 Compression Damping Force Rebound Damping Force Adjustment Adjustment To set the adjuster, you must gently To set the adjuster, you must gently turn the adjust screw 1 clockwise turn the adjust screw 2 clockwise until it stops, then back it out the rec- until it stops, then back it out the rec- ommended number of turns.
  • Page 28 REAR SHOCK ABSORBER SPRING REPLACEMENT PROCEDURE 1. Remove the rear shock absorber. (Refer to Service Manual) 2. Remove the rear shock absorber spring. (Refer to Service Manual) 3. Select the rear shock absorber spring according to the rider’s weight and preference by referring to the table below.
  • Page 29 3. Remove the support stand, etc., and ride onto the stopped motorcycle. Then, move the front and rear suspensions up and down several times. 4. Measure the distance L2 from the seat bolt to the chain adjuster lock-nut with riding the motorcycle normally in full riding gear. 5.
  • Page 30 After the sag measurement has been set 110 mm (4.33 in), test ride the motor- cycle and adjust the suspension for the rider and track conditions referring to the guide below. NOTE: When adjusting the damping force setting, attempt turning the adjuster 1/4 to 1/2 turn stops at a time for each adjustment.

  • Page 31: Front And Rear Balances Of The Suspensions

    FRONT AND REAR BALANCES OF BALANCING TIPS • Check the internal pressure in the THE SUSPENSIONS front forks. Because the internal Balancing the front to rear suspension pressure varies depending on the properly is the most critical adjust- outside air temperature or altitude, ment for suspension performance.

  • Page 32: Fuel, Engine Oil And Coolant Recommendations

    FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL OCTANE RATING ..................3-2 OXYGENATED FUEL RECOMMENDATION ............3-2 ENGINE OIL ......................3-3 ENGINE COOLANT SOLUTION ................. 3-5...

  • Page 33: Fuel Octane Rating

    Blends of this type may be used in your motorcycle NOTE: The RM-Z450 engine is if they are no more than 10% ethanol. designed to use premium unleaded Make sure this gasoline-ethanol blend gasoline only.

  • Page 34: Engine Oil

    NOTE: ENGINE OIL • To help minimize air pollution, Suzuki recommends that you use DESCRIPTION oxygenated fuels. Engine life depends on oil amount • Be sure that any oxygenated fuel and quality. Daily oil level checks and recommended periodic changes are two of the most octane ratings.
  • Page 35 SAE Engine Oil Viscosity Energy Conserving If SAE 10W-40 engine oil is not avail- Suzuki does not recommend the use able, select an alternative according “ENERGY CONSERVING” to the following chart. “RESOURCE CONSERVING” oils. Some engine oils which have an API classification of SJ, SL, SM or SN have an “ENERGY CONSERVING”...

  • Page 36: Engine Coolant Solution

    ENGINE COOLANT SOLUTION ENGINE COOLANT Engine coolant performs as a rust Use “SUZUKI SUPER LONG LIFE inhibitor and water pump lubricant as COOLANT” or “SUZUKI LONG LIFE well as an anti-freeze solution. There- COOLANT”. If “SUZUKI SUPER fore engine coolant should be used at...
  • Page 37 SUZUKI LONG LIFE COOLANT (Green) Water for mixing Use distilled water only. Water other than distilled water can corrode and clog the aluminium radiator. Required amount of water/coolant Solution capacity (total): 1100 ml (1.16/0.97 US/Imp. qt) 550 ml Water (0.58/0.49 US/Imp. qt)

  • Page 38: 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 39 When the following parts are BREAK-IN (RUNNING-IN) replaced AND INSPECTION BEFORE Follow the same procedure when any RIDING of the following parts are replaced: • Piston • Piston ring BREAK-IN (RUNNING-IN) • Cylinder • Crankshaft When the motorcycle is new •...
  • Page 40 INSPECTION BEFORE RIDING  WARNING  WARNING Checking maintenance items when the engine is running can be Failure to inspect your motorcy- hazardous. You could be severely cle before riding and to properly injured if your hands or clothing maintain your motorcycle get caught in moving engine...
  • Page 41 BEFORE RACE WHAT TO CHECK REMARKS EACH TIME AFTER 2 HOURS RIDING • Heat range, fouled electrode,  Spark plug tightness • Loose spark plug cap  Air cleaner element • Dust • Damage  Air cleaner • Loose outlet tube ...
  • Page 42 BEFORE RACE WHAT TO CHECK REMARKS EACH TIME AFTER 2 HOURS RIDING • Damage  Fuel hose • Hose connection  Fuel tank Leakage • Exhaust gas leakage  • Tightening torque Exhaust pipe and muffler  Damage Bolts and nuts including ...

  • Page 44: Riding Tips

    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 S-HAC MODE ................5-8 SELECTION OF ECM TUNING MAP ..............5-12...

  • Page 45: Instructions

    INSPECTION BEFORE ENGINE OIL RIDING TIPS LEVEL CHECK INSTRUCTIONS Leaving the engine at idling speed after riding will cause engine over- heat as this competition motorcy- cle does not have the radiator cooling fan and coolant reservoir. Riding motorcycle under severe conditions such as muddy “INSPECTION BEFORE...

  • Page 46: Starting The Engine

    STARTING THE ENGINE • Inspect the engine oil level, cool- ant level and air cleaner condition If the engine is started with insuffi- before starting the engine. cient or no oil, the engine compo- ( 6-19, 6-33, 6-14) nents will possibly be damaged. •...
  • Page 47 When the Engine is Cold: NOTE: When kick-starting the engine, make sure to remove the accessory 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 compression resistance is felt, release the kick starter lever...
  • Page 48 When the Engine is already Warm Conditions when the starter knob is used or Restarts: Kick down the kick starter lever slowly Engine condition Starter knob from the top position until engine Warm engine Push back (OFF)* compression resistance felt, Cold engine Pull out (ON) release the kick starter lever from this...

  • Page 49: 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 50 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 51: Selecting A S-Hac Mode

    SELECTING A S-HAC 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.
  • Page 52 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 53 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 54 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 55: Selection Of Ecm Tuning Map

    SELECTION OF ECM TUNING MAP NOTE: The changeover is executed immediately after the engine has been started. • Select White short wire (Lean mix- ture injection map) when: 1. Raining 2. In highly humidity • Select Gray short wire (Rich mix- ture injection map) when: 1.
  • Page 56 SHORT WIRE COUPLER CONNECTING PROCEDURE Improper mode select coupler can damage system. Keep dry when connecting the short wire coupler. 3. Connect the short wire coupler 2 to the mode select coupler. 4. Install the mode select coupler to the bracket. 5.

  • Page 58: Inspection And Maintenance

    INSPECTION AND MAINTENANCE 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 ....................6-14 SPARK PLUG ....................6-17 ENGINE OIL .......................

  • Page 59: Replacement Parts

    Use of replacement parts which  WARNING are not equivalent in quality to genuine SUZUKI parts can lead to Exhaust gas contains carbon performance problems and dam- monoxide, a dangerous gas that is age.
  • Page 60 Using poorly-made parts can cause negative impact on the motorcycle performance or dam- age to the motorcycle. When replacing parts on your vehicle, use only genuine Suzuki replacement parts or their equiva- lent.
  • Page 61 MAINTENANCE CHART It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding condi- tions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.
  • Page 62 Every Every Every Interval 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 63: Engine Run Time Indication Procedure

    ENGINE RUN TIME INDICATION PROCEDURE 3. After indicator light will be lit for 2 seconds (lamp check), engine run time will be displayed by indicator light lighting time. NOTE: • Lighting of lamp check and engine run time is made only at the first time, and when there is DTC avail- able, this DTC will be displayed repeatedly.
  • Page 64 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 65: Engine Run Time Reset Procedure

     36890-28H00: ENGINE RUN TIME RESET Battery wire (option) PROCEDURE NOTE: In case of TP sensor failure, 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 66 Throttle grip Disconnect the battery wire. Full open Full close – 10.0 Time (sec.)

  • Page 67: General Lubrication

    GENERAL LUBRICATION Apply grease or oil to the moving parts to increase durability and prevent wear. Lubricating electrical switches can damage the switches. Do not apply grease or oil to electrical switches. Follow the maintenance schedule closely. The disassembly necessary to lubri- cate many components is in itself valuable preventative maintenance.
  • Page 68 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 69: Fuel Tank

    FUEL TANK FUEL TANK REMOVAL 3. Disconnect the fuel pump coupler 1. Remove the bolts 1 and the seat 4. Remove the fuel tank bolt 6 and rubber band 7. 2. Remove the bolts 3 and the right and left radiator covers 4. 5.
  • Page 70 6. Place a rag under the fuel hose 8 8. Put the cleaned plug and cap to and unlock the fuel hose connec- the fuel hose and fuel pump. tor B by pulling the retainer A. 7. Remove the fuel hose connector B from fuel pipe.

  • Page 71: 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 perfor- mance Use the following procedure to remove the element and inspect it.  WARNING Starting the engine with the air cleaner element removed, can be hazardous, because the combus- tion gas could spit back from the...
  • Page 72 WASHING THE ELEMENT 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. Care- fully examine the air cleaner ele- ment for tears during cleaning.
  • Page 73 INSTALLING THE ELEMENT 2. Install them in the air cleaner box by engaging the projection A of 1. Fit the element 1 onto the ele- the element holder with the hole ment holder 2. B of the air cleaner box. NOTE: Fit the projection A of the ele- ment holder to the hole of the element Failure to position the air cleaner...
  • Page 74 SPARK PLUG To remove the spark plug, follow the procedure below. Dirt can damage the moving engine parts of your motorcycle if 1. Remove the seat. it enters an open spark plug hole. 2. Remove the radiator covers and fuel tank. Cover the spark plug hole while the spark plug is out of the hole.

  • Page 75: Spark Plug

    SPARK PLUG INSPECTION INSTALLATION Tighten the spark plug with specified tightening torque after tightening the spark plug temporarily with fingers.  09930-10121: Spark plug socket set  Spark plug: 11 N·m (1.1 kgf-m, 8.5 lbf-ft) Measure the spark plug gap A with a wire type feeler gauge.

  • Page 76: Engine Oil

    ENGINE OIL ENGINE OIL LEVEL CHECK Check the engine oil level according to the following procedure, after the “INSPECTION BEFORE ENGINE OIL LEVER CHECK” is performed. 1. Place the motorcycle on level ground on the accessory side stand. 2. Start the engine and run it for a few minutes.
  • Page 77 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 78 7. Replace the gasket 5 with a new  WARNING one and tighten each bolt to the specified torque. Children and pets may be harmed  Oil drain plug: by swallowing new or used oil. Repeated, prolonged contact with 12 N·m (1.2 kgf-m, 9.0 lbf-ft) used engine oil may cause skin ...
  • Page 79 INSTALLATION 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 equivalent.  Oil filter cap bolt: 11 N·m (1.1 kgf-m, 8.5 lbf-ft) 10. Apply engine oil lightly to the gas- ket 9 of new oil filter before instal- lation.
  • Page 80 Oil Strainer (No.1) Cleaning 16. Check the oil strainer for any dam- age or clogging. If the oil strainer damaged, replace strainer. If the oil strainer is clog- ging, clean the oil strainer in the following procedures. 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 81 18. Remove the magnet D using the 20. Insert the magnet and clip into the oil strainer. Hook the clip C to the suitable steel rod. groove E.  WARNING The strainer has a strong magnet. Magnetic force may affect pace- maker operation.
  • Page 82 Oil Strainer (No.2) Cleaning 21. Remove the bolt and remove the gearshift lever F. 23. Remove the bolts and remove the oil pump No.2 cover H. Remove the snap ring I and oil strainer No.2 J from the oil pump No.2 cover H.
  • Page 83 A to Engine damage may occur if you the specified torque. use oil that does not meet Suzuki’s specifications. NOTE: Replace the gasket with a new one. Be sure to use the oil specified in ...

  • Page 84: Idle Speed Adjustment

    IDLE SPEED ADJUSTMENT 1. Adjust the throttle cable play. ( 6-28) 2. Start the engine and warm it up. NOTE: Make this adjustment when the engine is hot. 4. Turn the idling adjust screw 1 and set the engine idle speed as fol- lows.

  • Page 85: Throttle Cable Adjustment

    THROTTLE CABLE ADJUSTMENT  WARNING Inadequate throttle cable play can cause engine speed to rise sud- denly when you turn the handle- 2.0 – 4.0 mm bars. This can lead to loss of (0.079 – 0.16 in) control and an accident. Measure the throttle cable play by Adjust the throttle cable play so turning the throttle grip.

  • Page 86: Fuel Hose

    THROTTLE CABLE BOOTS FUEL HOSE Lift the fuel tank by referring to the FUEL TANK section. The throttle cable has boots. Check that the boots are fit securely. Do not apply water directly to the boots when washing. Wipe off dirt from the boots with a wet cloth when the boots are dirty.

  • Page 87: Clutch Adjustment

    CLUTCH ADJUSTMENT MAJOR ADJUSTMENT 1. Loosen the lock nut 2. Turn Adjust the clutch cable play as fol- adjuster bolt 3 so the clutch lever lows: clearance A measured at the lever holder obtains 2 – 3 mm MINOR ADJUSTMENT (0.08 –...

  • Page 88: Drive Chain

    When inspecting the chain, look for When the drive chain needs to be the following: replaced, and when you cannot do it • Loose pins yourself, consult with your Suzuki • Damaged rollers dealer. The condition and adjustment • Dry or rusted links of the drive chain should be checked •...
  • Page 89 DRIVE CHAIN CLEANING AND DRIVE CHAIN ADJUSTMENT OILING Clean and oil the chain as follows: 1. Remove dirt and dust from the drive chain. 2. Clean the drive chain with a drive chain cleaner, or water and neu- tral detergent. Measure the drive chain slack at the center between the chain buffer and Cleaning the drive chain improp-...

  • Page 90: Engine Coolant

    ENGINE COOLANT COOLANT LEVEL  WARNING Engine coolant is harmful or fatal if swallowed or inhaled. Solution can be poisonous to animals. Store the coolant in the place 1. Loosen the axle nut 1. always kept away from the reach 2.
  • Page 91 2. Tighten radiator found, replace the radiator hose with securely. a new one. If you cannot replace it yourself, ask your Suzuki dealer to  CAUTION replace the radiator hose with a new one. Improperly tightening the radiator cap will prevent the cooling sys-...

  • Page 92: Brakes

    If any defect is found, replace the brake hose with a new one. If you cannot replace it yourself, ask your Suzuki dealer to replace the brake hose with a new one. 6-35...
  • Page 93  WARNING  WARNING Brake fluid will gradually absorb Brake fluid is harmful or fatal if moisture through the brake hoses. swallowed, and harmful if it comes Brake fluid with high water con- in contact with skin or eyes. Solu- tent lowers the boiling point and tion can be poisonous to animals.
  • Page 94 When the brake pad needs to be replaced, and when you cannot replace it yourself, ask your FRONT Suzuki dealer to replace it with a new one. Inspect and maintain the brake pad as recommended. REAR 6-37...
  • Page 95 REAR BRAKE PEDAL  WARNING ADJUSTMENT If you ride this motorcycle after brake system repair or brake pad replacement without pumping the An incorrectly adjusted brake brake lever/pedal, you may get pedal may force brake pads to poor braking performance which continuously rub against the disc, could result in an accident.

  • Page 96: Tires

    The rear brake pedal must be TIRES adjusted to set the clearance between  WARNING the pedal and the footrest. Adjust the brake pedal as follows: The tires on your motorcycle form the crucial link between your motorcycle and the road. Failure to take the precautions below may result in an accident due to tire failure.
  • Page 97 When the tire needs to be repaired or replaced, and when you cannot do it yourself, ask your Suzuki dealer or a qualified mechanic to perform tire repair or replacement because they have proper tools and experience.

  • Page 98: Spoke Nipple And Bead Stopper Nut

    SPOKE NIPPLE AND BEAD STOPPER NUT Improperly tightening the 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 tight- ness of the spoke nipples.

  • Page 99: Front Fork

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

  • Page 100: 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 102: Motorcycle Cleaning And Storage Procedure

    MOTORCYCLE CLEANING AND STORAGE PROCEDURE MOTORCYCLE CLEANING ................7-2 INSPECTION AFTER CLEANING ............... 7-4 STORAGE PROCEDURE ..................7-4 PROCEDURE FOR RETURNING TO SERVICE ..........7-5 CORROSION PREVENTION ................7-6...

  • Page 103: Motorcycle Cleaning

    WASHING THE MOTORCYCLE MOTORCYCLE CLEANING When washing the motorcycle, follow AND STORAGE the instruction below: PROCEDURE 1. Remove dirt and mud from the motorcycle with cool running water. You may use a soft sponge MOTORCYCLE CLEANING or brush. Do not use hard materi- als which can scratch the paint.
  • Page 104 3. Once the dirt has been completely removed, rinse off the detergent with plenty of water. Cleaning your motorcycle with any alkaline or strong acid cleaner, NOTE: The detergent used to wash gasoline, brake fluid, or any other the motorcycle can negatively affect solvent will damage the motorcy- plastic parts if the detergent is not cle parts.

  • Page 105: Inspection After Cleaning

    If necessary, apply the ate materials, equipment and skills. If brakes several times to let friction you cannot do it yourself, Suzuki rec- dry out the linings. ommends you to ask your Suzuki dealer. If you do it yourself, follow the...

  • Page 106: Procedure For Returning To Service

    ENGINE PROCEDURE FOR 1. Pour about 5 ml (0.17/0.18 US/ RETURNING TO SERVICE Imp. oz) of engine oil into the 1. Clean the entire motorcycle. spark plug hole. Reinstall the 2. Remove the oily rags from the air spark plug and crank the engine a cleaner intake and muffler outlet.

  • Page 107: Corrosion Prevention

    If the engine is hard to start, follow the CORROSION PREVENTION procedure below: It is important to take good care of your motorcycle to protect it from cor- Due to deterioration of fuel remaining rosion and keep it looking new for in the fuel line for long period, engine years to come.
  • Page 108 If the chips or scratches have gone through to the bare metal, have a Suzuki dealer make the repair. • Store your motorcycle in a dry, well-ventilated area. If you often...

  • Page 109: 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 110 ELECTRICAL Ignition type .............Electronic ignition (CDI) Spark plug ............NGK DIMR8C10 Generator ............Single-phase A.C. generator CAPACITIES Fuel tank............6.3 L (1.7/1.4 US/Imp. gal) Engine oil, oil change ........1050 ml (1.1/0.9 US/Imp. qt) With filter change......1100 ml (1.2/1.0 US/Imp. qt) Coolant ............1100 ml (1.2/1.0 US/Imp. qt)
  • Page 111 INDEX ACCESSORY SIDE STAND..2-10 GEARSHIFT LEVER ....... 2-9 AIR CLEANER....... 6-14 GENERAL CONSIDERATIONS ..1-2 GENERAL LUBRICATION .... 6-10 BRAKES ........6-35 BREAK-IN (RUNNING-IN)....4-2 IDLE SPEED ADJUSTMENT ..6-27 INSPECTION AFTER CLEANING ........7-4 INSPECTION BEFORE ENGINE OIL CLUTCH ADJUSTMENT ....
  • Page 112 RIGHT HANDLEBAR....... 2-6 SELECTING A S-HAC MODE ..5-8 SELECTION OF ECM TUNING MAP ........ 5-12 SELECTION OF S-HAC (SUZUKI HOLESHOT ASSIST CONTROL) MODE ......5-6 SERIAL NUMBER LOCATION ..1-4 SPARK PLUG........ 6-17 SPOKE NIPPLE AND BEAD STOPPER NUT ......6-41 STARTER KNOB......

Table of Contents

Save PDF