Suzuki RM-Z450L5 Manual

June ’14 (TK) 19

99505-01055-01E

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.

PREPARATION

WORKSHOP

A: Packed vehicle

B: Working space

SELF PROTECTION

UNCRATING THE MOTORCYCLE

Cut the strap by using scissors.

A: Strap

Remove the carton.

A: Crate

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.

CAUTION

Assembling the vehicle without proper clothes

and protective gear can be hazardous. You can

be injured if you do not wear proper clothes

and protective gear.

Be sure to wear proper clothes and shoes for

assembling and wear protective glasses, mask

or gloves as necessary.

CAUTION

Metal crates may have sharp edges and may

cause injury.

Wear proper protective clothes and gear.

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.

A: Bolt

Lift the steel frame to separate it from the base of the

crate.

A: Steel frame

B: Crate base

Open the vinyl package.

Take out the various component parts and spare parts

packaged from the crate.

A: Component parts

B: Spare parts

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.

SPARE PARTS

Check all spare parts.

Item Part Name Q’ty

1Magneto cover gasket 1

2Clutch cover outer gasket 1

3Water pump case O-ring 1

4Sprocket spacer O-ring 1

5Engine oil filter comp 1

6Oil filter cap O-ring 1

7Exhaust pipe gasket 1

8Muffler joint connector 1

9Drive chain joint set 1

0Clutch lever 1

ABrake lever 1

NOTE:

Please hand over the spare parts shown as Item 1–Ain the above table to your customer together with

motorcycle.

LOCATION OF PARTS

Check all the components which have been removed from the base of the crate.

Parts listed above are installed respectively into the positions as follows.

Item Part Name Q’ty Remarks

Number plate 1

Flange bolt

(with small washer) 1 6 × 12 mm

Handlebars assembly 1

Handlebar clamp 1

Flange bolt 4 8 × 35 mm

Strap 1 L:100

Strap 1 L:130

Fuel tank vent hose 1

Engine stop switch holder 2 Upper and Lower

Screw (with lock washer) 1 3 × 14 mm

S-HAC switch holder 2 Front and Rear

Screw (with lock washer) 1 4 × 14 mm

Clutch lever cover 1

Clutch adjuster cover 1

C Handlebar pad set 1

DHolder 1 For front brake

master cylinder

Flange bolt 2 6 × 22 mm

E Radiator louver 1 Left

Item Part Name Q’ty Remarks

Radiator cover 1 Left

Flange bolt

(with large washer) 2 6 × 12 mm

Flange bolt 2 6 × 16 mm

Stepped washer 2 OD:18.0 ID:6.5

T:4.5

GFront wheel spacer 2

Front axle nut 1 18 mm

Front fender 1

Flange bolt 4 6 × 16 mm

Collared spacer 4 OD:25.0 ID:6.5

T:6.5

Washer 4 OD:28.0 ID:6.5

I Front wheel assembly 1

JStand 1

K Spoke nipple wrench 1 Tool

L Short wire (Coupler) 2 ECM setting parts

MFuel hose plug 1 Special tool

Fuel pump cap 1 Special tool

NOwner’s service manual

set 1

NOTE:

• 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

IHACB

GFE

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

KKM

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.

A: Front brake master cylinder

B: Bolt

C: Bracket

Remove the bolts to take off the bracket from the han-

dlebar holder.

A: Bracket

B: Bolt

NOTE:

• Keep the position of front brake master cylinder

with its cap facing upwards until it is installed.

• The bolt is not necessary to assemble the motor-

cycle.

NOTE:

• Be careful not to damage the fuel tank.

• The bracket and bolts are not necessary to

assemble the motorcycle.

HANDLEBARS

Loosen the throttle housing retaining screws.

Insert the throttle assembly onto the handlebars.

A: Throttle assembly

B: Handlebars

C: Spacer

Install the handlebar assembly with the clamp and the

four bolts.

A: Clamp

B: 8 × 35 mm flange bolt

C: Arrow mark

D: Matching mark

Tighten the handlebar clamp bolts to the specified

torque.

Handlebar clamp bolt: 25 N·m (2.5 kgf-m)

A: 8 × 35 mm flange bolt

B: 8 × 35 mm flange bolt

NOTE:

Check the spacer is onto the handlebars.

NOTE:

• Install the clamp with the arrow mark facing front.

• Align the matching mark on the handlebars with

the mating surface of the left front side of the

clamp.

NOTE:

• First tighten the bolt Aof the front side with

specified torque and then tighten the bolt Bof

the rear side.

• Make sure that the clamp has no clearance at the

front side.

FRONT

A: Front brake hose

B: Throttle cables

C: Clutch cable

D: Engine stop switch wiring harness

E: S-HAC switch wiring harness

F: Cable guide

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.

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