Suzuki RM-Z450 User manual

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.
California Proposition 65 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. 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.
WARNING
To p
3rd cover2nd cover
Black
4/1
5 mm
RM-Z450 (99011-37K50-03A)

IMPORTANT
 WARNING/  CAUTION/
NOTICE /NOTE
Please read this manual and fol-
low its instructions carefully. To
emphasize special information,
the symbol and the words
WARNING, CAUTION, NOTICE
and NOTE have special mean-
ings. Pay particular attention to
messages highlighted by these
signal words:
NOTE: Indicates special informa-
tion to make maintenance easier
or instructions clearer.
FOREWORD
This manual is presented as a
means whereby you can maintain
your RM-Z450 in top working con-
dition at all times. Your riding skill
and the maintenance steps out-
lined in this manual will assure
you of top performance from your
machine under any type of com-
petition.
We sincerely wish you and your
Suzuki motorcycle a successful
partnership for many years of
happy riding.
All information, illustrations, pho-
tographs and specifications con-
tained in the manual are based on
the latest product information
available at the time of publica-
tion. Due to improvements or
other changes, there may be
some discrepancies in this man-
ual. Suzuki reserves the right to
make production changes at any
time, without notice and without
incurring any obligation to make
the same or similar changes to
motorcycle previous built or sold.
Suzuki Motor Corporation
believes in conservation and pro-
tection of Earth’s natural
resources. To that end, we
encourage every motorcycle
owner to recycle, trade in, or prop-
erly dispose of, as appropriate,
used motor oil, engine coolant,
and other fluid, and tires.
WARNING
Indicates a potential hazard
that could result in death or
serious injury.
CAUTION
Indicates a potential hazard
that could result in minor or
moderate injury.
NOTICE
Indicates a potential hazard
that could result in vehicle or
equipment damage.

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.

Apply oil. Use engine oil or
transmission oil unless otherwise
specified.

Apply or use brake fluid. (DOT 4)

Use special tool.

Indication of service data.

TABLE OF CONTENTS
1
2
3
4
5
6
7
8
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

1-1
1
THE SPORT OF MOTOCROSS
MOTORCYCLING
GENERAL CONSIDERATIONS .......................................................................... 1-2
INSPECT YOUR MACHINE BEFORE RIDING ................................................... 1-4
LABELS ............................................................................................................... 1-4

1-2
THE SPORT OF
MOTOCROSS
MOTORCYCLING
GENERAL CONSIDERATIONS
Wear a helmet and goggles
A helmet is the most important
piece of gear to wear. Helmets do
not reduce essential vision or
hearing. Generally, helmets do
not cause or intensify injury if you
crash. Helmets simply help your
skull protect your intelligence,
your memory, your personality,
and your life.
Your eyesight is equally valuable.
Wearing suitable eye protection
can help keep your vision
unblurred by the wind and help
shield your eyes from branches
and airborne matter like bugs,
dirt, or pebbles kicked up by tires.
Wear a helmet and eye protection
every time you ride.
Wear protective gear
Wear proper clothing when you
ride. Avoid loose clothes or
scarves, which could get caught
in moving parts. Abrasion injuries
can be minimized by wearing pro-
tective clothing including gloves,
strong boots that fit over the
ankle, long pants, and a long
sleeve shirt or jackets. Experi-
enced riders often wear a kidney
belt and chest or back protector
for additional comfort and protec-
tion.
Inspect your machine before
riding
Before each use, perform an
inspection per “INSPECTION
BEFORE RIDING” section start-
ing on page 4-3.
No Passengers
Suzuki RM-Zs are designed for
the rider only.
Practice before competing
Before you begin competing, you
should practice the skills you
need to ride safely.
Review the controls on your
motorcycle before riding.

1-3
Know your limits
Always ride within the boundaries
of your own skills. Knowing these
limits and staying within them will
help you avoid accidents. Ride
only in events appropriate for your
experience.
Safely competing on a motorcycle
requires that your mental and
physical skills are fully part of the
experience. You should not
attempt to operate a motorcycle,
especially one with two wheels, if
you are tired or under the influ-
ence of alcohol or other drugs.
Alcohol, illegal drugs, and even
some prescription and over-the-
counter drugs and cause drowsi-
ness, loss of coordination, loss of
balance, and loss of good judge-
ment. If you are tired or under the
influence of alcohol or other
drugs, PLEASE DO NOT RIDE
your motorcycle.
Conclusion
The actions of other riders are
unpredictable. Your motorcycle’s
condition can change. These fac-
tors can best be dealt with by giv-
ing every ride your full attention.
Circumstances beyond your con-
trol could lead to an accident. You
need to prepare for the unex-
pected by wearing a helmet and
other protective gear, and practic-
ing safe riding techniques to mini-
mize the damage to you and your
machine.
May all of your rides on your new
Suzuki be winning rides!

1-4
INSPECT YOUR MACHINE
BEFORE RIDING
Review the instructions in the
“INSPECTION BEFORE RIDING”
section of this manual. Perform an
entire pre-ride inspection before
you head out on the trail. Spend-
ing a few minutes preparing your
machine for a ride can help pre-
vent accidents due to mechanical
failure or costly.
LABELS
Read and follow all the labels on
the motorcycle. Make sure you
understand all of the labels. Do
not remove any labels from the
motorcycle.

2-1
2
FUEL, ENGINE OIL AND COOLANT
RECOMMENDATIONS
FUEL .................................................................................................................... 2-2
ENGINE OIL ......................................................................................................... 2-4
ENGINE COOLANT SOLUTION ......................................................................... 2-6

2-2
FUEL, ENGINE OIL AND
COOLANT
RECOMMENDATIONS
FUEL
Your motorcycle requires pre-
mium unleaded gasoline with a
minimum pump octane rating of
90 ((R+M)/2 method). In some
areas, the only fuels that are
available are oxygenated fuels.
NOTE:
• The RM-Z450 engine is
designed to use premium
unleaded gasoline only. Use
premium unleaded gasoline
under all riding conditions.
• If the engine develops some
trouble like lack of acceleration
or insufficient power, the cause
may be due to the fuel the
motorcycle uses. In such case,
try changing to a different gas
station. If the situation is not
improved by changing, consult
your Suzuki dealer.
Oxygenated fuels which meet the
minimum octane requirement and
the requirements described below
may be used in your motorcycle
without jeopardizing the New
Vehicle Limited Warranty.
NOTE: Oxygenated fuels are
fuels which contain oxygen-carry-
ing additives such as alcohol.
Gasoline/Ethanol Blends
Blends of unleaded gasoline and
ethanol (grain alcohol), also
known as “GASOHOL”, are com-
mercially available in some areas.
Blends of this type may be used in
your motorcycle if they are no
more than 10% ethanol ( ). Make
sure this gasoline-ethanol blend
has octane ratings no lower than
those recommended for gasoline.

2-3
Fuel Pump Labeling
In some states, pumps that dis-
pense oxygenated fuels are
required to be labeled for the type
and percentage of oxygenate, and
whether important additives are
present. Such labels may provide
enough information for you to
determine if a particular blend of
fuel meets the requirements listed
above. In other states, pumps
may not be clearly labeled as to
the content or type of oxygenate
and additives. If you are not sure
that the fuel you intend to use
meets these requirements, check
with the service station operator
or the fuel supplier.
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).
• If you are not satisfied with the
drivability of fuel economy of
your motorcycle when you are
using an oxygenated fuel, or if
engine pinging is experi-
enced, substitute another
brand as there are differences
between brands.
NOTICE
Spilled gasoline containing
alcohol can damage the
painted surfaces of your
motorcycle.
Be careful not to spill any fuel
when filling the fuel tank. Wipe
spilled gasoline up immedi-
ately.

2-4
ENGINE OIL
Suzuki recommends the use of
SUZUKI PERFORMANCE 4
MOTOR OIL or equivalent engine
oil. If SUZUKI PERFORMANCE 4
MOTOR OIL is not available,
select a proper engine oil accord-
ing to the following guideline.
Oil quality is a major contributor to
your engine’s performance and
life. Always select good quality
engine oil. Use oil with an API
(American Petroleum Institute)
classification of SG, SH, SJ, SL,
SM or SN with a JASO classifica-
tion of MA.
API: American Petroleum Institute
JASO: Japanese Automobile
Standards Organization
NOTE: SUZUKI highly recom-
mends the use of ECSTAR brand
engine oil. ECSTAR has been
specially formulated for your
SUZUKI product and contributes
to the desired motorcycle perfor-
mance and ideal riding experi-
ence.
SAE Engine Oil Viscosity
Suzuki recommends the use of
SAE 10W-40 engine oil. If SAE
10W-40 engine oil is not available,
select an alternative according to
the following chart.
SAE API JASO
10W-40 SG, SH, SJ, SL,
SM or SN MA
TEMP.
ENGINE OIL

2-5
JASO T903
The JASO T903 standard is an
index to select engine oils for 4-
stroke motorcycle and ATV
engines. Motorcycle and ATV
engines lubricate clutch and
transmission gears with engine
oil. JASO T903 specifies perfor-
mance requirements for motorcy-
cle and ATV clutches and
transmissions.
There are two classes, MA and
MB. The oil container shows the
classification as follows.
1Code number of oil sales company
2Oil classification
Energy Conserving
Suzuki does not recommend the
use of “ENERGY CONSERVING”
or “RESOURCE CONSERVING”
oils. Some engine oils which have
an API classification of SH, SJ,
SL, SM or SN have an “ENERGY
CONSERVING” or “RESOURCE
CONSERVING” indication in the
API classification donut mark.
These oils can affect engine life
and clutch performance.
API SG, SH, SJ, SL, SM or SN
Recommended
API SH, SJ, SL or SM API SN
Not recommended
A
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10W-40
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10W-40

2-6
ENGINE COOLANT SOLUTION
Use “SUZUKI SUPER LONG
LIFE COOLANT” or “SUZUKI
LONG LIFE COOLANT”. If
“SUZUKI SUPER LONG LIFE
COOLANT” and “SUZUKI LONG
LIFE COOLANT” are not avail-
able, use a glycol-based anti-
freeze compatible with an
aluminum radiator mixed with dis-
tilled water only at the ratio of
50:50.
NOTE: SUZUKI highly recom-
mends the use of ECSTAR brand
coolant. ECSTAR has been spe-
cially formulated for your SUZUKI
product and contributes to the
desired motorcycle performance
and ideal riding experience.
ENGINE COOLANT
Engine coolant performs as a rust
inhibitor and water pump lubricant
as well as an anti-freeze solution.
Therefore engine coolant should
be used at all times even though
the atmospheric temperature in
your area does not go down to the
freezing point.
WARNING
Engine coolant is harmful or
fatal if swallowed or inhaled.
Solution can be poisonous to
animals.
Do not drink antifreeze or cool-
ant solution. If swallowed, do
not induce vomiting. Immedi-
ately contact a poison control
center or a physician. Avoid
inhaling mist or hot vapors; if
inhaled, remove to fresh air. If
coolant gets in eyes, flush eyes
with water and seek medical
attention. Wash thoroughly
after handling. Keep out of the
reach of children and animals.
NOTICE
Spilled engine coolant can
damage the painted surfaces of
your motorcycle.
Be careful not to spill any fluid
when filling the radiator. Wipe
spilled engine coolant up
immediately.

2-7
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.
SUZUKI LONG LIFE COOLANT
(Green)
Water for Mixing
Use distilled water only. Water
other than distilled water can cor-
rode and clog the aluminum radia-
tor.
Required amount of engine cool-
ant/water solution capacity (total):
1100 ml (1.2 US qt)
NOTE: This 50% mixture will pro-
tect the cooling system from
freezing at temperatures above
–31°C (–24°F). If the motorcycle
is to be exposed to temperature
below –31°C (–24°F), this mixing
ratio should be increased up to
55% (–40°C/–40°F) or 60%
(–55°C/–67°F) coolant. The mix-
ing ratio should not exceed 60%
coolant.
Engine coolant 550 ml (0.6 US qt)
Water 550 ml (0.6 US qt)

3-1
3
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 ...................................................................................................... 3-10
SUSPENSION ADJUSTMENT .......................................................................... 3-10
SUSPENSION BALANCE ................................................................................. 3-22

3-2
CONTROLS, EQUIPMENT AND ADJUSTMENTS
LOCATION OF PARTS
1Clutch lever
2S-HAC switch
3Front brake fluid reservoir
4Front brake lever
5Engine stop switch
6Fuel tank cap
7Throttle grip

3-3
8Front fork compression damping force adjuster
9Starter knob
0Idle screw
AFront fork rebound damping force adjuster
BGearshift lever
CFootrests