Suzuki RM-Z450L5 Manual

L5
June ’14 (TK) 19
99505-01055-01E
© COPYRIGHT SUZUKI MOTOR JAPAN
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.

1
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.

2
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

3
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.

4
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.

5
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
A
Number plate 1
Flange bolt
(with small washer) 1 6 × 12 mm
B
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
F
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
H
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
J
IHACB
GFE
D
G

6
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
LL
II
NN
AA
EE
JJ
HH
KKM
M
GG
BB
DD
CC
FF

7
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.

8
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

9
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.

10
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.
A: Throttle assembly
B: Matching mark
C: Screw
Fit the rubber cover onto the throttle housing.
A: Rubber cover
WARNING
Improper throttle installing can interfere with
smooth throttle grip operation. It can result in
an accident.
Check to ensure that the throttle operates
freely and closes automatically.

11
FRONT BRAKE MASTER CYLINDER
Install the front brake master cylinder onto the handle-
bars.
A: Holder
B: Front brake master cylinder
C: 6 × 22 mm flange bolt
D: Matching mark
E: Spacer
Tighten the front brake master cylinder mounting bolts
to the specified torque.
Front brake master cylinder mounting bolt:
10 N·m (1.0 kgf-m)
A: 6 × 22 mm flange bolt
B: 6 × 22 mm flange bolt
C: Holder
D: Front brake master cylinder
E: Handlebars
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.
NOTE:
• First tighten the bolt Aof the upper side with
specified torque and then tighten the bolt Bof
the lower side.
• Make sure that the holder has no clearance at
the upper side.

12
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.
Insert the inner cable end into the recess in the clutch
lever, then pull on the outer cable housing and insert it
into the adjuster.
Do not adjust at this time.
Adjustment will be covered in the SERVICING section.
Install the lever cover and adjuster cover.
A: Clutch cable
B: Adjuster
C: Cable end
D: Adjuster cover
E: Lever cover
NOTE:
Before installing the cable, grease the cable end.

13
ENGINE STOP SWITCH
Hook the holders on the grooves of the engine stop
switch.
A: Engine stop switch
B: Holder (Upper)
C: Holder (Lower)
D: Thread cutting
Install the engine stop switch to the left of handlebars.
A: Engine stop switch
B: 3 × 14 mm screw (with lock washer)
S-HAC SWITCH
Hook the holders on the grooves of the S-HAC switch.
A: S-HAC switch
B: Holder (Front)
C: Holder (Rear)
D: Thread cutting
Install the S-HAC switch to the left of handlebars.
A: S-HAC switch
B: 4 × 14 mm screw (with lock washer)
C: Matching mark
NOTE:
Use the holder with an internal thread cutting at the
lower side.
NOTE:
Use the holder with an internal thread cutting at the
front side.
NOTE:
Align the matching mark on the handlebars with
mating surface of the S-HAC switch holder.

14
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 FENDER
Install the front fender with four sets of mounting parts
as shown.
A: Front fender
B: Collared spacer OD:25.0 mm ID:6.5 mm T:6.5 mm
Install the front fender to the front fork lower bracket.
A: Front fender
B: Collared spacer OD:25.0 mm ID:6.5 mm T:6.5 mm
C: Washer OD:28.0 mm ID:6.5 mm
D: 6 × 16 mm flange bolt
E: Front fork lower bracket
FRONT REAR
BRAKE DISC
To prevent brake squeaking and pad contamination,
carefully clean the front and rear brake disc plates with
alcohol or other non-petroleum based solvent.
This will remove the rust-preventive coating and dirt.
FRONT FRONT
FRONT
FRONT

15
TAKING OUT THE MOTORCYCLE
Bind a hoist band around the handlebar clamps as
shown in the photograph.
A: Hoist band
Remove the crate axle bracket from the crate base.
A: Crate axle bracket
B: Bolt
1. Lift the front of motorcycle by using a hoist.
2. Raise the rear of motorcycle.
3. Pull the crate base forward, then balance the
motorcycle.
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.
Be sure to bind a hoist band around the handle-
bar clamps.
NOTE:
The bracket and bolt are not necessary to assem-
ble the motorcycle.

16
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 LEFT
Attach the front wheel spacer to the front wheel hub.
A: Front wheel spacer
Remove the supporter from the brake pad of the left
front brake caliper.
Carefully insert the front brake disc plate between the
caliper brake pads.
A: Supporter
B: Pads
C: Disc plate
NOTE:
• The spacer faces at the correct direction as
shown in the illustration.
• When attaching the front wheel spacer, be care-
ful not to damage the oil seal lip.
Front wheel
hub
Front wheel
hub

17
Insert the front axle from the right side of fork leg and
fix the front wheel assembly to the front fork.
A: Front axle
Tighten the front axle nut to the specified torque.
Front axle nut: 35 N·m (3.5 kgf-m)
A: Axle nut
STAND
Insert the boss of stand to the hole of rear axle shaft.
A: Stand
Place the motorcycle on the stand, then remove the
hoist hook.
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.

18
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.

19
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.
A: Radiator cover
B: 6 × 12 mm flange bolt (with large washer)
C: Stepped washer OD:18.0 mm ID:6.5 mm T:4.5 mm
D: 6 × 16 mm flange bolt
HANDLEBAR PAD
Set the handlebar pad to the handlebar.
A: Handlebar pad
B: Handlebars
Install the handlebar pad cover as shown in the illus-
tration.
A: Handlebar pad cover
B: Handlebar pad
C: Handlebars
D: Velcro fastening
FRONT