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.