Suzuki RM-Z450 - Repair, Service Manual and Electrical Wiring Diagrams

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SUZUKI RM-Z450 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual / Repair Manual and Wiring Diagrams, for motorcycles Suzuki RM-Z450.


MANUALS INCLUDED:

- SUZUKI RM-Z450 2008 SERVICE MANUAL
- SUZUKI RM-Z450 2007 SERVICE MANUAL
- SUZUKI RM-Z450 2006 SERVICE MANUAL
- SUZUKI RM-Z450 2005 SERVICE MANUAL


CONTENTS:

foreword
- general considerations
- serial number location
- warnings for servicing
- precautions for servicing
- replacement parts
- symbol marks and materials
- abbreviations used in this manual
group index
01 general information
- location of parts
- accessory
- side stand
- fuel and oil recommendation
- operating instructions
- starting the engine
- stopping the engine
- transmission
- break-in (running-in)
- when the motorcycle is new
- when engine parts are replaced
- exterior parts
02 periodic maintenance
- periodic maintenance
- inspection before practice
- inspection before race (all items of inspection before practice on previous page plus)
- periodic maintenance chart
- spark plug
- air cleaner
- air cleaner element removal
- washing
- installation
- engine oil and oil filter
- inspection before engine oil level check
- engine oil level inspection
- engine oil change
- engine oil filter change
- oil strainers
- oil strainer (no.1) removal
- oil strainer (no.2) removal
- inspection
- oil strainer (no.2) installation
- oil strainer (no.1) installation
- engine coolant
- engine coolant level check
- engine coolant replenishment
- cooling system inspection
- clutch cable
- major adjustment
- minor adjustment
- throttle cable
- throttle cable adjustment
- throttle cable oil supply
- hot starter
- throttle body
- engine idle speed
- crankcase breather hose
- fuel hose
- valve clearance
- valve clearance adjustment
- cylinder head, cylinder and piston
- cylinder head inspection
- cylinder inspection
- piston inspection
- muffler silencer
- silencer inspection and replacement
- drive chain and sprockets
- drive chain slack
- crankcase driveshaft oil seal
- drive chain adjustment
- drive chain plate wear
- drive chain lubrication
- sprocket inspection
- drive chain guide, buffer and tensioner roller
- drive chain guide inspection
- drive chain buffer and roller inspection
- brakes
- brake fluid level
- brake pad
- front brake lever adjustment
- brake pedal height adjustment
- front fork
- rear suspension
- wheels and tires
- wheel rim and tires inspection
- spoke nipple and rim lock inspection
- tire pressure
- steering
- lubrication
- compression pressure check
- compression test procedure
- oil pressure check
- oil pressure test procedure
03 troubleshooting
- engine
- radiator (cooling system)
- chassis
- brakes
- electrical
04 machine tuning
- front fork tuning
- compression damping force adjustment
- rebound damping force adjustment
- oil quantity minor adjustment
- oil change (only for outer tube oil chamber)
- spring change
- front fork tuning procedure
- rear suspension tuning
- compression damping force adjustment
- rebound damping force adjustment
- spring pre-load adjustment
- rear suspension tuning procedure
- suspension balance
- balance test
- balancing tips
05 engine removal and installation
- engine removal and installation
- removal
- installation
06 cylinder head, cylinder and piston
- construction
- cylinder head, cylinder and piston
- engine top side disassembly
- cylinder head cover removal
- camshafts (automatic decomp.) and cam chain tension adjuster removal
- cylinder head removal
- cylinder removal
- piston and piston ring removal
- engine top components inspection and service
- automatic decomp. inspection
- camshaft inspection
- cam chain tension adjuster inspection
- cam chain no.2 guide inspection
- cylinder head and valve inspection
- intake pipe removal
- intake pipe installation
- ect sensor removal
- ect sensor inspection
- ect sensor installation
- cylinder inspection
- piston and piston ring inspection
- crankshaft and conrod inspection
- engine top side assembly
- piston and piston ring installation
- cylinder and cylinder head installation
- camshaft (automatic decomp.) and cam chain tension adjuster installation
- cylinder head cover installation
- cam chain, cam chain tensioner and cam chain no.1 guide
- removal
- inspection
- installation
07 clutch
- construction
- clutch
- clutch plate
- removal
- inspection
- installation
- primary drive gear and clutch sleeve hub
- removal
- inspection
- installation
- clutch release camshaft
- removal
- inspection
- installation
08 kick starter
- construction
- kick starter
- kick starter
- removal
- inspection
- installation
09 gearshifting
- construction
- gearshift linkage
- gearshift linkage
- removal
- inspection
- installation
- gear position (gp) switch
- removal
- inspection
- installation
10 transmission and crankshaft
- construction
- transmission and crankshaft
- engine bottom side
- primary drive gear removal
- crankcase separation
- transmission removal
- crankshaft removal
- transmission inspection
- conrod inspection
- crankshaft inspcection
- oil reed valve inspection
- oil seal inspection
- oil seal removal and installation
- bearing inspection
- bearing removal and installation
- crankshaft installation
- transmission installation
- crankcase installation
- primary drive gear installation
11 lubrication system
- engine lubrication system
- engine lubrication system chart
- engine oil level inspection
- engine oil change
- engine oil filter change
- oil pressure check
- oil strainer removal
- oil strainers inspection
- oil strainer installation
- oil reed valve removal
- oil reed valve inspection
- oil reed valve installation
- oil relief valve removal
- oil relief valve inspection
- oil relief valve installation
- oil seal removal
- oil seal inspection
- oil seal installation
- oil pump no.1 and no.2 removal
- oil pump no.1 and no.2 inspection
- oil pump no.1 and no.2 installation
12 fi system diagnosis
- precautions in servicing
- connector/coupler
- ecm/various sensors
- electrical circuit inspection procedure
- using the multi-circuit tester
- fi system technical features
- injection time (injection volume)
- compensation of injection time (volume)
- injection stop control
- fi system parts location
- fi system wiring diagram
- ecm terminal
- self-diagnosis function
- dealer mode
- diagnostic trouble code table
- tp sensor adjustment
- fail-safe function
- visual inspection
- self-diagnostic procedures
- self-diagnosis reset procedure
- dtc and defective condition
- “12” ckp sensor circuit malfunction
- “14” tp sensor circuit malfunction
- “15” ect sensor circuit malfunction
- “17” iap sensor circuit malfunction
- “21” iat sensor circuit malfunction
- “23” to sensor circuit malfunction
- “24” ignition system malfunction
- “31” gp switch circuit malfunction
- “32” fuel injector circuit malfunction
- “41” fp relay circuit malfunction
- “63” crankshaft rotation signal circuit malfunction
- sensors
- ckp sensor/crankshaft rotation signal sensor inspection
- ckp sensor/crankshaft rotation signal sensor removal and installation
- iap sensor inspection
- iap sensor removal and installation
- tp sensor inspection
- tp sensor removal and installation
- ect sensor inspection
- ect sensor removal and installation
- iat sensor inspection
- iat sensor removal and installation
- to sensor inspection
- to sensor removal and installation
13 fuel system and throttle body
- fuel system
- construction
- fuel tank and fuel pump removal
- fuel tank and fuel pump installation
- fuel pressure inspection
- fuel pump inspection
- fuel discharge amount inspection
- throttle body
- construction
- removal
- disassembly
- cleaning
- inspection
- reassembly
- installation
- fuel injector removal
- fuel injector inspection
- fuel injector installation
14 cooling system
- construction
- engine coolant
- replacement
- cooling circuit
- inspection
- radiator
- inspection
- removal
- installation
- water pump
- removal
- inspection
- installation
15 electrical system
- cautions in servicing
- connector
- coupler
- clamp
- switch
- semi-conductor equipped part
- connecting the battery
- wiring procedure
- using the multi-circuit tester
- location of electrical components
- construction
- generating system
- inspection
- ignition system
- troubleshooting
- inspection
- magneto rotor
- removal
- installation
- stator
- removal
- installation
16 front and rear wheels
- construction
- front wheel
- removal
- inspection
- dust seal and bearing replacement
- disc plate replacement
- installation
- rear wheel
- removal
- inspection
- dust seal and bearing replacement
- disc plate replacement
- rear sprocket replacement
- installation
- rear wheel spokes replacement
17 front and rear brakes
- construction
- brake fluid air bleeding
- brake fluid replacement
- brake pads replacement
- front brake pads
- rear brake pads
- brake disc inspection
- caliper
- front caliper removal and disassembly
- caliper inspection
- caliper cleaning
- front caliper reassembly and installation
- rear caliper removal and disassembly
- rear caliper reassembly and installation
- master cylinder
- front master cylinder removal and disassembly
- master cylinder inspection
- master cylinder cleaning
- front master cylinder reassembly and installation
- rear master cylinder removal and disassembly
- master cylinder inspection
- rear master cylinder reassembly and installation
- brake lever
- removal
- installation
- brake pedal
- removal
- installation
18 front fork and steering
- construction
- front fork, steering
- handlebar controls
- removal
- disassembly
- inspection
- reassembly
- installation
- steering
- removal
- inspection
- bearing replacement
- installation
19 rear suspension
- construction
- rear suspension
- rear shock absorber
- removal
- spring replacement
- inspection
- bearing replacement
- oil replacement
- disassembly and inspection
- reassembly
- installation
- disposal
- swingarm
- removal
- inspection
- bearing replacement
- installation
- rear suspension linkage
- removal
- inspection
- bearing replacement
- installation
20 servicing information
- service data
- tightening torque
- special tools
- wiring diagram
- wiring harness routing
- cable routing
- fuel hose routing
- radiator hose routing
- rear brake pedal set-up
- clutch cable adjuster
- hot starter lever installation
- front brake hose routing
- rear brake hose routing
- handlebar set-up
- rear wheel spokes installation
- chain roller installation
- specifications
- optional parts
- setting data