Suzuki RMX450Z Service Manual

Table of Contents 2- i
2
Section 2
CONTENTS
Suspension
Precautions.................................................2-1
Precautions............................................................. 2-1
Precautions for Suspension.................................. 2-1
Suspension General Diagnosis.............. 2A-1
Diagnostic Information and Procedures............2A-1
Suspension and Wheel Symptom Diagnosis......2A-1
Front Suspension.................................... 2B-1
Repair Instructions ..............................................2B-1
Front Fork Components......................................2B-1
Front Fork Removal and Installation ...................2B-2
Front Fork Disassembly ......................................2B-3
Front Fork Assembly...........................................2B-7
Front Fork Parts Inspection...............................2B-11
Front Suspension Adjustment...........................2B-12
Specifications.....................................................2B-15
Service Data .....................................................2B-15
Tightening Torque Specifications......................2B-16
Special Tools and Equipment...........................2B-16
Recommended Service Material.......................2B-16
Special Tool ......................................................2B-17
Rear Suspension ..................................... 2C-1
Repair Instructions ..............................................2C-1
Rear Shock Absorber Components ....................2C-1
Cushion Rod / Cushion Lever Components........2C-2
Swingarm Components.......................................2C-3
Rear Suspension Assembly Construction...........2C-4
Rear Shock Absorber Removal and
Installation.........................................................2C-5
Rear Shock Absorber Disassembly ....................2C-6
Rear Shock Absorber Assembly .........................2C-8
Rear Suspension Inspection .............................2C-10
Rear Shock Absorber Inspection ......................2C-10
Rear Suspension Oil Replacement...................2C-11
Rear Suspension Adjustment ...........................2C-14
Cushion Lever Removal and Installation...........2C-15
Cushion Lever Inspection .................................2C-16
Cushion Lever Bearing Removal and
Installation.......................................................2C-17
Cushion Rod Removal and Installation.............2C-18
Cushion Rod Inspection....................................2C-18
Cushion Rod Bearing Removal and
Installation.......................................................2C-19
Swingarm Removal and Installation..................2C-20
Swingarm Related Parts Inspection..................2C-23
Swingarm Bearing Removal and Installation ....2C-24
Specifications.....................................................2C-25
Service Data......................................................2C-25
Tightening Torque Specifications......................2C-25
Special Tools and Equipment...........................2C-26
Recommended Service Material.......................2C-26
Special Tool ......................................................2C-26
Wheels and Tires.....................................2D-1
Precautions...........................................................2D-1
Precautions for Wheel and Tire...........................2D-1
Repair Instructions ..............................................2D-2
Front Wheel Components ...................................2D-2
Front Wheel Assembly Construction...................2D-3
Front Wheel Assembly Removal and
Installation.........................................................2D-3
Front Wheel Related Parts Inspection ................2D-5
Front Wheel Dust Seal / Bearing Removal
and Installation..................................................2D-6
Rear Wheel Components....................................2D-9
Rear Wheel Assembly Construction .................2D-10
Rear Wheel Spoke Construction.......................2D-11
Rear Wheel Assembly Removal and
Installation.......................................................2D-11
Rear Wheel Related Parts Inspection...............2D-12
Rear Wheel Dust Seal / Bearing Removal and
Installation.......................................................2D-13
Specifications.....................................................2D-15
Service Data......................................................2D-15
Tightening Torque Specifications......................2D-16
Special Tools and Equipment...........................2D-16
Recommended Service Material.......................2D-16
Special Tool ......................................................2D-16

Suzuki RMX450Z Specifications

General

Displacement	449cc
Compression Ratio	12.5:1
Fuel System	Fuel injection
Starter	Electric
Transmission	5-speed constant mesh
Final Drive	Chain
Front Suspension	Inverted telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Engine Type	4-stroke, liquid-cooled, DOHC
Bore x Stroke	96.0 mm x 62.1 mm
Front Brakes	Single disc
Rear Brakes	Single disc
Front Tire	80/100-21
Fuel Tank Capacity	6.2 L (1.6 US gal)
Overall Length	2185 mm (86.0 in)
Ground Clearance	325mm
Seat Height	955mm
Wheelbase	1, 480mm