Suzuki RMX450Z Service Manual

Table of Contents 4- i
4
Section 4
CONTENTS
Brake
Precautions.................................................4-1
Precautions............................................................. 4-1
Precautions for Brake System .............................. 4-1
Brake Fluid Information......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Schematic and Routing Diagram........................4A-1
Front Brake Hose Routing Diagram....................4A-1
Rear Brake Hose Routing Diagram.....................4A-2
Diagnostic Information and Procedures............4A-3
Brake Symptom Diagnosis..................................4A-3
Repair Instructions ..............................................4A-3
Brake Pedal Height Inspection and
Adjustment........................................................4A-3
Brake Fluid Level Check .....................................4A-3
Brake Hose Inspection........................................4A-3
Air Bleeding from Brake Fluid Circuit ..................4A-3
Brake Fluid Replacement....................................4A-5
Front Brake Hose Removal and Installation........4A-7
Rear Brake Hose Removal and Installation........4A-7
Front Brake Master Cylinder Components..........4A-8
Front Brake Master Cylinder Assembly
Removal and Installation...................................4A-9
Front Brake Master Cylinder / Brake Lever
Disassembly and Assembly ............................4A-10
Front Brake Master Cylinder Parts Inspection ..4A-11
Rear Brake Master Cylinder Components ........4A-12
Rear Brake Master Cylinder Assembly
Removal and Installation.................................4A-12
Rear Brake Master Cylinder Disassembly and
Assembly ........................................................4A-13
Rear Brake Master Cylinder Parts Inspection...4A-14
Brake Lever Removal and Installation ..............4A-14
Rear Brake Pedal Construction ........................4A-15
Rear Brake Pedal Removal and Installation .....4A-16
Specifications.....................................................4A-16
Service Data .....................................................4A-16
Tightening Torque Specifications......................4A-17
Special Tools and Equipment...........................4A-17
Recommended Service Material.......................4A-17
Special Tool ......................................................4A-18
Front Brakes ............................................ 4B-1
Repair Instructions ..............................................4B-1
Front Brake Components....................................4B-1
Front Brake Pad Inspection.................................4B-2
Front Brake Pad Replacement............................4B-2
Front Brake Caliper Removal and Installation.....4B-2
Front Brake Caliper Disassembly and
Assembly...........................................................4B-3
Front Brake Caliper Parts Inspection ..................4B-5
Front Brake Disc Removal and Installation.........4B-5
Front Brake Disc Inspection................................4B-6
Specifications.......................................................4B-6
Service Data........................................................4B-6
Tightening Torque Specifications........................4B-7
Special Tools and Equipment.............................4B-7
Recommended Service Material.........................4B-7
Special Tool ........................................................4B-7
Rear Brakes.............................................. 4C-1
Repair Instructions ..............................................4C-1
Rear Brake Components.....................................4C-1
Rear Brake Pad Inspection .................................4C-1
Rear Brake Pad Replacement ............................4C-1
Rear Brake Caliper Removal and Installation .....4C-2
Rear Brake Caliper Disassembly and
Assembly...........................................................4C-3
Rear Brake Caliper Parts Inspection...................4C-4
Rear Brake Disc Removal and Installation..........4C-5
Rear Brake Disc Inspection.................................4C-6
Specifications.......................................................4C-6
Service Data........................................................4C-6
Tightening Torque Specifications........................4C-6
Special Tools and Equipment.............................4C-7
Recommended Service Material.........................4C-7
Special Tool ........................................................4C-7

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