Vehicle Segment:
High-performance motocross competition bike.
Key Competitors:
Honda CRF450R, Yamaha YZ450F, Kawasaki KX450F, KTM 450 SX-F.
Model Philosophy:
Designed for competitive motocross racing, emphasizing power, handling, and rider adjustability.
Manual Value Proposition:
Provides essential technical knowledge for owners and technicians to maintain, diagnose, and repair the 2009 Suzuki RM-Z450 efficiently, ensuring peak performance.
Engine Systems:
Complete engine disassembly, assembly, tuning, lubrication system, cooling system, fuel injection system, ignition system, exhaust system, starting system, oil pump.
Transmission Systems:
Clutch operation and adjustment, gearbox inspection and repair, gear shift mechanism, lubrication.
Chassis Systems:
Frame inspection, suspension (front forks, rear shock absorber) overhaul and adjustment, steering system, wheels, bearings, brakes (front and rear calipers, master cylinders, lines), drive chain and sprockets.
Electrical Systems:
Wiring diagrams, lighting, battery, charging system, ignition system components, ECU diagnosis, sensor testing.
Fuel System Details:
Detailed specifications for fuel pump, injectors, throttle body, ECU calibration, and troubleshooting fuel delivery issues.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug service, chain adjustment, brake fluid replacement, coolant flush, air filter cleaning/replacement.
Diagnostic Procedures:
Troubleshooting guides, common fault diagnosis, error code interpretation, component testing procedures.
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul of all major systems.
Troubleshooting Methodology:
Systematic approach to diagnosing problems using diagnostic tools, visual inspections, and component testing.
Depth Of Coverage:
Comprehensive, covering all aspects from basic maintenance to complete engine and chassis rebuilds. Includes detailed torque specifications, clearance measurements, and adjustment procedures.
Torque Specifications:
Extensive list of all critical torque specifications for engine, chassis, and suspension components.
Special Tools:
Identification and usage of specialized tools required for specific maintenance and repair procedures.
Digital Format:
PDF (Portable Document Format)
Searchability:
Searchable text for quick information retrieval.
Printability:
Printable pages for on-the-go referencing.
File Size:
Varies (typically 50-150 MB for comprehensive service manuals)
Image Resolution:
High-resolution diagrams and illustrations for clarity.
Binding:
N/A (Digital Download)
Paper Quality:
N/A (Digital Download)
Engine Type:
Four-stroke, Single-cylinder, Liquid-cooled, DOHC, 4-valve
Displacement:
449 cc (27.4 cu in)
Bore X Stroke:
96.0 mm x 62.1 mm (3.78 in x 2.44 in)
Compression Ratio:
12.0:1
Fuel System:
Fuel Injection (Suzuki's electronic fuel injection system with twin injectors)
Ignition System:
Digital CDI (Capacitor Discharge Ignition) with electronic timing advance
Estimated Horsepower:
Approximately 50-55 HP (at crankshaft, manufacturer estimate)
Estimated Torque:
Approximately 45-50 Nm (at crankshaft, manufacturer estimate)
Oil Type:
SAE 10W-40 motorcycle-specific synthetic oil (refer to manual for exact specification and API rating)
Coolant Type:
High-quality permanent antifreeze coolant (50% mixture with distilled water)
Engine Serial Number Location:
Typically stamped on the crankcase or cylinder block (refer to manual for exact location)
Transmission Type:
5-speed, constant mesh
Clutch Type:
Wet, multi-plate, cable-actuated
Gear Ratios:
Refer to manual for specific gear ratios (e.g., 1st: 2.333, 2nd: 1.867, 3rd: 1.471, 4th: 1.217, 5th: 1.045)
Transmission Oil Type:
SAE 10W-40 motorcycle-specific engine oil (shared with engine lubrication system)
Transmission Features:
Sequential, foot-shift operation
Overall Length:
2185 mm (86.0 in)
Overall Width:
825 mm (32.5 in)
Overall Height:
1265 mm (49.8 in)
Wheelbase:
1485 mm (58.5 in)
Ground Clearance:
335 mm (13.2 in)
Dry Weight:
102 kg (225 lbs)
Wet Weight:
Approximately 113 kg (249 lbs) (with all fluids)
Front Suspension Type:
Showa Separate Function Front Fork (SFF) with adjustable compression and rebound damping
Front Suspension Travel:
310 mm (12.2 in)
Rear Suspension Type:
Linkage type, Showa shock absorber with adjustable preload, compression, and rebound damping
Rear Suspension Travel:
320 mm (12.6 in)
Front Wheel:
21M/C x 1.60
Front Tire:
80/100-21 51M
Wheelbase Bolt Pattern:
N/A (spoked wheels)
Infotainment System:
N/A (Competition motocross bike, no infotainment features).
Rider Aids:
Adjustable suspension, fuel injection tuning couplers (for adjusting engine mapping).
Connectivity Features:
N/A (Competition motocross bike, no connectivity features).
Engine Oil Change Interval:
Every 15-20 hours of riding, or as recommended by the manual based on riding conditions.
Air Filter Cleaning Interval:
Every 5-10 hours of riding, or more frequently in dusty conditions.
Spark Plug Inspection:
Every 10-15 hours of riding.
Chain Adjustment Interval:
Regularly, before each riding session, and every 5-10 hours.
Engine Oil Capacity:
1.7 Liters (1.8 US qt) (with filter replacement)
Coolant Capacity:
Approximately 1.7 Liters (1.8 US qt)
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings, tires. (Detailed inspection and replacement intervals in manual).
Engine Specific Considerations:
Proper engine break-in is critical. Regular valve clearance checks and adjustment are vital for engine longevity and performance.
Suzuki Motorsports Legacy:
Suzuki has a rich heritage in motorcycle racing, including extensive success in motocross and supercross, often reflected in their RM-Z line's performance and technology.
Rmz450 Development:
The RM-Z450 line, introduced in 2005, quickly established itself as a potent motocross machine. The 2009 model featured significant updates, including the Showa SFF front forks and a refined fuel injection system, aimed at improving handling and power delivery.
Manufacturing Location:
Japan
