2004-2007 Suzuki RM-Z450 Service Manual

Diagnostics, repair procedures, and specifications for your 2004-2007 Suzuki RM-Z450. Includes detailed diagrams and part numbers. 99000-20803 is a key part number for thickness gauge.

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Suzuki Bike manual preview - 2004-2007 Suzuki RM-Z450 Service Manual

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Document Details

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Document Number / Seller:
24605 / Richard Robinson
File Size:
30.82 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Bike
Last updated / verified
May 18, 2025

Models Covered & Key Technical Specifications

Advanced Technical Safety Manual: Suzuki RM-Z450 manual, PDF (2004-07) Data-Compendium

Suzuki RM-Z450 (99000-20803) -- 2004-2007. Strategic Collection Folder | Series Digest.

  • Approved System Volume: 30.82 MB is the core file size for optimal transfer speed.
  • Factory Spacing Data: For efficient operation, 15-30C defines the ideal environmental operating range.
  • Primary Wattage Specs: The engine's output is rated at 30.82 MB for comprehensive data delivery.
  • General Cold Start Limits: For sustained performance, the maintenance intervals are specified as annual.
  • Essential Form Factor: The manual structure requires 19 sections for complete coverage logic.
  • Operational Liquid Volume: Engine oil capacity supports 1.5 L (1.58 US qt) for standard operation protocol.

Professional Workshop Service Manual & Technical Specifications

Advanced Technical Safety Manual: Suzuki RM-Z450 manual, PDF (2004-07) Data-Compendium

Suzuki RM-Z450 (99000-20803) -- 2004-2007. Suzuki RM-Z450 (2004-2007) Service Digest | Series Folder.

Top of description Service-Nexus System-Path Framework
General Information Engine Components Assembly
Periodic Maintenance Routine Checks Procedures
Troubleshooting Common Issues Solutions
Machine Tuning Carburetor & Ignition Adjustments
Engine Removal & Installation Core Components Procedures

Service sections detail the operation, inspection, and repair of your Suzuki RM-Z450. This manual covers everything from basic maintenance to complex engine overhauls, providing clear instructions and illustrations. It details procedures for the engine, chassis, transmission, fuel system, cooling system, electrical system, and more. Careful examination of the included schematics will enhance understanding.

Hydraulic schematics are included for all major systems, detailing fluid flow and component relationships. Steering component information is provided for proper handling and alignment. Inspection guidelines are provided for all critical parts to ensure longevity. Alignment specifications are included for optimal performance. Reference data is included for all essential measurements and tolerances.

The manual documents torque specifications for critical engine components to ensure proper clamp load consistency.

FAQ

What are the **proper** clearance measurements? keyboard_arrow_down

0.15 mm (0.006 in) is the specified service limit for camshaft journal oil clearance as detailed on page 91.

Specify the **standard** torque specifications. keyboard_arrow_down

10 N·m (1.0 kgf-m, 7.0 lb-ft) is the standard torque for the camshaft journal holder bolt.

What is the **necessary** safety precautions? keyboard_arrow_down

Never run the engine indoors or in a garage; exhaust gas that is colorless and odorless can cause death or severe injury. Only run the engine outdoors where fresh air is available.

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Reviews (5)

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The detailed sections on the engine and electrical system are incredibly helpful. Worth every penny!
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Rated 4 out of 5 stars
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This manual has been a lifesaver for my RM-Z450. The diagrams are clear and the instructions are easy to follow!
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Rated 4 out of 5 stars
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I appreciate the lifetime guarantee for downloads. Makes it much easier to keep my bike in top shape!