2015 RM-Z450 Technical Presentation Introduction History of RM-Z450 - RM-Z450 was introduced in 2005. Suzuki updated RM-Z450 in 2008, being the first production motocross bike with electronic fuel injection. - RM-Z450 continues to evolve since its introduction, to deliver higher level of performance. Fuel Injection 2005 model 2008 model Showa Separate Function front Fork 2013 model Introduction Racing achievement of RM-Z450 FIM Motocross World Championship Year Country Championship 2007 World MX1 World Motocross Rider Steve Ramon AMA Pro Motocross/Supercross Chmpionship Year Country Championship 2005 USA AMA Motocross Championship 2006 USA AMA Supercross Championship 2006 USA AMA Motocross Championship 2009 USA AMA Motocross Championship 2010 USA AMA Supercross Championship 2010 USA AMA Motocross Championship Rider Ricky Carmichael Ricky Carmichael Ricky Carmichael Chad Reed Ryan Dungey Ryan Dungey National Championship Year Country Championship 2005 Australia Australian Motocross Nationals 2008 New Zealand New Zealand Motocross Championship 2008 New Zealand New Zealand Supercross Championship 2008 Australia Australian Supercross Championship 2009 Germany ADAC MX MASTERS Championship 2010 Japan All Japan Motocross Championship 2010 Germany ADAC MX MASTERS Championship 2012 Germany ADAC MX MASTERS Championship 2013 Australia Australian Motocross Nationals 2013 Australia Australian Supercross Rider Daryl Hurley Daryl Hurley Daryl Hurley Chad Reed Ken Roczen Yoshitaka Atsuta Ken Roczen Marcus Schiffer Matt Moss Matt Moss 1 World title 6 AMA titles 10 National titles Engineering Target 1.Performance upgrade derived from Factory racing activity. 2.Improve engine start. 3.Improve cooling performance. 4.Weight reduction. 5.Meet AMA sound control. Engine design Holeshot Assist Control Improve engine start Improve cooling performance Improve shift feeling Hot starter is eliminated Meet AMA sound control Introducing SUZUKI HOLESHOT ASSIST CONTROL Suzuki Holeshot Assist Control Selectable launch mode system straight from factory race bike. Mode Character Good for condition A Smoother engine response Slippery Novice rider Retard ignition conditions timing (Only in start) B Aggressive engine Good grip skilled rider response conditions Advance ignition timing (Only in start) Normal Standard Off - Good for rider - Mechanism Suzuki Holeshot Assist Control Developed though factory racing activities. James Stewart AMA Supercross Championship Clement Dessalle MX1 World Championship Suzuki Holeshot Assist Control HOW TO OPERATE? Start engine Indicator light turns on: system check. Press hold switch 1 second Indicator light starts flashing, system is in A mode. Press hold switch 2 seconds Light starts flashing faster, system is in B mode. *Pictures shown above are factory race bike, some parts are different from production model. - System can be turned off when you press switch again. - System will be automatically turned off when 3 minutes passed after the system is activated. Suzuki Holeshot Assist Control HOW DOES IT WORK? (A-mode) Gate drop/ Start Light keeps flashing Shift up to 3rd gear Retard ignition timing or 1,2 sec. after start system is turned off. Ignition map returns to normal map. Increased thrust force Reduce chance of wheel spinning Stabilized starting performance Suzuki Holeshot Assist Control HOW DOES IT WORK? (B-mode) Gate drop/ Start Light keeps flashing Shift up to 4th gear Advance ignition timing or Close throttle or 4,5 sec. after start system is turned off. Ignition map returns to normal map. Increased power and response Increased acceleration Stabilized starting performance Suzuki Holeshot Assist Control Logic and Mechanism Control Mode Switch Press S-HAC switch Judge the launch operation Throttle position sensor ECM Change ignition map Ignition coil Gear position sensor Suzuki Holeshot Assist Control Logic and Mechanism Mode A: Retard Ignition Timing Ignition map returns to stock map 1.2 second after start Soften the engine response – Reduce chance of rear wheel spinning. Good for slippery conditions. Good for novice rider/ not good at start. Mode B: Advance Ignition Timing Ignition map returns to stock map at the first deceleration (Close throttle) Heighten the engine response – Increase power and response. Increase acceleration. Good for high-grip road conditions. Good for expert rider/ good at start. Indicator Light The indicator light has multi-function: Fuel injection self diagnosis indicator S-HAC indicator lights Engine run time indicator MX-tuner answer back lights Engine Design Improved Engine Start •New starter idle gear layout •Added breather gear •Revised kick gear ratio •Redesigned de-compressor •Redesigned EX-camshaft •Longer kick start lever •Hot-starter eliminated Improved Engine Start Kick starter /idle gear layout 2015 model 2014 model • Increased kick drive gear. • Kick idle gear is relocated. • Breather gear is added. • Increased efficiency of kick force to rotate crankshaft. Improved Engine Start New de-compressor system • Reduced lever operation angle. • Revised arm acting direction. • Optimized lift timing and amount. • More precise de-compression action. • More efficient movement of the system. Improved Engine Start New kick starter lever Increased kickable radius Easier to kick it down 30mm longer 2014 model 2015 model Improved Engine Start A race bike - straight from factory. RACE FACTORY Improved Cooling Performance Redesigned water pump cover and revised water hose connection. Equalized right/Left radiator water flow Increased water flow by 16%. Directly connected to water pump Improved Shift Feeling Increase precision of gear matching. Smoother shift touch and feeling Power / Torque Curve Torque Power Chassis Design Chassis Design TARGET 1. Weight reduction. 2. More nimble handling. 3. Increase flexibility in cornering. 4. Increase absorption feeling. Chassis Design Yellow highlighted parts are redesigned for 2015 model. Rear suspension Engine mount bracket upper Left Main frame Clutch lever holder Front forks Under bracket Swingarm Engine mount bracket front Rear brake caliper guard Rear brake disc guard Engine protectors Rear brake hose guide Drive chain roller Foot rest right Redesigned Frame Main frame is redesigned and reworked. The weight is reduced by 4%. Optimized balance and rigidity. The rigidity is maintained. Inner rib shapes are changed to optimize rigidity Shapes are changed to optimize rigidity Introducing SFF-Air Front Fork SFF-Air Front Fork 2015 model 2014 model Evolution of SFF system No more coil spring. Reduced weight. Increased inner tube diameter. Increased damper rod/piston size. Take over SFF construction. SFF-Air Front Fork RH fork: Air spring unit LH fork: Damper unit SFF-Air Front Fork Developed through Factory racing activities. James Stewart AMA Supercross Championship Yoshitaka Atsuta All Japan Motocross Championship SFF-Air Front Fork - Benefit Benefit of SFF-Air spring fork Adjustability In case of coil spring, rider need to change soft or hard spring depends on rider’s weight or skill level. With new SFF-Air fork, you don’t have to buy extra spring. You can change spring rate by air pump to find your right setting. Light weight Coil spring - the heaviest part of spring fork – is eliminated. SFF-Air is lighter than SFF type-2 by 1,100g. Stable suspension performance As SFF construction separates spring function and damper function, air spring is free from damper heat influence. That results in stable suspension performance. SFF-Air take over that benefit. SFF-Air Front Fork - LH Damper side Increased piston diameter From 38mm to 39mm Increased rod diameter From 12.5mm to 14mm Damper cartridge Left leg (Damper side) SFF-AIR suspension left leg (damper side) Improvement for L4 model - Increased inner tube diameter - Increased piston size - Increased rod size SFF-Air Front Fork - 3 air chambers SFF-AIR fork has 3 air chambers 1. Inner air chamber producing main air-spring force to stretch the fork 2. Balance air chamber producing air-spring force to shorten the fork 3. Outer air chamber producing sub air-spring force to stretch the fork Outer air chamber Maximum length Compression Inner air chamber Minimum length Balance air chamber At Maximum length (No compression load) At Minimum length (Fully-compressed) Inner air chamber Max. volume Min. volume Balance air chamber Min. volume Max. volume Outer air chamber Max. volume Min. volume SFF-Air Front Fork - 3 air chambers 2015 model 2014 model LH RH Coil spring Air spring RH No balance spring function on 2014 model LH Inner air chamber Outer air chamber Balance air chamber SFF-Air Front Fork - 3 air chambers Inner Air Outer Air Outer tube Piston Balance Air Inner tube SFF-Air Front Fork - 3 air chambers Location of valves for air chambers Inner air chamber Outer air chamber Balance air chamber SFF-Air Front Fork - 3 air chambers Identification mark on the front fork top Mark of inner air chamber Mark of outer air chamber SFF-Air Front Fork Location of air bypass Inner air chamber Inner air bypass Outer air bypass Balance air bypass SFF-Air Front Fork - 3 air chambers Air spring force character is fully adjustable by air pressure setting of the air chambers Inner air chamber: main pressure to determine air-spring force in overall stroke range Outer air chamber: sub pressure when needs harder setting beyond the inner air adjustable range by rider’s preference Balance air chamber: pressure to determine air spring force in initial stroke range STD Adjustable range Inner air chamber (kPa) Outer air chamber (kPa) Balance air chamber (kPa) 1200 0 1200 1000 – 1300 0 – 130 1000 – 1400 SFF-Air Front Fork - Specification RH front fork specification New RM-Z450 L5 Previous RM-Z450 L4 Front fork type SHOWA SFF-AIR SHOWA SFF Inner tube diameter 49 mm 48 mm Damper piston diameter 39 mm 38 mm Damper rod diameter 14 mm 12,5 mm Stock setting, damper side (left) Inner damper Oil level Outer damper Adjustability Damping Compression Stock setting, air-spring side (right) 314 cm³ 320 cm³ 13 clicks 8 clicks Oil level Inner 100 cm³ Outer 250 cm³ Balance Air pressure 10 cm³ Inner 1200 kPa Outer 0 kPa Balance 1200 kPa SFF-Air Front Fork - Air Spring Character Spring force comparison – coil spring vs. air spring Spring force Air spring has more progressive character than coil spring. Suspension stroke SFF-Air Front Fork - Air Pressure Setting Basic adjustment of air-spring force (inner air = balance air) Inner air Outer air Balance air Hard 1300 kPa 0 1300 kPa Standard 1200 kPa 0 1200 kPa Soft 1100 kPa 0 1100 kPa Spring force - Spring force is changed progressively by stroke amount. - Spring force change in initial stroke range is minimal. Suspension stroke SFF-Air Front Fork - Air Pressure Setting Adjust air-spring force in overall stroke range (adjust inner air only) Inner air Outer air Balance air Hard 1300kPa 0 1200kPa Standard 1200kPa 0 1200kPa Soft 1100kPa 0 1200kPa Spring force Spring force is changed hard or soft in overall stroke range. Suspension stroke SFF-Air Front Fork - Air Pressure Setting Adjust air-spring force in initial stroke range (adjust balance air) Inner air Outer air Balance air Hard 1200kPa 0 1100kPa Standard 1200kPa 0 1200kPa Soft 1200kPa 0 1300kPa Spring force Spring force is changed harder or softer in initial stroke range. Suspension stroke SFF-Air Front Fork - 3 Air Pressures Function Air pressure function of 3 air chambers Imagine an injector. SFF-Air Front Fork - 3 Air Pressures Function Plug at both ends. SFF-Air Front Fork - 3 Air Pressures Function A Piston B B “A” and “B” are in the same pressure now. (Atmospheric pressure) Then, imagine that both “A” and “B” are pressurized to 1200 kPa. SFF-Air Front Fork - 3 Air Pressures Function Piston goes up: A “A” volume decreases and the pressure becomes higher. Piston B B “B” volume increases and the pressure becomes lower. SFF-Air Front Fork - 3 Air Pressures Function Piston goes down: “A” volume increases and the pressure becomes lower. A Piston B B “B” volume decreases and the pressure becomes higher. SFF-Air Front Fork - 3 Air Pressures Function Inner Air Chamber A “A” is equivalent to inner air chamber. Piston Balance Air B “B” is equivalent to balance air chamber. B Balance Air Balance Air Chamber SFF-Air Front Fork - 3 Air Pressures Function Inner Air Chamber A “A” pressure force pushes down the piston. Piston Balance Air Chamber B B “B” pressure force pushes up the piston. Under free condition (no external force applied to the piston plunger), the piston comes to the position that “A” and “B” pressures are in balance. SFF-Air Front Fork - 3 Air Pressures Function With balance air pressure “B” AA A A Piston Piston Piston Piston 1200 kPa B B 1200 kPa Without balance air pressure “B” B B Due to existence of push-up force “B”, the piston moves up by less force in the initial stroke. Air spring force Air spring force Stroke Stroke SFF-Air Front Fork - 3 Air Pressures Function Put a cylinder case to cover the injector Inner air Inner Air Outer air Balance Air Balance Air Piston Outer Air Air spring force Balance air SFF-Air Front Fork - Important Points in Service 1. Check air pressure before riding. As well as the tire air pressure, check air pressure of all 3 air chambers before riding. SFF-Air Front Fork - Important Points in Service 2. Use hand-operated air pump for air charge, pressure check and adjustment. Never use a compressor. Instant high air pressure charge can damage the fork parts. Be sure to use a hand-operated air pump. SFF-Air Front Fork - Important Points in Service Recommended spec. of hand-operated air pump: Measuring range : 1000 – 1500 kPa Gauge scale : 50 kPa steps STD Adjustable range Inner air chamber (kPa) Outer air chamber (kPa) Balance air chamber (kPa) 1200 0 1200 1000 1300 0 – 130 1000 – 1400 SFF-Air Front Fork - Important Points in Service When applying pressure to outer air chamber for harder setting (Standard: 0 kPa) Measuring range : max. 350 kPa Gauge scale : 10 kPa steps For precise adjustment of outer air chamber to find the desirable harder setting, a separate gauge with lower scale is recommendable. STD Adjustable range Inner air chamber (kPa) Outer air chamber (kPa) Balance air chamber (kPa) 1200 0 1200 1000 – 1300 0 – 130 1000 – 1400 SFF-Air Front Fork - Important Points in Service Detachable gauge: This type is convenient to use with 2 different gauge scales: SFF-Air Front Fork - Important Points in Service Valve attachment: Screw down type is recommended to minimize air leakage at the moment of releasing the attachment from the valve. SFF-Air Front Fork - Important Points in Service Air adjustment valve: Is useful for quick and exact adjustment to the desirable air pressure. SFF-Air Front Fork - Important Points in Service 3. While air pressure charge, check and adjustment… …front wheel must be lifted from the ground ! SFF-Air Front Fork - Important Points in Service NG Air adjustment while seating SFF-Air Front Fork - Important Points in Service NG Air adjustment while front wheel contacts the ground. SFF-Air Front Fork - Important Points in Service OK Use a stand to lift up the front wheel. SFF-Air Front Fork - Important Points in Service NG OK SFF-Air Front Fork - Important Points in Service 4. Adjust air pressure in the following order: 1 Inner air STD: 1200 kPa 2 Outer air STD: 0 kPa Release air pressure 3 Balance air STD: 1200 kPa SFF-Air Front Fork - Important Points in Service Air adjustment order affects the extruded free length of inner tube. Normal condition Abnormal condition Correct order of air pressure adjustment Incorrect air pressure adjustment order Inner Outer Balance SFF-Air Front Fork - Important Points in Service Piston position changes by air-pressurized order: Now, piston is positioned at the center due to balanced air pressure. Piston 500 kpa 500 kpa Next, adjust air pressure to 1000 kPa in both right and left. Think over if the piston position stays at the center in any pressurized manner ! Piston Adjust to 1000 kpa Adjust to 1000 kpa SFF-Air Front Fork - Important Points in Service 1. Add air only to right side until the pressure is raised to 1000 kPa. Piston will move to left side and stop at the position that the right side pressure is raised to 1000 kPa. PISTON 1000 1000 kpa kpa Add air to 1000kpa 2. Add air only to ｌｅｆｔ side until the pressure is raised to 1000 kPa. PISTON 1000kpa 1000kpa SFF-Air Front Fork - Important Points in Service Make sure to adjust the air pressures in correct order to obtain the correct air spring setting. 1 2 Inner Air Outer Air act to push down the inner tube. 3 Balance Air act to push up the inner tube. SFF-Air Front Fork - Important Points in Service Change fork oil regularly All three air chambers require a specified amount of fork oil. Neglecting the scheduled periodic front fork oil replacement will change oil level in the air chambers. Replace the front fork oil periodically as scheduled. Fork oil of inner air chamber and outer air chamber move to balance air chamber gradually by the repeated front fork strokes during race over time. Front fork oil replacement - After 1st initial break-in - Every 3 races / every 6 hours Fork oil capacity (ml) Inner air chamber 100 Outer air chamber 250 Outer air chamber 10 SFF-Air Front Fork - Important Points in Service When releasing air pressure from the air chambers: Hold the front fork in vertical position, and then release air pressure to press the air valve using the tip of a screwdriver, etc. while placing a rag over the air valves. Otherwise oil may jet out from the air valves and it may stick to your eyes and mouth. Especially in the front fork disassembling, if the front fork is lying on a desk, fork oil stays around the valve area and oil may jet out from the air valve when releasing air pressure. Motorcycle Washing Notice for washing the motorcycle unit Motorcycle Washing On front fork, high pressure washers may damage the oil seal. Water jet may push mud, dust, etc. into the oil seal lip. Other Competitive Features RENTHAL Fat bar EXCEL Aluminum rims Waved brake discs Rich/lean couplers Features Summary Suzuki Holeshot Assist Control Renthal Fat bar SFF AIR suspension Redesigned main frame Rich/Lean couplers Redesigned kick lever Redesigned swingarm Improved engine start Waved brake disc RM-Z450 Spec. Comparison Items L5 Spec. L4 Spec. Throttle Body ID number 28H4 28H4 Idle r/min 2,100 ±50 r/min 2,000 ±50r/min Ignition timing 12°B.T.D.C. at 2100 r/min 12°B.T.D.C. at 2100 r/min Charge coil resistance 1.2 – 2.5 Ω 1.0 – 2.5 Ω Unchanged 0.17 – 0.7 Ω 9 – 14 kΩ 9– 14 kΩ Ignition coil Primary peak voltage 170 V or more 170 V or more Magneto no-load voltage (when engine is cold) 100 V (AC) or more at 5,000 r/min 100 V (AC) or more at 5,000 r/min Regulated voltage 13.5 – 15.0 V at 5,000 r/min 13.5 – 15.0 V at 5,000 r/min Ignition coil resistance Primary Secondary RM-Z450 Spec. Comparison Items L5 Spec. L4 Spec. SUSPENSION Front fork inner tube O.D. 49 mm 48 mm Front fork spring free length Standard 660 mm 660 mm Front fork spring free length Limit 653.5 mm 653.5 mm Front fork spring adjuster (Right front fork) MIN – 6 clicks turn clockwise MIN – 6 clicks turn clockwise Front fork damping force adjuster (Rebound) MAX – 12 clicks turn counterclockwise (Left front fork) MAX – 12 clicks turn counterclockwise (Left front fork) Front fork damping force adjuster (Compression) MAX – 9 clicks turn counterclockwise (Left front fork) MAX – 9 clicks turn counterclockwise (Left front fork) Front fork spring rate 9.8 N/mm (1.00 kgf/mm) (Right front fork) 9.8 N/mm (1.00 kgf/mm) (Right front fork) RM-Z450 Spec. Comparison Items L3 Spec. L4 Spec. Rear shock absorber damping force adjuster (Rebound) MAX – 12 clicks turn counterclockwise MAX – 12 clicks turn counterclockwise Rear shock absorber damping force adjuster (Compression - High speed) MAX – 2 turns counterclockwise. MAX – 2 turns counterclockwise. Rear shock absorber damping force adjuster (Compression - Low speed) MAX – 12 clicks turn counterclockwise MAX – 12 clicks turn counterclockwise Front fork oil type SHOWA SUSPENSION FLUID SS-19 or equivalent SHOWA SUSPENSION FLUID SS-19 or equivalent Front fork oil capacity 310 ml (Left leg) 310 ml (Left leg) Front fork oil capacity 326 ml (Left leg) 326 ml (Left leg) Front fork oil capacity Not applicable Not applicable Front fork oil capacity 350 ml (Right leg) When standard form spring is used 350 ml (Right leg) When standard form spring is used RM-Z450 Spec. Comparison Items L3 Spec. STANDARD Cam Height LIMIT L4 Spec. For USA, CANADA models IN.: 35.18 – 35.23 mm EX.:34.18 – 34.23 mm For USA, CANADA models IN.: 35.18 – 35.23 mm EX.:34.18 – 34.23 mm For EU model IN.: 34.98 – 35.03 mm EX.:34.18 – 34.23 mm For EU model IN.: 34.98 – 35.03 mm EX.:34.18 – 34.23 mm For USA, CANADA models IN.: 34.88 mm EX.: 33.88 mm For USA, CANADA models IN.: 34.88 mm EX.: 33.88 mm For EU model IN.: 34.68 mm EX.: 33.88 mm For EU model IN.: 34.68 mm EX.: 33.88 mm Compression Pressure (Automatic Decomp actuated) 400 kPa (4.0 kgf/cm2) or more Piston Diameter 76.965 – 76.980 mm Measure at 8 mm from the skirt end. RM-Z450 Spec. Comparison Items L3 Spec. L4 Spec. Engine Coolant Type Use an anti-freeze/coolant compatible with aluminum radiator Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. Engine Coolant Capacity Unchanged 950 ml Crankshaft rotation signal sensor resistance Not applicable 0.1 – 0.8 Ω Crankshaft rotation signal sensor peak voltage Not applicable 3.5 V or more CKP sensor resistance Unchanged 80 – 120 Ω CKP sensor peak voltage Unchanged 2.8 V or more Thank you very much for your attention !
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