2015 RM-Z450 - Valenti Racing

2015 RM-Z450 - Valenti Racing
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
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