Chassis Design
Magneto
Since Suzuki engineers focused on a battery-
less fuel injection system, the all-new Suzuki
RM-Z450 is equipped with a single-phase all-
charging system with which the magneto
supplies all of the necessary power. Switching
from carburetion to electronic fuel injection
requires an increased amount of data feedback
for optimal levels of performance. In previous
years, a single-pin magneto did the job.
However, implementing a high tech fuel
delivery system requires an all-new 18-pin
magneto to be designed. The 18-pin magneto
senses feedback on crankshaft position,
rotation speed and stroke which is fed back to
the ECU to calculate optimum injection and
ignition timings.
Electrical Design
Unveiling one of the most exciting motocross
bikes in history, Suzuki engineers went all the
way with an all-new look while effectively
utilizing wind flow dynamics.
Front Number Plate
An air-duct shaping that accentuates the front
number plate design helps guide fresh air to
the radiators for better cooling performance.
Front Fender
The front fender for 2008 incorporates a
sloped-down shape to efficiently guide wind to
the front number plate air ducts for improved
cooling performance.
Rear Fender
Finishing off the design of the all-new RM-
Z450, air intakes are shaped on to both sides
of the rear fender for heighten intake
efficiency while tying in a fresh new look.
Radiator Shrouds and Louvers
New 2-tone molded-plastic radiator shrouds
give the RM-Z450 a slim feel and stylish look
for 2008 while also complimenting an all-new
graphics design and color way. Redesigned
outer louver plates offer better cooling
performance by improving airflow to the
radiators.
Styling Design
Factory Race Team Hard Parts
Gold Chain
Factory gold-colored chain add the finishing
touches to the bike.
Hot Starter
Adding to the factory touches, the hot starter
has been relocated to the right hand side of
the handlebar letting your left hand focus on
operating the clutch in the time of need.
Disc Rotor
Helping the Suzuki RM-Z450 stop, race inspired
wave disc rotors are bolted on the front and
rear hubs. In addition to better cooling
performance, wave disc rotors offer more
efficiency slinging mud compared to traditional
round disc rotors in muddy conditions.
Front disc diameter: 250mm
Rear disc diameter: 240mm
Footrests
Newly designed pegs include increased
clearance between the mounting bracket and
footrest to prevent mud from caking up.
Seat
The gripper seat has been improved this year
by adding projected cross-shaped patterns on
the top surface to provide additional grip.
Frame
An all-new frame design incorporates multiple
changes learned throughout the racing season.
Both tank rails and bracket body were reduced in
size while the lower tube was enlarged to 30mm x
30mm making the RM-Z450 rail corners and blaze
through whoops even faster. Overall frame weight
has been reduced for more agile handling on
various terrains.
Slim Riding Position
The development of the chassis focused on
slimness while opening up the cockpit for
additional room to allow the rider to actively take
control of the machine.
Front Suspension
Inverted twin chamber SHOWA forks handle suspension
needs up front. Various sections within the fork were
modified to reduce weight and improve shock
absorption. Design changes resulted in a better
controlled feel and increased bottoming resistance. Front
suspension modifications include:
Weight Reduction-Reduced wall thickness on upper
bracket, cut-away section between the outer-tube
brackets extended, steering shaft press-fit section
shortened, lower handlebar holder reduced in size,
handlebar holder mounting rubber-section reduced in
size.
Improved shock absorption-Rebound/Compression valve
specifications optimized, main piston side-flow route
expanded, rod pipe diameter widened, separator internal
diameter widened, bush modified.
Improved rigidity-Handlebar holder bracket made of
castings
Rear Suspension
Covering the rear suspension is a
SHOWA piggyback-reservoir shock
that incorporates a newly designed
damper case and modified internal
structure. Design changes resulted in
a better controlled feel and
increased bottoming resistance. Rear
suspension modifications include:
Weight Reduction- Rod neck
shortened and reduced in size,
chamber cap flanges wall thickness
reduced
Better Shock absorption- Damper
case internal diameter's precision
increased, enlarged plug bolt
diameter, rebound/compression
valve specifications and
characteristics optimized
Rear Swingarm
To compliment the RM-Z450 frame, Suzuki
engineers designed a thinner wall thickness
swingarm to reduce weight and improve
terrain-traversing performance over bumps.
Fuel Pump
Enclosed inside a factory aluminum fuel tank,
the KEHIEN fuel pump provides plenty of fuel
pressure to operate the electronic fuel
injection. The body of the fuel pump is
enclosed within a rubber chamber while fuel
is returned from the regulator to the lower
part of the suction filter, creating a stable fuel
supply. Since fuel efficiency has been
increased, tank capacity has been reduced to
6.2 liters (1.6 U.S. Gallons).
Airbox
The airbox is constructed as a separate unit
which is sealed by a lid to prevent air leakage
and improve overall intake efficiency.
Transmission
Over the past years, Suzuki owners and factory
racers voiced concern for a competitive
transmission that would be flexible for both
winning races at the motocross track on
Saturdays and winning desert grand prix's on
Sundays. For 2008, the transmission has
received an extra gear that all riders will
appreciate. There's no question that the 5-speed
offers increased gear ratios for various terrains
and conditions. With a link-type shifting system,
the Suzuki RM-Z450 offers smooth transitions
when clicking thru gears. Whether you're
pounding out laps at the track or counting down
miles on desert loops, the Suzuki RM-Z450 5-
speed transmission has you covered.
Flywheel
Since Suzuki engineers were inside improving
and redesigning internal engine components,
research and development went into
increasing flywheel inertia. The results are a
smoother revving engine which improves the
overall acceleration feel of the RM-Z450.
Cylinder Head (Intake Port and Intake
Cams/Exhaust port, Exhaust Cams and Exhaust
Valves)
In order to fully take advantage of the all new electronic fuel
injection system, Suzuki engineers spent long hours in the dyno
room and the computer lab improving cylinder head air velocity.
The first step was changing the intake cam timing along with
redesigning the intake port angle to reduce intake resistance,
resulting in heightened intake efficiency to produce a linear,
quick response. The second step was to optimize the exhaust
port and cam timing to regulate exhaust pulses. Together
the changes result in maximized engine performance.
Combustion Chamber
While massaging the cylinder head internals,
the combustion chamber shape received
a make over with narrower intake and
exhaust valve angles; moving to 11.5 degrees
on the intake side and 10.0 degrees on
the exhaust side. Along with geometry
changes, side squish areas were increased for
improved air/fuel mixing and faster flame-
propagation speed when the mixture ignites,
resulting in better power output and improved
low-to-mid range response.
Aluminum fuel tank
Redesigned cylinder head
Front forks
Rear suspention
Swingarm
Louver
Hot starter
Footrest
Front brake disc
Rear brake disc
