CALLING ALL 2018+ Suzuki RMZ 450 OWNERS

MotofactioN
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8/1/2020 9:06pm Edited Date/Time 8/2/2020 8:35am
Or anyone who’s a really good bike mechanic Tongue

I removed my subframe to inspect the inside of my airboot and to remove my shock for some suspension work.

Upon putting my airboot back on, I ran into this problem.

Is this just really really bad design on Suzuki’s part? I don’t understand how I am supposed to get an Allen wrench in there and tighten this to the throttle body.

Anyone else who owns a 2018+ RMZ 450, and have removed your subframe or airboot, how did you tighten the god damn thing? Is it really this much of a pain in the ass to get to? Dizzy

Please help! Sad







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imoto34
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3151st
8/1/2020 9:16pm
Dont own that bike but is the clamp in the same position as when you removed it? Should be able to get the key back to it the same as removed. Some straight ball end Allen's are handy.
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kkawboy14
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8/1/2020 9:19pm
Seems like flipping it the other way gives you a clear shot to it
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Rotaholic
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8/1/2020 10:15pm
Just use the long end of the Allen, I have mine on a t bar. It is fiddly for sure, a wee bit of WD40 on the boot helps it slip over the throttle body.
sf702/410
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8/1/2020 10:37pm Edited Date/Time 8/1/2020 10:48pm
It's easy if you reposition the clamp for accessibility with the Allen key before reinstalling the assembly. Use some long curved nose pliers to reach in there and twist it until you can hit it with a long Allen key. Not bad

I think that's what I did, or maybe just a ball- end Allen key got on it.

The Shop

pdub187
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8/1/2020 11:53pm
Can you rotate the clamp?
wwoberg
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Soddy Daisy, TN US
8/2/2020 4:47am
As others have said, same way you took it off. A little soap, water, and elbow grease wouldn't hurt that dirty airbox while it's off either.
plowboy
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Norwich, KS US
8/2/2020 7:10am
I can't speak to the engineering that went into your Zook but if access to that fastener is the only WTF thing you've come across on your Zook...consider yourself extremely lucky. I build experimental aircraft (the first 2 or 3 prototype units used for proof of concept and FAA type certification). For years I wondered how such intelligent people could be so stupid. Experience has taught me that it's the process not the engineering that leads to things like your access problem.

Usually there are separate teams assigned to each system...think; frame, suspension, motor, controls, etc. The biggest problem occurs where these systems interface. Since each design team is a separate unit vying for budget dollars and facing schedules...they don't interact very well...if at all. In the past, there were INTEGRATION engineers that looked at those areas where one system joined the next. They are rare birds nowadays. The various engineering teams hated them because it exposed design problems which slows things down and costs money. Management hated them for the same reasons plus they had to pay their salaries. Bye bye.

Sorry for the long reply but you askedBlush

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MotofactioN
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8/2/2020 7:25am
pdub187 wrote:
Can you rotate the clamp?
You can’t rotate the clamp. It has a part that keeps it from rotating
MotofactioN
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8/2/2020 7:26am
sf702/410 wrote:
It's easy if you reposition the clamp for accessibility with the Allen key before reinstalling the assembly. Use some long curved nose pliers to reach in...
It's easy if you reposition the clamp for accessibility with the Allen key before reinstalling the assembly. Use some long curved nose pliers to reach in there and twist it until you can hit it with a long Allen key. Not bad

I think that's what I did, or maybe just a ball- end Allen key got on it.
Can’t reposition the clamp. It’s locked in place on the bolt.
MotofactioN
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8/2/2020 7:28am
kkawboy14 wrote:
Seems like flipping it the other way gives you a clear shot to it
You can’t flip it the other way, as the shape of the collar, there is a part that keeps you from doing that
MotofactioN
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8/2/2020 7:35am
And I got it off about 4-5 months ago with a really long Allen wrench at an awkward angle. Can’t find that wrench anymore.

When I went to move the subframe to the side, I guess I didn’t have the clamp super tight so it ended up pulling off.

Ball end hex key seems to be the way though. Gonna go buy a set today! Cool
Jbulz
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8/2/2020 8:26am
Allen socket on an extension? If it's still misaligned use a wobbler extension or u-joint?

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