CALLING ALL 2018+ Suzuki RMZ 450 OWNERS

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8/1/2020 9:06 PM

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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8/1/2020 9:16 PM

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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8/1/2020 9:19 PM

Seems like flipping it the other way gives you a clear shot to it

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8/1/2020 10:15 PM

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.

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8/1/2020 10:37 PM
Edited Date/Time: 8/1/2020 10:48 PM

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.

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8/1/2020 11:37 PM

How did you get in there to loosen it off if you can't get in there to tighten it?

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8/1/2020 11:53 PM

Can you rotate the clamp?

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8/2/2020 4:47 AM

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.

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8/2/2020 7:10 AM

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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If it ain't yer's don't take it, If it ain't the truth dont say it, If it ain't right don't do it...Marcus Aurelius

8/2/2020 7:25 AM

pdub187 wrote:

Can you rotate the clamp?

You can’t rotate the clamp. It has a part that keeps it from rotating

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8/2/2020 7:26 AM

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 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.

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8/2/2020 7:28 AM

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

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8/2/2020 7:35 AM

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

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8/2/2020 8:26 AM

Allen socket on an extension? If it's still misaligned use a wobbler extension or u-joint?

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8/2/2020 8:34 AM
Edited Date/Time: 8/2/2020 8:35 AM

Thisusernameisavailable wrote:

How did you get in there to loosen it off if you can't get in there to tighten it?


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