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Suzuki
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RM85
Suzuki RM85 User Manual
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1-
2 GENE
RA
L IN
STRUC
TIONS
LOCATION O
F PARTS
1
Clutch le
ver
2
En
gine sto
p sw
itch
3
Fr
ont
br
ak
e f
lu
id r
es
er
vo
ir
4
Thr
ottle grip
5
Fr
ont
br
ak
e le
ver
6
Fuel t
ank c
ap
7
Fuel v
a
lve
8
Car
bureto
r sta
rter kn
ob
9
G
ea
rs
h
if
t
le
v
er
0
Rear
brak
e fl
uid res
ervoi
r
A
Rear susp
ension compre
ssion
damp
ing ad
jus
ter
B
Kick start
er leve
r
C
Front sus
pension compressio
n
damp
ing ad
jus
ter
D
Fro
nt su
spensi
on re
bound
damp
ing ad
jus
ter
E
Rear
brak
e ped
al
F
Rear
suspe
nsi
on reb
oun
d
damp
ing ad
jus
ter
12
14
Table of Contents
General Instructions 1
12
Serial Number Location
5
Replacement Parts
7
Table of Contents
12
General Instructions
13
Location of Parts
13
Fuel and Oil Recommendation
14
Intructing Young Rider
15
This Is Important Advice to a Parent
15
Starting Engine
16
Starting off
18
Braking
18
Stopping Engine
19
Break-In (Running-In)
19
Periodic Maintenance 2
20
Periodic Maintenance
21
Periodic Maintenance Chart
22
Spark Plug
23
Air Cleaner
24
Transmission Oil
25
Transmission Oil Level Inspection/Replenishment
26
Transmission Oil Change
26
Engine Coolant
27
Engine Coolant Replenishment
28
Clutch Cable
28
Fuel Hose
29
Throttle Cable
29
Fuel Valve
30
Cylinder Head, Cylinder and Piston
31
Exhaust Valve
31
Drive Chain and Sprockets
32
Drive Chain Adjustment
33
Drive Chain Lubrication
33
Exhaust Silencer
32
Drive Chain Slack
32
Drive Chain Guide, Buffer, Tensioner Roller
34
Brakes
35
Brake Fluid Level
35
Brake Pad
35
Front Fork
36
Rear Suspension
37
Wheels and Tires
37
Steering
38
Lubrication
39
Tightening Torque
40
Troubleshooting
42
Troubleshooting
43
Machine Tuning
48
Carburetor Tuning
49
Carburetor Specifications
49
Carburetor Components/Functions
49
Principles of Carburetor Tuning
49
Carburetor Tuning in Practice
52
Judging Air/Fuel Mixture
53
Main/Slow Jet/Jet Needle Parts
53
Tuning Procedure
54
Front Fork Tuning
55
Front Fork
55
Front Fork Spring Replacement and Oil Level Adjustment
56
Rear Suspension Tuning
60
Rear Suspension
60
Suspension Balance
63
Balance Test
63
Balancing Tips
63
Engine Removal and Installation
64
Engine Removal and Installation
65
Cylinder, Piston and Exhaust Valve
70
Construction
71
Cylinder, Piston and Exhaust Valve
71
Engine Top End
72
Cylinder Head Removal
72
Cylinder Removal
72
Piston Removal
73
Exhaust Valve Removal
73
Cylinder Head Inspection
74
Cylinder Inspection
74
Piston and Piston Ring Inspection
75
Exhaust Valve Inspection
76
Conrod Inspection
77
Piston Ring and Piston Reassembly
77
Exhaust Valve Reassembly
77
Cylinder Reassembly
79
Exhaust Valve Governor Removal and Disassembly
81
Exhaust Valve Governor Inspection
82
Exhaust Valve Governor Reassembly and Installation
83
Clutch
84
Clutch
85
Construction
85
Clutch Plate Inspection
86
Clutch Plate Removal
86
Clutch Plate Reassembly
87
Clutch Rack and Pinion Inspection
87
Clutch Spring Inspection
87
Clutch Sleeve Hub Removal
88
Clutch Sleeve Hub Inspection
89
Clutch Sleeve Hub Reassembly
89
Kick Starter
92
Construction
93
Kick Starter
93
Removal
94
Inspection
95
Reassembly
95
Gearshifting
98
Construction
99
Gearshift Linkage
99
Removal
100
Gearshift Linkage
100
Inspection
101
Reassembly
101
Transmission and Crankshaft
104
Construction
105
Transmission and Crankshaft
105
Engine Bottom Side
106
Primary Drive Gear Removal
106
Crankcase Separation
106
Transmission Removal
107
Crankshaft Removal
107
Transmission Inspection
107
Crankshaft Inspection
109
Oil Seal Inspection, Removal and Installation
109
Bearing Inspection, Removal and Installation
110
Crankshaft Installation
111
Transmission Reassembly
112
Crankcase Reassembly
113
Primary Driven Gear Reassembly
114
Fuel System
116
Construction
117
Fuel System
117
Carburetor
118
Removal and Disassembly
118
Inspection
120
Reassembly
120
Reed Valve
120
Removal
120
Reassembly
121
Cooling System
122
Construction
123
Cooling System
123
Engine Coolant
124
Engine Coolant Replacement
124
Radiator
124
Radiator Cap Inspection
124
Radiator Removal
125
Cooling System Inspection
125
Radiator Installation
125
Water Pump
126
Water Pump Removal and Inspection
126
Water Pump Reassembly
127
Electrical System
128
Construction
129
Electrical System
129
Electrical Circuit
129
Ignition System
130
Ignition Coil Inspection
131
CDI Unit Inspection
131
Stator Coil Inspection
132
Magneto Rotor and Stator Removal and Reassembly
132
Front and Rear Wheels
134
Construction
135
Front and Rear Wheels
135
Front Wheel
136
Removal
136
Inspection
136
Front Wheel Bearing Removal
137
Front Wheel Bearing Reassembly
137
Front Wheel Installation
137
Rear Wheel
138
Removal
138
Inspection
138
Rear Wheel Bearing Removal
139
Rear Wheel Bearing Reassembly
139
Rear Wheel Installation
139
Disc Plate Replacement
140
Rear Sprocket Replacement
140
Front and Rear Brakes
142
Construction
143
Front and Rear Brakes
143
Brake Fluid
144
Brake Fluid Air Bleeding
144
Brake Fluid Replacement
145
Brake Pad Replacement
145
Brake Disc
146
Brake Disc Inspection
146
Brake Disc Replacement
146
Brake Caliper
147
Front Caliper Removal and Disassembly
147
Rear Caliper Removal and Disassembly
148
Caliper Inspection
149
Caliper Cleaning
150
Front Caliper Reassembly
150
Rear Caliper Reassembly
150
Master Cylinder
151
Front Master Cylinder Removal and Disassembly
151
Rear Master Cylinder Removal and Disassembly
152
Master Cylinder Inspection
153
Master Cylinder Cleaning
153
Front Master Cylinder Reassembly
153
Rear Master Cylinder Reassembly
154
Brake Pedal
155
Brake Pedal Removal and Reassembly
155
Front Fork and Steering
156
Construction
157
Front Fork and Steering
157
Front Fork
158
Removal
158
Disassembly
158
Inspection
160
Reassembly
162
Fork Oil
164
Reinstallation
166
Steering
167
Removal
167
Inspection
168
Bearing Replacement
168
Reassembly
169
Rear Suspension
170
Construction
171
Rear Suspension
171
Rear Shock Absorber
172
Rear Shock Absorber Removal
172
Spring Removal
173
Rear Shock Absorber Inspection
173
Spring Installation
174
Rear Shock Absorber Installation
174
Oil Replacement Procedure
175
Rear Shock Absorber Disassembly and Inspection
178
Rear Shock Absorber Reassembly
179
Rear Shock Absorber Disposal
179
Swingarm
180
Swingarm Removal
180
Swingarm Inspection
181
Bearing Replacement
181
Swingarm Reassembly
182
Rear Suspension Linkage
182
Rear Suspension Linkage Removal
182
Rear Suspension Linkage Inspection
183
Cushion Lever and Cushion Rod Bearing Replacement
183
Rear Suspension Linkage Reassembly
185
Servicing Information
186
Service Data
187
Drive Chain
188
Tire Pressure
190
Special Tools
192
Wire, Cable and Hose Routing
194
Specifications
202
Setting Data
204
5
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Suzuki RM85 Specifications
General
Brand
Suzuki
Model
RM85
Category
Motorcycle
Language
English
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