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    Suzuki RM85L 2002-2013 Service Repair Manual

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    $16.99
    This manual covers the RM85L (Large Wheel), a high-performance 85cc two-stroke mini motocross bike produced from 2002 to 2013. Engineered for young riders and aspiring racers, the RM85L features a...
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    Typ: Motorcycle
    Anbieter:
    Suzuki
    Art.-Nr: 89189
    Stichworte: 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 Misc Motorcycle Motorcycles RM85L Suzuki
    This manual covers the RM85L (Large Wheel), a high-performance 85cc two-stroke mini motocross bike produced from 2002 to 2013. Engineered for young riders and aspiring racers, the RM85L features a race-proven perimeter frame, long-travel suspension for superior handling, and a powerful liquid-cooled engine. Its design prioritizes agility and responsiveness, making it a competitive choice in its segment, known for its robust construction and capable performance on the track and off-road. This comprehensive service and repair manual provides detailed guidance for maintaining, diagnosing, and repairing the RM85L. It covers all essential systems, including engine overhaul, transmission and clutch service, fuel and ignition systems, suspension, brakes, and electrical components. With step-by-step procedures, troubleshooting guides, technical specifications, and exploded diagrams, this manual is an indispensable resource for owners, mechanics, and technicians to ensure the RM85L remains in optimal condition and performs at its peak.
    🏷️ Basic Information
    Identification
    Make:
    Suzuki
    Model:
    RM85L
    Model Designation:
    RM85L (Large Wheel)
    Product Type:
    Service Repair Manual
    Codes
    Chassis Code General:
    RM85L
    👋 Introduction
    Market Position
    Segment:
    Mini Motocross / Youth Dirt Bike
    Target Audience:
    Young riders, aspiring motocross racers, and recreational off-road enthusiasts.
    Competitive Analysis
    Key Competitors:
    KTM 85 SX, Yamaha YZ85, Kawasaki KX85, Honda CR85R.
    Key Features Vehicle
    Engine Type:
    High-performance 85cc, liquid-cooled, two-stroke, reed-valve induction.
    Chassis Design:
    Race-proven perimeter frame and long-travel suspension for superior handling.
    Key Features Manual
    Value Proposition:
    Empowers owners and technicians with the knowledge to maintain, diagnose, and repair the RM85L effectively.
    📋 Manual Details
    Coverage Areas
    Applicable Years:
    2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
    Page Count
    Estimated Page Count:
    300-400
    Manual Type
    Manual Type:
    Comprehensive Service & Repair Manual
    Language
    Language:
    English
    Format
    Format:
    PDF Download
    📖 Manual Coverage
    Systems Covered
    Engine Overhaul:
    Complete teardown, inspection, repair, and reassembly of the 85cc two-stroke engine.
    Transmission And Clutch:
    Inspection, adjustment, repair, and replacement of the gearbox, clutch assembly, and related components.
    Fuel System:
    Carburetor disassembly, cleaning, adjustment, and troubleshooting; fuel tank and petcock maintenance.
    Cooling System:
    Maintenance and troubleshooting of the liquid cooling system (if applicable, though RM85 is typically air-cooled).
    Ignition System:
    Spark plug specifications, ignition timing (if adjustable), CDI unit, and related electrical components.
    Exhaust System:
    Inspection, maintenance, and replacement of the exhaust pipe and silencer.
    Frame And Bodywork:
    Inspection, repair, and replacement of the frame, sub-frame, plastics, seat, and fenders.
    Suspension Front:
    Complete fork disassembly, seal replacement, oil level and type specifications, adjustments, and troubleshooting.
    Suspension Rear:
    Monoshock removal, linkage inspection and lubrication, shock absorber service (if applicable), and adjustment procedures.
    Brakes Front:
    Brake caliper maintenance, pad replacement, hydraulic system bleeding, and disc inspection.
    Brakes Rear:
    Brake caliper maintenance, pad replacement, hydraulic system bleeding, and drum/disc inspection.
    Wheels And Tires:
    Tire pressure recommendations, wheel bearing inspection and replacement, spoke tension adjustment, and rim maintenance.
    Electrical System:
    Wiring diagrams, troubleshooting guides for lighting, ignition, and kill switch circuits.
    Procedures Included
    Routine Maintenance:
    Oil changes, filter cleaning/replacement, chain adjustment, spark plug checks, air filter cleaning.
    Troubleshooting Guides:
    Step-by-step diagnostic procedures for common problems (e.g., hard starting, poor running, clutch slipping).
    Disassembly And Assembly:
    Detailed instructions for removing, inspecting, repairing, and reinstalling all major vehicle components.
    Rebuild Procedures:
    Complete engine rebuild, including piston, ring, crankshaft, and bearing replacement.
    Torque Specifications:
    Precise torque values for all critical fasteners to ensure proper assembly and prevent damage.
    Special Tool Requirements:
    Identification of and instructions for using any specialized tools required for specific procedures.
    Technical Depth
    Diagnostic Capabilities:
    Advanced troubleshooting for engine performance issues, electrical faults, and mechanical failures.
    Repair Methodology:
    Detailed repair instructions covering both minor adjustments and complete component overhauls.
    Technical Diagrams:
    Exploded views of all major assemblies for easy identification of parts and their relationships.
    Wiring Diagrams:
    Comprehensive electrical system schematics for accurate diagnosis and repair.
    📊 Manual Specifications
    File Format
    File Format:
    Portable Document Format (PDF)
    Print Quality
    Print Quality:
    High-resolution, suitable for printing individual pages or the entire manual.
    Binding Type
    Binding Type:
    N/A (Digital Download)
    Paper Type
    Paper Type:
    N/A (Digital Download)
    Searchability
    Text Searchability:
    Searchable PDF text allows for quick access to specific topics and keywords.
    Usability
    Navigation:
    Hyperlinked table of contents and cross-references for efficient navigation.
    ⚙️ Engine Specifications
    Primary Engine
    Engine Type:
    84.7cc liquid-cooled 2-stroke, reed valve, TM V-Force reed block.
    Bore X Stroke:
    48.0 mm x 46.8 mm
    Compression Ratio:
    9.7:1 (approx.)
    Cylinder Design:
    Aluminum alloy cylinder with chrome-plated bore.
    Crankshaft Design:
    Balanced crankshaft with roller bearings.
    Performance
    Horsepower Estimated:
    Approx. 25-28 HP (at crankshaft)
    Torque Estimated:
    Approx. 15-17 lb-ft (at crankshaft)
    Fuel System
    Carburetor Model:
    Mikuni VM28SS
    Carburetor Jetting Notes:
    Manual provides detailed jetting tables for various conditions and altitudes.
    Fuel Type:
    Unleaded gasoline with a minimum octane rating of 91 (95 RON).
    Fuel Oil Mixture:
    50:1 ratio using high-quality 2-stroke synthetic oil.
    🔧 Transmission
    Standard
    Transmission Type:
    6-speed constant mesh
    Clutch Type:
    Wet multi-plate
    Features
    Gear Ratios:
    Detailed gear ratios for each of the 6 speeds are specified in the manual.
    Transmission Oil Type:
    Suzuki Gear Oil API GL-4, SAE 80W or equivalent.
    Transmission Oil Capacity:
    Approx. 0.6 Liters (600ml)
    📐 Dimensions
    Exterior
    Overall Length:
    Approx. 1850 mm (72.8 in)
    Overall Width:
    Approx. 765 mm (30.1 in)
    Overall Height:
    Approx. 1175 mm (46.3 in)
    Wheelbase:
    Approx. 1320 mm (52.0 in)
    Ground Clearance:
    Approx. 330 mm (13.0 in)
    Seat Height:
    Approx. 850 mm (33.5 in)
    Weights
    Dry Weight:
    Approx. 76 kg (168 lbs)
    Curb Weight:
    Approx. 82 kg (181 lbs) (with fluids)
    Fuel Tank Capacity:
    4.5 Liters (1.2 US gal)
    🛡️ Safety Features
    Ratings
    Safety Ratings:
    N/A (Off-road vehicle, not subject to street-legal safety ratings)
    Active Features
    Braking System:
    Hydraulic disc brakes front and rear for responsive stopping power.
    Passive Features
    Frame Construction:
    High-tensile steel perimeter frame designed for rigidity and impact resistance.
    💡 Technology Features
    Infotainment
    Infotainment System:
    N/A (Performance-oriented dirt bike)
    Driver Assistance
    Rider Aids:
    N/A (Mechanical, rider-controlled operation)
    Connectivity
    Connectivity Features:
    N/A
    🔧 Maintenance
    Service Intervals
    Engine Oil Change:
    Check and top-up as needed. Full change typically after intensive use or rebuild.
    Air Filter Cleaning:
    Clean after every few rides or more frequently in dusty conditions.
    Chain Lubrication Adjustment:
    Lubricate and adjust tension before every ride or as per manual's recommendation.
    Spark Plug Inspection:
    Inspect every 10-15 hours of riding, replace as needed.
    Fork Oil Change:
    Recommended every 20-30 hours of riding for optimal suspension performance.
    Brake Pad Inspection:
    Inspect regularly for wear and replace as needed.
    Fluid Specifications
    Transmission Oil:
    Suzuki Gear Oil API GL-4, SAE 80W or equivalent.
    Coolant Type:
    High-quality motorcycle coolant (ethylene glycol based) mixed with distilled water.
    Brake Fluid Type:
    DOT 3 or DOT 4 hydraulic brake fluid.
    Known Issues
    Clutch Wear:
    Clutch plates can wear over time with aggressive riding; manual provides replacement procedures.
    Carburetor Fouling:
    Carburetor jets can get clogged due to fuel quality or debris; regular cleaning is advised.
    Suspension Seals:
    Fork seal leaks are common with heavy use; manual details seal replacement.
    Power Valve Adjustment:
    The powervalve system requires periodic inspection and adjustment for optimal performance.
    📚 Vehicle History
    Brand Heritage
    Suzuki Motorcycles:
    Suzuki has a long and successful history in motocross and off-road racing, known for its innovative and competitive machinery.
    Model Evolution
    Rm80 To Rm85:
    The RM85L is an evolution of the popular RM80, featuring an increased engine displacement and chassis refinements, including the larger wheel option for improved stability and performance.
    Production
    Production Period:
    2002-2013 (covered by this manual), with minor updates throughout this period.
    Manufacturing Location:
    Japan (typically)
    🏆 Awards & Recognition
    Recognitions
    Motocross Performance:
    The RM85 platform has historically been a strong competitor in its class, favored by young racers for its performance and handling characteristics.
    Ratings
    Industry Reviews:
    Period reviews often praised the RM85's powerful engine and capable chassis for its competitive class.
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