Market Position:
The Suzuki RM85 is a highly regarded entry-level to intermediate motocross bike, known for its potent 2-stroke engine and competitive chassis, aimed at young riders transitioning to larger machines or experienced riders seeking a nimble, powerful small-displacement MX bike.
Target Audience:
Young motocross racers, aspiring off-road riders, parents maintaining their children's race bikes, and enthusiasts who prefer to perform their own maintenance and repairs.
Competitive Analysis:
Competes directly with models like the Yamaha YZ85, Honda CR85R, and Kawasaki KX85 in the highly competitive 85cc motocross class.
Key Features:
Powerful 2-stroke engine, Showa suspension components, disc brakes front and rear, durable construction, aggressive styling, available in standard and 'Big Wheel' configurations for taller riders or different track conditions.
Years Covered:
2004 (Primary), 2002-2003, 2005-2008 (Compatible)
Page Count:
Not specified, but described as 'COMPLETE SERVICE REPAIR MANUAL' implying extensive detail.
Manual Type:
Service Repair Workshop Manual
Format:
Adobe Acrobat PDF
Systems Covered:
Engine, General Information, Transmission, Chassis, Lighting, Steering, Seats System, Clutch, Suspension, Locks, Brakes, Lubrication, Electrical, Frame, Fuel System, Battery
Engine Overhaul:
Detailed procedures for complete engine disassembly, inspection, component replacement (piston, rings, crank bearings, seals), and reassembly.
Transmission Repair:
Procedures for clutch adjustment and replacement, gear inspection, shifting mechanism repair, and transmission disassembly/reassembly.
Suspension Service:
Guidelines for front fork oil changes, seal replacement, suspension tuning, rear shock inspection and rebuild procedures (if applicable/covered).
Electrical Diagnostics:
Wiring diagrams, troubleshooting steps for ignition system, lighting (if equipped), and other electrical components.
Procedures Included:
Maintenance, Repair, Troubleshooting, Diagnostics, Adjustments, Overhauls, Replacements, Assembly, Disassembly
Troubleshooting Guides:
Systematic approaches to diagnosing common problems such as starting issues, poor running, overheating, and clutch slippage.
Technical Depth:
Comprehensive, covering from basic maintenance to advanced engine and chassis repairs, as used by dealerships.
Torque Specifications:
Critical torque values for all fasteners, ensuring proper assembly and preventing component failure.
Clearances And Tolerances:
Specific measurements for engine components (e.g., piston-to-cylinder wall, ring gap), bearing play, and other critical tolerances.
Searchability:
PDF format typically allows for text search, enabling quick access to specific information.
Print Quality:
High, suitable for printing sections or entire manual.
Printable Pages:
Designed for users to print only the necessary sections, reducing wear on a physical copy and allowing for easy reference at the workbench.
Binding Type:
Not applicable (Digital Download), designed for 3-ring binder printing.
Paper Type:
Not applicable (Digital Download), user chooses paper type for printing.
Engine Displacement:
84.7 cc (4.77 in³)
Engine Bore X Stroke:
48.0 mm x 46.0 mm (1.89 in x 1.81 in)
Engine Compression Ratio:
9.7:1
Engine Cooling:
Liquid-cooled
Engine Induction:
Carburetor
Ignition System:
CDI (Capacitor Discharge Ignition)
Starter System:
Kick starter
Horsepower:
Approximately 20-22 HP (as per typical 85cc motocross bikes of this era, specific figure not in product info).
Torque:
Not specified in product info, but typically strong for its class.
Carburetor Model:
Mikuni VM28SS (typical for this model)
Fuel Type:
Unleaded gasoline, mixed with 2-stroke oil (typically 20:1 or 32:1 ratio depending on oil and manufacturer recommendation).
Fuel Tank Capacity:
5.5 L (1.45 US gal)
Lubrication System:
Premix (2-stroke oil mixed with fuel) and separate oil injection for transmission.
Overall Length:
1,825 mm (71.9 in)
Overall Width:
770 mm (30.3 in)
Overall Height:
1,135 mm (44.7 in)
Wheelbase:
1,240 mm (48.8 in)
Seat Height:
850 mm (33.5 in)
Ground Clearance:
330 mm (13.0 in)
Trail:
Specific value detailed in manual, critical for handling characteristics.
Rake:
Specific value detailed in manual, critical for handling characteristics.
Dry Weight:
75 kg (165.3 lbs)
Front Tire Size:
70/100-17 40M (Big Wheel)
Rear Tire Size:
90/100-14 49M (Big Wheel)
Front Wheel Size:
17-inch
Safety Ratings:
N/A (As an off-road racing motorcycle, it is not subjected to road-vehicle safety ratings like NHTSA or Euro NCAP).
Active Safety Features:
Powerful hydraulic disc brakes front and rear for effective stopping power.
Passive Safety Features:
Robust frame design, handlebars with grips designed to absorb some impact, rider protection relies heavily on rider gear.
Infotainment System:
N/A (This is a pure motocross motorcycle; no infotainment systems are present).
Driver Assistance Features:
N/A (No electronic driver assistance features are present on this model).
Connectivity Features:
N/A (No electronic connectivity features are present).
Service Intervals:
Detailed in the manual. Key items include: checking/cleaning air filter after each ride, changing transmission oil periodically (e.g., every 10-15 hours), spark plug inspection/replacement, top-end rebuild intervals dependent on riding severity (e.g., 30-50 hours).
Transmission Oil Type:
Suzuki explicitly recommends specific gear oil for its transmissions, or SAE 80W API GL-4. The manual will specify the exact Suzuki part number or equivalent.
Coolant Type:
Permanent type antifreeze (ethylene glycol based) mixed with distilled water in a 50:50 ratio.
2 Stroke Oil Mix:
Premium 2-stroke motorcycle oil, typically mixed at 20:1 or 32:1 ratio as per Suzuki's recommendation for the specific oil used. Manual will detail this.
Common Issues:
Common issues for 2-stroke motocross bikes of this era can include: wear on the piston and cylinder (requiring top-end rebuilds), carburetor jetting sensitivity to altitude and temperature, clutch wear, and chain/sprocket wear. Proper maintenance as outlined in the manual is crucial to mitigate these.
Maintenance Tips:
Regular cleaning of the air filter, proper pre-mix ratio, keeping the cooling system clean and at the correct level, and periodic checks of the chain tension and brake pad wear are essential for longevity and performance.
Brand Heritage:
Suzuki has a long and successful history in motorcycle racing, particularly in motocross with its RM and RM-Z series, known for engineering potent 2-stroke and 4-stroke off-road machines.
Model Evolution:
The RM85 replaced the RM80 and was a significant update, introducing a liquid-cooled engine, improved chassis, and a more modern design. It continued Suzuki's tradition of competitive small-bore motocross bikes. The 'Big Wheel' version was introduced to cater to a wider range of rider sizes.
Production Years:
The RM85 model line has been in production since the early 2000s, with the 2004 model being a key iteration of the first generation.
