Suzuki RM85 Full Service & Repair Manual 2009-ONWARDS

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UGS: 148564

Mots clés: 2009 Motorcycle Motorcycles RM Series RM85 Suzuki

Variantes de produits

Description

The Suzuki RM85 is a high-performance mini motocross motorcycle, produced from 2009 onwards, designed for young riders and competitive racing. Available in standard and large wheel variants (RM85L), this model builds upon Suzuki's legacy in off-road racing, offering a potent liquid-cooled, 2-stroke engine with reed valve and case-reed induction. Its engineering emphasizes agility, power, and durability, featuring a rigid steel semi-double cradle frame, hydraulic disc brakes, and a 6-speed transmission with a wet multi-plate clutch. The RM85 is recognized for its class-leading performance, competing directly with models like the Kawasaki KX85, Yamaha YZ85, and KTM 85 SX. This comprehensive factory service and repair workshop manual provides detailed, professional-grade information for the Suzuki RM85. It covers all aspects of maintenance, troubleshooting, and repair, from basic servicing and fluid changes to complete engine and suspension rebuilds. The manual includes step-by-step instructions, detailed diagrams, and technical specifications for engine mechanicals, fuel and ignition systems, cooling, transmission, suspension, brakes, wheels, tires, and the electrical and bodywork systems. This documentation empowers owners and technicians to effectively maintain and repair the motorcycle, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Year:

2009 onwards

Codes

Model Code:

RM85L (Large Wheel), RM85 (Standard Wheel)

Chassis Codes:

RM85K9, RM85L0, RM85L1, etc. (Year specific)

👋 Introduction

Market Position

Segment:

Performance Mini Motocross Motorcycle

Competitive Analysis

Competitors:

Kawasaki KX85, Yamaha YZ85, KTM 85 SX

Key Features

Manual Value:

Provides professional-grade repair and maintenance information, empowering owners and technicians.

Coverage Scope:

Covers all aspects of repair, servicing, and troubleshooting for the specified model years.

Documentation Quality:

Includes detailed photos, diagrams, and step-by-step instructions, mirroring factory technician manuals.

Licensing:

Lifetime use, no additional fees or subscription requirements.

📋 Manual Details

Coverage Areas

Market Coverage:

Global (assumed based on professional mechanic use)

Page Count

Estimated Pages:

Hundreds (as stated in description)

Manual Type

Type:

Factory Service & Repair Workshop Manual

Language

Language:

English (implied by product description)

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the engine.

Fuel System:

Carburetor tuning, cleaning, rebuilding, fuel tank, fuel lines, and petcock.

Ignition System:

CDI unit, spark plug, ignition coil, and wiring.

Cooling System:

Liquid cooling system, radiator, water pump, coolant hoses, and thermostat.

Exhaust System:

Exhaust pipe, silencer, and packing replacement.

Transmission Drivetrain:

Clutch operation, gear shifting mechanism, and gear lubrication.

Suspension Front:

Front fork service (oil change, seal replacement, adjustment), steering stem bearing service.

Suspension Rear:

Rear shock absorber service, linkage maintenance, swingarm bearing service.

Brakes Front:

Brake caliper service, master cylinder overhaul, brake pad replacement, brake disc inspection.

Brakes Rear:

Rear brake mechanism service, brake pedal, and linkage adjustment.

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure, and mounting.

Electrical System:

Wiring diagrams, lighting, battery maintenance, troubleshooting electrical faults.

Bodywork Chassis:

Plastic panel removal and installation, seat, fuel tank, handlebars, and footpegs.

Procedures Included

Maintenance:

Regular servicing, lubrication, filter changes, adjustments.

Troubleshooting:

Diagnostic procedures for common problems and performance issues.

Repair:

Step-by-step instructions for component repair and replacement.

Rebuilds:

Complete engine and suspension component rebuilds.

Adjustments:

Carburetor jetting, clutch lever, throttle cable, and suspension settings.

Technical Depth

Depth:

Comprehensive, from basic maintenance to advanced engine and chassis overhauls.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Yes, individual pages or the entire manual can be printed.

Binding Type

Digital Access:

Unlimited device usage, no expiry.

Paper Type

Digital Compatibility:

Compatible with Windows and MAC computers, tablets, and smartphones.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, Reed valve, Case-reed induction

Displacement:

84.7 cc

Bore X Stroke:

48.0 mm x 46.6 mm

Compression Ratio:

9.5:1 (typical)

Performance

Horsepower:

Approximately 21-22 HP (estimated, varies by tuning)

Torque:

Approximately 10-11 lb-ft (estimated)

Fuel System

Carburetor:

Mikuni VM28

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Oil Mixture:

50:1 (2-stroke oil)

Ignition System

Ignition:

Digital CDI

Cooling System

Cooling:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Features

Clutch:

Wet multi-plate, cable-actuated

Final Drive:

Chain drive (RK 428, 114 links typical)

Transmission Oil Capacity:

Approx. 650-700 ml

Transmission Oil Specification:

API GL-4, SAE 80W/90 gear oil (check manual for exact spec)

📐 Dimensions

Exterior

Overall Length:

Approx. 1850 mm (Standard), 1905 mm (Large Wheel)

Overall Width:

Approx. 765 mm

Overall Height:

Approx. 1180 mm

Wheelbase:

Approx. 1275 mm (Standard), 1315 mm (Large Wheel)

Ground Clearance:

Approx. 320 mm

Seat Height:

Approx. 845 mm (Standard), 870 mm (Large Wheel)

Weights

Dry Weight:

Approx. 75 kg

Curb Weight:

Not specified, but typically higher than dry weight

Fuel Tank Capacity:

5.0 Liters (1.3 US gal)

Wheels Tires

Front Tire Size:

70/100-17 (Standard), 70/100-19 (Large Wheel)

Rear Tire Size:

90/100-14 (Standard), 90/100-16 (Large Wheel)

Front Wheel Type:

Spoked

Rear Wheel Type:

Spoked

🛡️ Safety Features

Ratings

Safety Features:

As a motocross bike, safety features are minimal, focusing on rider control and mechanical reliability.

Active Features

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Passive Features

Frame Construction:

Rigid steel semi-double cradle frame designed for off-road durability and handling.

💡 Technology Features

Infotainment

Features:

Not applicable to this model; a pure motocross machine.

Driver Assistance

Features:

Not applicable to this model.

Connectivity

Features:

Not applicable to this model.

🔧 Maintenance

Service Intervals

Oil Change Transmission:

Every 10-15 hours of riding or annually.

Air Filter Cleaning:

After every few rides or as needed based on conditions.

Spark Plug Replacement:

Every 20-30 hours of riding or as needed.

Top End Rebuild:

Every 30-50 hours of riding (piston, rings, cylinder inspection/replacement).

Fluid Specifications

2 Stroke Oil:

High-quality 2-stroke premix oil, 50:1 ratio recommended.

Coolant:

Mixture of ethylene glycol-based coolant and distilled water (50/50).

Fork Oil:

Specific weight and viscosity fork oil (e.g., Showa SS-01 or equivalent, check manual for exact type and quantity).

Known Issues

Clutch Wear:

Clutch plates can wear relatively quickly with aggressive riding, requiring periodic replacement.

Suspension Seals:

Front fork seals can sometimes leak, requiring replacement.

Carburetor Jetting:

May require adjustment based on altitude, temperature, and modifications.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation

Model Evolution

Predecessor:

Suzuki RM80

Key Updates:

The RM85 represents a significant upgrade from the RM80, featuring a larger engine, improved chassis, liquid cooling, and modern motocross technology.

Production

Production Start Year:

🏆 Awards & Recognition

Recognitions

Industry Standing:

The RM85 is consistently recognized as a top-tier entry in the 85cc motocross class for its performance and handling.