2005-2012 Suzuki RM85 RM85L 2-Stroke Motorcycle Repair

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Taper: Motorcycle

Distributeur:

UGS: 149948

Mots clés: 2005 2006 2007 2008 2009 2010 2011 2012 Motorcycle Motorcycles RM Series RM85 RM85L Suzuki

Variantes de produits

Description

The RM85 and RM85L are high-performance, 2-stroke off-road motorcycles designed for youth motocross competition. Produced from 2005 through 2012, these models are engineered to deliver a lightweight, agile, and powerful riding experience, characteristic of a long-standing heritage in motocross racing. Key features include a liquid-cooled, single-cylinder engine with Reed valve induction and an Exhaust Control System for optimized power delivery, paired with a robust 6-speed transmission. The chassis is built for durability and responsive handling, with adjustable suspension components and available in standard (RM85) and large wheel (RM85L) configurations to accommodate different rider sizes. This comprehensive service manual provides detailed guidance for the maintenance, repair, and troubleshooting of the RM85 and RM85L models. It covers all essential systems, including the engine, fuel, lubrication, transmission, steering, suspension, brakes, and electrical components. The manual offers step-by-step procedures for routine maintenance, component disassembly and reassembly, performance tuning, and diagnostic analysis. By consulting this manual, owners and technicians can ensure the optimal performance, reliability, and longevity of their RM85 or RM85L motorcycle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

RM85 / RM85L

Vehicle Type:

Off-road Motorcycle (Motocross)

Engine Type:

2-Stroke

Codes

Vin Code Country:

J (Japan)

👋 Introduction

Market Position

Market Segment:

Youth Motocross / Off-Road Competition

Competitive Analysis

Key Competitors:

KTM 85 SX, Kawasaki KX85, Yamaha YZ85, Honda CR85R

Key Features

Engine Design:

Lightweight, high-revving 2-stroke engine optimized for motocross performance.

Chassis Suspension:

Compact chassis, adjustable suspension components (often with both standard and large wheel versions - RM85L).

Manual Utility:

Provides essential information for owners and mechanics to maintain and repair the RM85/RM85L, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Areas

Covered Years:

2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012

Covered Models:

RM85, RM85L

Page Count

Estimated Page Count:

Estimated 300-500 pages (typical for comprehensive service manuals)

Manual Type

Primary Manual Type:

Repair Manual / Service Manual / Workshop Manual

Secondary Manual Type:

Owner's Manual (implied by product description mentioning routine maintenance)

Language

Language:

English (assumed based on product description and common industry practice for this market)

Format

File Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine disassembly, assembly, inspection, repair, tuning (carburetor, ignition), top-end rebuild, bottom-end rebuild.

Fuel System:

Carburetor (Mikuni VM series), fuel tank, fuel lines, fuel filter maintenance and troubleshooting.

Lubrication Cooling:

2-stroke oil injection system, gearbox lubrication, component lubrication points.

Transmission Drivetrain:

Clutch operation, gearbox overhaul, gear inspection, drive chain adjustment, sprocket replacement.

Steering Suspension:

Handlebar components, steering stem bearings, front forks (oil change, seal replacement, internal components), rear shock absorber (rebuild, adjustment, linkage maintenance).

Brakes:

Front and rear brake systems (hydraulic calipers, master cylinders, brake lines, brake pads, brake fluid specifications and bleeding procedures).

Electrical System:

Ignition system (CDI, spark plug), lighting (if applicable for specific models/regions), wiring diagrams, battery maintenance (if applicable), troubleshooting electrical faults.

Bodywork Chassis:

Frame inspection, seat removal, fuel tank, plastics, fenders, chain guard, skid plate.

Intake Exhaust:

Airbox, air filter maintenance, reed valve inspection, exhaust pipe and silencer cleaning/maintenance.

Procedures Included

Maintenance:

Routine checks, fluid changes, filter cleaning/replacement, chain lubrication, spark plug inspection, carburetor cleaning.

Troubleshooting:

Diagnostic procedures for common problems, identifying symptoms, and root cause analysis.

Repair Rebuild:

Complete engine rebuild, gearbox overhauls, suspension servicing, brake system repairs, carburetor tuning.

Installation Removal:

Engine removal and installation, wheel removal, suspension component replacement.

Technical Depth

Depth:

Comprehensive: Covers routine maintenance through complete engine and component overhauls with detailed procedures and specifications.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High Resolution (suitable for printing)

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

RM85: Likely based on a Suzuki RM85 engine platform (e.g., RP02, RP07 variants depending on year).

Engine Displacement:

84.7 cc

Bore X Stroke:

48.0 mm x 46.8 mm

Compression Ratio:

Approx. 8.4:1 (varies slightly by year/spec)

Engine Layout:

Single-cylinder, Liquid-cooled, 2-stroke

Valvetrain:

Reed valve induction, Suzuki's Exhaust Control System (SECS)

Performance

Horsepower:

Approximately 16-18 hp (at crankshaft, depending on year and specific tuning)

Torque:

Approximately 7-8 lb-ft (at crankshaft)

Fuel System

Carburetor Model:

Mikuni VM28SS

Fuel Type:

Unleaded Gasoline (91 octane or higher recommended)

Fuel Oil Mix:

50:1 ratio (for pre-mix if oil injection system bypassed or for specific applications, otherwise relies on Suzuki P.E.P.S. oil injection)

Lubrication

Transmission Oil Type:

Suzuki Gear Oil SUZ SGO API GL-4 SAE 10W-30 or equivalent

Cooling System

Cooling Method:

Liquid-cooled

Coolant Type:

Suzuki Long Life Antifreeze, Type 550 (50/50 mixture with distilled water)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh manual

Clutch Type:

Wet, multi-plate

Features

Gear Ratios:

Specific ratios would be detailed in the manual, critical for motocross performance.

Final Drive:

Chain drive (520 pitch, specific sprocket teeth count varies)

📐 Dimensions

Exterior

Overall Length:

Approx. 1,785 mm (RM85) / 1,865 mm (RM85L)

Overall Width:

Approx. 735 mm

Overall Height:

Approx. 1,120 mm (RM85) / 1,150 mm (RM85L)

Wheelbase:

Approx. 1,240 mm (RM85) / 1,280 mm (RM85L)

Weights

Dry Weight:

Approx. 71 kg (RM85) / 72 kg (RM85L)

Fuel Tank Capacity:

5.0 liters (1.3 US gal)

Seat Height:

Approx. 850 mm (RM85) / 870 mm (RM85L)

🛡️ Safety Features

Ratings

Safety Standard:

Not rated by NCAP or similar automotive crash safety bodies as it is an off-road competition vehicle.

Active Features

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

Passive Features

Frame Construction:

High-tensile steel frame designed for rigidity and impact resistance.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a competition motorcycle, no infotainment features).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids like ABS or traction control on this model).

Connectivity

Connectivity:

N/A (No Bluetooth or smartphone integration).

Engine Management

Engine Management System:

Basic CDI ignition system with mechanical governor for throttle input and Suzuki Exhaust Control System (SECS) for optimizing power delivery across the RPM range.

🔧 Maintenance

Service Intervals

Oil Change Frequency:

Refer to manual for gearbox oil change intervals (typically every 10-20 hours of riding or annually).

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (every few rides).

Spark Plug Inspection:

Inspect and clean/replace spark plug at regular intervals (e.g., every 15-25 hours).

Top End Rebuild:

Recommended every 40-60 hours of aggressive riding for optimal performance.

Fluid Specifications

Gearbox Oil Capacity:

Approx. 0.75 Liters (refer to manual for exact specification and level check procedure).

Fork Oil Type:

Suzuki Fork Oil SGO #10 or equivalent (viscosity and volume specific to each fork leg, detailed in manual).

Brake Fluid Type:

DOT 3 or DOT 4 Brake Fluid (ensure it's compatible with hydraulic systems).

Known Issues

Common Wear Items:

Clutch plates, piston rings, spark plugs, chain and sprockets, fork seals, wheel bearings.

Carburetor Tuning:

Can be sensitive to altitude and temperature changes, requiring periodic adjustment.

Cooling System:

Regular coolant flushes and inspection of hoses and radiator for leaks are important.

📚 Vehicle History

Brand Heritage

Heritage:

Suzuki has a long and successful history in motocross racing, with the RM series being a staple in competitive dirt biking for decades.

Model Evolution

Rm Series Lineage:

The RM85 is an evolution of Suzuki's smaller displacement motocross bikes, building on the success of models like the RM80 and RM81.

Rm85L Distinction:

The 'L' designation typically indicates a larger wheel configuration (e.g., 19-inch front, 16-inch rear for RM85L vs. 17-inch rear for standard RM85), often aimed at slightly older or taller riders.

Production

Production Period:

The RM85 platform has been in continuous production in various forms since the early 2000s, with this manual covering a specific generation.

🏆 Awards & Recognition

Recognitions

Motocross Reputation:

The RM85 is widely recognized as a competitive and capable entry-level motocross bike for young riders.