Suzuki RM85 2002-2012 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Suzuki Model: RM85 Generation Production Years: 2002-2012 👋 Introduction Market Position Category: Competition Motocross Motorcycle Competitive Analysis Competitors: KTM 85 SX, Yamaha YZ85, Honda CR85R,...

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Type: Motorcycle

Vendor:

Sku: 155875

Tags: 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 Motorcycle Motorcycles RM Series RM85 Suzuki

Product variants

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Generation

Production Years:

2002-2012

👋 Introduction

Market Position

Category:

Competition Motocross Motorcycle

Competitive Analysis

Competitors:

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

Key Features

Target Audience:

Junior motocross riders, mechanics, and DIY enthusiasts

📋 Manual Details

Coverage Areas

Years Covered:

2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, troubleshooting, and overhaul

Transmission:

Gearbox disassembly, assembly, inspection, and repair procedures

Suspension:

Front fork and rear shock absorber service, adjustment, and component replacement

Brakes:

Front and rear brake system maintenance, caliper service, and bleeding procedures

Electrical:

Ignition system, lighting, wiring diagrams, and troubleshooting

Cooling System:

Liquid cooling system components, radiator, and water pump service

Fuel System:

Carburetor service, adjustment, and fuel tank maintenance

Frame And Bodywork:

Chassis inspection, handlebars, footpegs, and body panel removal/installation

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, and general upkeep

Troubleshooting:

Diagnostic procedures for common issues, electrical faults, and performance problems

Repair:

Detailed step-by-step repair instructions for all major components

Disassembly Assembly:

Comprehensive guides for taking apart and putting back together vehicle systems

Adjustments:

Carburetor adjustments, clutch adjustments, and other critical settings

Special Tools:

Identification and usage instructions for specialized service tools

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine rebuilds

📊 Manual Specifications

File Format

Quality:

High-resolution, suitable for printing

Print Quality

Printability:

Yes, all pages are printable

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

Requirements

Software Requirement:

Adobe Reader

Os Compatibility:

Windows, Mac, Linux

⚙️ Engine Specifications

Primary Engine

Type:

2-stroke, liquid-cooled

Bore X Stroke:

48.0 mm x 46.8 mm (typical for RM85)

Displacement:

84.7 cc

Performance

Horsepower:

Approximately 20-22 HP (estimated, varies by year and specific tune)

Torque:

Approximate torque figures not readily available but significant for class

Fuel System

Carburetor:

Mikuni VM28SS (typical for this era RM85)

Ignition

System:

Digital CDI

Lubrication

System:

Premix oil/fuel, automatic oil injection (may vary by specific market/tune)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Features

Clutch:

Wet multi-plate

📐 Dimensions

Exterior

Length:

Approximately 1835 mm (typical)

Width:

Approximately 765 mm (typical)

Height:

Approximately 1140 mm (typical)

Weights

Dry Weight:

Approximately 77 kg (typical)

Wheels Tires

Front Tire Size:

70/100-17 (typical)

Rear Tire Size:

80/100-14 (typical)

🛡️ Safety Features

Ratings

Safety Focus:

Designed for motocross competition, emphasizes rider control and chassis stability.

Active Features

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Passive Features

Frame Construction:

High-tensile steel frame provides a balance of strength and rigidity.

💡 Technology Features

Infotainment

System:

N/A (Competition Motocross Motorcycle)

Driver Assistance

Features:

N/A (Competition Motocross Motorcycle)

🔧 Maintenance

Service Intervals

Oil Change Frequency:

Refer to the manual's periodic maintenance chart; typically after every few riding hours for off-road use.

Fluid Specifications

Engine Oil:

Suzuki recommends specific 2-stroke premix oils; consult manual for precise specifications and ratios.

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors; refer to manual for specific type and mixture.

Transmission Oil:

Refer to the manual for the specific Suzuki gear oil recommendation (e.g., SAE 80 API GL-4).

Known Issues

Common Wear Items:

Piston, piston rings, clutch plates, and air filter are common wear items requiring regular inspection and replacement.

Carburetor Tuning:

Carburetor tuning can be sensitive to altitude and temperature changes; requires careful adjustment.

Preventative Maintenance

Air Filter Cleaning:

Crucial to keep the air filter clean and properly oiled to prevent engine damage.

Chain And Sprockets:

Regular cleaning, lubrication, and tension adjustment are vital for drivetrain longevity.

Torque Specifications

Importance:

The manual provides critical torque specifications for all fasteners to ensure proper assembly and prevent component failure.

📚 Vehicle History

Brand Heritage

Suzuki Legacy:

Suzuki has a strong heritage in motocross, with successful models like the RM series dating back decades.

Model Evolution

Rm85 Development:

The RM85 succeeded the popular RM80, offering updated styling, improved performance, and a more competitive chassis.

Production

Manufacturing Location:

Primarily Japan (Suzuki Motor Corporation)

🏆 Awards & Recognition

Recognitions

Model Accolades:

The RM85 has consistently been praised by enthusiasts and media for its performance and handling in its class.