Segment:
Entry-level to intermediate motocross/off-road racing motorcycle.
Competitors:
Primarily competed against models like the Kawasaki KX85, Yamaha YZ85, and Honda CR85/CR85R during its production years.
Bike Features:
Lightweight, powerful 2-stroke engine, agile handling, designed for competitive junior motocross racing. RM85L variant features larger wheels for taller riders or different track conditions.
Value:
An essential resource for owners and mechanics to maintain, repair, and optimize the performance of their Suzuki RM85/RM85L. Empowers DIY repairs, saving costs and ensuring proper upkeep.
Coverage Summary:
Comprehensive repair, service, restoration, maintenance, and troubleshooting for Suzuki RM85 and RM85L 'Big Wheel' models from 2002-2004.
Specific Systems Covered:
Engine, Transmission, Chassis, Suspension (Front Forks & Rear Swingarm), Brakes, Fuel System (Carburetor), Electrical System (Ignition, Lighting), Lubrication, Cooling System, Bodywork, Drive Train.
Manual Type:
Service Repair Manual / Workshop Manual / Factory Manual
Format:
PDF (Downloadable)
Engine Mechanical:
Engine overhaul, cylinder, piston, crankshaft, connecting rod, carburetor (pilot jet, main jet, mixture screw, idle), valve clearance (if applicable, though typically not on 2-strokes of this era, but covers related components like reeds), lubrication, cooling system, exhaust, intake.
Transmission Drivetrain:
Gearbox, gears, clutch, drive shaft, primary reduction gear, kickstart mechanism, gearshift operation.
Suspension Steering:
Front forks (oil level, seals, springs), rear shock absorber, swingarm, linkage, triple trees, steering system, handling adjustments.
Brakes:
Front and rear brake systems (hydraulic), pads, discs, calipers, fluid specifications, bleeding procedures.
Electrical Ignition:
Ignition system (magneto, coil, spark plug), charging system, battery, lighting, switches, wiring diagrams (likely included), error codes (if applicable).
Fuel System:
Carburetor specifications, adjustments, cleaning, fuel pump (if applicable), fuel tank, fuel lines.
Bodywork Plastics:
Fenders, seat, handle bars, plastics, hull, body panels, muffler, installation, removal.
Maintenance Tasks:
Oil changes, filter replacements, spark plug checks, chain adjustment, brake inspections, lubrication schedule, coolant changes (if applicable).
Troubleshooting Diagnostics:
Step-by-step guides for diagnosing and fixing common problems (e.g., no spark, starting issues, poor performance), error code interpretation.
Repair Rebuild:
Detailed instructions for engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, carburetor rebuilds.
Installation Replacement:
Procedures for installing and replacing various parts and components, from minor electrical parts to major engine assemblies.
Depth Level:
Expert-level, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic adjustments to complete engine disassembly and reassembly.
Illustrations Diagrams:
Illustrated with clear step-by-step instructions, likely including exploded views and schematic diagrams for complex systems.
Compatibility:
Windows, Linux, Mac OS (requires PDF reader)
Access Method:
Instant Digital Download
Compression:
May be zipped (.zip, .rar) requiring unzipping software (e.g., WinZip, WinRAR)
File Size:
Can be large, up to 5 GB (user advised to check storage space)
Print Capability:
Printable on any computer and printer
Text Searchability:
Likely contains searchable text for quick information retrieval
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
84.7 cc (approx.)
Bore X Stroke:
43.5 mm x 55.2 mm (typical for this class, specific to RM85)
Compression Ratio:
Approximately 10.5:1 (typical, manual will confirm)
Horsepower:
Approx. 20-25 HP (estimated, actual may vary by year and tuning, manual provides precise figures).
Torque:
Specific torque figures will be detailed in the manual.
Carburetor:
Mikuni VM28SS (common for this model, manual will specify exact type and jetting).
Fuel Type:
Unleaded gasoline
Fuel Mixture:
Pre-mix (gasoline and 2-stroke oil ratio will be specified in the manual).
Engine Oil Type:
Specified 2-stroke premix oil (manual will provide specific viscosity and API classification).
Reed Valve System:
Likely a petal reed valve intake system for improved performance.
Dry Weight:
Approx. 78 kg (172 lbs) for RM85, RM85L may vary slightly due to wheel size.
Wet Weight:
Manual will provide specific wet weight including fluids.
Fuel Capacity:
Approx. 5.2 L (1.4 US gal)
Overall Length:
Specific dimensions will be detailed in the manual.
Overall Width:
Specific dimensions will be detailed in the manual.
Overall Height:
Specific dimensions will be detailed in the manual.
Wheelbase:
Specific wheelbase for RM85 and RM85L variants will be provided in the manual.
Ground Clearance:
Specific ground clearance will be detailed in the manual.
Seat Height:
Specific seat height will be detailed in the manual.
Oil Change Frequency:
Pre-mix oil: constant mixing with fuel. Transmission oil: specified intervals for checks and changes (details in manual).
Spark Plug Maintenance:
Regular checks and replacement as per manual's schedule, crucial for 2-stroke performance.
Air Filter Cleaning:
Frequent cleaning and oiling recommended, especially for off-road use, detailed in manual.
Transmission Oil Type:
Manual will specify recommended SAE viscosity grade and API classification for transmission oil (e.g., SAE 10W-30 API GL-4).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (manual will confirm exact specification).
Coolant Type:
Manual will specify type of coolant (e.g., ethylene glycol-based) and mixture ratio if liquid-cooled.
Common Problems:
Typical for this era and class: carburetor jetting issues, clutch wear, piston ring wear, fork seal leaks, chain and sprocket wear. Manual provides solutions for all.
Preventative Maintenance:
Adhering to the service schedule outlined in the manual is key to preventing common issues and ensuring longevity.
