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Suzuki RM85/LK5 User Manual

Suzuki RM85/LK5
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K5
July ’04 Printed in Japan (TK) 02
99505-01095-01E
FOREWORD
This motorcycle has been designed and produced utilizing Suzuki’s most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this set-up manual carefully before performing any work. Take special
care to properly perform the required assembly and servicing marked by either a
Warning or a Caution. Failure to follow the directions in either of these two (2) cate-
gories could lead to serious problems. #and areas are
denoted to emphasize certain areas and carry the following meanings:
#
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.
Question and Answer IconNeed help?

Do you have a question about the Suzuki RM85/LK5 and is the answer not in the manual?

Suzuki RM85/LK5 Specifications

General IconGeneral
Displacement84.7 cc
LubricationPremix
IgnitionCDI
Final DriveChain
Front BrakesSingle hydraulic disc
Rear BrakesSingle hydraulic disc
Front Tire70/100-17
Rear Tire90/100-14
Fuel Tank Capacity5.0 L
Overall Width740 mm
Engine Type2-stroke, single-cylinder
Bore x Stroke48.0 mm x 46.8 mm
Fuel SystemCarburetor
Transmission6-speed
Front SuspensionInverted fork
Rear SuspensionMonoshock
Ground Clearance330 mm
Seat Height850 mm

Summary

Foreword and Safety Information

Warning Definition

Indicates a potential hazard that could result in death or injury.

Caution Definition

Indicates a potential hazard that could result in motorcycle damage.

Location of Motorcycle Parts

Front Brake Master Cylinder Positioning

Keep position of front brake master cylinder with caps upward.

Spare Parts Identification

Dismounted Parts Identification

Identifies parts dismounted from motorcycle.

Motorcycle Assembly Procedures

Removing the Handlebar Bracket

Remove the bracket from the handlebar mounting position.

Handlebars and Throttle Assembly Installation

Install the throttle assembly onto the handlebars.

Handlebar Clamp Bolt Tightening

Tighten handlebar clamp bolts to the specified torque.

Front Fork Installation

Install the front fork assembly with front brake caliper.

Front Fork Bracket Bolt Tightening

Tighten front fork bracket bolts to specified torque.

Front Brake Master Cylinder Installation

Install the front brake master cylinder onto handlebars.

Master Cylinder Holder Installation

Install the holder according to the mark "UP".

Brake Fluid Leakage Check

Check for brake fluid leakage after installation.

Front Fender Mounting

Install the front fender with mounting parts.

Brake Disc Cleaning

Clean front and rear brake disc plates.

Front Wheel Assembly Mounting

Mount the front wheel assembly properly.

Disc Plate and Spacer Installation

Insert disc plate and attach spacers to wheel hub.

Front Axle Installation and Cotter Pin

Install front axle and cotter pin correctly.

Stand Installation

Insert the boss of stand to the hole of frame.

Front Fork Protector Mounting

Install front fork protector to the front fork.

Brake Hose Clip Installation

Install brake hose clip to the front fork protector.

Front Brake Hose Guide Installation

Install guide to the front fork lower bracket.

Throttle Operation Check

Check throttle operates freely and closes automatically.

Clutch Cable Routing

Pass clutch cable through lever cover.

Clutch Cable Adjustment and Greasing

Adjust clutch cable and grease cable end.

Engine Stop Switch Installation

Install engine stop switch to left of handlebars.

Clamping Engine Stop Switch Wiring

Clamp wiring harness with straps.

Clamping Throttle Cable

Clamp throttle cable to handlebar bridge pipe.

Front Number Plate Installation

Insert front number plate to boss of front fork lower bracket.

Cable and Hose Routing Warning

Route brake hose and cables correctly.

Rear Fender Mounting

Insert rear fender into boss of frame.

Rear Fender Tightening

Securely tighten the rear fender nuts.

Frame Cover Installation

Install frame cover to the frame.

Seat Assembly Installation

Fix seat assembly to rear part of frame cover.

Radiator Louver Installation

Install radiator louver as shown in the photograph.

Radiator Cover Installation

Install radiator cover with flange bolt and stepped washer.

Fuel Tank Vent Hose Installation

Install fuel tank vent hose, avoid bending or twisting.

Fuel Label Application

Stick the label on the fuel tank.

Servicing Procedures

Brake Fluid Level Check

Check and add brake fluid to reservoirs.

Brake Fluid Handling Caution

Be careful not to spill brake fluid on components.

Brake Air Bleeding Procedure

Bleed air from the brake hydraulic circuit.

Rear Brake Bleeding

Bleed air from the rear brake system.

Front Brake Lever Play Adjustment

Check and adjust front brake lever play.

Throttle Cable Play Adjustment

Check and adjust throttle cable play.

Throttle Operation Warning

Check throttle return and idle speed.

Clutch Lever Play Adjustment

Check and adjust clutch lever play.

Rear Brake Pedal Height Adjustment

Check and adjust rear brake pedal height.

Drive Chain Slack Adjustment

Check and adjust drive chain slack.

Rear Axle Nut Tightening

Tighten rear axle nut to specified torque.

Sprocket Alignment Caution

Ensure rear sprocket alignment with engine sprocket.

Master Link Clip Check

Verify master link clip installation.

Front Fork Rebound Damping Adjustment

Adjust the setting of the rebound damping force.

Front Fork Adjuster Screw Warning

Do not force adjuster screw past stopped position.

Front Fork Compression Damping Adjustment

Adjust the setting of the compression damping force.

Front Fork Adjuster Screw Warning (Compression)

Do not force adjuster screw past stopped position.

Front Fork Air Pressure Adjustment

Equalize air pressure in the front forks.

Front Fork Air Pressure Caution

Do not pump air into the front fork.

Rear Suspension Rebound Damping Adjustment

Adjust the setting of the rebound damping force.

Rear Suspension Adjuster Screw Warning

Do not force adjuster screw past stopped position.

Rear Suspension Compression Damping Adjustment

Adjust the setting of the compression damping force.

Rear Suspension Adjuster Screw Warning (Compression)

Do not force adjuster screw past stopped position.

Tire Pressure Check

Check and set cold tire pressure for front and rear.

Transmission Oil Level Check

Check transmission oil level carefully.

Transmission Oil Capacity

Note the transmission oil capacity for refilling.

Engine Coolant Level Check

Check and fill engine coolant level.

Hot Radiator Cap Warning

Do not open radiator cap when engine is hot.

Torque Specifications

Front Fork Torque Specifications

Torque values for front fork mounting bolts.

Axle Torque Specifications

Torque values for axle nuts.

Absorber Torque Specifications

Torque values for rear shock absorber nuts.

Brake Torque Specifications

Torque values for brake caliper and master cylinder bolts.

Other Torque Specifications

Torque value for rear swing arm pivot nut.

Bolt Torque Chart by Diameter

Torque values based on bolt diameter and type.

Cable and Harness Routing

Throttle, Clutch, and Brake Hose Routing

Route throttle, clutch cables and brake hose correctly.

Brake Hose Routing Guidance

Route brake hose in front of number plate.

Engine Stop Switch Lead Wire Routing

Route engine stop switch lead wire under steering head.

Magneto and CDI Unit Wiring Routing

Route magneto and CDI unit wiring correctly.

Safety Check Out and Pre-Delivery Inspection

Engine and Transmission Checks

Check engine and transmission functions.

Chassis Component Checks

Check chassis components and operations.

Electrical System Checks

Check electrical switch operations.

Road Test Inspection

Inspect motorcycle performance during road test.

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