Table of Contents
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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.
K5
99505-01095-01E
July '04 Printed in Japan (TK) 02
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Table of Contents
Related Manuals for Suzuki RM85/LK5
Summary of Contents for Suzuki RM85/LK5
- Page 1 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.
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Page 2: Location Of Parts
LOCATION OF PARTS Carefully remove the various component parts packaged around the motorcycle. Check off each of the components as shown in the photograph. Two complete sets are required for units packed two par crate. 1. Remove the carton, then remove the bolts of the motorcycle holding bracket. 2. - Page 3 Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Number plate Front fender Flange bolt 6 × 20 mm Flange bolt 6 × 20 mm Washer OD:14.0 ID:6.5 Stepped washer OD:16.0 ID:6.5 T:3.5 Radiator louver Stepped washer OD:17.0 ID:6.5 T:7.0 Handlebars assembly Front axle Clamp...
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Page 4: Spare Parts
The photograph shown indicate the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: Throttle assembly Engine stop switch assembly Clutch cable SPARE PARTS Item Part Name Q’ty Cylinder head O-ring No.1 Cylinder head O-ring No.2 Exhaust pipe O-ring Cylinder cover gasket No.1 Cylinder cover gasket No.2... -
Page 5: Removing The Bracket
Before assembling the motorcycle, thoroughly understand the “Safety Check Out” described on page 27. After completion of assembly, carefully check the motorcycle referring to the “Safety Check Out”, then deliver the motorcycle to the customer. ASSEMBLY REMOVING THE BRACKET Remove the bracket from the handlebar mounting position. -
Page 6: Front Fork
Tighten the handlebar clamp bolts to the specified torque. Handlebar clamp bolt: 26 N·m (2.6 kgf-m) NOTE: To install the handlebars correctly, first tighten the bolt A A A A of the front side with specified torque and then tighten the bolt B B B B of the rear FRONT side. - Page 7 FRONT FORK (RM85L) Keep the position of front brake master cylinder with its cap facing upwards until it is installed. Install the front fork assembly with front brake caliper to the left side. Insert each fork leg assembly into the lower and upper brackets.
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Page 8: Front Brake Master Cylinder
The line drawings on page 25 and 26 show the proper routing of the control cables, hose and wirings. Refer to them in addition to following the instructions carefully. A: Clutch cable B: Throttle cable C: Front brake hose D: Engine stop switch wiring harness FRONT BRAKE MASTER CYLINDER Remove the bolts and holder from the front brake mas- ter cylinder. -
Page 9: Front Fender
FRONT FENDER Install the front fender with four sets of mounting parts as shown. Each of the four mounting bolts requires two stepped washers. A: Front fender B: Stepped washer OD:17.0 mm ID:6.5 mm T:7.0 mm C: Stepped washer OD:16.0 mm ID:6.5 mm T:3.5 mm D: 6 ×... - Page 10 Carefully insert the front brake disc plate between the caliper brake pads. A: Pads B: Disc plate LEFT RIGHT Attach the spacers to the front wheel hub as shown in the photographs. NOTE: The large flange side of the spacer faces the hub.
- Page 11 STAND Insert the boss of stand to the hole of frame as shown in the photograph. A: Stand Place the motorcycle on the stand, then remove the hoist hook. LEFT RIGHT FRONT FORK PROTECTOR Install the front fork protector to the front fork. A: Front fork protector B: 6 ×...
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Page 12: Clutch Cable
FRONT BRAKE HOSE GUIDE Pass the front brake hose through the guide. Install the guide to the front fork lower bracket. A: Front brake hose guide B: Front brake hose C: 6 × 20 mm flange bolt D: Front fork lower bracket THROTTLE Install the throttle assembly at correct position. -
Page 13: Engine Stop Switch
Turn the clutch cable adjuster and lock nut in as far as possible and align the slots. Insert the inner cable end into the recess in the clutch lever, then pull on the outer cable housing and insert it into the adjuster. Do not adjust at this time. -
Page 14: Front Number Plate
CLAMP Clamp the engine stop switch wiring harness with har- ness straps. A: Strap L:120 mm B: Engine stop switch wiring harness Clamp the throttle cable to the handlebar bridge pipe. NOTE: The larger diameter side of the cable clamp should be connected to the handlebars. -
Page 15: Rear Fender
Install the front number plate with flange bolt. Pass the strap of the number plate around the handle- bar bridge pipe and through the guide. Route the brake hose in front of the number plate. Route the throttle cable and clutch cable below the number plate mounting boss. - Page 16 LEFT RIGHT Install the rear fender with fitting parts as shown in the photograph. Securely tighten the two nuts I fixed temporarily. A: Rear fender B: 6 × 20 mm flange bolt C: 6 × 30 mm flange bolt D: Washer OD:20.0 mm ID:6.5 mm T:1.2 mm E: 6 mm self-lock nut F: Frame G: Spacer...
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Page 17: Radiator Cover
RADIATOR LOUVER Insert the boss of radiator louver into the hole of radia- tor. Install the radiator louver as shown in the photograph. A: Radiator louver B: Boss C: Hole RADIATOR COVER Install the radiator cover with flange bolt and stepped washer. -
Page 18: Brake Fluid
SERVICING FRONT REAR BRAKE FLUID Keep the motorcycle upright and place the handlebars straight. Check the brake fluid level in both the front and rear master cylinder reservoirs. If the fluid level is below the lower level indicated in the figure, add the correct type of brake fluid. -
Page 19: Front Brake Lever
REAR The procedure to bleed the rear brake is identical to that of the front. A: Bleeder valve FRONT BRAKE LEVER Check the brake lever play. Front brake lever play: 5–20 mm If adjustment is necessary, carry out the procedure below: 1. -
Page 20: Rear Brake Pedal
CLUTCH CABLE Check the clutch lever play at the clutch lever end when the lever is lightly pulled in towards the grip. Clutch lever play: 10–15 mm If adjustment is necessary, carry out the procedure below. 1. Loosen the lock nut E of the clutch lever adjuster. Turn in the adjuster D as far as possible. - Page 21 5. After adjusting, tighten the axle nut to the specified torque. 6. Tighten the lock nuts securely. Rear axle nut: 72 N·m (7.2 kgf-m) 40–50 mm Make sure that the rear sprocket is properly aligned with the engine sprocket. Verify the reference marks on the swing-arm by sighting down along the chain from the rear end of the motorcycle.
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Page 22: Rear Suspension
Compression Damping Force Adjustment Adjust the setting of the compression damping force to the standard position. To adjust, turn the adjuster B clockwise until it stops and then turn it counterclockwise until 7 clicks are felt. Do not force the adjuster screw B B B B past the stopped position or you may damage the adjuster. -
Page 23: Tire Pressure
Compression Damping Force Adjustment Adjust the setting of the compression damping force to the standard position. To adjust, turn the adjuster B clockwise until it stops and then turn it counterclockwise until approximately 3/4 turns are felt and the two punch marks align. Do not force the adjuster screw B B B B past the stopped position or you may damage the adjuster. -
Page 24: Engine Coolant
ENGINE COOLANT Keep the motorcycle upright. Remove the radiator cap and check the coolant level. The engine coolant should be kept filled to bottom of the filler neck. If level is lower than this level, add a 50:50 mixture of engine coolant and distilled water to the correct level. -
Page 25: Tightening Torque
TIGHTENING TORQUE Item Part Name N·m kgf-m Item Part Name N·m kgf-m FRONT FORK AXLE Handlebar clamp bolt Front axle nut Steering stem head nut Rear axle nut Front fork upper bracket bolt ABSORBER Front fork lower bracket bolt Rear shock absorber nut (Upper) BRAKE Rear shock absorber nut (Lower) Front brake caliper mounting bolt... -
Page 26: Cable Routing
CABLE ROUTING Throttle cable Clamp Brake hose Throttle cable Handlebars Clamp Cross the throttle cable and clutch cable above the number plate mounting boss. Clutch cable Brake hose Clutch cable Radiator hose Clamp Throttle cable... -
Page 27: Harness Routing
HARNESS ROUTING Clamp CDI unit Ignition coil Engine stop switch lead wire Engine stop switch lead wire should be passed under the steering stem head. Clamp Cushion Cushion Engine stop switch lead wire Magneto lead wire CDI unit lead wire Magneto lead wire Engine stop switch lead wire Clamp... -
Page 28: Safety Check-Out
SAFETY CHECK OUT COLD INFLATION TIRE PRESSURE FRONT REAR After completion of the setting-up the motorcy- 70–110 kPa 70–110 kPa cle all the following items should be double- 0.7–1.1 kg/cm 0.7–1.1 kg/cm checked to confirm that the operation and func- 10–16 psi 10–16 psi tion of the motorcycle are satisfactory.