User Manuals: Suzuki RM85 Youth Motocross Bike

User Manuals: Suzuki RM85 Youth Motocross Bike

Manuals and User Guides for Suzuki RM85 Youth Motocross Bike. We have 1 Suzuki RM85 Youth Motocross Bike manual available for free PDF download: Owner's Service Manual

Suzuki RM85 Owner's Service Manual

Suzuki RM85 Owner's Service Manual (206 pages)

RM85; RM85L Suzuki

Brand: Suzuki | Category: Motorcycle | Size: 9 MB

Table of Contents

General Instructions 1

12
- Serial Number Location
  5
- Replacement Parts
  7
- Table of Contents
  12
- General Instructions
  13
- Location of Parts
  13
- Fuel and Oil Recommendation
  14
- Intructing Young Rider
  15
  - This Is Important Advice to a Parent
    15
  - Starting Engine
    16
  - Starting off
    18
  - Braking
    18
  - Stopping Engine
    19
  - Break-In (Running-In)
    19
Periodic Maintenance 2

20
- Periodic Maintenance
  21
  - Periodic Maintenance Chart
    22
- Spark Plug
  23
- Air Cleaner
  24
- Transmission Oil
  25
  - Transmission Oil Level Inspection/Replenishment
    26
  - Transmission Oil Change
    26
- Engine Coolant
  27
  - Engine Coolant Replenishment
    28
- Clutch Cable
  28
- Fuel Hose
  29
- Throttle Cable
  29
- Fuel Valve
  30
- Cylinder Head, Cylinder and Piston
  31
- Exhaust Valve
  31
- Drive Chain and Sprockets
  32
  - Drive Chain Adjustment
    33
  - Drive Chain Lubrication
    33
- Exhaust Silencer
  32
  - Drive Chain Slack
    32
- Drive Chain Guide, Buffer, Tensioner Roller
  34
- Brakes
  35
  - Brake Fluid Level
    35
  - Brake Pad
    35
- Front Fork
  36
- Rear Suspension
  37
- Wheels and Tires
  37
- Steering
  38
- Lubrication
  39
- Tightening Torque
  40
  - Troubleshooting
    42
  - Troubleshooting
    43
Machine Tuning

48
- Carburetor Tuning
  49
  - Carburetor Specifications
    49
  - Carburetor Components/Functions
    49
  - Principles of Carburetor Tuning
    49
  - Carburetor Tuning in Practice
    52
    
    Judging Air/Fuel Mixture
    53
    
    Main/Slow Jet/Jet Needle Parts
    53
    
    Tuning Procedure
    54
- Front Fork Tuning
  55
  - Front Fork
    55
  - Front Fork Spring Replacement and Oil Level Adjustment
    56
- Rear Suspension Tuning
  60
  - Rear Suspension
    60
- Suspension Balance
  63
  - Balance Test
    63
  - Balancing Tips
    63
    
    Engine Removal and Installation
    64
    
    Engine Removal and Installation
    65
Cylinder, Piston and Exhaust Valve

70
- Construction
  71
  - Cylinder, Piston and Exhaust Valve
    71
- Engine Top End
  72
  - Cylinder Head Removal
    72
  - Cylinder Removal
    72
  - Piston Removal
    73
  - Exhaust Valve Removal
    73
  - Cylinder Head Inspection
    74
  - Cylinder Inspection
    74
  - Piston and Piston Ring Inspection
    75
  - Exhaust Valve Inspection
    76
  - Conrod Inspection
    77
  - Piston Ring and Piston Reassembly
    77
  - Exhaust Valve Reassembly
    77
  - Cylinder Reassembly
    79
  - Exhaust Valve Governor Removal and Disassembly
    81
  - Exhaust Valve Governor Inspection
    82
  - Exhaust Valve Governor Reassembly and Installation
    83
Clutch

84
- Clutch
  85
- Construction
  85
- Clutch Plate Inspection
  86
- Clutch Plate Removal
  86
- Clutch Plate Reassembly
  87
- Clutch Rack and Pinion Inspection
  87
- Clutch Spring Inspection
  87
- Clutch Sleeve Hub Removal
  88
- Clutch Sleeve Hub Inspection
  89
- Clutch Sleeve Hub Reassembly
  89
Kick Starter

92
- Construction
  93
  - Kick Starter
    93
  - Removal
    94
  - Inspection
    95
  - Reassembly
    95
Gearshifting

98
- Construction
  99
  - Gearshift Linkage
    99
  - Removal
    100
  - Gearshift Linkage
    100
  - Inspection
    101
  - Reassembly
    101
Transmission and Crankshaft

104
- Construction
  105
  - Transmission and Crankshaft
    105
- Engine Bottom Side
  106
  - Primary Drive Gear Removal
    106
  - Crankcase Separation
    106
  - Transmission Removal
    107
  - Crankshaft Removal
    107
  - Transmission Inspection
    107
  - Crankshaft Inspection
    109
  - Oil Seal Inspection, Removal and Installation
    109
  - Bearing Inspection, Removal and Installation
    110
  - Crankshaft Installation
    111
  - Transmission Reassembly
    112
  - Crankcase Reassembly
    113
  - Primary Driven Gear Reassembly
    114
Fuel System

116
- Construction
  117
  - Fuel System
    117
- Carburetor
  118
  - Removal and Disassembly
    118
  - Inspection
    120
  - Reassembly
    120
- Reed Valve
  120
  - Removal
    120
  - Reassembly
    121
Cooling System

122
- Construction
  123
  - Cooling System
    123
- Engine Coolant
  124
  - Engine Coolant Replacement
    124
- Radiator
  124
  - Radiator Cap Inspection
    124
  - Radiator Removal
    125
  - Cooling System Inspection
    125
  - Radiator Installation
    125
- Water Pump
  126
  - Water Pump Removal and Inspection
    126
  - Water Pump Reassembly
    127
Electrical System

128
- Construction
  129
  - Electrical System
    129
  - Electrical Circuit
    129
- Ignition System
  130
  - Ignition Coil Inspection
    131
  - CDI Unit Inspection
    131
  - Stator Coil Inspection
    132
  - Magneto Rotor and Stator Removal and Reassembly
    132
Front and Rear Wheels

134
- Construction
  135
  - Front and Rear Wheels
    135
- Front Wheel
  136
  - Removal
    136
  - Inspection
    136
  - Front Wheel Bearing Removal
    137
  - Front Wheel Bearing Reassembly
    137
  - Front Wheel Installation
    137
- Rear Wheel
  138
  - Removal
    138
  - Inspection
    138
  - Rear Wheel Bearing Removal
    139
  - Rear Wheel Bearing Reassembly
    139
  - Rear Wheel Installation
    139
- Disc Plate Replacement
  140
- Rear Sprocket Replacement
  140
Front and Rear Brakes

142
- Construction
  143
  - Front and Rear Brakes
    143
- Brake Fluid
  144
  - Brake Fluid Air Bleeding
    144
  - Brake Fluid Replacement
    145
  - Brake Pad Replacement
    145
- Brake Disc
  146
  - Brake Disc Inspection
    146
  - Brake Disc Replacement
    146
- Brake Caliper
  147
  - Front Caliper Removal and Disassembly
    147
  - Rear Caliper Removal and Disassembly
    148
  - Caliper Inspection
    149
  - Caliper Cleaning
    150
  - Front Caliper Reassembly
    150
  - Rear Caliper Reassembly
    150
- Master Cylinder
  151
- Brake Pedal
  155
  - Brake Pedal Removal and Reassembly
    155
Front Fork and Steering

156
- Construction
  157
  - Front Fork and Steering
    157
- Front Fork
  158
  - Removal
    158
  - Disassembly
    158
  - Inspection
    160
  - Reassembly
    162
  - Fork Oil
    164
  - Reinstallation
    166
- Steering
  167
  - Removal
    167
  - Inspection
    168
  - Bearing Replacement
    168
  - Reassembly
    169
Rear Suspension

170
- Construction
  171
  - Rear Suspension
    171
- Rear Shock Absorber
  172
  - Rear Shock Absorber Removal
    172
  - Spring Removal
    173
  - Rear Shock Absorber Inspection
    173
  - Spring Installation
    174
  - Rear Shock Absorber Installation
    174
  - Oil Replacement Procedure
    175
  - Rear Shock Absorber Disassembly and Inspection
    178
  - Rear Shock Absorber Reassembly
    179
  - Rear Shock Absorber Disposal
    179
- Swingarm
  180
  - Swingarm Removal
    180
  - Swingarm Inspection
    181
  - Bearing Replacement
    181
  - Swingarm Reassembly
    182
- Rear Suspension Linkage
  182
  - Rear Suspension Linkage Removal
    182
  - Rear Suspension Linkage Inspection
    183
  - Cushion Lever and Cushion Rod Bearing Replacement
    183
  - Rear Suspension Linkage Reassembly
    185
  - Servicing Information
    186
  - Service Data
    187
    
    Drive Chain
    188
    
    Tire Pressure
    190
  - Special Tools
    192
  - Wire, Cable and Hose Routing
    194
  - Specifications
    202
  - Setting Data
    204

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