Suzuki RM85K4 2003 Referenzhandbuch

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTERCYCLE

DATE:

Jun. 1, 2003

PAGE:

SUBUJECT:

NOTICE OF SET-UP MANUAL

APPLICABLE MODEL:

RM85K4/LK4

EFFECTIVE ENGINE OR FRAME NO.:

REFERENCE:

This bulletin is to inform you of set-up procedures of RM85K4/LK4. Please inform your dealers of

this notice.

RM85K4/LK4 set-up manual will not be issued because the set-up procedures for this model

remain unchanged from RM85K2 except the differences described below.

To set-up RM85K4/LK4, please use the RM85K2 set-up manual and this service bulletin.

DIFFERENCE BETWEEN RM85K2 AND RM85K4/LK4

RM85K2 set-up manual: 99505-01032-011

1. LOCATION OF PARTS [Page: 2, 4, 6]

Item Part Name Q’ty Remarks

Number plate 1

Flange bolt 1 6 × 20 mm

Washer 1 OD:14.0 ID:6.5

B Radiator louver 1

Handlebars assembly 1

Clamp 2

Flange bolt 4 8 × 35 mm

Clutch lever cover 1

Fuel tank vent hose 1

Screw 1 5 × 16 mm

For throttle assembly

Clamp 1 For throttle cable

Strap 2 L:120

Engine stop switch holder 2 Upper and lower

Screw (with lock washer) 1 3 × 14 mm

Radiator cover 1

*Flange bolt 36 × 12 mm

Stepped washer 3 OD:16.0 ID:6.5 T:3.5

EFront fork assembly 2 Right and Left

Flange bolt 6 8 × 40 mm

Seat assembly 1

Flange bolt 2 6 × 16 mm

Washer 2 OD:20.0 ID:6.5 T:1.6

Rear fender 1

Washer 2 OD:26.0 ID:6.5

Flange bolt 3 6 × 30 mm

Washer 4 OD:20.0 ID:6.5 T:1.2

*Self-lock nut 26 mm

Flange bolt 1 6 × 20 mm

Washer 2 OD:18.0 ID:6.5 T:1.6

Flange self-lock nut 2 6 mm (Black)

Item Part Name Q’ty Remarks

Front fender 1

Flange bolt 4 6 × 16 mm

Stepped washer 4 OD:16.0 ID:6.5 T:3.5

*Stepped washer 4OD:17.0 ID:6.5 T:6.0

Front axle 1

Front wheel spacer 2

Washer 1 OD:20.0 ID:12.5

Axle nut 1 12 mm

Cotter pin 1 L:27.0

Front brake hose cover 1

Flange bolt 2 6 × 12 mm

*Stepped washer 2OD:16.0 ID:6.5 T:3.5

KFront brake hose clip 2 Right and Left

*Flange bolt 26 × 16 mm

LFront brake hose guide 1

Flange bolt 1 6 × 20 mm

MFront fork protector 2 Right and Left

Flange bolt 6 6 × 10 mm

N Front wheel assembly 1

OFrame cover 2 Right and Left

Strap 2 L:140

*P Side stand assembly 1Spec is eliminated.

Flange bolt 2

Main jet 3 Exchanging parts

Spark plug and spoke

nipple wrench 1

R Fuel label 1

S Owner’s manual 1

*T Stand 1

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTERCYCLE

DATE

: Jun. 1, 2003

PAGE

: 2

2. SPARE PARTS [Page: 2, 4, 6]

3. ASSEMBLY

Part Name Q’ty

Piston pin bearing 1

Piston pin circlip 2

Cylinder head O-ring No.1 2

Cylinder head O-ring No.2 2

Cylinder cover gasket No.1 2

Cylinder cover gasket No.2 1

Cylinder gasket 2

Crankcase gasket 1

Clutch cover gasket 1

Piston complete 1

Piston pin 1

Piston ring 2

Exhaust valve rod bush 2

Exhaust flange O-ring 2

Brake lever 1

Clutch lever 1

FRONT FORK (RM85L) [Page: 9, 10]

Insert each fork leg assembly into the lower and

upper brackets. Adjust the line of front fork to the top

face of the upper bracket and air valve is positioned

at the front.

A: Caliper D: Line

B: Right fork leg E: Front fork upper bracket

C: Left fork leg F: Air pressure

FRONT FORK [Page: 11, 12 Paragraph: 1, 2]

Tighten the lower bracket side bolts to the specified

torque.

"Front fork lower bracket bolt:

23 N·m (2.3 kgf-m)

A: Front fork assembly

B: 8 × 40 mm flange bolt

Keep the position of front brake master cylin-

der with its cap facing upwards until it is

installed.

Install the front fork assembly with front brake

caliper to the left side.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTERCYCLE

DATE

: Jun. 1, 2003

PAGE

: 3

Tighten the upper bracket side bolts to the specified

torque.

"Front fork upper bracket bolt:

23 N·m (2.3 kgf-m)

A: Front fork assembly

B: 8 × 40 mm flange bolt

FRONT FENDER [Page: 13, 14 Paragraph: 2]

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:6.0 mm

C: Stepped washer OD:16.0 mm ID:6.5 mm T:3.5 mm

D: 6 × 16 mm flange bolt

STAND [Page: 17, 18 Paragraph: 2, 3]

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.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTERCYCLE

DATE

: Jun. 1, 2003

PAGE

: 4

BRAKE HOSE CLIP [Page: 19, 20 Paragraph: 1]

Align the groove of front brake hose with the groove

of brake hose clip.

Install the brake hose clip to the front fork protector.

A: Brake hose clip

B: Front brake hose

C: Groove

D: 6 × 16 mm flange bolt

E: Front fork protector

FRONT BRAKE HOSE COVER

[Page: 19, 20 Paragraph: 2]

Install the front brake hose cover to the left fork leg.

A: Brake hose cover

B: 6 × 12 mm flange bolt

C: Stepped washer OD:16.0 mm ID:6.5 mm T:3.0 mm

REAR FENDER [Page: 25, 26 Paragraph: 3]

Install the rear fender with fitting parts as shown in

the photograph.

Securely tighten the two nuts Ifixed 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

H: Second muffler

I: 6 mm flange self-lock nut (Black)

J: Rubber cushion

K: Washer OD:18.0 mm ID:6.5 mm

RADIATOR COVER [Page: 27, 28 Paragraph: 3]

Install the radiator cover with flange bolt and stepped

washer.

A: Radiator cover

B: 6 × 12 mm flange bolt

C: Stepped washer OD:16.0 mm ID:6.5 mm T:3.5 mm

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTERCYCLE

DATE

: Jun. 1, 2003

PAGE

: 5

4. SERVICING

40–50 mm

(1.6–2.0 in)

REAR BRAKE PEDAL

[Page: 35, 36 Paragraph: 1]

Check the rear brake pedal height.

Rear brake pedal height: 0–10 mm (0–0.4 in)

If the rear brake pedal height is not adjusted cor-

rectly, adjust in the following manner:

1. Loosen the lock nut A.

2. Adjust the brake pedal height by turning the

adjuster Bto locate the pedal to the correct height

below the top face of the footrest C.

3. Tighten the lock nut A.

DRIVE CHAIN [Page: 35, 36 Paragraph: 3, 4]

Check the drive chain slack.

Drive chain slack: 40–50 mm (1.6–2.0 in)

If it is too tight or too loose, follow these procedures.

Loosen the axle nut. Loosen the lock nut. Adjust the

slack in the drive chain by turning the right and left

chain adjuster bolts. Proper chain slack is obtained

when the drive chain slack is up and down, at a point

midway between the two sprockets.

A: Axle nut

B: Lock nut

C: Adjuster bolt

D: Reference marks

After adjusting, tighten the axle nut to the specified

torque. Tighten the lock nuts securely.

"Rear axle nut: 72 N·m (7.2 kgf-m)

FRONT FORK [Page: 37, 38 Paragraph: 2, 3]

Rebound Damping Force Adjustment

Adjust the setting of the rebound damping force to

the standard position. To adjust, turn the adjuster

screw Aclockwise until it stops, then turn it counter-

clockwise until 1-1/8 turns are felt.

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.

Do not force the adjuster screw A

Apast the

stopped position or you may damage the

adjuster. Be sure to adjust the damping force

on both front forks equally.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTERCYCLE

DATE

: Jun. 1, 2003

PAGE

: 6

Compression Damping Force Adjustment

Adjust the setting of the compression damping force

to the standard position. To adjust, turn the adjuster

screw Bclockwise until it stops, then turn it counter-

clockwise until 7 clicks are felt.

REAR SUSPENSION

[Page: 39, 40 Paragraph: 1, 2]

Rebound Damping Force Adjustment

(FOR RM85K4)

Adjust the setting of the rebound damping force to

the standard position. To adjust, turn the adjuster

screw Aclockwise until it stops and then turn it coun-

terclockwise until approximately 1-1/2 turns are felt

and the two punch marks align.

(FOR RM85LK4)

Adjust the setting of the rebound damping force to

the standard position. To adjust, turn the adjuster

screw Aclockwise until it stops and then turn it coun-

terclockwise until approximately 1-1/4 turns are felt

and the two punch marks align.

Compression Damping Force Adjustment

Adjust the setting of the compression damping force

to the standard position. To adjust, turn the adjuster

screw Bclockwise until it stops and then turn it coun-

terclockwise until approximately 1-3/4 turns are felt

and the two punch marks align.

Do not force the adjuster screw B

Bpast the

stopped position or you may damage the

adjuster. Be sure to adjust the damping force

on both front forks equally.

Do not force the adjuster screw A

Apast the

stopped position or you may damage the

adjuster.

Do not force the adjuster screw A

Apast the

stopped position or you may damage the

adjuster.

Do not force the adjuster screw B

Bpast the

stopped position or you may damage the

adjuster.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTERCYCLE

DATE

: Jun. 1, 2003

PAGE

: 7

[Page: 43, 44 Paragraph: 1]

!&(FOR CANADA)

Use 30 : 1 pre-mixture of unleaded gasoline

minimum 95 octane (RON) and oil. For the oil

to be mixed with gasoline, any of the following

brands or its equivalent will do.

*MOTUL 800 2T

Use 30 : 1 pre-mixture of unleaded gasoline

minimum 90 pump octane (R/2+M/2) and oil.

For the oil to be mixed with gasoline, any of

the following brands or its equivalent will do.

*MOTUL 800 2T

Do not allow two different brands to get mixed

in the fuel-oil mixture.

4. TIGHTENING TORQUE [Page: 45, 46, 47]

Item Part Name N·mkgf-m

FRONT FORK

A Handlebar clamp bolt 26 2.6

B Steering stem head nut 65 6.5

*C Front fork upper bracket bolt 23 2.3

*D Front fork lower bracket bolt 23 2.3

BRAKE

E Front brake caliper mounting bolt 23 2.3

F Front brake master cylinder mounting bolt 10 1.0

G Rear brake caliper mounting bolt 23 2.3

H Rear brake master cylinder mounting bolt 10 1.0

I Rear brake push rod lock nut 18 1.8

J Brake caliper air bleeder 7.5 0.75

Item Part Name N·mkgf-m

AXLE

K Front axle nut 44 4.4

*L Rear axle nut 72 7.2

ABSORBER

M Rear shock absorber nut (Upper) 60 6.0

N Rear shock absorber nut (Lower) 60 6.0

OTHERS

O Rear swing arm pivot nut 58 5.8

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTERCYCLE

DATE

: Jun. 1, 2003

PAGE

: 8

5. HARNESS ROUTING [Page: 49]

CDI unit

Ignition coil

Cushion

Exhaust breather hose

Clamp

Magneto lead wire

Engine stop switch

lead wire

CDI unit lead wire

Clamp

Magneto lead wire

Engine stop switch lead wire

Cushion

Revised

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