Suzuki RM85/LK5 Guida utente

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.

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. Remove the bolt, washer, plate and nut of the front wheel.

3. Remove the bolts from the crate, then lift the steel frame to separate it from the base of the crate.

Check all the components which have been removed from the base of the crate.



Keep the position of front brake master cylinder with their caps facing upward until they are installed.

1 3

FFGG

Parts listed above are installed respectively into the positions as follows.

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 3 6 × 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 2 6 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 × 20 mm

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

Stepped washer 4 OD:17.0 ID:6.5 T:7.0

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

JFront brake hose clip 2 Inner and Outer

Flange bolt 2 6 × 16 mm

KFront brake hose guide 1

Flange bolt 1 6 × 20 mm

LFront fork protector 2 Right and Left

Flange bolt 6 6 × 10 mm

M Front wheel assembly 1

NFrame cover 2 Right and Left

Strap 2 L:140

OStand 1

Main jet 3 Exchanging parts

Spark plug and spoke

nipple wrench 1

Q Owner’s manual 1

R Fuel label 1 For limited market

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The parts shown as Item R in the above table are supplied for limited markets.

A C

RFGKEHL

BJMO

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

1Cylinder head O-ring No.1 2

2Cylinder head O-ring No.2 2

3Exhaust pipe O-ring 2

4Cylinder cover gasket No.1 2

5Cylinder cover gasket No.2 1

6Cylinder gasket 2

7Crankcase gasket 1

8Clutch cover gasket 1

9Piston complete 1

0Piston ring 2

APiston pin bearing 1

BPiston pin 1

CPiston pin circlip 2

DExhaust valve rod bush 2

EBrake lever 1

FClutch lever 1

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.

A: Bracket

B: Bolt

HANDLEBARS

Loosen the throttle housing retaining screws.

Insert the throttle assembly onto the handlebars.

A: Throttle assembly

B: Handlebars

Install the handlebars assembly using the two clamps

and the four bolts.

A: Clamp

B: 8 × 35 mm flange bolt

C: Dot mark

D: Punch mark

NOTE:

The bracket and bolts are no longer needed

and these may be discarded.

NOTE:

The punch mark on the clamps shows front

side.

Align the dot mark on the handlebars with the

mating surface of the front side of left clamp.

Tighten the handlebar clamp bolts to the specified

torque.

"Handlebar clamp bolt: 26 N·m (2.6 kgf-m)



A: 8 × 35 mm flange bolt

B: 8 × 35 mm flange bolt

C: Dot mark

D: Punch mark

1. Lift the front of motorcycle by using a hoist.

2. Raise the rear of motorcycle.

3. Pull the crate base forward, then balance the

motorcycle.

FRONT FORK



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

B: Right fork leg

C: Left fork leg

D: Line

E: Front fork upper bracket

F: Air pressure

NOTE:

To install the handlebars correctly, first tighten

the bolt A

Aof the front side with specified

torque and then tighten the bolt B

Bof the rear

side.

Make sure that the clamp has no clearance at

the front side as shown in the illustration.

FRONT

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.

FRONT FORK (RM85L)



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

B: Right fork leg

C: Left fork leg

D: Line

E: Front fork upper bracket

F: Air pressure

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

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

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.

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.

Install the front brake master cylinder onto the handle-

bars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the master cylinder mounting bolts to the

specified torque.

"Front brake master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: Holder

B: Front brake master cylinder

C: Flange bolt

D: Flange bolt

E: Dot mark



A: Bolt

B: Holder

C: Front brake master cylinder

D: Handlebars

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.

NOTE:

To install the holder correctly, first tighten the

bolt C

Cof the upper side with specified torque

and then tighten the bolt D

Dof the lower side.

NOTE:

Install the holder in position according to the

mark “UP”.

Make sure that the holder has no clearance at

the upper side as shown.

Check for brake fluid leakage.

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 × 20 mm flange bolt

Install the front fender to the front fork lower bracket.

A: 6 × 20 mm flange bolt

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

C: Front fork lower bracket

FRONT REAR

BRAKE DISC

To prevent brake squeaking and pad contamination,

carefully clean the front and rear brake disc plates with

alcohol or other non-petroleum based solvent.

This will remove the rust-preventive coating and dirt.

Mount the front wheel assembly properly.

A: Right fork leg

B: Left fork leg

C: Cotter pin L:27.0 mm

D: Axle nut

E: Washer OD:20.0 mm ID:12.5 mm

F: Spacer

G: Front axle

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.

A: Front wheel spacer

LEFT RIGHT

Insert the front axle from the left side of the fork legs.



Place the washer on the right end of the front axle.

A: Front axle

B: Washer OD:20.0 mm ID:12.5 mm

Tighten the front axle nut to the specified torque.

"Front axle nut: 44 N·m (4.4 kgf-m)

A: Axle nut 12 mm

B: Cotter pin L:27.0 mm

NOTE:

The large flange side of the spacer faces the

hub.

Never use force to install the front axle.

If it cannot be installed by hand, it is not cor-

rectly aligned.

Insert the cotter pin through the axle shaft and

bend the ends properly.

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