2009-2012 Suzuki RM85 RM85L RM 85 Service & Repair Manual

FOREWORD This manual is presented as a means whereby you can maintain your RM85 in top working condition at all times. Your riding skill and the maintenance steps outlined in this manual will assure you of top performance from your machine under any type of competition. We sincerely wish you and your Suzuki motorcycle a successful partnership for many years of happy riding. All information, illustrations, photographs and speci- fications contained in the manual are based on the latest product information available at the time of publication. Due to improvements or other changes, there may be some discrepancies in this manual. Suzuki reserves the right to make production changes at any time, without notice and without incurring any obligation to make the same or similar changes to vehicles previous built or sold. Suzuki Motor Corporation believes in conservation and protection of Earth’s natural resources. To that end, we encourage every vehicle owner to recycle, trade in, or properly dispose of, as appropriate, used motor oil, engine coolant, and other fluid, and tires. WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE carry special meanings. Pay special attention to the messages highlighted by these signal words: Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. WARNING CAUTION

GENERAL CONSIDERATIONS • Wear a helmet and goggles A helmet is the most important piece of gear to wear. Helmets do not reduce essential vision or hearing. Generally, helmets do not cause or inten- sify injury if you crash. Helmets simply help your skull protect your intelligence, your memory, your personality, and your life. Your eyesight is equally valuable. Wearing suitable eye protection can help keep your vision unblurred by the wind and help shield your eyes from branches and airborne matter like bugs, dirt, or pebbles kicked up by tires. Wear a helmet and eye protection every time you ride. • Wear protective gear Wear proper clothing when you ride. Avoid loose clothes or scarves, which could get caught in moving parts. Abrasion injuries can be minimized by wearing protective clothing including gloves, strong boots that fit over the ankle, long pants, and a long sleeve shirt or jackets. Experienced riders often wear a kidney belt and chest or back protector for additional comfort and protection. • Inspect your machine before riding Before each use, perform an inspection per “PE- RIODIC MAINTENANCE” section starting on page 2-2. • No Passengers Suzuki RMs are designed for the rider only. • Weight limit 55 kg (120 lbs) • Ride with teammates Share the fun of motocross riding. A riding partner can also be great help if one of you gets stranded or injured. Of course, your friends will need their own motorcycles because motocross models are not designed for passengers. If none of your friends rides motocross, ask your Suzuki dealer how to go about joining a club. If your friends do ride, you can all join a club – or start one of your own! • Practice on level ground Before you begin riding, you should find a good place to practice the skills you need to ride safely. Find a flat, open area with enough space to ma- neuver. Check with your Suzuki dealer or call po- lice department if you do not know where you can ride. Review the controls on your motorcycle before riding. • Know your limits Always ride within the boundaries of your own skills. Knowing these limits and staying within them will help you avoid accidents. Ride only in events appropriate for your experience. Safely competing on a motorcycle requires that your mental and physical skills are fully part of the experience. You should not attempt to operate a motor vehicle, especially one with two wheels, if you are tired or under the influence of alcohol or other drugs. Alcohol, illegal drugs, and even some prescription and over-the-counter drugs and cause drowsiness, loss of coordination, loss of balance, and loss of good judgement. If you are tired or under the influence of alcohol or other drugs, PLEASE DO NOT RIDE your motorcycle. • Conclusion. The actions of other riders are unpredictable. Your motorcycle’s condition can change. These factors can best be dealt with by giving every ride your full attention. Circumstances beyond your control could lead to an accident. You need to prepare for the unex- pected by wearing a helmet and other protective gear, and practicing safe riding techniques to mini- mize the damage to you and your machine. May all of your rides on your new Suzuki be winning rides!

SERIAL NUMBER LOCATION The frame number 1 is stamped on the steering head. The engine serial number 2 is stamped on the right side of the crankcase assembly. Write down the serial numbers here for your future reference. Frame No. Engine No.

LOCATION OF LABELS Read and follow all of the warnings labeled on your motorcycle. Make sure you understand all of the labels. Keep the labels on your motorcycle. Do not re- move them for any reason. 3 USE 30:1 PRE-MIXTURE OF GASOLINE AND RECOMMENDED OIL. SE SERVIR D’UNE PROPORTION PREMELANGEE 30:1 D’ESSENCE ET D’HUILE RECOMMANDEE. 2 Failure to follow these safety precautions may increase your risk of injury; • This competition motorcycle is only for use by those with the physical and mental maturity to ride safely. • Adult must supervise operation. • Wear a helmet, eye protection, and bright protective clothing. • Don’t ride after consuming alcohol or other drugs. • Closed course competition use only – do not use on public streets, roads, or highways. This motorcycle does not meet federal and state safety (and other) standards for street use or off-road use. • Single rider only – weight limit 120 pounds (55 kg). • Slow down on slippery surfaces, unfamiliar terrain, or when visibility is reduced. • Do not touch any moving parts or heated areas. • Read owner’s manual carefully. WARNING • The owner’s manual contains important safety information and instructions. If the motorcycle has been resold, obtain the owner’s manual from the previous owner or contact your local Suzuki dealer for assistance. • This motorcycle is sold “AS IS” with NO WARRANTY OF ANY KIND. The purchaser assumes all responsibilities concerning quality, performance, maintenance, and repair. 1 MED BY: SUZUKI MOTOR CORPORATION THIS VEHICLE IS DESIGNED AND MANUFACTURED FOR COMPETITION USE ONLY AND IS NOT EQUIPPED OR APPROVED FOR OPERATION ON PUBLIC STREETS, ROADS OR HIGHWAYS. MADE IN TAIWAN

WARNINGS FOR SERVICING Never run the engine indoors or in a garage. Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe injury. Only run the engine outdoors where there is fresh air. Hot engine and muffler can burn you. Wait until the engine and muffler cools before servicing. Fuel can catch on fire if you do not handle it properly. Gasoline vapors can catch fire eas- ily. Do not smoke when servicing the machine. Do not service the machine in an area where there are open flames or sparks. Brake fluids and engine coolant can be hazardous to humans and pets. Brake fluid and engine coolant are harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes. Keep brake fluid and engine coolant away from children. Call your doctor immediately if swallowed, and induce vomiting. Flush eyes or skin with water if either brake fluid or engine coolant gets in eyes or comes in contact with skin. ! WARNING ! WARNING ! WARNING ! WARNING

Servicing the machine with engine running can be hazardous. You can be caught in the moving parts such as the drive chain, sprockets, etc. Be sure to stop the engine when servicing the machine. PRECAUTIONS FOR SERVICING • Replace gaskets, circlips, O-rings and cotter pins with new ones. • Take care not to expand the end gap larger than required to slip the circlip over the shaft when in- stalling a circlip. • Use special tools where specified. • Use genuine SUZUKI parts and recommended oil. • When two or more persons work together, pay attention to the safety of each other. • After reassembly, inspect parts for tightness and operation. Servicing the machine without proper clothes and protective gear can be hazardous. You can be injured if you do not wear proper clothes and protective gear. Be sure to wear proper clothes and shoes for servicing and wear protective glasses, mask or gloves as necessary. REPLACEMENT PARTS Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high quality parts which are designed and built specially for SUZUKI vehicles. NOTE: Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage. ! WARNING ! WARNING

SYMBOL MARKS AND MATERIALS SYMBOL MARK MATERIALS Apply SUZUKI SUPER GREASE “A” 99000-25030 Apply SUZUKI SILICONE GREASE 99000-25100 Apply THREAD LOCK “1342” 99000-32050 Apply SUZUKI BOND “1207B” 99104-31140 Use or apply DOT4 Brake fluid. Apply THREAD LOCK SUPER “1303” 99000-32030

Use SUZUKI FORK OIL SS-05 99000-99001-SS5 SYMBOL MARK MATERIALS Use SUZUKI REAR SUSPENSION OIL SS-25 99000-99001-S25 Use engine coolant. Apply engine oil or transmission oil. Tighten a nut or bolt to the specified torque. Replace a part with a new one when reassembling.

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2009-2012 Suzuki RM85 RM85L RM 85 Service & Repair Manual

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