Suzuki RM85/LK5 User guide

K5
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.

1
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
2
AA
CC
DD
EE
FFGG
HH
M
II
BB
JJ
KK
LN
O
P
L
M
N
O
P
RR
QQ

2
Parts listed above are installed respectively into the positions as follows.
Item Part Name Q’ty Remarks
A
Number plate 1
Flange bolt 1 6 × 20 mm
Washer 1 OD:14.0 ID:6.5
B Radiator louver 1
C
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
D
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
F
Seat assembly 1
Flange bolt 2 6 × 16 mm
Washer 2 OD:20.0 ID:6.5 T:1.6
G
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
H
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
I
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
P
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)
TL
OD ID
NOTE:
The parts shown as Item R in the above table are supplied for limited markets.
N
EL
I
A C
ID
RFGKEHL
BJMO
N

3
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

4
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.

5
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
AA
Aof the front side with specified
torque and then tighten the bolt B
BB
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.

6
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.

7
#
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
CC
Cof the upper side with specified torque
and then tighten the bolt D
DD
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.

8
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

9
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.