2008 Suzuki RM85 — Engine Rebuild Simulator

2008 SUZUKI RM85

Engine Rebuild Simulator — Loading...

Steps

Specs

Torque

Parts

Engine

TypeSingle-cylinder, 2-stroke, liquid-cooled

Displacement84.7 cc (5.17 cu in)

Bore × Stroke48.0 × 46.8 mm

Compression Ratio9.5 : 1

Valve SystemReed valve (fiberglass or carbon)

Exhaust ValveAluminum AETC power valve

IgnitionCDI — fixed 18° BTDC

StartingKick start

LubricationPremix (32:1 – 40:1)

CoolingLiquid (water-cooled)

Power Output~29 hp @ 12,000 rpm

Fuel System

CarburetorKeihin PE28 (28mm flat-slide)

Main Jet#122 (stock)

Pilot Jet#42

Needle Clip3rd position (middle)

Fuel Capacity5.0 L (1.32 US gal)

Break-in Mix20:1 (first 3 hours)

Transmission

Type6-speed constant mesh

1st / 2nd / 3rd1.857 / 1.400 / 1.100

4th / 5th / 6th0.923 / 0.800 / 0.700

Primary Reduction3.400 (68/20 teeth)

Final DriveChain (13T drive / 49T rear)

Clutch TypeWet multi-plate

Trans. Oil650 ml of 10W-40 4-stroke

Piston & Top End

Piston Diameter47.955 – 47.970 mm

Piston Clearance0.030 – 0.045 mm

Ring End Gap (std)0.15 – 0.35 mm

Ring Width0.97 – 0.99 mm

Wrist Pin Dia.15.000 – 15.006 mm

Small End Bore15.006 – 15.017 mm

Bore Std.48.000 – 48.015 mm

Bore Wear Limit48.100 mm (replace cylinder)

Dimensions

Overall Length2,145 mm (84.4 in)

Overall Width735 mm (28.9 in)

Seat Height850 mm (33.5 in)

Wheelbase1,240 mm (48.8 in)

Ground Clearance325 mm (12.8 in)

Dry Weight65 kg (143.3 lbs)

Coolant Capacity0.6 L

Suspension & Brakes

Front ForkInverted cartridge 38mm

Front Travel274 mm (10.8 in)

Front Compression20-way adjustable

Rear ShockLink-type, fully adjustable

Rear Travel277 mm (10.9 in)

Front Tire70/90-M17

Rear Tire90/90-MM19

BrakesSingle disc front & rear

All values from Suzuki RM85 Service Manual. Use calibrated torque wrench.

Top End

Cylinder Head Nuts (M8 × 4)

28 N·m20.5 lb-ft

Cross-pattern, 3 passes. Critical — prevents warping.

Cylinder Base Nuts (M8 × 4)

25 N·m18.0 lb-ft

Cross-pattern tightening sequence.

Spark Plug (M14×1.25)

28 N·m20.5 lb-ft

NGK BR8EG / BR9EG. Thread lightly first.

Power Valve Cover Bolts (M6 × 2)

10 N·m7.3 lb-ft

Do not overtighten aluminum threads.

Exhaust Manifold Nuts (M8 × 2)

23 N·m16.5 lb-ft

Replace gasket if flattened.

Reed Cage Bolts (M6 × 4)

12 N·m8.7 lb-ft

Even tightening sequence.

Bottom End

Crankcase Bolts (M6 × 11)

10 N·m7.3 lb-ft

Even cross-pattern.

Crankcase Bolt M8 (× 1)

23 N·m16.5 lb-ft

Near cylinder base, larger bolt.

⚠ Primary Drive Gear Nut (M16)

70 N·m50.5 lb-ft

LEFT-HAND thread — CW to remove!

Clutch Hub Nut (M16)

70 N·m50.5 lb-ft

Standard thread. Use clutch holder.

Clutch Spring Bolts (M6 × 5)

8 N·m5.8 lb-ft

Cross-pattern. Min spring: 32.8mm.

Flywheel Nut (M12)

55 N·m40.0 lb-ft

Apply Loctite 243. Flywheel holder needed.

Water Pump Cover (M6 × 3)

10 N·m7.3 lb-ft

Replace O-ring on assembly.

Ignition Cover (M6 × 6)

10 N·m7.3 lb-ft

Replace gasket if oil contaminated.

Drivetrain

Drive Sprocket Bolt (M8)

23 N·m16.5 lb-ft

13T stock. Bend lock tab after.

Rear Sprocket Nuts (M8 × 6)

72 N·m52.0 lb-ft

49T stock. Cross-pattern.

Rear Axle Nut (M20)

44 N·m32.0 lb-ft

Chain slack: 25–35mm.

Front Axle Nut (M18)

43 N·m31.0 lb-ft

Green = installed | Red = removed. Click to highlight in 3D view.

⚠ Critical Torque Specs

STEP 1 OF 25

Engine

Fuel System

Transmission

Piston & Top End

Dimensions

Suspension & Brakes

Top End

Bottom End

Drivetrain

⚠ Critical Torque Specs

✓ Engine Rebuild Complete!