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

MOTERCYCLE

DATE

:    

Jun. 1, 2003

PAGE

:        2  

OF

  8

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.

Summary of Contents for RM85K4 2003

Page 1: ...cover 1 Flange bolt 3 6 12 mm Stepped washer 3 OD 16 0 ID 6 5 T 3 5 E Front 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...

Page 2: ...utch 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 a...

Page 3: ...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...

Page 4: ...e 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 tigh...

Page 5: ...ning 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...

Page 6: ...ndard position To adjust turn the adjuster screw A clockwise until it stops and then turn it coun terclockwise until approximately 1 1 4 turns are felt and the two punch marks align Compression Dampin...

Page 7: ...to get mixed in the fuel oil mixture 4 TIGHTENING TORQUE Page 45 46 47 Item Part Name N m kgf m FRONT FORK A Handlebar clamp bolt 26 2 6 B Steering stem head nut 65 6 5 C Front fork upper bracket bol...

Page 8: ...DATE Jun 1 2003 PAGE 8 OF 8 5 HARNESS ROUTING Page 49 CDI unit Ignition coil Cushion Exhaust breather hose Clamp Clamp Magneto lead wire Engine stop switch lead wire CDI unit lead wire Clamp Magneto l...

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