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

MOTERCYCLE

DATE

:    

Jun. 1, 2003

PAGE

:        4  

OF

  8

BRAKE HOSE CLIP [Page: 19, 20  Paragraph: 1]

Align the groove of front brake hose with the groove
of brake hose clip.
Install the brake hose clip to the front fork protector.

A: Brake hose clip
B: Front brake hose
C: Groove
D: 6 × 16 mm flange bolt
E: Front fork protector

FRONT BRAKE HOSE COVER 
[Page: 19, 20  Paragraph: 2]

Install the front brake hose cover to the left fork leg.

A: Brake 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 tighten the two nuts 

I

 fixed temporarily.

A: Rear fender
B: 6 × 20 mm flange bolt
C: 6 × 30 mm flange bolt
D: Washer OD:20.0 mm ID:6.5 mm T:1.2 mm
E: 6 mm self-lock nut
F: Frame
G: Spacer
H: Second muffler
I: 6 mm flange self-lock nut (Black)
J: Rubber cushion
K: Washer OD:18.0 mm ID:6.5 mm

RADIATOR COVER [Page: 27, 28  Paragraph: 3]

Install the radiator cover with flange bolt and stepped
washer.

A: Radiator cover
B: 6 × 12 mm flange bolt
C: Stepped washer OD:16.0 mm ID:6.5 mm T:3.5 mm

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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