The History of the Suzuki RM80 from 1977 to 2001 Suzuki RM80 Tuning tips, Suspension tuning, Best Value Mods SUBSCRIBE for more dirt bike history´s, RM60 RM80 RM85 tips Flaws: magneto cover leaks, pistons wear fast Fixes: Boyesen magneto cover , Wiseco Pro-Lite piston Best Value Mods: Engine: Boyesen magneto cover, Wiseco piston Suspension: Emulator Valve, fork spring preload
This bike is a great design that suffers from one big problem: poor quality materials used in the engine components. The forks are a little soft too. Here are some tips on improving the longevity of the RM80.
Engine: The cylinder bore and the crankshaft bearings wear out quicker than on other Japanese dirt bikes. The cylinder uses a steel sleeve that can be rebored to accept oversize piston and rings. Wiseco Pro-Lite forged pistons are much better quality than original cast Suzuki pistons. The cylinder can only be overbored twice, any larger and the liner can´t transfer out the heat and the engine will lose power. The cylinder has rough transitions between the liner and the ports and turning down the head .010-inches will help broaden the powerband. Don´t waste a lot of money on porting because the cylinder won´t last forever! The connecting rod and main crankshaft bearings need to be changed at least once a racing season. The water pump impeller is made of plastic and tends to melt when the engine gets really hot. Boyesen Engineering makes an aluminium impeller that pumps more volume of water and won´t melt from hot coolant.
Magneto Leaks: Replace the magneto cover with one made of aluminium. This will help seal water out from the generating coils, a common cause of ignition failure. Boyesen Engineering sells aluminium magneto covers for RM80s.
Forks: The forks need stiffer springs but no manufacturer makes springs for the RM80. However most tuners add 10mm-long aluminium spacers between the fork caps and the springs. Race Tech´s Emulator Valve significantly improves the fork damping. Change the fork oil to 10 weight for Emulator valves, and 15 weight for the stock forks.
Shock: The best mod for increasing the service life and the performance of the shock, is to plate the inside bore of the shock body with Apticote 2000 nickel silicon-carbide. Pro-Action offers this service. !!!KEEP ON BRAAAAPIN!!! DirtBikeDudeZ