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Yamaha YZ85(W), Service Manual

The Yamaha YZ85(W) Service Manual is a comprehensive guide specifically designed to assist owners with maintaining and repairing their Yamaha YZ85(W) motorcycle. This manual is available for download, free of charge, from our website, ensuring easy access to essential information for all Yamaha YZ85(W) riders.

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ENG

CHAPTER 5

ENGINE

ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1
EXHAUST PIPE   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-2
SILENCER FIBER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . .  5-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-4
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-6

CYLINDER HEAD, CYLINDER AND PISTON 

 . . . . . . . . . . . . . . . . . . .  5-7

CYLINDER HEAD  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-7
REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . .  5-8
CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . .  5-8
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .  5-9
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-10
REMOVING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . .  5-11
CHECKING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . .  5-11
COMBINATION OF PISTON AND CYLINDER . . . . . . . . . . . . . . . . .  5-13
CHECKING THE PISTON RING . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-14
CHECKING THE PISTON PIN  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-14
CHECKING THE SMALL END BEARING . . . . . . . . . . . . . . . . . . . . .  5-15
INSTALLING THE PISTON AND CYLINDER . . . . . . . . . . . . . . . . . .  5-16

CLUTCH 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-18

CLUTCH  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-18
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-20
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . .  5-21
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . .  5-21
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . .  5-22
CHECKING THE CLUTCH HOUSING  . . . . . . . . . . . . . . . . . . . . . . .  5-22
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-22
CHECKING THE PRESSURE PLATE. . . . . . . . . . . . . . . . . . . . . . . .  5-22
CHECKING THE PUSH LEVER SHAFT . . . . . . . . . . . . . . . . . . . . . .  5-23
CHECKING THE CLUTCH PUSH RODS  . . . . . . . . . . . . . . . . . . . . .  5-23
INSTALLING THE CLUTCH  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-23

Summary of Contents for YZ85(W)

Page 1: ...2007 YZ85W1 5PA 28197 E0 SERVICE MANUAL YZ85 W YZ85LW W ...

Page 2: ...85LW W SERVICE MANUAL 2006 by Yamaha Motor Co Ltd First edition April 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited EAS00000 ...

Page 3: ... models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety A...

Page 4: ...top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears Sub section titles appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a...

Page 5: ...icate the following Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap based grease Molybdenum disulfide grease Symbols to in the exploded diag...

Page 6: ...GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 CARBURETOR CARB 7 ELECTRICAL SYSTEM ELEC 8 TUNING TUN 9 TROUBLESHOOTING TRBL SHTG 10 ...

Page 7: ... MODEL LABEL 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 FUEL AND ENGINE MIXING OIL 1 4 CHECKING THE CONNECTIONS 1 5 SPECIAL TOOLS 1 6 ...

Page 8: ...EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label is affixed to the frame This information will be needed to order spare parts VEHICLE IDENTIFICATION ...

Page 9: ...in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS00022 GAS...

Page 10: ...lling oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate Oil seal CAUTION Do not spin the bearing with compressed air because this will damage the bearing surfaces Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips ...

Page 11: ...ver mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl of old premix prior to filling with the new type Recommended fuel Premium unleaded gasoline only with a research octane number of 95 or higher Fuel tank capacity 5 0 L 1 10 Imp gal 1 32 US gal Mixing oil Recommended oil Yamalube 2 ...

Page 12: ...all connections Loose connection Connect properly NOTE NOTE If the pin on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE NOTE Make sure all connections are tight 5 Check continuity with the pocket tester NOTE NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at mos...

Page 13: ...case as well as remove the crankshaft from either case 90890 01189 YM 1189 Flywheel puller This tool is used to remove the flywheel magneto 90890 01235 YU 1235 Rotor holding tool This tool is used when loosening or tightening the flywheel magneto securing nut Dial gauge set 90890 01252 Dial gauge and stand YU 3097 YU 1256 Dial gauge and stand Stand These tools are used to check each part for runou...

Page 14: ...ttachment 90890 01436 YM 01436 Rod puller Rod puller attachment M10 These tools are used to pull up the fork damper rod 90890 01442 YM 01442 Fork seal diver This tool is used when install the fork oil seal 90890 01454 YM 01454 Damper rod holder Use this tool to remove and install the damper rod 90890 01495 YM 01495 Drive gear holder This tool is used when removing or tightening the primary drive g...

Page 15: ...90890 06754 YM 34487 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components 90890 85505 Yamaha bond No 1215 Three Bond No 1215 This sealant Bond is used for crankcase mating surface etc SPECIAL TOOLS ...

Page 16: ...SPECIFICATIONS 2 7 ELECTRICAL SPECIFICATIONS 2 11 CONVERSION TABLE 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 TIGHTENING TORQUES 2 13 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 14 LUBRICATION POINTS AND LUBRICANT TYPES 2 16 ENGINE 2 16 CHASSIS 2 16 CABLE ROUTING 2 17 ...

Page 17: ... 1 903 mm 74 9 in YZ85LW Overall width 758 mm 29 8 in Overall height 1 161mm 45 7 in YZ85 1 205 mm 47 4 in YZ85LW Seat height 864 mm 34 0 in YZ85 904 mm 35 6 in YZ85LW Wheelbase 1 255 mm 49 4 in YZ85 1 286 mm 50 6 in YZ85LW Minimum ground clearance 351 mm 13 8 in YZ85 393 mm 15 5 in YZ85LW Dry weight Without oil and fuel 66 kg 145 5 lb YZ85 69 kg 152 2 lb YZ85LW GENERAL SPECIFICATIONS ...

Page 18: ...r JASO standard MA Periodic oil change 0 50 L 0 44 Imp qt 0 53 US qt Total amount 0 55 L 0 48 Imp qt 0 58 US qt Cooling system Coolant capacity including all routes 0 54 L 0 48 Imp qt 0 57 US qt Radiator capacity 0 32 L 0 28 Imp qt 0 34 US qt Radiator cap opening pressure 93 123 kPa 0 93 1 23 kg cm2 13 2 17 5 psi Radiator core Width 117 8 mm 4 64 in Height 240 0 mm 9 45 in Depth 32 0 mm 1 26 in Wa...

Page 19: ...in 0 1 mm 0 004 in Height H 20 0 mm 0 79 in Piston pin bore in the piston Diameter 14 004 14 015 mm 0 5513 0 5518 in 14 040 mm 0 5528 in Offset 1 0 mm 0 039 in Offset direction Exhaust side Piston pin Outside diameter 13 996 14 000 mm 0 5510 0 5512 in 13 975 mm 0 5502 in Piston ring Ring type Plain Dimensions B T 0 8 2 0 mm 0 032 0 079 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 8 mm 0 032 ...

Page 20: ...ch release method Inner push cam push Clutch cable free play at the end of the clutch lever 10 0 15 0 mm 0 39 0 59 in Friction plates Thickness 2 9 3 1 mm 0 114 0 122 in 2 7 mm 0 106 in Plate quantity 7 Clutch plates Thickness 1 8 2 2 mm 0 071 0 087 in Plate quantity 6 Max warpage 0 1 mm 0 004 in Clutch springs Free length 33 0 mm 1 30 in 31 0 mm 1 22 in Spring quantity 5 Clutch housing thrust cle...

Page 21: ... Max main axle runout 0 01 mm 0 004 in Max drive axle runout 0 01 mm 0 004 in Shifting mechanism Shift mechanism type Cam drum Guide bar Guide bar bending limit 0 05 mm 0 002 in Air filter type Wet element Air filter oil glade Form air filter oil or 2 stroke motor oil Carburetors Model manufacturer PWK28 KEIHIN Throttle cable free play at the flange of the throttle grip 3 0 5 0 mm 0 118 0 197 in I...

Page 22: ...SPEC 2 6 Item Standard Limit Reed valve Thickness T 0 42 mm 0 017 in Valve stopper height 7 4 7 8 mm 0 291 0 307 in Valve bending limit 0 2 mm 0 008 in ENGINE SPECIFICATIONS ...

Page 23: ...17 1 40 YZ85 19 1 40 YZ85LW Material Aluminum Wheel travel 275 mm 10 83 in Wheel runout Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Rear wheel Wheel type Spoke wheel Rim Size 14 1 60 YZ85 16 1 85 YZ85LW Material Aluminum Wheel travel 282 mm 11 10 in YZ85 287 mm 11 30 in YZ85LW Wheel runout Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 ...

Page 24: ...er thickness 220 3 mm 8 66 0 12 in Thickness limit 2 5 mm 0 10 in Deflection limit 0 15 mm 0 006 in Brake pad lining thickness 4 0 mm 0 16 in 0 8 mm 0 03 in Master cylinder inside diameter 11 0 mm 0 433 in Caliper cylinder inside diameter 22 2 mm 0 874 in 2 Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal position vertical height above footrest top 4 0 10 0 mm 0 1...

Page 25: ... 0 30 kg mm 16 8 lb in YZ85LW Spring stroke K1 0 275 mm 0 10 82 in Inner tube outer diameter 36 mm 1 42 in Inner tube bending limit 0 2 mm 0 008 in Optional spring available Yes Fork oil Recommended oil Suspension oil 01 Quantity each front fork leg 318 cm3 11 2 Imp oz 10 8 US oz Level from the top of the outer tube with the outer tube fully compressed and without the fork spring 90 mm 3 54 in Reb...

Page 26: ...LW for AUS NZL Spring stroke STD K1 102 mm 4 02 in Optional spring available Yes Standard spring preload gas air pressure 1 000 kPa 10 0 kg cm2 142 psi Rebound damping adjusting positions Minimum 20 Standard 6 YZ85 12 YZ85LW for EUR 7 YZ85LW for AUS NZL Maximum 1 Compression damping adjusting positions Minimum 20 Standard 9 YZ85 12 YZ85LW for EUR 7 YZ85LW for AUS NZL Maximum 1 from the fully turne...

Page 27: ...at 20 C 68 F W L W R Charging coil 1 resistance color 720 1 080 Ω at 20 C 68 F G W B R Charging coil 2 resistance color 44 66 Ω at 20 C 68 F B G L C D I unit model manufacturer 5PA 01 YAMAHA Ignition coils Model manufacturer 2JN YAMAHA Minimum ignition spark gap 6 mm 0 24 in Primary coil resistance 0 18 0 28 Ω at 20 C 68 F Secondary coil resistance 6 3 9 5 kΩ at 20 C 68 F Spark plug cap Material R...

Page 28: ... threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Tightening torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 281...

Page 29: ...6 2 12 1 2 8 7 Exhaust pipe stay Bolt M6 1 12 1 2 8 7 Silencer Bolt M6 1 12 1 2 8 7 Fiber silencer Bolt M6 2 12 1 2 8 7 Crankcase Screw M6 11 8 0 8 5 8 Left crankcase cover Screw M6 4 5 0 5 3 6 Right crankcase cover Bolt M6 4 10 1 0 7 2 Right crankcase cover Bolt M6 1 10 1 0 7 2 Clutch cover Bolt M6 6 10 1 0 7 2 Transmission oil drain bolt Bolt M8 1 10 1 0 7 2 Kickstarter crank Bolt M6 1 10 1 0 7 ...

Page 30: ...t Nut M6 1 5 0 5 3 6 Clutch lever holder Bolt M5 2 4 0 4 2 9 Front brake master cylinder cap Screw M4 2 2 0 2 1 4 Front brake hose union bolt Bolt M10 2 26 2 6 19 Front fork and brake caliper bracket Bolt M8 2 30 3 0 22 Brake caliper support bolt Bolt M8 1 23 2 3 17 Front brake caliper and bleed screw Bolt M7 1 6 0 6 4 3 Rear brake caliper and brake caliper bracket Bolt M8 2 23 2 3 17 Rear brake c...

Page 31: ...frame upper Bolt M8 1 26 2 6 19 Rear frame lower Bolt M8 2 16 1 6 12 Swingarm and brake hose holder Screw M5 4 1 0 1 0 7 Drive chain support Nut M8 2 16 1 6 12 Drive chain support cover Nut M6 1 7 0 7 5 1 Drive chain guide and swingarm Bolt M6 2 10 1 0 7 2 Fuel tank Bolt M6 2 7 0 7 5 1 Fuel cock Screw M6 2 4 0 4 2 9 Fuel tank bracket and fuel tank Bolt M6 4 7 0 7 5 1 Seat set bracket and fuel tank...

Page 32: ... surface Yamaha bond No 1215 Lubrication point Lubricant Steeling bearings and bearing race upper and lower Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point and metal to metal moving parts Throttle tube guide inner surface Rear brake pedal Swing arm bearing and bushing inner surface Swingarm oil seal dust seal and bushing Pivot shaft Reray arm oil seal bearing...

Page 33: ...her hose Engine stop switch lead Ground lead Ignition coil Primary coil lead orange color Damper Clamp Air vent hoses CDI magneto lead Carburetor overflow hose Transmission oil breather hose Radiator breather hose Clutch cable Spark plug lead Radiator hose Brake hose holder CABLE ROUTING ...

Page 34: ...r hose through the wire holder located at the right side of the vehi cle Route the air vent hose and carburetor over flow hose from the left side of the vehicle Do not flatten out the radiator breather hose Securely install the spark plug cap to the spark plug Route the spark plug lead by the inner side of the vehicle than the radiator hose and throttle cable Clamp the brake hose with the brake ho...

Page 35: ...n oil breather hose through the hose guide Clamp it between these parts Clamp it using the white PVC tape as a guide Pass the sub wire harness on the left side of the CDI unit Cut the tip of the clamp near the position of chain double dashed line Tighten the sub wire harness to the CDI unit Posi tion the lock section under the CDI unit Route the reservoir tank hose by the outer side of the vehicle...

Page 36: ...the clamp section to the rear side Touch the brake pipe to the stopper When installing the brake hose install it so that the bend section of the brake hose attachment is pointed in the direction as shown in the illustration CABLE ROUTING ...

Page 37: ... cable shall be routed crossways above the number plate attaching sec tion At this time make sure to route the clutch cable to the front side of the throttle cable Route the clutch cable in front of the throttle cable Fasten the engine stop switch lead to the handle bar with the plastic band Pass the brake hose in front of the number plate Vertical direction 40 10 CABLE ROUTING ...

Page 38: ...CKING THE EXHAUST SYSTEM 3 13 CHECKING THE COOLANT LEVEL 3 14 CHECKING THE COOLING SYSTEM 3 15 CHANGING THE COOLANT 3 15 CHASSIS 3 17 ADJUSTING THE FRONT BRAKE 3 17 ADJUSTING THE REAR BRAKE 3 18 CHECKING THE BRAKE FLUID LEVEL 3 19 CHECKING THE FRONT AND REAR BRAKE PADS 3 20 CHECKING THE FRONT AND REAR BRAKE HOSES 3 20 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 21 ADJUSTING THE SHIFT PEDAL 3 22 ADJUSTIN...

Page 39: ... Piston pin and small end bearing Check piston pin and small end bearing for damage Replace 4 Cylinder head Check cylinder head for carbon deposits Clean Check cylinder head gasket for damage Tighten cylinder head bolts if necessary Replace cylinder head gasket 5 Cylinder Check cylinder for score marks or wear Clean Replace 6 Clutch Check clutch housing friction plates clutch plates and clutch spr...

Page 40: ...brake fluid Every year 22 Front fork Check operation and for oil leakage Adjust if necessary Clean dust seal and lubricate with lithium soap based grease Replace fork oil Replace oil seals 23 Shock absorber assembly Check operation and adjust Tighten if necessary Lubricate with molybdenum disulfide grease After washing the vehicle or riding in the rain 24 Drive chain roller and support guide Check...

Page 41: ... covers left and right 2 3 Air scoop 1 4 Fuel pipe 1 Disconnect 5 Fuel cock 1 6 O ring 1 7 Grommet 2 8 Collar 2 9 Hose 1 Disconnect 10 Joint pipe 1 11 Hose 1 Disconnect 12 Fuel tank cap 1 13 Fuel tank 1 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb SEAT SIDE COVERS AND FUEL TANK ...

Page 42: ... 14 Number plate 1 For installation reverse the removal procedure 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb SEAT SIDE COVERS AND FUEL TANK ...

Page 43: ... ENGINE IDLING SPEED NOTE NOTE Prior to adjusting the engine idling speed the air filter element should be clean and the engine should have adequate compression 1 Start the engine and let it warm up for sev eral minutes 2 Adjust engine idling speed a Turn the throttle stop screw in direction or until the engine runs at the lowest possible speed 3 Adjust throttle cable free play Refer to ADJUSTING ...

Page 44: ...usting nut in direction or until the specified throttle cable free play is obtained c Tighten the locknut WARNING After adjusting the throttle cable free play start the engine and turn the handlebar to the right or left to ensure that this does not cause the engine idling speed to change Throttle cable free play at the flange of the throttle grip 3 0 5 0 mm 0 12 0 20 in Direction Throttle cable fr...

Page 45: ...ear Replace the spark plug insulator Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean spark plug with a spark plug cleaner or wire brush 6 Measure spark plug gap with a wire thickness gauge Out of specification Regap 7 Install spark plug NOTE NOTE Before installing the spark plug clean the spark plug and gasket surface 8 Connect spark plug cap Spark plug type manuf...

Page 46: ... direction b Set the dial gauge to zero at TDC c From TDC rotate the rotor clockwise until the dial gauge indicates that the piston in at a specified distance from TDC 4 Check ignition timing Punch mark on rotor should be aligned with punch mark on stator Not aligned Adjust 5 Adjust ignition timing a Loosen the screws stator b Align the punch mark on the rotor with punch mark on stator by moving t...

Page 47: ...filler cap transmission drain bolt 5 Drain transmission oil completely from the crankcase 6 Install transmission oil drain bolt gasket transmission oil drain bolt along with the new gasket 7 Fill transmission oil with the specified amount of the recom mended transmission oil 8 Install transmission oil filler cap 9 Start the engine warm it up for several min utes and then turn it off 10 Check oil l...

Page 48: ...ERS AND FUEL TANK 2 Remove air filter case cover a Set the air filter case cover as shown and install it to the seat rail of the rear frame while rotating air filter case cover in the direction of the arrow b Using a conventional screwdriver hold up the front of the air filter case cover Then engage the groove in the cover over the air filter case edge Clutch cable free play at the end of the clut...

Page 49: ...formance and possible overheat ing 3 Clean air filter element with solvent NOTE NOTE After cleaning remove the remaining solvent by squeezing the element CAUTION Do not twist the element when squeezing the element Leaving too much of solvent in the ele ment may result in poor starting 4 Check air filter element Damage Replace 5 Apply foam air filter oil or equivalent oil To the element NOTE NOTE S...

Page 50: ...ING THE CARBURETOR JOINT 1 Remove carburetor Refer to CARBURETOR in chapter 7 2 Check carburetor joint Cracks damage Replace Refer to CARBURETOR in chapter 7 3 Install carburetor joint carburetor EAS00096 CHECKING THE HOSES The following procedure applies to all of the fuel and vacuum hoses 1 Check fuel hose carburetor breather hose over flow hose Cracks damage Replace Loose connection Connect pro...

Page 51: ...wing procedure applies to all of the exhaust pipes mufflers and gaskets 1 Remove seat side cover right Refer to SEAT SIDE COVERS AND FUEL TANK 2 Remove silencer exhaust joint exhaust pipe gasket 3 Check silencer exhaust joint exhaust pipe Cracks damage Replace 4 Install gasket exhaust pipe exhaust joint silencer Exhaust pipe bolt 12 Nm 1 2 m kg 8 7 ft lb Silencer bolt 12 Nm 1 2 m kg 8 7 ft lb CHEC...

Page 52: ...kwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counterclockwise to remove 3 Check coolant level Coolant level low Add coolant CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentrati...

Page 53: ...diator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap...

Page 54: ... lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze 6 Install radiator cap 7...

Page 55: ...ake lever a Loosen the locknut b Turn the adjusting bolt in direction or until the brake lever is in the desired position c Tighten the locknut CAUTION After adjusting the brake lever position make sure there is no brake drag Standard brake lever position 95 mm 3 74 in Extent of adjustment 76 97 mm 2 99 3 82 in Direction Brake lever distance is increased Direction Brake lever distance is decreased...

Page 56: ...ht between the maxi mum and the minimum as shown In this adjustment the bolt end should protrude out of the lower adjusting nut but not be less than 2 0 mm 0 08 in away from the brake pedal c Tighten the locknut to specification CAUTION After adjusting the brake pedal position make sure there is no brake drag Brake pedal height 4 0 10 0 mm 0 16 0 39 in Direction Brake pedal is raised Direction Bra...

Page 57: ...ll with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic pa...

Page 58: ...re applies to all of the brake hoses and brake hose clamps 1 Check brake hose Cracks damage wear Replace 2 Check brake hose holder Loose Tighten the holder bolt NOTE NOTE Align the brake hose holder with the projec tion on the front fork and clamp the brake hose Pass the brake hose behind the rib on the front fork 3 Hold the vehicle upright and apply the brake several times 4 Check brake hose Brak...

Page 59: ... to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plastic hose tightly to the bleed screw Front Rear d Place the other end of the hose into a...

Page 60: ...al a Install the shift pedal with the bottom of the pedal outer diameter as close to the center of the engine mounting bolt as possible EAS00138 ADJUSTING THE DRIVE CHAIN SLACK NOTE NOTE The drive chain slack must be checked at the tightest point on the chain CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swi...

Page 61: ...adjusting nuts in direction or until the specified drive chain slack is obtained NOTE NOTE To maintain the proper wheel alignment adjust both sides evenly Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks on each side of chain puller alignment c Tighten the wheel axle nut to specification d Tighten the locknuts to specification Drive chain slack 35 0 45 ...

Page 62: ...0147 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so that there is no danger of it falling over NOTE NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove han...

Page 63: ... binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD in chapter 4 5 Install upper bracket handlebar Refer to HANDLEBAR and STEERING HEAD in chapter 4 EAS00149 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so that there is n...

Page 64: ... fork legs evenly Uneven adjustment can result in poor han dling and loss of stability Securely support the vehicle so that there is no danger of it falling over Front fork internal pressure bleeding NOTE NOTE If the front fork initial movement feels stiff dur ing a run bleed the front fork internal pressure 1 Elevate the front wheel by placing a suitable stand under the engine 2 Remove the air bl...

Page 65: ...pension is softer Adjusting positions Minimum 20 clicks in direction Standard 7 clicks in direction Maximum 1 clicks in direction with the adjusting screw fully turned in direction Direction Compression damping is increased suspension is harder Direction Compression damping is decreased suspension is softer Adjusting positions Minimum 20 clicks in direction Standard YZ85 10 clicks in direction Sta...

Page 66: ...move all dirt and mud from around the locknut and adjuster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster b Turn the adjusting nut in direction or c Tighten the locknut Ring nut wrench 90890 01268 Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Adjusting length Standard YZ85 ...

Page 67: ...und damping is increased suspension is harder Direction Rebound damping is decreased suspension is softer Adjusting positions Minimum 20 clicks in direction Standard YZ85 6 clicks in direction Standard YZ85LW 12 clicks in direction for EUR Standard YZ85LW 7 clicks in direction for AUS NZL Maximum 1 clicks in direction with the adjusting knob fully turned in direction Direction Compression damping ...

Page 68: ...r temperature The tire pressure and the suspension must be adjusted according to the total weight including rider and the antici pated riding speed WARNING It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately Adjusting positions Minimum 20 clicks in direction Standard YZ85 9 clicks in direction Standard YZ85LW 12 clicks in direction f...

Page 69: ...eat care and replace the tube as soon as possible with a good quality replacement After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufac turer and of the same design No guaran tee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is use...

Page 70: ...ten spoke with a spoke wrench NOTE NOTE Be sure to tighten the spokes before and after break in After a practice or a race check spokes for looseness EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspens...

Page 71: ...STER CYLINDER 4 23 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 25 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 25 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 26 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 27 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 29 FRONT BRAKE CALIPER 4 31 REAR BRAKE CALIPER 4 33 DISASSEMBLING THE FRONT BRAKE CALIPER 4 35 DISASSEMBLING THE REAR...

Page 72: ...SHOCK ABSORBER AND GAS CYLINDER 4 66 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4 66 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 67 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 4 68 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 68 SWINGARM AND DRIVE CHAIN 4 70 REMOVING THE SWINGARM 4 72 REMOVING THE DRIVE CHAIN 4 73 CHECKING THE SWINGARM 4 73 CHECKING THE DRIVE CHAIN 4 74 CH...

Page 73: ...disc Remove the parts in the order listed NOTE NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 1 Front wheel axle 1 2 Front wheel 1 3 Collar 2 4 Front brake disc 1 For installation reverse the removal procedure 70 Nm 7 0 m kg 50 ft lb 12 Nm 1 2 m kg 8 7 ft lb FRONT WHEEL AND BRAKE DISC ...

Page 74: ... Order Job Part Q ty Remarks Disassembling the front wheel Disassemble the parts in the order listed Oil seal 2 Wheel bearing 2 Collar 1 For assembly reverse the disassembly procedure FRONT WHEEL AND BRAKE DISC ...

Page 75: ...lever when removing the brake caliper 3 Elevate front wheel NOTE NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 4 Remove front wheel axle nut front wheel axle front wheel collar EAS00526 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace NOTE NOTE The bending value is shown by one half of the dial gauge reading WARNING Do...

Page 76: ...e specified limits Replace 5 Check collars Damage wear Replace 6 Check wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings oil seals Damage wear Replace 7 Replace wheel bearings oil seals a Clean the outside of the front wheel hub b Remove the oil seals with a flat head screwdriver NOTE NOTE To prevent damaging the wheel place a rag between the screwdriver and the wheel...

Page 77: ...el bearings and oil seals in the reverse order of disassembly CAUTION Do not contact the wheel bearing inner race or balls Contact should be made only with the outer race NOTE NOTE Use a socket that matches the diameter of the wheel bearing outer race and oil seal FRONT WHEEL AND BRAKE DISC ...

Page 78: ...move the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm 0 06 in below the edge of the brake disc 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace 4 Adjust brake disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the br...

Page 79: ...thin specification replace the brake disc EAS00546 INSTALLING THE FRONT WHEEL 1 Lubricate front wheel axle oil seal lips 2 Install collar front wheel front wheel axle NOTE NOTE Install the brake disc between the brake pads correctly 3 Tighten front wheel axle Brake disc bolt 12 Nm 1 2 m kg 8 7 ft lb LOCTITE Recommended lubricant Lithium soap based grease 70 Nm 7 0 m kg 51 ft lb FRONT WHEEL AND BRA...

Page 80: ...e vehicle on a suitable stand so that the rear wheel is elevated Rear brake caliper Remove Refer to REMOVING THE REAR BRAK PADS 1 Rear wheel axle nut 1 2 Locknut 2 Loosen 3 Adjusting bolt 2 Loosen 4 Rear wheel axle 1 5 Washer 2 6 Drive chain puller 2 7 Rear wheel 1 16 Nm 1 6 m kg 11 ft lb 16 Nm 1 6 m kg 11 ft lb 90 Nm 9 0 m kg 65 ft lb REAR WHEEL AND BRAKE DISC ...

Page 81: ...CHAS 4 9 Order Job Part Q ty Remarks 8 Collar 2 For installation reverse the removal procedure 16 Nm 1 6 m kg 11 ft lb 16 Nm 1 6 m kg 11 ft lb 90 Nm 9 0 m kg 65 ft lb REAR WHEEL AND BRAKE DISC ...

Page 82: ...emarks Removing the rear brake disc and rear wheel sprocket Remove the parts in the order listed 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Rear wheel 1 For installation reverse the disassembly procedure 12 Nm 1 2 m kg 8 7 ft lb 42 Nm 4 2 m kg 30 ft lb REAR WHEEL AND BRAKE DISC ...

Page 83: ...Order Job Part Q ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed Oil seal 2 Circlip 1 Bearing 2 Collar 1 For assembly reverse the disassembly procedure REAR WHEEL AND BRAKE DISC ...

Page 84: ... on a suitable stand so that the rear wheel is elevated 2 Remove protector brake caliper NOTE NOTE Do not depress the brake pedal when remov ing the brake caliper 3 Loosen locknut adjusting bolt 4 Remove wheel axle nut wheel axle rear wheel NOTE NOTE Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove left collar right collar REAR WHEEL AND BRAKE DISC ...

Page 85: ...er 3 3 Check spokes Refer to CHECKING THE FRONT WHEEL 4 Measure radial wheel runout lateral wheel runout Refer to CHECKING THE FRONT WHEEL EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check rear wheel sprocket More than 1 4 tooth wear Replace the rear wheel sprocket and drive chain as set Bent teeth Replace the rear wheel sprocket and drive chain as a set Correct Drive chain roller Re...

Page 86: ... NOTE NOTE Tighten the self locking nuts in stages and in a crisscross pattern EAS00572 INSTALLING THE REAR WHEEL 1 Lubricate rear wheel axle wheel bearings oil seal lips 2 Tighten rear wheel axle nut brake caliper bolts side front Rear wheel sprocket self locking nut 42 Nm 4 2 m kg 30 ft lb Recommended lubricant Lithium soap based grease 90 Nm 9 0 m kg 65 ft lb 23 Nm 2 3 m kg 17 ft lb 10 Nm 1 0 m...

Page 87: ...art Q ty Remarks Removing the front brake pads Remove the parts in the order listed 1 Brake caliper 1 2 Brake pad 2 3 Brake pad support 2 4 Bleed screw 1 For installation reverse the removal procedure 6 Nm 0 6 m kg 4 3 ft lb 23 Nm 2 3 m kg 17 ft lb FRONT AND REAR BRAKES ...

Page 88: ...ed 1 Protector 1 2 Spacer 1 3 Brake pad pin 2 4 Rear brake caliper 1 5 Brake pad 2 6 Brake pad shim 1 7 Brake pad spring 1 8 Bleed screw 1 For installation reverse the removal procedure 23 Nm 2 3 m kg 17 ft lb 18 Nm 1 8 m kg 13 ft lb 6 Nm 0 6 m kg 4 3 ft lb 10 Nm 1 0 m kg 7 2 ft lb 23 Nm 2 3 m kg 17 ft lb FRONT AND REAR BRAKES ...

Page 89: ...ents Use only clean or new brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get immediate medical attention EAS00581 REPLACING...

Page 90: ...iper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad support 5 Lubricate brake pad bolts brake caliper guide bar CAUTION Do not allow grease to contact the brake pads Remove any excess grease 6 Install brake caliper 7 Check brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEV...

Page 91: ...mble the brake caliper 1 Loosen brake pad pins 2 Remove brake caliper 3 Remove brake pad pins brake pads along with the brake pad shims brake pad spring 4 Measure brake pad wear limit Out of specification Replace the brake pads as a set 5 Install brake pad spring brake pad shims onto the brake pads brake pads brake pad pins brake caliper NOTE NOTE Always install new brake pads brake pad shims and ...

Page 92: ...stall the brake pad pins 6 Tighten brake pad pins brake caliper front rear LOCK TITE 7 Check brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Bleed screw 6 Nm 0 6 ...

Page 93: ...rain Refer to CHANGING THE BRAKE FLUID in chapter 3 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake lever cover 1 5 Brake lever 1 6 Brake master cylinder holder 1 7 Brake master cylinder 1 For installation reverse the removal procedure 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 ft lb 26 Nm 2 6 m kg 19 ft lb 9 Nm 0 9 m kg 6 5 ft lb FRONT AND REAR BRAKES ...

Page 94: ...arts in the order listed Brake master cylinder cap 1 Brake master cylinder reservoir dia phragm 1 Brake master cylinder reservoir float 1 Brake master cylinder boot 1 Circlip 1 Washer 1 Brake master cylinder kit 1 For assembly reverse the disassembly procedure 2 Nm 0 2 m kg 1 4 ft lb FRONT AND REAR BRAKES ...

Page 95: ...ke fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir tank 1 5 Brake fluid reservoir hose 1 6 Hose holder 1 7 Union bolt 1 8 Copper washer 2 9 Brake hose 1 10 Brake master cylinder 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 1 Nm 0 1 m kg 0 7 ft lb 26 Nm 2 6 m kg 19 ft l...

Page 96: ...Q ty Remarks Removing the rear brake master cylinder Remove the parts in the order listed Brake master cylinder kit 1 Circlip 1 Brake master cylinder joint 1 O ling 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 97: ...ainer under the master cylinder and the end of the brake hose 2 Remove brake master cylinder bracket brake master cylinder 3 Remove brake master cylinder boot circlip EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove union bolt copper washers brake hose NOTE NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 2 Remove bra...

Page 98: ...h compressed air Front Rear 2 Check brake master cylinder kit Damage scratches wear Replace Front Rear 3 Check rear brake fluid reservoir Cracks damage Replace rear brake fluid reservoir diaphragm Cracks damage Replace 4 Check front brake master cylinder reservoir Cracks damage Replace front brake master cylinder reservoir dia phragm Damage wear Replace 5 Check brake hoses Cracks damage wear Repla...

Page 99: ...rake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 2 Install copper washers brake hose union bolt WARNING Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 CAUTION Install the brake hose so that its pipe por tion directs as shown and lightly touches the projection on the brake master cyli...

Page 100: ... already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up an...

Page 101: ...er to CABLE ROUTING in chapter 2 CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection as shown 3 Fill brake fluid reservoir to the maximum level mark WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fl...

Page 102: ...e fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake pedal operation WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of co...

Page 103: ...ake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Protector 1 2 Brake hose holder 1 3 Union bolt 1 4 Copper washer 2 5 Brake hose 1 6 Brake caliper 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0 m kg 7 2 ft lb 23 Nm 2 3 m kg 17 ft lb 26 Nm 2 6 m kg 19 ft lb FRONT AND REAR BRAKES ...

Page 104: ... the parts in the order listed Brake pad 2 Brake caliper bracket 1 Brake pad support 2 Sleeve boot 1 Brake caliper piston 2 Brake caliper piston seal 4 Pin boot 1 Bleed screw 1 For assembly reverse the disassembly procedure 6 Nm 0 6 m kg 4 3 ft lb 30 Nm 3 0 m kg 22 ft lb FRONT AND REAR BRAKES ...

Page 105: ... Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake pad pin 2 Loosen 5 Protector 1 6 Brake caliper 1 For installation reverse the removal procedure 23 Nm 2 3 m kg 17 ft lb 10 Nm 1 0 m kg 7 2 ft lb 23 Nm 2 3 m kg 17 ft lb 26 Nm 2 6 m kg 19 ft lb 18 Nm 1 8 m kg 13 ft lb FRONT AND REAR BRAKES ...

Page 106: ...ar brake caliper Remove the parts in the order listed Brake pad pin 2 Brake pad 2 Brake pad shim 1 Brake caliper seal 2 Brake caliper piston 1 Brake pad spring 1 Bleed screw 1 For assembly reverse the disassembly procedure 6 Nm 0 6 m kg 4 3 ft lb FRONT AND REAR BRAKES ...

Page 107: ...tons brake caliper piston seals a Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper WARNING Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis tons b Remove the brake caliper piston seals EAS00626 DISASSEMBLING THE REAR BRAKE CAL...

Page 108: ...ake caliper WARNING Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston seals EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Eve...

Page 109: ...liper piston seals Front Rear 2 Check front brake caliper bracket Cracks damage Replace guide pin Rust damage Replace sleeve boot Crack damage Replace pin boot Wear damage Replace EAS00634 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake co...

Page 110: ...rake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing p...

Page 111: ...EAR BRAKE CALIPER WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals 1 Install brake pad spring brake pad shim brake pad pins 2 Install brake ...

Page 112: ...ate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock...

Page 113: ...rk Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 FRONT AND REAR BRAKES ...

Page 114: ... Protector Front brake caliper Number plate Refer to SEAT SIDE COVERS AND FUEL TANK in chapter 3 1 Cap bolt 1 Loosen 2 Upper bracket pinch bolt 1 Loosen 3 Lower bracket pinch bolt 2 Loosen 4 Front fork 1 For installation reverse the removal procedure 20 Nm 2 0 m kg 14 ft lb 4 Nm 0 4 m kg 2 9 ft lb 20 Nm 2 0 m kg 14 ft lb 22 Nm 2 2 m kg 16 ft lb FRONT FORK Refer to FRONT AND REAR BRAKES ...

Page 115: ...ted Guide protector 1 Cap bolt 1 O ring 1 Damper adjusting rod 1 Nut 1 Washer 1 Fork spring 1 Spring guide 1 Dust seal 1 Oil seal clip 1 Inner tube 1 Outer tube 1 Piston metal 1 Slide metal 1 Oil seal washer 1 55 Nm 5 5 m kg 40 ft lb 15 Nm 1 5 m kg 11 ft lb 28 Nm 2 8 m kg 20 ft lb 1 Nm 0 1 m kg 0 7 ft lb FRONT FORK ...

Page 116: ...il seal 1 Plug 1 Base valve 1 Gasket 1 O ring 2 Damper rod 1 O ring 1 Air bleed screw 1 For assembly reverse the disassembly procedure 55 Nm 5 5 m kg 40 ft lb 15 Nm 1 5 m kg 11 ft lb 28 Nm 2 8 m kg 20 ft lb 1 Nm 0 1 m kg 0 7 ft lb FRONT FORK ...

Page 117: ...at there is no danger of it falling over NOTE NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Remove front wheel protector front brake caliper number plate 3 Loosen cap bolt 4 Loosen upper bracket pinch bolt lower bracket pinch bolts WARNING Before loosening the upper and lower bracket pinch bolts support the front fork leg 5 Remove front fork leg FRONT FORK ...

Page 118: ...ut c Remove the cap bolt 2 Remove nut washer fork spring spring guide 3 Drain fork oil NOTE NOTE Stroke the damper rod several times while draining the fork oil 4 Remove dust seal oil seal clip with a flat head screwdriver CAUTION Do not scratch the inner tube 5 Remove inner tube a Push in slowly the inner tube just before it bottoms out and then pull it back quickly b Repeat this step until the i...

Page 119: ...th of the front fork legs 1 Check inner tube outer tube Bends damage scratches Replace WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure spring free length Out of specification Replace 3 Check damper rod Bend damage Replace Obstruction Blow out all of the oil pas sages with compressed air damper rod adjusting rod Bend damage Replace Damper rod holde...

Page 120: ...heck cap bolt Damage wear Replace air bleed screw Damage wear Replace EAS00661 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE NOTE When assembling the front fork leg be sure to replace the following parts outer...

Page 121: ... the inner tube 2 Install gasket base valve 3 Tighten base valve LOCTITE NOTE NOTE While holding the damper rod with the damper rod holder tighten the base valve 4 Lubricate inner tube s outer surface 5 Install spring guide nut NOTE NOTE Install the spring guide with its cut facing downward 55 Nm 5 5 m kg 40 ft lb Damper rod holder 90890 01454 YM 01454 Recommended lubricant Suspension oil 01 FRONT...

Page 122: ...ased grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 7 Install piston metal NOTE NOTE Install the piston metal on to the slot on inner tube 8 Install outer tube 9 Install slide metal oil seal washer with the fork seal driver Fork seal driver 90890 014...

Page 123: ...NOTE While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil Fork seal driver 90890 01442 YM 01442 Quantity each front fork leg 0 32 L 0 28 Imp qt 0 34 US qt Recommended oil Suspension oil 01 Front fork leg oil level from the top of the outer tube with the outer tube fully compressed and without the fork spring Standard 9...

Page 124: ...and the washer NOTE NOTE Use the side of the rod holder that is marked A d Remove the rod puller and adapter e Install the nut and position it as specified f Loosen the rebound damping force adjust ing screw finger tight NOTE NOTE Record the set position of the adjuster the amount of turning out the fully turned in posi tion Rod puller 90890 01437 YM 01437 Rod puller attachment M10 90890 01436 YM ...

Page 125: ...ake sure that there is a clearance of 0 1 mm 0 0 04 in between the front fork cap bolt and locknut h Hold the cap bolt and tighten the nut to specification i Remove the rod holder j Temporarily tighten the cap bolt 15 Install protector guide Nut 15 Nm 1 5 m kg 11 ft lb FRONT FORK ...

Page 126: ...r holder 2 Tighten cap bolt 3 Adjust front fork top end 4 Tighten upper bracket pinch bolt lower bracket pinch bolt WARNING Make sure the brake hoses are routed prop erly 5 Install protector 6 Adjust spring preload rebound damping compression damping Refer to ADJUSTING THE FRONT FORK LEGS in chapter 3 28 Nm 2 8 m kg 20 ft lb Front fork top end standard YZ85 24 mm 0 94 in YZ85LW 0 mm 0 00 in 22 Nm ...

Page 127: ...utch cable 1 2 Clutch lever holder 1 3 Clutch lever 1 4 Engine stop switch 1 5 Brake master cylinder cap 1 6 Brake master cylinder 1 7 Throttle cable cap 1 8 Grip cap lower 1 9 Grip cap upper 1 10 Throttle cable 1 11 Right grip 1 12 Tube guide 1 13 Collar 1 1 Nm 0 1 m kg 0 7 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 27 Nm 2 7 m kg 1 9 ft lb 9 Nm 0 9 m kg 6 5 ft lb HANDLEBAR ...

Page 128: ...s 14 Left grip 1 15 Handlebar upper holder 2 16 Handlebar 1 For installation reverse the removal procedure 1 Nm 0 1 m kg 0 7 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 27 Nm 2 7 m kg 1 9 ft lb 9 Nm 0 9 m kg 6 5 ft lb HANDLEBAR ...

Page 129: ... damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS00670 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so that there is no danger of it falling over 2 Install handlebar handlebar upper holder CAUTION First tighten the bolts on the front side of the handlebar holder and then on the rear s...

Page 130: ...l on the handlebar surface with a lac quer thinner Install the left grip to the handlebar so that the arrow mark L faces straight upward 4 Install right grip apply the adhesive on the tube guide NOTE NOTE Before applying the adhesive wipe off grease or oil on the tube guide surface with a lac quer thinner Locate the mating mark on the grip as shown 5 Install collar tube guide grip cap upper thrott...

Page 131: ...all the bracket so that the arrow mark face upward 9 Install engine stop switch clutch lever holder clamp NOTE NOTE The engine stop switch and clutch lever holder should be installed according to the dimen sions shown 10 Install clutch cable NOTE NOTE Apply the lithium soap base grease on the clutch cable end 1 Nm 0 1 m kg 0 7 ft lb 4 Nm 0 4 m kg 2 9 ft lb 9 Nm 0 9 m kg 6 5 ft lb 4 Nm 0 4 m kg 2 9...

Page 132: ...ver free play Refer to ADJUSTING THE CLUTCH CABLE FREE PRAY in chapter 3 12 Clamp the clamp portion of the number plate to the handlebar 13 Insert the end of the fuel tank breather hose into the hole of the steering stem HANDLEBAR ...

Page 133: ... to HANDLEBAR Front fender 1 Steering stem nut 1 2 Washer 1 3 Upper bracket 1 4 Steering ring nut 1 5 Lower bracket 1 6 Bearing race cover 1 7 Washer 1 8 Upper bearing 1 9 Lower bearing 1 10 Bearing race 2 For installation reverse the removal procedure 4 Nm 0 4 m kg 2 9 ft lb Loosen it 1 turn 38 Nm 3 8 m kg 27 ft lb 1st 1st 2nd 3rd 22 Nm 2 2 m kg 16 ft lb 125 Nm 12 5 m kg 90 ft lb 20 Nm 2 0 m kg 1...

Page 134: ...steering stem nut washer upper bracket steering ring nut with the ring nut wrench WARNING Securely support the lower bracket so that there is no danger of it falling EAS00682 CHECKING THE STEERING HEAD 1 Wash bearings bearing races 2 Check bearings bearing races Damage pitting Replace Steering nut wrench 90890 01403 YU 33975 Recommended cleaning solvent Kerosene STEERING HEAD ...

Page 135: ...steering head pipe could be damaged NOTE NOTE Always replace the bearing balls and bearing races as a set Whenever the steering head is disassembled replace the dust seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races 2 Install lower bracket upper bearing washer...

Page 136: ...ng nut 4 Install upper bracket washer steering stem nut 5 Install front fork legs Refer to INSTALLING THE FRONT FORK LEGS NOTE NOTE Temporarily tighten the upper and lower bracket pinch bolts 4 Nm 0 4 m kg 2 9 ft lb Steering nut wrench 90890 01403 YU 33975 38 Nm 3 8 m kg 27 ft lb 4 Nm 0 4 m kg 2 9 ft lb 125 Nm 12 5 m kg 90 ft lb STEERING HEAD ...

Page 137: ...IPE in chapter 5 1 Clamp 1 Loosen 2 Rear frame 1 3 Washer bolt 1 1 4 Self locking nut washer bolt 1 1 1 5 Rear shock absorber 1 6 Spring guide 1 7 Spring 1 8 Adjuster 1 9 Locknut 1 For installation reverse the removal procedure 36 Nm 3 6 m kg 26 ft lb 16 Nm 1 6 m kg 12 ft lb 26 Nm 2 6 m kg 19 ft lb 36 Nm 3 6 m kg 26 ft lb REAR SHOCK ABSORBER ASSEMBLY Refer to SEAT SIDE COVERS AND FUEL TANK in chap...

Page 138: ...gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pres sure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EAS00689 DISPOSING OF A REAR SHOCK ABSORBER AND GAS...

Page 139: ...e vehicle on a suitable stand so that the rear wheel is elevated 2 Remove seat and right side cover Refer to SEAT SIDE COVERS AND FUEL TANK in chapter 3 silencer Refer to EXHAUST PIPE in chapter 5 3 Loosen air filter clamp 4 Remove rear frame 5 Remove rear shock absorber lower bolt washer 6 Remove rear shock absorber upper bolt washer self locking nut rear shock absorber REAR SHOCK ABSORBER ASSEMB...

Page 140: ...ce dust seals Damage wear Replace bolts Bends damage wear Replace EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate spacers bolts 2 Install rear shock absorber NOTE NOTE When installing the rear shock absorber assembly lift up the swingarm Install the connecting arm front bolt from the right 3 Tighten rear shock absorber upper nut rear shock absorber lower bolt 4 Install rear frame ...

Page 141: ...ST PIPE in chapter 5 seat and right side cover Refer to SEAT SIDE COVERS AND FUEL TANK in chapter 3 6 Adjust spring preload rebound damping compression damping Refer to ADJUSTING THE REAR SHOCK ABSORBER in chapter 3 REAR SHOCK ABSORBER ASSEMBLY ...

Page 142: ...e holder Rear brake caliper Left crankcase cover Refer to CDI MAGNETO in chapter 5 1 Drive chain 1 2 Drive chain support 1 3 Drive chain support cover 1 4 Pivot shaft 1 5 Swingarm 1 For installation reverse the removal procedure 16 Nm 1 6 m kg 12 ft lb 53 Nm 5 3 m kg 38 ft lb 7 Nm 0 7 m kg 5 1 ft lb 63 Nm 6 3 m kg 46 ft lb 36 Nm 3 6 m kg 26 ft lb SWINGARM AND DRIVE CHAIN Refer to FRONT AND REAR BR...

Page 143: ...ts in the order listed Relay arm 1 Connecting rod 1 Cover 2 Dust seal 2 Collar 5 Bushing 5 Oil seal 8 Bearing 9 Bushing 2 Drive chain guide 1 For assembly reverse the disassembly procedure 53 Nm 5 3 m kg 38 ft lb 54 Nm 5 4 m kg 39 ft lb 10 Nm 1 0 m kg 7 2 ft lb SWINGARM AND DRIVE CHAIN ...

Page 144: ...n chapter 5 3 Measure swingarm side play swingarm vertical movement a Measure the tightening torque of the pivot shaft nut b Measure the swingarm side play by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers d Check the swingarm vertical movement by moving the swingarm up and down If swingarm vertical move...

Page 145: ...tand so that the rear wheel is elevated 2 Remove master link clip master link master link plate drive chain EAS00707 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING Do not attempt to straighten a bent pivot shaft 3 Wash pivot shaft collar bearings Recommended cleaning solvent Kerosene SWINGARM AND D...

Page 146: ...pacers Damage scratches Replace EAS00710 CHECKING THE DRIVE CHAIN 1 Measure Measure the dimension between 15 links on the inner side and outer side of the roller and calculate the dimension between pin centers Dimension between pin centers Inner dimension Outer dimension 2 15 link section of the drive chain Out of specification Replace the drive chain front drive sprocket and rear drive sprocket a...

Page 147: ... chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it 4 Check drive chain rollers Damage wear Replace the drive chain drive chain side plates Damage wear Replace the drive chain Cracks Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below the swingarm 5 Lubricate drive chain...

Page 148: ...eaches indicator Replace EAS00711 INSTALLING THE SWINGARM 1 Install bearing bushing swingarm oil seal with the swingarm NOTE NOTE Apply the molybdenum disulfide grease on the bearing and bushing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers First install the bushing and then the bearing to a specified depth from inside Installed depth of b...

Page 149: ...3 Install bearing oil seal with the connecting rod NOTE NOTE Apply the molybdenum disulfide grease on the bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers 4 Install connecting rod Installed depth of bearings Depth 4 5 mm 0 18 in Depth 0 5 mm 0 02 in Depth 4 0 mm 0 16 in Installed depth of bearings 6 5 mm 0 26 in 53 Nm 5 3 m kg 38 ft l...

Page 150: ...ain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 EAS00714 INSTALLING THE DRIVE CHAIN 1 Lubricate drive chain master link 2 Install master link master link plate 54 Nm 5 4 m kg 39 ft lb 63 Nm 6 3 m kg 46 ft lb Drive chain slack 35 45 mm 1 38 1 77 in Recommended lubricant Engine oil or chain lubricant suitable for non O ring chains SWINGARM AND DRIVE CHAIN ...

Page 151: ...i cally shorten the drive chain s life 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits Drive chain slack 35 45 mm 1 38 1 77 in SWINGAR...

Page 152: ...HECKING THE CYLINDER AND PISTON 5 11 COMBINATION OF PISTON AND CYLINDER 5 13 CHECKING THE PISTON RING 5 14 CHECKING THE PISTON PIN 5 14 CHECKING THE SMALL END BEARING 5 15 INSTALLING THE PISTON AND CYLINDER 5 16 CLUTCH 5 18 CLUTCH 5 18 REMOVING THE CLUTCH 5 20 CHECKING THE FRICTION PLATES 5 21 CHECKING THE CLUTCH PLATES 5 21 CHECKING THE CLUTCH SPRINGS 5 22 CHECKING THE CLUTCH HOUSING 5 22 CHECKIN...

Page 153: ...GEAR 5 34 CDI MAGNETO 5 36 REMOVING THE ROTOR 5 37 CHECKING THE CDI MAGNETO 5 37 CHECKING THE WOODRUFF KEY 5 37 INSTALLING THE CDI MAGNETO 5 38 CRANKCASE AND CRANKSHAFT 5 40 CRANKCASE AND CRANKSHAFT 5 40 DISSASSEMBLING THE CRANKCASE 5 41 REMOVING THE CRANKSHAFT ASSEMBLY 5 41 REMOVING THE CRANKSHAFT BEARING 5 42 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 42 CHECKING THE CRANKCASE 5 43 CHECKING TH...

Page 154: ...rocket Remove the parts in the order listed Drive chain Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 1 Left crank case cover 1 2 Nut 1 3 Lock washer 1 4 Drive sprocket 1 For installation reverse the removal procedure 60 Nm 6 0 m kg 43 ft lb 5 Nm 0 5 m kg 3 6 ft lb ENGINE ...

Page 155: ...ht side cover 1 Silencer 1 2 Exhaust pipe joint 1 3 Exhaust pipe spring 2 4 Exhaust pipe 1 5 Exhaust pipe gasket 2 For installation reverse the removal procedure 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb ENGINE Refer to SEAT SIDE COVERS AND FUEL TANK in chapter 3 ...

Page 156: ...r 4 Install inner pipe NOTE NOTE Fully apply Yamaha bond No 1215 Three bond No 1215 or equivalent as shown 5 Install washer bolt fiber LOCTITE silencer bolt silencer right side cover seat Yamaha bond No 1215 Three Bond No 1215 90890 85505 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb ENGINE ...

Page 157: ...ain Refer to CHANGING THE COOLANT in chapter 3 Seat Fuel tank Carburetor Refer to CARBURETOR in chapter 7 Exhaust pipe Silencer Clutch cable Refer to HANDLEBAR in chapter 4 Radiator hose Refer to RADIATOR in chapter 6 CDI magneto lead Disconnect Loosen 63 Nm 6 3 m kg 46 ft lb 63 Nm 6 3 m kg 46 ft lb ENGINE Refer to SEAT SIDECOVERS AND FUEL TANK in chapter 3 Refer to EXHAUST PIPE ...

Page 158: ... Drive chain Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 1 Engine mount nut 2 2 Engine mount bolt 2 3 Pivot shaft nut 1 4 Pivot shaft 1 5 Engine 1 For installation reverse the removal procedure 63 Nm 6 3 m kg 46 ft lb 63 Nm 6 3 m kg 46 ft lb ENGINE ...

Page 159: ...ne pivot shaft engine mount bolt front engine mount bolt lower NOTE NOTE Do not fully tighten the bolts 2 Tighten pivot shaft nut engine mount nut front engine mount nut lower 63 Nm 6 3 m kg 46 ft lb 69 Nm 6 9 m kg 50 ft lb 69 Nm 6 9 m kg 50 ft lb ENGINE ...

Page 160: ...in Refer to CHANGING THE COOLANT in chapter 3 Seat Fuel tank Radiator hose Refer to RADIATOR in chapter 6 1 Spark plug 1 2 Cylinder head nut 4 3 Copper washer 4 4 Cylinder head 1 5 O ring 2 For installation reverse the removal procedure 20 Nm 2 0 m kg 14 ft lb 30 Nm 3 0 m kg 22 ft lb CYLINDER HEAD CYLINDER AND PISTON Refer to SEAT SIDECOVERS AND FUEL TANK in chapter 3 ...

Page 161: ...er NOTE NOTE Do not use a sharp instrument to avoid damag ing or scratching spark plug bore threads 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is ex...

Page 162: ...der head several times EAS00233 INSTALLING THE CYLINDER HEAD 1 Lubricate O rings 2 Install O rings 3 Install cylinder head copper washer cylinder head nuts NOTE NOTE Tighten the cylinder head nuts in stage using a crisscross pattern 4 Install spark plug spark plug cap radiator hoses Recommended lubricart Lithium soap based grease 30 Nm 3 0 m kg 22 ft lb CYLINDER HEAD CYLINDER AND PISTON ...

Page 163: ...ylinder head Refer to CYLINDER HEAD 1 Cylinder nut 4 2 Cylinder 1 3 Dowel pin 4 4 Cylinder gasket 1 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Small end bearing 1 9 Piston ring 1 For installation reverse the removal procedure 28 Nm 2 8 m kg 20 ft lb 13 Nm 1 3 m kg 9 4 ft lb 13 Nm 1 3 m kg 9 4 ft lb CYLINDER HEAD CYLINDER AND PISTON ...

Page 164: ...in deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 3 Remove piston ring NOTE NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS00257 CHECKING THE CYLINDER AND PISTON 1 Check piston wall...

Page 165: ...piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula f If out of specification replace the cylinder and the piston and piston rings as a set Standard 47 500 47 514 mm 1 8701 1 8706 in Wear limit 47 6 mm 1 8740 in Taper limit T 0 05 mm 0 0020 in Out of round R 0 05 mm 0 0020 in C maximum of D1 D6 T maximum of D1 or D2 maxmum of D5 or D6 R maximum ...

Page 166: ...linder mark Cylinder size A 47 500 47 502 mm 1 8701 1 8702 in B 47 504 47 506 mm 1 8702 1 8703 in C 47 508 47 510 mm 1 8704 1 8705 in D 47 512 47 514 mm 1 87055 1 87063 in Piston mark color Piston size A red 47 457 47 460 mm 1 8684 1 8685 in B orange 47 461 47 464 mm 1 8685 1 8687 in C green 47 465 47 468 mm 1 8687 1 8688 in D purple 47 469 47 472 mm 1 8689 1 8690 in Cylinder mark Piston mark colo...

Page 167: ... ring into the cylinder with the piston crown 3 Measure piston ring end gap Out of specification Replace the piston ring CHECKING THE PISTON PIN 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the fuel and engine mixing oil 2 Measure piston pin outside diameter Out of specification Replace the piston pin Piston ring side clearance Piston ring 0 030 0 065 mm 0 00...

Page 168: ...k small end bearing Signs of heat discoloration Replace Piston pin outside diameter 13 996 14 000 mm 0 5510 0 5512 in Limit 13 975 mm 0 5502 in Piston pin bore inside diameter 14 004 14 015 mm 0 5513 0 5518 in Limit 14 040 mm 0 5528 in Piston pin to piston clearance Piston pin bore size Piston pin outside diameter Piston pin to piston clearance 0 008 0 015 mm 0 0003 0 0006 in Limit 0 065 mm 0 0026...

Page 169: ...d bearing with the recomended lubricant dowel pin 3 Install piston piston pin piston pin clip NOTE NOTE Apply engine oil the piston pin Make sure the arrow mark on the piston points towards the exhaust side of the cylin der Before installing the piston pin clip cover the crankcase opening with a clean rag to pre vent the clip from falling into the crankcase Do not allow the clip open ends to meet ...

Page 170: ...ant 5 Install cylinder cylinder nut NOTE NOTE While compressing the piston ring with one hand install the cylinder with the other hand Tighten the nuts in stage using a crisscross pattern Recommended lubricant Engine oil 28 Nm 2 8 m kg 20 ft lb CYLINDER HEAD CYLINDER AND PISTON ...

Page 171: ...OIL in chapter 3 Clutch cable Disconnect 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Compression spring 5 5 Pressure plate 1 6 Push rod 1 1 7 Ball 1 8 Push rod 2 1 9 Friction plate 1 2 10 Clutch plate 1 6 11 Friction plate 2 5 12 Clutch boss nut 1 70 Nm 7 0 m kg 51 ft lb 6 Nm 0 6 m kg 4 3 ft lb 10 Nm 1 0 m kg 7 2 ft lb CLUTCH ...

Page 172: ...Clutch boss 1 15 Washer 1 16 Primary drive gear 1 17 Spacer 1 18 Washer 1 19 Push lever shaft 1 20 Spring 1 21 Oil seal 1 22 Bearing 1 For installation reverse the removal procedure 70 Nm 7 0 m kg 51 ft lb 6 Nm 0 6 m kg 4 3 ft lb 10 Nm 1 0 m kg 7 2 ft lb CLUTCH ...

Page 173: ... them 2 Remove compression spring bolts compression springs pressure plate 3 Remove push rod 1 ball push rod 2 4 Remove friction plate 1 clutch plate friction plate 2 5 Remove clutch boss nut washer clutch boss NOTE NOTE While holding the clutch boss with the univer sal clutch holder loosen the clutch boss nut 6 Remove washer primary driven gear spacer Universal clutch holder 90890 04086 YM 91042 ...

Page 174: ... a set NOTE NOTE Measure the friction plate at four places EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check clutch plate Damage Replace the clutch plates as a set 2 Measure clutch plate warpage with a surface plate and thickness gauge Out of specification Replace the clutch plates as a set Friction plate thickness 2 9 3 1 mm 0 114 0 112 in Lim...

Page 175: ...h housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE NOTE Pitting on the clutch housing dogs will cause erratic clutch operation EAS00285 CHECKING THE CLUTCH BOSS 1 Check clutch boss splines Damage pitting wear Replace the clutch boss NOTE NOTE Pitting on the clutch boss splines will cause erratic clutch operation EAS00286 CHECKING THE PRESSURE PLATE...

Page 176: ...push rod 1 ball push rod 2 Wear damage bend Replace EAS00298 INSTALLING THE CLUTCH 1 Install washer spacer primary driven gear with the recommended lubricant 2 Install washer clutch boss 3 Install washer NOTE NOTE Install the conical washer to the main axle as shown in the illustration Recommended lubricant Transmission oil CLUTCH ...

Page 177: ...OTE Install the clutch plates and friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Use the friction plate for the first and final while paying attention to the difference in sur face pattern 7 Install push rod 2 ball push rod 1 with the recommended lubricant 70 Nm 7 0 m kg 51 ft lb Universal clutch holder 90890 04086 YM 91042 Recommende...

Page 178: ... the clutch boss 9 Install clutch spring clutch spring bolt NOTE NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 10 Install dowel pin clutch cover gasket clutch cover NOTE NOTE Tighten the bolts in stage using a crisscross pattern 6 Nm 0 6 m kg 4 3 ft lb 10 Nm 1 0 m kg 7 2 ft lb CLUTCH ...

Page 179: ...er 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Water pump housing Refer to WATER PUMP in chapter 6 Radiator hose 2 Refer to RADIATOR in chapter 6 Brake pedal Clutch Refer to CLUTCH 1 Kick starter crank 1 2 Right crankcase cover 1 3 Gascket 1 4 Dowel pin 2 5 Primary drive gear nut 1 6 Washer 1 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 79 Nm 7 9 m kg 5...

Page 180: ...ob Part Q ty Remarks 7 Primary drive gear 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 79 Nm 7 9 m kg 57 ft lb KICK STARTER AND SHIFT SHAFT ...

Page 181: ... parts in the order listed shaft 1 Circlip 1 2 Washer 2 3 Kick idle gear 1 4 Spring guide 1 5 Torsion spring 1 6 Washer 1 7 Kick starter gear clip 1 8 Kick starter gear 1 9 Kick starter shaft 1 10 Shift pedal 1 11 Shift shaft 1 12 Stopper lever spring 1 13 Circlip 1 10 Nm 1 0 m kg 7 2 ft lb KICK STARTER AND SHIFT SHAFT ...

Page 182: ...Job Part Q ty Remarks 14 Washer 1 15 Stopper lever 1 16 Collar 1 17 Shift shaft spring 1 18 Oil seal 1 19 Oil seal 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb KICK STARTER AND SHIFT SHAFT ...

Page 183: ...rankcase CHECKING THE KICK STARTER 1 Check kick starter gear smooth movement Unsmooth movement Replace kick starter shaft Wear damage Replace 2 Check kick starter gear Wear damage Replace kick idle gear Wear damage Replace gear teeth Wear damage Replace 3 Measure kick starter gear clip friction force Out of specification Replace with the spring gauge Drive gear holder 90890 01495 YM 01495 Kick sta...

Page 184: ...ECKING THE PRIMARY DRIVE GEAR AND PRIMARY DRIVEN GEAR 1 Check primary drive gear Damage wear Replace primary driven gear Damage wear Replace 2 Check primary driven gear circumferencial play Free play exists Replace EAS00331 INSTALLING THE SHIFT SHAFT 1 Install stopper lever washer circlip torsion spring with thw collar NOTE NOTE Install the torsion spring with its shorter end aligning with the sto...

Page 185: ...haft NOTE NOTE Apply transmission oil on the shift shaft When installing the shift shaft align the stop per lever roller with the slot on segment When installing the shift shaft make sure that the torsion spring is in the position as shown 4 Check shift lever position Gaps and are not equal except in neutral Replace the shift shaft KICK STARTER AND SHIFT SHAFT ...

Page 186: ... shaft assembly NOTE NOTE Apply the transmission oil on the kick shaft Apply the lithium soap base grease on the kick shaft stopper Slide the kick starter shaft assembly into the crankcase make sure the clip and kick starter shaft stopper fit into their home positions 4 Install torsion spring NOTE NOTE Turn the torsion spring clockwise and hook into the proper hole in the crankcase INSTALLING THE ...

Page 187: ...ustration 3 Tighten primary drive gear nut NOTE NOTE Hold the drive gear holder onto the crank case using the M6 bolts 4 Install primary driven gear Refer to CLUTCH 5 Install dowel pin gasket right crankcase cover 6 Install right crankcase cover NOTE NOTE Mesh the impeller shaft gear with primary drive gear 79 Nm 7 9 m kg 57 ft lb Drive gear holder 90890 01495 YM 01495 KICK STARTER AND SHIFT SHAFT...

Page 188: ...r crank NOTE NOTE Install the kick starter crank closest to but not contacting the pillar tube and exhaust pipe 9 Install shift pedal NOTE NOTE Install the shift pedal with the bottom of the pedal outer diameter as close to the center of the engine mounting bolt as possible 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 189: ...arts in the order listed Seat Fuel tank 1 CDI magneto lead 1 Disconnect 2 Left crankcase cover 1 3 Left crankcase cover gasket 1 4 Rotor 1 5 Stator 1 6 Woodruff key 1 For installation reverse the removal procedure 5 Nm 0 5 m kg 3 6 ft lb 33 Nm 3 3 m kg 24 ft lb 8 Nm 0 8 m kg 5 8 ft lb CDI MAGNETO ...

Page 190: ...E NOTE When installing the flywheel puller turn it counterclockwise CHECKING THE CDI MAGNETO 1 Check rotor inner surface stator outer surface Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator CHECKING THE WOODRUFF KEY 1 Check woodruff key Damage Replace Rotor holding tool 90890 01235 YU 1325 Flywheel puller 90890 01189 YM 1189 CDI MAGNETO ...

Page 191: ...lling the woodruff key make sure that its flat surface is in parallel with the crankshaft center line When installing the rotor align the keyway of the rotor with the woodruff key 3 Install washer nut with the rotor holding tool 4 Adjust ignition timing Refer to CHECKING THE IGNITION TIMING in chapter 3 33 Nm 3 3 m kg 24 ft lb Rotor holding tool 90890 01235 YU 1325 Ignition timing B T D C 0 9 mm 0...

Page 192: ...the ignition timing 7 Connect CDI magneto lead Refer to CABLE ROUTING in chapter 2 8 Install gasket left crankcase cover left crankcase cover NOTE NOTE Tighten the screws in stage using a crisscross pattern 8 Nm 0 8 m kg 5 8 ft lb 5 Nm 0 5 m kg 3 6 ft lb CDI MAGNETO ...

Page 193: ... AND PISTON Primary drive gear Refer to CLUTCH Kick idle gear Stopper lever Rotor and stator Refer to CDI MAGNETO 1 Crank case oil seal holder 1 2 Right crankcase 1 3 Left crankcase 1 4 Dowel pin 2 5 Crankshaft 1 6 Oil seal 2 7 Bearing 2 For installation reverse the removal procedure 8 Nm 0 8 m kg 5 8 ft lb 8 Nm 0 8 m kg 5 8 ft lb 20 Nm 2 0 m kg 14 ft lb CRANKCASE AND CRANKSHAFT Refer to KICK STAR...

Page 194: ...e case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw realign and start over If the cases do not separate check for a remaining case screw or fitting Do not force EAS00388 REMOVING THE CRANKSHAFT ASSEMBLY 1 Remove crankshaft with the crankcase s...

Page 195: ...g puller as shown in CAUTION Do not use the removed bearing EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1 Measure crankshaft runout Out of specification Replace the crank shaft bearing or both NOTE NOTE Turn the crankshaft slowly 2 Measure small end free play Out of specification Replace the small end bearing or piston pin Maximum crankshaft runout 0 08 mm 0 003 in Maximum small end free p...

Page 196: ...CASE 1 Check contacting surface Scratches Replace engine mounting boss crankcase Cracks damage Replace EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace Big end side clearance 0 20 0 70 mm 0 008 0 028 in Crankshaft width 44 90 44 95 mm 1 768 1 770 in...

Page 197: ... the connecting rod at top dead center with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft assembly bottoms against the bearing EAS00416 ASSEMBLING THE CRANKCASE 1 Apply sealant onto the crankcase mating surfaces NOTE NOTE Do not allow any sealant to come into contact with the oil gallery Crankshaft installer p...

Page 198: ... crankcase the connect ing rod should be positioned at TDC 3 Install clamp screw NOTE NOTE Tighten the crankcase tightening screws in stage using a crisscross pattern 4 Install crankcase oil seal holder bolt LOCTITE 5 Remove sealant forced out on the cylinder mating surface 6 Apply Transmission oil To the crank pin bearing oil delivery hole and connecting rod end washer 7 Check crankshaft and tran...

Page 199: ...e parts in the order listed Engine Refer to ENGINE Crankcase Separate Refer to CRANKCASE AND CRANKSHAFT 1 Shift fork guide bar 2 2 Shift drum 1 3 Shift fork R 1 4 Shift fork L 1 5 Shift fork C 1 6 Bearing 1 7 Circlip 1 8 2ND pinion gear 1 9 6TH pinion gear 1 10 Washer 1 11 Circlip 1 TRANSMISSION ...

Page 200: ...r 1 13 Circlip 1 14 Washer 1 15 5TH pinion gear 1 16 Main axle 1 17 Bearing 1 18 Circlip 1 19 Washer 1 20 1ST wheel gear 1 21 5TH wheel gear 1 22 Circlip 1 23 Washer 1 24 4TH wheel gear 1 25 3RD wheel gear 1 26 6TH wheel gear 1 27 Drive axle 1 TRANSMISSION ...

Page 201: ...ENG 5 48 Order Job Part Q ty Remarks 28 2ND wheel gear 1 29 Washer 1 30 Bearing 1 31 Oil seal 1 32 Bearing 2 For installation reverse the removal procedure TRANSMISSION ...

Page 202: ...e transmission drive axle with a soft hammer AS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check shift fork pin shift fork cam follower Bends damage scoring wear Replace the shift fork 2 Check shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace WARNING Do not attempt to straighten a bent shift fork guide bar 3 Check shi...

Page 203: ...e runout with a centering device and dial gauge Out of specification Replace the main axle 2 Measure drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle 3 Check transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s transmission shift fork groove...

Page 204: ...nion gear onto the main axle NOTE NOTE Apply the molybdenum disulfide oil on the 5TH and 6TH pinion gears inner circumfer ence and on the end surface Apply the transmission oil on the 3RD 4TH and 2ND pinion gears inner circumference 2 Install 2ND wheel gear 6TH wheel gear 3RD wheel gear 4TH wheel gear 5TH wheel gear 1ST wheel gear onto the drive axle NOTE NOTE Apply the molybdenum disulfide oil on...

Page 205: ...e the circlip end is positioned at axle spline groove 4 Install collar NOTE NOTE Apply the lithium soap base grease on the oil seal lip When installing the collar into the crankcase pay careful attention to the crankcase oil seal lip 5 Install main axle drive axle 6 Install shift fork L shift fork C shift fork R shift fork pin TRANSMISSION ...

Page 206: ...TH pinion gear on the main axle 7 Install shift cam NOTE NOTE Apply the transmission oil on the shift cam 8 Install shift fork guide bar NOTE NOTE Apply the transmission oil on the guide bars Be sure the long bar is inserted into the shift fork L and shift fork R and the short one into shift fork C 9 Check shifter operation transmission operation TRANSMISSION ...

Page 207: ...COOL CHAPTER 6 COOLING SYSTEM RADIATOR 6 1 CHECKING THE RADIATOR 6 2 INSTALLING THE RADIATOR 6 2 WATER PUMP 6 4 CHECKING THE WATER PUMP 6 5 INSTALLING THE WATER PUMP 6 5 ...

Page 208: ...EAT SIDECOVERS AND FUEL TANK in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator guard 1 2 Radiator inlet hose 1 3 Radiator outlet hose 1 4 Radiator breather hose 1 5 Radiator 1 6 Radiator cap 1 For installation reverse the removal procedure 1 Nm 0 1 m kg 0 7 ft lb 1 Nm 0 1 m kg 0 7 ft lb 1 Nm 0 1 m kg 0 7 ft lb RADIATOR ...

Page 209: ...ressure Replace the radiator cap a Install the radiator cap tester and radia tor cap tester adapter to the radiator cap b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure EAS00456 INSTALLING THE RADIATOR 1 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 Radiator cap opening pressure 93 123 ...

Page 210: ... faulty part a Attach the radiator cap tester to the radi ator b Apply 100 kPa 1 0 kg cm2 14 22 psi of pressure c Measure the indicated pressure with the gauge Radiator cap tester 90890 01325 YU 24460 01 Radiator cap tester adapter 90890 01352 YU 33984 RADIATOR ...

Page 211: ... unless the coolant level is extremely low or the coolant contains engine oil Right crankcase cover Refer to PRIMARY DRIVE GEAR in chapter 5 1 Water pump housing 1 2 Gasket 1 3 Impeller 1 4 Water pump impeller shaft 1 5 Bearing 1 6 Oil seal 2 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 14 Nm 1 4 m kg 10 ft lb WATER PUMP ...

Page 212: ... movement Replace 3 Check impeller Cracks damage wear Replace 4 Check water pump impeller shaft Damage wear Replace water pump drive gear Damage wear Replace EAS00479 INSTALLING THE WATER PUMP 1 Install oil seal NOTE NOTE Lubricate the oil seal with a thin coat of lithium soap based grease WATER PUMP ...

Page 213: ...thium soap base grease on the oil seal lip and water pump impeller shaft And install the shaft while turning it Hold the impeller shaft on its width across the flats with spanners etc and install the impeller 4 Install gasket water pump housing copper washer 5 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 6 Check cooling system...

Page 214: ...VE 7 1 CHECKING THE CARBURETOR 7 4 CHECKING THE REED VALVE 7 5 ASSEMBLY THE REED VALVE 7 6 ASSEMBLING THE CARBURETOR 7 6 INSTALLING THE REED VALVE 7 8 INSTALLING THE CARBURETOR 7 8 MEASURING AND ADJUSTING THE FUEL LEVEL 7 9 CHECKING THE FUEL COCK 7 9 ...

Page 215: ...retor and reed valve Remove the parts in the order listed 1 Clamp 2 Loosen 2 Carburetor assembly 1 3 Carburetor joint 1 4 Reed valve assembly 1 5 Reed valve stopper 2 6 Reed valve 2 For installation reverse the removal procedure 8 Nm 0 8 m kg 5 8 ft lb 1 Nm 0 1 m kg 0 7 ft lb CARBURETOR AND REED VALVE ...

Page 216: ... the order listed Mixing chamber top 1 Throttle valve 1 Jet needle 1 Ring 1 Throttle valve spring 1 Gascket mixing chamber top 1 Float chamber 1 Gascket float chamber 1 Float pin 1 Float 1 Needle valve 1 Main jet 1 Main nozzle holder 1 Main nozzle 1 Pilot jet 1 CARBURETOR AND REED VALVE ...

Page 217: ...CARB 7 3 Order Job Part Q ty Remarks Starter plunger 1 Throttle stop screw 1 Pilot air screw 1 For assembly reverse the disassembly procedure CARBURETOR AND REED VALVE ...

Page 218: ...r in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check float chamber body Dirt Clean 4 Check float chamber rubber gasket Cracks damage wear Replace 5 Check float Damage Replace 6 Check needle valve needle valve seat Damage wear Replace Obstruction Clean CARBURETOR AND REED VALVE ...

Page 219: ...ove it up and down Tightness Replace the piston valve 9 Check hose joints Cracks damage Replace 10 Check carburetor breather hoses fuel hoses Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air CHECKING THE REED VALVE 1 Measure reed valve bending Out of limit Replace valve stopper height Out of specification Replace Reed valve bending limit 0 2 mm 0 008 in Valve sto...

Page 220: ...radually to avoid warp ing EAS00487 ASSEMBLING THE CARBURETOR CAUTION Before assembling the carburetor wash all of the parts in a petroleum based sol vent Always use a new gasket 1 Install pilot air screw throttle stop screw NOTE NOTE Turn in the pilot air screw until it is lightly seated Turn out the pilot air screw by the number of turns recorded before removing 1 Nm 0 1 m kg 0 7 ft lb Pilot air...

Page 221: ...rburetor 4 Install needle valve float float pin NOTE NOTE After installing the needle valve to the float install them to the carburetor Check the float for smooth movement 5 Install float chamber gascket float chamber hose holder carburetor breather hose 6 Install carburetor breather hose overflow hose 7 Install jet needle throttle valve CARBURETOR AND REED VALVE ...

Page 222: ...cable Align the cut in the ring with the throttle cable INSTALLING THE REED VALVE 1 Install reed valve assembly NOTE NOTE Install the reed valve assembly with its projec tion facing upward 2 Install carburetor joint EAS00492 INSTALLING THE CARBURETOR 1 Adjust engine idle speed Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3 8 Nm 0 8 m kg 5 8 ft lb CARBURETOR AND REED VALVE ...

Page 223: ...he needle valve but not compressing the needle valve 2 Adjust fuel level a Check the needle valve seat and needle valve b If either is worn replace them as a set c If both are fine adjust the float level by slightly bending the float tang d Measure the fuel height again e Repeat steps c to d until the fuel level is within specification EAS00505 CHECKING THE FUEL COCK 1 Check fuel cock Cracks damag...

Page 224: ...ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 8 1 CHECKING SWITCH CONTINUITY 8 2 IGNITION SYSTEM 8 3 TROUBLESHOOTING 8 3 ...

Page 225: ...ELEC 8 1 EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Ignition coil Engine stop switch CDI unit CDI magneto ELECTRICAL COMPONENTS ...

Page 226: ...ever insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end of the cou pler taking care not to loosen or damage the leads NOTE NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times Ω 1 0 Pocket tester 90890 03112 YU 3112 CHECKIN...

Page 227: ...1 Spark plug Check the condition of the spark plug Check the spark plug type Measure the spark plug gap Refer to CHECKING THE SPARK PLUG in chapter 3 Standard spark plug BR10EG NGK Spark plug gap 0 5 0 6 mm 0 0197 0 0236 in Is the spark plug in good condition is it of the correct type and is its gap within speci fication YES NO Re gap or replace the spark plug 2 Ignition spark gap Disconnect the s...

Page 228: ...plug cap 4 Ignition coil resistance Disconnect the ignition coil connectors from the ignition coil terminals Connect the pocket tester Ω 1 to the ignition coil as shown Positive tester probe orange Negative tester probe black Measure the primary coil resistance Primary coil resistance 0 18 0 28 Ω at 20 C 68 F Connect the pocket tester Ω 1k to the ignition coil as shown Positive tester probe spark ...

Page 229: ...ontinuity Is the engine stop switch OK YES NO Replace the engine stop switch 6 Pickup coil resistance Disconnect the pickup coil coupler from the wire harness Connect the pocket tester Ω 100 to the pickup coil terminal as shown Positive tester probe white red Negative tester probe white blue Measure the pickup coil resistance Pickup coil resistance 248 372 Ω at 20 C 68 F between white red and whit...

Page 230: ...080 Ω at 20 C 68 F Connect the pocket tester Ω 10 to the charging coil Positive tester probe green blue Negative tester probe black Measure the charging coil resistance Charging coil resistance 44 66 Ω at 20 C 68 F Is the charging coil OK YES NO Replace the charg ing coil 8 Wiring Check the entire ignition system s wiring Refer to WIRING DIAGRAM Is the ignition system s wiring properly con nected ...

Page 231: ... AND EXAMPLES OF CARBURETOR SETTING 9 5 EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM 9 5 CHANGE OF THE HEAT RANGE OF SPARK PLUGS 9 6 CHASSIS 9 7 SELECTION OF THE SECONDARY REDUCTION RATIO SPROCKET 9 7 DRIVE AND DRIVEN SPROCKETS SETTING PARTS 9 8 TIRE PRESSURE 9 9 FRONT FORK SETTING 9 9 CHANGE IN LEVEL AND CHARACTERISTICS OF FORK OIL 9 10 SETTING OF SPRING AFTER REPLACEMENT 9 10 FRONT FORK S...

Page 232: ...icle for conditions pick up of engine speed road surface con ditions and for the discoloration of the spark plug s After taking these into consideration he must select the best possible carburetor settings It is advisable to make a note of settings atmospheric conditions road surface condi tion lap time etc so that the memorandum can be used as a reference useful for future ATMOSPHERIC CONDITIONS ...

Page 233: ...il fouled too rich EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE OPENING Throttle valve opening Full open Full closed Discoloration Condition of spark plug Normal Insulator is dry and burnt brown Over burned too lean Insulator is whitish Oil fouled too rich Insulator is sooty and wet Setting part Throttle valve opening Pilot jet Pilot air screw Diameter of straight portion Clip position Main ...

Page 234: ...re enrich at low speeds and turning it out will lean it PILOT JET ADJUSTMENT The richness of air fuel mixture with the throttle fully closed to 1 2 open can be set by turning the pilot jet It is changed when adjustment cannot be made by the pilot air screw alone A larger size jet results in a richer mixture at low speeds and a smaller size in a leaner mix ture JET NEEDLE ADJUSTMENT The richness of...

Page 235: ...needle clip by one groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will not pick up speed quickly In this case step down the jet needle clip by one groove and move up the needle to enrich the mixture CARBURETOR SETTING PARTS Standard clip position No 2 groove Part name Size Part number Main jet Rich 148 4MX 14943 87 145 4MX 149...

Page 236: ...t high speeds Hard breathing Shearing noise Whitish spark plug Lean mixture Increase main jet calibration no Gradually Discoloration of spark plug If tan color it is in good condition If cannot be corrected Clogged float valve seat Clogged fuel hose Clogged fuel cock At full throttle Speed pick up stops Slow speed pick up Slow response Sooty spark plug Rich mixture Decrease main jet calibration no...

Page 237: ...igher calibration no and lower the jet needle clip position Check air filter for fouling Poor engine operation Turn in pilot air screw Adjust the throttle stop screw Check throttle valve operation This should be taken simply for an example It is necessary to set the carburetor while check ing the operating conditions of the engine and discoloration of spark plugs Normally carburetor setting is mad...

Page 238: ...IS SELECTION OF THE SECONDARY REDUCTION RATIO SPROCKET Requirement for selection of secondary gear reduction ratio It is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners Actually however as the speed depends on the ground condition of the day of the race be sure to run through the c...

Page 239: ...rd the end of the straight line with care taken to avoid the engine over revving NOTE NOTE Riding technique varies from rider to rider and the performance of a vehicle also vary from vehicle to vehicle Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level of your riding technique DRIVE AND DRIVEN SPROCKETS SETTING PARTS YZ85 For EUR C...

Page 240: ...pend ing on the rider s feeling of an actual run and the circuit conditions The front fork setting includes the following three factors 1 Setting of air spring characteristics Change the fork oil level 2 Setting of spring preload Change the spring 3 Setting of damping force Change the compression damping Change the rebound damping The spring acts on the load and the damp ing force acts on the cush...

Page 241: ...in relation to oil level change Load Stroke Max oil level Standard oil level Min oil level SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by rear suspension take care so that the vehi cle front and rear are balanced in position etc when setting the front fork 1 Use of soft spring Generally a soft spring gives a soft riding feeling Rebound damping tends to beco...

Page 242: ...Turn in one or two clicks Change the compression damping Turn out one or two clicks FRONT FORK SETTING PARTS Front fork spring YZ85 YZ85LW NOTE NOTE The I D mark slits is proved on the end of the spring TYPE SPRING RATE SPRING PART NUMBER I D MARK slits SOFT 0 280 4ES 23141 50 I STD 0 290 4ES 23141 40 STIFF 0 300 4ES 23141 60 II TYPE SPRING RATE SPRING PART NUMBER I D MARK slits SOFT 0 290 4ES 231...

Page 243: ...ender hold ing bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length between the rear wheel axle center and the rear fender hold ing bolt 3 Loosen the locknut and make adjust ment by turning the spring adjuster to achieve the standard figure from the sub traction of the length from the length NOTE NOTE If the vehicle is new and after it is bro...

Page 244: ...bound damp ing to compensate for its greater spring load Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be fol lowed more or less by a change in the com pression damping For correction turn the compression damping adjuster on the softer side CAUTION When using a rear shock absorber other than cu...

Page 245: ...12 M0 Brown STD 4 6 4ES 22212 K0 Green STIFF 4 8 4ES 22212 G0 Red TYPE SPRING RATE SPRING PART NUMBER I D COLOR SOFT 4 8 4ES 22212 G0 Red STD 5 0 4ES 22212 F0 STIFF 5 2 4ES 22212 H0 Blue TYPE SPRING RATE SPRING PART NUMBER I D COLOR SOFT 4 6 4ES 22212 K0 Green STD 4 8 4ES 22212 G0 Red STIFF 5 0 4ES 22212 F0 TYPE SPRING RATE SPRING PART NUMBER I D COLOR SOFT 5 0 4ES 22212 F0 STD 5 2 4ES 22212 H0 Bl...

Page 246: ...ng Turn adjuster clockwise about 2 clicks to increase damping Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 in Spring Replace with stiff spring Stiff toward stroke end Oil level oil amount Decrease oil level by about 5 mm 0 2 in Soft toward stroke end bottoming out Oil level oil amount Increase oil level by about 5 mm 0 2 in Stiff initial movement Compression damping Turn adjust...

Page 247: ... to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Compression damping Turn adjuster clockwise about 2 clicks to increase damping Spring set length Set sunken length for 75 80 mm 3 0 3 1 in when one passenger is astride seat Spring Replace with soft spring Bottoming out Compression damping Turn a...

Page 248: ...D PERFORMANCE 10 2 ENGINE 10 2 FUEL SYSTEM 10 2 FAULTY GEAR SHIFTING 10 2 SHIFTING IS DIFFICULT 10 2 SHIFT PEDAL DOES NOT MOVE 10 2 JUMPS OUT OF GEAR 10 2 FAULTY CLUTCH 10 3 CLUTCH SLIPS 10 3 CLUTCH DRAGS 10 3 OVERHEATING 10 3 ENGINE 10 3 COOLING SYSTEM 10 3 FUEL SYSTEM 10 3 CHASSIS 10 3 ELECTRICAL SYSTEMS 10 3 POOR BRAKING PERFORMANCE 10 4 FAULTY FRONT FORK LEGS 10 4 LEAKING OIL 10 4 MALFUNCTION ...

Page 249: ...maged reed valve FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel strainer Clogged fuel tank drain hose Clogged rollover valve Clogged rollover valve hose Deteriorated or contaminated fuel Fuel cock Clogged or damaged fuel hose Carburetor s Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Damaged float Worn needle valve Improperly installed needle valve...

Page 250: ...it Faulty pickup coil Broken generator rotor woodruff key EAS00848 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURES ENGINE Air filter Clogged air filter element FUEL SYSTEM Carburetor s Faulty diaphragm Incorrect fuel level Loose or clogged main jet EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted s...

Page 251: ...EAS00855 OVERHEATING ENGINE Clogged coolant passages Cylinder head s and piston s Heavy carbon buildup Transmission oil Incorrect oil level Incorrect oil viscosity Inferior oil quality COOLING SYSTEM Coolant Low coolant level Radiator Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin Water pump Damaged or faulty water pump Hose s and pipe s Damaged hose Improperly connec...

Page 252: ...l viscosity Incorrect oil level EAS00864 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Bro...

Page 253: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 254: ...hwarz Rot B W Schwarz Weiß G L Grün Blau G W Grün Weiß W L Weiß Blau W R Weiß Rot ELECTRICAL COMPONENTS Engine stop switch Ignition coil CDI unit CDI magneto Spark plug COLOR CODE B Black O Orange B R Black Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red G L B R W L W R G W B W L B G W W R B R G L W L B G W W R B R G L W L O O G W W R B R G L B B W B W B OFF RUN B W...

Page 255: ...nder CDI Magnet Zündkerze FARB CODIERUNG B Schwarz O Orange B R Schwarz Rot B W Schwarz Weiß G L Grün Blau G W Grün Weiß W L Weiß Blau W R Weiß Rot ELECTRICAL COMPONENTS Engine stop switch Ignition coil CDI unit CDI magneto Spark plug COLOR CODE B Black O Orange B R Black Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red OFF RUN YZ85W1 YZ85 W YZ85LW W 2007 WIRING DIAG...

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