Yamaha YZ85(W) Service Manual

2007YZ85W15PA-28197-E0SERVICE MANUALYZ85(W)YZ85LW(W)

GENINFO1-3EAS00023LOCK WASHERS / PLATES AND COTTER PINSAfter removal, replace all lock washers / plates and cotter pins. After the bolt or nut has be

CHAS4-28NOTE:NOTE:• While holding the brake hose, tighten the union bolt as shown.• Turn the handlebar to the left and right to make sure the brake ho

CHAS4-296. Check:• brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.

CHAS4-30• When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brak

CHAS4-31EAS00613FRONT BRAKE CALIPEROrder Job / Part Q’ty RemarksRemoving the front brake caliper Remove the parts in the order listed.Brake fluid Drai

CHAS4-32EAS00614Order Job / Part Q’ty RemarksDisassembling the front brake caliperRemove the parts in the order listed.Brake pad 2Brake caliper bracke

CHAS4-33EAS00616REAR BRAKE CALIPEROrder Job / Part Q’ty RemarksRemoving the rear brake caliper Remove the parts in the order listed.Brake fluid Drain.

CHAS4-34EAS00617Order Job / Part Q’ty RemarksDisassembling the rear brake caliper Remove the parts in the order listed.Brake pad pin 2Brake pad 2Brake

CHAS4-35EAS00619DISASSEMBLING THE FRONT BRAKE CALIPERNOTE:NOTE:Before disassembling the brake caliper, drain the brake fluid from the entire brake sys

CHAS4-361. Remove:• union bolt • copper washers • brake hose NOTE:NOTE:Put the end of the brake hose into a container and pump out the brake fluid c

CHAS4-371. Check:• brake caliper pistons Rust / scratches / wear → Replace the brake caliper pistons.• brake caliper cylinders Scratches / wear

GENINFO1-4FUEL AND ENGINE MIXING OILMix oil with the gas at the ratio specified below. Always use fresh, name-brand gasoline, and mix the oil and gas

CHAS4-381. Install:• brake caliper bracket• brake pads• brake caliper • copper washers • brake hose • union bolt WARNINGProper brake hose routing is

CHAS4-393. Bleed:• brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.4. Check:• brake fluid level Below the minimum level mark

CHAS4-40WARNINGProper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” in chapter 2.CAUTION:When installing

CHAS4-415. Check:• brake fluid level Below the minimum level mark → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAK

CHAS4-42EAS00646FRONT FORKFRONT FORK LEGSOrder Job / Part Q’ty RemarksRemoving the front fork legs Remove the parts in the order listed.Front wheel Re

CHAS4-43EAS00648Order Job / Part Q’ty RemarksDisassembling the front fork legs Remove the parts in the order listed.Guide protector 1Cap bolt 1O-ring

CHAS4-44Order Job / Part Q’ty RemarksOil seal 1Plug 1Base valve 1Gasket 1O-ring 2Damper rod 1O-ring 1Air bleed screw 1For assembly, reverse the disass

CHAS4-45EAS00650REMOVING THE FRONT FORK LEGSThe following procedure applies to both of the front fork legs.1. Stand the vehicle on a level surface.WAR

CHAS4-46EAS00652DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of the front fork legs.1. Remove:• cap bolt (from the dampe

CHAS4-476. Remove:• slide metal• oil seal washer• oil seal• piston metal• oil seal clip• dust seal7. Remove:• base valve • damper rod NOTE:NOTE:While

GENINFO1-5EAS00026CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors for stains, rust, moisture, etc.1. Disconnect:• lead• coupler• con

CHAS4-48CAUTION:• The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu-larly sensi

CHAS4-491. Install:• damper rod assembly • inner tube CAUTION:Allow the damper rod assembly to slide slowly down the inner tube until it pro-trudes fr

CHAS4-506. Install:• dust seal • oil seal clip • oil seal • oil seal washer • slide metal CAUTION:Make sure the numbered side of the oil seal face

CHAS4-5110.Install:• oil seal (with the fork seal driver )11.Install:• oil seal clip NOTE:NOTE:Adjust the oil seal clip so that it fits into the

CHAS4-5214.Install:• fork spring • washer • cap bolt a. Install the fork spring, and washer.NOTE:NOTE:Install the spring with the smaller pitch fac-

CHAS4-53g. Fully tighten the cap bolt onto the damper rod by hand.NOTE:NOTE:Make sure that there is a clearance of 0 ~ 1 mm (0 ~ 0.04 in) between

CHAS4-54EAS00662INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of the front fork legs.1. Install:•front fork leg Temporarily ti

CHAS4-55EAS00664HANDLEBAROrder Job / Part Q’ty RemarksRemoving the handlebar Remove the parts in the order listed.Number plate Refer to “SEAT, SIDE CO

CHAS4-56Order Job / Part Q’ty Remarks14 Left grip 115 Handlebar upper holder 216 Handlebar 1For installation, reverse the removal procedure.1 Nm (0.1

CHAS4-57EAS00666REMOVING THE HANDLEBAR1. Stand the vehicle on a level surface.WARNINGSecurely support the vehicle so that there is no danger of it fal

GENINFO1-6EAS00027SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate spec

CHAS4-58NOTE:NOTE:• The upper handlebar holders should be installed with the punched mark forward.• First tighten the bolts on the front side of the

CHAS4-596. Install:• throttle cable cap • grip cap (lower) • cover (grip cap) 7. Adjust:• throttle cable free play Refer to “ADJUSTING THE THROTTLE CA

CHAS4-6011.Adjust:• clutch lever free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PRAY” in chapter 3.12.Clamp the clamp portion of the number pla

CHAS4-61EAS00675STEERING HEADUNDER BRACKETOrder Job / Part Q’ty RemarksRemoving the lower bracket Remove the parts in the order listed.Number plate Re

CHAS4-62EAS00677REMOVING THE LOWER BRACKET1. Stand the vehicle on a level surface.WARNINGSecurely support the vehicle so that there is no danger of it

CHAS4-633. Replace:• lower bearing• bearing racesa. Remove the bearing races from the steering head pipe with a long rod and hammer.b. Remove the

CHAS4-643. Install:• steering ring nut (with the ring nut wrench )a. Tighten the steering ring nut.b. Loosen it one turn.c. Retighten the steering ri

CHAS4-65EAS00685REAR SHOCK ABSORBER ASSEMBLYOrder Job / Part Q’ty RemarksRemoving the rear shock absorber assemblyRemove the parts in the order listed

CHAS4-66EAS00687HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDERWARNINGThis rear shock absorber and gas cylinder contain highly compressed nitrogen g

CHAS4-67EAS00694REMOVING THE REAR SHOCK ABSORBER ASSEMBLY1. Stand the vehicle on a level surface.WARNINGSecurely support the vehicle so that there is

GENINFO1-7Tool No. Tool name / Function IllustrationRadiator cap tester 90890-01325 YU-24460-01 Radiator cap tester adapter 90890-01352 YU-33984Radiat

CHAS4-68EAS00696CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER1. Check:• rear shock absorber rod Bends / damage → Replace the rear shoc

CHAS4-695. Install:• silencer Refer to “EXHAUST PIPE” in chapter 5.• seat and right side cover Refer to “SEAT, SIDE COVERS AND FUEL TANK” in chapter 3

CHAS4-70EAS00700SWINGARM AND DRIVE CHAINOrder Job / Part Q’ty RemarksRemoving the swingarm and drive chainRemove the parts in the order listed.Rear wh

CHAS4-71Order Job / Part Q’ty RemarksDisassembling the swingarm Disassemble the parts in the order listed.Relay arm 1Connecting rod 1Cover 2Dust seal

CHAS4-72EAS00703REMOVING THE SWINGARM1. Stand the vehicle on a level surface.WARNINGSecurely support the vehicle so that there is no danger of it fall

CHAS4-73EAS00706REMOVING THE DRIVE CHAIN1. Stand the vehicle on a level surface.WARNINGSecurely support the vehicle so that there is no danger of it f

CHAS4-744. Check:•collars • oil seals Damage / wear → Replace.• bearings Damage / pitting → Replace.• bushings Damage / wear → Replace.5. Che

CHAS4-75NOTE:NOTE:• While measuring the 15-link section, push down on the drive chain to increase its ten-sion.• Perform this measurement at two or th

CHAS4-766. Check:•drive sprocket• rear wheel sprocket More than 1 / 4 tooth wear → Replace the drive chain sprockets as a set. Bent teeth → Replace

CHAS4-772. Install:• bearing • oil seal (with the relay arm)NOTE:NOTE:• Apply the molybdenum disulfide grease on the bearing when installing.• Insta

GENINFO1-8Tool No. Tool name / Function Illustration90890-06754 YM-34487Dynamic spark tester Ignition checker This instrument is necessary for checki

CHAS4-785. Install:•relay arm 6. Install:• swingarm • pivot shaft • pivot shaft nut 7. Install:• rear shock absorber• rear wheel Refer to “REAR WHEEL

CHAS4-793. Install:• master link clip CAUTION:• The closed end of the master link clip must face in the direction of drive chain rotation.• Never in

ENGCHAPTER 5ENGINEENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1DRIVE SPROCKET . . . .

ENGKICK STARTER AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . .

ENG5-1ENGINEENGINEDRIVE SPROCKETOrder Job / Part Q’ty RemarksRemoving the drive sprocket Remove the parts in the order listed.Drive chain Loosen.Refer

ENG5-2EXHAUST PIPE Order Job / Part Q’ty RemarksRemoving the exhaust pipe Remove the parts in the order listed.SeatRight side cover1 Silencer 12 Exhau

ENG5-3SILENCER FIBER REPLACEMENT1. Remove:• seat• right side cover• bolt (silencer) • silencer • bolt (fiber) • washer2. Remove:• inner pipe 3. Replac

ENG5-4EAS00191ENGINEOrder Job / Part Q’ty RemarksRemoving the engine Remove the parts in the order listed.NOTE:NOTE:Place a suitable stand under the f

ENG5-5Order Job / Part Q’ty RemarksCDI magneto lead Disconnect.Drive chain Loosen.Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3.1 Engine mou

ENG5-6EAS00192INSTALLING THE ENGINE1. Install:• engine • pivot shaft • engine mount bolt (front) • engine mount bolt (lower) NOTE:NOTE:Do not fully ti

SPECCHAPTER 2SPECIFICATIONSGENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1ENGINE SPECIFICATIONS . . . . .

ENG5-7EAS00221CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEADOrder Job / Part Q’ty RemarksRemoving the cylinder head Remove the parts in the order li

ENG5-8EAS00222REMOVING THE CYLINDER HEAD1. Remove:• cylinder head nutsNOTE:NOTE:• Loosen the nuts in the proper sequence as shown.• Loosen each nut 1

ENG5-9d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern.NOTE:NOTE:To e

ENG5-10EAS00251CYLINDER AND PISTONOrder Job / Part Q’ty RemarksRemoving the cylinder and piston Remove the parts in the order listed.Cylinder head Ref

ENG5-11EAS00253REMOVING THE CYLINDER AND PISTON1. Remove:• piston pin clip NOTE:NOTE:Before removing the piston pin clip, cover the crankcase opening

ENG5-122. Measure:• piston-to-cylinder clearancea. Measure cylinder bore “C” with the cylinder bore gauge.NOTE:NOTE:Measure cylinder bore “C” by takin

ENG5-13COMBINATION OF PISTON AND CYLINDER1. Check:• cylinder mark 2. Check:•piston mark 3. Combination:• combine the piston and cylinder by the fol-lo

ENG5-14EAS00263CHECKING THE PISTON RING1. Measure:• piston ring side clearance Out of specification → Replace the piston and piston ring as a set.NOTE

ENG5-153. Measure:• piston pin bore inside diameter Out of specification → Replace the piston.4. Calculate:• piston-pin-to-piston clearance Out of sp

ENG5-16EAS00267INSTALLING THE PISTON AND CYLINDER1. Install:• piston ring NOTE:NOTE:• Take care not to scratch the piston or damage the piston ring.•

SPEC2-1SPECIFICATIONSGENERAL SPECIFICATIONSItem Standard LimitModel code YZ855PAG (EUR, CAN), 5PAH (AUS,NZL) • • •YZ85LW5SHG (EUR), 5SHH (AUS,NZL) • •

ENG5-174. Lubricate:•piston• piston ring• cylinder (with the recommended lubricant)5. Install:• cylinder • cylinder nut NOTE:NOTE:• While compressing

ENG5-18EAS00274CLUTCH CLUTCHOrder Job / Part Q’ty RemarksRemoving the clutchTransmission oil DrainRefer to “CHANGING THE TRANSMISSION OIL” in chapter

ENG5-19Order Job / Part Q’ty Remarks13 Conical washer 114 Clutch boss 115 Washer 116 Primary drive gear 117 Spacer 118 Washer 119 Push lever shaft 120

ENG5-20EAS00276REMOVING THE CLUTCH1. Remove:•clutch cover •gasketNOTE:NOTE:Loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross p

ENG5-21EAS00280CHECKING THE FRICTION PLATESThe following procedure applies to all of the friction plates.1. Check:• friction plate Damage / wear → Re

ENG5-22EAS00282CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of the clutch springs.1. Check:•clutch spring Damage → Replace the cl

ENG5-23CHECKING THE PUSH LEVER SHAFT1. Check:• push lever shaft Wear / damage → Replace.EAS00288CHECKING THE CLUTCH PUSH RODS1. Check:• push rod 1 •

ENG5-244. Install:• clutch boss nut NOTE:NOTE:While holding the clutch boss with the univer-sal clutch holder , tighten the clutch boss nut.5. Lubric

ENG5-258. Install:• pressure plate 1 NOTE:NOTE:Align the punch mark on the pressure plate with the punch mark on the clutch boss.9. Install:•clutc

ENG5-26EAS00327KICK STARTER AND SHIFT SHAFT PRIMARY DRIVE GEAROrder Job / Part Q’ty RemarksRemoving the primary drive gear Remove the parts in the ord

SPEC2-2ENGINE SPECIFICATIONSItem Standard LimitEngineEngine type Liquid cooled 2-stroke, gasoline • • •Displacement 84.7 cm3 (5.17 cu.in) • • •Cylinde

ENG5-27Order Job / Part Q’ty Remarks7 Primary drive gear 1For installation, reverse the removal procedure.10 Nm (1.0 m•kg, 7.2 ft•lb)10 Nm (1.0 m•kg,

ENG5-28KICK STARTER AND SHIFT SHAFTOrder Job / Part Q’ty RemarksRemoving the kick starter shaft and shiftRemove the parts in the order listed.shaft1 C

ENG5-29Order Job / Part Q’ty Remarks14 Washer 115 Stopper lever 116 Collar 117 Shift shaft spring 118 Oil seal 119 Oil seal 1For installation, reverse

ENG5-30REMOVING THE PRIMARY DRIVE GEAR1. Remove:• nut (primary drive gear) NOTE:NOTE:Hold the drive gear holder onto the crank-case using the M6 bol

ENG5-31EAS00328CHECKING THE SHIFT SHAFT1. Check:• shift shaft Bends / damage / wear → Replace.• spring Damage / wear → Replace.EAS00330CHECKING TH

ENG5-322. Install:• stopper lever assembly (with the shift shaft )NOTE:NOTE:Apply the transmission oil on the stopper lever assembly.3. Install:• s

ENG5-33INSTALLING THE KICK STARTER SHAFT ASSEMBLY1. Install:• kick starter gear • washer • torsion spring NOTE:NOTE:Make sure the stopper of the tor

ENG5-34INSTALLING THE PRIMARY DRIVE GEAR1. Install:• straight key 2. Install:• primary drive gear • washer • primary drive gear nut NOTE:NOTE:Install

ENG5-357. Install:• bolt (right crankcase cover) • copper washer (oil drain bolt) • oil drain bolt • copper washer (coolant drain bolt) • coolant dr

ENG5-36EAS00343CDI MAGNETO Order Job / Part Q’ty RemarksRemoving the CDI magneto Remove the parts in the order listed.SeatFuel tank1 CDI magneto lead

SPEC2-3Item Standard LimitCylinderBore 47.500 ~ 47.514 mm (1.8701 ~ 1.8706 in) 47.6 mm (1.874 in)Max. taper limit • • • 0.05 mm (0.0020 in)Max. out-o

ENG5-37EAS00346REMOVING THE ROTOR1. Remove:•nut • washer NOTE:NOTE:While holding the rotor with the rotor holding tool , loosen the rotor nut.2. Remo

ENG5-38INSTALLING THE CDI MAGNETO1. Install:• stator •screw NOTE:NOTE:Temporarily tighten the screw at this point.2. Install:• woodruff key •rotor NOT

ENG5-395. Tighten:• screw (stator) 6. Check:• ignition timing Re-check the ignition timing.7. Connect:• CDI magneto lead Refer to “CABLE ROUTING” in

ENG5-40EAS00381CRANKCASE AND CRANKSHAFTCRANKCASE AND CRANKSHAFTOrder Job / Part Q’ty RemarksRemoving the crankcase and crankshaftRemove the parts in t

ENG5-41EAS00385DISSASSEMBLING THE CRANKCASE1. Remove:• right crankcase (with the crankcase separating tool )NOTE:NOTE:• Fully tighten the tool holdi

ENG5-42REMOVING THE CRANKSHAFT BEARING1. Remove:• bearing NOTE:NOTE:• Remove the bearing from the crankcase by pressing its inner race as shown in .•

ENG5-433. Measure:• big end side clearance Out of specification → Replace the big end bearing, crankshaft pin, or connecting rod.4. Measure:• cranksh

ENG5-44EAS00408INSTALLING THE CRANKSHAFT1. Install:• crankshaft assembly NOTE:NOTE:• Install the crankshaft assembly with the crankshaft installer pot

ENG5-452. Install:• dowel pin • right crankcase (onto the left crankcase )NOTE:NOTE:• Turn the shift cam to the position shown in the figure so th

ENG5-46EAS00419TRANSMISSIONOrder Job / Part Q’ty RemarksRemoving the transmission Remove the parts in the order listed.Engine Refer to “ENGINE”.Crankc

YZ85W1 / YZ85 (W) / YZ85LW (W)SERVICE MANUAL©2006 by Yamaha Motor Co., Ltd.First edition, April 2006All rights reserved.Any reproduction or unauthor

SPEC2-4Item Standard LimitCrankshaftCrank width “A” 44.90 ~ 44.95 mm (1.768 ~ 1.770 in) • • •Runout limit “C” 0.03 mm (0.0012 in) 0.05 mm (0.002 in) (

ENG5-47Order Job / Part Q’ty Remarks12 3RD pinion gear 113 Circlip 114 Washer 115 5TH pinion gear 116 Main axle 117 Bearing 118 Circlip 119 Washer 120

ENG5-48Order Job / Part Q’ty Remarks28 2ND wheel gear 129 Washer 130 Bearing 131 Oil seal 132 Bearing 2For installation, reverse the removal procedur

ENG5-49EAS00420REMOVING THE TRANSMISSION1. Remove:• right crankcase Refer to “CRANKCASE AND CRANK-SHAFT”.2. Remove:• main axle •drive axle NOTE:NOTE:•

ENG5-50EAS00422CHECKING THE SHIFT DRUM ASSEMBLY1. Check:• shift drum grooves Damage / scratches / wear → Replace the shift drum assembly.• shift drum

ENG5-514. Check:• transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblie

ENG5-523. Install:• washer • circlip NOTE:NOTE:• Be sure the circlip sharp-edged corner is positioned opposite side to the washer and gear .• Be su

ENG5-53NOTE:NOTE:• Mesh the shift fork-L with the 6th wheel gear and shift fork-R with the 5TH wheel gear on the drive axle.• Mesh the shift fo

COOLCHAPTER 6COOLING SYSTEMRADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1CHECKING THE RAD

COOL6-1EAS00454COOLING SYSTEMRADIATOR Order Job / Part Q’ty RemarksRemoving the radiator Remove the parts in the order listed.Air scoop Refer to “SEAT

COOL6-2EAS00455CHECKING THE RADIATOR1. Check:• radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or

SPEC2-5Item Standard LimitTransmissionTransmission type Constant mesh, 6-speed • • •Primary reduction system Spur gear • • •Primary reduction ratio 65

COOL6-32. Check:• cooling system Leaks → Repair or replace any faulty part.a. Attach the radiator cap tester to the radi-ator.b. Apply 100 kPa (1.0

COOL6-4EAS00468WATER PUMP Order Job / Part Q’ty RemarksRemoving the water pump Remove the parts in the order listed.NOTE:NOTE:It is not necessary to r

COOL6-5EAS00472CHECKING THE WATER PUMP1. Check:• oil seal Damage / wear → Replace.2. Check:• bearing Rough movement → Replace.3. Check:• impeller

COOL6-62. Install:• bearing NOTE:NOTE:Install the bearing by pressing its outer race parallel.3. Install:• water pump impeller shaft • washer • impell

CARBCHAPTER 7CARBURETORCARBURETOR AND REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1CHECKING THE CARBURETOR . . . . . . . . .

CARB7-1EAS00480CARBURETORCARBURETOR AND REED VALVE Order Job / Part Q’ty RemarksRemoving the carburetor and reed valveRemove the parts in the order l

CARB7-2Order Job / Part Q’ty RemarksDisassembling the carburetor Remove the parts in the order listedMixing chamber top 1Throttle valve 1Jet needle 1R

CARB7-3Order Job / Part Q’ty RemarksStarter plunger 1Throttle stop screw 1Pilot air screw 1For assembly, reverse the disassembly procedure.CARBURETOR

CARB7-4EAS00485CHECKING THE CARBURETOR1. Check:• carburetor body• float chamber• jet housing Cracks / damage → Replace.2. Check:• fuel passages Obstr

CARB7-57. Check:• jet needle • main nozzle •main jet • main nozzle holder • pilot jet •starter plunger Bends / damage / wear → Replace. Obstruction

SPEC2-6Item Standard LimitReed valveThickness “T” 0.42 mm (0.017 in) • • •Valve stopper height 7.4 ~ 7.8 mm (0.291 ~ 0.307 in) • • •Valve bending limi

CARB7-6ASSEMBLY THE REED VALVE1. Install:• reed valve • reed valve stopper • screw (reed valve) LOCTITE®NOTE:NOTE:• Install the reed valve with the re

CARB7-72. Install:• starter plunger 3. Install:• pilot jet • main nozzle • main jet holder •main jet NOTE:NOTE:Install the main nozzle with its chamfe

CARB7-88. Install:• throttle cable • mixing chamber top • gascket (mixing chamber top) • spring (throttle valve) • ring • throttle valve NOTE:NOTE:•

CARB7-92. Adjust:• throttle cable free playRefer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.EAS00498MEASURING AND ADJUSTING THE FUEL LEV

ELECCHAPTER 8ELECTRICAL SYSTEMELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1CHECKING SWITCH CONTINUITY . .

ELEC8-1EAS00729ELECTRICAL SYSTEMELECTRICAL COMPONENTSIgnition coilEngine stop switchCDI unitCDI magnetoELECTRICAL COMPONENTS

ELEC8-2CEAS00730CHECKING SWITCH CONTINUITYCheck each switch for continuity with the pocket tester. If the continuity reading is incor-rect, check the

ELEC8-3EAS00736IGNITION SYSTEMTROUBLESHOOTINGCheck:1. Spark plug2. Ignition spark gap3. Spark plug cap resistance4. Ignition coil resistance5. Engine

ELEC8-4EAS00744 EAS007463. Spark plug cap resistance• Remove the spark plug cap from the spark plug lead.• Connect the pocket tester (“Ω × 1k” range)

ELEC8-5EAS00750 EAS007485. Engine stop switch• Check the engine stop switch for continuity.• Connect the pocket tester (Ω × 1) to the engine stop swi

SPEC2-7CHASSIS SPECIFICATIONSItem Standard LimitFrameFrame type Semi double cradle • • •Material Steel • • •Caster angle 26.3° (YZ85) • • •26.9° (YZ85

ELEC8-6EAS00775 EAS007547. Charging coil resistance• Disconnect the charging coil coupler from the wire harness.• Connect the pocket tester (Ω × 100)

TUNCHAPTER 9TUNINGENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1CARBURETOR SETTING . .

TUN9-1TUNINGENGINECARBURETOR SETTING• The role of fuel is to cool the engine, and in the case of a 2-stroke engine, to lubricate the engine in additio

TUN9-2TEST RUNAfter warming up the engine equipped with the standard type carburetor(s) and spark plug(s), run two or three laps of the circuit and ch

TUN9-3MAIN JET ADJUSTMENTThe richness of air-fuel mixture with 3 / 4 ~ 4 / 4throttle can be set by changing the main jet .1. Spark plug is too hot. S

TUN9-4JET NEEDLE GROOVE POSITION ADJUSTMENTShould the engine be hard to run smoothly at intermediate speeds, the jet needle must be adjusted. If the

TUN9-5ROAD CONDITION AND EXAMPLES OF CARBURETOR SETTINGNOTE:Optimum pilot air screw setting can be obtained by adding the ex-factory number of the sam

TUN9-6* marked: In case of hard breathing, check the carburetor breather hoses for clogging.Symptom Setting CheckingClosed to 1 / 4 throttle Poor a

TUN9-7NOTE:NOTE:• When checking the discoloration of spark plugs, be sure to stop the engine immediately after a run and check.• Avoid racing.• When c

TUN9-8• In actuality, it is very difficult to achieve set-tings suitable for the entire course and some settings may be sacrificed. Thus, the settings

SPEC2-8Item Standard LimitFront tireTire type Tube • • •Size 70 / 100-17 40M (YZ85) • • •70 / 100-19 42M (YZ85LW) • • •Model (manufacturer) D739FA (DU

TUN9-9TIRE PRESSURETire pressure should be adjust to suit the road surface condition of the circuit.• Under a rainy, muddy, sandy, or slippery conditi

TUN9-10CHANGE IN LEVEL AND CHARACTERISTICS OF FORK OILDamping characteristic near the final stroke can be changed by changing the fork oil amount.CAUT

TUN9-112. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a se

TUN9-12REAR SUSPENSION SETTINGThe rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions.

TUN9-13SETTING OF SPRING AFTER REPLACEMENTAfter replacement, be sure to adjust the spring to the set length [sunken length 75 ~ 85 mm (3.0 ~ 3.3 in)]

TUN9-14REAR SHOCK ABSORBER SETTING PARTS• Rear shock spring YZ85:For EURFor CAN, AUS, NZLYZ85LW:For EURFor AUS, NZLNOTE:NOTE:The I.D. color is marke

TUN9-15SUSPENSION SETTING•Front forkNOTE:• If any of the following symptoms is experienced with the standard position as the base, make reset-ting by

TUN9-16• Rear shock absorberNOTE:• If any of the following symptoms is experienced with the standard position as the base, make reset-ting by referenc

TRBLSHTGCHAPTER 10TROUBLESHOOTINGSTARTING FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1ENGINE . . . . . .

TRBLSHTG10-1EAS00844TROUBLESHOOTINGNOTE:The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpfu

SPEC2-9Item Standard LimitSteeringSteering bearing type Taper roller bearing • • •Lock to lock angle (left) 45° • • •Lock to lock angle (right) 45° •

TRBLSHTG10-2EAS00846INCORRECT ENGINE IDLING SPEEDENGINEAir filter• Clogged air filter elementFUEL SYSTEMCarburetor(s)• Faulty starter plunger• Loose o

TRBLSHTG10-3EAS00851FAULTY CLUTCHCLUTCH SLIPSClutch• Improperly assembled clutch• Improperly adjusted clutch cable• Loose or fatigued clutch spring• W

TRBLSHTG10-4EAS00857POOR BRAKING PERFORMANCE• Worn brake pad• Worn brake disc• Air in hydraulic brake system• Leaking brake fluid• Faulty brake calipe

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

COMPOSANTS ELECTRIQUESCoupe-circuit du moteurBobine d’allumageBloc CDIVolant magnétique CDIBougieCODE DE COULEURB . . . . . . . NoirO. . . . . . . O

COMPOSANTS ELECTRIQUESCoupe-circuit du moteurBobine d’allumageBloc CDIVolant magnétique CDIBougieCODE DE COULEURB . . . . . . . NoirO. . . . . . . O

SPEC2-10Item Standard LimitRear suspensionSuspension type Swingarm (link type monocross suspension)• • •Rear shock absorber assembly type Coil spring

SPEC2-11ELECTRICAL SPECIFICATIONSItem Standard LimitIgnition systemIgnition system type CDI • • •Ignition timing (B.T.D.C.) 0.9 mm (0.035 in) • • •Ad

SPEC2-12EAS00028CONVERSION TABLEAll specification data in this manual are listed in SI and METRIC UNITS.Use this table to convert METRIC unit data to

SPEC2-13TIGHTENING TORQUESENGINE TIGHTENING TORQUESItem FastenerThreadsizeQ’tyTightening torqueRemarksNm m•kg ft•lbSpark plug — M14 1 20 2.0 14Cylinde

EAS00002NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-ers and their qualified mechanics. It is not

SPEC2-14CHASSIS TIGHTENING TORQUESItem FastenerThreadsizeQ’tyTightening torqueRemarksNm m•kg ft•lbUpper bracket and outer tube Bolt M8 2 22 2.2 16Lowe

SPEC2-15NOTE:1. First, tighten the steering nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen the steering nu

SPEC2-16EAS00031LUBRICATION POINTS AND LUBRICANT TYPESENGINEEAS00032CHASSISLubrication point LubricantOil seal lipsO-ringsBearingsCrankshaft pinsPisto

SPEC2-17EAS00035CABLE ROUTINGCable guideBrake hoseThrottle cableFuel tank breather hoseEngine stop switch leadGround leadIgnition coilPrimary coil lea

SPEC2-18Pass the fuel tank breather hose between the han-dlebar and tension bar, then insert its end into the hole of the steering stem.Fasten the gro

SPEC2-19Sub-wire harnessCDI unitIgnition coilClutch cableCable guideTransmission oil breather hoseCDI unit bandClampBrake hoseBrake hose holderBrake f

SPEC2-20Install the clip pointing the clamp section to the rear side.Touch the brake pipe to the stopper.When installing the brake hose, install it so

SPEC2-21Master cylinderThrottle cableClutch cableClampEngine stop switch leadBrake hoseCable guideThis is the number plate attaching section. The clut

CHKADJCHAPTER 3PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1P

CHKADJ3-13EAS00036PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustm

EAS00007HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all inst

CHKADJ3-2NOTE:• Hydraulic brake service• Regularly check and, if necessary, correct the brake fluid level.• Every two years replace the internal compo

CHKADJ3-3EAS00042SEAT, SIDE COVERS AND FUEL TANKOrder Job / Part Q’ty RemarksRemoving the seat, side covers and fuel tankRemove the parts in the orde

CHKADJ3-4Order Job / Part Q’ty Remarks14 Number plate 1For installation, reverse the removal procedure.4 Nm (0.4 m•kg, 2.9 ft•lb)7 Nm (0.7 m•kg, 5.1 f

CHKADJ3-5ENGINE ADJUSTING THE PILOT AIR SCREW1. Adjust:• pilot air screw NOTE:NOTE:To optimize the fuel flow at a smaller throttle opening, each vehic

CHKADJ3-6EAS00058ADJUSTING THE THROTTLE CABLE FREE PLAYNOTE:NOTE:Prior to adjusting the throttle cable free play, the engine idling speed should be ad

CHKADJ3-7EAS00060CHECKING THE SPARK PLUG1. Disconnect:• spark plug cap2. Remove:• spark plugCAUTION:Before removing the spark plug, blow away any dirt

CHKADJ3-8EAS00062CHECKING THE IGNITION TIMING1. Remove:• air scoop• spark plug• left crankcase cover2. Attach:• dial gauge • dial gauge stand 3. Adjus

CHKADJ3-96. Check:• ignition timing Re-check the ignition timing.EAS00074CHANGING THE TRANSMISSION OIL1. Start the engine, warm it up for several min-

CHKADJ3-10EAS00081ADJUSTING THE CLUTCH CABLE FREE PLAY1. Check:• clutch cable free play Out of specification → Adjust.2. Adjust:• clutch cable free p

CHKADJ3-11• fitting bolt • washer • air filter guide • air filter element CAUTION:Never operate the engine without the air fil-ter element installed.

EAS00008SYMBOLSThe following symbols are not relevant to every vehicle.Symbols to indicate the subject of each chapter.General informationSpecific

CHKADJ3-127. Apply:• lithium-soap-base grease On the matching surface on air filter ele-ment.8. Install:• air filter element • washer• fitting boltN

CHKADJ3-13EAS00098CHECKING THE CRANKCASE BREATHER HOSE1. Check:• crankcase breather hose Cracks / damage → Replace. Loose connection → Connect prope

CHKADJ3-14EAS00102CHECKING THE COOLANT LEVEL1. Stand the vehicle on a level surface.NOTE:NOTE:• Place the vehicle on a suitable stand.• Make sure the

CHKADJ3-15EAS00104CHECKING THE COOLING SYSTEM1. Remove:• air scoop Refer to “SEAT, SIDE COVERS AND FUEL TANK”.2. Check:•radiator • radiator hose joint

CHKADJ3-165. Fill:• coolant (with the specified amount of the recom-mended coolant)Handling notes for coolantCoolant is potentially harmful and should

CHKADJ3-178. Check:• coolant level Refer to “CHECKING THE COOLANT LEVEL”.NOTE:NOTE:Before checking the coolant level, wait a few minutes until the coo

CHKADJ3-18EAS00111ADJUSTING THE REAR BRAKE1. Check:• brake pedal height Out of specification → Adjust.2. Adjust:• brake pedal heighta. Loosen the loc

CHKADJ3-19EAS00115CHECKING THE BRAKE FLUID LEVEL1. Stand the vehicle on a level surface.NOTE:NOTE:• Place the vehicle on a suitable stand.• Make sure

CHKADJ3-20EAS00118CHECKING THE FRONT AND REAR BRAKE PADSThe following procedure applies to all of the brake pads.1. Check:• front brake pad• rear brak

CHKADJ3-21EAS00135BLEEDING THE HYDRAULIC BRAKE SYSTEMWARNINGBleed the hydraulic brake system when-ever:• the system is disassembled.• a brake hose is

EAS00010TABLE OF CONTENTSGENERAL INFORMATIONGEN INFO1SPECIFICATIONSSPEC2PERIODIC CHECKS AND ADJUSTMENTSCHKADJ3CHASSISCHAS4ENGINEENG5COOLING SYSTEMCOOL

CHKADJ3-22i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.j. Tighten the bleed screw

CHKADJ3-231. Elevate the rear wheel by placing the suit-able stand under the engine.WARNINGSecurely support the vehicle so that there is no danger of

CHKADJ3-24EAS00143LUBRICATING THE DRIVE CHAINThe drive chain consists of many interacting parts. If the drive chain is not maintained prop-erly, it wi

CHKADJ3-25a. Remove the steering ring nut using the steering nut wrench .b. Tighten the steering ring nut with a steering nut wrench .NOTE:NOTE:

CHKADJ3-262. Check:• inner tube Damage / scratches → Replace.• oil seal Oil leakage → Replace.3. Hold the vehicle upright and apply the front brake

CHKADJ3-271. Adjust:• rebound dampinga. Turn the adjusting screw in direction or .Compression dampingCAUTION:Never go beyond the maximum or minimum

CHKADJ3-28EAS00159ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYWARNINGSecurely support the vehicle so that there is no danger of it falling over.Spring p

CHKADJ3-29Rebound dampingCAUTION:Never go beyond the maximum or minimum adjustment positions.1. Adjust:• rebound dampinga. Turn the adjusting screw

CHKADJ3-30NOTE:NOTE:This is the position which is back by the spe-cific number of clicks from the fully turned-in position. (Which align the punch mar

CHKADJ3-312. Check:• tire surfaces Damage / wear → Replace the tire.WARNING• Do not use a tubeless tire on a wheel designed only for tube tires to av

GENINFOCHAPTER 1GENERAL INFORMATIONVEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1VEHICLE IDENTIFICATI

CHKADJ3-32WARNINGNew tires have a relatively low grip on the road surface until they have been slightly worn.NOTE:NOTE:Align the mark with the valve

CHASCHAPTER 4CHASSISFRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1REMOVING THE FRONT WHEEL . . . . . . . . .

CHASHANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55REMOVING THE HANDLEBAR . . . . . . . . .

CHAS4-1EAS00512CHASSISFRONT WHEEL AND BRAKE DISCOrder Job / Part Q’ty RemarksRemoving the front wheel and brake discRemove the parts in the order list

CHAS4-2Order Job / Part Q’ty RemarksDisassembling the front wheel Disassemble the parts in the order listed.Oil seal 2Wheel bearing 2Collar 1For asse

CHAS4-3EAS00519REMOVING THE FRONT WHEEL1. Stand the vehicle on a level surface.WARNINGSecurely support the vehicle so that there is no danger of it fa

CHAS4-42. Check:•tire• front wheel Damage / wear → Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3.3. Check:• spokes Re

CHAS4-5c. Remove the wheel bearings with a gen-eral bearing puller .d. Install the new wheel bearings and oil seals in the reverse order of disasse

CHAS4-6EAS00531CHECKING THE BRAKE DISCSThe following procedure applies to all of the brake discs.1. Check:•brake discs Damage / galling → Replace.2.

CHAS4-7d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specific

GENINFO1-1EAS00014GENERAL INFORMATIONVEHICLE IDENTIFICATIONEAS00017VEHICLE IDENTIFICATION NUMBERThe vehicle identification number is stamped into th

CHAS4-8AS00551REAR WHEEL AND BRAKE DISCREAR WHEELOrder Job / Part Q’ty RemarksRemoving the rear wheel Remove the parts in the order listed.NOTE:NOTE:P

CHAS4-9Order Job / Part Q’ty Remarks8Collar 2For 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

CHAS4-10EAS00560REAR BRAKE DISC AND REAR WHEEL SPROCKETOrder Job / Part Q’ty RemarksRemoving the rear brake disc and rear wheel sprocketRemove the par

CHAS4-11Order Job / Part Q’ty RemarksDisassembling the rear wheel Disassemble the parts in the order listed.Oil seal 2Circlip 1Bearing 2Collar 1For as

CHAS4-12EAS00561REMOVING THE REAR WHEEL1. Stand the vehicle on a level surface.WARNINGSecurely support the vehicle so that there is no danger of it fa

CHAS4-13EAS00566CHECKING THE REAR WHEEL1. Check:• rear wheel axle• rear wheel• wheel bearings• oil seals Refer to “CHECKING THE FRONT WHEEL”.2. Check:

CHAS4-142. Replace:• rear wheel sprocketa. Remove the self-locking nuts and the rear wheel sprocket.b. Clean the rear wheel drive hub with a clean clo

CHAS4-15EAS00577FRONT AND REAR BRAKESFRONT BRAKE PADSOrder Job / Part Q’ty RemarksRemoving the front brake pads Remove the parts in the order listed.1

CHAS4-16EAS00578REAR BRAKE PADSOrder Job / Part Q’ty RemarksRemoving the rear brake pads Remove the parts in the order listed.1Protector 12 Spacer 13

CHAS4-17EAS00579CAUTION:Disc brake components rarely require dis-assembly. Therefore, always follow these preventive measures:WARNING• Never disassemb

GENINFO1-2EAS00020IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DISASSEMBLY1. Before removal and disassembly, remove all dirt, mud, dust and foreig

CHAS4-183. Measure:• brake pad wear limit Out of specification → Replace the brake pads as a set.4. Install:• brake padsNOTE:NOTE:Always install new

CHAS4-198. Check:• brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.

CHAS4-20a. Connect a clear plastic hose tightly to the bleed screw . Put the other end of the hose into an open container.b. Loosen the bleed screw

CHAS4-21EAS00584FRONT BRAKE MASTER CYLINDEROrder Job / Part Q’ty RemarksRemoving the front brake master cylinderRemove the parts in the order listed.B

CHAS4-22EAS00585Order Job / Part Q’ty RemarksDisassembling the rear brake master cylinderRemove the parts in the order listed.Brake master cylinder ca

CHAS4-23EAS00586REAR BRAKE MASTER CYLINDEROrder Job / Part Q’ty RemarksRemoving the rear brake master cylinderRemove the parts in the order listed.Bra

CHAS4-24EAS00587Order Job / Part Q’ty RemarksRemoving the rear brake master cylinderRemove the parts in the order listed.Brake master cylinder kit 1Ci

CHAS4-25EAS00588DISASSEMBLING THE FRONT BRAKE MASTER CYLINDERNOTE:NOTE:Before disassembling the front brake master cylinder, drain the brake fluid fro

CHAS4-26EAS00592CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERSThe following procedure applies to the both of the brake master cylinders.1. Check:•

CHAS4-27EAS00598ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDERWARNING• Before installation, all internal brake com-ponents should be cleane