Yamaha YZ85, YZ85W1 User Manual

Page 1
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
YZ85(W)
YZ85W1
YZ85LW(W)
5PA-28199-85
Page 2
PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ AUF RECYCLINGPAPIER GEDRUCKT
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2006.04-1.4×1 CR (E,F,G)
Page 3
OWNER’S MANUAL
YZ85(W)
YZ85W1
YZ85LW(W)
5PA-28199-85-E0
Page 4
Page 5

INTRODUCTION

EAU41541
Congratulations on your purchase of the Yamaha YZ85(W)/YZ85W1/YZ85LW(W). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR MOTORCYCLE. MAKE SURE YOU UNDER-
STAND ALL INSTRUCTIONS.
PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MOTORCYCLE.
NEVER OPERATE A MOTORCYCLE WITHOUT PROPER TRAINING OR INSTRUCTION.
AN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warn­ings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil­ities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s use of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability to operate the motorcycle safely.
MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERA­TOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE
OPERATION.
OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
Page 6

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
EAU41090
WARNING
Failure to follow WARNING instructions could result in severe injury or death motorcycle operator, a bystander or a person inspecting or repairing the motor-
to the
cycle.
CAUTION:
NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
NOTE:
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
EWA10030
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
Page 7
IMPORTANT MANUAL INFORMATION
EWA14350
WARNING
THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPER­ATE THIS MOTORCYCLE ON ANY PUBLIC STREET, ROAD OR HIGHWAY. SUCH USE IS PROHIBITED BY LAW. THIS MOTORCYCLE COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS. PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERAT­ING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
Page 8
IMPORTANT MANUAL INFORMATION
YZ85(W)/YZ85W1/YZ85LW(W)
OWNERS MANUAL
©2006 by Yamaha Motor Co., Ltd.
1st edition, March 2006
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
EAU10200
Page 9

TABLE OF CONTENTS

SAFETY INFORMATION ..................1-1
Location of important labels ...........1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view........................................2-2
Controls and instruments ................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Handlebar switch ............................3-1
Clutch lever ....................................3-1
Shift pedal ......................................3-1
Brake lever .....................................3-2
Brake pedal ....................................3-2
Fuel tank cap ..................................3-3
Fuel ................................................3-3
Fuel tank breather hose .................3-5
Fuel cock ........................................3-5
Starter (choke) knob .......................3-6
Kickstarter ......................................3-6
Seat ................................................3-6
Adjusting the front fork ...................3-7
Front fork bleeding .........................3-8
Adjusting the shock absorber
assembly .....................................3-9
Removable sidestand ...................3-12
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2
OPERATION AND IMPORTANT
RIDING POINTS ................................ 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-1
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Checking the spark plug ................ 6-8
Transmission oil ............................. 6-9
Coolant ........................................ 6-10
Cleaning the air filter element ...... 6-12
Adjusting the carburetor ............... 6-14
Adjusting the throttle cable
free play .................................... 6-14
Tires ............................................. 6-15
Spoke wheels .............................. 6-17
Accessories and replacement
parts ......................................... 6-17
Adjusting the clutch lever
free play .................................... 6-17
Checking the front and rear brake
pads .......................................... 6-18
Checking the brake fluid level ...... 6-19
Changing the brake fluid .............. 6-20
Drive chain slack .......................... 6-20
Cleaning and lubricating the
drive chain ................................6-21
Checking and lubricating the
cables .......................................6-22
Checking and lubricating the
throttle grip and cable ............... 6-22
Checking and lubricating the
brake and shift pedals ............... 6-23
Checking and lubricating the
brake and clutch levers .............6-23
Lubricating the swingarm pivots ... 6-24 Lubricating the rear suspension ... 6-24
Checking the front fork .................6-24
Checking the steering ..................6-25
Checking the wheel bearings .......6-26
Supporting the motorcycle ...........6-26
Front wheel .................................. 6-27
Rear wheel ...................................6-27
Troubleshooting ...........................6-29
Troubleshooting charts ................. 6-30
MOTORCYCLE CARE AND
STORAGE ..........................................7-1
Care ...............................................7-1
Storage ...........................................7-3
SPECIFICATIONS ............................ 8-1
CONSUMER INFORMATION ............9-1
Identification numbers ....................9-1
Page 10

SAFETY INFORMATION

Safe riding
Always make pre-operation
1
checks. Careful checks may help prevent an accident.
This motorcycle is designed for off-
road use only, therefore, it is illegal to operate it on public streets, roads, or highways, even a dirt or gravel one. Off-road use on public lands may be illegal. Please check local regulations before riding.
This motorcycle is designed to car-
ry the operator only. No passen­gers.
Many accidents involve inexperi-
enced operators.
Make sure that the operator is qualified and that you only lend your motorcycle to other quali­fied operators.
Know your skills and limits. Staying within your limits may help you to avoid an accident.
Many accidents have been caused
by error of the motorcycle opera­tor. A typical error made by the op­erator is veering wide on a turn due to EXCESSIVE SPEED or un-
EAU41460
dercornering (insufficient lean an­gle for the speed). Never travel faster than warranted by condi­tions.
Ride cautiously in unfamiliar ar-
eas. You may encounter hidden obstacles that could cause an ac­cident.
The posture of the operator is im-
portant for proper control. The op­erator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motor­cycle.
Never ride under the influence of
alcohol or other drugs.
Be sure the transmission is in neu-
tral before starting the engine.
Protective apparel
The majority of fatalities from motor­cycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the pre­vention or reduction of head injuries.
Always wear an approved helmet.
Wear a face shield or goggles.
Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident.
Never touch the engine or exhaust
system during or after operation. They become very hot and can cause burns. Always wear protec­tive clothing that covers your legs, ankles, and feet.
Modifications
Modifications made to this motorcycle not approved by Yamaha, or the re­moval of original equipment, may ren­der the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.
1-1
Page 11
SAFETY INFORMATION
Loading and accessories
Adding accessories to your motorcycle can adversely affect stability and han­dling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding accessories to your motorcycle. Use extra care when riding a motorcycle that has added ac­cessories. Here are some general guidelines to follow if adding accesso­ries to your motorcycle: Loading
Accessory weight should be kept
as low and close to the motorcycle as possible. Make sure to distrib­ute the weight as evenly as possi­ble on both sides of the motorcycle to minimize imbalance or instabili­ty.
Shifting weights can create a sud-
den imbalance. Make sure that ac­cessories are securely attached to the motorcycle before riding. Check accessory mounts fre­quently.
Never attach any large or heavy
items to the handlebar, front fork, or front fender.
Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be re­sponsible for the proper selection, in­stallation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any ac­cessories. Keep these guidelines in mind for mounting accessories in addition to those provided under “Loading”.
Never install accessories or that
would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspen­sion travel, steering travel or con­trol operation.
Accessories fitted to the handle­bar or the front fork area can create instability due to improper weight distribution or aerody­namic changes. If accessories are added to the handlebar or
1-2
front fork area, they must be as lightweight as possible and should be kept to a minimum.
Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody­namic effects. Wind may at­tempt to lift the motorcycle, or the motorcycle may become un­stable in cross winds.
Certain accessories can dis­place the operator from his or her normal riding position. This improper position limits the free­dom of movement of the opera­tor and may limit control ability, therefore, such accessories are not recommended.
Use caution when adding electri-
cal accessories. If electrical acces­sories exceed the capacity of the motorcycles electrical system an electric failure could result, which could cause a dangerous loss of engine power.
1
Page 12
SAFETY INFORMATION
Gasoline and exhaust gas
GASOLINE IS HIGHLY FLAMMA-
BLE:
1
Be sure to always use a fresh mixture of oil and gasoline.
Always turn the engine off when refueling.
Take care not to spill any gaso­line on the engine or exhaust pipe/muffler when refueling.
Never refuel while smoking or in the vicinity of an open flame.
Never start the engine or let it run
for any length of time in a closed area. The exhaust fumes are poi­sonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has ad­equate ventilation.
Always turn the engine off before
leaving the motorcycle unattend­ed. When parking the motorcycle, note the following:
The engine and exhaust pipe/muffler may be hot, there­fore, park the motorcycle in a
place where pedestrians or chil­dren are not likely to touch these hot areas.
Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.
Do not park the motorcycle near a flammable source (e.g., a ker­osene heater, or near an open flame), otherwise it could catch fire.
When transporting the motorcycle
in another vehicle, make sure that it is kept upright and that the fuel cock is turned to “OFF”. If the motorcycle should lean over, gas­oline may leak out of the carbure­tor or fuel tank.
If you should swallow any gaso-
line, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.
1-3
Page 13
Location of important labels
Please read the following important labels carefully before operating this vehicle.
YZ85(W)/YZ85W1
SAFETY INFORMATION
EAU41851
1
1-4
Page 14
SAFETY INFORMATION
For Canada
1
1
CAUTION
Use premium unleaded gasoline/oil premix only.
3XJ-2415E-A0
2
ATTENTION
Utiliser de préférence un mélange huile/super sans plomb.
3XJ-2415E-B0
4
WARNING
Rinding as a passenger can cause the vehicle to go out of control.
Loss of control can cause a collision or rollover, which can result in severe injury or death.
NEVER ride as a passenger.
3XJ-2151H-A1
5
3
Un passager pourrait causer une perte de contrôle du véhicule.
Une perte de contrôle peut provoquer une collision ou un renversement, résultant en des blessures sérieuses, voire mortelles.
AUCUN passager permis.
4AA-22259-60
AVERTISSEMENT
3XJ-2151H-B1
1-5
Page 15
SAFETY INFORMATION
6
WARNING
BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNERS MANUAL AND ALL LABELS.
NEVER CARRY A PASSENGER. You increase your risk of losing control if you carry a passenger.
NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS. You can collide with another vehicle if you operate this vehicle on a public road.
ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. EXPERIENCED RIDER ONLY.
7
AVERTISSEMENT
LIRE LE MANUEL DU PROPRIETAIRE ANSI QUE TOUTES LES ETIQUETTES AVANT DUTILISER CE VEHICULE.
NE JAMAIS TRANSPORTER DE PASSAGER. La conduite avec passager augmente les risques de perte de contrôle.
NE JAMAIS ROULER SUR DES CHEMINS PUBLICS. Vous pourriez entrer en collision avec un aulre véhicule
TOUJOURS PORTER UN CASQUE DE MOTOCYCLISTE APPROUVE, des lunettes et des vêlements de protection.
EXCLUSIVEMENT POUR L’USAGE D’UN CONDUCTEUR EXPERIMENTE.
5PA-2118K-00
5PA-2118K-10
10
Cold tire normal pressure should be set as
TIRE INFOMATION
follows. FRONT : 100kPa, {1.00kgf/cm2}, 15psi REAR : 100kPa, {1.00kgf/cm
11
.
INFORMATION SUR LES PNEUS
La pression des pneus à froid doit normalement être réglée comme suit.
AVANT : 100kPa, {1.00kgf/cm ARRIERE
: 100kPa, {1.00kgf/cm2}, 15psi
2
}, 15psi
2
}, 15psi
3RV-21668-A0
3RV-21668-B0
1
1-6
Page 16
SAFETY INFORMATION
For Europe
10
9
TIRE INFORMATION
Cold tire normal pressure should be set as follows. FRONT : 100kPa, {1.00kgf/cm
REAR : 100kPa, {1.00kgf/cm
2
}
, 15psi
2
}, 15psi
3RV-21668-A0
1
3
8
Before you operate this vehicle, read the owners manual. Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propriétaire avant dutiliser ce véhicule. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario.
5PA-21568-00
12
YAMAHA MOTOR CO., LTD.
SHIZUOKA JAPAN
YAMAHA
4GB-2155A-00
1-7
Page 17
For Oceania and South Africa
SAFETY INFORMATION
8
Before you operate this vehicle, read the owners manual. Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propriétaire avant dutiliser ce véhicule. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario.
5PA-21568-00
103
TIRE INFORMATION
Cold tire normal pressure should be set as
follows. FRONT : 100kPa, {1.00kgf/cm REAR : 100kPa, {1.00kgf/cm
2
}
, 15psi
2
}, 15psi
3RV-21668-A0
1
1-8
Page 18
YZ85LW(W)
1
SAFETY INFORMATION
1-9
Page 19
For Europe
SAFETY INFORMATION
1
2
Before you operate this vehicle, read the owners manual. Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propriétaire avant dutiliser ce véhicule. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario.
5PA-21568-00
3
4
Cold tire normal pressure should be set as follows. FRONT : 100kPa, {1.00kgf/cm
REAR : 100kPa, {1.00kgf/cm
TIRE INFORMATION
5
YAMAHA MOTOR CO., LTD.
SHIZUOKA JAPAN
YAMAHA
4GB-2155A-00
2
}
, 15psi
2
}, 15psi
1
3RV-21668-A0
1-10
Page 20
SAFETY INFORMATION
For Oceania
1
41
TIRE INFORMATION
Cold tire normal pressure should be set as follows. FRONT : 100kPa, {1.00kgf/cm
REAR : 100kPa, {1.00kgf/cm
2
}
, 15psi
2
}, 15psi
3RV-21668-A0
2
Before you operate this vehicle, read the owners manual. Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propriétaire avant dutiliser ce véhicule. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario.
5PA-21568-00
1-11
Page 21
Left view
1. Radiator cap (page 6-10)
2. Fuel cock (page 3-5)
3. Shock absorber assembly spring preload adjusting nut (page 3-9)
4. Air filter element (page 6-12)
5. Seat (page 3-6)
6. Shift pedal (page 3-1)
7. Starter (choke) knob (page 3-6)

DESCRIPTION

EAU10410
2
2-1
Page 22
DESCRIPTION
Right view
2
EAU10420
1. Shock absorber assembly compression damping force adjusting screw (page 3-9)
2. Kickstarter (page 3-6)
3. Front fork rebound damping force adjusting screw (page 3-7)
4. Bleed screw (page 3-8)
5. Front fork compression damping force adjusting screw (page 3-7)
6. Spark plug cap (page 6-8)
7. Oil filler cap (page 6-9)
8. Coolant drain bolt (page 6-11)
9. Transmission oil drain bolt (page 6-9)
10.Brake pedal (page 3-2)
11.Shock absorber assembly rebound damping force adjusting screw (page 3-9)
2-2
Page 23
Controls and instruments
1. Clutch lever (page 3-1)
2. Left handlebar switch (page 3-1)
3. Brake lever (page 3-2)
4. Throttle grip (page 6-14)
5. Fuel tank cap (page 3-3)
DESCRIPTION
EAU10430
2
2-3
Page 24

INSTRUMENT AND CONTROL FUNCTIONS

Handlebar switch
EAU40660
Clutch lever
EAU12850
3
1. Engine stop button ENGINE STOP 1. Clutch lever 1. Shift pedal
ENGINE STOP button
EAU12670
Hold this button pushed until the engine stops in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.
The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handle­bar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation.
EAU12870
Shift pedal
The shift pedal is located on the left side of the engine and is used in com­bination with the clutch lever when shifting the gears of the 6-speed con­stant-mesh transmission equipped on this motorcycle.
3-1
Page 25
INSTRUMENT AND CONTROL FUNCTIONS
EAU41261
Brake lever
The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handle­bar grip.
1. Brake lever
2. Locknut
3. Adjusting bolt
4. Distance between brake lever and handlebar grip
The brake lever is equipped with a po­sition adjusting bolt. Adjust the distance between the brake lever and the han­dlebar grip as follows.
1. Loosen the locknut.
2. While holding the lever pushed away from the handlebar grip, turn the adjusting bolt in direction (a) to increase the distance, and in direc­tion (b) to decrease it.
Distance between the brake lever and the handlebar grip:
Minimum (shortest):
76 mm (2.99 in)
Standard:
95 mm (3.74 in)
Maximum (longest):
97 mm (3.82 in)
3. Tighten the locknut.
EAU12941
Brake pedal
3
1. Brake pedal
The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.
3-2
Page 26
INSTRUMENT AND CONTROL FUNCTIONS
Fuel tank cap
3
1. Fuel tank cap
To remove the fuel tank cap, turn it counterclockwise, and then pull it off. To install the fuel tank cap, insert it into the tank opening, and then turn it clock­wise.
WARNING
Make sure that the fuel tank cap is properly closed before riding.
EAU13180
EWA11090
EAU41831
Fuel
This motorcycle has been designed to use a premixed fuel of gasoline and 2­stroke engine oil. Always mix the gaso­line and oil in a clean container before filling the fuel tank.
ECA15601
CAUTION:
Always use fresh gasoline, and fill the fuel tank with a fresh mix just be­fore riding. Do not use premixed fuel that is more than a few hours old.
Mixing gasoline and 2-stroke engine oil
Pour 2-stroke engine oil into a clean container, and then add gasoline. To mix the fuel thoroughly, shake the con­tainer from side to side.
1. 2-stroke engine oil
2. Gasoline
3. Container
Recommended fuel:
Premium unleaded gasoline only
Recommended 2-stroke engine oil:
See page 8-1.
Fuel tank capacity:
5.0 L (1.32 US gal) (1.10 Imp.gal)
Mixing ratios (gasoline to oil):
Break-in period: 15:1 After break-in: 30:1
ECA15590
CAUTION:
Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the piston rings as well as to the exhaust system.
3-3
Page 27
INSTRUMENT AND CONTROL FUNCTIONS
Your Yamaha engine has been de­signed to use premium unleaded gaso­line with a pump octane number [(R+M)/2] of 91 or higher, or a research octane number of 95 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand. If the recommended 2-stroke engine oil is not available, use an equivalent oil.
ECA15551
CAUTION:
Never mix two brands of 2-stroke en­gine oil in the same batch. Always use the same type of oil to ensure maximum engine performance. Should it be necessary to use a dif­ferent oil brand, be sure to drain the fuel tank and the carburetor float chamber of the old premixed fuel prior to filling with the new type.
Filling the fuel tank
1. Fuel level
2. Fuel tank filler tube
Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
EWA10880
WARNING
Do not overfill the fuel tank, oth-
erwise it may overflow when the fuel warms up and expands.
Avoid spilling fuel on the hot en-
gine.
ECA10070
CAUTION:
Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfac­es or plastic parts.
3
3-4
Page 28
INSTRUMENT AND CONTROL FUNCTIONS
Fuel tank breather hose
3
1. Fuel tank breather hose
2. One-way valve
Before operating the motorcycle:
Check the fuel tank breather hose
connection.
Check the fuel tank breather hose
for cracks or damage, and replace it if damaged.
Make sure that the end of the fuel
tank breather hose is not blocked, and clean it if necessary.
NOTE:
If the fuel tank breather hose falls out, reinstall it on the fuel tank cap with the arrow mark on the one-way valve point­ed downward as shown.
EAU41360
EAU41280
Fuel cock
The fuel cock supplies fuel from the tank to the carburetor while filtering it al­so. The fuel cock has two positions:
OFF
1. Arrow mark positioned over “OFF”
With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.
ON
1. Arrow mark positioned over “ON”
With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.
3-5
Page 29
INSTRUMENT AND CONTROL FUNCTIONS
EAU13640
Starter (choke) knob
1. Starter (choke) knob 1. Kickstarter lever
Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction (a) to turn on the starter (choke). Move the knob in direction (b) to turn off the starter (choke).
Kickstarter
To start the engine, fold out the kick­starter lever, move it down lightly with your foot until the gears engage, and then push it down smoothly but force­fully. This model is equipped with a pri­mary kickstarter, allowing the engine to be started in any gear if the clutch is disengaged. However, shifting the transmission into the neutral position before starting is recommended.
EAU13650
EAU13960
Seat
To remove the seat
Remove the bolts, and then pull the seat off.
3
1. Bolt
To install the seat
1. Insert the projections on the front of the seat into the seat holders as shown.
3-6
Page 30
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Projection
2. Seat holder
2. Place the seat in the original posi­tion, and then tighten the bolts.
NOTE:
Make sure that the seat is properly se­cured before riding.
EAU41470
Adjusting the front fork
This front fork is equipped with rebound damping force adjusting screws and compression damping force adjusting screws.
EWA10180
WARNING
Always adjust both fork legs equal­ly, otherwise poor handling and loss of stability may result.
Rebound damping force
1. Rebound damping force adjusting screw
To increase the rebound damping force and thereby harden the rebound damp­ing, turn the adjusting screw on each fork leg in direction (a). To decrease the rebound damping force and thereby
3-7
soften the rebound damping, turn the adjusting screw on each fork leg in di­rection (b).
Rebound damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard:
7 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
Compression damping force
1. Rubber cap
2. Compression damping force adjusting screw
1. Remove the rubber cap by pulling it out of the front fork leg.
Page 31
INSTRUMENT AND CONTROL FUNCTIONS
2. To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw on each fork leg in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw on each fork leg in direction (b).
Compression damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard:
YZ85(W)/YZ85W1: 10 click(s) in direction (b)* YZ85LW(W): 9 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
3. Install the rubber cap.
ECA10100
CAUTION:
Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
NOTE:
Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec­ifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the num­ber of clicks of each damping force ad­justing mechanism and to modify the specifications as necessary.
EAU14790
Front fork bleeding
3
1. Bleed screw
When riding in extremely rough condi­tions, the air temperature and pressure in the front fork will rise. This will in­crease the spring preload and harden the front suspension. If this occurs, bleed the front fork as follows.
1. Elevate the front wheel by placing a suitable stand under the engine.
NOTE:
When bleeding the front fork, there should be no weight on the front end of the vehicle.
2. Remove the bleed screws and al­low all of the air to escape from each fork leg.
3-8
Page 32
INSTRUMENT AND CONTROL FUNCTIONS
WARNING
Always bleed both fork legs, other­wise poor handling and loss of sta­bility may result.
3. Install the bleed screws.
3
EWA10200
EAU41330
Adjusting the shock absorber assembly
This shock absorber assembly is equipped with a spring preload adjust­ing nut, a rebound damping force ad­justing screw and a compression damping force adjusting screw.
ECA10100
CAUTION:
Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
Spring preload
Adjust the spring preload as follows.
1. Loosen the locknut.
2. To increase the spring preload and thereby harden the suspension, turn the adjusting nut in direction (a). To decrease the spring pre­load and thereby soften the sus­pension, turn the adjusting nut in direction (b).
NOTE:
A special wrench can be obtained
at a Yamaha dealer to make this adjustment.
The spring preload setting is deter-
mined by measuring distance A, shown in the illustration. The long­er distance A is, the lower the spring preload; the shorter dis­tance A is, the higher the spring preload. With each complete turn of the adjusting nut, distance A is changed by 1.5 mm (0.06 in).
1. Locknut
2. Spring preload adjusting nut
3-9
Page 33
INSTRUMENT AND CONTROL FUNCTIONS
1. Distance A
Spring preload:
Minimum (soft):
Distance A = 218.5 mm (8.60 in)
Standard: YZ85(W)/YZ85W1
Distance A = 215.0 mm (8.46 in) For Europe only: Distance A =
212.0 mm (8.35 in)
Standard: YZ85LW(W)
Distance A = 207.0 mm (8.15 in) For Europe only: Distance A =
212.0 mm (8.35 in)
Maximum (hard):
Distance A = 202.5 mm (7.97 in)
3. Tighten the locknut to the specified torque.
ECA10120
CAUTION:
Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque.
Rebound damping force
To increase the rebound damping force and thereby harden the rebound damp­ing, turn the adjusting screw in direction (a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting screw in di­rection (b).
1. Rebound damping force adjusting screw
Rebound damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard: YZ85(W)/YZ85W1
6 click(s) in direction (b)* For Europe only: 12 click(s) in di­rection (b)*
Standard: YZ85LW(W)
7 click(s) in direction (b)* For Europe only: 12 click(s) in di­rection (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
Compression damping force
To increase the compression damping force and thereby harden the compres­sion damping, turn the adjusting screw in direction (a). To decrease the com­pression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b).
3
Tightening torque:
Locknut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
3-10
Page 34
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Compression damping force adjusting screw
Compression damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard: YZ85(W)/YZ85W1
9 click(s) in direction (b)* For Europe only: 12 click(s) in di­rection (b)*
Standard: YZ85LW(W)
7 click(s) in direction (b)* For Europe only: 12 click(s) in di­rection (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
NOTE:
Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec-
ifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the num­ber of clicks of each damping force ad­justing mechanism and to modify the specifications as necessary.
EWA10220
WARNING
This shock absorber contains highly pressurized nitrogen gas. For prop­er handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held re­sponsible for property damage or personal injury that may result from improper handling.
Do not tamper with or attempt to
open the gas cylinder.
Do not subject the shock ab-
sorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure.
3-11
Do not deform or damage the
gas cylinder in any way, as this will result in poor damping per­formance.
Always have a Yamaha dealer
service the shock absorber.
Page 35
EAU41381
Removable sidestand
1. Sidestand
This motorcycle is equipped with a re­movable sidestand.
NOTE:
Make sure that the sidestand is proper­ly secured when the motorcycle is be­ing supported or is being transported.
EWA14601
WARNING
Never apply force on the motor-
cycle while it is on the side­stand.
Always remove the sidestand
before starting out.
INSTRUMENT AND CONTROL FUNCTIONS
3
3-12
Page 36

PRE-OPERATION CHECKS

The condition of a vehicle is the owners responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec­tion, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.
4
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle.
EAU15591
EWA11150
4-1
Page 37
Pre-operation check list
ITEM CHECKS PAGE
Fuel
Transmission oil
Coolant
Front brake
Rear brake
Clutch
Throttle grip
Check fuel level in fuel tank.
Always use a fresh mixture of gasoline and oil.
Check fuel line for leakage.
Check oil level in transmission case.
If necessary, add recommended oil to specified level.
Check coolant level.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
PRE-OPERATION CHECKS
EAU15605
3-3
6-9
6-10
4
6-18, 6-19
6-18, 6-19
6-17
6-14, 6-22
grip housing.
4-2
Page 38
PRE-OPERATION CHECKS
ITEM CHECKS PAGE
Check chain slack.
Drive chain
Wheels and tires
Shift pedal
4
Brake pedal
Steering Check that the handlebar can be turned smoothly and has no excessive play. 6-25
Front fork and rear shock ab­sorber assembly
Chassis fasteners
Moving parts and cables
Exhaust system
Ignition system Check that all leads and cables are properly connected. 6-8
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Check for loose spokes and tighten if necessary.
Make sure that operation is smooth.
Correct if necessary.
Make sure that operation is smooth.
Lubricate pedal pivoting point if necessary.
Check that they operate smoothly and there is no oil leakage. 3-7, 3-8, 3-9, 6-24
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.
Check that the control cables move smoothly.
Check that the control cables are not caught when the handlebars are turned or
when the front forks travel up and down.
Lubricate moving parts and cables if necessary.
Check that the exhaust pipe is tightly mounted and has no cracks.
Check for leakage.
6-20, 6-21
6-15, 6-17
6-23
6-23
6-22, 6-23, 6-24, 6-24
4-3
Page 39

OPERATION AND IMPORTANT RIDING POINTS

EAU41400
EWA14610
WARNING
This model is designed for off-
road use only. Become thor­oughly familiar with all operat­ing controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thor­oughly understand.
Never start the engine or oper-
ate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of con­sciousness and death within a short time. Always make sure that there is adequate ventila­tion.
Before starting out, make sure
that the sidestand is removed. If the sidestand is not removed, it will contact the ground, which could distract the operator or af­fect the balance of the motor­cycle, resulting in a possible loss of control.
EAU41300
Starting and warming up a cold engine
1. Turn the fuel cock lever to “ON”.
2. Shift the transmission into the neu­tral position.
3. Turn the starter (choke) on and completely close the throttle. (See page 3-6.)
4. Start the engine by pushing the kickstarter lever down.
ECA11130
CAUTION:
For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold!
5. When the engine is warm, turn the starter (choke) off.
NOTE:
The engine is warm when it responds normally to the throttle with the starter (choke) turned off.
EAU16660
Starting a warm engine
Follow the same procedure as for start­ing a cold engine with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open.
NOTE:
If the engine does not start after several kicks, try again with the throttle 1/4 to 1/2 open.
5
5-1
Page 40
OPERATION AND IMPORTANT RIDING POINTS
Shifting
1. Shift pedal
2. Neutral position
5
Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the il­lustration.
NOTE:
To shift the transmission into the neu­tral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it.
EAU16671
ECA10260
CAUTION:
Even with the transmission in
the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long dis­tances. The transmission is properly lubricated only when the engine is running. Inade­quate lubrication may damage the transmission.
Always use the clutch while
changing gears to avoid damag­ing the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.
EAU16690
To start out and accelerate
1. Pull the clutch lever to disengage the clutch.
2. Shift the transmission into first gear.
3. Open the throttle gradually and si­multaneously release the clutch le­ver slowly.
4. Once the motorcycle has reached a speed high enough to change gears, close the throttle, and at the same time, quickly pull the clutch lever in.
5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral posi­tion.)
6. Open the throttle halfway and gradually release the clutch lever.
7. Follow the same procedure when shifting to the next gear.
EAU16710
To decelerate
1. Close the throttle and apply both the front and the rear brakes to slow the motorcycle.
2. Downshift through the gears and shift the transmission into the neu­tral position when the motorcycle is almost completely stopped.
5-2
Page 41
OPERATION AND IMPORTANT RIDING POINTS
EAU41502
Engine break-in
1. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows.
Recommended 2-stroke engine oil:
See page 8-1.
Mixing ratio (gasoline to oil):
15:1
2. Start and warm up the engine. Check the operation of the controls and the engine stop button. (See page 3-1.)
3. Operate the motorcycle in the low­er gears at moderate throttle open­ings for five to eight minutes. Stop the engine and check the spark plug condition (see page 6-8); it will show a rich condition during break-in.
4. Allow the engine to cool. Restart the engine and operate the motor­cycle as in the step above for five minutes. Then, very briefly shift to the higher gears and check the full-throttle response. Stop the en­gine and check the spark plug.
5. After again allowing the engine to cool, restart and run the motor­cycle for five more minutes. Full throttle and the higher gears may be used, but sustained full-throttle operation should be avoided. Stop the engine and check the spark plug again.
6. Allow the engine to cool, remove the cylinder head and cylinder, and inspect the piston and cylinder. Remove any high spots on the pis­ton with #600-grit wet sandpaper. Clean all components and careful­ly reassemble the cylinder head and cylinder.
EWA10320
WARNING
If you are not familiar with mainte­nance work, have a Yamaha dealer do it for you.
7. Drain the break-in oil-fuel mixture from the fuel tank and refill with the specified mix. (See page 3-3.)
8. Start the engine and check the op­eration of the motorcycle through­out its entire operating range. Stop the engine and check the spark
plug condition. Restart the motor­cycle and ride it for about 10 to 15 more minutes. The motorcycle will
now be ready to ride normally. After the engine break-in period, thor­oughly check the motorcycle for loose parts, oil leakage and any other prob­lems. Be sure to inspect and make ad­justments thoroughly, especially cable and drive chain slack and loose spokes. In addition, check all fittings and fasteners for looseness, and tight­en if necessary.
ECA15560
CAUTION:
When any of the following parts
have been replaced, they must
be broken in.
Cylinder or crankshaft:
About one hour of break-in op-
eration is necessary.
Piston, rings or transmission
gears:
These parts require about 30
minutes of break-in operation at
half-throttle or less. Observe the
condition of the engine carefully
during operation.
5
5-3
Page 42
OPERATION AND IMPORTANT RIDING POINTS
If any engine trouble should oc-
cur during the engine break-in period, immediately have a Yamaha dealer check the vehi­cle.
5
EAU17190
Parking
When parking, stop the engine, and then turn the fuel cock lever to “OFF”.
EWA10310
WARNING
Since the engine and exhaust
system can become very hot, park in a place where pedestri­ans or children are not likely to touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle may overturn.
5-4
Page 43
EAU17240
Safety is an obligation of the owner. Pe­riodic inspection, adjustment and lubri­cation will keep your vehicle in the safest and most efficient condition pos­sible. The most important points of in­spection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a gen­eral guide under normal riding condi­tions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHI­CAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTER­VALS MAY NEED TO BE SHORT­ENED.
EWA10320
WARNING
If you are not familiar with mainte­nance work, have a Yamaha dealer do it for you.

PERIODIC MAINTENANCE AND MINOR REPAIR

6
6-1
Page 44
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41794
Periodic maintenance and lubrication chart
The following chart is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are in doubt as to what intervals to follow in maintaining and lubricating your motorcycle, consult your Yamaha dealer.
NOTE:
From the seventh race, repeat the maintenance intervals starting from Every race”.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM ROUTINE
Check piston for carbon deposits and cracks or dam-
1
* Piston
6
2*Piston rings
*
3
4 * Cylinder head
Piston pin and small end bearing
age.
Clean.
Replace.
Check piston ring end gap and rings for damage.
Replace.
Check piston pin and small end bearing for damage.
Replace.
Check cylinder head for carbon deposits.
Clean.
Check cylinder head gasket for damage.
Tighten cylinder head bolts if necessary.
Replace cylinder head gasket.
6-2
After
break-in
Every
race
Every
third race
√√
Every
fifth raceAsrequired
Page 45
PERIODIC MAINTENANCE AND MINOR REPAIR
NO. ITEM ROUTINE
Check cylinder for score marks or wear.
5*Cylinder
6 * Clutch
7 * Transmission
Shift forks, guide bars,
8 *
shift cam
Rotor nut
9 *
(flywheel magneto)
10 * Kickstarter system
11 * Exhaust system
12 * Crankshaft
Clean.
Replace.
Check clutch housing, friction plates, clutch plates
and clutch springs for wear or damage.
Adjust.
Replace.
Change the transmission oil.
Check transmission for damage.
Replace bearings.
Check all parts for wear and damage.
Replace if necessary.
Tighten. √√
Check idle gear for damage.
Replace if necessary.
Check exhaust pipe and muffler for carbon deposits.
Clean.
Check crankshaft for carbon deposits and damage.
Clean.
After
break-in
Every
race
Every
third race
Every
fifth raceAsrequired
√ √
√ √
6
6-3
Page 46
PERIODIC MAINTENANCE AND MINOR REPAIR
NO. ITEM ROUTINE
13 * Carburetor
14 Spark plug
15 Drive chain
16 * Cooling system
6
17 * Chassis fasteners
18 * Air filter element
19 * Frame Clean and check for damage. 20 * Fuel line Clean and check for leakage. √√
Check carburetor settings and for obstructions.
Adjust and clean.
Check condition.
Clean and regap.
Replace.
Check chain slack, alignment and condition.
Adjust and thoroughly lubricate chain with Yamaha
chain and cable lube or equivalent.
Replace.
Check coolant level and for leakage.
Check hoses for cracks or damage.
Check radiator cap spring operation.
Change coolant. Every 2 years
Check all chassis fitting and fasteners.
Correct or tighten if necessary.
Clean.
Replace.
After
break-in
Every
race
√ √
Every
third race
fifth raceAsrequired
Every
6-4
Page 47
PERIODIC MAINTENANCE AND MINOR REPAIR
NO. ITEM ROUTINE
Adjust lever position and pedal height.
Lubricate pivot points.
Check brake disk surface.
Check fluid level and for leakage.
21 * Brakes
22 * Front fork
Shock absorber assem-
23 *
bly
Tighten brake disk bolts, caliper bolts, master cylinder bolts and union bolts.
Replace brake pads.
Replace brake fluid. Every year
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.
Check operation and adjust.
Tighten if necessary.
Lubricate with molybdenum disulfide grease.
After
break-in
√√
Every
race
Every
third race
Every
fifth raceAsrequired
(After
washing
the motorcycle or riding in
the rain)
6
6-5
Page 48
PERIODIC MAINTENANCE AND MINOR REPAIR
NO. ITEM ROUTINE
Drive chain roller and
24 *
support guide
25 * Rear suspension
26 * Steering head
27 * Tires and wheels
6
Moving parts and ca-
28 *
bles
Throttle grip housing
29 *
and cable
Check for wear or damage.
Replace if necessary.
Check operation and tighten if necessary.
Lubricate with molybdenum disulfide grease.
Check operation, free play, and tighten if necessary.
Clean and lubricate with lithium-soap-based grease.
Replace bearings.
Check tire air pressure, wheel runout, spokes for
looseness, and tires for wear.
Tighten sprocket bolts if necessary.
Check wheel bearings for looseness.
Lubricate wheel bearings with lithium-soap-based
grease.
Replace wheel bearings.
Lubricate.
Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
After
break-in
√√ √ √
Every
race
√ √
Every
third race
Every
fifth raceAsrequired
EAU42010
NOTE:
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
6-6
Page 49
PERIODIC MAINTENANCE AND MINOR REPAIR
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
6
6-7
Page 50
PERIODIC MAINTENANCE AND MINOR REPAIR
Checking the spark plug
The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic mainte­nance and lubrication chart. In addition, the condition of the spark plug can re­veal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
6
1. Spark plug cap
2. Remove the spark plug as shown, with a spark plug wrench available at a Yamaha dealer.
EAU19612
1. Spark plug wrench
To check the spark plug
1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the vehicle is ridden normally).
NOTE:
If the spark plug shows a distinctly dif­ferent color, the engine could be oper­ating improperly. Do not attempt to diagnose such problems yourself. In­stead, have a Yamaha dealer check the vehicle.
2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.
Specified spark plug:
NGK/BR10EG
To install the spark plug
1. Measure the spark plug gap with a wire thickness gauge and, if nec­essary, adjust the gap to specifica­tion.
1. Spark plug gap
Spark plug gap:
0.5–0.6 mm (0.020–0.024 in)
6-8
Page 51
PERIODIC MAINTENANCE AND MINOR REPAIR
2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads.
3. Install the spark plug with the spark plug wrench, and then tight­en it to the specified torque.
Tightening torque:
Spark plug:
20 Nm (2.0 m·kgf, 14 ft·lbf)
NOTE:
If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the speci­fied torque as soon as possible.
4. Install the spark plug cap.
EAU41441
Transmission oil
The transmission oil must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha deal­er check and repair the motorcycle. In addition, the transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart.
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place the motorcycle on a level surface and hold it in an upright po­sition.
3. Place an oil pan under the trans­mission to collect the used oil.
4. Remove the oil filler cap and drain bolt to drain the oil from the trans­mission.
1. Oil filler cap
2. Transmission oil drain bolt
5. Install the transmission oil drain bolt, and then tighten it to the spec­ified torque.
6
Tightening torque:
Transmission oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
6. Add the specified amount of the recommended transmission oil, and then install and tighten the oil filler cap.
6-9
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0.50 L (0.53 US qt) (0.44 Imp.qt)
Page 52
PERIODIC MAINTENANCE AND MINOR REPAIR
CAUTION:
In order to prevent clutch slip-
page (since the transmission oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher.
Make sure that no foreign mate-
rial enters the transmission.
7. Start the engine, and then let it idle
6
for several minutes while checking the transmission for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.
ECA10452
EAU20070
Coolant
The coolant level should be checked before each ride. In addition, the cool­ant must be changed at the intervals specified in the periodic maintenance and lubrication chart.
EAUM1291
To check the coolant level
1. Place the vehicle on a level sur­face and hold it in an upright posi­tion.
EWA10380
WARNING
Never attempt to remove the radiator cap when the engine is hot.
2. Remove the radiator cap and check the coolant level in the radi­ator.
1. Radiator cap
NOTE:
The coolant level must be checked
on a cold engine since the level varies with engine temperature.
Make sure that the vehicle is posi-
tioned straight up when checking the coolant level. A slight tilt to the side can result in a false reading.
NOTE:
The coolant should be at the brim of the radiator filler. The level will change with variation of engine temperature.
6-10
Page 53
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Correct coolant level
3. If the coolant is below this level, add coolant, and then install the radiator cap.
NOTE:
If the engine overheats, see page 6-30 for further instructions.
EAUM1311
To change the coolant
1. Place the vehicle on a level sur­face and let the engine cool if nec­essary.
2. Place a container under the engine to collect the used coolant.
EWA10380
WARNING
Never attempt to remove the radiator cap when the engine is hot.
3. Remove the radiator cap.
1. Radiator cap
4. Remove the coolant drain bolt to drain the cooling system.
5. After the coolant is completely drained, thoroughly flush the cool­ing system with clean tap water.
6. Install the coolant drain bolt, and then tighten it to the specified torque.
NOTE:
Check the washer for damage and re­place it if necessary.
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
7. Pour the recommended coolant into the radiator until it is full.
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol anti­freeze containing corrosion inhibitors for aluminum engines
Coolant quantity:
Radiator capacity (including all routes):
0.54 L (0.57 US qt) (0.48 Imp.qt)
6
1. Coolant drain bolt
6-11
Page 54
PERIODIC MAINTENANCE AND MINOR REPAIR
CAUTION:
If coolant is not available, use
distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.
If water has been used instead
of coolant, replace it with cool­ant as soon as possible, other­wise the cooling system will not be protected against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
6
check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.
8. Install the radiator cap, start the engine, let it idle for several min­utes, and then turn it off.
9. Remove the radiator cap to check the coolant level in the radiator. If necessary, add sufficient coolant until it reaches the top of the radia­tor, and then install the radiator cap.
ECA10471
10. Start the engine, and then check the vehicle for coolant leakage. If coolant is leaking, have a Yamaha dealer check the cooling system.
EAU41431
Cleaning the air filter element
The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more fre­quently if you are riding in unusually wet or dusty areas.
1. Remove the seat. (See page 3-6.)
2. Remove the air filter case cover as shown.
1. Air filter case cover
6-12
Page 55
3. Remove the air filter element by removing the wing bolt and wash­er.
1. Wing bolt
2. Washer
3. Sponge material
4. Remove the sponge material from the air filter element frame.
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
The sponge material should be wet but not dripping.
Recommended oil:
Yamaha foam air filter oil or other quality foam air filter oil
7. Pull the sponge material over the
1. Sponge material
2. Air filter element frame
5. Clean the sponge material with solvent, and then squeeze the re­maining solvent out.
6. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the ex­cess oil out.
air filter element frame.
8. Insert the air filter element into the air filter case with the projection facing upward, and then install the washer and wing bolt.
1. Sponge material
2. Projection
6
6-13
Page 56
PERIODIC MAINTENANCE AND MINOR REPAIR
CAUTION:
Make sure that the air filter ele-
ment is properly seated in the air filter case.
The engine should never be op-
erated without the air filter ele­ment installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn.
9. Install the air filter case cover in the original position as shown.
6
10. Install the seat.
ECA10480
EAU39930
Adjusting the carburetor
The carburetor is an important part of the engine and requires very sophisti­cated adjustment. Therefore, most car­buretor adjustments should be left to a Yamaha dealer, who has the neces­sary professional knowledge and expe­rience. The adjustment described in the following section, however, may be ser­viced by the owner as part of routine maintenance.
ECA10550
CAUTION:
The carburetor has been set and ex­tensively tested at the Yamaha fac­tory. Changing these settings without sufficient technical knowl­edge may result in poor perfor­mance of or damage to the engine.
EAU21370
Adjusting the throttle cable free play
1. Throttle cable free play
The throttle cable free play should mea­sure 3.0–5.0 mm (0.12–0.20 in) at the throttle grip. Periodically check the throttle cable free play and, if neces­sary, adjust it as follows.
NOTE:
The engine idling speed must be cor­rectly adjusted before checking and ad­justing the throttle cable free play.
1. Loosen the locknut.
6-14
Page 57
PERIODIC MAINTENANCE AND MINOR REPAIR
2. To increase the throttle cable free play, turn the adjusting nut in direc­tion (a). To decrease the throttle cable free play, turn the adjusting nut in direction (b).
1. Locknut
2. Throttle cable free play adjusting nut
3. Tighten the locknut.
EAU41820
Tires
To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points regarding the specified tires.
Tire air pressure
The tire air pressure should be checked and, if necessary, adjusted before each ride.
EWA14380
WARNING
The tire air pressure must be
checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).
The tire air pressure must be ad-
justed in accordance with the weight of the rider, the riding speed, and the riding condi­tions.
Standard tire air pressure:
Front:
100 kPa (15 psi) (1.00 kgf/cm²)
Rear:
100 kPa (15 psi) (1.00 kgf/cm²)
Tire inspection
2
1
1. Tire sidewall
2. Tire tread depth
The tires must be checked before each ride.
ECA15580
CAUTION:
Be sure the bead stoppers are
tightened. Loose bead stoppers will cause the tire to slip off the rim if tire pressure is too low.
Be sure the valve stem is posi-
tioned straight. A tilted valve stem indicates that the tire has slipped from its original posi­tion on the rim. Rotate the tire so that the valve stem is posi­tioned straight.
6
6-15
Page 58
PERIODIC MAINTENANCE AND MINOR REPAIR
If the center tread depth reaches the specified limit, if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer re­place the tire immediately.
Minimum tire tread depth (front and rear):
4.0 mm (0.16 in)
Tire information
This motorcycle is equipped with spoke wheels and tube tires.
WARNING
6
The front and rear tires should
be of the same make and de­sign, otherwise the handling characteristics of the vehicle cannot be guaranteed.
After extensive tests, only the
tires listed below have been ap­proved for this model by Yamaha Motor Co., Ltd.
EWA10460
Front tire:
Size:
YZ85 70/100-17 40M YZ85LW 70/100-19 42M YZ85LWW 70/100-19 42M YZ85W 70/100-17 40M YZ85W1 70/100-17 40M
Manufacturer/model:
YZ85 DUNLOP/D739FA (ZAF) YZ85 DUNLOP/D756F (AUT)(BEL)(CHE)(DEU)(DNK)(ES P)(FIN)(FRA)(GBR)(GRC)(IRL)(N LD)(NOR)(PRT)(SWE) YZ85LW DUNLOP/D756F YZ85LWW DUNLOP/D756F YZ85W DUNLOP/D756F YZ85W1 DUNLOP/D756F
Rear tire:
Size:
YZ85 90/100-14 49M YZ85LW 90/100-16 52M YZ85LWW 90/100-16 52M YZ85W 90/100-14 49M YZ85W1 90/100-14 49M
Manufacturer/model:
DUNLOP/D756
EWA14390
WARNING
Have a Yamaha dealer replace
excessively worn tires. Operat­ing the motorcycle with exces-
sively worn tires decreases riding stability and can lead to loss of control.
The replacement of all wheel-
and brake-related parts, includ­ing the tires, should be left to a Yamaha dealer, who has the necessary professional knowl­edge and experience.
It is not recommended to patch
a punctured tube. If unavoid­able, however, patch the tube very carefully and replace it as soon as possible with a high­quality product.
6-16
Page 59
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21940
Spoke wheels
To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points regarding the specified wheels.
The wheel rims should be checked
for cracks, bends or warpage, and the spokes for looseness or dam­age before each ride. If any dam­age is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse han­dling characteristics, and a short­ened tire life.
Ride at moderate speeds after
changing a tire since the tire sur­face must first be broken in for it to develop its optimal characteris­tics.
EAU40431
Accessories and replacement parts
EWA14481
WARNING
The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be se­curely mounted to maintain the in­herent stability of the original design. Genuine Yamaha Parts and Accessories are designed and test­ed to be compatible with your vehi­cle. Yamaha recommends the use of Genuine Yamaha Parts and Acces­sories before making a purchase. Use of non-Yamaha-approved ac­cessories or replacement parts may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of accessories or parts manufactured by other compa­nies, Yamaha cannot be held liable for any consequences caused by the use of items which have not been approved by Yamaha.
EAU22031
Adjusting the clutch lever free play
1. Clutch lever free play
2. Locknut (clutch lever)
3. Adjusting bolt
6
The clutch lever free play should mea­sure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch le­ver free play and, if necessary, adjust it as follows.
1. Loosen the locknut at the clutch le­ver.
2. To increase the clutch lever free play, turn the adjusting bolt in di­rection (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b).
6-17
Page 60
PERIODIC MAINTENANCE AND MINOR REPAIR
3. If the specified clutch lever free play could be obtained as de­scribed above, tighten the locknut and skip the rest of the procedure, otherwise, proceed as follows.
4. Fully turn the adjusting bolt in di­rection (a) to loosen the clutch ca­ble.
5. Loosen the locknut further down the clutch cable.
6
1. Locknut (clutch cable)
2. Adjusting nut
6. To increase the clutch lever free play, turn the adjusting nut in direc­tion (a). To decrease the clutch le­ver free play, turn the adjusting nut in direction (b).
7. Tighten both locknuts.
EAU22390
Checking the front and rear brake pads
The front and rear brake pads must be checked for wear at the intervals spec­ified in the periodic maintenance and lubrication chart.
EAU22400
Front brake pads
1. Lining thickness
Check each front brake pad for dam­age and measure the lining thickness. If a brake pad is damaged or if the lining thickness is less than 0.8 mm (0.03 in), have a Yamaha dealer replace the brake pads as a set.
Rear brake pads
EAU22500
1. Lining thickness
Check each rear brake pad for damage and measure the lining thickness. If a brake pad is damaged or if the lining thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the brake pads as a set.
6-18
Page 61
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22580
Checking the brake fluid level
Front brake
1. Minimum level mark
Rear brake
1. Minimum level mark
Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions:
When checking the fluid level,
make sure that the top of the brake fluid reservoir is level.
Use only the recommended quality
brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking perfor­mance.
Recommended brake fluid:
DOT 4
Refill with the same type of brake
fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.
Be careful that water does not en-
ter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al­ways clean up spilled fluid immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to grad­ually go down. However, if the brake fluid level goes down sud­denly, have a Yamaha dealer check the cause.
6
Insufficient brake fluid may allow air to enter the brake system, possibly caus­ing it to become ineffective.
6-19
Page 62
PERIODIC MAINTENANCE AND MINOR REPAIR
Changing the brake fluid
Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte­nance and lubrication chart. In addition, have the oil seals of the master cylin­ders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
6
EAU22730
EAU22760
Drive chain slack
The drive chain slack should be checked before each ride and adjusted if necessary.
EAU41410
To check the drive chain slack
1. Install the removable sidestand and place the motorcycle on it.
NOTE:
When checking and adjusting the drive chain slack, there should be no weight on the motorcycle.
2. Shift the transmission into the neu­tral position.
3. Move the rear wheel by pushing the motorcycle to locate the tight­est portion of the drive chain, and then measure the drive chain slack as shown.
Drive chain slack:
35.0–45.0 mm (1.38–1.77 in)
1. Drive chain slack
4. If the drive chain slack is incorrect, adjust it as follows.
EAU41480
To adjust the drive chain slack
1. Loosen the axle nut and the lock­nut on each side of the swingarm.
2. To tighten the drive chain, turn the adjusting bolt on each side of the swingarm in direction (a). To loos­en the drive chain, turn the adjust­ing bolt on each side of the swingarm in direction (b), and then push the rear wheel forward.
6-20
Page 63
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Using the alignment marks on each chain puller, make sure that both chain pullers are in the same position for proper wheel alignment.
1. Axle nut
2. Locknut
3. Drive chain slack adjusting bolt
4. Alignment marks
ECA10570
CAUTION:
Improper drive chain slack will over­load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.
3. Tighten both locknuts and the axle nut to the specified torques.
Tightening torques:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
EAU23013
Cleaning and lubricating the drive chain
The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica­tion chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.
ECA10581
CAUTION:
The drive chain must be lubricated after washing the motorcycle and riding in the rain.
1. Remove all dirt and mud from the drive chain with a brush or cloth.
NOTE:
For a thorough cleaning, have a Yamaha dealer remove the drive chain and soak it in solvent.
2. Spray Yamaha Chain and Cable Lube or a high-quality spray-type drive chain lubricant on both sides and on the middle of the chain,
6
6-21
Page 64
PERIODIC MAINTENANCE AND MINOR REPAIR
making sure that all side plates and rollers have been sufficiently oiled.
EAU41840
Checking and lubricating the cables
The operation of all control cables and the condition of the cables should be checked before each ride, and the ca­bles and cable ends should be lubricat­ed if necessary. If a cable is damaged
Checking and lubricating the throttle grip and cable
The operation of the throttle grip should be checked before each ride. In addi­tion, the cable should be lubricated at the intervals specified in the periodic maintenance chart.
EAU23111
or does not move smoothly, have a Yamaha dealer check or replace it.
Recommended lubricant:
Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API SE)
EWA10710
6
WARNING
Damage to the outer housing of ca­bles may result in internal rusting and cause interference with cable movement. Replace damaged ca­bles as soon as possible to prevent unsafe conditions.
6-22
Page 65
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23131
Checking and lubricating the brake and shift pedals
The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lu­bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-pur­pose grease)
EAU23140
Checking and lubricating the brake and clutch levers
Brake lever
Clutch lever
Recommended lubricant:
Lithium-soap-based grease (all-pur­pose grease)
6
The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lu­bricated if necessary.
6-23
Page 66
PERIODIC MAINTENANCE AND MINOR REPAIR
Lubricating the swingarm piv­ots
The swingarm pivots must be lubricat­ed at the intervals specified in the peri­odic maintenance and lubrication chart.
6
Recommended lubricant:
Lithium-soap-based grease
EAUM1650
EAU23250
Lubricating the rear suspen­sion
The pivoting points of the rear suspen­sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
EAU23271
Checking the front fork
The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main­tenance and lubrication chart.
To check the condition
EWA10750
WARNING
Securely support the vehicle so that there is no danger of it falling over.
Check the inner tubes for scratches, damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur­face and hold it in an upright posi­tion.
2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.
6-24
Page 67
ECA10590
CAUTION:
If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or re­pair it.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23280
Checking the steering
Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as fol­lows at the intervals specified in the pe­riodic maintenance and lubrication chart.
1. Place a stand under the engine to raise the front wheel off the ground.
EWA10750
WARNING
Securely support the vehicle so that there is no danger of it falling over.
2. Hold the lower ends of the front fork legs and try to move them for­ward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering.
6
6-25
Page 68
PERIODIC MAINTENANCE AND MINOR REPAIR
Checking the wheel bearings
The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica­tion chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.
6
EAU23290
EAU24350
Supporting the motorcycle
Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up­right. Check that the motorcycle is in a stable and level position before starting any maintenance. A strong wooden box can be placed under the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle by using a motorcycle stand or, if an additional motorcycle stand is not available, by placing a jack un­der the frame in front of the rear wheel.
2. Raise the front wheel off the ground by using a motorcycle stand.
To service the rear wheel
Raise the rear wheel off the ground by using a motorcycle stand or, if a motor­cycle stand is not available, by placing
a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm.
6-26
Page 69
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24360
Front wheel
EAU41340
To remove the front wheel
EWA10820
WARNING
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no danger of it falling over.
1. Loosen the axle nut.
1. Washer
2. Axle nut
4. Pull the wheel axle out, and then remove the wheel.
1. Wheel axle
EAU41420
To install the front wheel
1. Lift the wheel up between the fork legs.
2. Insert the wheel axle from the right side.
3. Lower the front wheel so that it is on the ground.
4. Install the washer and axle nut, and then tighten the axle nut to the specified torque.
EAU25080
Rear wheel
EAU41310
To remove the rear wheel
EWA10820
WARNING
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no danger of it falling over.
1. Loosen the axle nut.
2. Lift the rear wheel off the ground according to the procedure on page 6-26.
3. Loosen the locknut and drive chain adjusting bolt on each side of the swingarm.
4. Remove the axle nut and washer.
6
2. Lift the front wheel off the ground according to the procedure on page 6-26.
3. Remove the axle nut and washer.
Tightening torque:
Axle nut:
70 Nm (7.0 m·kgf, 50 ft·lbf)
6-27
Page 70
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Make sure that the retainer on the
swingarm is inserted into the slot in the brake caliper bracket.
Make sure that there is enough
space between the brake pads be­fore installing the wheel.
1. Axle nut
2. Washer
3. Locknut
4. Drive chain slack adjusting bolt
5. Push the wheel forward, and then
6
remove the drive chain from the rear sprocket.
NOTE:
If the drive chain is difficult to re-
move, remove the wheel axle first, and then lift the wheel upward enough to remove the drive chain from the rear sprocket.
The drive chain cannot be disas-
sembled.
6. While supporting the brake caliper and slightly lifting the wheel, pull the wheel axle out.
1. Wheel axle
NOTE:
A rubber mallet may be useful to tap the wheel axle out.
7. Remove the wheel.
ECA11070
CAUTION:
Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut.
EAU41320
To install the rear wheel
1. Install the wheel and the brake cal­iper bracket by inserting the wheel axle from the right-hand side.
6-28
1. Retainer
2. Slot
2. Install the drive chain onto the rear sprocket.
3. Install the washer and axle nut, and then lower the rear wheel so that it is on the ground.
4. Adjust the drive chain slack. (See page 6-20.)
5. Tighten the axle nut to the speci­fied torque.
Page 71
PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
EAU25870
Troubleshooting
Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur dur­ing operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems your­self. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly. Use only genuine Yamaha replace­ment parts. Imitation parts may look like Yamaha parts, but they are often inferi­or, have a shorter service life and can lead to expensive repair bills.
6
6-29
Page 72
PERIODIC MAINTENANCE AND MINOR REPAIR
Troubleshooting charts
EAU41491
Starting problems or poor engine performance
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
Check the fuel level in the fuel tank.
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start. Check the compression.
6
2. Compression
Operate the kickstarter.
3. Ignition
Remove the spark plug and check the electrodes.
There is compression.
There is no compression.
Wet
Dry
Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
Check the ignition.
Have a Yamaha dealer check the vehicle.
EWA10840
Open the throttle halfway and operate the kickstarter.
The engine does not start. Have a Yamaha dealer check the vehicle.
6-30
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PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EWAT1040
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the de-
tent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
Wait until the engine has cooled.
Check the coolant level in the radiator.
The coolant level is low. Check the cooling system for leakage.
The coolant level is OK.
There is leakage.
There is no leakage.
Start the engine. If the engine overheats again, have a
Yamaha dealer check
Have a Yamaha dealer check
and repair the cooling system.
Add coolant. (See NOTE.)
and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.
6
6-31
Page 74

MOTORCYCLE CARE AND STORAGE

Care
While the open design of a motorcycle reveals the attractiveness of the tech­nology, it also makes it more vulnera­ble. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go un­noticed on a car, however, it detracts from the overall appearance of a motor­cycle. Frequent and proper care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
7
plastic bag after the engine has cooled down.
2. Make sure that all caps and covers as well as all electrical couplers and connectors, including the spark plug cap, are tightly in­stalled.
3. Remove extremely stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such prod-
EAU41351
ucts onto seals, gaskets, sprock­ets, the drive chain and wheel axles. Always rinse the dirt and de­greaser off with water.
Cleaning
ECA10770
CAUTION:
Avoid using strong acidic wheel
cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the af­fected area any longer than in­structed. Also, thoroughly rinse the area off with water, immedi­ately dry it, and then apply a cor­rosion protection spray.
Improper cleaning can damage
windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic.
Do not use any harsh chemical
products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive
7-1
cleaning products, solvent or thinner, fuel (gasoline), rust re­movers or inhibitors, brake flu­id, antifreeze or electrolyte.
Do not use high-pressure wash-
ers or steam-jet cleaners since they cause water seepage and deterioration in the following ar­eas: seals (of wheel and swing­arm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning com­pounds for plastic may leave scratches on the windshield. Test the product on a small hid­den part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.
Page 75
MOTORCYCLE CARE AND STORAGE
After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning. After riding in the rain or near the sea Since sea salt is extremely corrosive, carry out the following steps after each ride in the rain or near the sea.
1. Clean the motorcycle with cold wa­ter and a mild detergent, after the engine has cooled down.
ECA10790
CAUTION:
Do not use warm water since it in­creases the corrosive action of the salt.
2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion.
After cleaning
1. Dry the motorcycle with a chamois or an absorbing cloth.
2. Immediately dry the drive chain and lubricate it to prevent it from rusting.
3. Use a chrome polish to shine chrome, aluminum and stainless­steel parts, including the exhaust system. (Even the thermally in­duced discoloring of stainless­steel exhaust systems can be re­moved through polishing.)
4. To prevent corrosion, it is recom­mended to apply a corrosion pro­tection spray on all metal, including chrome- and nickel-plat­ed, surfaces.
5. Use spray oil as a universal clean­er to remove any remaining dirt.
6. Touch up minor paint damage caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely before storing or covering it.
EWA11130
WARNING
Make sure that there is no oil or
wax on the brakes or tires.
7-2
If necessary, clean the brake
discs and brake linings with a regular brake disc cleaner or ac­etone, and wash the tires with warm water and a mild deter­gent. Before riding at higher speeds, test the motorcycle’s braking performance and cor­nering behavior.
ECA10800
CAUTION:
Apply spray oil and wax spar-
ingly and make sure to wipe off any excess.
Never apply oil or wax to any
rubber and plastic parts, but treat them with a suitable care product.
Avoid using abrasive polishing
compounds as they will wear away the paint.
NOTE:
Consult a Yamaha dealer for advice on what products to use.
7
Page 76
MOTORCYCLE CARE AND STORAGE
Storage
Short-term
Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
CAUTION:
Storing the motorcycle in a
poorly ventilated room or cover­ing it with a tarp, while it is still wet, will allow water and humid­ity to seep in and cause rust.
To prevent corrosion, avoid
damp cellars, stables (because of the presence of ammonia)
7
and areas where strong chemi­cals are stored.
Long-term
Before storing your motorcycle for sev­eral months:
1. Follow all the instructions in the Care section of this chapter.
2. For motorcycles equipped with a fuel cock that has an “OFF” posi­tion: Turn the fuel cock lever to OFF.
EAU41511
ECA10810
3. Drain the fuel tank and fuel lines, and the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up.
4. Perform the following steps to pro­tect the cylinder, piston rings, etc. from corrosion. a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit spark­ing during the next step.)
d. Turn the engine over several
times with the starter. (This will coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then install the spark plug and the spark plug cap.
7-3
EWA10950
WARNING
To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.
5. Lubricate all control cables and the pivoting points of all levers and pedals.
6. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alterna­tively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.
7. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.
NOTE:
Make any necessary repairs before storing the motorcycle.
Page 77

SPECIFICATIONS

Dimensions:
Overall length:
YZ85 1818 mm (71.6 in) (AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)( FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)( SWE) YZ85 1821 mm (71.7 in) (ZAF) YZ85LW 1903 mm (74.9 in) YZ85LWW 1903 mm (74.9 in) YZ85W 1818 mm (71.6 in) YZ85W1 1818 mm (71.6 in)
Overall width:
758 mm (29.8 in)
Overall height:
YZ85 1161 mm (45.7 in) YZ85LW 1205 mm (47.4 in) YZ85LWW 1205 mm (47.4 in) YZ85W 1161 mm (45.7 in) YZ85W1 1161 mm (45.7 in)
Seat height:
YZ85 864 mm (34.0 in) YZ85LW 904 mm (35.6 in) YZ85LWW 904 mm (35.6 in) YZ85W 864 mm (34.0 in) YZ85W1 864 mm (34.0 in)
Wheelbase:
YZ85 1255 mm (49.4 in) (AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)( FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)( SWE) YZ85 1258 mm (49.5 in) (ZAF) YZ85LW 1286 mm (50.6 in)
YZ85LWW 1286 mm (50.6 in) YZ85W 1255 mm (49.4 in) YZ85W1 1255 mm (49.4 in)
Ground clearance:
YZ85 351 mm (13.82 in) YZ85LW 393 mm (15.47 in) YZ85LWW 393 mm (15.47 in) YZ85W 351 mm (13.82 in) YZ85W1 351 mm (13.82 in)
Weight:
With oil and fuel:
YZ85 71.0 kg (157 lb) YZ85LW 73.9 kg (163 lb) YZ85LWW 73.9 kg (163 lb) YZ85W 71.0 kg (157 lb) YZ85W1 71.0 kg (157 lb)
Engine:
Engine type:
Liquid cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
84.7 cm³ (5.17 cu.in)
Bore × stroke:
47.5 × 47.8 mm (1.87 × 1.88 in)
Compression ratio:
8.20 :1
Starting system:
Kickstarter
Lubrication system:
Premix
Engine oil:
Type:
YAMALUBE 2-R
Transmission oil:
Type:
YAMALUBE 4 (10W30) or SAE10W30 type SE motor oil
Oil change quantity:
0.50 L (0.53 US qt) (0.44 Imp.qt)
Cooling system:
Radiator capacity (including all routes):
0.54 L (0.57 US qt) (0.48 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
5.0 L (1.32 US gal) (1.10 Imp.gal)
Carburetor:
Manufacturer:
KEIHIN
Type × quantity:
PWK28 x 1
Spark plug (s):
Manufacturer/model:
NGK/BR10EG
Spark plug gap:
0.5–0.6 mm (0.020–0.024 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Spur gear
8
8-1
Page 78
SPECIFICATIONS
8
Primary reduction ratio:
65/18 (3.611)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
YZ85 47/14 (3.357) (ZAF) YZ85 48/14 (3.428) (AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)( FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)( SWE) YZ85LW 52/14 (3.714) YZ85LWW 52/14 (3.714) YZ85W 47/14 (3.357) YZ85W1 48/14 (3.428)
Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
Gear ratio:
1st:
27/11 (2.454)
2nd:
32/17 (1.882)
3rd:
26/17 (1.529)
4th:
22/17 (1.294)
5th:
26/23 (1.130)
6th:
25/25 (1.000)
Chassis:
Frame type:
Semi double cradle
Caster angle:
YZ85 26.30 ° YZ85LW 26.90 ° YZ85LWW 26.90 ° YZ85W 26.30 ° YZ85W1 26.30 °
Trail:
YZ85 88.0 mm (3.46 in) YZ85LW 105.5 mm (4.15 in) YZ85LWW 105.5 mm (4.15 in) YZ85W 88.0 mm (3.46 in) YZ85W1 88.0 mm (3.46 in)
Front tire:
Type:
With tube
Size:
YZ85 70/100-17 40M YZ85LW 70/100-19 42M YZ85LWW 70/100-19 42M YZ85W 70/100-17 40M YZ85W1 70/100-17 40M
Manufacturer/model:
YZ85 DUNLOP/D739FA (ZAF) YZ85 DUNLOP/D756F (AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)( FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)( SWE) YZ85LW DUNLOP/D756F YZ85LWW DUNLOP/D756F YZ85W DUNLOP/D756F YZ85W1 DUNLOP/D756F
Rear tire:
Type:
With tube
Size:
YZ85 90/100-14 49M YZ85LW 90/100-16 52M YZ85LWW 90/100-16 52M YZ85W 90/100-14 49M YZ85W1 90/100-14 49M
Manufacturer/model:
DUNLOP/D756
Tire air pressure (measured on cold tires):
Front:
100 kPa (15 psi) (1.00 kgf/cm²)
Rear:
100 kPa (15 psi) (1.00 kgf/cm²)
Front wheel:
Wheel type:
Spoke wheel
Rim size:
YZ85 17x1.40 YZ85LW 19x1.40 YZ85LWW 19x1.40 YZ85W 17x1.40 YZ85W1 17x1.40
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
YZ85 14x1.60 YZ85LW 16x1.85 YZ85LWW 16x1.85 YZ85W 14x1.60 YZ85W1 14x1.60
8-2
Page 79
SPECIFICATIONS
Front brake:
Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
275.0 mm (10.83 in)
Rear suspension:
Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
YZ85 282.0 mm (11.10 in) YZ85LW 287.0 mm (11.30 in) YZ85LWW 287.0 mm (11.30 in) YZ85W 282.0 mm (11.10 in) YZ85W1 282.0 mm (11.10 in)
Electrical system:
Ignition system:
CDI
8
8-3
Page 80

CONSUMER INFORMATION

Identification numbers
Record the vehicle identification num­ber and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. VEHICLE IDENTIFICATION NUMBER:
MODEL LABEL INFORMATION:
9
EAU40790
Vehicle identification number
1. Vehicle identification number 1. Model label
The vehicle identification number is stamped into the steering head pipe. Record this number in the space pro­vided.
NOTE:
EAU26400
Model label
The model label is affixed to the loca­tion shown. Record the information on this label in the space provided. This in­formation will be needed when ordering spare parts from a Yamaha dealer.
The vehicle identification number is used to identify your motorcycle and may be used to register your motor­cycle with the licensing authority in your area.
EAU26460
9-1
Page 81
INDEX
A
Accessories and replacement parts ..... 6-17
Air filter element, cleaning .................... 6-12
B
Brake and clutch levers, checking
and lubricating .................................... 6-23
Brake and shift pedals, checking
and lubricating .................................... 6-23
Brake fluid, changing ............................ 6-20
Brake fluid level, checking .................... 6-19
Brake lever ............................................. 3-2
Brake pedal ............................................ 3-2
C
Cables, checking and lubricating.......... 6-22
Carburetor, adjusting ............................ 6-14
Care........................................................ 7-1
Clutch lever............................................. 3-1
Clutch lever free play, adjusting ........... 6-17
Coolant ................................................. 6-10
D
Drive chain, cleaning and lubricating .... 6-21
Drive chain slack .................................. 6-20
E
Engine break-in ...................................... 5-3
Engine, starting a warm.......................... 5-1
Engine stop button.................................. 3-1
F
Front and rear brake pads, checking .... 6-18
Front fork, adjusting................................ 3-7
Front fork, bleeding................................. 3-8
Front fork, checking .............................. 6-24
Fuel......................................................... 3-3
Fuel cock ................................................ 3-5
Fuel tank breather hose.......................... 3-5
Fuel tank cap...........................................3-3
H
Handlebar switch.....................................3-1
I
Identification numbers .............................9-1
K
Kickstarter ...............................................3-6
L
Labels, location of ...................................1-4
M
Model label..............................................9-1
P
Parking....................................................5-4
Part locations ..........................................2-1
Periodic maintenance and lubrication
chart......................................................6-2
Pre-operation check list...........................4-2
R
Rear suspension, lubricating .................6-24
S
Safety information ...................................1-1
Seat.........................................................3-6
Shifting ....................................................5-2
Shift pedal ...............................................3-1
Shock absorber assembly, adjusting ......3-9
Sidestand ..............................................3-12
Spark plug, checking...............................6-8
Specifications..........................................8-1
Starter (choke) knob................................3-6
Starting and warming up a cold
engine ...................................................5-1
Steering, checking.................................6-25
Storage....................................................7-3
Supporting the motorcycle ....................6-26
Swingarm pivots, lubricating ................. 6-24
T
Throttle cable free play, adjusting......... 6-14
Throttle grip and cable, checking
and lubricating .................................... 6-22
Tires...................................................... 6-15
Transmission oil......................................6-9
Troubleshooting .................................... 6-29
Troubleshooting charts ......................... 6-30
V
Vehicle identification number.................. 9-1
W
Wheel bearings, checking..................... 6-26
Wheel (front) ......................................... 6-27
Wheel (rear).......................................... 6-27
Wheels.................................................. 6-17
Page 82
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2006.04-1.4×1 CR
(E)
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