maintenance YAMAHA YZ85 2003 User Guide

SPEC
2 - 9
MAINTENANCE SPECIFICATIONS
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 17 × 1.40/Aluminum ----
Rear rim size/material 14 × 1.60/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428DS/DAIDO ----
Number of links 117 links + joint ----
Chain slack 35 ~ 45 mm (1.4 ~ 1.8 in) ----
Chain length (10 links) ---- 122.1 mm (4.81 in)
Front disc brake:
Disc outside dia. × Thickness 220 × 3.0 mm (8.66 × 0.12 in) 220 × 2.5 mm
(8.66 × 0.10 in)
Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 4.0 mm (0.16 in) 0.8 mm (0.03 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 22.22 mm (0.875 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 190 × 3.0 mm (7.84 × 0.12 in) 190 × 2.5 mm
(7.84 × 0.12 in)
Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 3.7 mm (0.15 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 12.7 mm (0.500 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)4 ~ 10 mm (0.16 ~ 0.39 in) ----
Clutch lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

SPEC
2 - 10
MAINTENANCE SPECIFICATIONS
YZ85LW
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension:
Front fork travel 275 mm (10.8 in) ----
Fork spring free length 430 mm (16.9 in) 425 mm (16.7 in)
Spring rate, STD K = 2.94 N/mm
(0.30 kg/mm, 16.8 lb/in)----
Optional spring Yes ----
Oil capacity318 cm
3
(11.2 Imp oz, 10.8 US oz) ----
Oil level 90 mm (3.54 in) ----
<Min.~Max.>
(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 120 mm (3.15 ~ 4.72 in) ----
Oil grade Suspension oil “01”----
Inner tube outer diameter 36 mm (1.42 in) ----
Front fork top end Zero mm (Zero in) ----
Rear suspension: AUS, NZ EUROPE
Shock absorber travel 102 mm (4.02 in)←----
Spring free length 220 mm (8.66 in)←----
Fitting length 207 mm (8.15 in) 212 mm (8.35 in) ----
<Min.~Max.> 202.5 ~ 218.5 mm
(7.97 ~ 8.60 in)←----
Spring rate, STD K = 51.0 N/mm
(5.20 kg/mm,
291.2 lb/in)K = 47.0 N/mm
(4.80 kg/mm,
268.8 lb/in)----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)←----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)

SPEC
2 - 11
MAINTENANCE SPECIFICATIONS
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 19 × 1.40/Aluminum ----
Rear rim size/material 16 × 1.85/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428DS/DAIDO ----
Number of links 123 links + joint ----
Chain slack 35 ~ 45 mm (1.4 ~ 1.8 in) ----
Chain length (10 links) ---- 122.1 mm (4.81 in)
Front disc brake:
Disc outside dia. × Thickness 220 × 3.0 mm (8.66 × 0.12 in) 220 × 2.5 mm
(8.66 × 0.10 in)
Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 4.0 mm (0.16 in) 0.8 mm (0.03 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 22.22 mm (0.875 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 190 × 3.0 mm (7.84 × 0.12 in) 190 × 2.5 mm
(7.84 × 0.12 in)
Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 3.7 mm (0.15 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 12.7 mm (0.500 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)4 ~ 10 mm (0.16 ~ 0.39 in) ----
Clutch lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

SPEC
2 - 12
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the steering nut approximately 38 Nm (3.8 m  kg, 27 ft  lb) by using the steering
nut wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 4 Nm (0.4 m  kg, 2.9 ft  lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Upper bracket and outer tube M8 × 1.25 2 22 2.2 16
Lower bracket and outer tube M8 × 1.25 4 20 2.0 14
Upper bracket and steering stem M22 × 1.0 1 125 12.5 90
Handlebar holder and upper bracket M8 × 1.25 4 27 2.7 19
Steering stem and steering ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and front fork cap bolt M40 × 1.0 2 28 2.8 20
Front fork and base valve M22 × 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M10 × 1.0 2 15 1.5 11
Front fork bleed screw and front fork cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 × 1.0 6 7 0.7 5.1
Front fork and brake hose guide M5 × 0.8 1 4 0.4 2.2
Front fork and brake hose holder M6 × 1.0 1 10 1.0 7.2
Throttle grip cap M5 × 0.8 2 4 0.4 2.2
Throttle cable cap M4 × 0.7 2 1 0.1 0.7
Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Clutch lever holder M5 × 0.8 2 4 0.4 2.2
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Front brake hose union bolt M10 × 1.25 2 26 2.6 19
Front fork and brake caliper bracket M8 × 1.25 2 30 3.0 22
Brake caliper support bolt M8 × 1.25 1 23 2.3 17
Front brake caliper and bleed screw M7 × 1.0 1 6 0.6 4.3
Rear brake caliper and brake caliper bracket M8 × 1.25 2 23 2.3 17
Rear brake caliper and pad pin M10 × 1.0 2 18 1.8 13
Rear brake caliper and bleed screw M8 × 1.25 1 6 0.6 4.3
Front wheel axle and axle nut M12 × 1.25 1 70 7.0 50
Front brake disc M6 × 1.0 3 12 1.2 8.7
Rear brake disc M6 × 1.0 4 12 1.2 8.7
Rear brake master cylinder M6 × 1.0 2 10 1.0 7.2
Rear brake reservoir tank M6 × 1.0 1 10 1.0 7.2
Rear brake hose union bolt M10 × 1.25 2 26 2.6 19
Rear wheel axle and axle nut M14 × 1.5 1 90 9.0 65

SPEC
2 - 13
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Nipple (spoke)—64 3 0.3 2.2
Rear wheel sprocket M8 × 1.25 4 42 4.2 30
Rear brake caliper protector M6 × 1.0 1 10 1.0 7.2
Engine mounting:
Engine and frame (front) M10 × 1.25 1 69 6.9 50
Engine and frame (lower) M10 × 1.25 1 69 6.9 50
Pivot shaft and nut M12 × 1.25 1 63 6.3 45
Relay arm and frame M10 × 1.25 1 54 5.4 39
Relay arm and connecting rod M12 × 1.25 1 53 5.3 38
Connecting rod and swingarm M12 × 1.25 1 53 5.3 38
Rear shock absorber and frame M10 × 1.25 1 36 3.6 25
Rear shock absorber and relay arm M10 × 1.25 1 36 3.6 25
Rear frame (upper) M8 × 1.25 1 26 2.6 19
Rear frame (lower) M8 × 1.25 2 16 1.6 11
Swingarm and brake hose holder M5 × 0.8 4 1 0.1 0.7
Drive chain tensioner (upper) M8 × 1.25 1 23 2.3 17
Drive chain tensioner (lower) M6 × 1.0 1 10 1.0 7.2
Drive chain support M8 × 1.25 2 16 1.6 11
Drive chain support cover M6 × 1.0 1 7 0.7 5.1
Seal guard and swingarm M6 × 1.0 2 10 1.0 7.2
Fuel tank M6 × 1.0 2 7 0.7 5.1
Fuel cock M6 × 1.0 2 4 0.4 2.9
Fuel tank bracket and fuel tank M6 × 1.0 4 7 0.7 5.1
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Radiator cover M6 × 1.0 3 4 0.4 2.9
Front fender M6 × 1.0 4 7 0.7 5.1
Rear fender M6 × 1.0 4 7 0.7 5.1
Flap guard M6 × 1.0 2 7 0.7 5.1
Side cover M6 × 1.0 2 7 0.7 5.1
Seat M6 × 1.0 2 7 0.7 5.1
Number plate M6 × 1.0 1 7 0.7 5.1

SPEC
2 - 14
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Ignition timing (B.T.D.C.) 0.9 mm (0.035 in) ----
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufac-
turer5PA-00/YAMAHA ----
Charging coil 1 resistance (color) 720 ~ 1,080 Ω at 20 °C (68 °F)
(Green/White – Black/Red)----
Charging coil 2 resistance (color) 44 ~ 66 Ω at 20°C (68 °F)
(Black – Green/Blue)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20°C (68 °F)
(White/Blue – White/Red)----
CDI unit-model/manufacturer 5PA-00/YAMAHA ----
Ignition coil:
Model/manufacturer 5PA-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) ----
Secondary coil resistance 6.3 ~ 9.5 kΩ at 20 °C (68 °F) ----
Spark plug cap:
Resistance 4 ~ 6 kΩ at 20 °C (68 °F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M6 × 1.0 2 8 0.8 5.8
Rotor M10 × 1.25 1 33 3.3 24
Ignition coil M6 × 1.0 2 7 0.7 5.1

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule 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 a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks
PISTON
Inspect and clean
Replace







Inspect crack
Inspect carbon deposits
and eliminate them
PISTON RING
Inspect
Replace





Check ring end gap
PISTON PIN, SMALL END BEARING
Inspect
Replace




CYLINDER HEAD
Inspect and clean
Retighten







Inspect carbon deposits
and eliminate them
Check gasket
CYLINDER
Inspect and clean
Replace




Inspect score marks
Inspect wear
CLUTCH
Inspect and adjust
Replace





Inspect housing, friction
plate, clutch plate and
spring
TRANSMISSION
Replace oil
Inspect
Replace bearing






Yamalube 4 (10W-30) or
SAE 10W-30 SE motor oil
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect

Inspect wear
ROTOR NUT
Retighten




KICK SHAFT
Inspect idle gear
Replace




EXHAUST PIPE, SILENCER
Inspect
Clean





CRANK
Inspect and clean



CARBURETOR
Inspect, adjust and clean



SPARK PLUG
Inspect and clean
Replace





DRIVE CHAIN
Lubricate, slack, alignment
Replace




Chain slack: 35 ~ 45 mm
(1.4 ~ 1.8 in)

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses








Every two years
OUTSIDE NUTS AND BOLTS
Retighten



AIR FILTER
Clean and lubricate
Replace




Use foam air-filter oil
FRAME
Clean and inspect



FUEL TANK, COCK
Clean and inspect



BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid























Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal









Suspension oil “01”
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube


Lithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten







(After
rain ride)


Molybdenum disulfide
grease
DRIVE CHAIN GUIDE, ROLLERS AND
SUPPORT
Inspect


SWINGARM
Inspect and retighten
Lube







Molybdenum disulfide
grease
RELAY ARM, CONNECTING ROD
Inspect and retighten
Lube







Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing







Lithium base grease ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks


3

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate












Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection
Inspect and Lubricate






Yamaha cable lube or
SAE 10W-30 motor oil ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh mixture of oil and gasoline is filled in the fuel
tank. Check the fuel line for leakage.P.1-12
Transmission oilCheck that the oil level is correct. Check the crankcase for leak-
age.P.3-12 ~ 13
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10
Brakes Check the play of front brake and effect of front and rear brake. P.3-16 ~ 21
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-22 ~ 24
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-31 ~ 32
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-32 ~ 34
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-24 ~ 30
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Exhaust pipe and silencerCheck that the exhaust pipe is tightly mounted and has no
cracks.P.4-2
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-22
Lubrication Check for smooth operation. Lubricate if necessary. P.3-35
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-16
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 19