Swingarm YAMAHA YZ85 2004 User Guide

3 - 27
INSP
ADJ
REAR SHOCK ABSORBER INSPECTION

STANDARD POSITION:
This is the position which is back by the spe-
cific number of clicks from the fully turned-in
position.
CAUTION:
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
WARNING
Always adjust each front fork to the same
setting. Uneven adjustment can cause poor
handling and loss of stability.
3. Install:

Rubber cap
Extent of adjustment
Maximum Minimum
Fully turned in
position20 clicks out (from
maximum position)
Standard position:
YZ85: 10 clicks out
YZ85LW: 9 clicks out
EC36K000
REAR SHOCK ABSORBER INSPECTION
1. Inspect:

Swingarm smooth action
Abnormal noise/unsmooth action →
Grease the pivoting points or repair the piv-
oting points.
Damage/oil leakage → Replace.
5PA30620

4 - 51
ENG
EC4M3000
REMOVAL POINTS
EC4F3100
Drive sprocket
1. Remove:

Nut (drive sprocket) 1

Lock washer 2
NOTE:

Straighten the lock washer tab.

Loosen the nut while applying the rear brake.5PA41510
2. Remove:

Drive sprocket 1

Drive chain 2
NOTE:
Remove the drive sprocket together with the
drive chain.
5PA41520
EC4M3301
Engine removal
1. Remove:

Pivot shaft 1
NOTE:
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.5PA41530
2. Remove:

Engine 1
From right side.
NOTE:
Make sure that the couplers, hoses and cables
are disconnected.
5PA41540
ENGINE REMOVAL

5 - 51
CHASSWINGARM
EC570000
SWINGARM
5PAR0019
Extent of removal:
1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM REMOVAL
WARNING
Support the machine securely so there is no
danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Real wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Brake hose holder
Rear brake caliper
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
1 Drive chain support 1
2 Bolt (connecting rod) 1 Hold the swingarm.
3 Bolt (rear shock absorber-relay
arm)1
4 Pivot shaft 1
5 Swingarm 1
1

5 - 52
CHAS
EC578000
SWINGARM DISASSEMBLY
5PAR0020
Extent of removal:
1 Swingarm disassembly
2 Connecting rod removal and disassembly
3 Relay arm removal and disassembly
Extent of removal Order Part name Q’ty Remarks
SWINGARM DISASSEMBLY
1 Relay arm 1
2 Connecting rod 1
3 Cover 2
4 Dust seal 2
5 Collar 5
6 Bushing 4
7 Oil seal 8
8 Bearing 9
Refer to “REMOVAL POINTS”.
9 Bushing (swingarm)
2
1
2
2
3
3
SWINGARM

5 - 53
CHAS
EC573000
REMOVAL POINTS
Bearing and bushing
1. Remove:

Bearing 1

Bushing (swingarm) 2
From swingarm.
NOTE:
Remove the bushing by pressing.5PA51640
2. Remove:

Bearing 1
From relay arm and connecting rod.
NOTE:
Remove the bearing by pressing its outer race.
5PAR0021
1
5PAR0022
INSPECTION
Wash the bearings, bushings, collars, and cov-
ers in a solvent.
Swingarm
1. Inspect:

Bearing 1

Bushing 2

Collar 3
Free play exists/unsmooth revolution/rust
→ Replace bearing, bushing and collar as
a set.
2. Inspect:

Oil seal 4
Damage → Replace.
5PA51680
SWINGARM

5 - 54
CHAS
Relay arm
1. Inspect:

Bearing 1

Bearing (polylube bearing) 2

Bushing 3
Free play exists/unsmooth revolution/rust
→ Replace bearing and bushing as a set.
2. Inspect:

Bearing (polylube bearing) 2
Loss of solid lubrication → Replace.

Oil seal 4
Damage → Replace.
NOTE:
Polylube bearings, with solid lubrication, have
been adopted with the intent to make the nee-
dle bearings, used in this model, maintenance
free. With polylube bearings, no grease nipple
and regular lubrication is necessary. However,
grease should be applied to all oil seals and
collars when removed or installed.
Connecting rod
1. Inspect:

Bearing 1

Bushing 2
Free play exists/unsmooth revolution/rust
→ Replace bearing and bushing as a set.
2. Inspect:

Oil seal 3
Damage → Replace.
5PAR0023
5PA51700
EC575000
ASSEMBLY AND INSTALLATION
Bearing, bushing and oil seal
1. Install:

Bearing 1

Bushing (swingarm) 2

Oil seal 3
To swingarm.
NOTE:

Apply the molybdenum disulfide grease on
the bearing and bushing when installing.

Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.

First install the bushing and then the bearing
to a specified depth from inside.
Installed depth of bearings and
bushings:
Bearing a: 4.5 mm (0.18 in)
Bushing b: 4.5 mm (0.18 in)
5PA51730
5PA51740
SWINGARM

5 - 55
CHAS
2. Install:

Bearing 1

Oil seal 2
To relay arm.
NOTE:

Apply the molybdenum disulfide grease on
the bearing when installing.

Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of bearings:
Depth a: 4.5 mm (0.18 in)
Depth b: 0.5 mm (0.02 in)
Depth c: 4.0 mm (0.16 in)
5PA51750
5PA51760
c1
3. Install:

Bearing 1

Oil seal 2
To connecting rod.
NOTE:

Apply the molybdenum disulfide grease on
the bearing when installing.

Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of bearings a:
6.5 mm (0.26 in)
5PA51760
Swingarm
1. Install:

Collar 1
To swingarm 2.
NOTE:
Apply the molybdenum disulfide grease on the
collars, bearings, bushings and oil seal lips.
5PA51770
SWINGARM

5 - 56
CHAS
2. Install:

Bushing 1

Collar 2

Dust seal 3

Cover 4
To relay arm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bushings, dust seals, collars, cover lips, bear-
ings and oil seal lips.
3. Install:

Bushing 1
To connecting rod 2.
NOTE:
Apply the molybdenum disulfide grease on the
bushings, bearings and oil seal lips.
5PAR0025
5PA51790
4. Install:

Connecting rod 1

Washer 2

Bolt (connecting rod) 3

Nut (connecting rod) 4
To swingarm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
5PA51800
T R..53 Nm (5.3 m · kg, 38 ft · lb)
5. Install:

Relay arm 1

Bolt (relay arm) 2

Nut (relay arm) 3
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
5PA51810
T R..54 Nm (5.4 m · kg, 39 ft · lb)
SWINGARM

5 - 57
CHAS
6. Install:

Swingarm 1

Pivot shaft 2

Washer 3

Nut (pivot shaft) 4
NOTE:

Apply the molybdenum disulfide grease on
the pivot shaft.

Insert the pivot shaft from right side.
7. Check:

Swingarm side play a
Free play exists → Replace collars.

Swingarm up and down movement b
Unsmooth movement/binding/rough spots
→ Grease or replace bearings, bushings
and collars.
5PA51820
T R..63 Nm (6.3 m · kg, 45 ft · lb)
5PA51830
8. Install:

Washer 1

Bolt (rear shock absorber-relay arm) 2
NOTE:

Apply the molybdenum disulfide grease on
the bolt.

Insert the bolt from left side.
5PA51840
T R..36 Nm (3.6 m · kg, 25 ft · lb)
9. Install:

Bolt (connecting rod) 1

Nut (connecting rod) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
5PA51850
T R..53 Nm (5.3 m · kg, 38 ft · lb)
10. Install:

Drive chain support 1

Drive chain support cover 2

Bolt (drive chain support cover) 3

Nut (drive chain support cover) 4

Bolt (drive chain support) 5

Nut (drive chain support) 6
5PAR0026
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..16 Nm (1.6 m · kg, 11 ft · lb)
SWINGARM

5 - 58
CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
5PA51870
Extent of removal:
1 Rear shock absorber removal
2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
Seat Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
Silencer Refer to “EXHAUST PIPE AND
SILENCER” section in the CHAPTER 4.
1 Clamp (air cleaner joint) 1 Only loosening.
2Rear frame 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (rear shock absorber-frame) 1
5 Rear shock absorber 1
6 Locknut 1 Only loosening.
7 Adjuster 1 Only loosening.
8 Spring guide 1
9 Spring (rear shock absorber) 1
1
2