maintenance YAMAHA YZ85 2008 Owners Manual

INTRODUCTION
EAU41541
Congratulations on your purchase of the Yamaha YZ85(X)/YZ85LW(X). 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 warn-
ings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil-
ities, 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 OPERA-
TOR 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.
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TABLE OF CONTENTS
SAFETY INFORMATION .................. 1-1
Safe riding ....................................... 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 .................. 4-2OPERATION 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 engine idling
speed ........................................ 6-14
Adjusting the throttle cable free
play ........................................... 6-15
Tires ............................................. 6-15
Spoke wheels .............................. 6-17
Accessories and replacement
parts ......................................... 6-17
Adjusting the clutch lever free
play ........................................... 6-18
Checking the front brake lever
free play .................................... 6-18Checking the front and rear
brake pads ................................ 6-19
Checking the brake fluid level ...... 6-20
Changing the brake fluid .............. 6-21
Drive chain slack .......................... 6-21
Cleaning and lubricating the
drive chain ................................ 6-22
Checking and lubricating the
cables ....................................... 6-23
Checking and lubricating the
throttle grip and cable ............... 6-23
Checking and lubricating the
brake and shift pedals ............... 6-24
Checking and lubricating the
brake and clutch levers ............. 6-24
Lubricating the swingarm pivots ... 6-25
Lubricating the rear suspension ... 6-25
Checking the front fork ................. 6-25
Checking the steering .................. 6-26
Checking the wheel bearings ....... 6-27
Supporting the motorcycle ........... 6-27
Front wheel .................................. 6-28
Rear wheel ................................... 6-28
Troubleshooting ........................... 6-30
Troubleshooting charts ................. 6-31
MOTORCYCLE CARE AND
STORAGE.......................................... 7-1
Matte color caution ......................... 7-1
Care ............................................... 7-1
Storage ........................................... 7-3
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
6
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Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, 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 gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
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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 technicalskills.
NO. ITEM ROUTINEAfter
break-inEvery
raceEvery
third raceEvery
fifth raceAs
required
1
*PistonCheck piston for carbon deposits and cracks or dam-
age.
Clean.√
√ √
Replace.
√ √
2*
Piston ringsCheck piston ring end gap and rings for damage.√
Replace.
3*Piston pin and small
end bearingCheck piston pin and small end bearing for damage.√√√
Replace.√
√ 4*Cylinder headCheck cylinder head for carbon deposits.
Clean.√
√ √
Check cylinder head gasket for damage.
Replace cylinder head gasket. Tighten cylinder head bolts if necessary.√
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
√
5
*CylinderCheck cylinder for score marks or wear.
Clean.√
Replace.√ NO. ITEM ROUTINEAfter
break-inEvery
raceEvery
third raceEvery
fifth raceAs
required
6*ClutchCheck clutch housing, friction plates, clutch plates
and clutch springs for wear or damage.
Adjust.√ √
Replace.√
7*TransmissionChange the transmission oil.√
Check transmission for damage.√
Replace bearings.√
8*Shift forks, guide bars,
shift cam Replace if necessary. Check all parts for wear and damage.
√
9*Rotor nut
(flywheel magneto)Tighten.√√√
10*Kickstarter systemCheck idle gear for damage.
√
Replace if necessary.
11*Exhaust system Check exhaust pipe and muffler for carbon deposits.√ √
Clean.√
√
√ √
√ 12*CrankshaftCheck crankshaft for carbon deposits and damage.
Clean.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
NO. ITEM ROUTINEAfter
break-inEvery
raceEvery
third raceEvery
fifth raceAs
required
√
√
√ 13*CarburetorCheck carburetor settings and for obstructions.√
Adjust and clean.√
14 Spark plugCheck condition.
Clean and regap.√
Replace.√
15 Drive chainCheck chain slack, alignment and condition.
Adjust and thoroughly lubricate chain with Yamaha
chain and cable lube or equivalent.√
√
√
√ √
Replace.√
16* *
Cooling systemCheck coolant level and for leakage.√ √
Check hoses for cracks or damage.√
Check radiator cap spring operation.√
Change coolant. Every 2 years√
17*Chassis fastenersCheck all chassis fitting and fasteners.
Correct or tighten if necessary.√
18*Air filter elementClean.
√
Replace.√
19*FrameClean and check for damage.√
20*Fuel line Clean and check for leakage.√√
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
√ √
21*BrakesAdjust lever position and pedal height.
Lubricate pivot points.
Check brake disk surface.
Check fluid level and for leakage.
Tighten brake disk bolts, caliper bolts, master cylinder
bolts and union bolts.√
Replace brake pads.√
Replace brake fluid. Every year√
22*Front fork
Replace oil seals. Replace fork oil. 
Clean dust seal and lubricate with lithium-soap-based
grease.
Adjust if necessary. Check operation and for oil leakage.
√
√√
√ NO. ITEM ROUTINEAfter
break-inEvery
raceEvery
third raceEvery
fifth raceAs
required
√ √
√
23*Shock absorber assem-
blyCheck operation and adjust.
Tighten if necessary.
Lubricate with
lithium-soap-based grease
.√(After
washing
the
motorcycle
or riding in
the rain)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
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NOTE:

Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid levels.
√ √√
√ 24*Drive chain roller and
support guideReplace if necessary. Check for wear or damage.
√
25*Rear suspensionCheck operation and tighten if necessary.
Lubricate with
lithium-soap-based grease
.
NO. ITEM ROUTINEAfter
break-inEvery
raceEvery
third raceEvery
fifth raceAs
required
√
√
√
√ √ √
√ √√ √
√
√
√
√
√ 26*Steering headCheck operation, free play, and tighten if necessary.
Clean and lubricate with lithium-soap-based grease.
Replace bearings.
27*Tires and wheelsCheck 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.
28*Moving parts and ca-
blesLubricate.
29*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6 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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
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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 mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with a spark plug wrench available
at a Yamaha dealer.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 dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer checkthe vehicle.2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
1. Spark plug cap
1. Spark plug wrench
Specified spark plug:
NGK/BR10EG1. Spark plug gapSpark plug gap:
0.5–0.6 mm (0.020–0.024 in)
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