Fork oil YAMAHA YZ65 2021 Owners Manual

Table of contents
Location of important la bels ........... 1-1
Safety information ............................ 2-1
Description ....................................... 3-1
Left view ......................................... 3-1
Right view ....................................... 3-2
Controls and instruments ............... 3-3
Instrument an d control functions ... 4-1
Handlebar switch............................ 4-1
Clutch lever .................................... 4-1
Shift pedal ...................................... 4-2
Brake lever...................................... 4-2
Brake pedal .................................... 4-3
Fuel tank cap .................................. 4-3
Fuel ................................................. 4-4
Fuel tank breather hose.................. 4-6
Fuel cock ........................................ 4-7
Starter (choke) knob ....................... 4-7
Kickstarter ...................................... 4-8
Seat ................................................ 4-8
Adjusting the front fork ................... 4-9
Front fork bleeding ....................... 4-11
Adjusting the shock absorber assembly ................................... 4-12
Removable sidestand ................... 4-16
YPVS system ................................ 4-17
For your safety – pre-operation
checks ............................................... 5-1
Operation an d important ri din g
points ................................................ 6-1
Engine break-in .............................. 6-1
Starting and warming up a cold
engine ......................................... 6-3
Starting a warm engine .................. 6-3
Shifting ........................................... 6-4
Parking ........................................... 6-5
Perio dic maintenance an d
a d justment ........................................ 7-1
Periodic maintenance and lubrication chart .......................... 7-2
Checking the spark plug ................ 7-6 Transmission oil .............................. 7-7
Coolant ............................................ 7-8
Cleaning the air filter element ....... 7-10
Adjusting the carburetor ............... 7-12
Adjusting the engine idling
speed ......................................... 7-12
Adjusting the throttle grip free play ............................................ 7-13
Tires .............................................. 7-14
Spoke wheels ................................ 7-16
Adjusting the clutch lever free play ............................................ 7-16
Checking the brake lever free play ............................................ 7-17
Checking the shift pedal ............... 7-18
Checking the front and rear brake pads ................................. 7-18
Checking the brake fluid level ....... 7-19
Changing the brake fluid ............... 7-20
Drive chain slack ........................... 7-21
Cleaning and lubricating the drive chain ................................. 7-22
Checking and lubricating the
cables ........................................ 7-23
Checking and lubricating the throttle grip and cable ............... 7-23
Checking and lubricating the brake and clutch levers ............. 7-24
Checking and lubricating the
brake pedal ................................ 7-24
Lubricating the rear suspension.... 7-25
Lubricating the swingarm pivots ... 7-25
Checking the front fork ................. 7-26
Checking the steering ................... 7-26
Checking the wheel bearings ........ 7-27
Supporting the motorcycle ........... 7-27
Front wheel ................................... 7-28
Rear wheel .................................... 7-29
Troubleshooting ............................ 7-30
Troubleshooting chart ................... 7-31
Motorcycle care an d stora ge .......... 8-1
Matte color caution ......................... 8-1
Care................................................. 8-1
Storage............................................ 8-4
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For your safety – pre-operation checks
5-2
5
Drive chain• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary. 7-21,
7-22
Drive sprocket • Check the drive sprocket nut torque.
• Tighten if necessary.
—
Wheels an d tires •Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
• Check for loose spokes and tighten if necessary. 7-14,
7-16
Shift ped al • Make sure that operation is smooth.
• Check the shift pedal bolt torque.
• Correct if necessary. 7-18
Brake ped al • Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary. 7-24
Brake an d clutch le-
vers • Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
7-24
Steerin g • Check that the handlebar can be turned smoothly and
has no excessive play. 7-26
Front fork and rear
shock a bsor ber as-
sem bly • Check that they operate smoothly and there is no oil
leakage. 4-9,
4-11,
4-12, 7-26
Chassis fasteners • Make sure that all nuts, bolts and screws are properly
tightened.
• Check all cotter pins for damage and correct install- ment.
• Tighten or replace if necessary. —
Movin g parts an d ca-
b les • Check the control cables for damage.
• 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. 7-23,
7-24,
7-25, 7-25
Exhaust system • Check that the exhaust pipe and muffler are tightly
mounted and have no cracks.
• Check for leakage. —
En gine stop switch • Check operation. 4-1
I g nition system • Check that all leads and cables are properly connected. 7-6
ITEM
CHECKSPAGE
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Periodic maintenance an d a djustment
7-3
7
10 *Rotor nut
(flywheel magneto) Tighten.
11 *
Kickstarter system Check idle gear for damage. Replace if necessary.
Check exhaust pipe and muffler for
carbon deposits.

12 *Exhaust system
Clean.
 Check crankshaft for carbon depositsand damage.13 *Crankshaft
Clean.
 


14 *
Carburetor Check carburetor settings and for
obstructions.
Adjust and clean. Check condition.
15Spark plug Clean and regap.
Replace.
 Check chain slack, alignment and
condition.
16 *Drive chain Adjust and thoroughly lubricate chain
with Yamaha chain and cable lube or
equivalent.
Replace.
NO. ITEM ROUTINE
After
break-in
Everyrace
Every
third race
Every
fifth race
As
required
7 *Clutch Check clutch housing, friction plates,
clutch plates and clutch springs for
wear or damage.
Adjust.
Replace.

8 *
Transmission Change the transmission oil. Check transmission for damage. Replace bearings.
9 *Shift forks, guide
bars, shift cam Check all parts for wear and damage. Replace if necessary.
UBR882E0.book Page 3 Wednesd
ay, February 26, 2020 11:39 AM

Periodic maintenance an d a djustment
7-4
7
23 *Front fork 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. Replace protector seal.
NO. ITEM ROUTINE
After
break-in
Everyrace
Every
third race
Every
fifth race
As
required
Check coolant level and for leakage.
17 *
Cooling system Check hoses for cracks or damage. Check radiator cap spring operation. Change coolant.
Every 2 years
Every year Check all chassis fitting and fasteners.
18
*Chassis fasteners
Correct or tighten if necessary.
19Air filter element Clean. Replace.
20 *Frame Clean and check for damage.

21
*Fuel line Clean and check for leakage.
22 *
Brakes Adjust 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.
UBR882E0.book Page 4 Wednesd ay, February 26, 2020 11:39 AM

Periodic maintenance an d a djustment
7-26
7
EAU23273
Checkin g 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 con dition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation 1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. WARNING! To avoi d injury,
securely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
NOTICE
ECA10591
If any d amage is foun d or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23285
Checkin g the steerin g
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Raise the front wheel off the ground. (See page 7-27.)
WARNING! To avoi d injury, se-
curely support the vehicle so
there is no d anger of it fallin g
over.
[EWA10752]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
UBR882E0.book Page 26 Wednesday, February 26, 2020 11:39 AM

Specifications
9-1
9
Dimensions:
Overall length:1615 mm (63.6 in)
Overall width:
760 mm (29.9 in)
Overall height: 1000 mm (39.4 in)
Seat height: 755 mm (29.7 in)
Wheelbase:
1140 mm (44.9 in)
Ground clearance: 265 mm (10.43 in)
Wei ght:
Curb weight:
61 kg (134 lb)
Maximum rider weight:
50.0 kg (110 lb)
Engine:
Combustion cycle:
2-stroke
Cooling system:
Liquid cooled
Number of cylinders: Single cylinder
Displacement: 65 cm³
Bore × stroke:
43.5 × 43.6 mm (1.71 × 1.72 in)
Starting system: Kickstarter
Engine oil:
Engine oil:
YAMALUBE 2R
Recommended brand:
Transmission oil:
Type: Motor oil SAE 10W-30 type SE or higher or
Gear oil SAE 85W GL-3
Quantity: 0.50 L (0.53 US qt, 0.44 Imp.qt)
Coolant quantity:
Radiator (including all routes):
0.38 L (0.40 US qt, 0.33 Imp.qt)
Fuel:
Recommended fuel:Unleaded gasoline (E10 acceptable)
Octane number (RON):
98
Fuel tank capacity: 3.5 L (0.9 US gal, 0.8 Imp.gal)
Car buretor:
Type × quantity:
PWK28 × 1
Drivetrain:
Gear ratio:
1st:
2.455 (27/11)
2nd: 1.882 (32/17)
3rd: 1.529 (26/17)
4th:
1.263 (24/19)
5th: 1.095 (23/21)
6th: 0.960 (24/25)
Front tire:
Type:With tube
Size: 60/100-14 30M
Manufacturer/model:
MAXXIS/MAXXCROSS SI
Rear tire:
Type:With tube
Size:
80/100-12 41M
Manufacturer/model: MAXXIS/MAXXCROSS SI
Front brake:
Type:
Hydraulic single disc brake
Rear brake:
Type:
Hydraulic single disc brake
Front suspension:
Type:Telescopic fork
Rear suspension:
Type:
Swingarm
UBR882E0.book Page 1 Wednesd ay, February 26, 2020 11:39 AM

11-1
11
Index
A
Air filter element, cleaning .................... 7-10
B
Brake and clutch levers, checking and
lubricating .......................................... 7-24
Brake fluid, changing ........................... 7-20
Brake fluid level, checking ................... 7-19
Brake lever ............................................. 4-2
Brake lever free play, checking ............ 7-17
Brake pedal ............................................ 4-3
Brake pedal, checking and lubricating .......................................... 7-24
C
Cables, checking and lubricating ......... 7-23
Carburetor, adjusting ........................... 7-12
Care ........................................................ 8-1
Clutch lever ............................................ 4-1
Clutch lever free play, adjusting ........... 7-16
Coolant ................................................... 7-8
D
Drive chain, cleaning and lubricating ... 7-22
Drive chain slack .................................. 7-21
E
Engine break-in ...................................... 6-1
Engine idling speed .............................. 7-12
Engine overheating............................... 7-32
Engine serial number............................ 10-1
Engine, starting a warm ......................... 6-3
Engine stop switch ................................. 4-1
F
Front and rear brake pads, checking ... 7-18
Front fork, adjusting ............................... 4-9
Front fork, bleeding .............................. 4-11
Front fork, checking ............................. 7-26
Fuel......................................................... 4-4
Fuel cock ................................................ 4-7
Fuel tank breather hose ......................... 4-6
Fuel tank cap.......................................... 4-3
H
Handlebar switch ................................... 4-1
I
Identification numbers.......................... 10-1
K
Kickstarter .............................................. 4-8
L
Labels, location ...................................... 1-1
M
Matte color, caution ............................... 8-1
P
Parking ................................................... 6-5 Part locations .......................................... 3-1
Periodic maintenance and lubrication
chart ..................................................... 7-2
R
Rear suspension, lubricating ................ 7-25
S
Safety defects, reporting (For CANADA customers) .......................................... 10-2
Safety information................................... 2-1
Seat......................................................... 4-8
Shifting .................................................... 6-4
Shift pedal............................................... 4-2
Shift pedal, checking ............................ 7-18
Shock absorber assembly, adjusting ... 4-12
Sidestand .............................................. 4-16
Spark plug, checking .............................. 7-6
Specifications ......................................... 9-1
Starter (choke) knob ............................... 4-7
Starting and warming up a cold engine ................................................... 6-3
Steering, checking ................................ 7-26
Storage ................................................... 8-4
Supporting the motorcycle ................... 7-27
Swingarm pivots, lubricating ................ 7-25
T
Throttle grip and cable, checking and lubricating ........................................... 7-23
Throttle grip free play, adjusting ........... 7-13
Tires ...................................................... 7-14
Transmission oil ...................................... 7-7
Troubleshooting .................................... 7-30
Troubleshooting chart........................... 7-31
V
Vehicle identification number ............... 10-1
W
Wheel bearings, checking..................... 7-27
Wheel (front).......................................... 7-28
Wheel (rear) ........................................... 7-29
Wheels .................................................. 7-16
Y
YPVS system ........................................ 4-17
UBR882E0.book Page 1 Wednesd ay, February 26, 2020 11:39 AM