lock YAMAHA YZ85 2002 Betriebsanleitungen (in German)

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 7 are designed as
thumb tabs to indicate the chapter’s number
and content.
1General information
2Specifications
3Regular inspection and adjustments
4Engine
5Chassis
6Electrical
7Tuning
Illustrated symbols 8 to D are used to identify
the specifications appearing in the text.
8With engine mounted
9Special tool
0Filling fluid
ALubricant
BTightening
CSpecified value, Service limit
DResistance (
W), Voltage (V), Electric current (A)
Illustrated symbols E to I in the exploded
diagrams indicate grade of lubricant and loca-
tion of lubrication point.
EApply transmission oil
FApply engine oil
GApply molybdenum disulfide oil
HApply lightweight lithium-soap base grease
IApply molybdenum disulfide grease
Illustrated symbols J to K in the exploded
diagrams indicate where to apply a locking
agent and where to install new parts.
JApply locking agent (LOCTITE®)
KUse new one 12
34
56
78
90
AB
CD
EFG
HI
JK
GEN
INFO
SPEC
INSP
ADJ
ENG
CHAS–+ELEC
TUN
T R..
EMG
BM

1 - 4
GEN
INFO
IMPORTANT INFORMATION
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is overhauled.
All gasket surfaces, oil seal lips, and O-
rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
5PA10120
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s) 1 and oil seal(s) 2
with their manufacturer’s marks or numbers
facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-weight
lithium base grease to the seal lip(s). Oil
the bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
5PA10130
5PA10140

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GEN
INFO
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good overall
performance, and extend the life of many com-
ponents.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering. A plastic bag secured with a
rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprock-
ets, or wheel axles.
3. Rinse the dirt and degreaser off with a gar-
den hose; use only enough pressure to do
the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been
hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess
water from the chain with a paper towel
and lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
8. Automotive wax may be applied to all
painted or chromed surfaces. Avoid combi-
nation cleaner-waxes, as they may contain
abrasives.
9. After completing the above, start the
engine and allow it to idle for several min-
utes.

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GEN
INFO
CLEANING AND STORAGE
EC1B2001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the car-
buretor float bowl.
2. Remove the spark plug, pour a tablespoon
of SAE 10W-30 motor oil in the spark plug
hole, and reinstall the plug. With the engine
stop switch pushed in, kick the engine over
several times to coat the cylinder walls with
oil.
3. Remove the drive chain, clean it thoroughly
with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe out-
let to prevent moisture from entering.
7. If the machine is to be stored in a humid or
salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do not
apply oil to rubber parts or the seat cover.
NOTE:
Make any necessary repairs before the
machine is stored.

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 1 115 11.5 85
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 1 110 11.0 80

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INSP
ADJ
EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap
1, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:
Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
5PA30010
1. Place the machine on a level place, and
hold it in an upright position.
2. Remove:
lRadiator cap
3. Check:
lCoolant level
Coolant level a low ® Add coolant.
1Radiator
5PA30020
ENGINE/COOLANT LEVEL INSPECTION

3 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
CAUTION:
lDo not apply pressure more than speci-
fied pressure.
lRadiator should be filled fully.
4. Inspect:
lPressure
Impossible to maintain the specified pres-
sure for 10 seconds ® Repair.
lRadiator 1
lRadiator hose joint 2
Coolant leakage ® Repair or replace.
lRadiator hose 3
Swelling ® Replace.
5PA30080
CLUTCH ADJUSTMENT
1. Check:
lClutch lever free play a
Out of specification ® Adjust.
Clutch lever free play
a:
10 ~ 15 mm (0.39 ~ 0.59 in)
5PA30090
2. Adjust:
lClutch lever free play
NOTE:
lMake minute adjustment on the lever side.
lAfter adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
lLoosen the locknut 1.
lTurn the adjuster 2 until free play a is
within the specified limits.
lTighten the locknut.
5PA30100

INSP
ADJREGLAGE DE L’EMBRAYAGE
KUPPLUNGSEINSTELLUNG
ATTENTION:
lNe pas appliquer de pression supérieure à la
pression spécifiée.
lLe radiateur doit être entièrement rempli.
4. Contrôler:
lPression
Impossible de maintenir la pression spécifiée
pendant 10 secondes ® Réparer.
lRadiateur 1
lRaccords du tuyau de radiateur 2
Fuite de liquide de refroidissement ® Réparer
ou remplacer.
lTuyau du radiateur 3
Gonflement ® Remplacer.
REGLAGE DE L’EMBRAYAGE
1. Contrôler:
lJeu du levier d’embrayage a
Hors spécifications ® Régler.
Jeu du levier d’embrayage a
:
10 à 15 mm (0,39 à 0,59 in)
2. Régler:
lJeu du levier d’embrayage
N.B.:
lFaire un réglage plus fin du côté du levier.
lAprès le réglage, contrôler le fonctionnement du
levier d’embrayage. Étapes du réglage du jeu du levier
d’embrayage:
lDesserrer le contre-écrou 1.
lFaire tourner le dispositif de réglage 2
jusqu’à ce que le jeu a se situe dans les limi-
tes spécifiées.
lSerrer le contre-écrou.
ACHTUNG:
lDen vorgeschriebenen Druck nicht über-
schreiten.
lDer Kühler muß bis zum Rand gefüllt
sein.
4. Kontrollieren:
lDruck
Druckverlust innerhalb von 10 Sekunden
® Erneuern.
lKühlerschlauch 1
lKühlerschlauchanschlüsse 2
Undichtigkeit ® instand setzen oder erneu-
ern.
lKühlerschläuche 3
Quellung ® Erneuern.
KUPPLUNGSEINSTELLUNG
1. Kontrollieren:
lKupplungszugspiel a
Unvorschriftsmäßig ® Einstellen.
Kupplungszugspiel am
Hebeldrehpunkt
a
10–15 mm
2. Einstellen:
lKupplungszugspiel
HINWEIS:
lFeineinstellung des Kupplungszugspiels auf
der Hebelseite vornehmen.
lNach der Einstellung des Seilzugspiels die
Funktion des Kupplungshebels prüfen. Arbeitsschritte: Kupplungszugspiel ein-
stellen
lSicherungsmutter 1 lockern.
lEinstellschraube 2 drehen, bis sich das
Kupplungszugspiel a innerhalb der vor-
geschriebenen Grenzen befindet.
lSicherungsmuttern festziehen.
3 - 9

3 - 10
INSP
ADJTHROTTLE CABLE ADJUSTMENT/
THROTTLE LUBRICATION
EC35A001
THROTTLE CABLE ADJUSTMENT
1. Check:
lThrottle grip free play a
Out of specification ® Adjust.
Throttle grip free play
a:
3 ~ 5 mm (0.12 ~ 0.20 in)
5PA30110
2. Adjust:
lThrottle grip free play
Throttle grip free play adjustment steps:
lLoosen the locknut 1.
lTurn the adjuster 2 until the specified free
play is obtained.
lTighten the locknut.
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.
5PA30120
THROTTLE LUBRICATION
1. Remove:
lThrottle cable cap 1
5PA30130
2. Apply:
lLithium soap base grease
On the throttle cable end a and tube guide
cable winding portion b.
3. Install:
lThrottle grip cap
5PA30140
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)

3- 14
INSP
ADJ
REGLAGE DU CABLE DES GAZ/
GRAISSAGE DE L’ACCELERATEUR
GASZUGSPIEL EINSTELLEN/GASZUG SCHMIEREN
REGLAGE DU CABLE DES GAZ
1. Contrôler:
lJeu de la poignée des gaz a
Hors spécifications ® Régler.
Jeu de la poignée des gaz a
:
3 à 5 mm (0,12 à 0,20 in)
2. Régler:
lJeu de la poignée des gaz
Étapes du réglage du jeu de la poignée des
gaz:
lDesserrer le contre-écrou 1.
lFaire tourner le dispositif de réglage 2
jusqu’à obtention du jeu spécifié.
lSerrer le contre-écrou.
N.B.:
Avant de régler le jeu de câble des gaz, régler le
régime de ralenti du moteur.
AVERTISSEMENT
Après le réglage, faire pivoter le guidon dans
un sens et dans l’autre pour contrôler que le
régime de ralenti n’augmente pas.
GRAISSAGE DE L’ACCELERATEUR
1. Déposer:
lCouvercle du logement du câble des gaz 1
2. Appliquer:
lGraisse à savon de lithium
A l’extrémité du câble des gaz a et sur la por-
tion d’enroulement du câble b.
3. Monter:
lCapuchon de la poignée de gaz
T R..1 Nm (0,1 m • kg, 1,4 ft • lb)
GASZUGSPIEL EINSTELLEN
1. Kontrollieren:
lGaszugspiel am Gasdrehgriff a
Unvorschriftsmäßig ® Einstellen.
Gaszugspiel am Gasdrehgriff
a
3–5 mm
2. Einstellen:
lGaszugspiel am Gasdrehgriff
Arbeitsschritte: Gaszugspiel am Gas-
drehgriff einstellen
lSicherungsmutter 1 lockern.
lEinstellschraube 2 verdrehen, bis das
vorgeschriebene Spiel erreicht ist.
lSicherungsmutter festziehen.
HINWEIS:
Bevor das Gaszugspiel justiert wird, sollte
die Leerlaufdrehzahl eingestellt sein.
WARNUNG
Nach der Einstellung den Lenker nach
links und rechts drehen, um zu überprü-
fen, ob sich die Leerlaufdrehzahl verän-
dert.
GASZUG SCHMIEREN
1. Demontieren:
lGaszugkappe 1
2. Auftragen:
lLithiumfett
am Gaszugende a und im Bereich der
Gaszugscheibe b.
3. Montieren:
lGasdrehgriffkappe
T R..1 Nm (0,1 m · kg)
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