oil YAMAHA YZ85 2002 User Guide

SPEC
2 - 7
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M14 ´ 1.25 1 20 2.0 14
Cylinder head (nut) M8 ´ 1.25 4 30 3.0 22
(stud bolt) M8 ´ 1.25 4 13 1.3 9.4
Cylinder (nut) M8 ´ 1.25 4 28 2.8 20
(stud bolt) M8 ´ 1.25 4 13 1.3 9.4
Impeller M8 ´ 1.25 1 14 1.4 10
Coolant drain bolt M6 ´ 1.0 1 10 1.0 7.2
Water pump housing M6 ´ 1.0 2 10 1.0 7.2
Air filter element M6 ´ 1.0 1 2 0.2 1.4
Carburetor joint M6 ´ 1.0 4 8 0.8 5.8
Reed valve M3 ´ 0.5 4 1 0.1 0.7
Exhaust pipe M6 ´ 1.0 2 12 1.2 8.7
Exhaust pipe stay M6 ´ 1.0 1 12 1.2 8.7
Silencer M6 ´ 1.0 1 12 1.2 8.7
Fiber (silencer) M6 ´ 1.0 2 10 1.0 7.2
Crankcase M6 ´ 1.0 11 8 0.8 5.8
Left crankcase cover M6 ´ 1.0 4 5 0.5 3.6
Right crankcase cover M6 ´ 1.0 4 10 1.0 7.2
Right crankcase cover M6 ´ 1.0 1 10 1.0 7.2
Clutch cover M6 ´ 1.0 6 10 1.0 7.2
Transmission oil drain bolt M8 ´ 1.25 1 10 1.0 7.2
Kickstarter crank M6 ´ 1.0 1 10 1.0 7.2
Primary drive gear M12 ´ 1.0 1 79 7.9 57
Clutch boss M12 ´ 1.0 1 70 7.0 50
Clutch spring M5 ´ 0.8 5 6 0.6 4.3
Drive sprocket M16 ´ 1.0 1 60 6.0 43
Crankcase bearing stopper M6 ´ 1.0 2 8 0.8 5.8
Shift pedal M6 ´ 1.0 1 10 1.0 7.2

SPEC
2 - 8
MAINTENANCE SPECIFICATIONS
CHASSIS
YZ85
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 = 2.84 N/mm
(0.29 kg/mm, 16.2 lb/in)----
Optional spring Yes ----
Oil capacity318 cm
3
(11.2 lmp oz, 10.8 US oz) ----
Oil level 90 mm (3.54 in) ----

(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 24 mm (0.94 in) ----
Rear suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Shock absorber travel 102 mm (4.02 in)¬----
Spring free length 220 mm (8.66 in)¬----
Fitting length 215 mm (8.46 in) 212 mm (8.35 in) ----
202.5 ~ 218.5 mm
(7.97 ~ 8.60 in)¬----
Spring rate, STD K = 49.0 N/mm
(5.00 kg/mm,
280.0 lb/in)K = 45.0 N/mm
(4.60 kg/mm,
257.6 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 - 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 lmp oz, 10.8 US oz) ----
Oil level 90 mm (3.54 in) ----

(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) ----
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 - 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 W at 20 °C (68 °F)
(Green/White – Black/Red)----
Charging coil 2 resistance (color) 44 ~ 66 W at 20 °C (68 °F)
(Black – Green/Blue)----
Pickup coil resistance (color) 248 ~ 372 W 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 W at 20 °C (68 °F) ----
Secondary coil resistance 6.3 ~ 9.5 kW 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

SPEC
2 - 9
CARACTERISTIQUES D’ENTRETIEN
Roue:
Type de roue avant Roue à rayons ----
Type de roue arrière Roue à rayons ----
Taille/matériau de la jante avant 17 ´ 1,40/Aluminium ----
Taille/matériau de la jante arrière 14 ´ 1,60/Aluminium ----
Limite de voilage de la jante:
Radial ---- 2,0 mm (0,08 in)
Latéral ---- 2,0 mm (0,08 in)
Chaîne de transmission:
Type/fabricant DID428DS/DAIDO ----
Nombre de maillons 117 maillons+ attache ----
Jeu de la chaîne 35
à 45 mm (1,4 à 1,8 in) ----
Longueur de la chaîne (10 maillons) ---- 122,1 mm (4,81 in)
Frein à disque avant:
Diamètre extérieur ´ Epaisseur 220 ´ 3,0 mm (8,66 ´ 0,12 in) 220 ´ 2,5 mm
(8,66 ´ 0,10 in)
Limite de déflexion ---- 0,15 mm (0,006 in)
Epaisseur de plaquette 4,0 mm (0,16 in) 0,8 mm (0,03 in)
Diamètre intérieur du maître cylindre 11,0 mm (0,433 in) ----
Diamètre intérieur du cylindre d’étrier 22,22 mm (0,875 in) ´ 2 ----
Type de liquide de frein DOT n° 4 ----
Frein à disque arrière:
Diamètre extérieur ´ Epaisseur 190 ´ 3,0 mm (7,84 ´ 0,12 in) 190 ´ 2,5 mm
(7,84 ´ 0,12 in)
Limite de déflexion ---- 0,15 mm (0,006 in)
Epaisseur de plaquette 3,7 mm (0,15 in) 1,0 mm (0,04 in)
Diamètre intérieur du maître cylindre 12,7 mm (0,500 in) ----
Diamètre intérieur du cylindre d’étrier 27,0 mm (1,063 in) ´ 1 ----
Type de liquide de frein DOT n° 4 ----
Levier et pédale de frein:
Position du levier de frein 95 mm (3,74 in) ----
Hauteur de la pédale de frein
(distance verticale sous le sommet du
repose-pied)7 mm (0,28 in) ----
Jeu du levier d’embrayage 10
à 15 mm (0,39 à 0,59 in) ----
Jeu de la poignée des gaz 3
à 5 mm (0,12 à 0,20 in) ---- Elément Standard Limite

SPEC
2 - 11
CARACTERISTIQUES D’ENTRETIEN
Roue:
Type de roue avant Roue à rayons ----
Type de roue arrière Roue à rayons ----
Taille/matériau de la jante avant 19 ´ 1,40/Aluminium ----
Taille/matériau de la jante arrière 16 ´ 1,85/Aluminium ----
Limite de voilage de la jante:
Radial ---- 2,0 mm (0,08 in)
Latéral ---- 2,0 mm (0,08 in)
Chaîne de transmission:
Type/fabricant DID428DS/DAIDO ----
Nombre de maillons 121 maillons + attache ----
Jeu de la chaîne 35
à 45 mm (1,4 à 1,8 in) ----
Longueur de la chaîne (10 maillons) ---- 122,1 mm (4,81 in)
Frein à disque avant:
Diamètre extérieur ´ Epaisseur 220 ´ 3,0 mm (8,66 ´ 0,12 in) 220 ´ 2,5 mm
(8,66 ´ 0,10 in)
Limite de déflexion ---- 0,15 mm (0,006 in)
Epaisseur de plaquette 4,0 mm (0,16 in) 0,8 mm (0,03 in)
Diamètre intérieur du maître cylindre 11,0 mm (0,433 in) ----
Diamètre intérieur du cylindre d’étrier 22,22 mm (0,875 in) ´ 2 ----
Type de liquide de frein DOT n° 4 ----
Frein à disque arrière:
Diamètre extérieur ´ Epaisseur 190 ´ 3,0 mm (7,84 ´ 0,12 in) 190 ´ 2,5 mm
(7,84 ´ 0,12 in)
Limite de déflexion ---- 0,15 mm (0,006 in)
Epaisseur de plaquette 3,7 mm (0,15 in) 1,0 mm (0,04 in)
Diamètre intérieur du maître cylindre 12,7 mm (0,500 in) ----
Diamètre intérieur du cylindre d’étrier 27,0 mm (1,063 in) ´ 1 ----
Type de liquide de frein DOT n° 4 ----
Levier et pédale de frein:
Position du levier de frein 95 mm (3,74 in) ----
Hauteur de la pédale de frein
(distance verticale sous le sommet du
repose-pied)5 mm (0,20 in) ----
Jeu du levier d’embrayage 10
à 15 mm (0,39 à 0,59 in) ----
Jeu de la poignée des gaz 3
à 5 mm (0,12 à 0,20 in) ---- Elément Standard Limite

2 - 16
SPEC
EC240000
CABLE ROUTING DIAGRAM
1Hose guide
2Brake hose
3Throttle cable
4Fuel tank breather hose
5Engine stop switch lead
6CDI magneto lead
7Clamp
8Carburetor breather hose
9Carburetor overflow hose
0Transmission oil breather hose
ARadiator breather hose
BClutch cable
CSpark plug leadDCable guide
EBrake hose holder
ÈPass the fuel tank breather hose between the
handlebar and tension bar, then insert its end
into the hole of the steering stem.
ÉFasten the ground lead together with the ignition
coil.
ÊClamp the brake hose with the brake hose
holder.
ËFit the brake hose into the guides of the protec-
tor.
CABLE ROUTING DIAGRAM

2 - 17
SPEC
1Sub-wire harness
2CDI unit
3Ignition coil
4Clutch cable
5Cable guide
6CDI unit band
7Clamp
8Brake hose
9Brake hose holder
0Hose guide
AReservoir hoseBReservoir tank
CBrake master cylinder
ÈClamp the sub-wire harness at the tape on it.
ÉPass the sub-wire harness on the left of the CDI
unit.
ÊPass the reservoir hose between the brake hose
and swingarm bracket.
ËPass the reservoir hose through the hose guides.
ÌInstall the brake hose so that its pipe portion
directs as shown and lightly touches the projec-
tion on the brake master cylinder.
5PA20070
CABLE ROUTING DIAGRAM

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
ll
l
lInspect crack
Remove carbon
PISTON RING
Inspect
Replace
ll
llCheck ring end gap
PISTON PIN, SMALL END BEARING
Inspect
Replace
l
l
CYLINDER HEAD
Inspect and clean
Retighten
l
ll
lRemove carbon
Check gasket
CYLINDER
Inspect and clean
Replace
ll
lInspect score marks
Inspect wear
CLUTCH
Inspect and adjust
Replace
ll
l
Inspect housing, friction
plate, clutch plate and
spring
TRANSMISSION
Replace oil
Inspect
Replace bearing
ll
l
lYamalube 4 (10W-30) or
SAE 10W-30 SE motor oil
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
l Inspect wear
ROTOR NUT
Retighten
l
l
KICK SHAFT
Inspect idle gear
Replace
l
l
EXHAUST PIPE, SILENCER
Inspect
Clean
ll
l
CRANK
Inspect and clean
ll
CARBURETOR
Inspect, adjust and clean
ll
SPARK PLUG
Inspect and clean
Replace
ll
l
DRIVE CHAIN
Lubricate, slack, alignment
Replace
ll
lChain slack: 35 ~ 45 mm
(1.4 ~ 1.8 in)


3

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses
ll
ll
l
Every two years
OUTSIDE NUTS AND BOLTS
Retighten
ll
AIR FILTER
Clean and lubricate
Replace
ll
lUse foam air-filter oil
FRAME
Clean and inspect
ll
FUEL TANK, COCK
Clean and inspect
ll
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
l
l
l
l
ll
l
l
l
l
l
l
Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal
l
ll
l
l
Suspension oil “01”
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube
llLithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten
l
ll
ll(After
rain ride)
l
Molybdenum disulfide
grease
CHAIN GUARD AND ROLLERS
Inspect
l
SWINGARM
Inspect and retighten
Lube
l
ll
l
Molybdenum disulfide
grease
RELAY ARM, CONNECTING ROD
Inspect and retighten
Lube
l
ll
l
Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing
ll
l
l
Lithium base grease ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks


3