radiator YAMAHA YZ85 2002 User Guide

3 - 7
INSP
ADJ
RADIATOR CAP INSPECTION
CAUTION:
lDo not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
lDo not use water containing impurities or
oil.
7. Install:
lRadiator cap
Start the engine and warm it up for a sev-
eral minutes.
8. Check:
lCoolant level
Coolant level low ® Add coolant. Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING
lWhen coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
lWhen coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.
lWhen coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
lSeal (radiator cap) 1
lValve and valve seat 2
Crack/damage ® Replace.
Exist fur deposits 3 ® Clean or replace.
5PA30050

3 - 8
INSP
ADJRADIATOR CAP OPENING PRESSURE INSPECTION/
COOLING SYSTEM INSPECTION
RADIATOR CAP OPENING PRESSURE
INSPECTION
1. Attach:
lRadiator cap tester 1
lRadiator cap tester adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
3. Inspect:
lPressure
Impossible to maintain the specified pres-
sure for 10 seconds ® Replace.
Radiator cap tester:
YU-24460-01/90890-01325
Radiator cap tester adapter:
YU-33984/90890-01352
Radiator cap opening pressure:
95 ~ 125 kPa (0.95 ~ 1.25 kg/cm2,
13.5 ~ 17.8 psi)
5PA30060
COOLING SYSTEM INSPECTION
1. Inspect:
lCoolant level
2. Attach:
lRadiator cap tester 1
lRadiator cap tester adapter 2
3. Apply the specified pressure.
Radiator cap tester:
YU-24460-01/90890-01325
Radiator cap tester adapter:
YU-33984/90890-01352
Standard pressure:
180 kPa (1.8 kg/cm2, 25.6 psi)
5PA30070

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

4 - 3
ENGRADIATOR
EC450001
RADIATOR
5PA40030
Extent of removal:
1 Radiator removal
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Air scoop Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Radiator guard 1
2 Radiator hose clamp 4 Only loosening.
3 Radiator hose 1 1
4 Radiator hose 2 1
5Radiator 1
6 Radiator breather hose 1
1

4 - 4
ENGRADIATOR
EC456000
HANDLING NOTE
WARNING
Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury.
When the engine has cooled, open the radi-
ator cap by the following procedure:
Place a thick rag, like a towel, over the radi-
ator cap, slowly rotate the cap counter-
clockwise to the detent. This procedure
allows any residual pressure to escape.
When the hissing sound has stopped,
press down on the cap while turning coun-
terclockwise and remove it.
EC454000
INSPECTION
Radiator
1. Inspect:
lRadiator core 1
Obstruction ® Blow out with compressed
air through rear of the radiator.
Bent fin ® Repair or replace.
5PA40040
EC455000
ASSEMBLY AND INSTALLATION
Radiator
1. Install:
lRadiator breather hose 1
To radiator 2.
5PA40050
2. Install:
lRadiator 1
lBolt (radiator) 2
5PA40060

4 - 5
ENGRADIATOR
3. Install:
lRadiator hose 1 1
lRadiator hose 2 2
Refer to “CABLE ROUTING DIAGRAM”
section in the CHAPTER 2.
4. Tighten:
lRadiator hose clamp
5PA40070
5. Install:
lRadiator guard 1
lBolt (radiator guard) 2
NOTE:
Fit the hooks a on the inner side first into the
radiator.
5PA40080

4 - 15
ENGCYLINDER HEAD, CYLINDER AND PISTON
EC470000
CYLINDER HEAD, CYLINDER AND PISTON
EC478000
CYLINDER HEAD AND CYLINDER
5PA40390
Extent of removal:
1 Cylinder head removal
2 Cylinder removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD AND CYLIN-
DER REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Radiator hose 1 Disconnect at cylinder head side.
Radiator hose 2 Disconnect at radiator side.
1 Spark plug 1
2 Nut (cylinder head) 4 Loosen each nut 1/4 turn, and remove
them after all nuts are loosened.
3 Cylinder head 1
4 Nut (cylinder) 4
5 Cylinder 1
1
2

4 - 25
ENG
4. Install:
lO-ring 1
NOTE:
Apply the lithium soap base grease on the O-
rings.
5PA40690
5. Install:
lCylinder head 1
lCopper washer 2
lNut (cylinder head) 3
NOTE:
Tighten the nuts (cylinder head) in stage, using
a crisscross pattern.
5PA40700
T R..30 Nm (3.0 m · kg, 22 ft · lb)
6. Install:
lSpark plug 1
lSpark plug cap 2
lRadiator hose 1 3
lRadiator hose 2 4
5PA40710
T R..20 Nm (2.0 m · kg, 14 ft · lb)
CYLINDER HEAD, CYLINDER AND PISTON

4 - 33
ENGKICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
PRIMARY DRIVE GEAR
5PA40960
Extent of removal:
1 Primary drive gear removal
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVE GEAR
REMOVAL
Drain the transmission oil. Refer to “TRANSMISSION OIL
REPLACEMENT” section in the CHAP-
TER 3.
Brake pedal
Radiator hose 2 Disconnect at water pump side.
1 Kickstarter crank 1
2 Right crankcase cover 1
3 Nut (primary drive gear) 1 Only loosening.
Refer to “REMOVAL POINTS”.
4 Primary driven gear 1 Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
5 Primary drive gear 1
1

4 - 49
ENG
EC4M0000
ENGINE REMOVAL
5PA41490
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
WARNING
Support the machine securely so there is no
danger of it falling over.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR AND REED
VALVE” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Clutch cable Disconnect at engine side.
Radiator hose 1 Disconnect at cylinder head side.
Radiator hose 2 Disconnect at water pump side.
Spark plug cap
Disconnect the CDI magneto
lead.
ENGINE REMOVAL