warning YAMAHA YZ85 2002 User Guide

3 - 18
INSP
ADJREAR BRAKE ADJUSTMENT/
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
EC364002
REAR BRAKE ADJUSTMENT
1. Check:
lBrake pedal height a
Out of specification ® Adjust.
Brake pedal height
a:
7 mm (0.28 in)
5PA30330
2. Adjust:
lBrake pedal height
Pedal height adjustment steps:
lLoosen the locknut 1.
lTurn the adjusting nut 2 until the pedal
height a is within specified height.
lTighten the locknut.
WARNING
lAdjust the pedal height between the
maximum
È and the minimum
É as
shown. (In this adjustment the bolt
3
end
b should protrude out of the lower
adjusting nut
4 but not be less than
2 mm (0.08 in)
c away from the brake
pedal
5).
lAfter the pedal height adjustment, make
sure that the rear brake does not drag.
5PA30340
ÈÉ
5PA30350
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT
1. Remove:
lRubber cap
2. Inspect:
lBrake pad thickness a
Out of limit ® Replace as a set.
Brake pad thickness:
4.0 mm (0.16 in)
: 0.8 mm (0.03 in)5PA30360

3 - 21
INSP
ADJ
BRAKE FLUID LEVEL INSPECTION
3. Inspect:
lBrake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section.
4. Check:
lBrake pedal operation
A softy or spongy feeling ® Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section.
BRAKE FLUID LEVEL INSPECTION
1. Place the brake master cylinder (reservoir
tank) so that its top is in a horizontal posi-
tion.
2. Inspect:
lBrake fluid level
Fluid at lower level a ® Fill up.
ÈFront
ÉRear
WARNING
lUse only designated quality brake fluid to
avoid poor brake performance.
lRefill with same type and brand of brake
fluid; mixing fluids could result in poor
brake performance.
lBe sure that water or other contaminants
do not enter master cylinder when refill-
ing.
lClean up spilled fluid immediately to
avoid erosion of painted surfaces or plas-
tic parts.
lInstall the brake caliper 0 and tighten the
pad pins A.
T R..
Bolt (brake caliper):
23 Nm (2.3 m • kg, 17 ft • lb)
Pad pin:
18 Nm (1.8 m • kg, 13 ft • lb)
NOTE:
Apply the LOCTITE® on the bolt (brake cali-
per rear side).
Recommended brake fluid:
DOT #4
5PA30460
È
5PA30470
É

3 - 26
INSP
ADJFRONT FORK COMPRESSION DAMPING FORCE
ADJUSTMENT
lSTANDARD POSITION:
This is the position which is back by the spe-
cific number of clicks from the fully turned-in
position.
CAUTION:
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
WARNING
Always adjust each front fork to the same
setting. Uneven adjustment can cause poor
handling and loss of stability.
Standard position:
YZ85: 7 clicks out
YZ85LW: 9 clicks out
EC36J001
FRONT FORK COMPRESSION DAMPING
FORCE ADJUSTMENT
1. Remove:
lRubber cap
2. Adjust:
lCompression damping force
By turning the adjuster 1.
Stiffer
a
® Increase the compression
damping force. (Turn the adjuster
1
in.)
Softer
b
® Decrease the compression
damping force. (Turn the adjuster
1
out.)
Extent of adjustment
Maximum Minimum
Fully turned in
position20 clicks out (from
maximum position)
5PA30610

3 - 27
INSP
ADJ
REAR SHOCK ABSORBER INSPECTION
lSTANDARD POSITION:
This is the position which is back by the spe-
cific number of clicks from the fully turned-in
position.
CAUTION:
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
WARNING
Always adjust each front fork to the same
setting. Uneven adjustment can cause poor
handling and loss of stability.
3. Install:
lRubber cap
Standard position:
YZ85: 10 clicks out
YZ85LW: 7 clicks out
EC36K000
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
lSwingarm smooth action
Abnormal noise/unsmooth action ®
Grease the pivoting points or repair the piv-
oting points.
Damage/oil leakage ® Replace.
5PA30620

3 - 33
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
lTighten the steering ring nut 3 using
steering nut wrench 4.
NOTE:
Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering nut wrench:
YU-33975/90890-01403
T R..
Steering ring nut (initial tighten-
ing):
38 Nm (3.8 m • kg, 27 ft • lb)
lLoosen the steering ring nut one turn.
lRetighten the steering ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Steering ring nut (final tighten-
ing):
4 Nm (0.4 m • kg, 2.9 ft • lb)
lCheck the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
lInstall the upper bracket 5, steering stem
nut 6, handlebar 7, handlebar upper
holder 8 and number plate 9.
NOTE:
lThe upper handlebar holder should be
installed with the punched mark a for-
ward.
lInsert the end of fuel breather hose 0 into
the hole of the steering stem.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.
T R..
Steering stem nut:
115 Nm (11.5 m • kg, 85 ft • lb)
Handlebar upper holder:
27 Nm (2.7 m • kg, 19 ft • lb)
Pinch bolt (upper bracket):
22 Nm (2.2 m • kg, 16 ft • lb)
Number plate:
7 Nm (0.7 m • kg, 5.1 ft • lb)
5PA30750
5PA30760

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 - 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

5 - 1
CHAS
EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1 Front wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
1 Nut (front wheel axle) 1
2 Front wheel axle 1
3 Front wheel 1
4 Collar 2
5 Oil seal 2
6 Bearing 2 Refer to “REMOVAL POINTS”.
7 Brake disc 1
2
31
3
5PA50010




5

5 - 2
CHAS
EC598100
REAR WHEEL
5PA50020
Extent of removal:
1 Rear wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10Brake disc
1
2
31
3
FRONT WHEEL AND REAR WHEEL

5 - 4
CHAS
EC514200
Wheel axle
1. Measure:
lWheel axle bends
Out of specification ® Replace.
Use the dial gauge 1.
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent axle.
Wheel axle bending limit:
0.5 mm (0.020 in)
5PA50070
Brake disc
1. Measure:
lBrake disc deflection
Use the dial gauge 1.
Out of specification ® Inspect wheel
runout.
If wheel runout is in good condition, replace
the brake disc.
2. Measure:
lBrake disc thickness a
Out of limit ® Replace.
Brake disc deflection limit:
0.15 mm (0.006 in)
Brake disc thickness:
3.0 mm (0.12 in)
: 2.5 mm (0.10 in)
5PA50080
FRONT WHEEL AND REAR WHEEL