wheel YAMAHA YZ85 2002 Owner's Manual

4 - 46
ENG
EC4L3000
REMOVAL POINTS
Rotor
1. Remove:
lNut (rotor) 1
lWasher 2
Use the rotor holding tool 3.
Rotor holding tool:
YU-1235/90890-01235
5PA41390
2. Remove:
lRotor 1
Use the flywheel puller 2.
NOTE:
When installing the flywheel puller, turn it
counterclockwise.
Flywheel puller:
YM-1189/90890-01189
5PA41400
EC4L4000
INSPECTION
EC4L4101
CDI magneto
1. Inspect:
lRotor inner surface a
lStator outer surface b
Damage ® Inspect the crankshaft runout
and crankshaft bearing.
If necessary, replace CDI magneto and/or
stator.
5PA41410
EC4L4200
Woodruff key
1. Inspect:
lWoodruff key 1
Damage ® Replace.
5PA41420
CDI MAGNETO

4 - 62
ENG
2. Install:
l2nd wheel gear (32T) 1
l6th wheel gear (25T) 2
l3rd wheel gear (26T) 3
l4th wheel gear (22T) 4
l5th wheel gear (26T) 5
l1st wheel gear (27T) 6
To drive axle 7.
NOTE:
lApply the molybdenum disulfide oil on the
1st, 2nd, 3rd and 4th wheel gears inner cir-
cumference and on the end surface.
lApply the transmission oil on the 5th and 6th
wheel gears inner circumference.
5PA41880
3. Install:
lWasher 1
lCirclip 2
NOTE:
lBe sure the circlip sharp-edged corner a is
positioned opposite side to the washer and
gear b.
lBe sure the circlip end c is positioned at
axle spline groove d.
5PA41900
5PA41890
4. Install:
lCollar 1
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lWhen installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
5PA41910
TRANSMISSION, SHIFT CAM AND SHIFT FORK

4 - 63
ENG
5. Install:
lMain axle 1
lDrive axle 2
To left crankcase.
5PA41920
Shift cam and shift fork
1. Install:
lShift fork 1 (L) 1
lShift fork 2 2
lShift fork 3 (R) 3
lStraight pin 4
NOTE:
lMesh the shift fork #1 (L) with the 6th wheel
gear 5 and #3 (R) with the 5th wheel gear 7
on the drive axle.
lMesh the shift fork #2 with the 3rd/4th pinion
gear 6 on the main axle.
5PA41930
5PA41940
2. Install:
lShift cam 1
NOTE:
Apply the transmission oil on the shift cam.
5PA41950
TRANSMISSION, SHIFT CAM AND SHIFT FORK

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 - 3
CHAS
EC593000
REMOVAL POINTS
EC523101
Rear wheel
1. Remove:
lWheel 1
NOTE:
Push the wheel forward and remove the drive
chain 2.
5PA50030
EC513201
Wheel bearing (if necessary)
1. Remove:
lBearing 1
NOTE:
Remove the bearing using a general bearing
puller 2.
5PA50040
EC594000
INSPECTION
EC514100
Wheel
1. Measure:
lWheel runout
Out of limit ® Repair or replace.
2. Inspect:
lBearing
Rotate inner race with a finger.
Rough spot/seizure ® Replace.
NOTE:
Replace the bearings, oil seal and wheel collar
as a set.
Wheel runout limit:
Radial 1: 2.0 mm (0.08 in)
Lateral 2: 2.0 mm (0.08 in)
5PA50050
5PA50060
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

5 - 5
CHAS
EC595000
ASSEMBLY AND INSTALLATION
Front wheel
1. Install:
lBearing (left) 1
lSpacer 2
lBearing (right) 3
lOil seal 4
NOTE:
lApply the lithium soap base grease on the
bearing and oil seal lip when installing.
lUse a socket that matches the outside diam-
eter of the race of the bearing.
lLeft side of bearing shall be installed first.
lInstall the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
lBrake disc 1
lBolt (brake disc) 2
5PA50090
5PA50100
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
lCollar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5PA50110
4. Install:
lWheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
5PA50120
FRONT WHEEL AND REAR WHEEL

5 - 6
CHAS
5. Install:
lWasher 1
lWheel axle 2
NOTE:
Apply the lithium soap base grease on the
wheel axle.
5PA50130
6. Install:
lWasher 1
lNut (wheel axle) 2
5PA50140
T R..70 Nm (7.0 m · kg, 50 ft · lb)
Rear wheel
1. Install:
lBearing (left) 1
lCirclip 2
lSpacer 3
lBearing (right) 4
lOil seal 5
NOTE:
lApply the lithium soap base grease on the
bearing and oil seal lip when installing.
lInstall the bearing with seal facing outward.
lUse a socket that matches the outside diam-
eter of the race of the bearing.
lLeft side of bearing shall be installed first.
lInstall the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
5PA50150
FRONT WHEEL AND REAR WHEEL

5 - 7
CHAS
2. Install:
lBrake disc 1
lBolt (brake disc) 2
NOTE:
Tighten the bolts (brake disc) in stage, using a
crisscross pattern.
5PA50160
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
lRear wheel sprocket 1
lBolt (rear wheel sprocket) 2
lWasher (rear wheel sprocket) 3
lNut (rear wheel sprocket) 4
NOTE:
Tighten the nuts (rear wheel sprocket) in
stage, using a crisscross pattern.5PA50170
T R..42 Nm (4.2 m · kg, 30 ft · lb)
4. Install:
lCollar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5PA50180
5. Install:
lWheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
5PA50190
6. Install:
lDrive chain 1
NOTE:
Push the wheel 2 forward and install the drive
chain.
5PA50200
FRONT WHEEL AND REAR WHEEL