boot YAMAHA YZ85 2002 Owners Manual

IMPORTANT NOTICE
THIS MACHINE IS DESIGNED STRICTLY
FOR COMPETITION USE, ONLY ON A
CLOSED COURSE. It is illegal for this
machine to be operated on any public street,
road, or highway. Off-road use on public lands
may also be illegal. Please check local regula-
tions before riding.
1. THIS MACHINE IS TO BE OPERATED
BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this
machine at maximum power until you
are totally familiar with its character-
istics.
2. THIS MACHINE IS DESIGNED TO BE
RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this
machine.
3. ALWAYS WEAR PROTECTIVE
APPAREL.
When operating this machine, always
wear an approved helmet with gog-
gles or a face shield. Also wear heavy
boots, gloves, and protective cloth-
ing. Always wear proper fitting cloth-
ing that will not be caught in any of
the moving parts or controls of the
machine.
4. ALWAYS MAINTAIN YOUR MACHINE
IN PROPER WORKING ORDER.
For safety and reliability, the machine
must be properly maintained. Always
perform the pre-operation checks
indicated in this manual. Correcting a
mechanical problem before you ride
may prevent an accident.
5. GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refu-
eling. Take care to not spill any gaso-
line on the engine or exhaust system.
Never refuel in the vicinity of an open
flame, or while smoking.
SAFETY INFORMATION

5 - 11
CHAS
BRAKE CALIPER DISASSEMBLY
5PA50270
ÈFront
ÉRear
Extent of removal:
1 Front brake caliper disassembly
2 Rear brake caliper disassembly
Extent of removal Order Part name Q’ty Remarks
BRAKE CALIPER DISASSEM-
BLY
1 Brake pad 2
2 Brake caliper bracket 1
3 Brake caliper piston 2 Refer to “REMOVAL POINTS”.
4 Dust seal 2
Refer to “REMOVAL POINTS”.
5 Piston seal 2
6 Pin boot 1
7 Sleeve boot 1
8 Pad pin 2
9 Brake pad 2
0 Brake caliper piston 1 Refer to “REMOVAL POINTS”.
A Dust seal 1
Refer to “REMOVAL POINTS”.
B Piston seal
1
2
1
FRONT BRAKE AND REAR BRAKE

5 - 12
CHAS
BRAKE MASTER CYLINDER DISASSEMBLY
5PA50280
ÈFront
ÉRear
Extent of removal:
1 Front brake master cylinder disassembly
2 Rear brake master cylinder disassembly
Extent of removal Order Part name Q’ty Remarks
BRAKE MASTER CYLINDER
DISASSEMBLY
1 Brake master cylinder cap 1
2 Diaphragm 1
3 Brake master cylinder boot 1
4 Circlip 1 Use a long nose circlip pliers.
5 Washer 1
6 Push rod 1
7 Brake master cylinder kit
1
12
21
FRONT BRAKE AND REAR BRAKE

5 - 16
CHAS
3. Inspect: (only front brake caliper)
lBrake caliper bracket 1
Cranks/damage ® Replace the brake cali-
per assembly.
lGuide pin 2
Rust/damage ® Replace the brake caliper
assembly.
lSleeve boot 3
lPin boot 4
Wear/damage ® Replace.5PA50420
4. Inspect: (only front brake caliper)
lBrake caliper support bolt 1
Scorches/rust/damage ® Replace.
5PA50430
EC534301
Brake hose
1. Inspect:
lBrake hose 1
Crack/damage ® Replace.
5PA50440
EC5A5000
ASSEMBLY AND INSTALLATION
WARNING
lAll internal parts should be cleaned in
new brake fluid only.
lInternal parts should be lubricated with
brake fluid when installed.
lReplace the piston seals and dust seals
whenever a caliper is disassembled.
Brake caliper piston
1. Clean:
lBrake caliper
lPiston seal
lDust seal
lBrake caliper piston
Clean them with brake fluid.
FRONT BRAKE AND REAR BRAKE

5 - 17
CHAS
2. Install:
lPiston seal 1
lDust seal 2
WARNING
Always use new piston seals and dust
seals.
NOTE:
Fit the piston seals and dust seals onto the slot
on brake caliper correctly.
ÈFront
ÉRear
È
5PA50450
É
5PA50460
3. Install:
lBrake caliper piston 1
NOTE:
Apply the brake fluid on the brake caliper pis-
ton wall.
CAUTION:
lFor the front brake caliper, install the pis-
ton with its shallow depressed side
a
facing the caliper. For the rear brake cali-
per, install the piston with its depressed
side
b facing the brake caliper.
lNever force to insert.
ÈFront
ÉRear
È
5PA50470
É
5PA50480
Front brake caliper
1. Install:
lSleeve boot 1
On brake caliper bracket 2.
5PA50490
FRONT BRAKE AND REAR BRAKE

5 - 18
CHAS
2. Install:
lPin boot 1
On brake caliper 2.
NOTE:
Apply the lithium soap base grease on the pin
boot inner surface.
5PA50500
3. Install:
lBrake caliper bracket 1
lBolt (brake caliper bracket) 2
lBrake pad 3
5PA50510
T R..30 Nm (3.0 m · kg, 22 ft · lb)
4. Install:
lBrake caliper 1
NOTE:
lApply the lithium soap base grease on the
guide pin 2.
lInstall the brake caliper into the guide pin
and turn it clockwise.
5PA50520
5. Install:
lBrake caliper support bolt 1
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
Rear brake caliper
1. Install:
lPad support 1
lBrake pad 2
lPad pin 3
NOTE:
lInstall the brake pad fitted with brake pad
shim 4 on the brake caliper piston side.
lTemporarily tighten the pad pins at this point.
5PA50530
T R..23 Nm (2.3 m · kg, 17 ft · lb)
5PA50540
FRONT BRAKE AND REAR BRAKE

5 - 20
CHAS
4. Install:
[Front]
lBrake master cylinder kit 1
lWasher 2
lCirclip 3
lBrake master cylinder boot 4
To brake master cylinder 5.
[Rear]
lBrake master cylinder kit 1
lPush rod 2
lCirclip 3
lBrake master cylinder boot 4
To brake master cylinder 5.
NOTE:
lApply the brake fluid on the brake master cyl-
inder kit.
lApply the lithium soap base grease on the tip
of the push rod.
lWhen installing the circlip, use a long nose
circlip pliers.
ÈFront
ÉRear
È
5PA50590
É
5PA50600
Front brake master cylinder
1. Install:
lBrake master cylinder 1
lBrake master cylinder bracket 2
lBolt (brake master cylinder bracket) 3
NOTE:
lInstall the bracket so that the arrow mark
a
face upward.
lFirst tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
5PA50610
FRONT BRAKE AND REAR BRAKE