drain bolt YAMAHA YZ85 2002 Owners Manual

GEN
INFO
1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2Engine stop switch
3Front brake lever
4Throttle grip
5Fuel tank cap
6Radiator cap
7Kickstarter crank
8Fuel tank
9Coolant drain bolt
0Rear brake pedal
ARadiator
BValve joint
CFuel cock
DAir filter
EDrive chain
FShift pedal
GStarter knob
HFront forkNOTE:
lThe machine you have purchased may differ
slightly from those shown in the following.
lDesigns and specifications are subject to
change without notice.
5PA10020
5PA10010
5PA10030
1

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

3 - 5
INSP
ADJ
EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap
1, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:
Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
5PA30010
1. Place the machine on a level place, and
hold it in an upright position.
2. Remove:
lRadiator cap
3. Check:
lCoolant level
Coolant level a low ® Add coolant.
1Radiator
5PA30020
ENGINE/COOLANT LEVEL INSPECTION

3 - 6
INSP
ADJ
COOLANT REPLACEMENT
COOLANT REPLACEMENT
WARNING
Do not remove the radiator cap when the
engine is hot.
CAUTION:
Take care so that coolant does not splash
on painted surfaces. If it splashes, wash it
away with water.
1. Place a container under the engine.
2. Remove:
lCoolant drain bolt 1
3. Remove:
lRadiator cap
Drain the coolant completely.
4. Clean:
lCooling system
Thoroughly flush the cooling system with
clean tap water.
5. Install:
lCopper washer
lCoolant drain bolt
5PA30030
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
6. Fill:
lRadiator
lEngine
To specified level.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing anti-
corrosion for aluminum engine
Coolant
1 and water (soft water)
2
mixing ratio:
50 %/50 %
Coolant capacity:
0.54 L (0.48 Imp qt, 0.57 US qt)
5PA30040

3 - 12
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
5. Install:
lAir filter guide 1
To air filter element 2.
5PA30170
6. Apply:
lLithium soap base grease
On the matching surface a on air filter ele-
ment.
5PA30180
7. Install:
lAir filter element 1
lWasher
lFitting bolt
NOTE:
Install the air filter element with its projection
a facing upward.
5PA30190
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
TRANSMISSION OIL REPLACEMENT
1. Start the engine and warm it up for several
minutes, and then turn off the engine and
wait for five minute.
2. Place the machine on a level place and
hold it on upright position by placing the
suitable stand under the engine.
3. Place a suitable container under the
engine.
4. Remove:
lOil drain bolt 1
lOil filler cap 2
Drain the transmission oil.
5PA30200

3 - 13
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
5. Measure:
lTransmission oil capacity
Out of specification ® Adjust.
Oil capacity (periodic oil change):
0.50 L (0.44 Imp qt, 0.52 US qt)
6. Install:
lCopper washer
lOil drain bolt 1
5PA30210
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Fill:
lTransmission oil
Recommended oil:
Yamalube 4 (10W-30) or SAE
10W-30 type SE motor oil
Oil capacity (periodic oil change):
0.50 L (0.44 Imp qt, 0.52 US qt)
8. Check:
lOil leakage
9. Install:
lOil filter cap 1
5PA30220

3 - 19
INSP
ADJ
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
3. Replace:
lBrake pad
4. Inspect:
lBrake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section.
5. Check:
lBrake lever operation
A softy or spongy feeling ® Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section. Brake pad replacement steps:
lRemove the brake caliper support bolt 1.
lTurn the brake caliper 2 counterclockwise
a.
lReplace the brake pads 3.
lConnect the transparent hose 4 to the
bleed screw 5 and place the suitable con-
tainer under its end.
lLoosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
lTighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
lInstall the brake caliper 6 and brake cali-
per support bolt 7.
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
T R..
Brake caliper support bolt:
30 Nm (3.0 m • kg, 22 ft • lb)
5PA30370
5PA30380
5PA30390
5PA30400

4 - 26
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC490000
CLUTCH AND PRIMARY DRIVEN GEAR
EC498000
CLUTCH PLATE AND FRICTION PLATE
5PA40720
Extent of removal:
1 Clutch plate and friction plate removal
Extent of removal Order Part name Q’ty Remarks
CLUTCH PLATE AND FRIC-
TION PLATE REMOVAL
Preparation for removal Drain the transmission oil. Refer to “TRANSMISSION OIL
REPLACEMENT” section in the CHAP-
TER 3.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Bolt (clutch spring) 5
3 Clutch spring 5
4 Pressure plate 1
5 Friction plate 7
6 Clutch plate 6
1

4 - 40
ENG
6. Install:
lRight crankcase cover 1
NOTE:
Mesh the impeller shaft gear 2 with primary
drive gear 3.
5PA41200
7. Install:
lBolt (right crankcase cover) 1
lCopper washer (oil drain bolt) 2
lOil drain bolt 3
lCopper washer (coolant drain bolt)
4
lCoolant drain bolt 5
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
5PA41210
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
8. Install:
lKickstarter crank 1
lWasher 2
lBolt (kickstarter crank) 3
NOTE:
Install the kickstarter crank closest to but not con-
tacting the pillar tube 4 and exhaust pipe 5.
5PA41220
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
9. Install:
lShift pedal 1
lBolt (shift pedal) 2
NOTE:
Install the shift pedal with the bottom of the
pedal outer diameter a as close to the center
of the engine mounting bolt 3 as possible.
5PA41230
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR

4 - 44
ENG
2. Install:
lBearing 1
NOTE:
Install the bearing by pressing its outer race
parallel.
5PA41330
Impeller shaft
1. Install:
lImpeller shaft 1
lWasher 2
lImpeller 3
NOTE:
lTake care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.
lWhen installing the impeller shaft, apply the
lithium soap base grease on the oil seal lip
and impeller shaft. And install the shaft while
turning it.
lHold the impeller shaft on its width across
the flats a with spanners, etc. and install the
impeller.
5PA41340
T R..14 Nm (1.4 m · kg, 10 ft · lb)
5PA41350
2. Install:
lGasket (water pump housing) 1
5PA41360
3. Install:
lWater pump housing 1
lBolt (water pump housing) 2
lCopper washer (coolant drain bolt)
3
lCoolant drain bolt 4
5PA41370
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
WATER PUMP