relay YAMAHA YZ85 2002 Owners Manual

SPEC
2 - 13
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Nipple (spoke) — 64 3 0.3 2.2
Rear wheel sprocket M8 ´ 1.25 4 42 4.2 30
Rear brake caliper protector M6 ´ 1.0 1 10 1.0 7.2
Engine mounting:
Engine and frame (front) M10 ´ 1.25 1 69 6.9 50
Engine and frame (lower) M10 ´ 1.25 1 69 6.9 50
Pivot shaft and nut M12 ´ 1.25 1 63 6.3 45
Relay arm and frame M10 ´ 1.25 1 54 5.4 39
Relay arm and connecting rod M12 ´ 1.25 1 53 5.3 38
Connecting rod and swingarm M12 ´ 1.25 1 53 5.3 38
Rear shock absorber and frame M10 ´ 1.25 1 36 3.6 25
Rear shock absorber and relay arm M10 ´ 1.25 1 36 3.6 25
Rear frame (upper) M8 ´ 1.25 1 26 2.6 19
Rear frame (lower) M8 ´ 1.25 2 16 1.6 11
Swingarm and brake hose holder M5 ´ — 4 4 0.4 2.9
Drive chain tensioner (upper) M8 ´ 1.25 1 23 2.3 17
Drive chain tensioner (lower) M6 ´ 1.0 1 10 1.0 7.2
Drive chain case M8 ´ 1.25 2 11 1.1 8
Seal guard and swingarm M6 ´ 1.0 2 10 1.0 7.2
Fuel tank M6 ´ 1.0 2 7 0.7 5.1
Fuel cock M6 ´ 1.0 2 4 0.4 2.9
Fuel tank bracket and fuel tank M6 ´ 1.0 4 7 0.7 5.1
Seat set bracket and fuel tank M6 ´ 1.0 1 7 0.7 5.1
Radiator cover M6 ´ 1.0 3 4 0.4 2.9
Front fender M6 ´ 1.0 4 7 0.7 5.1
Rear fender M6 ´ 1.0 4 7 0.7 5.1
Flap guard M6 ´ 1.0 2 7 0.7 5.1
Side cover M6 ´ 1.0 2 7 0.7 5.1
Seat M6 ´ 1.0 2 7 0.7 5.1
Number plate M6 ´ 1.0 1 7 0.7 5.1

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses
ll
ll
l
Every two years
OUTSIDE NUTS AND BOLTS
Retighten
ll
AIR FILTER
Clean and lubricate
Replace
ll
lUse foam air-filter oil
FRAME
Clean and inspect
ll
FUEL TANK, COCK
Clean and inspect
ll
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid
l
l
l
l
ll
l
l
l
l
l
l
Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal
l
ll
l
l
Suspension oil “01”
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube
llLithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten
l
ll
ll(After
rain ride)
l
Molybdenum disulfide
grease
CHAIN GUARD AND ROLLERS
Inspect
l
SWINGARM
Inspect and retighten
Lube
l
ll
l
Molybdenum disulfide
grease
RELAY ARM, CONNECTING ROD
Inspect and retighten
Lube
l
ll
l
Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing
ll
l
l
Lithium base grease ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks


3

5 - 51
CHASSWINGARM
EC570000
SWINGARM
5PA51620
Extent of removal:
1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is no
danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Real wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Brake hose holder
Rear brake caliper
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
1 Drive chain case 1
2 Bolt (connecting rod) 1 Hold the swingarm.
3 Bolt (rear shock absorber-relay
arm)1
4 Pivot shaft 1
5 Swingarm 1
1

5 - 52
CHAS
EC578000
SWINGARM DISASSEMBLY
5PA51630
Extent of removal:
1 Swingarm disassembly
2 Connecting rod removal and disassembly
3 Relay arm removal and disassembly
Extent of removal Order Part name Q’ty Remarks
SWINGARM DISASSEMBLY
1 Relay arm 1
2 Connecting rod 1
3 Cover 2
4 Collar 5
5 Dust seal 2
6 Bushing 4
7 Oil seal 8
8 Bearing 8
Refer to “REMOVAL POINTS”.
9 Bushing (swingarm) 2
0 Bearing (relay arm-rear shock
absorber)1 Refer to “REMOVAL POINTS”.
1
2
3
2
3
3
SWINGARM

5 - 53
CHAS
EC573000
REMOVAL POINTS
Bearing and bushing
1. Remove:
lBearing 1
lBushing (swingarm) 2
From swingarm.
NOTE:
Remove the bushing by pressing.5PA51640
2. Remove:
lBearing 1
From relay arm and connecting rod.
NOTE:
Remove the bearing by pressing its outer race.
5PA51650
Bearing (relay arm-rear shock absorber)
1. Remove:
lStopper ring 1
NOTE:
Press in the bearing while pressing its outer
race and remove the stopper ring.
5PA51660
2. Remove:
lBearing 1
NOTE:
Remove the bearing by pressing its outer race.
5PA51670
SWINGARM

5 - 54
CHAS
INSPECTION
Wash the bearings, bushings, collars, and cov-
ers in a solvent.
Swingarm
1. Inspect:
lBearing 1
lBushing 2
lCollar 3
Free play exists/unsmooth revolution/rust
® Replace bearing, bushing and collar as
a set.
2. Inspect:
lOil seal 4
Damage ® Replace.
5PA51680
Relay arm
1. Inspect:
lBearing 1
lBushing 2
Free play exists/unsmooth revolution/rust
® Replace bearing and bushing as a set.
2. Inspect:
lOil seal 3
Damage ® Replace.
5PA51690
Connecting rod
1. Inspect:
lBearing 1
lBushing 2
Free play exists/unsmooth revolution/rust
® Replace bearing and bushing as a set.
2. Inspect:
lOil seal 3
Damage ® Replace.
5PA51700
SWINGARM

5 - 55
CHAS
EC575000
ASSEMBLY AND INSTALLATION
Bearing (relay arm-rear shock absorber)
1. Install:
lBearing 1
NOTE:
lApply the lithium soap base grease on the
bearing when installing.
lInstall the bearing parallel until the stopper
ring groove appears by pressing its outer
race.
5PA51710
2. Install:
lStopper ring 1
NOTE:
After installing the stopper ring, push back the
bearing until it contacts the stopper ring.
5PA51720
Bearing, bushing and oil seal
1. Install:
lBearing 1
lBushing (swingarm) 2
lOil seal 3
To swingarm.
NOTE:
lApply the molybdenum disulfide grease on
the bearing and bushing when installing.
lInstall the bearing by pressing it on the side
having the manufacture’s marks or numbers.
lFirst install the bushing and then the bearing
to a specified depth from inside.
Installed depth of bearings and
bushings:
Bearing a: 4.5 mm (0.18 in)
Bushing b: 4.5 mm (0.18 in)
5PA51730
5PA51740
SWINGARM

5 - 56
CHAS
2. Install:
lBearing 1
lOil seal 2
To relay arm.
NOTE:
lApply the molybdenum disulfide grease on
the bearing when installing.
lInstall the bearing by pressing it on the side
having the manufacture’s marks or numbers.
3. Install:
lBearing 1
lOil seal 2
To connecting rod.
NOTE:
lApply the molybdenum disulfide grease on
the bearing when installing.
lInstall the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of bearings:
Depth a: 4.5 mm (0.18 in)
Depth b: 0.5 mm (0.02 in)
Installed depth of bearings a:
6.5 mm (0.26 in)
5PA51750
5PA51760
Swingarm
1. Install:
lCollar 1
To swingarm 2.
NOTE:
Apply the molybdenum disulfide grease on the
collars, bearings, bushings and oil seal lips.
2. Install:
lBushing 1
lDust seal 2
lCollar 3
lCover 4
To relay arm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bushings, dust seals, collars, cover lips, bear-
ings and oil seal lips.
5PA51770
5PA51780
SWINGARM

5 - 57
CHAS
3. Install:
lBushing 1
To connecting rod 2.
NOTE:
Apply the molybdenum disulfide grease on the
bushings, bearings and oil seal lips.
5PA51790
4. Install:
lConnecting rod 1
lWasher 2
lBolt (connecting rod) 3
lNut (connecting rod) 4
To swingarm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
5PA51800
T R..53 Nm (5.3 m · kg, 38 ft · lb)
5. Install:
lRelay arm 1
lBolt (relay arm) 2
lNut (relay arm) 3
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
6. Install:
lSwingarm 1
lPivot shaft 2
lWasher 3
lNut (pivot shaft) 4
NOTE:
lApply the molybdenum disulfide grease on
the pivot shaft.
lInsert the pivot shaft from right side.
5PA51810
T R..54 Nm (5.4 m · kg, 39 ft · lb)
5PA51820
T R..63 Nm (6.3 m · kg, 45 ft · lb)
SWINGARM

5 - 58
CHAS
7. Check:
lSwingarm side play a
Free play exists ® Replace collars.
lSwingarm up and down movement b
Unsmooth movement/binding/rough spots
® Grease or replace bearings, bushings
and collars.
5PA51830
8. Install:
lWasher 1
lBolt (rear shock absorber-relay arm) 2
NOTE:
lApply the molybdenum disulfide grease on
the bolt.
lInsert the bolt from left side.
5PA51840
T R..36 Nm (3.6 m · kg, 25 ft · lb)
9. Install:
lBolt (connecting rod) 1
lNut (connecting rod) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
5PA51850
T R..53 Nm (5.3 m · kg, 38 ft · lb)
10. Install:
lDrive chain case 1
lBolt (drive chain case) 2
lNut (drive chain case) 3
5PA51860
T R..11 Nm (1.1 m · kg, 8 ft · lb)
SWINGARM