oil YAMAHA YZ85 2003 Owner's Manual

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate












Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection
Inspect and Lubricate






Yamaha cable lube or
SAE 10W-30 motor oil ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks

INSP
ADJ
PROGRAMME D’ENTRETIEN
TETE DE FOURCHE
Contrôler le jeu et resserrer
Nettoyer et lubrifier
Remplacer le roulement







Graisse à base de lithium
PNEUS, ROUES
Contrôler la pression de gonflage, le
voile de roue, l’usure des pneus et la ten-
sion des rayons
Resserrer le boulon de la roue dentée
Contrôler les roulements
Remplacer les roulements
Lubrifier












Graisse à base de lithium
ACCELERATEUR, CABLE DE COM-
MANDE
Contrôler le cheminement et le raccorde-
ment
Contrôler et lubrifier






Lubrifiant pour câbles
Yamaha ou huile moteur
SAE 10W-30 ElémentAprès
rodageA cha-
que
courseToutes
les trois
coursesToutes
les cinq
coursesSi
néces-
saireRemarques
3 - 3

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh mixture of oil and gasoline is filled in the fuel
tank. Check the fuel line for leakage.P.1-12
Transmission oilCheck that the oil level is correct. Check the crankcase for leak-
age.P.3-12 ~ 13
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10
Brakes Check the play of front brake and effect of front and rear brake. P.3-16 ~ 21
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-22 ~ 24
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-31 ~ 32
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-32 ~ 34
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-24 ~ 30
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Exhaust pipe and silencerCheck that the exhaust pipe is tightly mounted and has no
cracks.P.4-2
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-22
Lubrication Check for smooth operation. Lubricate if necessary. P.3-35
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-16
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 19

3 - 7
INSP
ADJ
RADIATOR CAP INSPECTION
CAUTION:

Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.

Do not use water containing impurities or
oil.
7. Install:

Radiator cap
Start the engine and warm it up for a sev-
eral minutes.
8. Check:

Coolant level
Coolant level low → Add coolant. Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING

When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.

When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.

When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:

Seal (radiator cap) 1

Valve and valve seat 2
Crack/damage → Replace.
Exist fur deposits 3 → Clean or replace.
5PA30050

3 - 11
INSP
ADJ
AIR FILTER CLEANING
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove:

Seat

Fitting bolt 1

Washer 2

Air filter element 3

Air filter guide 4
5PA30150
2. Clean:

Air filter element
Clean them with solvent.
NOTE:
After cleaning, remove the remaining solvent
by squeezing the element.
CAUTION:

Do not twist the element when squeezing
the element.

Leaving too much of solvent in the ele-
ment may result in poor starting.
5PA30160
3. Inspect:

Air filter element
Damage → Replace.
4. Apply:

Foam-air-filter oil or engine mixing oil
To the element.
NOTE:
Squeeze out the excess oil. Element should be
wet but not dripping.

3 - 12
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
5. Install:

Air filter guide 1
To air filter element 2.
5PA30170
6. Apply:

Lithium soap base grease
On the matching surface a on air filter ele-
ment.
5PA30180
7. Install:

Air filter element 1

Washer

Fitting 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:

Oil drain bolt 1

Oil filler cap 2
Drain the transmission oil.
5PA30200

3 - 13
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
5. Measure:

Transmission oil capacity
Out of specification → Adjust.
Oil capacity (periodic oil change):
0.50 L (0.44 Imp qt, 0.52 US qt)
6. Install:

Copper washer

Oil drain bolt 1
5PA30210
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Fill:

Transmission 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:

Oil leakage
9. Install:

Oil filter cap 1
5PA30220

3 - 22
INSP
ADJ
SPROCKETS INSPECTION
1. Inspect:

Sprocket teeth a
Excessive wear → Replace.
NOTE:
Replace the drive sprocket, rear wheel
sprocket and drive chain as a set.
5PA30480
EC369002
DRIVE CHAIN INSPECTION
1. Remove:

Master link clip

Joint 1

Drive chain 2
5PA30490
2. Clean:

Drive chain
Place it in kerosene, and brush off as much
dirt as possible. Then remove the chain
from the kerosene and dry the chain.
5PA30500
3. Measure:

Drive chain length (10 links) a
Out of limit → Replace.
Drive chain length (10 links):
: 122.1 mm (4.81 in)
5PA30510
4. Check:

Drive chain stiffness a
Clean and oil the chain and hold as illus-
trated.
Stiff → Replace drive chain.
5PA30520
SPROCKETS INSPECTION/
DRIVE CHAIN INSPECTION

3 - 23
INSP
ADJ
DRIVE CHAIN SLACK ADJUSTMENT
5. Install:

Drive chain 1

Joint 2

Master link clip 3
CAUTION:
Be sure to install the master link clip to the
direction as shown.
aTurning direction5PA30530
6. Lubricate:

Drive chain
Drive chain lubricant:
SAE 10W-30 motor oil or suit-
able chain lubricants
5PA30540
EC36A060
DRIVE CHAIN SLACK ADJUSTMENT
1. Elevate the rear wheel by placing the suit-
able stand under the engine.
2. Check:

Drive chain slack
a
In the center between the drive axle and
rear wheel axle.
Out of specification → Adjust.
NOTE:
Before checking and/or adjusting, rotate the
rear wheel through several revolutions and
check the slack several times to find the tight-
est point. Check and/or adjust chain slack with
rear wheel in this “tight chain” position.
Drive chain slack:
35 ~ 45 mm (1.4 ~ 1.8 in)
5PA30550

3 - 24
INSP
ADJDRIVE CHAIN SUPPORT INSPECTION/
FRONT FORK INSPECTION
3. Adjust:

Drive chain slack
Drive chain slack adjustment steps:

Loosen the axle nut 1 and locknuts 2.

Adjust chain slack by turning the adjusters 3.
To tighten
→ Turn adjuster
3 clockwise.
To loosen
→ Turn adjuster
3 counter-
clockwise and push wheel forward.

Turn each adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks a on each side of chain
puller alignment.)
NOTE:
Turn the adjuster so that the chain is in line
with the sprocket, as viewed from the rear.
CAUTION:
Too small chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.

Tighten the axle nut while pushing down
the drive chain.
T R..
Axle nut:
90 Nm (9.0 m  kg, 65 ft  lb)

Tighten the locknuts.
5PAR0004
DRIVE CHAIN SUPPORT INSPECTION
1. Inspect:

Drive chain support wear limit
Limit reaches indicator a → Replace.
Refer to “SWINGARM” section in the
CHAPTER 5.
5PAR0005
a a
EC36C000
FRONT FORK INSPECTION
1. Inspect:

Front fork smooth action
Operate the front brake and stroke the front
fork.
Unsmooth action/oil leakage → Repair or
replace.
5PA30570