washer YAMAHA YZ85 2003 Owner's Manual

4 - 42
ENG
REMOVAL POINTS
Impeller shaft
1. Remove:

Impeller 1

Washer 2

Impeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats a with spanners, etc. and remove the
impeller.
5PA41250
EC4G3210
Oil seal
NOTE:

It is not necessary to disassemble the water
pump, unless there is an abnormality such
as excessive change in coolant level, discol-
oration of coolant, or milky transmission oil.

Replace the oil seal whenever it is remov-
aled.
1. Remove:

Bearing 1
2. Remove:

Oil seal 1
5PA41260
5PA41270
INSPECTION
EC444200
Impeller shaft
1. Inspect:

Impeller shaft 1
Bend/wear/damage → Replace.
Fur deposits → Clean.
5PA41280
WATER PUMP

4 - 44
ENG
2. Install:

Bearing 1
NOTE:
Install the bearing by pressing its outer race
parallel.
5PA41330
Impeller shaft
1. Install:

Impeller shaft 1

Washer 2

Impeller 3
NOTE:

Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.

When 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.

Hold 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:

Gasket (water pump housing) 1
5PA41360
3. Install:

Water pump housing 1

Bolt (water pump housing) 2

Copper washer (coolant drain bolt)
3

Coolant 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

4 - 46
ENG
EC4L3000
REMOVAL POINTS
Rotor
1. Remove:

Nut (rotor) 1

Washer 2
Use the rotor holding tool 3.
Rotor holding tool:
YU-1235/90890-01235
5PA41390
2. Remove:

Rotor 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:

Rotor inner surface a

Stator 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:

Woodruff key 1
Damage → Replace.
5PA41420
CDI MAGNETO

4 - 47
ENG
EC4L5000
ASSEMBLY AND INSTALLATION
CDI magneto
1. Install:

Stator 1

Screw (stator) 2
NOTE:
Temporarily tighten the screw (stator) at this
point.5PA41430
2. Install:

Woodruff key 1

Rotor 2
NOTE:

Clean the tapered portions of the crankshaft
and rotor.

When installing the woodruff key, make sure
that its flat surface a is in parallel with the
crankshaft center line b.

When installing the rotor, align the keyway c
of the rotor with the woodruff key.
5PA41440
3. Install:

Washer 1

Nut (rotor) 2
Use the rotor holding tool 3.
Rotor holding tool:
YU-1235/90890-01235
5PA41450
T R..33 Nm (3.3 m · kg, 24 ft · lb)
4. Adjust:

Ignition timing
Refer to “IGNITION TIMING CHECK” sec-
tion in the CHAPTER 3.
Ignition timing (B.T.D.C.):
0.9 mm (0.035 in)
CDI MAGNETO

4 - 50
ENG
5PA41490
Extent of removal:
1 Engine removal
Extent of removal Order Part name Q’ty Remarks
1 Left crankcase cover 1
2 Nut (drive sprocket) 1
Refer to “REMOVAL POINTS”. 3 Lock washer 1
4 Drive sprocket 1
5 Engine mounting bolt 2
6 Pivot shaft 1
Refer to “REMOVAL POINTS”.
7Engine 1
1
ENGINE REMOVAL

4 - 51
ENG
EC4M3000
REMOVAL POINTS
EC4F3100
Drive sprocket
1. Remove:

Nut (drive sprocket) 1

Lock washer 2
NOTE:

Straighten the lock washer tab.

Loosen the nut while applying the rear brake.5PA41510
2. Remove:

Drive sprocket 1

Drive chain 2
NOTE:
Remove the drive sprocket together with the
drive chain.
5PA41520
EC4M3301
Engine removal
1. Remove:

Pivot shaft 1
NOTE:
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.5PA41530
2. Remove:

Engine 1
From right side.
NOTE:
Make sure that the couplers, hoses and cables
are disconnected.
5PA41540
ENGINE REMOVAL

4 - 52
ENG
EC4M5000
ASSEMBLY AND INSTALLATION
Engine installation
1. Install:

Engine 1
Install the engine from right side.

Pivot shaft 2

Engine mounting bolt (front) 3

Engine mounting bolt (lower) 4
NOTE:
Apply the molybdenum disulfide grease on the
pivot shaft.
5PA41550
T R..63 Nm (6.3 m · kg, 45 ft · lb)
T R..69 Nm (6.9 m · kg, 50 ft · lb)
T R..69 Nm (6.9 m · kg, 50 ft · lb)
Drive sprocket
1. Install:

Drive sprocket 1

Drive chain 2
NOTE:
Install the drive sprocket together with the
drive chain.
5PA41560
2. Install:

Lock washer 1

Nut (drive sprocket) 2
NOTE:
Tighten the nut while applying the rear brake.
3. Bend the lock washer tab to lock the nut.
5PA41570
T R..60 Nm (6.0 m · kg, 43 ft · lb)
4. Install:

Gasket (left crankcase cover)

Left crankcase cover 1

Screw (left crankcase cover) 2
NOTE:
Tighten the screws in stage, using a crisscross
pattern.
5PA41580
T R..5 Nm (0.5 m · kg, 3.6 ft · lb)
ENGINE REMOVAL

4 - 58
ENG
4. Install:

Dowel pin 1

Right crankcase 2
To left crankcase 3.
NOTE:

Turn the shift cam 4 to the position shown in
the figure so that it does not contact the
crankcase when installing the crankcase.

Fit the right crankcase onto the left crank-
case. Tap lightly on the case with soft ham-
mer.

When installing the crankcase, the connect-
ing rod should be positioned at TDC (top
dead center).
5PA41760
5PA41770
5. Install:

Clamp 1

Screw (crankcase) 2
NOTE:
Tighten the crankcase tightening screws in
stage, using a crisscross pattern.
5PA41780
T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
6. Install:

Crankcase oil seal holder 1

Bolt (crankcase oil seal holder) 2
7. Remove:

Sealant
Forced out on the cylinder mating surface.
8. Apply:

Engine oil
To the crank pin, bearing, oil delivery hole
and connecting rod end washer.
9. Check:

Crankshaft and transmission operation
Unsmooth operation → Repair.
5PAR0010
T R..20 Nm (2.0 m · kg, 14 ft · lb)
CRANKCASE AND CRANKSHAFT

4 - 62
ENG
2. Install:

2nd wheel gear (32T) 1

6th wheel gear (25T) 2

3rd wheel gear (26T) 3

4th wheel gear (22T) 4

5th wheel gear (26T) 5

1st wheel gear (27T) 6
To drive axle 7.
NOTE:

Apply the molybdenum disulfide oil on the
1st, 2nd, 3rd and 4th wheel gears inner cir-
cumference and on the end surface.

Apply the transmission oil on the 5th and 6th
wheel gears inner circumference.
5PA41880
3. Install:

Washer 1

Circlip 2
NOTE:

Be sure the circlip sharp-edged corner a is
positioned opposite side to the washer and
gear b.

Be sure the circlip end c is positioned at
axle spline groove d.
5PA41900
5PA41890
4. Install:

Collar 1
NOTE:

Apply the lithium soap base grease on the oil
seal lip.

When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
5PAR0011
TRANSMISSION, SHIFT CAM AND SHIFT FORK

5 - 6
CHAS
5. Install:

Washer 1

Wheel axle 2
NOTE:
Apply the lithium soap base grease on the
wheel axle.
5PA50130
6. Install:

Washer 1

Nut (wheel axle) 2
5PA50140
T R..70 Nm (7.0 m · kg, 50 ft · lb)
Rear wheel
1. Install:

Bearing (left) 1

Circlip 2

Spacer 3

Bearing (right) 4

Oil seal 5
NOTE:

Apply the lithium soap base grease on the
bearing and oil seal lip when installing.

Install the bearing with seal facing outward.

Use a socket that matches the outside diam-
eter of the race of the bearing.

Left side of bearing shall be installed first.

Install 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