height YAMAHA YZ85 2003 Owners Manual

SPEC
2 - 1
GENERAL SPECIFICATIONS
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: YZ85 YZ85LW
YZ85R (USA)
YZ85LC (EUROPE)
YZ85(R)
(CDN, AUS, NZ, ZA)YZ85LW (EUROPE)
YZ85LWR (AUS, NZ)
Model code number: YZ85 YZ85LW
5PA4
(USA, CDN, EUROPE,
NZ, ZA)
5PA5
(AUS)5SH4
(EUROPE, NZ)
5SH5
(AUS)
Dimensions: YZ85 YZ85LW
Overall length 1,821 mm (71.7 in) 1,903 mm (74.9 in)
(USA, S, NZ, ZA)
1,818 mm (71.6 in)
(F, D, I, GB, E, CDN,
AUS)
Overall width 758 mm (28.9 in)←
Overall height 1,161 mm (45.7 in) 1,205 mm (47.4 in)
Seat height 864 mm (34.0 in) 904 mm (35.6 in)
Wheelbase 1,258 mm (49.5 in) 1,286 mm (50.6 in)
(USA, S, NZ, ZA)
1,255 mm (49.4 in)
(F, D, I, GB, E, CDN,
AUS)
Minimum ground clearance 351 mm (13.8 in) 393 mm (15.5 in)
Basic weight: YZ85 YZ85LW
With oil and full fuel tank 71 kg (156.5 lb) 73.9 kg (162.9 lb)
Engine:
Engine type Liquid cooled 2-stroke, gasoline
Cylinder arrangement Single cylinder, forward inclined
Displacement 84.7 cm
3 (2.98 Imp oz, 2.86 US oz)
Bore × stroke 47.5 × 47.8 mm (1.870 × 1.882 in)
Compression ratio 8.2 : 1
Starting system Kickstarter
Lubrication system: Premix (30 : 1) (Yamalube 2-R)
Oil type or grade (2-cycle):
Transmission oil Yamalube 4 (10W-30) or SAE 10W-30 type SE
motor oil
Periodic oil change 0.50 L (0.44 Imp qt, 0.52 US qt)
Total amount 0.55 L (0.48 Imp qt, 0.58 US qt)
Coolant capacity (including all routes): 0.54 L (0.48 Imp qt, 0.57 US qt)
Air filter: Wet type element
2

SPEC
2 - 5
MAINTENANCE SPECIFICATIONS
Crankshaft:
Crank width “A”44.90 ~ 44.95 mm
(1.768 ~ 1.770 in)----
Runout limit “C”0.03 mm (0.0012 in) 0.08 mm
(0.003 in)
Big end side clearance “D”0.20 ~ 0.70 mm
(0.008 ~ 0.028 in)----
Small end free play “F”0.5 ~ 1.2 mm
(0.020 ~ 0.047 in)2.0 mm
(0.08 in)
Clutch:
Friction plate thickness 2.9 ~ 3.1 mm
(0.114 ~ 0.122 in)2.7 mm
(0.106 in)
Quantity 7 ----
Clutch plate thickness 1.8 ~ 2.2 mm (0.071 ~ 0.087 in) ----
Quantity 6 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch spring free length 34.0 mm (1.34 in) 32.0 mm
(1.26 in)
Quantity 5 ----
Clutch housing thrust clearance 0.10 ~ 0.35 mm
(0.0039 ~ 0.0138 in)----
Clutch housing radial clearance 0.022 ~ 0.051 mm
(0.0009 ~ 0.0020 in)----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm
(0.002 in)
Kickstarter:
Type Kick and mesh type ----
Carburetor:
Type/manufacturer PWK28/ KEIHIN ----
I. D. mark 5PA1 00 ----
Main jet (M.J) #138 ----
Jet needle-clip position (J.N) NBKF-2 ----
Main nozzle (N.J)ø3.4 ----
Cutaway (C.A) 3.0 ----
Pilot jet (P.J) #45 ----
Pilot air screw (example) (P.A.S) 2 ----
Starter jet (G.S) #62 ----
Float height (F.H) 18 ~ 20 mm (0.71 ~ 0.79 in) ----Item Standard Limit

SPEC
2 - 6
MAINTENANCE SPECIFICATIONS
Reed valve:
Thickness “T”0.42 mm (0.017 in) ----
Valve stopper height 7.4 ~ 7.8 mm (0.291 ~ 0.307 in) ----
Valve bending limit ---- 0.2 mm
(0.008 in)
Cooling:
Radiator core size
Width 117.8 mm (4.64 in) ----
Height 240 mm (9.45 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm
2,
13.5 ~ 17.8 psi)----
Radiator capacity 0.32 L (0.28 Imp qt, 0.34 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit

SPEC
2 - 9
MAINTENANCE SPECIFICATIONS
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 17 × 1.40/Aluminum ----
Rear rim size/material 14 × 1.60/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428DS/DAIDO ----
Number of links 117 links + joint ----
Chain slack 35 ~ 45 mm (1.4 ~ 1.8 in) ----
Chain length (10 links) ---- 122.1 mm (4.81 in)
Front disc brake:
Disc outside dia. × Thickness 220 × 3.0 mm (8.66 × 0.12 in) 220 × 2.5 mm
(8.66 × 0.10 in)
Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 4.0 mm (0.16 in) 0.8 mm (0.03 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 22.22 mm (0.875 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 190 × 3.0 mm (7.84 × 0.12 in) 190 × 2.5 mm
(7.84 × 0.12 in)
Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 3.7 mm (0.15 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 12.7 mm (0.500 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)4 ~ 10 mm (0.16 ~ 0.39 in) ----
Clutch lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

SPEC
2 - 11
MAINTENANCE SPECIFICATIONS
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 19 × 1.40/Aluminum ----
Rear rim size/material 16 × 1.85/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428DS/DAIDO ----
Number of links 123 links + joint ----
Chain slack 35 ~ 45 mm (1.4 ~ 1.8 in) ----
Chain length (10 links) ---- 122.1 mm (4.81 in)
Front disc brake:
Disc outside dia. × Thickness 220 × 3.0 mm (8.66 × 0.12 in) 220 × 2.5 mm
(8.66 × 0.10 in)
Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 4.0 mm (0.16 in) 0.8 mm (0.03 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 22.22 mm (0.875 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 190 × 3.0 mm (7.84 × 0.12 in) 190 × 2.5 mm
(7.84 × 0.12 in)
Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 3.7 mm (0.15 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 12.7 mm (0.500 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)4 ~ 10 mm (0.16 ~ 0.39 in) ----
Clutch lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses








Every two years
OUTSIDE NUTS AND BOLTS
Retighten



AIR FILTER
Clean and lubricate
Replace




Use foam air-filter oil
FRAME
Clean and inspect



FUEL TANK, COCK
Clean and inspect



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























Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal









Suspension oil “01”
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube


Lithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten







(After
rain ride)


Molybdenum disulfide
grease
DRIVE CHAIN GUIDE, ROLLERS AND
SUPPORT
Inspect


SWINGARM
Inspect and retighten
Lube







Molybdenum disulfide
grease
RELAY ARM, CONNECTING ROD
Inspect and retighten
Lube







Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing







Lithium base grease ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks


3

3 - 18
INSP
ADJREAR BRAKE ADJUSTMENT/
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
EC364002
REAR BRAKE ADJUSTMENT
1. Check:

Brake pedal height a
Out of specification → Adjust.
Brake pedal height
a:
4 ~ 10 mm (0.16 ~ 0.39 in)
5PA30330
2. Adjust:

Brake pedal height
Pedal height adjustment steps:

Loosen the locknut 1.

Turn the adjusting nut 2 until the pedal
height a is within specified height.

Tighten the locknut.
WARNING

Adjust the pedal height between the
maximum
È and the minimum
É as
shown. (In this adjustment the bolt
3
end
b should protrude out of the lower
adjusting nut
4 but not be less than
2 mm (0.08 in)
c away from the brake
pedal
5).

After the pedal height adjustment, make
sure that the rear brake does not drag.
5PA30340
ÈÉ
5PA30350
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT
1. Remove:

Rubber cap
2. Inspect:

Brake pad thickness a
Out of limit → Replace as a set.
Brake pad thickness:
4.0 mm (0.16 in)
: 0.8 mm (0.03 in)5PA30360

4 - 10
ENGCARBURETOR AND REED VALVE
Float height
1. Measure:

Float height a
Out of specification → Adjust.
Float height:
18 ~ 20 mm (0.71 ~ 0.79 in)
Measurement and adjustment steps:

Hold the carburetor in an upside down
position.

Measure the distance between the mating
surface of the float chamber and top of the
float using a vernier calipers.
NOTE:
The float arm should be resting on the nee-
dle valve, but not compressing the needle
valve.

If the float height is not within specification,
inspect the valve seat and needle valve.

If either is worn, replace them both.

If both are fine, adjust the float height by
bending the float tab b on the float.

Recheck the float height.
5PA40180
5PA40190
EC464600
Float
1. Inspect:

Float 1
Damage → Replace.
5PA40200
EC464701
Reed valve
1. Measure:

Reed valve bending a
Out of limit → Replace.
Reed valve bending limit:
0.2 mm (0.008 in)
5PA40210

4 - 11
ENG

Valve stopper height b
Out of specification → Replace.
Valve stopper height:
7.4 ~ 7.8 mm (0.291 ~ 0.307 in)
5PA40220
EC465000
ASSEMBLY AND INSTALLATION
Reed valve
1. Install:

Reed valve 1

Reed valve stopper 2

Screw (reed valve) 3
NOTE:

Install the reed valve with the reed valve
bending as shown.

Note the cut a in the lower corner of the
reed valve and stopper.
CAUTION:
Tighten each screw gradually to avoid
warping.
5PA40230
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)
2. Install:

Reed valve assembly 1
NOTE:
Install the reed valve assembly with its projec-
tion a facing upward.
5PA40240
3. Install:

Carburetor joint 1

Bolt (carburetor joint) 2
5PA40250
T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
CARBURETOR AND REED VALVE

5 - 21
CHAS
2. Install:

Brake lever 1

Bolt (brake lever) 2

Nut (brake lever) 3
NOTE:
Apply the lithium soap base grease on the
brake lever sliding surface, bolt and contacting
surface of the brake master cylinder piston.
Rear brake master cylinder
1. Install:

Reservoir hose 1

Reservoir tank 2
5PA50620
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
5PA50630
2. Install:

Brake master cylinder 1

Bolt (brake master cylinder) 2
5PA50640
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:

Brake pedal 1

Spring 2

O-ring 3

Washer 4

Cotter pin 5
NOTE:
Apply the lithium soap base grease on the
brake pedal shaft and O-rings.5PA50650
4. Install:

Pin 1

Washer 2

Cotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTER 3.
5PA50655
FRONT BRAKE AND REAR BRAKE