washer YAMAHA YZ85 2003 Owners Manual

1 - 4
GEN
INFO
IMPORTANT INFORMATION
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is overhauled.
All gasket surfaces, oil seal lips, and O-
rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
5PA10120
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s) 1 and oil seal(s) 2
with their manufacturer’s marks or numbers
facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-weight
lithium base grease to the seal lip(s). Oil
the bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
5PA10130
5PA10140

1 - 17
GEN
INFO
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good overall
performance, and extend the life of many com-
ponents.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering. A plastic bag secured with a
rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprock-
ets, or wheel axles.
3. Rinse the dirt and degreaser off with a gar-
den hose; use only enough pressure to do
the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been
hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess
water from the chain with a paper towel
and lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
8. Automotive wax may be applied to all
painted or chromed surfaces. Avoid combi-
nation cleaner-waxes, as they may contain
abrasives.
9. After completing the above, start the
engine and allow it to idle for several min-
utes.

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:

Coolant drain bolt 1
3. Remove:

Radiator cap
Drain the coolant completely.
4. Clean:

Cooling system
Thoroughly flush the cooling system with
clean tap water.
5. Install:

Copper washer

Coolant drain bolt
5PA30030
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
6. Fill:

Radiator

Engine
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 - 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 - 15
INSP
ADJ
SILENCER FIBER REPLACEMENT
SILENCER FIBER REPLACEMENT
1. Remove:

Seat

Right side cover

Bolt (silencer) 1

Silencer 2

Bolt (fiber) 3

Washer
5PA30260
2. Remove:

Inner pipe 1
3. Replace:

Fiber 2
4. Install:

Inner pipe
NOTE:
Fully apply Quick gasket® (Yamaha bond
No.1215) or equivalent as shown.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No.1215:
90890-85505
5PA30270
5. Install:

Washer

Bolt (fiber) 1

Silencer 2

Bolt (silencer) 3

Right side cover

Seat
5PA30280
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

3 - 34
INSP
ADJ

Check the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.

Install the upper bracket 5, washer, steer-
ing stem nut 6, handlebar 7, handlebar
upper holder 8 and number plate 9.
NOTE:

The upper handlebar holder should be
installed with the punched mark a for-
ward.

Insert the end of fuel breather hose 0 into
the hole of the steering stem.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.
T R..
Steering stem nut:
125 Nm (12.5 m  kg, 90 ft  lb)
Handlebar upper holder:
27 Nm (2.7 m  kg, 19 ft  lb)
Pinch bolt (upper bracket):
22 Nm (2.2 m  kg, 16 ft  lb)
Number plate:
7 Nm (0.7 m  kg, 5.1 ft  lb)
5PA30760
STEERING HEAD INSPECTION AND ADJUSTMENT

4 - 23
ENG
NOTE:
When you purchase a cylinder, you cannot
designate its size. Choose the piston that
matches the above chart.
ASSEMBLY AND INSTALLATION
Piston ring and piston
1. Install:

Piston ring 1
NOTE:

Take care not to scratch the piston or dam-
age the piston ring.

Align the piston ring gap with the pin 2.

After installing the piston ring, check the
smooth movement of it.
5PA40620
2. Install:

Gasket (cylinder) 1

Small end bearing 2

Dowel pin 3
NOTE:

Apply the engine oil on the bearing (crank-
shaft and connecting rod) and connecting
rod big end washers.

Install the gasket with the seal print side
toward the crankcase.
5PA40630
CYLINDER HEAD, CYLINDER AND PISTON

4 - 25
ENG
4. Install:

O-ring 1
NOTE:
Apply the lithium soap base grease on the O-
rings.
5PA40690
5. Install:

Cylinder head 1

Copper washer 2

Nut (cylinder head) 3
NOTE:
Tighten the nuts (cylinder head) in stage, using
a crisscross pattern.
5PA40700
T R..30 Nm (3.0 m · kg, 22 ft · lb)
6. Install:

Spark plug 1

Spark plug cap 2

Radiator hose 1 3

Radiator hose 2 4
5PA40710
T R..20 Nm (2.0 m · kg, 14 ft · lb)
CYLINDER HEAD, CYLINDER AND PISTON