brake YAMAHA YZ85 2004 Service Manual

5 - 18
CHAS
Front brake caliper
1. Install:

Sleeve boot 1
On brake caliper bracket 2.
5PA50490
2. Install:

Pin boot 1
On brake caliper 2.
NOTE:
Apply the lithium soap base grease on the pin
boot inner surface.
5PA50500
3. Install:

Brake caliper bracket 1

Bolt (brake caliper bracket) 2

Brake pad 3
5PA50510
T R..30 Nm (3.0 m · kg, 22 ft · lb)
4. Install:

Brake caliper 1
NOTE:

Apply the lithium soap base grease on the
guide pin 2.

Install the brake caliper into the guide pin
and turn it clockwise.
5PA50520
5. Install:

Brake caliper support bolt 1
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
5PA50530
T R..23 Nm (2.3 m · kg, 17 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 19
CHAS
Rear brake caliper
1. Install:

Pad support 1

Brake pad 2

Pad pin 3
NOTE:

Install the brake pad fitted with brake pad
shim 4 on the brake caliper piston side.

Temporarily tighten the pad pins at this point.5PA50540
2. Install:

Brake caliper 1

Bolt (brake caliper front side) 2

Bolt (brake caliper rear side) 3

Plate

Protector 4

Bolt (protector) 5
3. Tighten

Pad pin 6
Brake master cylinder kit
1. Clean:

Brake master cylinder

Brake master cylinder kit
Clean them with brake fluid.
2. Install:

Brake master cylinder cup (primary) 1

Brake master cylinder cup (secondary) 2
To brake master cylinder piston 3.
NOTE:
Apply the brake fluid on the brake master cylin-
der cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
ÈFront
ÉRear
5PA50550
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..18 Nm (1.8 m · kg, 13 ft · lb)
ÈÉ
5PA50560
ÈÉ
5PA50570
FRONT BRAKE AND REAR BRAKE

5 - 20
CHAS
3. Install:

Spring 1
To brake master cylinder piston 2.
NOTE:
Install the spring at the smaller dia. side.
ÈFront
ÉRear
ÈÉ
5PA50580
4. Install:
[Front]

Brake master cylinder kit 1

Washer 2

Circlip 3

Brake master cylinder boot 4
To brake master cylinder 5.
[Rear]

Brake master cylinder kit 1

Push rod 2

Circlip 3

Brake master cylinder boot 4
To brake master cylinder 5.
NOTE:

Apply the brake fluid on the brake master cyl-
inder kit.

Apply the lithium soap base grease on the tip
of the push rod.

When installing the circlip, use a long nose
circlip pliers.
ÈFront
ÉRear
Front brake master cylinder
1. Install:

Brake master cylinder 1

Brake master cylinder bracket 2

Bolt (brake master cylinder bracket) 3
NOTE:

Install the bracket so that the arrow mark
a
face upward.

First tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
È
5PA50590
É
5PA50600
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
5PA50610
FRONT BRAKE AND REAR BRAKE

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

5 - 22
CHAS
Front brake hose
1. Install:

Copper washer 1

Brake hose 2

Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as shown and lightly
touches the projection b on the brake
master cylinder.
5PA50660
T R..30 Nm (3.0 m · kg, 22 ft · lb)
5PA50670
2. Install:

Protector 1

Bolt (protector) 2
NOTE:
Fit the brake hose into the guides a of the pro-
tector.
5PA50680
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:

Brake hose holder 1

Bolt (brake hose holder) 2
NOTE:

Align the brake hose holder with the projec-
tion a on the front fork and clamp the brake
hose.

Pass the brake hose behind the rib b on the
front fork.
5PA50690
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 23
CHAS
4. Install:

Copper washer 1

Brake hose 2

Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a lightly touches the projection b on
the brake caliper.
5PA50700
5PA50710
T R..26 Nm (2.6 m · kg, 19 ft · lb)
Rear brake hose
1. Install:

Copper washer 1

Brake hose 2

Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as shown and lightly
touches the projection b on the brake
master cylinder.
5PA50720
5PA50730
T R..26 Nm (2.6 m · kg, 19 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 24
CHAS
2. Install:

Copper washer 1

Brake hose 2

Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a lightly touches the projection b on
the brake caliper.
5PA50740
5PA50750
T R..26 Nm (2.6 m · kg, 19 ft · lb)
3. Install:

Brake hose holder 1

Screw (brake hose holder) 2
5PA50760
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 25
CHAS
Brake fluid
1. Fill:

Brake fluid
Until the fluid level reaches “LOWER” level
line a.
WARNING

Use only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.

Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor perfor-
mance.

Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
ÈFront
ÉRear
2. Air bleed:

Brake system
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section in the CHAPTER 3.
Recommended brake fluid:
DOT #4
È
5PA50770
É
5PA50780
3. Inspect:

Brake fluid level
Fluid at lower level → Fill up.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section in the CHAPTER 3.
FRONT BRAKE AND REAR BRAKE

5 - 26
CHAS
4. Install:
[Front]

Reservoir float

Diaphragm

Brake master cylinder cap 1

Screw (brake master cylinder cap) 2
[Rear]

Diaphragm

Reservoir tank cap 1

Bolt (reservoir tank) 2
CAUTION:
After installation, while pulling the brake
lever in or pushing down on the brake
pedal, check whether there is any brake
fluid leaking where the union bolts are
installed respectively at the brake master
cylinder and brake caliper.
ÈFront
ÉRear
È
5PA50800
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)É
5PA50810
FRONT BRAKE AND REAR BRAKE

5 - 27
CHASFRONT FORK
EC550000
FRONT FORK
5PA50820
Extent of removal:
1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front brake caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Number plate
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Brake hose holder 1
3 Pinch bolt (upper bracket) 1 Only loosening.
4 Cap bolt 1 Loosen when disassembling the front fork.
5 Pinch bolt (lower bracket) 2 Only loosening.
6 Front fork 1
1