YAMAHA YZ85 2004 Manual PDF

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 - 7
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M14 × 1.25 1 20 2.0 14
Cylinder head (nut) M8 × 1.25 4 30 3.0 22
(stud bolt) M8 × 1.25 4 13 1.3 9.4
Cylinder (nut) M8 × 1.25 4 28 2.8 20
(stud bolt) M8 × 1.25 4 13 1.3 9.4
Impeller M8 × 1.25 1 14 1.4 10
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 2 10 1.0 7.2
Air filter element M6 × 1.0 1 2 0.2 1.4
Carburetor joint M6 × 1.0 4 8 0.8 5.8
Reed valve M3 × 0.5 4 1 0.1 0.7
Exhaust pipe M6 × 1.0 2 12 1.2 8.7
Exhaust pipe stay M6 × 1.0 1 12 1.2 8.7
Silencer M6 × 1.0 1 12 1.2 8.7
Fiber (silencer) M6 × 1.0 2 12 1.2 8.7
Crankcase M6 × 1.0 11 8 0.8 5.8
Left crankcase cover M6 × 1.0 4 5 0.5 3.6
Right crankcase cover M6 × 1.0 4 10 1.0 7.2
Right crankcase cover M6 × 1.0 1 10 1.0 7.2
Clutch cover M6 × 1.0 6 10 1.0 7.2
Transmission oil drain bolt M8 × 1.25 1 10 1.0 7.2
Kickstarter crank M6 × 1.0 1 10 1.0 7.2
Primary drive gear M12 × 1.0 1 79 7.9 57
Clutch boss M12 × 1.0 1 70 7.0 50
Clutch spring M5 × 0.8 5 6 0.6 4.3
Drive sprocket M16 × 1.0 1 60 6.0 43
Crankcase bearing stopper M6 × 1.0 2 8 0.8 5.8
Crankcase oil seal holder M8 × 1.25 1 20 2.0 14
Shift pedal M6 × 1.0 1 10 1.0 7.2

SPEC
2 - 8
MAINTENANCE SPECIFICATIONS
CHASSIS
YZ85
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension:
Front fork travel 275 mm (10.8 in) ----
Fork spring free length 430 mm (16.9 in) 425 mm (16.7 in)
Spring rate, STD K = 2.84 N/mm
(0.29 kg/mm, 16.2 lb/in)----
Optional spring Yes ----
Oil capacity318 cm
3
(11.2 Imp oz, 10.8 US oz) ----
Oil level 90 mm (3.54 in) ----

(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 120 mm (3.15 ~ 4.72 in) ----
Oil grade Suspension oil “01”----
Inner tube outer diameter 36 mm (1.42 in) ----
Front fork top end 24 mm (0.94 in) ----
Rear suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Shock absorber travel 102 mm (4.02 in)←----
Spring free length 220 mm (8.66 in)←----
Fitting length 215 mm (8.46 in) 212 mm (8.35 in) ----
202.5 ~ 218.5 mm
(7.97 ~ 8.60 in)←----
Spring rate, STD K = 49.0 N/mm
(5.00 kg/mm,
280.0 lb/in)K = 45.0 N/mm
(4.60 kg/mm,
257.6 lb/in)----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)←----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)

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 - 10
MAINTENANCE SPECIFICATIONS
YZ85LW
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension:
Front fork travel 275 mm (10.8 in) ----
Fork spring free length 430 mm (16.9 in) 425 mm (16.7 in)
Spring rate, STD K = 2.94 N/mm
(0.30 kg/mm, 16.8 lb/in)----
Optional spring Yes ----
Oil capacity318 cm
3
(11.2 Imp oz, 10.8 US oz) ----
Oil level 90 mm (3.54 in) ----

(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 120 mm (3.15 ~ 4.72 in) ----
Oil grade Suspension oil “01”----
Inner tube outer diameter 36 mm (1.42 in) ----
Front fork top end Zero mm (Zero in) ----
Rear suspension: AUS, NZ EUROPE
Shock absorber travel 102 mm (4.02 in)←----
Spring free length 220 mm (8.66 in)←----
Fitting length 207 mm (8.15 in) 212 mm (8.35 in) ----
202.5 ~ 218.5 mm
(7.97 ~ 8.60 in)←----
Spring rate, STD K = 51.0 N/mm
(5.20 kg/mm,
291.2 lb/in)K = 47.0 N/mm
(4.80 kg/mm,
268.8 lb/in)----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)←----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)

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

SPEC
2 - 12
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the steering nut approximately 38 Nm (3.8 m  kg, 27 ft  lb) by using the steering
nut wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 4 Nm (0.4 m  kg, 2.9 ft  lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Upper bracket and outer tube M8 × 1.25 2 22 2.2 16
Lower bracket and outer tube M8 × 1.25 4 20 2.0 14
Upper bracket and steering stem M22 × 1.0 1 125 12.5 90
Handlebar holder and upper bracket M8 × 1.25 4 27 2.7 19
Steering stem and steering ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and front fork cap bolt M40 × 1.0 2 28 2.8 20
Front fork and base valve M22 × 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M10 × 1.0 2 15 1.5 11
Front fork bleed screw and front fork cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 × 1.0 6 7 0.7 5.1
Front fork and brake hose guide M5 × 0.8 1 4 0.4 2.2
Front fork and brake hose holder M6 × 1.0 1 10 1.0 7.2
Throttle grip cap M5 × 0.8 2 4 0.4 2.2
Throttle cable cap M4 × 0.7 2 1 0.1 0.7
Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Clutch lever holder M5 × 0.8 2 4 0.4 2.2
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Front brake hose union bolt M10 × 1.25 2 26 2.6 19
Front fork and brake caliper bracket M8 × 1.25 2 30 3.0 22
Brake caliper support bolt M8 × 1.25 1 23 2.3 17
Front brake caliper and bleed screw M7 × 1.0 1 6 0.6 4.3
Rear brake caliper and brake caliper bracket M8 × 1.25 2 23 2.3 17
Rear brake caliper and pad pin M10 × 1.0 2 18 1.8 13
Rear brake caliper and bleed screw M8 × 1.25 1 6 0.6 4.3
Front wheel axle and axle nut M12 × 1.25 1 70 7.0 50
Front brake disc M6 × 1.0 3 12 1.2 8.7
Rear brake disc M6 × 1.0 4 12 1.2 8.7
Rear brake master cylinder M6 × 1.0 2 10 1.0 7.2
Rear brake reservoir tank M6 × 1.0 1 10 1.0 7.2
Rear brake hose union bolt M10 × 1.25 2 26 2.6 19
Rear wheel axle and axle nut M14 × 1.5 1 90 9.0 65

SPEC
2 - 13
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Nipple (spoke)—64 3 0.3 2.2
Rear wheel sprocket M8 × 1.25 4 42 4.2 30
Rear brake caliper protector M6 × 1.0 1 10 1.0 7.2
Drive chain puller adjust bolt and locknut M8 × 1.25 2 16 1.6 11
Engine mounting:
Engine and frame (front) M10 × 1.25 1 69 6.9 50
Engine and frame (lower) M10 × 1.25 1 69 6.9 50
Pivot shaft and nut M12 × 1.25 1 63 6.3 45
Relay arm and frame M10 × 1.25 1 54 5.4 39
Relay arm and connecting rod M12 × 1.25 1 53 5.3 38
Connecting rod and swingarm M12 × 1.25 1 53 5.3 38
Rear shock absorber and frame M10 × 1.25 1 36 3.6 25
Rear shock absorber and relay arm M10 × 1.25 1 36 3.6 25
Rear frame (upper) M8 × 1.25 1 26 2.6 19
Rear frame (lower) M8 × 1.25 2 16 1.6 11
Swingarm and brake hose holder M5 × 0.8 4 1 0.1 0.7
Drive chain tensioner (upper) M8 × 1.25 1 23 2.3 17
Drive chain tensioner (lower) M6 × 1.0 1 10 1.0 7.2
Drive chain support M8 × 1.25 2 16 1.6 11
Drive chain support cover M6 × 1.0 1 7 0.7 5.1
Seal guard and swingarm M6 × 1.0 2 10 1.0 7.2
Fuel tank M6 × 1.0 2 7 0.7 5.1
Fuel cock M6 × 1.0 2 4 0.4 2.9
Fuel tank bracket and fuel tank M6 × 1.0 4 7 0.7 5.1
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Radiator cover M6 × 1.0 3 4 0.4 2.9
Front fender M6 × 1.0 4 7 0.7 5.1
Rear fender M6 × 1.0 4 7 0.7 5.1
Flap guard M6 × 1.0 2 7 0.7 5.1
Side cover M6 × 1.0 2 7 0.7 5.1
Seat M6 × 1.0 2 7 0.7 5.1
Number plate M6 × 1.0 1 7 0.7 5.1

SPEC
2 - 14
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Ignition timing (B.T.D.C.) 0.9 mm (0.035 in) ----
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufac-
turer5PA-00/YAMAHA ----
Charging coil 1 resistance (color) 720 ~ 1,080 Ω at 20 °C (68 °F)
(Green/White – Black/Red)----
Charging coil 2 resistance (color) 44 ~ 66 Ω at 20°C (68 °F)
(Black – Green/Blue)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20°C (68 °F)
(White/Blue – White/Red)----
CDI unit-model/manufacturer 5PA-00/YAMAHA ----
Ignition coil:
Model/manufacturer 5PA-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) ----
Secondary coil resistance 6.3 ~ 9.5 kΩ at 20 °C (68 °F) ----
Spark plug cap:
Resistance 4 ~ 6 kΩ at 20 °C (68 °F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M6 × 1.0 2 8 0.8 5.8
Rotor M10 × 1.25 1 33 3.3 24
Ignition coil M6 × 1.0 2 7 0.7 5.1

2 - 15
SPEC
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm mkg ftlb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
5PA20050
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg
× m/sec
2 Force
Nm
m  kgNewton meter
Meter kilogramN
× m
m
× kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute—Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS