radiator YAMAHA YZ85 2006 User Guide

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 - 7
INSP
ADJ
RADIATOR CAP INSPECTION
CAUTION:

Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.

Do not use water containing impurities or
oil.
7. Install:

Radiator cap
Start the engine and warm it up for a sev-
eral minutes.
8. Check:

Coolant level
Coolant level low → Add coolant. Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING

When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.

When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.

When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:

Seal (radiator cap) 1

Valve and valve seat 2
Crack/damage → Replace.
Exist fur deposits 3 → Clean or replace.
5PA30050

3 - 8
INSP
ADJRADIATOR CAP OPENING PRESSURE INSPECTION/
COOLING SYSTEM INSPECTION
RADIATOR CAP OPENING PRESSURE
INSPECTION
1. Attach:

Radiator cap tester 1

Radiator cap tester adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
3. Inspect:

Pressure
Impossible to maintain the specified pres-
sure for 10 seconds → Replace.
Radiator cap tester:
YU-24460-01/90890-01325
Radiator cap tester adapter:
YU-33984/90890-01352
Radiator cap opening pressure:
93 ~ 123 kPa (0.93 ~ 1.23 kg/cm2,
13.2 ~ 17.5 psi)
5PA30060
COOLING SYSTEM INSPECTION
1. Inspect:

Coolant level
2. Attach:

Radiator cap tester 1

Radiator cap tester adapter 2
3. Apply the specified pressure.
Radiator cap tester:
YU-24460-01/90890-01325
Radiator cap tester adapter:
YU-33984/90890-01352
Standard pressure:
180 kPa (1.8 kg/cm2, 25.6 psi)
5PA30070

3 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
CAUTION:

Do not apply pressure more than speci-
fied pressure.

Radiator should be filled fully.
4. Inspect:

Pressure
Impossible to maintain the specified pres-
sure for 10 seconds → Repair.

Radiator 1

Radiator hose joint 2
Coolant leakage → Repair or replace.

Radiator hose 3
Swelling → Replace.
5PA30080
CLUTCH ADJUSTMENT
1. Check:

Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play
a:
10 ~ 15 mm (0.39 ~ 0.59 in)
5PA30090
2. Adjust:

Clutch lever free play
NOTE:

Make minute adjustment on the lever side.

After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:

Loosen the locknut 1.

Turn the adjuster 2 until free play a is
within the specified limits.

Tighten the locknut.
5PA30100

4 - 3
ENGRADIATOR
EC450001
RADIATOR
5PA40030
Extent of removal:
1 Radiator removal
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Air scoop Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Radiator guard 1
2 Radiator hose clamp 4 Only loosening.
3 Radiator hose 1 1
4 Radiator hose 2 1
5 Radiator breather hose 1
6Radiator 1
1

4 - 4
ENGRADIATOR
EC456000
HANDLING NOTE
WARNING
Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury.
When the engine has cooled, open the radi-
ator cap by the following procedure:
Place a thick rag, like a towel, over the radi-
ator cap, slowly rotate the cap counter-
clockwise to the detent. This procedure
allows any residual pressure to escape.
When the hissing sound has stopped,
press down on the cap while turning coun-
terclockwise and remove it.
EC454000
INSPECTION
Radiator
1. Inspect:

Radiator core 1
Obstruction → Blow out with compressed
air through rear of the radiator.
Bent fin → Repair or replace.
5PA40040
EC455000
ASSEMBLY AND INSTALLATION
Radiator
1. Install:

Radiator breather hose 1
To radiator 2.
5PA40050
2. Install:

Radiator 1

Bolt (radiator) 2
5PA40060

4 - 5
ENGRADIATOR
3. Install:

Radiator hose 1 1

Radiator hose 2 2
Refer to “CABLE ROUTING DIAGRAM”
section in the CHAPTER 2.
4. Tighten:

Radiator hose clamp
5PA40070
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)
5. Install:

Radiator guard 1

Bolt (radiator guard) 2
NOTE:
Fit the hooks a on the inner side first into the
radiator.
5PA40080

4 - 15
ENGCYLINDER HEAD, CYLINDER AND PISTON
EC470000
CYLINDER HEAD, CYLINDER AND PISTON
EC478000
CYLINDER HEAD AND CYLINDER
5PA40390
Extent of removal:
1 Cylinder head removal
2 Cylinder removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD AND CYLIN-
DER REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Radiator hose 1 Disconnect at cylinder head side.
Radiator hose 2 Disconnect at radiator side.
1 Spark plug 1
2 Nut (cylinder head) 4 Loosen each nut 1/4 turn, and remove
them after all nuts are loosened.
3 Cylinder head 1
4 Nut (cylinder) 4
5 Cylinder 1
1
2

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

4 - 33
ENGKICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
PRIMARY DRIVE GEAR
5PAR0008
Extent of removal:
1 Primary drive gear removal
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVE GEAR
REMOVAL
Drain the transmission oil. Refer to“TRANSMISSION OIL
REPLACEMENT” section in the CHAP-
TER 3.
Brake pedal
Radiator hose 2 Disconnect at water pump side.
1 Kickstarter crank 1
2 Right crankcase cover 1
3 Primary driven gear 1 Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
4 Nut (primary drive gear) 1 Refer to “REMOVAL POINTS”.
5Primary drive gear
1
1