transmission oil YAMAHA YZ85 2008 Owners Manual
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Page 9 of 82
TABLE OF CONTENTS
SAFETY INFORMATION .................. 1-1
Safe riding ....................................... 1-1
Location of important labels ........... 1-4
DESCRIPTION .................................. 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instruments ................2-3
INSTRUMENT AND CONTROL
FUNCTIONS....................................... 3-1
Handlebar switch ............................ 3-1
Clutch lever .................................... 3-1
Shift pedal ......................................3-1
Brake lever ..................................... 3-2
Brake pedal .................................... 3-2
Fuel tank cap .................................. 3-3
Fuel ................................................ 3-3
Fuel tank breather hose ................. 3-5
Fuel cock ........................................ 3-5
Starter (choke) knob ....................... 3-6
Kickstarter ......................................3-6
Seat ................................................ 3-6
Adjusting the front fork ................... 3-7
Front fork bleeding ......................... 3-8
Adjusting the shock absorber
assembly ..................................... 3-9
Removable sidestand ................... 3-12
PRE-OPERATION CHECKS.............. 4-1
Pre-operation check list .................. 4-2OPERATION AND IMPORTANT
RIDING POINTS................................ 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-1
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Checking the spark plug ................ 6-8
Transmission oil ............................. 6-9
Coolant ........................................ 6-10
Cleaning the air filter element ...... 6-12
Adjusting the carburetor ............... 6-14
Adjusting the engine idling
speed ........................................ 6-14
Adjusting the throttle cable free
play ........................................... 6-15
Tires ............................................. 6-15
Spoke wheels .............................. 6-17
Accessories and replacement
parts ......................................... 6-17
Adjusting the clutch lever free
play ........................................... 6-18
Checking the front brake lever
free play .................................... 6-18Checking the front and rear
brake pads ................................ 6-19
Checking the brake fluid level ...... 6-20
Changing the brake fluid .............. 6-21
Drive chain slack .......................... 6-21
Cleaning and lubricating the
drive chain ................................ 6-22
Checking and lubricating the
cables ....................................... 6-23
Checking and lubricating the
throttle grip and cable ............... 6-23
Checking and lubricating the
brake and shift pedals ............... 6-24
Checking and lubricating the
brake and clutch levers ............. 6-24
Lubricating the swingarm pivots ... 6-25
Lubricating the rear suspension ... 6-25
Checking the front fork ................. 6-25
Checking the steering .................. 6-26
Checking the wheel bearings ....... 6-27
Supporting the motorcycle ........... 6-27
Front wheel .................................. 6-28
Rear wheel ................................... 6-28
Troubleshooting ........................... 6-30
Troubleshooting charts ................. 6-31
MOTORCYCLE CARE AND
STORAGE.......................................... 7-1
Matte color caution ......................... 7-1
Care ............................................... 7-1
Storage ........................................... 7-3
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DESCRIPTION
2-2
2
EAU10420
Right view1. Shock absorber assembly compression damping force adjusting screw
(page 3-9)
2. Kickstarter (page 3-6)
3. Front fork rebound damping force adjusting screw (page 3-7)
4. Bleed screw (page 3-8)
5. Front fork compression damping force adjusting screw (page 3-7)
6. Spark plug cap (page 6-8)
7. Transmission oil filler cap (page 6-9)
8. Coolant drain bolt (page 6-11)9. Brake pedal (page 3-2)
10.Transmission oil drain bolt (page 6-9)
11.Shock absorber assembly rebound damping force adjusting screw
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PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Always use a fresh mixture of gasoline and oil.
Check fuel line for leakage.3-3
Transmission oilCheck oil level in transmission case.
If necessary, add recommended oil to specified level.6-9
CoolantCheck coolant level.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-10
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-19, 6-20
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-19, 6-20
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-18
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-15, 6-23
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OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU41502
Engine break-in 1. Before starting the engine, fill the
fuel tank with a break-in oil-fuel
mixture as follows.
2. Start and warm up the engine.
Check the operation of the controls
and the engine stop button. (See
page 3-1.)
3. Operate the motorcycle in the low-
er gears at moderate throttle open-
ings for five to eight minutes. Stop
the engine and check the spark
plug condition (see page 6-8); it
will show a rich condition during
break-in.
4. Allow the engine to cool. Restart
the engine and operate the motor-
cycle as in the step above for five
minutes. Then, very briefly shift to
the higher gears and check the
full-throttle response. Stop the en-
gine and check the spark plug.5. After again allowing the engine to
cool, restart and run the motor-
cycle for five more minutes. Full
throttle and the higher gears may
be used, but sustained full-throttle
operation should be avoided. Stop
the engine and check the spark
plug again.
6. Allow the engine to cool, remove
the cylinder head and cylinder, and
inspect the piston and cylinder.
Remove any high spots on the pis-
ton with #600-grit wet sandpaper.
Clean all components and careful-
ly reassemble the cylinder head
and cylinder.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
7. Drain the break-in oil-fuel mixture
from the fuel tank and refill with the
specified mix. (See page 3-3.)
8. Start the engine and check the op-
eration of the motorcycle through-
out its entire operating range. Stop
the engine and check the sparkplug condition. Restart the motor-
cycle and ride it for about 10 to 15
more minutes. The motorcycle will
now be ready to ride normally.
After the engine break-in period, thor-
oughly check the motorcycle for loose
parts, oil leakage and any other prob-
lems. Be sure to inspect and make ad-
justments thoroughly, especially cable
and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tight-
en if necessary.
CAUTION:
ECA15560
When any of the following parts
have been replaced, they must
be broken in.
Cylinder or crankshaft:
About one hour of break-in op-
eration is necessary.
Piston, rings or transmission
gears:
These parts require about 30
minutes of break-in operation at
half-throttle or less. Observe the
condition of the engine carefully
during operation.
Recommended 2-stroke engine oil:
See page 8-1.
Mixing ratio (gasoline to oil):
15:1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
√
5
*CylinderCheck cylinder for score marks or wear.
Clean.√
Replace.√ NO. ITEM ROUTINEAfter
break-inEvery
raceEvery
third raceEvery
fifth raceAs
required
6*ClutchCheck clutch housing, friction plates, clutch plates
and clutch springs for wear or damage.
Adjust.√ √
Replace.√
7*TransmissionChange the transmission oil.√
Check transmission for damage.√
Replace bearings.√
8*Shift forks, guide bars,
shift cam Replace if necessary. Check all parts for wear and damage.
√
9*Rotor nut
(flywheel magneto)Tighten.√√√
10*Kickstarter systemCheck idle gear for damage.
√
Replace if necessary.
11*Exhaust system Check exhaust pipe and muffler for carbon deposits.√ √
Clean.√
√
√ √
√ 12*CrankshaftCheck crankshaft for carbon deposits and damage.
Clean.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6 2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
EAU41441
Transmission oil The transmission oil must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the transmission oil must be
changed at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place the motorcycle on a level
surface and hold it in an upright po-
sition.
3. Place an oil pan under the trans-
mission to collect the used oil.
4. Remove the oil filler cap and drain
bolt to drain the oil from the trans-
mission.5. Install the transmission oil drain
bolt, and then tighten it to the spec-
ified torque.
6. Add the specified amount of the
recommended transmission oil,
and then install and tighten the oil
filler cap.
Tightening torque:
Spark plug:
20 Nm (2.0 m·kgf, 14 ft·lbf)
1. Oil filler cap
2. Transmission oil drain bolt
Tightening torque:
Transmission oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0.50 L (0.53 US qt) (0.44 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
CAUTION:
ECA10452
In order to prevent clutch slip-
page (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-rial enters the transmission.
7. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUM1292
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
2. Remove the radiator cap and
check the coolant level in the radi-
ator.
NOTE:
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
NOTE:The coolant should be at the bottom of
the radiator filler neck. The level will
change with variation of engine temper-ature.1. Radiator cap
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU22730
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU41410
To check the drive chain slack
1. Install the removable sidestand
and place the motorcycle on it.NOTE:When checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU41480
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing bolt on each side of the
swingarm in direction (b), and then
push the rear wheel forward.
Drive chain slack:
35.0–45.0 mm (1.38–1.77 in)
1. Drive chain slack
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SPECIFICATIONS
8-1
8
Dimensions:Overall length:
YZ85 1818 mm (71.6 in)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)
YZ85 1821 mm (71.7 in) (ZAF)
YZ85LW 1903 mm (74.9 in)
YZ85LWX 1903 mm (74.9 in)
YZ85X 1818 mm (71.6 in)
Overall width:
758 mm (29.8 in)
Overall height:
YZ85 1161 mm (45.7 in)
YZ85LW 1205 mm (47.4 in)
YZ85LWX 1205 mm (47.4 in)
YZ85X 1161 mm (45.7 in)
Seat height:
YZ85 864 mm (34.0 in)
YZ85LW 904 mm (35.6 in)
YZ85LWX 904 mm (35.6 in)
YZ85X 864 mm (34.0 in)
Wheelbase:
YZ85 1255 mm (49.4 in)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)
YZ85 1258 mm (49.5 in) (ZAF)
YZ85LW 1286 mm (50.6 in)
YZ85LWX 1286 mm (50.6 in)
YZ85X 1255 mm (49.4 in)Ground clearance:
YZ85 351 mm (13.82 in)
YZ85LW 393 mm (15.47 in)
YZ85LWX 393 mm (15.47 in)
YZ85X 351 mm (13.82 in)
Weight:With oil and fuel:
YZ85 71.0 kg (157 lb)
YZ85LW 73.9 kg (163 lb)
YZ85LWX 73.9 kg (163 lb)
YZ85X 71.0 kg (157 lb)Engine:Engine type:
Liquid cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
84.7 cm³
Bore × stroke:
47.5 × 47.8 mm (1.87 × 1.88 in)
Compression ratio:
8.20 :1
Starting system:
Kickstarter
Lubrication system:
PremixEngine oil:Type:
YAMALUBE 2-RTransmission oil:Type:
YAMALUBE 4 (10W30) or SAE 10W30
type SE motor oilOil change quantity:
0.50 L (0.53 US qt) (0.44 Imp.qt)
Cooling system:Radiator capacity (including all routes):
0.54 L (0.57 US qt) (0.48 Imp.qt)Air filter:Air filter element:
Wet elementFuel:Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
5.0 L (1.32 US gal) (1.10 Imp.gal)Carburetor:Manufacturer:
KEIHIN
Type × quantity:
PWK28 x 1Spark plug (s):Manufacturer/model:
NGK/BR10EG
Spark plug gap:
0.5–0.6 mm (0.020–0.024 in)Clutch:Clutch type:
Wet, multiple-discTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
65/18 (3.611)
Secondary reduction system:
Chain drive
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INDEX
AAccessories and replacement parts ..... 6-17
Air filter element, cleaning .................... 6-12BBrake and clutch levers, checking
and lubricating .................................... 6-24
Brake and shift pedals, checking
and lubricating .................................... 6-24
Brake fluid, changing ............................ 6-21
Brake fluid level, checking .................... 6-20
Brake lever ............................................. 3-2
Brake pedal ............................................ 3-2CCables, checking and lubricating .......... 6-23
Carburetor, adjusting ............................ 6-14
Care ........................................................ 7-1
Clutch lever............................................. 3-1
Clutch lever free play, adjusting ........... 6-18
Coolant ................................................. 6-10DDrive chain, cleaning and lubricating .... 6-22
Drive chain slack .................................. 6-21EEngine break-in ...................................... 5-3
Engine idling speed .............................. 6-14
Engine, starting a warm .......................... 5-1
Engine stop button.................................. 3-1FFront and rear brake pads, checking .... 6-19
Front brake lever free play, checking ... 6-18
Front fork, adjusting ................................ 3-7
Front fork, bleeding................................. 3-8
Front fork, checking .............................. 6-25
Fuel......................................................... 3-3Fuel cock ................................................. 3-5
Fuel tank breather hose .......................... 3-5
Fuel tank cap........................................... 3-3
HHandlebar switch..................................... 3-1IIdentification numbers ............................. 9-1KKickstarter ............................................... 3-6LLabels, location of ...................................1-4MMatte color, caution .................................7-1
Model label .............................................. 9-1PParking ....................................................5-4
Part locations .......................................... 2-1
Periodic maintenance and
lubrication chart.....................................6-2
Pre-operation check list........................... 4-2RRear suspension, lubricating ................. 6-25SSafety information ...................................1-1
Seat ......................................................... 3-6
Shifting ....................................................5-2
Shift pedal ............................................... 3-1
Shock absorber assembly, adjusting ...... 3-9
Sidestand .............................................. 3-12
Spark plug, checking ...............................6-8
Specifications .......................................... 8-1
Starter (choke) knob................................ 3-6
Starting and warming up a cold
engine ................................................... 5-1Steering, checking ................................ 6-26
Storage ................................................... 7-3
Supporting the motorcycle .................... 6-27
Swingarm pivots, lubricating ................. 6-25
TThrottle cable free play, adjusting ......... 6-15
Throttle grip and cable, checking
and lubricating .................................... 6-23
Tires ...................................................... 6-15
Transmission oil ...................................... 6-9
Troubleshooting .................................... 6-30
Troubleshooting charts ......................... 6-31VVehicle identification number .................. 9-1WWheel bearings, checking..................... 6-27
Wheel (front) ......................................... 6-28
Wheel (rear) .......................................... 6-28
Wheels .................................................. 6-17
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