brake YAMAHA YZ85 2010 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
7


Be sure the valve stem is posi-
tioned straight. A tilted valve
stem indicates that the tire has
slipped from its original posi-
tion on the rim. Rotate the tire
so that the valve stem is posi-
tioned straight.
If the center tread depth reaches the
specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
WARNING
EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING
EWA14390


Have a Yamaha dealer replace
excessively worn tires. Operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
Minimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
Front tire:
Size:
YZ85 70/100-17 40M
YZ85LW 70/100-19 42M
YZ85LWZ 70/100-19 42M
YZ85Z 70/100-17 40M
Manufacturer/model:
YZ85 DUNLOP/D739FA (ZAF)
YZ85 DUNLOP/D756F
(AUT)(BEL)(CHE)(DEU)(DNK)(ES
P)(FIN)(FRA)(GBR)(GRC)(IRL)(IT
A)(NLD)(NOR)(POL)(PRT)(SVN)(
SWE)
YZ85LW DUNLOP/D739FA (ZAF)
YZ85LW DUNLOP/D756F
(AUT)(BEL)(CHE)(DEU)(DNK)(ES
P)(FIN)(FRA)(GBR)(GRC)(IRL)(IT
A)(NLD)(NOR)(POL)(PRT)(SVN)(
SWE)
YZ85LWZ DUNLOP/D756F
YZ85Z DUNLOP/D756F
Rear tire:
Size:
YZ85 90/100-14 49M
YZ85LW 90/100-16 52M
YZ85LWZ 90/100-16 52M
YZ85Z 90/100-14 49M
Manufacturer/model:
DUNLOP/D756
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
7decrease the clutch lever free play,
turn the adjusting nut in direction
(b).
7. Tighten the locknut at the clutch
cable.
8. Tighten the locknut at the clutch le-
ver, and then slide the rubber cov-
er to its original position.
EAU37912
Checking the front brake lever
free play There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14211
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the vehicle. Air in the
hydraulic system will diminish thebraking performance, which may re-
sult in loss of control and an acci-
dent.1. No brake lever free play
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
7
EAU44820
Checking the shift pedal The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
EAU22390
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22410
Front brake pads
Each front brake pad is provided with a
wear indicator, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicator while applying the
brake. If a brake pad has worn to thepoint that the wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU46291
Rear brake pads
Each rear brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that a wear
indicator groove almost appears, have
a Yamaha dealer replace the brake
pads as a set.
1. Brake pad wear indicator
1. Brake pad wear indicator groove
U5PA88E0.book Page 19 Tuesday, June 9, 2009 8:44 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
7
EAU22580
Checking the brake fluid level Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
7
EAU22731
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.

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.TIPWhen checking and adjusting the drive
chain slack, there should be no weight
on 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.
EAU41482
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
drive chain slack adjusting bolt on
each side of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting bolt on each side
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
Drive chain slack:
35.0–45.0 mm (1.38–1.77 in)
1. Drive chain slack
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
7
EAU41842
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe conditions.[EWA10711]EAU23111
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU23142
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Yamaha Chain and Cable Lube or 4-
stroke engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
7
EAU23182
Checking and lubricating the
brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
EAUM1650
Lubricating the swingarm piv-
ots The swingarm pivots must be lubricat-
ed at the intervals specified in the peri-
odic maintenance and lubrication chart.
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-25
7
EAU23250
Lubricating the rear suspen-
sion The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU23272
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-28
7
EAU25080
Rear wheel
EAU41312
To remove the rear wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 7-26.
3. Loosen the locknut and drive chain
adjusting bolt on each side of the
swingarm.
4. Remove the axle nut and washer.5. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
TIP

If the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.


The drive chain does not need to
be disassembled in order to re-
move and install the rear wheel.
6. While supporting the brake caliper
and slightly lifting the wheel, pull
the wheel axle out.TIPA rubber mallet may be useful to tap the
wheel axle out.7. Remove the wheel. NOTICE: Do
not apply the brake after the
wheel has been removed to-
gether with the brake disc, oth-
erwise the brake pads will be
forced shut.
[ECA11071]
EAU41325
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.
1. Axle nut
2. Washer
3. Locknut
4. Drive chain slack adjusting bolt
1. Wheel axle
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-29
7 2. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the right-hand side.
TIP

Make sure that the slot in the brake
caliper bracket is fit over the retain-
er on the swingarm.


Make sure that there is enough
space between the brake pads be-
fore installing the wheel.
3. Install the washer and axle nut.
4. Lower the rear wheel so that it is
on the ground, install the remov-
able sidestand, and then rest the
motorcycle on it.5. Adjust the drive chain slack. (See
page 7-21.)
6. Tighten the locknuts and the axle
nut to their specified torques.
EAU25871
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING
EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
1. Retainer
2. Slot
21
Tightening torque:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
U5PA88E0.book Page 29 Tuesday, June 9, 2009 8:44 AM