transmission YAMAHA YZ85 2012 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2012, Model line: YZ85, Model: YAMAHA YZ85 2012Pages: 88, PDF Size: 1.82 MB
Page 9 of 88
TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS ............................................1-1
SAFETY INFORMATION .................. 2-1
DESCRIPTION .................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................3-3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 4-1
Handlebar switch ............................ 4-1
Clutch lever .................................... 4-1
Shift pedal ......................................4-1
Brake lever ..................................... 4-2
Brake pedal .................................... 4-2
Fuel tank cap .................................. 4-3
Fuel ................................................ 4-3
Fuel tank breather hose ................. 4-5
Fuel cock ........................................ 4-5
Starter (choke) knob ....................... 4-6
Kickstarter ......................................4-6
Seat ................................................ 4-7
Adjusting the front fork ................... 4-7
Front fork bleeding ......................... 4-9
Adjusting the shock absorber assembly ..................................... 4-9
Removable sidestand ................... 4-12 FOR YOUR SAFETY
–
PRE-OPERATION CHECKS ............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS ................................ 6-1
Starting and warming up a cold engine .............................. 6-1
Starting a warm engine .................. 6-1
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 7-1
Periodic maintenance and lubrication chart .......................... 7-2
Checking the spark plug ................ 7-8
Transmission oil ............................. 7-9
Coolant ........................................ 7-10
Cleaning the air filter element ...... 7-12
Adjusting the carburetor ............... 7-14
Adjusting the engine idling speed ........................................ 7-14
Adjusting the throttle grip free play ........................................... 7-15
Tires ............................................. 7-15
Spoke wheels .............................. 7-17
Adjusting the clutch lever free play ........................................... 7-17
Checking the brake lever free play ........................................... 7-18 Checking the shift pedal ............... 7-19
Checking the front and
rear brake pads ......................... 7-19
Checking the brake fluid level ...... 7-20
Changing the brake fluid .............. 7-21
Drive chain slack .......................... 7-22
Cleaning and lubricating the drive chain .......................... 7-23
Checking and lubricating the cables ................................. 7-23
Checking and lubricating
the throttle grip and cable ......... 7-24
Checking and lubricating the brake and clutch levers ....... 7-24
Checking and lubricating the brake pedal ......................... 7-25
Lubricating the swingarm pivots ... 7-25
Lubricating the rear suspension ... 7-25
Checking the front fork ................. 7-26
Checking the steering .................. 7-26
Checking the wheel bearings ....... 7-27
Supporting the motorcycle ........... 7-27
Front wheel .................................. 7-28
Rear wheel ................................... 7-29
Troubleshooting ........................... 7-30
Troubleshooting charts ................. 7-32
MOTORCYCLE CARE AND
STORAGE .......................................... 8-1
Matte color caution ......................... 8-1
Care ............................................... 8-1
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SAFETY INFORMATION
2-2
2
Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to excessive speed or under-
cornering (insufficient lean angle
for the speed). Never travel faster
than warranted by conditions.
Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.
The posture of the operator is im-
portant for proper control. The op-
erator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcy-
cle.
Never ride under the influence of
alcohol or other drugs.
Be sure the transmission is in neu-
tral before starting the engine.Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
Always wear an approved helmet.
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison-
ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
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Page 22 of 88
SAFETY INFORMATION
2-4
2electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be
appropriate. Refer to page 7-15 for tire
specifications and more information on
replacing your tires.
Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
Remove all loose items from the
motorcycle.
Check that the fuel cock (if
equipped) is in the “ OFF” position
and that there are no fuel leaks.
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
Shift the transmission in gear (for
models with a manual transmis-
sion).
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the lo-
cation for the straps carefully so
the straps will not rub against
painted surfaces during transport.
The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce excessive-
ly during transport.
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Page 24 of 88
DESCRIPTION
3-2
3
EAU10420
Right view1. Shock absorber assembly compression damping force adjusting screw (page 4-9)
2. Kickstarter (page 4-6)
3. Front fork rebound damping force adjusting screw (page 4-7)
4. Bleed screw (page 4-9)
5. Front fork compression damping force adjusting screw (page 4-7)
6. Spark plug cap (page 7-8)
7. Transmission oil filler cap (page 7-9)
8. Coolant drain bolt (page 7-11) 9. Brake pedal (page 4-2)
10.Transmission oil drain bolt (page 7-9)
11.Shock absorber assembly rebound damping force adjusting screw
(page 4-9)U1SN80E0.book Page 2 Thursday, June 9, 2011 11:24 AM
Page 26 of 88
INSTRUMENT AND CONTROL FUNCTIONS
4-1
4
EAU40660
Handlebar switch
EAU12671
Engine stop button “ENGINE STOP ”
Hold this button pushed until the engine
stops in case of an emergency, such as
when the vehicle overturns or when the
throttle cable is stuck.
EAU12850
Clutch lever The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
EAU12871
Shift pedal The shift pedal is located on the left
side of the motorcycle and is used in
combination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
1. Engine stop button “ENGINE STOP ”
1. Clutch lever
1. Shift pedal
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INSTRUMENT AND CONTROL FUNCTIONS
4-6
4
ON
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
EAU13640
Starter (choke) knob Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the knob in direction (a) to turn on
the starter (choke).
Move the knob in direction (b) to turn off
the starter (choke).
EAU13650
Kickstarter To start the engine, fold out the kick-
starter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but force-
fully. This model is equipped with a pri-
mary kickstarter, allowing the engine to
be started in any gear if the clutch is
disengaged. However, shifting the
transmission into the neutral position
before starting is recommended.
1. Arrow mark positioned over
“ON”
1. Starter (choke) knob
1. Kickstarter lever
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Page 38 of 88
FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner ’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel
Check fuel level in fuel tank.
Always use a fresh mixture of gasoline and oil.
Check fuel line for leakage.
Check fuel tank breather hose for obstructions, cracks or damage, and check
hose connection. 4-3, 4-5
Transmission oil
Check oil level in transmission case.
If necessary, add recommended oil to specified level. 7-9
Coolant
Check coolant level.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage. 7-10
Front brake
Check 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 specified brake fluid to specified level.
Check hydraulic system for leakage. 7-19, 7-20
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OPERATION AND IMPORTANT RIDING POINTS
6-1
6
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU41307
Starting and warming up a
cold engine 1. Turn the fuel cock lever to “ON ”.
2. Shift the transmission into the neu- tral position.
3. Turn the starter (choke) on and completely close the throttle. (See
page 4-6.)
4. Start the engine by pushing the kickstarter lever down.
5. When the engine is warm, turn the starter (choke) off.TIPThe engine is warm when it responds
quickly to the throttle with the starter
(choke) turned off.NOTICE
ECA11042
For maximum engine life, never ac-
celerate hard when the engine is
cold!
EAU16660
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm. Instead, start
the engine with the throttle slightly
open.TIPIf the engine does not start after several
kicks, try again with the throttle 1/4 to
1/2 open.
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OPERATION AND IMPORTANT RIDING POINTS
6-2
6
EAU16671
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.TIPTo shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
NOTICE
ECA10260
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16690
To start out and accelerate1. Pull the clutch lever to disengage the clutch.
2. Shift the transmission into first gear.
3. Open the throttle gradually and si- multaneously release the clutch le-
ver slowly. 4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle, and at the
same time, quickly pull the clutch
lever in.
5. Shift the transmission into second gear. (Make sure not to shift the
transmission into the neutral posi-
tion.)
6. Open the throttle halfway and gradually release the clutch lever.
7. Follow the same procedure when shifting to the next gear.
EAU16710
To decelerate1. Close the throttle and apply both the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and shift the transmission into the neu-
tral position when the motorcycle
is almost completely stopped.
1. Shift pedal
2. Neutral positionU1SN80E0.book Page 2 Thursday, June 9, 2011 11:24 AM
Page 43 of 88
OPERATION AND IMPORTANT RIDING POINTS
6-3
6
EAU41503
Engine break-in
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.1. Before starting the engine, fill thefuel 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 4-1.)
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 7-8); 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 motorcy-
cle 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.
7. Drain the break-in oil-fuel mixture from the fuel tank and refill with the
specified mix. (See page 4-3.) 8. Start the engine and check the op-
eration of the motorcycle through-
out its entire operating range. Stop
the engine and check the spark
plug 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.
NOTICE
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:
Recommended 2-stroke engine oil: See page 9-1.
Mixing ratio (gasoline to oil): 15:1
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