maintenance YAMAHA YZ85 2013 Owners Manual

INTRODUCTION
EAU41544
Congratulations on your purchase of the Yamaha YZ85(D)/YZ85LW(D). This model is the result of Yamaha’s vast experi-
ence in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsman-
ship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur- rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and this
manual. If there is any question concerning this manual, please consult a Yamaha dealer.
WARNING
EWA10031
Please read this manual carefully and completely before operating this motorcycle.
WARNING
EWA14351
This motorcycle is designed and manufactured for off-road use only. It is illegal to operate this motorcycle on any
public street, road or highway. Such use is prohibited by law. This motorcycle complies with almost all state off-
highway noise level and spark arrester laws and regulations. Please check your local riding laws and regulations
before operating this motorcycle.AN IMPORTANT SAFETY MESSAGE:●
Read this manual completely before operating your motorcycle. Make sure you understand all instructions.
●
Pay close attention to the warning and notice labels on the motorcycle.
●
Never operate a motorcycle without proper training or instruction.
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INTRODUCTIONAN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warn-
ings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil-
ities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s
use of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability t o
operate the motorcycle safely.
Motorcycles are single track vehicles. Their safe use and operation are dependent upon the use of proper riding
techniques as well as the expertise of the operator. Every operator should know the following requirements before
riding this motorcycle.
He or she should:●
Obtain thorough instructions from a competent source on all aspects of motorcycle operation.
●
Observe the warnings and maintenance requirements in this Owner’s Manual.
●
Obtain qualified training in safe and proper riding techniques.
●
Obtain professional technical service as indicated in this Owner’s Manual and/or when made necessary by mechanical
conditions.
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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 ........................................... 7-18
Checking the brake lever free play ........................................... 7-19 Checking the shift pedal ............... 7-19
Checking the front and rear brake
pads .......................................... 7-20
Checking the brake fluid level ...... 7-20
Changing the brake fluid .............. 7-22
Drive chain slack .......................... 7-22
Cleaning and lubricating the drive chain .......................... 7-23
Checking and lubricating the cables ................................. 7-24
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 rear suspension ... 7-25
Lubricating the swingarm pivots ... 7-26
Checking the front fork ................. 7-26
Checking the steering .................. 7-27
Checking the wheel bearings ....... 7-27
Supporting the motorcycle ........... 7-27
Front wheel .................................. 7-28
Rear wheel ................................... 7-29
Troubleshooting ........................... 7-31
Troubleshooting charts ................. 7-32
MOTORCYCLE CARE AND
STORAGE .......................................... 8-1
Matte color caution ......................... 8-1
Care ............................................... 8-1
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2-1
2
SAFETY INFORMATION
EAU41468
Be a Responsible Owner
As the vehicle’s owner, you are respon-
sible for the safe and proper operation
of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this motorcycle.
He or she should:●
Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
●
Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
●
Obtain qualified training in safe
and proper riding techniques.
●
Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
●
Never operate a motorcycle with-
out proper training or instruction.
Take a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized motorcycle dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 5-1
for a list of pre-operation checks.
●
This motorcycle is designed for off-
road use only, therefore, it is illegal
to operate it on public streets,
roads, or highways, even a dirt or
gravel one. Off-road use on public
lands may be illegal. Please check
local regulations before riding.
●
This motorcycle is designed to car-
ry the operator only. No passen-
gers.
●
The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore: Wear a brightly colored jacket.
Use extra caution when you are approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
Ride where other motorists can see you. Avoid riding in another
motorist’s blind spot.
Never maintain a motorcycle without proper knowledge. Con-
tact an authorized motorcycle
dealer to inform you on basic
motorcycle maintenance. Cer-
tain maintenance can only be
carried out by certified staff.
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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:
ITEMCHECKS 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 ob
structions, 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. 7-20, 7-20
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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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PERIODIC MAINTENANCE AND ADJUSTMENT
7-1
7
EAU42073
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
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.
WARNING
EWA15122
Turn off the engine when performing
maintenance unless otherwise
specified.●
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
●
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 2-2 for more in-
formation about carbon monox-
ide.WARNING
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-2
7
EAU41799
Periodic maintenance and lubrication chart The following chart is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather,
terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are in
doubt as to what intervals to follow in maintaining and lubricating your motorcycle, consult your Yamaha dealer.TIPItems marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.NO. ITEM ROUTINEAfter
break-in Every
race Every
third race Every
fifth race As
required
1 *Piston Check piston for carbon deposits and cracks or dam-
age.
Clean. √
√
√
Replace. √
√
2 *Piston rings Check piston ring end gap and rings for damage.
√
Replace.
3 *Piston pin and small
end bearing
Check piston pin and small end bearing for damage. √√√
Replace. √
√
4
*Cylinder head Check cylinder head for carbon deposits.
Clean.
√
√
√
Check cylinder head gasket for damage.
Replace cylinder head gasket. Tighten cylinder head nuts if necessary. √
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
7
√
5 *Cylinder Check cylinder for score marks or wear.
Clean.
√
Replace. √
NO. ITEM ROUTINE
After
break-in Every
race Every
third race Every
fifth race As
required
6 *Clutch Check clutch housing, friction plates, clutch plates
and clutch springs for wear or damage.
Adjust. √
√
Replace. √
7 *Transmission Change 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 system Check idle gear for damage.
√
Replace if necessary.
11 *Exhaust system Check exhaust pipe and muffler for carbon deposits.
√
√
Clean. √
√
√
√
√
12
*Crankshaft Check crankshaft for carbon deposits and damage.
Clean.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
7
NO.ITEM ROUTINEAfter
break-in Every
race Every
third race Every
fifth race As
required
√
√
√
13
*Carburetor Check carburetor settings and for obstructions.
√
Adjust and clean. √
14 Spark plug Check condition.
Clean and regap.
√
Replace. √
15 Drive chain Check chain slack, alignment and condition.
Adjust and thoroughly lubricate chain with Yamaha
chain and cable lube or equivalent. √
√
√
√
√
Replace. √
16 * *
Cooling system Check coolant level and for leakage.
√
√
Check hoses for cracks or damage. √
Check radiator cap spring operation. √
Change coolant. Every 2 years√
17 *Chassis fasteners Check all chassis fitting and fasteners.
Correct or tighten if necessary. √
18 Air filter element Clean.
√
Replace. √
19 *Frame Clean and check for damage. √
20 *Fuel line Clean and check for leakage. √√
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