clutch YAMAHA YZ85 2014 Owners Manual

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 ........... 7-28
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
U1SN82E0.book Page 1 Friday, June 7, 2013 3:51 PM

DESCRIPTION
3-3
3
EAU10431
Controls and instruments
1
2
3
4
5
1. Clutch lever (page 4-1)
2. Engine stop button (page 4-1)
3. Brake lever (page 4-2)
4. Throttle grip (page 7-15)
5. Fuel tank cap (page 4-3)U1SN82E0.book Page 3 Friday, June 7, 2013 3:51 PM

INSTRUMENT AND CONTROL FUNCTIONS
4-1
4
EAU40661
Handle bar switch
EAU53961
En gine stop button “ENGINE STOP”
Hold this button pushed until the en-
gine stops.
EAU12851
Clutch leverThe clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the han-
dlebar grip. To engage the clutch, re-
lease the lever. The lever should be
pulled rapidly and released slowly for
smooth clutch operation.
EAU12872
Shift pe dalThe 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
4ON
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
EAU13641
Starter (choke) kno
bStarting 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).
EAU13651
KickstarterTo 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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FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-2
5
Rear 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
Clutch • Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.
7-18
Throttle g rip • Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-
ble and grip housing. 7-15, 7-24
Drive chain • Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary. 7-22, 7-23
Wheels an d tires •Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
• Check for loose spokes and tighten if necessary. 7-15, 7-17
Shift pe dal • Make sure that operation is smooth.
• Correct if necessary.
7-19
Brake ped al • Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary. 7-25
Brake an d clutch levers • Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
7-24
Steerin g • Check that the handlebar can be turned smoothly and has no excessive play. 7-27
ITEM
CHECKS PAGE
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OPERATION AND IMPORTANT RIDING POINTS
6-2
6
EAU16672
ShiftingShifting 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
ECA10261
Even with the transmission in
the neutral position, do not
coast for lon g period s of time
with the eng ine off, and d o not
tow the motorcycle for lon g d is-
tances. The transmission is
properly lu bricated only when
the en gine is runnin g. Ina de-
quate lu brication may damag e
the transmission.
 Always use the clutch while
chan gin g g ears to avoi d d am-
a g in g the en gine, transmission,
an d d rive train, which are not
d esi gne d to withstan d the
shock of forced shifting.
EAU16691
To start out an d accelerate
1. 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
lever 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.
EAU16711
To decelerate
1. 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 position
U1SN82E0.book Page 2 Friday, June 7, 2013 3:51 PM

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
7-10
7
NOTICE
ECA10453
In or der to prevent clutch slip-
pa ge (since the transmission oil
also lu bricates the clutch), do
not mix any chemical additives.
Do not use oils with a d iesel
specification of “CD” or oils of a
hi gher quality than specifie d. In
a ddition, do not use oils lab eled
“ENERGY CONSERVING II” or
hi gher.
 Make sure that no forei gn mate-
rial enters the transmission.7. Start the engine, and then let it idle for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
EAU20071
CoolantThe 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.
EAUM1296
To check the coolant level1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion.TIPThe coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
 Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.2. Remove the radiator cap and
check the coolant level in the radi-
ator. WARNING! Never attempt
to remove the ra diator cap
when the en gine is hot.
[EWA10382]
TIPThe coolant should be at the bottom of
the radiator filler neck. The level will
change with variation of engine tem-
perature.1. Radiator cap
1. Correct coolant level
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
7
EAU48374
Adjustin g the clutch lever free
playThe clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch
lever free play and, if necessary, adjust
it as follows.
1. Slide the rubber cover back at the clutch lever.
2. Loosen the locknut.
3. To increase the clutch lever free play, turn the clutch lever free play
adjusting bolt in direction (a). To
decrease the clutch lever free
play, turn the adjusting bolt in di-
rection (b).
TIPIf the specified clutch lever free play
could be obtained as described above,
skip steps 4–7.4. Fully turn the adjusting bolt in di-rection (a) to loosen the clutch ca-
ble.
5. Slide the rubber cover back fur- ther down the clutch cable, and
then loosen the locknut.
6. To increase the clutch lever free play, turn the clutch lever free play
adjusting nut in direction (a). To decrease the clutch lever free
play, turn the adjusting nut in di-
rection (b).
7. Tighten the locknut at the clutch cable, and then slide the rubber
cover to its original position.
8. Tighten the locknut at the clutch lever, and then slide the rubber
cover to its original position.1. Clutch lever free play
2. Locknut
3. Clutch lever free play adjusting bolt
4. Rubber cover
1
(a)
23
4
1. Locknut
2. Clutch lever free play adjusting nut
3. Rubber cover
1
2
3
(a)(b)
U1SN82E0.book Page 18 Friday, June 7, 2013 3:51 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
7
EAU23098
Checking an d lu bricatin g the
ca blesThe 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 lubri-
cated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or re-
place it. WARNING! Dama ge to the
outer housin g of cab les may result
in internal rustin g an d cause inter-
ference with ca ble movement. Re-
place damag ed cab les as soon as
possi ble to prevent unsafe con di-
tions.
[EWA10712] EAU23115
Checkin
g an d lu bricatin g the
throttle grip an d ca bleThe operation of the throttle grip
should be checked before each ride. In
addition, the cable should be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
chart.
The throttle cable is equipped with a
rubber cover. Make sure that the cover
is securely installed. Even though the
cover is installed correctly, it does not
completely protect the cable from wa-
ter entry. Therefore, use care not to
pour water directly onto the cover or
cable when washing the vehicle. If the
cable or cover becomes dirty, wipe
clean with a moist cloth.
EAU23144
Checkin g an d lu bricatin g the
b rake an d clutch leversThe operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Brake lever
Clutch lever
Recommen ded lu bricant:
Yamaha cable lubricant or other
suitable cable lubricant
U1SN82E0.book Page 24 Friday, June 7, 2013 3:51 PM