Yamaha Yz85 2007 Service Manual
Yamaha Yz85 2007 Service Manual
Yamaha Yz85 2007 Service Manual
YZ85W1
YZ85(W)
YZ85LW(W)
SERVICE MANUAL
5PA-28197-E0
EAS00000
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the
vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols to indicate the subject of each
chapter.
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Carburetor(s)
Electrical system
Tuning
Troubleshooting
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS
SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
CHASSIS
CHAS
4
ENGINE
ENG
5
COOLING SYSTEM
COOL
6
CARBURETOR
CARB
7
ELECTRICAL SYSTEM
ELEC
8
TUNING
TUN
9
TROUBLESHOOTING TRBL
SHTG 10
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
GENERAL INFORMATION
VEHICLE IDENTIFICATION
EAS00017
EAS00018
MODEL LABEL
The model label is affixed to the frame. This
information will be needed to order spare
parts.
1-1
GEN
IMPORTANT INFORMATION INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced as
an assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS00022
lip
lip
spring
oil
grease
1-2
GEN
IMPORTANT INFORMATION INFO
EAS00023
EAS00024
CAUTION:
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip , make sure the
sharp-edged corner is positioned opposite
the thrust that the circlip receives.
Shaft
1-3
GEN
FUEL AND ENGINE MIXING OIL INFO
Recommended fuel
Premium unleaded gasoline
only with a research octane
number of 95 or higher.
NOTE:
If knocking or pinging occurs, use a different
brand of gasoline or higher octane grade.
CAUTION:
Never mix two types of oil in the same
batch; clotting of the oil could result. If you
wish to change oil types, be sure to drain
the fuel tank and the carburetor float bowl
of old premix prior to filling with the new
YAMALUBE “2-R” type.
Mixing oil
Recommended oil
Yamalube “2-R”
(Yamalube racing 2-cycle oil)
Mixing ratio: 30 : 1
If unavailable, use an equivalent
type of oil.
1-4
GEN
CHECKING THE CONNECTIONS INFO
EAS00026
4. Connect:
• lead
• coupler
• connector
NOTE:
Make sure all connections are tight.
5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112, YU-3112-C
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-5
GEN
SPECIAL TOOLS INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
90890-01268
This tool is used to loosen and tighten the
exhaust and steering ringnut.
Crankshaft installing tool Crankshaft installing tool
For EUR, OCE
90890-01274 Crankshaft installing pot
90890-01275
90890-01277 Crankshaft installing bolt
For U.S.A, CAN Adapter (M10)
YU-90050
YM-1277 These tools are used to install the crankshaft.
Piston pin puller set
90890-01304
YU-1304
This tool is used to remove the piston pin.
1-6
GEN
SPECIAL TOOLS INFO
Tool No. Tool name / Function Illustration
Radiator cap tester Radiator cap tester
90890-01325
YU-24460-01 Radiator cap tester adapter
Radiator cap
tester adapter These tools are used for checking the cooling
90890-01352
YU-33984 system.
Steering nut wrench
90890-01403
YU-33975
This tool is used when tighten the steering
ring nut to specification.
Rod holder
90890-01434
YM-01434
This tool is used to hold the fork spring.
Rod puller Rod puller
90890-01437
YM-01437 Rod puller attachment (M10)
Rod puller
attachment These tools are used to pull up the fork
90890-01436
YM-01436 damper rod.
Fork seal diver
90890-01442
YM-01442
This tool is used when install the fork oil seal.
Damper rod holder
90890-01454
YM-01454
Use this tool to remove and install the damper
rod.
Drive gear holder
90890-01495
YM-01495
This tool is used when removing or tightening
the primary drive gear securing nut.
Pocket tester
90890-03112
YU-3112-C
Use this tool to inspect the coil resistance,
output voltage and amperage.
Universal clutch holder
90890-04086
This tool is used to hold the clutch when
YM-91042
removing or installing the clutch boss
securing nut.
1-7
GEN
SPECIAL TOOLS INFO
Tool No. Tool name / Function Illustration
Dynamic spark tester
Ignition checker
90890-06754
YM-34487
This instrument is necessary for checking the
ignition system components.
Yamaha bond No.1215
(Three Bond No.1215®)
90890-85505
This sealant (Bond) is used for crankcase
mating surface, etc.
1-8
SPEC
CHAPTER 2
SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code YZ85
5PAG (EUR, CAN), 5PAH (AUS,NZL) •••
YZ85LW
5SHG (EUR), 5SHH (AUS,NZL) •••
Dimensions
Overall length 1,818 mm (71.6 in) (YZ85) •••
1,903 mm (74.9 in) (YZ85LW) •••
Overall width 758 mm (29.8 in) •••
Overall height 1,161mm (45.7 in) (YZ85) •••
1,205 mm (47.4 in) (YZ85LW) •••
Seat height 864 mm (34.0 in) (YZ85) •••
904 mm (35.6 in) (YZ85LW) •••
Wheelbase 1,255 mm (49.4 in) (YZ85) •••
1,286 mm (50.6 in) (YZ85LW) •••
Minimum ground clearance 351 mm (13.8 in) (YZ85) •••
393 mm (15.5 in) (YZ85LW) •••
Dry weight
Without oil and fuel 66 kg (145.5 lb) (YZ85) •••
69 kg (152.2 lb) (YZ85LW) •••
2-1
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Liquid cooled 2-stroke, gasoline •••
Displacement 84.7 cm3 (5.17 cu.in) •••
Cylinder arrangement Single cylinder, forward inclined •••
Bore × stroke 47.5 × 47.8 mm (1.870 × 1.882 in) •••
Compression ratio 8.2 : 1 •••
Fuel
Recommended fuel Premium unleaded gasoline only •••
Fuel tank capacity
Total 5.0L (1.09 Imp gal, 1.30 US gal) •••
Lubrication system Premix (30 : 1) (Yamalube 2-R) •••
Transmission oil
Recommended oil Yamalube 4 (10W-30) or SAE 10W-30 •••
API service SG type or higher
JASO standard MA
Periodic oil change 0.50 L (0.44 Imp qt, 0.53 US qt) •••
Total amount 0.55 L (0.48 Imp qt, 0.58 US qt) •••
Cooling system
Coolant capacity (including all routes) 0.54 L (0.48 Imp qt, 0.57 US qt) •••
Radiator capacity 0.32 L (0.28 Imp qt, 0.34 US qt) •••
Radiator cap opening pressure 93 ~ 123 kPa (0.93 ~ 1.23 kg / cm2, •••
13.2 ~ 17.5 psi)
Radiator core
Width 117.8 mm (4.64 in) •••
Height 240.0 mm (9.45 in) •••
Depth 32.0 mm (1.26 in) •••
Water pump
Water pump type Single suction centrifugal pump •••
Reduction ratio 25 / 18 (1.388) •••
Starting system Kickstarter •••
Spark plug
Model (manufacturer) × quantity BR10EG (NGK) × 1 •••
Spark plug gap 0.5 ~ 0.6 mm (0.0197 ~ 0.0236 in) •••
Cylinder head
Volume 7.14 cm3 (0.44 cu.in) •••
Max. warpage ••• 0.03 mm
(0.0012 in)
2-2
ENGINE SPECIFICATIONS SPEC
2-3
ENGINE SPECIFICATIONS SPEC
2-4
ENGINE SPECIFICATIONS SPEC
2-5
ENGINE SPECIFICATIONS SPEC
2-6
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Semi double cradle •••
Material Steel •••
Caster angle 26.3° (YZ85) •••
26.9° (YZ85LW) •••
Trail 88.0 mm (3.46 in) (YZ85) •••
105.5 mm (4.15 in) (YZ85LW) •••
Front wheel
Wheel type Spoke wheel •••
Rim
Size 17 × 1.40 (YZ85) •••
19 × 1.40 (YZ85LW) •••
Material Aluminum •••
Wheel travel 275 mm (10.83 in) •••
Wheel runout
Radial wheel runout limit ••• 2.0 mm
(0.08 in)
Lateral wheel runout limit ••• 2.0 mm
(0.08 in)
Rear wheel
Wheel type Spoke wheel •••
Rim
Size 14 × 1.60 (YZ85) •••
16 × 1.85 (YZ85LW) •••
Material Aluminum •••
Wheel travel 282 mm (11.10 in) (YZ85) •••
287 mm (11.30 in) (YZ85LW) •••
Wheel runout
Radial wheel runout limit ••• 2.0 mm
(0.08 in)
Lateral wheel runout limit ••• 2.0 mm
(0.08 in)
2-7
CHASSIS SPECIFICATIONS SPEC
2-8
CHASSIS SPECIFICATIONS SPEC
2-9
CHASSIS SPECIFICATIONS SPEC
2-10
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Ignition system
Ignition system type CDI •••
Ignition timing (B.T.D.C.) 0.9 mm (0.035 in) •••
Advancer type Digital •••
C.D.I.
Magneto model (manufacturer) 5PA-01 (YAMAHA) •••
Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F) (W / L-W / R) •••
Charging coil 1 resistance (color) 720 ~ 1,080 Ω at 20 °C (68 °F) (G / W-B / R) •••
Charging coil 2 resistance (color) 44 ~ 66 Ω at 20 °C (68 °F) (B-G / L) •••
C.D.I. unit model (manufacturer) 5PA-01 (YAMAHA) •••
Ignition coils
Model (manufacturer) 2JN (YAMAHA) •••
Minimum ignition spark gap 6 mm (0.24 in) •••
Primary coil resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) •••
Secondary coil resistance 6.3 ~ 9.5 kΩ at 20 °C (68 °F) •••
Spark plug cap
Material Resin •••
Resistance 5 kΩ •••
2-11
CONVERSION TABLE /
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC
EAS00028 EAS00030
2-12
TIGHTENING TORQUES SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
2-13
TIGHTENING TORQUES SPEC
CHASSIS TIGHTENING TORQUES
2-14
TIGHTENING TORQUES SPEC
NOTE:
1. First, tighten the steering nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut
wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 4 Nm (0.4 m•kg, 2.9 ft•lb).
2-15
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EAS00031
EAS00032
CHASSIS
Lubrication point Lubricant
Steeling bearings and bearing race (upper and lower)
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Throttle tube guide inner surface
Rear brake pedal
Swing arm bearing and bushing inner surface
Swingarm oil seal , dust seal and bushing
Pivot shaft
Reray arm oil seal, bearing, bushing, collar and bolt surface
Connecting rod oil seal, bearing, bushing and bolt surface
Front wheel oil seal (left and right)
Front wheel axle shaft
Front wheel collar
Rear wheel oil seal (left and right)
Rear wheel axle shaft
Rear wheel collar
2-16
CABLE ROUTING SPEC
EAS00035
CABLE ROUTING
Cable guide Radiator breather hose
Brake hose Clutch cable
Throttle cable Spark plug lead
Fuel tank breather hose Radiator hose
Engine stop switch lead Brake hose holder
Ground lead
Ignition coil
Primary coil lead (orange color)
Damper
Clamp
Air vent hoses
CDI magneto lead
Carburetor overflow hose
Transmission oil breather hose
2-17
CABLE ROUTING SPEC
Pass the fuel tank breather hose between the han- Securely install the spark plug cap to the spark
dlebar and tension bar, then insert its end into the plug. Route the spark plug lead by the inner side of
hole of the steering stem. the vehicle than the radiator hose and throttle
Fasten the ground lead together with the ignition cable.
coil. Clamp the brake hose with the brake hose holder.
Insert the primary coil lead (orange color) in the Fit the brake hose into the guides of the protector.
ignition coil. 40 mm (1.57 in)
Pass the transmission oil breather hose through
the wire holder located at the right side of the vehi-
cle. Route the air vent hose and carburetor over-
flow hose from the left side of the vehicle.
Do not flatten out the radiator breather hose.
2-18
CABLE ROUTING SPEC
Sub-wire harness Route the clutch cable in front of the throttle cable.
CDI unit Pass the transmission oil breather hose through
Ignition coil the hose guide.
Clutch cable Clamp it between these parts.
Cable guide Clamp it using the white PVC tape as a guide.
Transmission oil breather hose Pass the sub-wire harness on the left side of the
CDI unit band CDI unit.
Clamp Cut the tip of the clamp near the position of chain
Brake hose double-dashed line.
Brake hose holder Tighten the sub-wire harness to the CDI unit. Posi-
Brake fluid reservoir hose tion the lock section under the CDI unit.
Reservoir tank Route the reservoir tank hose by the outer side of
Brake master cylinder the vehicle than the brake hose.
Pass the brake fluid reservoir hose through the
cable guides.
2-19
CABLE ROUTING SPEC
Install the clip pointing the clamp section to the
rear side.
Touch the brake pipe to the stopper.
When installing the brake hose, install it so that the
bend section of the brake hose attachment is
pointed in the direction as shown in the illustration.
2-20
CABLE ROUTING SPEC
Master cylinder This is the number plate attaching section. The
Throttle cable clutch cable and throttle cable shall be routed
Clutch cable crossways above the number plate attaching sec-
Clamp tion. At this time, make sure to route the clutch
Engine stop switch lead cable to the front side of the throttle cable.
Brake hose Route the clutch cable in front of the throttle cable.
Cable guide Fasten the engine stop switch lead to the handle-
bar with the plastic band.
Pass the brake hose in front of the number plate.
Vertical direction
40° ± 10°
2-21
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
ADJUSTING THE PILOT AIR SCREW . . . . . . . . . . . . . . . . . . . . . . . 3-5
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . 3-5
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . 3-6
CHECKING THE SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
CHANGING THE TRANSMISSION OIL . . . . . . . . . . . . . . . . . . . . . . 3-9
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . 3-10
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . 3-10
CHECKING THE CARBURETOR JOINT . . . . . . . . . . . . . . . . . . . . . 3-12
CHECKING THE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
CHECKING THE CRANKCASE BREATHER HOSE. . . . . . . . . . . . . 3-13
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3-13
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3-15
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . 3-19
CHECKING THE FRONT AND REAR BRAKE PADS . . . . . . . . . . . . 3-20
CHECKING THE FRONT AND REAR BRAKE HOSES . . . . . . . . . . 3-20
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . 3-21
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . 3-22
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . 3-24
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . 3-26
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . 3-28
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
CHECKING AND TIGHTENING THE SPOKES . . . . . . . . . . . . . . . . 3-32
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . 3-32
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . 3-32
INTRODUCTION / PERIODIC MAINTENANCE CHK
AND LUBRICATION INTERVALS ADJ
3
EAS00036
EAS00037
3-1
PERIODIC MAINTENANCE CHK
AND LUBRICATION INTERVALS ADJ
After Every Every Every As
NO. ITEM ROUTINE
break-in race third race fifth race required
• Check coolant level and for leakage. √ √
• Check hoses for cracks or damage. √
16 * Cooling system
• Check radiator cap spring operation. √
• Change coolant. Every 2 years √
• Check all chassis fitting and fasteners.
17 * Chassis fasteners √ √
• Correct or tighten if necessary.
• Clean. √ √
18 * Air filter element
• Replace. √
19 * Frame • Clean and check for damage. √ √
20 * Fuel line • Clean and check for leakage. √ √
• Adjust lever position and pedal height.
• Lubricate pivot points.
• Check brake disk surface.
√ √
• Check fluid level and for leakage.
21 * Brakes • Tighten brake disk bolts, caliper bolts, master cylinder
bolts and union bolts.
• Replace brake pads. √
• Replace brake fluid. Every year √
• Check operation and for oil leakage.
• Adjust if necessary.
√ √
• Clean dust seal and lubricate with lithium-soap-based
22 * Front fork grease.
• Replace fork oil. √ √
• Replace oil seals. √
• Check operation and adjust.
√ √
• Tighten if necessary.
√
Shock absorber (After
23 *
assembly washing
• Lubricate with molybdenum disulfide grease. √
the vehicle
or riding in
the rain)
Drive chain roller and • Check for wear or damage.
24 * √
support guide • Replace if necessary.
• Check operation and tighten if necessary. √ √
25 * Rear suspension
• Lubricate with molybdenum disulfide grease. √ √
• Check operation, free play, and tighten if necessary. √ √
26 * Steering head • Clean and lubricate with lithium-soap-based grease. √
• Replace bearings. √
• Check tire air pressure, wheel runout, spokes for loose-
√ √
ness, and tires for wear.
• Tighten sprocket bolts if necessary. √ √
27 * Tires and wheels • Check wheel bearings for looseness. √
• Lubricate wheel bearings with lithium-soap-based
√
grease.
• Replace wheel bearings. √
Moving parts and
28 * • Lubricate. √ √
cables
• Check operation and free play.
Throttle grip housing
29 * • Adjust the throttle cable free play if necessary. √ √
and cable
• Lubricate the throttle grip housing and cable.
NOTE:
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
CHK
SEAT, SIDE COVERS AND FUEL TANK ADJ
EAS00042
3-3
CHK
SEAT, SIDE COVERS AND FUEL TANK ADJ
3-4
ADJUSTING THE PILOT AIR SCREW / CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
ENGINE
ADJUSTING THE PILOT AIR SCREW
1. Adjust:
• pilot air screw
NOTE:
To optimize the fuel flow at a smaller throttle
opening, each vehicles pilot air screw has
been individually set at the factory. Before
adjusting the pilot air screw, turn it in fully and
count the number of turns. Record this number
as the factory-set number of turns out.
EAS00054
3. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
3-5
CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
EAS00058
1. Check:
• throttle cable free play
Out of specification → Adjust.
2. Adjust:
• throttle cable free play
Handlebar side
a. Loosen the locknut .
b. Turn the adjusting nut in direction or
until the specified throttle cable free play
is obtained.
Throttle cable free play is
Direction
increased.
Throttle cable free play is
Direction
decreased.
c. Tighten the locknut.
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
3-6
CHK
CHECKING THE SPARK PLUG ADJ
EAS00060
CAUTION:
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from fall-
ing into the cylinder.
3. Check:
• spark plug type
Incorrect → Change.
4. Check:
• electrode
Damage / wear → Replace the spark plug.
• insulator
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• spark plug gap
(with a wire thickness gauge)
Out of specification → Regap.
7. Install:
• spark plug
Spark plug
20 Nm (2.0 m•kg, 14 ft•lb)
NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
8. Connect:
• spark plug cap
3-7
CHK
CHECKING THE IGNITION TIMING ADJ
EAS00062
3. Adjust:
• top dead center (TDC)
4. Check:
• ignition timing
Punch mark on rotor should be aligned with
punch mark on stator.
Not aligned → Adjust.
5. Adjust:
• ignition timing
3-8
CHECKING THE IGNITION TIMING / CHK
CHANGING THE TRANSMISSION OIL ADJ
Screw (stator)
8 Nm (0.8 m•kg, 5.8 ft•lb)
6. Check:
• ignition timing
Re-check the ignition timing.
EAS00074
Quantity
Total amount
0.5 L (0.44 Imp qt, 0.53 US qt)
8. Install:
• transmission oil filler cap
9. Start the engine, warm it up for several min-
utes, and then turn it off.
10.Check:
• oil leakage
3-9
ADJUSTING THE CLUTCH CABLE FREE PLAY / CHK
CLEANING THE AIR FILTER ELEMENT ADJ
EAS00081
2. Adjust:
• clutch cable free play
EAS00090
3-10
CHK
CLEANING THE AIR FILTER ELEMENT ADJ
• fitting bolt
• washer
• air filter guide
• air filter element
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible overheat-
ing.
3. Clean:
• air filter element
(with solvent)
NOTE:
After cleaning, remove the remaining solvent
by squeezing the element.
CAUTION:
• Do not twist the element when squeezing
the element.
• Leaving too much of solvent in the ele-
ment may result in poor starting.
4. Check:
• air filter element
Damage → Replace.
5. Apply:
• foam-air-filter oil or equivalent oil
To the element.
NOTE:
Squeeze out the excess oil. Element should be
wet but not dripping.
6. Install:
• air filter guide
• air filter element
3-11
CLEANING THE AIR FILTER ELEMENT / CHECKING CHK
THE CARBURETOR JOINT / CHECKING THE HOSES ADJ
7. Apply:
• lithium-soap-base grease
On the matching surface on air filter ele-
ment.
8. Install:
• air filter element
• washer
• fitting bolt 2 Nm (0.2 m•kg, 1.4 ft•lb)
NOTE:
• Install the air filter element with its projection
facing upward.
• Make sure the air filter element is properly
installed in the air filter case.
EAS00094
EAS00096
3-12
CHECKING THE CRANKCASE BREATHER HOSE / CHK
CHECKING THE EXHAUST SYSTEM ADJ
EAS00098
EAS00100
3-13
CHK
CHECKING THE COOLANT LEVEL ADJ
EAS00102
2. Remove:
• radiator cap
CAUTION:
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause seri-
ous injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radia-
tor cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped,
press down on the radiator cap and turn it
counterclockwise to remove.
3. Check:
• coolant level
Coolant level low → Add coolant.
CAUTION:
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
6. Install:
• radiator cap
3-14
CHECKING THE COOLING SYSTEM / CHK
CHANGING THE COOLANT ADJ
EAS00104
EAS00105
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause seri-
ous injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radia-
tor cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped,
press down on the radiator cap and turn it
counterclockwise to remove.
3. Drain:
• coolant
4. Install:
• copper washer
• coolant drain bolt
3-15
CHK
CHANGING THE COOLANT ADJ
5. Fill:
• coolant
(with the specified amount of the recom-
mended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
0.54 L (0.48 Imp qt, 0.57 US qt)
CAUTION:
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with
water.
• Do not mix different types of antifreeze.
6. Install:
• radiator cap
7. Start the engine, warm it up for several min-
utes, and then stop it.
3-16
CHANGING THE COOLANT / CHK
ADJUSTING THE FRONT BRAKE ADJ
8. Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
EAS00106
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
• brake lever position
(distance from the throttle grip to the
brake lever)
Locknut
5 Nm (0.5 m•kg, 3.6 ft•lb)
CAUTION:
After adjusting the brake lever position,
make sure there is no brake drag.
3-17
CHK
ADJUSTING THE REAR BRAKE ADJ
EAS00111
2. Adjust:
• brake pedal height
WARNING
Adjust the pedal height between the maxi-
mum and the minimum as shown. (In
this adjustment, the bolt end should
protrude out of the lower adjusting nut
but not be less than 2.0 mm (0.08 in)
away from the brake pedal ).
Locknut
17 Nm (1.7 m•kg, 12 ft•lb)
CAUTION:
After adjusting the brake pedal position,
make sure there is no brake drag.
3-18
CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
EAS00115
2. Check:
• brake fluid level
Below the minimum level mark → Add
the recommended brake fluid to the proper
level.
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
3-19
CHECKING THE FRONT AND REAR BRAKE PADS / CHK
CHECKING THE FRONT AND REAR BRAKE HOSES ADJ
EAS00118
Front brake
Rear brake
EAS00131
3-20
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00135
WARNING
Bleed the hydraulic brake system when-
ever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
1. Bleed:
• hydraulic brake system
3-21
BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING CHK
THE SHIFT PEDAL / ADJUSTING THE DRIVE CHAIN SLACK ADJ
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
EAS00137
EAS00138
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
3-22
CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
1. Elevate the rear wheel by placing the suit-
able stand under the engine.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
3. Check:
• drive chain slack
Out of specification → Adjust.
4. Adjust:
• drive chain slack
Locknut
16 Nm (1.6 m•kg, 11 ft•lb)
3-23
LUBRICATING THE DRIVE CHAIN / CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
EAS00143
Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
EAS00147
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness → Adjust the steering
head.
3. Remove:
• handlebar
• upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
4. Adjust:
• steering head
3-24
CHECKING AND ADJUSTING THE STEERING HEAD / CHK
CHECKING THE FRONT FORK ADJ
a. Remove the steering ring nut using the
steering nut wrench .
b. Tighten the steering ring nut with a
steering nut wrench .
NOTE:
• Set the torque wrench at a right angle to the
steering nut wrench.
• Install the steering ring nut with its larger
chamfered side downward.
WARNING
Do not overtighten the ring nut.
5. Install:
• upper bracket
• handlebar
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
EAS00149
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
3-25
CHECKING THE FRONT FORK / CHK
ADJUSTING THE FRONT FORK LEGS ADJ
2. Check:
• inner tube
Damage / scratches → Replace.
• oil seal
Oil leakage → Replace.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
• front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 4.
EAS00155
WARNING
• Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
dling and loss of stability.
• Securely support the vehicle so that there
is no danger of it falling over.
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
3-26
CHK
ADJUSTING THE FRONT FORK LEGS ADJ
1. Adjust:
• rebound damping
Rebound damping is
Direction increased (suspension is
harder).
Rebound damping is
Direction decreased (suspension is
softer).
Adjusting positions
Minimum: 20 clicks in direction *
Standard: 7 clicks in direction *
Maximum: 1 clicks in direction *
* with the adjusting screw fully turned-in
direction
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• compression damping
Compression damping is
Direction increased (suspension is
harder).
Compression damping is
Direction decreased (suspension is
softer).
Adjusting positions
Minimum: 20 clicks in direction *
Standard (YZ85): 10 clicks in
direction *
Standard (YZ85LW): 9 clicks in
direction *
Maximum: 1 clicks in direction *
* with the adjusting screw fully turned-in
direction
3-27
CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
EAS00159
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
Spring preload
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• spring preload
NOTE:
• Be sure to remove all dirt and mud from
around the locknut and adjuster before
adjustment.
• The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
Spring preload is
Direction increased (suspension is
harder).
Spring preload is
Direction decreased (suspension is
softer).
Adjusting length
Standard (YZ85): 215 mm (8.46 in)
Standard (YZ85LW):
207 mm (8.15 in) (for AUS, NZL)
212 mm (8.35 in) (for EUR)
3-28
CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• rebound damping
Rebound damping is
Direction increased (suspension is
harder).
Rebound damping is
Direction decreased (suspension is
softer).
Adjusting positions
Minimum: 20 clicks in direction *
Standard (YZ85): 6 clicks in direction *
Standard (YZ85LW): 12 clicks in
direction * (for EUR)
Standard (YZ85LW): 7 clicks in
direction * (for AUS, NZL)
Maximum: 1 clicks in direction *
* with the adjusting knob fully turned-in
direction
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• compression damping
Compression damping is
Direction increased (suspension is
harder).
Compression damping is
Direction decreased (suspension is
softer).
3-29
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY / CHK
CHECKING THE TIRES ADJ
NOTE:
This is the position which is back by the spe-
cific number of clicks from the fully turned-in
position. (Which align the punch mark on
the adjuster with the punch mark on the
bracket.)
Adjusting positions
Minimum: 20 clicks in direction *
Standard (YZ85): 9 clicks in direction *
Standard (YZ85LW): 12 clicks in
direction * (for EUR)
Standard (YZ85LW): 7 clicks in
direction * (for AUS, NZL)
Maximum: 1 clicks in direction *
* with the adjusting knob fully turned-in
direction
EAS00164
WARNING
• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including rider) and the antici-
pated riding speed.
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-30
CHK
CHECKING THE TIRES ADJ
2. Check:
• tire surfaces
Damage / wear → Replace the tire.
WARNING
• Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
• When using tube tires, be sure to install
the correct tube.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
• Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality
replacement.
• After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufac-
turer and of the same design. No guaran-
tee concerning handling characteristics
can be given if a tire combination other
than one approved by Yamaha is used on
this vehicle.
Front tire
YZ85:
YZ85LW:
Rear tire
YZ85:
3-31
CHECKING THE TIRES / CHECKING AND TIGHTENING THE SPOKES /
LUBRICATING THE LEVERS AND PEDALS / CHK
LUBRICATING THE REAR SUSPENSION ADJ
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn.
NOTE:
Align the mark with the valve installation
point.
EAS00169
2. Tighten:
• spoke (with a spoke wrench )
3 Nm (0.3 m•kg, 2.2 ft•lb)
NOTE:
Be sure to tighten the spokes before and after
break-in. After a practice or a race check
spokes for looseness.
EAS00171
Recommended lubricant
Lithium-soap-based grease
EAS00174
Recommended lubricant
Molybdenum disulfide grease
3-32
CHAS
CHAPTER 4
CHASSIS
CHASSIS
FRONT WHEEL AND BRAKE DISC
4-1
FRONT WHEEL AND BRAKE DISC CHAS
4-2
FRONT WHEEL AND BRAKE DISC CHAS
EAS00519
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2. Remove:
• front brake caliper
NOTE:
Do not apply the brake lever when removing
the brake caliper.
3. Elevate:
• front wheel
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
4. Remove:
• front wheel axle nut
• front wheel axle
• front wheel
• collar
EAS00526
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent wheel
axle.
4-3
FRONT WHEEL AND BRAKE DISC CHAS
2. Check:
• tire
• front wheel
Damage / wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Check:
• spokes
Refer to “CHECKING AND TIGHTENING
THE SPOKES” in chapter 3.
NOTE:
After tightening the spokes, measure the front
wheel runout.
4. Measure:
• front wheel radial runout
• front wheel lateral runout
Over the specified limits → Replace.
5. Check:
• collars
Damage / wear → Replace.
6. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
Damage / wear → Replace.
7. Replace:
• wheel bearings
• oil seals
4-4
FRONT WHEEL AND BRAKE DISC CHAS
c. Remove the wheel bearings with a gen-
eral bearing puller .
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing inner race
or balls . Contact should be made only
with the outer race .
NOTE:
Use a socket that matches the diameter of
the wheel bearing outer race and oil seal.
4-5
FRONT WHEEL AND BRAKE DISC CHAS
EAS00531
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
4. Adjust:
• brake disc deflection
4-6
FRONT WHEEL AND BRAKE DISC CHAS
EAS00546
Recommended lubricant
Lithium-soap-based grease
2. Install:
• collar
• front wheel
• front wheel axle
NOTE:
Install the brake disc between the brake pads
correctly.
3. Tighten:
• front wheel axle 70 Nm (7.0 m•kg, 51 ft•lb)
4-7
REAR WHEEL AND BRAKE DISC CHAS
AS00551
4-8
REAR WHEEL AND BRAKE DISC CHAS
4-9
REAR WHEEL AND BRAKE DISC CHAS
EAS00560
4-10
REAR WHEEL AND BRAKE DISC CHAS
4-11
REAR WHEEL AND BRAKE DISC CHAS
EAS00561
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• protector
• brake caliper
NOTE:
Do not depress the brake pedal when remov-
ing the brake caliper.
3. Loosen:
• locknut
• adjusting bolt
4. Remove:
• wheel axle nut
• wheel axle
• rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
5. Remove:
• left collar
• right collar
4-12
REAR WHEEL AND BRAKE DISC CHAS
EAS00566
EAS00568
4-13
REAR WHEEL AND BRAKE DISC CHAS
2. Replace:
• rear wheel sprocket
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00572
Recommended lubricant
Lithium-soap-based grease
2. Tighten:
• rear wheel axle nut
90 Nm (9.0 m•kg, 65 ft•lb)
• brake caliper bolts (side)
23 Nm (2.3 m•kg, 17 ft•lb)
(front)
10 Nm (1.0 m•kg, 7.2 ft•lb)
4-14
FRONT AND REAR BRAKES CHAS
EAS00577
4-15
FRONT AND REAR BRAKES CHAS
EAS00578
4-16
FRONT AND REAR BRAKES CHAS
EAS00579
CAUTION:
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
WARNING
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake com-
ponents.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS00581
1. Remove:
• brake caliper
2. Remove:
• brake pads
4-17
FRONT AND REAR BRAKES CHAS
3. Measure:
• brake pad wear limit
Out of specification → Replace the brake
pads as a set.
4. Install:
• brake pads
NOTE:
Always install new brake pads and a new
brake pad spring as a set.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
5. Lubricate:
• brake pad bolts
• brake caliper guide bar
Recommended lubricant
Lithium-soap-based grease
CAUTION:
• Do not allow grease to contact the brake
pads.
• Remove any excess grease.
6. Install:
• brake caliper 23 Nm (2.3 m•kg, 17 ft•lb)
7. Check:
• brake fluid level
Below the minimum level mark → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
4-18
FRONT AND REAR BRAKES CHAS
8. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00583
1. Loosen:
• brake pad pins
2. Remove:
• brake caliper
3. Remove:
• brake pad pins
• brake pads
(along with the brake pad shims)
• brake pad spring
4. Measure:
• brake pad wear limit
Out of specification → Replace the brake
pads as a set.
5. Install:
• brake pad spring
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad pins
• brake caliper
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
4-19
FRONT AND REAR BRAKES CHAS
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
6. Tighten:
• brake pad pins
18 Nm (1.8 m•kg, 13 ft•lb)
• brake caliper (front)
23 Nm (2.3 m•kg, 17 ft•lb)
(rear)
23 Nm (2.3 m•kg, 17 ft•lb)
LOCK TITE®
7. Check:
• brake fluid level
Below the minimum level mark → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-20
FRONT AND REAR BRAKES CHAS
EAS00584
4-21
FRONT AND REAR BRAKES CHAS
EAS00585
4-22
FRONT AND REAR BRAKES CHAS
EAS00586
4-23
FRONT AND REAR BRAKES CHAS
EAS00587
4-24
FRONT AND REAR BRAKES CHAS
EAS00588
1. Remove:
• union bolt
• copper washers
• brake hose
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
2. Remove:
• brake master cylinder bracket
• brake master cylinder
3. Remove:
• brake master cylinder boot
• circlip
EAS00589
2. Remove:
• brake master cylinder
3. Remove:
• circlip
• brake master cylinder joint
4-25
FRONT AND REAR BRAKES CHAS
EAS00592
3. Check:
• rear brake fluid reservoir
Cracks / damage → Replace.
• rear brake fluid reservoir diaphragm
Cracks / damage → Replace.
4. Check:
• front brake master cylinder reservoir
Cracks/damage → Replace.
• front brake master cylinder reservoir dia-
phragm
Damage / wear → Replace.
5. Check:
• brake hoses
Cracks / damage / wear → Replace.
Refer to “CHECKING THE FRONT AND
REAR BRAKE HOSES” in chapter 3.
4-26
FRONT AND REAR BRAKES CHAS
EAS00598
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents.
1. Install:
• brake master cylinder
9 Nm (0.9 m•kg, 6.5 ft•lb)
NOTE:
• Install the brake master cylinder holder
with the “UP” mark facing up.
• First, tighten the upper bolt, then the lower
bolt.
2. Install:
• copper washers
• brake hose
• union bolt 26 Nm (2.6 m•kg, 19 ft•lb)
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
Install the brake hose so that its pipe por-
tion directs as shown and lightly
touches the projection on the brake
master cylinder.
4-27
FRONT AND REAR BRAKES CHAS
NOTE:
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
3. Fill:
• brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could
cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Below the minimum level mark → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
4-28
FRONT AND REAR BRAKES CHAS
6. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00608
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection as shown.
3. Fill:
• brake fluid reservoir
(to the maximum level mark )
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
4-29
FRONT AND REAR BRAKES CHAS
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Below the minimum level mark → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
• brake pedal operation
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.
7. Adjust:
• brake pedal position
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
4-30
FRONT AND REAR BRAKES CHAS
EAS00613
4-31
FRONT AND REAR BRAKES CHAS
EAS00614
4-32
FRONT AND REAR BRAKES CHAS
EAS00616
4-33
FRONT AND REAR BRAKES CHAS
EAS00617
4-34
FRONT AND REAR BRAKES CHAS
EAS00619
1. Remove:
• union bolt
• copper washers
• brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
• brake caliper pistons
• brake caliper piston seals
WARNING
• Cover the brake caliper pistons with a rag.
Be careful not to get injured when the pis-
tons are expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
tons.
EAS00626
4-35
FRONT AND REAR BRAKES CHAS
1. Remove:
• union bolt
• copper washers
• brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
• brake caliper piston
• brake caliper piston seals
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
EAS00633
4-36
FRONT AND REAR BRAKES CHAS
1. Check:
• brake caliper pistons
Rust / scratches / wear → Replace the brake
caliper pistons.
• brake caliper cylinders
Scratches / wear → Replace the brake cali-
per assembly.
• brake caliper body
Cracks / damage → Replace the brake cali-
per assembly.
• brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed
air.
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Front
Rear
2. Check:
• front brake caliper bracket
Cracks / damage → Replace.
• guide pin
Rust / damage → Replace.
• sleeve boot
Crack / damage → Replace.
• pin boot
Wear / damage → Replace.
EAS00634
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.
4-37
FRONT AND REAR BRAKES CHAS
1. Install:
• brake caliper bracket
30 Nm (3.0 m•kg, 22 ft•lb)
• brake pads
• brake caliper
23 Nm (2.3 m•kg, 17 ft•lb)
• copper washers
• brake hose
• union bolt 26 Nm (2.6 m•kg, 19 ft•lb)
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
When installing the brake hose onto the
brake caliper , make sure the brake pipe
touches the projection on the brake
caliper.
2. Fill:
• brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could
cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4-38
FRONT AND REAR BRAKES CHAS
3. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
• brake fluid level
Below the minimum level mark → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
5. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00642
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.
1. Install:
• brake pad spring
• brake pad shim
• brake pad pins
2. Install:
• brake caliper (front)
23 Nm (2.3 m•kg, 17 ft•lb)
(rear)
23 Nm (2.3 m•kg, 17 ft•lb)
LOCK TITE®
• protector 10 Nm (1.0 m•kg, 7.2 ft•lb)
• copper washers
• brake hose
• union bolt 26 Nm (2.6 m•kg, 19 ft•lb)
4-39
FRONT AND REAR BRAKES CHAS
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
When installing the brake hose onto the
brake caliper , make sure the brake pipe
touches the projection on the brake
caliper.
3. Fill:
• brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could
cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-40
FRONT AND REAR BRAKES CHAS
5. Check:
• brake fluid level
Below the minimum level mark → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-41
FRONT FORK CHAS
EAS00646
FRONT FORK
FRONT FORK LEGS
4-42
FRONT FORK CHAS
EAS00648
4-43
FRONT FORK CHAS
4-44
FRONT FORK CHAS
EAS00650
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2. Remove
• front wheel
• protector
• front brake caliper
• number plate
3. Loosen:
• cap bolt
4. Loosen:
• upper bracket pinch bolt
• lower bracket pinch bolts
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
5. Remove:
• front fork leg
4-45
FRONT FORK CHAS
EAS00652
Rod holder
90890-01434, YM-01434
2. Remove:
• nut
• washer
• fork spring
• spring guide
3. Drain:
• fork oil
NOTE:
Stroke the damper rod several times while
draining the fork oil.
4. Remove:
• dust seal
• oil seal clip
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
5. Remove:
• inner tube
4-46
FRONT FORK CHAS
6. Remove:
• slide metal
• oil seal washer
• oil seal
• piston metal
• oil seal clip
• dust seal
7. Remove:
• base valve
• damper rod
NOTE:
While holding the inner tube with the damper
rod holder , loosen the base valve.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• spring free length
Out of specification → Replace.
3. Check:
• damper rod
Bend / damage → Replace.
Obstruction → Blow out all of the oil pas-
sages with compressed air.
• damper rod adjusting rod
Bend / damage → Replace.
4-47
FRONT FORK CHAS
CAUTION:
• The front fork leg has a built-in damper
adjusting rod and a very sophisticated
internal construction, which are particu-
larly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
4. Check:
• base valve assembly
Damage / wear → Replace.
5. Check:
• cap bolt
Damage / wear → Replace.
• air bleed screw
Damage / wear → Replace.
EAS00661
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
When assembling the front fork leg, be sure to
replace the following parts:
– outer tube and inner tube bushing
– oil seal
– dust seal
– Before assembling the front fork leg, make
sure all of the components are clean.
4-48
FRONT FORK CHAS
1. Install:
• damper rod assembly
• inner tube
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube until it pro-
trudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
2. Install:
• gasket
• base valve
3. Tighten:
• base valve 55 Nm (5.5 m•kg, 40 ft•lb)
LOCTITE®
NOTE:
While holding the damper rod with the
damper rod holder , tighten the base valve.
4. Lubricate:
• inner tube’s outer surface
Recommended lubricant
Suspension oil “01”
5. Install:
• spring guide
• nut
NOTE:
Install the spring guide with its cut facing
downward.
4-49
FRONT FORK CHAS
6. Install:
• dust seal
• oil seal clip
• oil seal
• oil seal washer
• slide metal
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
7. Install:
• piston metal
NOTE:
Install the piston metal on to the slot on inner
tube.
8. Install:
• outer tube
9. Install:
• slide metal
• oil seal washer
(with the fork seal driver )
4-50
FRONT FORK CHAS
10.Install:
• oil seal
(with the fork seal driver )
11.Install:
• oil seal clip
NOTE:
Adjust the oil seal clip so that it fits into the
outer tube’s groove.
12.Install:
• dust seal
13.Fill:
• front fork leg
(with the specified amount of the recom-
mended fork oil)
NOTE:
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
4-51
FRONT FORK CHAS
14.Install:
• fork spring
• washer
• cap bolt
Rod puller
90890-01437, YM-01437
Rod puller attachment (M10)
90890-01436, YM-01436
Rod holder
90890-01434, YM-01434
Distance
18 mm (0.71 in)
4-52
FRONT FORK CHAS
g. Fully tighten the cap bolt onto the
damper rod by hand.
NOTE:
Make sure that there is a clearance of 0 ~ 1
mm (0 ~ 0.04 in) between the front fork cap
bolt and locknut .
Nut
15 Nm (1.5 m•kg, 11 ft•lb)
15.Install:
• protector guide .
4-53
FRONT FORK CHAS
EAS00662
2. Tighten:
• cap bolt 28 Nm (2.8 m•kg, 20 ft•lb)
3. Adjust:
• front fork top end
4. Tighten:
• upper bracket pinch bolt
22 Nm (2.2 m•kg, 16 ft•lb)
• lower bracket pinch bolt
20 Nm (2.0 m•kg, 14 ft•lb)
WARNING
Make sure the brake hoses are routed prop-
erly.
5. Install:
• protector 7 Nm (0.7 m•kg, 5.1 ft•lb)
6. Adjust:
• spring preload
• rebound damping
• compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
4-54
HANDLEBAR CHAS
EAS00664
HANDLEBAR
4-55
HANDLEBAR CHAS
4-56
HANDLEBAR CHAS
EAS00666
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2. Remove:
• grip
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
EAS00668
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS00670
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2. Install:
• handlebar
• handlebar upper holder
27 Nm (2.7 m•kg, 19 ft•lb)
CAUTION:
• First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
4-57
HANDLEBAR CHAS
NOTE:
• The upper handlebar holders should be
installed with the punched mark forward.
• First tighten the bolts on the front side of the
FWD handlebar upper holder, and then tighten the
bolts on the rear side.
3. Install:
• left grip
• apply the adhesive to the handlebar .
NOTE:
• Before applying the adhesive, wipe off grease
or oil on the handlebar surface with a lac-
quer thinner.
• Install the left grip to the handlebar so that the
arrow mark (L) faces straight upward.
4. Install:
• right grip
• apply the adhesive on the tube guide .
NOTE:
• Before applying the adhesive, wipe off grease
or oil on the tube guide surface with a lac-
quer thinner.
• Locate the mating mark on the grip as
shown.
5. Install:
• collar
• tube guide
• grip cap (upper)
• throttle cable
NOTE:
Apply the lithium soap base grease on the
throttle cable end and tube guide cable wind-
ing portion.
4-58
HANDLEBAR CHAS
6. Install:
• throttle cable cap
1 Nm (0.1 m•kg, 0.7 ft•lb)
• grip cap (lower)
4 Nm (0.4 m•kg, 2.9 ft•lb)
• cover (grip cap)
7. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
8. Install:
• brake master cylinder
• brake master cylinder bracket
9 Nm (0.9 m•kg, 6.5 ft•lb)
NOTE:
Install the bracket so that the arrow mark
face upward.
9. Install:
• engine stop switch
• clutch lever holder
4 Nm (0.4 m•kg, 2.9 ft•lb)
• clamp
NOTE:
The engine stop switch and clutch lever holder
should be installed according to the dimen-
sions shown.
15 mm
10 mm (0.6 in)
(0.4 in)
10.Install:
• clutch cable
NOTE:
Apply the lithium soap base grease on the
clutch cable end.
4-59
HANDLEBAR CHAS
11.Adjust:
• clutch lever free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PRAY” in chapter 3.
12.Clamp the clamp portion of the number
plate to the handlebar.
13.Insert the end of the fuel tank breather hose
into the hole of the steering stem.
4-60
STEERING HEAD CHAS
EAS00675
STEERING HEAD
UNDER BRACKET
4-61
STEERING HEAD CHAS
EAS00677
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2. Remove:
• steering stem nut
• washer
• upper bracket
• steering ring nut
(with the ring nut wrench )
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00682
2. Check:
• bearings
• bearing races
Damage / pitting → Replace.
4-62
STEERING HEAD CHAS
3. Replace:
• lower bearing
• bearing races
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
• Always replace the bearing balls and bearing
races as a set.
• Whenever the steering head is disassembled,
replace the dust seal.
4. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends / cracks / damage → Replace.
EAS00683
Recommended lubricant
Lithium-soap-based grease
2. Install:
• lower bracket
• upper bearing
• washer
• bearing race cover
Refer to “CHECKING THE STEERING
HEAD”.
4-63
STEERING HEAD CHAS
3. Install:
• steering ring nut
4 Nm (0.4 m•kg, 2.9 ft•lb)
(with the ring nut wrench )
4. Install:
• upper bracket
• washer
• steering stem nut
125 Nm (12.5 m•kg, 90 ft•lb)
5. Install:
• front fork legs
Refer to “INSTALLING THE FRONT FORK
LEGS”.
NOTE:
Temporarily tighten the upper and lower
bracket pinch bolts.
4-64
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00685
4-65
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00687
WARNING
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you
understand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.
• Do not tamper or attempt to open the rear
shock absorber or gas cylinder.
• Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause
an explosion due to excessive gas pres-
sure.
• Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
4-66
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00694
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• seat and right side cover
Refer to “SEAT, SIDE COVERS AND FUEL
TANK” in chapter 3.
• silencer
Refer to “EXHAUST PIPE” in chapter 5.
3. Loosen:
• air filter clamp
4. Remove:
• rear frame
5. Remove:
• rear shock absorber lower bolt
• washer
6. Remove:
• rear shock absorber upper bolt
• washer
• self-locking nut
• rear shock absorber
4-67
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00696
Recommended lubricant
Molybdenum disulfide grease
2. Install:
• rear shock absorber
NOTE:
• When installing the rear shock absorber
assembly, lift up the swingarm.
• Install the connecting arm front bolt from the
right.
3. Tighten:
• rear shock absorber upper nut
36 Nm (3.6 m•kg, 26 ft•lb)
• rear shock absorber lower bolt
36 Nm (3.6 m•kg, 26 ft•lb)
4. Install:
• rear frame (upper)
26 Nm (2.6 m•kg, 19 ft•lb)
• rear frame (lower)
16 Nm (1.6 m•kg, 12 ft•lb)
• clamp
4-68
REAR SHOCK ABSORBER ASSEMBLY CHAS
5. Install:
• silencer
Refer to “EXHAUST PIPE” in chapter 5.
• seat and right side cover
Refer to “SEAT, SIDE COVERS AND FUEL
TANK” in chapter 3.
6. Adjust
• spring preload
• rebound damping
• compression damping
Refer to “ADJUSTING THE REAR SHOCK
ABSORBER” in chapter 3.
4-69
SWINGARM AND DRIVE CHAIN CHAS
EAS00700
4-70
SWINGARM AND DRIVE CHAIN CHAS
4-71
SWINGARM AND DRIVE CHAIN CHAS
EAS00703
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
• brake hose holder and rear brake caliper
Refer to “FRONT AND REAR BRAKES”.
• left crankcase cover
Refer to “CDI MAGNETO” in chapter 5.
3. Measure:
• swingarm side play
• swingarm vertical movement
Swingarm sideplay
(at the end of the swingarm)
1.0 mm (0.04 in)
4-72
SWINGARM AND DRIVE CHAIN CHAS
EAS00706
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• master link clip
• master link
• master link plate
• drive chain
EAS00707
2. Check:
• pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash:
• pivot shaft
• collar
• bearings
4-73
SWINGARM AND DRIVE CHAIN CHAS
4. Check:
• collars
• oil seals
Damage / wear → Replace.
• bearings
Damage / pitting → Replace.
• bushings
Damage / wear → Replace.
5. Check:
• connecting rod
• relay arm
Damage / wear → Replace.
6. Check:
• bearings
• oil seals
Damage / wear → Replace.
• dust seals
Damage / pitting → Replace.
7. Check:
• bushings
Damage / wear → Replace.
• spacers
Damage / scratches → Replace.
EAS00710
4-74
SWINGARM AND DRIVE CHAIN CHAS
NOTE:
• While measuring the 15-link section, push
down on the drive chain to increase its ten-
sion.
• Perform this measurement at two or three dif-
ferent places.
2. Check:
• drive chain
Stiffness → Clean and lubricate or replace.
3. Clean:
• drive chain
4. Check:
• drive chain rollers
Damage / wear → Replace the drive chain.
• drive chain side plates
Damage / wear → Replace the drive chain.
Cracks → Replace the drive chain and
make sure the battery breather hose is
properly routed away from the drive chain
and below the swingarm.
5. Lubricate:
• drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
4-75
SWINGARM AND DRIVE CHAIN CHAS
6. Check:
• drive sprocket
• rear wheel sprocket
More than 1 / 4 tooth wear → Replace
the drive chain sprockets as a set.
Bent teeth → Replace the drive chain
sprockets as a set.
Correct
Drive chain roller
Drive chain sprocket
EAS00711
4-76
SWINGARM AND DRIVE CHAIN CHAS
2. Install:
• bearing
• oil seal
(with the relay arm)
NOTE:
• Apply the molybdenum disulfide grease on
the bearing when installing.
• Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
3. Install:
• bearing
• oil seal
(with the connecting rod)
NOTE:
• Apply the molybdenum disulfide grease on
the bearing when installing.
• Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
4. Install:
• connecting rod
53 Nm (5.3 m•kg, 38 ft•lb)
4-77
SWINGARM AND DRIVE CHAIN CHAS
5. Install:
• relay arm 54 Nm (5.4 m•kg, 39 ft•lb)
6. Install:
• swingarm
• pivot shaft
• pivot shaft nut
63 Nm (6.3 m•kg, 46 ft•lb)
7. Install:
• rear shock absorber
• rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
8. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
EAS00714
Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
2. Install:
• master link
• master link plate
4-78
SWINGARM AND DRIVE CHAIN CHAS
3. Install:
• master link clip
CAUTION:
• The closed end of the master link clip
must face in the direction of drive chain
rotation.
• Never install a new drive chain onto worn
drive chain sprockets; this will dramati-
cally shorten the drive chain’s life.
4. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
4-79
ENG
CHAPTER 5
ENGINE
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
SILENCER FIBER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . 5-21
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . 5-22
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . 5-22
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
CHECKING THE PRESSURE PLATE. . . . . . . . . . . . . . . . . . . . . . . . 5-22
CHECKING THE PUSH LEVER SHAFT . . . . . . . . . . . . . . . . . . . . . . 5-23
CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . 5-23
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
ENG
KICK STARTER AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
KICK STARTER AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 5-28
REMOVING THE PRIMARY DRIVE GEAR. . . . . . . . . . . . . . . . . . . . 5-30
REMOVING THE KICK SHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . . 5-30
CHECKING THE KICK STARTER. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
CHECKING THE STOPPER LEVER. . . . . . . . . . . . . . . . . . . . . . . . . 5-31
CHECKING THE PRIMARY DRIVE GEAR AND PRIMARY
DRIVEN GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
INSTALLING THE KICK STARTER SHAFT ASSEMBLY . . . . . . . . . 5-33
INSTALLING THE KICK IDLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . 5-33
INSTALLING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . 5-34
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
REMOVING THE TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . 5-50
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
ENGINE ENG
ENGINE
ENGINE
DRIVE SPROCKET
5-1
ENGINE ENG
EXHAUST PIPE
5-2
ENGINE ENG
SILENCER FIBER REPLACEMENT
1. Remove:
• seat
• right side cover
• bolt (silencer)
• silencer
• bolt (fiber)
• washer
2. Remove:
• inner pipe
3. Replace:
• fiber
4. Install:
• inner pipe
NOTE:
Fully apply Yamaha bond No. 1215 (Three
bond No. 1215®) or equivalent as shown.
5. Install:
• washer
• bolt (fiber) 12 Nm (1.2 m•kg, 8.7 ft•lb)
LOCTITE®
• silencer
• bolt (silencer)
12 Nm (1.2 m•kg, 8.7 ft•lb)
• right side cover 7 Nm (0.7 m•kg, 5.1 ft•lb)
• seat 7 Nm (0.7 m•kg, 5.1 ft•lb)
5-3
ENGINE ENG
EAS00191
ENGINE
5-4
ENGINE ENG
5-5
ENGINE ENG
EAS00192
2. Tighten:
• pivot shaft nut 63 Nm (6.3 m•kg, 46 ft•lb)
• engine mount nut (front)
69 Nm (6.9 m•kg, 50 ft•lb)
• engine mount nut (lower)
69 Nm (6.9 m•kg, 50 ft•lb)
5-6
CYLINDER HEAD, CYLINDER AND PISTON ENG
EAS00221
5-7
CYLINDER HEAD, CYLINDER AND PISTON ENG
EAS00222
EAS00229
2. Check:
• cylinder head
Damage / scratches → Replace.
• cylinder head water jacket
Mineral deposits / rust → Eliminate.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylin-
der head.
5-8
CYLINDER HEAD, CYLINDER AND PISTON ENG
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
EAS00233
Recommended lubricart
Lithium-soap-based grease
2. Install:
• O-rings
3. Install:
• cylinder head
• copper washer
• cylinder head nuts
30 Nm (3.0 m•kg, 22 ft•lb)
NOTE:
Tighten the cylinder head nuts in stage, using
a crisscross pattern.
4. Install:
• spark plug
• spark plug cap
• radiator hoses.
5-9
CYLINDER HEAD, CYLINDER AND PISTON ENG
EAS00251
5-10
CYLINDER HEAD, CYLINDER AND PISTON ENG
EAS00253
2. Remove:
• piston pin
• piston
• small end bearing
CAUTION:
Do not use a hammer to drive the piston
pin out.
NOTE:
Before removing the piston pin, deburr the pis-
ton pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set .
3. Remove:
• piston ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
EAS00257
5-11
CYLINDER HEAD, CYLINDER AND PISTON ENG
2. Measure:
• piston-to-cylinder clearance
47.500 ~ 47.514 mm
Standard
(1.8701 ~ 1.8706 in)
Wear limit 47.6 mm (1.8740 in)
Taper limit “T” 0.05 mm (0.0020 in)
Out of round “R” 0.05 mm (0.0020 in)
“C” = maximum of D1 ~ D6
maximum of D1 or D2 –
“T” =
maxmum of D5 or D6
maximum of D1 D3 or D5 –
“R” =
minimum of D2 D4 or D6
b. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
20.0 mm (0.79 in) from the bottom edge of the
piston
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.040 ~ 0.045 mm
(0.0016 ~ 0.0018 in)
<Limit>: 0.10 mm (0.0039 in)
5-12
CYLINDER HEAD, CYLINDER AND PISTON ENG
COMBINATION OF PISTON AND CYLINDER
1. Check:
• cylinder mark
Piston mark
Piston size
(color)
47.457 ~ 47.460 mm
A (red)
(1.8684 ~ 1.8685 in)
47.461 ~ 47.464 mm
B (orange)
(1.8685 ~ 1.8687 in)
47.465 ~ 47.468 mm
C (green)
(1.8687 ~ 1.8688 in)
47.469 ~ 47.472 mm
D (purple)
(1.8689 ~ 1.8690 in)
3. Combination:
• combine the piston and cylinder by the fol-
lowing chart.
5-13
CYLINDER HEAD, CYLINDER AND PISTON ENG
EAS00263
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
3. Measure:
• piston ring end gap
Out of specification → Replace the piston
ring.
5-14
CYLINDER HEAD, CYLINDER AND PISTON ENG
3. Measure:
• piston pin bore inside diameter
Out of specification → Replace the piston.
4. Calculate:
• piston-pin-to-piston clearance
Out of specification → Replace the piston
pin and piston as a set.
Piston-pin-to-piston clearance =
Piston pin bore size –
Piston pin outside diameter
Piston-pin-to-piston clearance
0.008 ~ 0.015 mm
(0.0003 ~ 0.0006 in)
<Limit>: 0.065 mm (0.0026 in)
5-15
CYLINDER HEAD, CYLINDER AND PISTON ENG
EAS00267
2. Install:
• gasket (cylinder)
• small end bearing
(with the recomended lubricant)
• dowel pin
Recommended lubricant
Engine oil
3. Install:
• piston
• piston pin
• piston pin clip
NOTE:
• Apply engine oil the piston pin.
• Make sure the arrow mark on the piston
points towards the exhaust side of the cylin-
der.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre-
vent the clip from falling into the crankcase.
• Do not allow the clip open ends to meet the
piston pin slat .
5-16
CYLINDER HEAD, CYLINDER AND PISTON ENG
4. Lubricate:
• piston
• piston ring
• cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Install:
• cylinder
• cylinder nut 28 Nm (2.8 m•kg, 20 ft•lb)
NOTE:
• While compressing the piston ring with one
hand, install the cylinder with the other hand.
• Tighten the nuts in stage, using a crisscross
pattern.
5-17
CLUTCH ENG
EAS00274
CLUTCH
CLUTCH
5-18
CLUTCH ENG
5-19
CLUTCH ENG
EAS00276
2. Remove:
• compression spring bolts
• compression springs
• pressure plate
3. Remove:
• push rod 1
• ball
• push rod 2
4. Remove:
• friction plate 1
• clutch plate
• friction plate 2
5. Remove:
• clutch boss nut
• washer
• clutch boss
NOTE:
While holding the clutch boss with the univer-
sal clutch holder , loosen the clutch boss
nut.
6. Remove:
• washer
• primary driven gear
• spacer
5-20
CLUTCH ENG
EAS00280
EAS00281
5-21
CLUTCH ENG
EAS00282
2. Measure:
• clutch spring free length
Out of specification → Replace the clutch
springs as a set.
EAS00284
EAS00285
EAS00286
5-22
CLUTCH ENG
CHECKING THE PUSH LEVER SHAFT
1. Check:
• push lever shaft
Wear / damage → Replace.
EAS00288
EAS00298
Recommended lubricant
Transmission oil
2. Install:
• washer
• clutch boss
3. Install:
• washer
NOTE:
Install the conical washer to the main axle
as shown in the illustration.
5-23
CLUTCH ENG
4. Install:
• clutch boss nut
70 Nm (7.0 m•kg, 51 ft•lb)
NOTE:
While holding the clutch boss with the univer-
sal clutch holder , tighten the clutch boss
nut.
5. Lubricate:
• friction plates
• clutch plates
(with the recommended lubricant)
Recommended lubricant
Transmission oil
6. Install:
• friction plate 1
• clutch plate
• friction plate 2
NOTE:
• Install the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
• Use the friction plate for the first and final
while paying attention to the difference in sur-
face pattern.
7. Install:
• push rod 2
• ball
• push rod 1
(with the recommended lubricant)
Recommended lubricant
Transmission oil
5-24
CLUTCH ENG
8. Install:
• pressure plate 1
NOTE:
Align the punch mark on the pressure plate
with the punch mark on the clutch boss.
9. Install:
• clutch spring
• clutch spring bolt
6 Nm (0.6 m•kg, 4.3 ft•lb)
NOTE:
Tighten the clutch spring bolts in stages and in
a crisscross pattern.
10.Install
• dowel pin
• clutch cover gasket
• clutch cover 10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
5-25
KICK STARTER AND SHIFT SHAFT ENG
EAS00327
5-26
KICK STARTER AND SHIFT SHAFT ENG
5-27
KICK STARTER AND SHIFT SHAFT ENG
5-28
KICK STARTER AND SHIFT SHAFT ENG
5-29
KICK STARTER AND SHIFT SHAFT ENG
REMOVING THE PRIMARY DRIVE GEAR
1. Remove:
• nut (primary drive gear)
NOTE:
Hold the drive gear holder onto the crank-
case using the M6 bolts .
2. Check:
• kick starter gear
Wear / damage → Replace.
• kick idle gear
Wear / damage → Replace.
• gear teeth
Wear / damage → Replace.
3. Measure:
• kick starter gear clip friction force
Out of specification → Replace.
(with the spring gauge )
5-30
KICK STARTER AND SHIFT SHAFT ENG
EAS00328
EAS00330
5-31
KICK STARTER AND SHIFT SHAFT ENG
2. Install:
• stopper lever assembly
(with the shift shaft )
NOTE:
Apply the transmission oil on the stopper lever
assembly.
3. Install:
• stopper lever
• shift shaft
NOTE:
• Apply transmission oil on the shift shaft.
• When installing the shift shaft, align the stop-
per lever roller with the slot on segment.
• When installing the shift shaft, make sure that
the torsion spring is in the position as
shown.
4. Check:
• shift lever position
Gaps and are not equal except in
neutral → Replace the shift shaft.
5-32
KICK STARTER AND SHIFT SHAFT ENG
INSTALLING THE KICK STARTER SHAFT
ASSEMBLY
1. Install:
• kick starter gear
• washer
• torsion spring
NOTE:
Make sure the stopper of the torsion spring
fits into the hole in the other side of the
stopper of the kick starter shaft .
2. Install:
• spring guide
NOTE:
Slide the spring guide into the kick starter
shaft, make sure the groove in the spring
guide fits on the stopper of the torsion spring.
3. Install:
• kick starter shaft assembly
NOTE:
• Apply the transmission oil on the kick shaft.
• Apply the lithium soap base grease on the
kick shaft stopper.
• Slide the kick starter shaft assembly into the
crankcase, make sure the clip and kick
starter shaft stopper fit into their home
positions , .
4. Install:
• torsion spring
NOTE:
Turn the torsion spring clockwise and hook into
the proper hole in the crankcase.
5-33
KICK STARTER AND SHIFT SHAFT ENG
INSTALLING THE PRIMARY DRIVE GEAR
1. Install:
• straight key
2. Install:
• primary drive gear
• washer
• primary drive gear nut
NOTE:
Install the conical washer to the crankshaft
as shown in the illustration.
3. Tighten:
• primary drive gear nut
79 Nm (7.9 m•kg, 57 ft•lb)
NOTE:
Hold the drive gear holder onto the crank-
case using the M6 bolts .
4. Install:
• primary driven gear
Refer to “CLUTCH”.
5. Install:
• dowel pin
• gasket (right crankcase cover)
6. Install:
• right crankcase cover
NOTE:
Mesh the impeller shaft gear with primary
drive gear .
5-34
KICK STARTER AND SHIFT SHAFT ENG
7. Install:
• bolt (right crankcase cover)
10 Nm (1.0 m•kg, 7.2 ft•lb)
• copper washer (oil drain bolt)
• oil drain bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
• copper washer (coolant drain bolt)
• coolant drain bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
8. Install:
• kick starter crank
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
Install the kick starter crank closest to but not
contacting the pillar tube and exhaust pipe
.
9. Install:
• shift pedal 10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
Install the shift pedal with the bottom of the
pedal outer diameter as close to the center
of the engine mounting bolt as possible.
5-35
CDI MAGNETO ENG
EAS00343
CDI MAGNETO
5-36
CDI MAGNETO ENG
EAS00346
2. Remove:
• rotor
(with the flywheel puller )
• woodruff key
Flywheel puller
90890-01189, YM-1189
NOTE:
When installing the flywheel puller, turn it
counterclockwise.
5-37
CDI MAGNETO ENG
INSTALLING THE CDI MAGNETO
1. Install:
• stator
• screw
NOTE:
Temporarily tighten the screw at this point.
2. Install:
• woodruff key
• rotor
NOTE:
• Clean the tapered portions of the crankshaft
and rotor.
• When installing the woodruff key, make sure
that its flat surface is in parallel with the
crankshaft center line .
• When installing the rotor, align the keyway
of the rotor with the woodruff key.
3. Install:
• washer
• nut 33 Nm (3.3 m•kg, 24 ft•lb)
(with the rotor holding tool )
4. Adjust:
• ignition timing
5-38
CDI MAGNETO ENG
5. Tighten:
• screw (stator)
8 Nm (0.8 m•kg, 5.8 ft•lb)
6. Check:
• ignition timing
Re-check the ignition timing.
7. Connect:
• CDI magneto lead
Refer to “CABLE ROUTING” in chapter 2.
8. Install:
• gasket (left crankcase cover)
• left crankcase cover
5 Nm (0.5 m•kg, 3.6 ft•lb)
NOTE:
Tighten the screws in stage, using a crisscross
pattern.
5-39
CRANKCASE AND CRANKSHAFT ENG
EAS00381
5-40
CRANKCASE AND CRANKSHAFT ENG
EAS00385
NOTE:
• Fully tighten the tool holding bolts, but make
sure the tool body is parallel with the case. If
necessary, one screw may be backed out
slightly to level tool body.
• As pressure is applied, alternately tap on the
front engine mounting boss and transmission
shafts.
CAUTION:
• Turn the segment to the position shown
in the figure so that it does not contact the
crankcase.
• Use soft hammer to tap on the case half.
Tap only on reinforced portions of case.
Do not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If one end “hangs
up”, take pressure off the push screw,
realign, and start over. If the cases do not
separate, check for a remaining case
screw or fitting. Do not force.
M6×1.0 EAS00388
NOTE:
Make appropriate bolts as shown available
by yourself and attach the tool with them.
CAUTION:
Do not use a hammer to drive out the
crankshaft.
5-41
CRANKCASE AND CRANKSHAFT ENG
REMOVING THE CRANKSHAFT BEARING
1. Remove:
• bearing
NOTE:
• Remove the bearing from the crankcase by
pressing its inner race as shown in .
• If the bearing is removed together with the
crankshaft, remove the bearing using a gen-
eral bearing puller as shown in .
CAUTION:
Do not use the removed bearing.
EAS00394
2. Measure:
• small end free play
Out of specification → Replace the small
end bearing or piston pin.
5-42
CRANKCASE AND CRANKSHAFT ENG
3. Measure:
• big end side clearance
Out of specification → Replace the big end
bearing, crankshaft pin, or connecting rod.
4. Measure:
• crankshaft width
Out of specification → Replace the crank-
shaft.
Crankshaft width
44.90 ~ 44.95 mm
(1.768 ~ 1.770 in)
EAS00399
EAS00401
2. Check:
• oil seals
Damage / wear → Replace.
5-43
CRANKCASE AND CRANKSHAFT ENG
EAS00408
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.
NOTE:
Hold the connecting rod at top dead center
with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.
EAS00416
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
5-44
CRANKCASE AND CRANKSHAFT ENG
2. Install:
• dowel pin
• right crankcase
(onto the left crankcase )
NOTE:
• Turn the shift cam to the position shown in
the figure so that it does not contact the
crankcase when installing the crankcase.
• Fit the right crankcase onto the left crank-
case. Tap lightly on the case with soft ham-
mer.
• When installing the crankcase, the connect-
ing rod should be positioned at TDC.
3. Install:
• clamp
• screw
8 Nm (0.8 m•kg, 5.8 ft•lb)
NOTE:
Tighten the crankcase tightening screws in
stage, using a crisscross pattern.
4. Install:
• crankcase oil seal holder
• bolt 20 Nm (2.0 m•kg, 14 ft•lb)
LOCTITE®
5. Remove:
• sealant
• forced out on the cylinder mating surface.
6. Apply:
• Transmission oil
To the crank pin, bearing, oil delivery hole
and connecting rod end washer.
7. Check:
• crankshaft and transmission operation
Unsmooth operation → Repair.
5-45
TRANSMISSION ENG
EAS00419
TRANSMISSION
5-46
TRANSMISSION ENG
5-47
TRANSMISSION ENG
5-48
TRANSMISSION ENG
EAS00420
AS00421
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat sur-
face.
Bends → Replace.
WARNING
Do not attempt to straighten a bent shift
fork guide bar.
3. Check:
• shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
5-49
TRANSMISSION ENG
EAS00422
EAS00423
2. Measure:
• drive axle runout
(with a centering device and dial gauge )
Out of specification → Replace the drive
axle.
3. Check:
• transmission gears
Blue discoloration / pitting / wear → Replace
the defective gear(s).
• transmission gear dogs
Cracks / damage / rounded edges →
Replace the defective gear(s).
• transmission shift fork groove
Wear / damage → Replace.
5-50
TRANSMISSION ENG
4. Check:
• transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5. Check:
• transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• circlips
Bends / damage / looseness → Replace.
2. Install:
• 2ND wheel gear
• 6TH wheel gear
• 3RD wheel gear
• 4TH wheel gear
• 5TH wheel gear
• 1ST wheel gear
(onto the drive axle )
NOTE:
• Apply the molybdenum disulfide oil on the
1ST, 2ND, 3RD and 4TH wheel gears inner
circumference and on the end surface.
• Apply the transmission oil on the 5TH and
6TH wheel gears inner circumference.
5-51
TRANSMISSION ENG
3. Install:
• washer
• circlip
NOTE:
• Be sure the circlip sharp-edged corner is
positioned opposite side to the washer and
gear .
• Be sure the circlip end is positioned at axle
spline groove .
4. Install:
• collar
NOTE:
• Apply the lithium soap base grease on the oil
seal lip.
• When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
5. Install:
• main axle
• drive axle
6. Install:
• shift fork-L
• shift fork-C
• shift fork-R
• shift fork pin
5-52
TRANSMISSION ENG
NOTE:
• Mesh the shift fork-L with the 6th wheel
gear and shift fork-R with the 5TH
wheel gear on the drive axle.
• Mesh the shift fork-C with the 3RD / 4TH
pinion gear on the main axle.
7. Install:
• shift cam
NOTE:
Apply the transmission oil on the shift cam.
8. Install:
• shift fork guide bar
NOTE:
• Apply the transmission oil on the guide bars.
• Be sure the long bar is inserted into the shift
fork-L and shift fork-R and the short one into
shift fork-C.
9. Check:
• shifter operation
• transmission operation
5-53
COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
COOLING SYSTEM
RADIATOR
6-1
RADIATOR COOL
EAS00455
2. Check:
• radiator hoses
Cracks / damage → Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
EAS00456
6-2
RADIATOR COOL
2. Check:
• cooling system
Leaks → Repair or replace any faulty part.
6-3
WATER PUMP COOL
EAS00468
WATER PUMP
6-4
WATER PUMP COOL
EAS00472
2. Check:
• bearing
Rough movement → Replace.
3. Check:
• impeller
Cracks / damage / wear → Replace.
4. Check:
• water pump impeller shaft
Damage / wear → Replace.
• water pump drive gear
Damage / wear → Replace.
EAS00479
6-5
WATER PUMP COOL
2. Install:
• bearing
NOTE:
Install the bearing by pressing its outer race
parallel.
3. Install:
• water pump impeller shaft
• washer
• impeller 14 Nm (1.4 m•kg, 10 ft•lb)
NOTE:
• Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.
• When installing the water pump impeller
shaft, apply the lithium-soap-base grease on
the oil seal lip and water pump impeller shaft.
And install the shaft while turning it.
• Hold the impeller shaft on its width across the
flats with spanners, etc. and install the
impeller.
4. Install:
• gasket
• water pump housing
10 Nm (1.0 m•kg, 7.2 ft•lb)
• copper washer
5. Fill:
• cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
6. Check:
• cooling system
Refer to “CHECKING THE COOLING SYS-
TEM” in chapter 3.
6-6
CARB
CHAPTER 7
CARBURETOR
CARBURETOR
CARBURETOR AND REED VALVE
7-1
CARBURETOR AND REED VALVE CARB
7-2
CARBURETOR AND REED VALVE CARB
7-3
CARBURETOR AND REED VALVE CARB
EAS00485
2. Check:
• fuel passages
Obstruction → Clean.
3. Check:
• float chamber body
Dirt → Clean.
4. Check:
• float chamber rubber gasket
Cracks / damage / wear → Replace.
5. Check:
• float
Damage → Replace.
6. Check:
• needle valve
• needle valve seat
Damage / wear → Replace.
Obstruction → Clean.
7-4
CARBURETOR AND REED VALVE CARB
7. Check:
• jet needle
• main nozzle
• main jet
• main nozzle holder
• pilot jet
• starter plunger
Bends / damage / wear → Replace.
Obstruction → Clean.
Blow out the jets with compressed air.
8. Check:
• piston valve movement
Insert the piston valve into the carbure-
tor body and move it up and down.
Tightness → Replace the piston valve.
9. Check:
• hose joints
Cracks / damage → Replace.
10.Check:
• carburetor breather hoses
• fuel hoses
Cracks / damage / wear → Replace.
Obstruction → Clean.
Blow out the hoses with compressed air.
7-5
CARBURETOR AND REED VALVE CARB
ASSEMBLY THE REED VALVE
1. Install:
• reed valve
• reed valve stopper
• screw (reed valve)
1 Nm (0.1 m•kg, 0.7 ft•lb)
LOCTITE®
NOTE:
• Install the reed valve with the reed valve
bending as shown.
• Note the cut in the lower corner of the reed
valve and stopper.
• Tighten each screw gradually to avoid warp-
ing.
EAS00487
1. Install:
• pilot air screw
• throttle stop screw
NOTE:
• Turn in the pilot air screw until it is lightly
seated.
• Turn out the pilot air screw by the number of
turns recorded before removing.
7-6
CARBURETOR AND REED VALVE CARB
2. Install:
• starter plunger
3. Install:
• pilot jet
• main nozzle
• main jet holder
• main jet
NOTE:
Install the main nozzle with its chamfered side
facing the carburetor.
4. Install:
• needle valve
• float
• float pin
NOTE:
• After installing the needle valve to the float,
install them to the carburetor.
• Check the float for smooth movement.
5. Install:
• float chamber
• gascket (float chamber)
• hose holder (carburetor breather hose)
6. Install:
• carburetor breather hose
• overflow hose
7. Install:
• jet needle
• throttle valve
7-7
CARBURETOR AND REED VALVE CARB
8. Install:
• throttle cable
• mixing chamber top
• gascket (mixing chamber top)
• spring (throttle valve)
• ring
• throttle valve
NOTE:
• While compressing the spring, connect the
throttle cable.
• Align the cut in the ring with the throttle
cable.
2. Install:
• carburetor joint
8 Nm (0.8 m•kg, 5.8 ft•lb)
EAS00492
7-8
CARBURETOR AND REED VALVE CARB
2. Adjust:
• throttle cable free play
Fuel height
18 ~ 20 mm (0.71 ~ 0.79 in)
2. Adjust:
• fuel level
EAS00505
7-9
ELEC
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
Ignition coil
Engine stop switch
CDI unit
CDI magneto
8-1
CHECKING SWITCH CONTINUITY ELEC
CEAS00730
CAUTION:
Never insert the tester probes into the cou-
pler terminal slots. Always insert the
probes from the opposite end of the cou-
pler taking care not to loosen or damage
the leads.
Pocket tester
90890-03112, YU-3112
NOTE:
• Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and
forth between the switch positions a few
times.
8-2
IGNITION SYSTEM ELEC
EAS00736 EAS00740
NO YES
8-3
IGNITION SYSTEM ELEC
EAS00744 EAS00746
YES NO
8-4
IGNITION SYSTEM ELEC
EAS00750 EAS00748
8-5
IGNITION SYSTEM ELEC
EAS00775 EAS00754
YES NO
8-6
TUN
CHAPTER 9
TUNING
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS . . 9-1
TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE
OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
MAIN JET ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
PILOT AIR SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
PILOT JET ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
JET NEEDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
JET NEEDLE GROOVE POSITION ADJUSTMENT . . . . . . . . . . . . . 9-4
CARBURETOR SETTING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
ROAD CONDITION AND EXAMPLES OF CARBURETOR
SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
EXAMPLES OF CARBURETOR SETTING DEPENDING ON
SYMPTOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
CHANGE OF THE HEAT RANGE OF SPARK PLUGS. . . . . . . . . . . 9-6
CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
SELECTION OF THE SECONDARY REDUCTION RATIO
(SPROCKET). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
DRIVE AND DRIVEN SPROCKETS SETTING PARTS . . . . . . . . . . 9-8
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
FRONT FORK SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
CHANGE IN LEVEL AND CHARACTERISTICS OF FORK OIL . . . . 9-10
SETTING OF SPRING AFTER REPLACEMENT . . . . . . . . . . . . . . . 9-10
FRONT FORK SETTING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
REAR SUSPENSION SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
CHOOSING SET LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
SETTING OF SPRING AFTER REPLACEMENT . . . . . . . . . . . . . . . 9-13
REAR SHOCK ABSORBER SETTING PARTS. . . . . . . . . . . . . . . . . 9-14
SUSPENSION SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
ENGINE TUN
TUNING
ENGINE
CARBURETOR SETTING
• The role of fuel is to cool the engine, and in
the case of a 2-stroke engine, to lubricate
the engine in addition to power generation.
Accordingly, if a mixture of air and fuel is
too lean, abnormal combustion will occur,
and engine seizure may result. If the mix-
ture is too rich, spark plugs will get wet with
oil, thus making it impossible to bring the
engine into full play or if the worst comes to
the worst, the engine may stall.
• The richness of the air-fuel mixture required
for the engine will vary with atmospheric
conditions of the day and therefore, the set-
tings of the carburetor must be properly
suited to the atmospheric conditions (air
pressure, humidity and temperature).
• Finally, the rider himself must make a test
run and check his vehicle for conditions
(pick-up of engine speed, road surface con-
ditions) and for the discoloration of the
spark plug(s).
After taking these into consideration, he
must select the best possible carburetor
settings.
* It is advisable to make a note of settings,
atmospheric conditions, road surface condi-
tion, lap-time, etc. so that the memorandum
can be used as a reference useful for
future.
ATMOSPHERIC CONDITIONS AND
CARBURETOR SETTINGS
Air
Air temp. Humidity pressure Mixture Setting
(altitude)
High High Low (high) Richer Leaner
Low Low High (low) Leaner Richer
9-1
ENGINE TUN
TEST RUN
After warming up the engine equipped with the
standard type carburetor(s) and spark plug(s),
run two or three laps of the circuit and check
the smooth operation of the engine and discol-
oration of spark plug(s).
Pilot jet
Pilot air screw
Diameter of
Jet needle
straight
portion
Clip position
Main jet
Throttle valve opening
Full-open
Full-closed
9-2
ENGINE TUN
MAIN JET ADJUSTMENT
The richness of air-fuel mixture with 3 / 4 ~ 4 / 4
throttle can be set by changing the main jet .
9-3
ENGINE TUN
JET NEEDLE GROOVE POSITION
ADJUSTMENT
Should the engine be hard to run smoothly at
intermediate speeds, the jet needle must be
adjusted. If the mixture is too rich or too lean at
intermediate speed operation, irregular engine
operation and poor acceleration will result.
Whether or not the richness of the mixture is
proper is hard to be determined by means of
the spark plug and therefore, it should be
judged from your feeling of actual engine oper-
ation.
9-4
ENGINE TUN
Diameter of straight portion Rich Lean
Clip position φ 2.405 mm (0.0947 in) φ 2.415 mm (0.0951 in) φ 2.425 mm (0.0955 in)
Rich 1 richer NBKE-3rd groove NBKF-3rd groove NBKG-3rd groove
0.5 richer NBLE-2nd groove NBLF-2nd groove NBLG-2nd groove
STD NBKE-2nd groove NBKF-2nd groove (STD) NBKG-2nd groove
0.5 leaner NBLE-1st groove NBLF-1st groove NBLG-1st groove
Lean 1 leaner NBKE-1st groove NBKF-1st groove NBKG-1st groove
ROAD CONDITION AND EXAMPLES OF CARBURETOR SETTING
Conditions General condition Sandy condition
Under 10 °C 15 ~ 25 °C Over 30 °C Under 10 °C 15 ~ 25 °C Over 30 °C
(50 °F) (59 ~ 77 °F) (86 °F) (50 °F) (59 ~ 77 °F) (86 °F)
Parts (Winter) (Spring, Autumn) (Summer) (Winter) (Spring, Autumn) (Summer)
Main jet #140 #138 #135 ~ #138 #142 #142 #142
Jet needle NBKF-2 NBKF-2 NBKF-2 NBKF-2 NBKF-2 NBKF-2
Pilot jet #45 #45 #45 #48 #48 #48
Pilot air screw Zero Zero +1/4 –1/2 –1/2 Zero ~ +1/2
NOTE:
Optimum pilot air screw setting can be obtained by adding the ex-factory number of the same screw
back-out turns to any required value provided in the chart.
For example, if the ex-factory number is “2”, add “2” to the value chosen in the chart.
9-5
ENGINE TUN
* marked: In case of hard breathing, check the carburetor breather hoses for clogging.
BR10EG / NGK
Standard spark plug
(resistance type)
• In principle, it is advisable to first use spark
plugs of standard heat range, and judging
from the discoloration of spark plugs, adjust
carburetor settings.
• If the calibration No. of the main jet must be
changed by ±30, it is advisable to change
the heat range of spark plugs and newly
select the proper main jet.
9-6
ENGINE / CHASSIS TUN
NOTE:
• When checking the discoloration of spark
plugs, be sure to stop the engine immediately
after a run and check.
• Avoid racing.
• When changing the heat range of spark
plugs, never attempt to change it more than
±1 rank.
• When using a spark plug other than standard,
check its heat range against the standard and
check that it is a resistance type.
• Note that even if the discoloration seems
proper, it may slightly vary with the spark plug
maker and oil in use.
CHASSIS
SELECTION OF THE SECONDARY
REDUCTION RATIO (SPROCKET)
Secondary Number of rear wheel sprocketteeth
=
reduction ratio Number of drive sprocket teeth
YZ85:
47 / 14 (3.357)
(for EUR, CAN)
Standard secondary
48 / 14 (3.429)
reduction ratio
(for AUS, NZL)
YZ85LW:
52 / 14 (3.714)
<Requirement for selection of secondary gear
reduction ratio>
• It is generally said that the secondary gear
ratio should be reduced for a longer straight
portion of a speed course and should be
increased for a course with many corners.
Actually, however, as the speed depends
on the ground condition of the day of the
race, be sure to run through the circuit to
set the vehicle suitable for the entire
course.
9-7
CHASSIS TUN
• In actuality, it is very difficult to achieve set-
tings suitable for the entire course and
some settings may be sacrificed. Thus, the
settings should be matched to the portion
of the course that has the greatest effect on
the race result. In such a case, run through
the entire course while making notes of lap
times to find the best balance; then, deter-
mine the secondary reduction ratio.
• If a course has a long straight portion
where a vehicle can run at maximum
speed, the vehicle is generally set such that
it can develop its maximum revolutions
toward the end of the straight line, with care
taken to avoid the engine over-revving.
NOTE:
Riding technique varies from rider to rider and
the performance of a vehicle also vary from
vehicle to vehicle. Therefore, do not imitate
other rider’s settings from the beginning but
choose your own setting according to the level
of your riding technique.
9-8
CHASSIS TUN
TIRE PRESSURE
Tire pressure should be adjust to suit the road
surface condition of the circuit.
Extent of adjustment
60 ~ 80 kPa
(0.6 ~ 0.8 kgf / cm2, 9.0 ~ 12 psi)
Extent of adjustment
100 ~ 120 kPa
(1.0 ~ 1.2 kgf / cm2, 15 ~ 18 psi)
9-9
CHASSIS TUN
CHANGE IN LEVEL AND
CHARACTERISTICS OF FORK OIL
Damping characteristic near the final stroke can
be changed by changing the fork oil amount.
CAUTION:
Adjust the oil level in 5 mm (0.2 in) incre-
ments or decrements. Too low oil level
causes the front fork to produce a noise at
full rebound or the rider to feel some pres-
sure on his hands or body. Alternatively,
[kg (lb)] too high oil level will develop unexpectedly
early oil lock with the consequent shorter
front fork travel and deteriorated perfor-
mance an characteristics. Therefore, adjust
the front fork within the specified range.
9-10
CHASSIS TUN
2. Use of stiff spring
Generally a stiff spring gives a stiff riding
feeling. Rebound damping tends to become
weaker, resulting in lack of a sense of con-
tact with the road surface or in a vibrating
handlebar.
To set a stiff spring:
• Change the rebound damping.
Turn in one or two clicks.
• Change the compression damping.
Turn out one or two clicks.
9-11
CHASSIS TUN
REAR SUSPENSION SETTING
The rear suspension setting should be made
depending on the rider’s feeling of an actual
run and the circuit conditions.
The rear suspension setting includes the fol-
lowing two factors:
1. Setting of spring preload
• Change the set length of the spring.
• Change the spring.
2. Setting of damping force
• Change the rebound damping.
• Change the compression damping.
Standard figure
75 ~ 85 mm (3.0 ~ 3.3 in)
NOTE:
• If the vehicle is new and after it is broken in,
the same set length of the spring may change
because of the initial fatigue, etc. of the
spring. Therefore, be sure to make reevalua-
tion.
• If the standard figure cannot be achieved by
adjusting the spring adjuster and changing
the spring set length, replace the spring with
an optional one and make re-adjustment.
9-12
CHASSIS TUN
SETTING OF SPRING AFTER
REPLACEMENT
After replacement, be sure to adjust the spring
to the set length [sunken length 75 ~ 85 mm
(3.0 ~ 3.3 in)] and set it.
1. Use of soft spring
• Set the soft spring for less rebound damp-
ing to compensate for its less spring load.
Run with the rebound damping adjuster
one or two clicks on the softer side and
readjust it to suit your preference.
2. Use of stiff spring
• Set the soft spring for more rebound damp-
ing to compensate for its greater spring
load. Run with the rebound damping
adjuster one or two clicks on the stiffer side
and readjust it to suit your preference.
* Adjusting the rebound damping will be fol-
lowed more or less by a change in the com-
pression damping. For correction, turn the
compression damping adjuster on the
softer side.
CAUTION:
When using a rear shock absorber other
than currently installed, use the one whose
overall length does not exceed the stan-
dard as it may result in faulty performance.
Never use one whose overall length is
greater than standard.
9-13
CHASSIS TUN
REAR SHOCK ABSORBER SETTING
PARTS
• Rear shock spring
YZ85:
For EUR
SPRING SPRING I.D.
TYPE
RATE PART NUMBER COLOR
SOFT 4.4 4ES-22212-M0 Brown
STD 4.6 4ES-22212-K0 Green
STIFF 4.8 4ES-22212-G0 Red
YZ85LW:
For EUR
SPRING SPRING I.D.
TYPE
RATE PART NUMBER COLOR
SOFT 4.6 4ES-22212-K0 Green
STD 4.8 4ES-22212-G0 Red
STIFF 5.0 4ES-22212-F0 –
9-14
CHASSIS TUN
SUSPENSION SETTING
• Front fork
NOTE:
• If any of the following symptoms is experienced with the standard position as the base, make reset-
ting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 75 ~ 85 mm
(3.0 ~ 3.3 in).
Section
Symptom Large Medium Small Check Adjust
Jump
gap gap gap
Compression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Stiff over entire range Oil level (oil amount) Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Spring Replace with soft spring.
Outer tube Check for any bends, dents, and other noticeable
Unsmooth Inner tube scars, etc. If any, replace affected parts.
movement over
Under bracket Retighten to specified torque.
entire range
tightening torque
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
Poor initial movement decrease damping.
Oil seal Apply grease in oil seal wall.
Compression damping Turn adjuster clockwise (about 2 clicks) to increase
Soft over entire damping.
range, bottoming out Oil level (oil amount) Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Spring Replace with stiff spring.
Stiff toward
Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in).
stroke end
Soft toward stroke
Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
end, bottoming out
Compression damping Turn adjuster counterclockwise (about 2 clicks) to
Stiff initial movement
decrease damping.
Compression damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
Low front, tending to decrease damping.
lower front posture Balance with rear end Set sunken length for 80 ~ 85 mm (3.1 ~ 3.3 in)
when one passenger is astride seat (lower rear pos-
ture).
Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
Compression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
“Obtrusive” front, Balance with rear end Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
tending to upper when one passenger is astride seat (upper rear pos-
front posture ture).
Spring Replace with soft spring.
Oil level (oil amount) Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
9-15
CHASSIS TUN
• Rear shock absorber
NOTE:
• If any of the following symptoms is experienced with the standard position as the base, make reset-
ting by reference to the adjustment procedure given in the same chart.
• Adjust the damping in 2-click increments or decrements.
Section
Symptom Large Medium Small Check Adjust
Jump
gap gap gap
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Stiff, tending to sink
Spring set length Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger is astride seat.
Rebound damping Turn adjuster clockwise (about 2 clicks) to increase
Spongy and unstable damping.
Spring Replace with stiff spring.
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
Heavy and dragging decrease damping.
Spring Replace with soft spring.
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Compression damping Turn adjuster clockwise (about 2 clicks) to increase
Poor road gripping damping.
Spring set length Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger is astride seat.
Spring Replace with soft spring.
Compression damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Bottoming out Spring set length Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger in astride seat.
Spring Replace with stiff spring.
Rebound damping Turn adjuster clockwise (about 2 clicks) to increase
Bouncing damping.
Spring Replace with soft spring.
Compression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Stiff travel Spring set length Set sunken length for 80 ~ 85 mm (3.1 ~ 3.3 in)
when one passenger is astride seat.
Spring Replace with soft spring.
9-16
TRBL
SHTG
CHAPTER 10
TROUBLESHOOTING
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
ELECTRICAL SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man-
ual for checks, adjustments, and replacement of parts.
STARTING FAILURES
ENGINE FUEL SYSTEM
Cylinder(s) and cylinder head(s) Fuel tank
• Loose spark plug • Empty fuel tank
• Loose cylinder head or cylinder • Clogged fuel strainer
• Damaged cylinder gasket • Clogged fuel tank drain hose
• Worn or damaged cylinder • Clogged rollover valve
Piston(s) and piston ring(s) • Clogged rollover valve hose
• Improperly installed piston ring • Deteriorated or contaminated fuel
• Damaged, worn or fatigued piston ring Fuel cock
• Seized piston ring • Clogged or damaged fuel hose
• Seized or damaged piston Carburetor(s)
Air filter • Deteriorated or contaminated fuel
• Improperly installed air filter • Clogged pilot jet
• Clogged air filter element • Clogged pilot air passage
Crankcase and crankshaft • Sucked-in air
• Improperly assembled crankcase • Damaged float
• Seized crankshaft • Worn needle valve
Reed valve • Improperly installed needle valve seat
• Deformed reed valve stopper • Incorrect fuel level
• Improperly seald reed valve stopper • Improperly installed pilot jet
• Incorrect tightened manifold • Clogged starter jet
• Damaged gasket • Faulty starter plunger
• Damaged reed valve • Improperly adjusted starter cable
ELECTRICAL SYSTEMS
Spark plug(s) Ignition system
• Incorrect spark plug gap • Faulty CDI unit
• Incorrect spark plug heat range • Faulty pickup coil
• Fouled spark plug • Broken generator rotor woodruff key
• Worn or damaged electrode Switches and wiring
• Worn or damaged insulator • Faulty engine stop switch
• Faulty spark plug cap • Broken or shorted wiring
Ignition coil(s) • Improperly grounded circuit
• Cracked or broken ignition coil body • Loose connections
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
10-1
INCORRECT ENGINE IDLING SPEED / POOR MEDIUM-AND- TRBL
HIGH-SPEED PERFORMANCE / FAULTY GEAR SHIFTING SHTG
EAS00846
EAS00848
EAS00850
10-2
TRBL
FAULTY CLUTCH / OVERHEATING SHTG
EAS00851
FAULTY CLUTCH
CLUTCH SLIPS CLUTCH DRAGS
Clutch Clutch
• Improperly assembled clutch • Unevenly tensioned clutch springs
• Improperly adjusted clutch cable • Warped pressure plate
• Loose or fatigued clutch spring • Bent clutch plate
• Worn friction plate • Swollen friction plate
• Worn clutch plate • Bent clutch push rod
Transmission oil • Broken clutch boss
• Incorrect oil level • Burnt primary driven gear bushing
• Incorrect oil viscosity (low) • Match marks not aligned
• Deteriorated oil Transmission oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS00855
OVERHEATING
ENGINE FUEL SYSTEM
Clogged coolant passages Carburetor(s)
• Cylinder head(s) and piston(s) • Incorrect main jet setting
• Heavy carbon buildup • Incorrect fuel level
Transmission oil • Damaged or loose carburetor joint
• Incorrect oil level Air filter
• Incorrect oil viscosity • Clogged air filter element
• Inferior oil quality CHASSIS
COOLING SYSTEM Brake(s)
Coolant • Dragging brake
• Low coolant level ELECTRICAL SYSTEMS
Radiator Spark plug(s)
• Damaged or leaking radiator • Incorrect spark plug gap
• Faulty radiator cap • Incorrect spark plug heat range
• Bent or damaged radiator fin Ignition system
Water pump • Faulty CDI unit
• Damaged or faulty water pump
• Hose(s) and pipe(s)
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
10-3
POOR BRAKING PERFORMANCE / TRBL
FAULTY FRONT FORK LEGS / UNSTABLE HANDLING SHTG
EAS00857
EAS00861
EAS00864
UNSTABLE HANDLING
Handlebar Rear shock absorber assembly(-ies)
• Bent or improperly installed handlebar • Faulty rear shock absorber spring
Steering head components • Leaking oil or gas
• Improperly installed upper bracket Tire(s)
• Improperly installed lower bracket • Uneven tire pressures (front and rear)
(improperly tightened ring nut) • Incorrect tire pressure
• Bent steering stem • Uneven tire wear
• Damaged ball bearing or bearing race Wheel(s)
Front fork leg(s) • Incorrect wheel balance
• Uneven oil levels (both front fork legs) • Broken or loose spoke
• Unevenly tensioned fork spring (both front • Damaged wheel bearing
fork legs) • Bent or loose wheel axle
• Broken fork spring • Excessive wheel runout
• Bent or damaged inner tube Frame
• Bent or damaged outer tube • Bent frame
Swingarm • Damaged steering head pipe
• Worn bearing or bushing • Improperly installed bearing race
• Bent or damaged swingarm
10-4
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
YZ85W1 / YZ85(W) / YZ85LW(W) YZ85W1 / YZ85(W) / YZ85LW(W) YZ85W1 / YZ85(W) / YZ85LW(W)
2007 WIRING DIAGRAM 2007 SCHEMA DE CABLAGE SCHALTPLAN 2007
COMPOSANTS ELECTRIQUES
Coupe-circuit du moteur
Bobine d’allumage
Bloc CDI
Volant magnétique CDI
Bougie
CODE DE COULEUR
B. . . . . . . Noir
O. . . . . . . Orange
B/R. . . . . Noir/Rouge
B/W . . . . Noir/Blanc
G/L. . . . . Vert/Bleu
G/W . . . . Vert/Blanc
W/L . . . . Blanc/Bleu
W/R . . . . Blanc/Rouge