Yamaha YZ85LW(R) Owner`s manual

OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
YZ85(W)
YZ85W1
YZ85LW(W)
5PA-28199-85
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
IMPRIMÉ SUR PAPIER RECYCLÉ
AUF RECYCLINGPAPIER GEDRUCKT
PRINTED IN JAPAN
2006.04-1.4×1 CR
(E,F,G)
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
OWNER’S MANUAL
YZ85(W)
YZ85W1
YZ85LW(W)
5PA-28199-85-E0
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U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
INTRODUCTION
EAU41541
Congratulations on your purchase of the Yamaha YZ85(W)/YZ85W1/YZ85LW(W). This model is the result of Yamaha’s vast
experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of
craftsmanship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
● READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR MOTORCYCLE. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MOTORCYCLE.
● NEVER OPERATE A MOTORCYCLE WITHOUT PROPER TRAINING OR INSTRUCTION.
AN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warnings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abilities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s
use of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability to
operate the motorcycle safely.
MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON
THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE
OPERATION.
● OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
● OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
● OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
IMPORTANT MANUAL INFORMATION
EAU41090
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
EWA10030
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
U5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM
IMPORTANT MANUAL INFORMATION
EWA14350
WARNING
THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPERATE THIS MOTORCYCLE ON ANY PUBLIC STREET, ROAD OR HIGHWAY. SUCH USE IS PROHIBITED BY LAW.
THIS MOTORCYCLE COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER
LAWS AND REGULATIONS. PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
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IMPORTANT MANUAL INFORMATION
EAU10200
YZ85(W)/YZ85W1/YZ85LW(W)
OWNER’S MANUAL
©2006 by Yamaha Motor Co., Ltd.
1st edition, March 2006
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1
Location of important labels ...........1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments ................2-3
INSTRUMENT AND CONTROL
FUNCTIONS .......................................3-1
Handlebar switch ............................3-1
Clutch lever ....................................3-1
Shift pedal ......................................3-1
Brake lever .....................................3-2
Brake pedal ....................................3-2
Fuel tank cap ..................................3-3
Fuel ................................................3-3
Fuel tank breather hose .................3-5
Fuel cock ........................................3-5
Starter (choke) knob .......................3-6
Kickstarter ......................................3-6
Seat ................................................3-6
Adjusting the front fork ...................3-7
Front fork bleeding .........................3-8
Adjusting the shock absorber
assembly .....................................3-9
Removable sidestand ...................3-12
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2
OPERATION AND IMPORTANT
RIDING POINTS ................................ 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-1
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Checking the spark plug ................ 6-8
Transmission oil ............................. 6-9
Coolant ........................................ 6-10
Cleaning the air filter element ...... 6-12
Adjusting the carburetor ............... 6-14
Adjusting the throttle cable
free play .................................... 6-14
Tires ............................................. 6-15
Spoke wheels .............................. 6-17
Accessories and replacement
parts ......................................... 6-17
Adjusting the clutch lever
free play .................................... 6-17
Checking the front and rear brake
pads .......................................... 6-18
Checking the brake fluid level ...... 6-19
Changing the brake fluid .............. 6-20
Drive chain slack .......................... 6-20
Cleaning and lubricating the
drive chain ................................ 6-21
Checking and lubricating the
cables ....................................... 6-22
Checking and lubricating the
throttle grip and cable ............... 6-22
Checking and lubricating the
brake and shift pedals ............... 6-23
Checking and lubricating the
brake and clutch levers ............. 6-23
Lubricating the swingarm pivots ... 6-24
Lubricating the rear suspension ... 6-24
Checking the front fork ................. 6-24
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-26
Supporting the motorcycle ........... 6-26
Front wheel .................................. 6-27
Rear wheel ................................... 6-27
Troubleshooting ........................... 6-29
Troubleshooting charts ................. 6-30
MOTORCYCLE CARE AND
STORAGE .......................................... 7-1
Care ............................................... 7-1
Storage ........................................... 7-3
SPECIFICATIONS ............................ 8-1
CONSUMER INFORMATION ............ 9-1
Identification numbers .................... 9-1
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SAFETY INFORMATION
EAU41460
Safe riding
●
1
●
●
●
●
Always
make
pre-operation
checks. Careful checks may help
prevent an accident.
This motorcycle is designed for offroad use only, therefore, it is illegal
to operate it on public streets,
roads, or highways, even a dirt or
gravel one. Off-road use on public
lands may be illegal. Please check
local regulations before riding.
This motorcycle is designed to carry the operator only. No passengers.
Many accidents involve inexperienced operators.
• Make sure that the operator is
qualified and that you only lend
your motorcycle to other qualified operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
Many accidents have been caused
by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn
due to EXCESSIVE SPEED or un-
●
●
●
●
dercornering (insufficient lean angle for the speed). Never travel
faster than warranted by conditions.
Ride cautiously in unfamiliar areas. You may encounter hidden
obstacles that could cause an accident.
The posture of the operator is important for proper control. The operator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcycle.
Never ride under the influence of
alcohol or other drugs.
Be sure the transmission is in neutral before starting the engine.
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the prevention or reduction of head injuries.
● Always wear an approved helmet.
1-1
●
●
●
●
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protective clothing that covers your legs,
ankles, and feet.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.
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SAFETY INFORMATION
Loading and accessories
Adding accessories to your motorcycle
can adversely affect stability and handling if the weight distribution of the
motorcycle is changed. To avoid the
possibility of an accident, use extreme
caution when adding accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added accessories. Here are some general
guidelines to follow if adding accessories to your motorcycle:
Loading
● Accessory weight should be kept
as low and close to the motorcycle
as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle
to minimize imbalance or instability.
● Shifting weights can create a sudden imbalance. Make sure that accessories are securely attached to
the motorcycle before riding.
Check accessory mounts frequently.
● Never attach any large or heavy
items to the handlebar, front fork,
or front fender.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be responsible for the proper selection, installation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any accessories.
Keep these guidelines in mind for
mounting accessories in addition to
those provided under “Loading”.
● Never install accessories or that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
cornering clearance, limit suspension travel, steering travel or control operation.
• Accessories fitted to the handlebar or the front fork area can
create instability due to improper
weight distribution or aerodynamic changes. If accessories
are added to the handlebar or
1-2
●
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or
the motorcycle may become unstable in cross winds.
• Certain accessories can displace the operator from his or
her normal riding position. This
improper position limits the freedom of movement of the operator and may limit control ability,
therefore, such accessories are
not recommended.
Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
engine power.
1
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SAFETY INFORMATION
1
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMABLE:
• Be sure to always use a fresh
mixture of oil and gasoline.
• Always turn the engine off when
refueling.
• Take care not to spill any gasoline on the engine or exhaust
pipe/muffler when refueling.
• Never refuel while smoking or in
the vicinity of an open flame.
● Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poisonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has adequate ventilation.
● Always turn the engine off before
leaving the motorcycle unattended. When parking the motorcycle,
note the following:
• The engine and exhaust
pipe/muffler may be hot, therefore, park the motorcycle in a
●
●
place where pedestrians or children are not likely to touch these
hot areas.
• Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
• Do not park the motorcycle near
a flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch
fire.
When transporting the motorcycle
in another vehicle, make sure that
it is kept upright and that the fuel
cock is turned to “OFF”. If the
motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank.
If you should swallow any gasoline, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately.
If any gasoline spills on your skin
or clothing, immediately wash the
affected area with soap and water
and change your clothes.
1-3
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SAFETY INFORMATION
EAU41851
Location of important labels
Please read the following important labels carefully before operating this vehicle.
1
YZ85(W)/YZ85W1
1-4
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SAFETY INFORMATION
For Canada
1
1
4
CAUTION
Use premium unleaded gasoline/oil premix only.
Rinding as a passenger can cause the vehicle
to go out of control.
Loss of control can cause a collision
or rollover, which can result in severe injury
or death.
3XJ-2415E-A0
2
WARNING
ATTENTION
NEVER ride as a passenger.
Utiliser de préférence un mélange huile/super sans plomb.
3XJ-2151H-A1
3XJ-2415E-B0
5
3
AVERTISSEMENT
Un passager pourrait causer une perte de
contrôle du véhicule.
Une perte de contrôle peut provoquer une
collision ou un renversement, résultant en
des blessures sérieuses, voire mortelles.
AUCUN passager permis.
3XJ-2151H-B1
4AA-22259-60
1-5
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SAFETY INFORMATION
6
10
WARNING
BEFORE YOU OPERATE THIS VEHICLE, READ
THE OWNER’S MANUAL AND ALL LABELS.
NEVER CARRY A PASSENGER. You increase
your risk of losing control if you carry a passenger.
NEVER OPERATE THIS VEHICLE ON PUBLIC
ROADS. You can collide with another vehicle if
you operate this vehicle on a public road.
ALWAYS WEAR AN APPROVED MOTORCYCLE
HELMET, eye protection, and protective clothing.
EXPERIENCED RIDER ONLY.
3RV-21668-A0
11
5PA-2118K-00
7
1
TIRE INFOMATION
Cold tire normal pressure should be set as
follows.
FRONT : 100kPa, {1.00kgf/cm2}, 15psi
REAR : 100kPa, {1.00kgf/cm2}, 15psi
INFORMATION SUR LES PNEUS
La pression des pneus à froid doit normalement
être réglée comme suit.
AVANT : 100kPa, {1.00kgf/cm2}, 15psi
ARRIERE : 100kPa, {1.00kgf/cm2}, 15psi
AVERTISSEMENT
3RV-21668-B0
LIRE LE MANUEL DU PROPRIETAIRE ANSI QUE TOUTES LES
ETIQUETTES AVANT D’UTILISER CE VEHICULE.
NE JAMAIS TRANSPORTER DE PASSAGER. La conduite avec
passager augmente les risques de perte de contrôle.
NE JAMAIS ROULER SUR DES CHEMINS PUBLICS.
Vous pourriez entrer en collision avec un aulre véhicule.
TOUJOURS PORTER UN CASQUE DE MOTOCYCLISTE
APPROUVE, des lunettes et des vêlements de protection.
EXCLUSIVEMENT POUR L’USAGE D’UN CONDUCTEUR
EXPERIMENTE.
5PA-2118K-10
1-6
U5PA85E0.book Page 7 Thursday, April 13, 2006 3:06 PM
SAFETY INFORMATION
For Europe
1
3
9
10
TIRE INFORMATION
Cold tire normal pressure should be set as
follows.
FRONT : 100kPa, {1.00kgf/cm2}, 15psi
REAR : 100kPa, {1.00kgf/cm2}, 15psi
8
3RV-21668-A0
Before you operate this vehicle, read the owner’s manual.
Prima di usare il veicolo, leggete il manuale di istruzioni.
Lire le manuel du propriétaire avant d’utiliser ce véhicule.
Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.
Antes de conducir este vehículo, lea el Manual del Propietario.
5PA-21568-00
12
YAMAHA MOTOR CO., LTD.
SHIZUOKA JAPAN
YAMAHA
1-7
4GB-2155A-00
U5PA85E0.book Page 8 Thursday, April 13, 2006 3:06 PM
SAFETY INFORMATION
For Oceania and South Africa
3
10
1
TIRE INFORMATION
Cold tire normal pressure should be set as
follows.
FRONT : 100kPa, {1.00kgf/cm2}, 15psi
REAR : 100kPa, {1.00kgf/cm2}, 15psi
3RV-21668-A0
8
Before you operate this vehicle, read the owner’s manual.
Prima di usare il veicolo, leggete il manuale di istruzioni.
Lire le manuel du propriétaire avant d’utiliser ce véhicule.
Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.
Antes de conducir este vehículo, lea el Manual del Propietario.
5PA-21568-00
1-8
U5PA85E0.book Page 9 Thursday, April 13, 2006 3:06 PM
SAFETY INFORMATION
YZ85LW(W)
1
1-9
U5PA85E0.book Page 10 Thursday, April 13, 2006 3:06 PM
SAFETY INFORMATION
For Europe
1
3
1
4
TIRE INFORMATION
Cold tire normal pressure should be set as
follows.
FRONT : 100kPa, {1.00kgf/cm2}, 15psi
REAR : 100kPa, {1.00kgf/cm2}, 15psi
2
3RV-21668-A0
Before you operate this vehicle, read the owner’s manual.
Prima di usare il veicolo, leggete il manuale di istruzioni.
Lire le manuel du propriétaire avant d’utiliser ce véhicule.
Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.
Antes de conducir este vehículo, lea el Manual del Propietario.
5PA-21568-00
5
YAMAHA MOTOR CO., LTD.
SHIZUOKA JAPAN
YAMAHA
1-10
4GB-2155A-00
U5PA85E0.book Page 11 Thursday, April 13, 2006 3:06 PM
SAFETY INFORMATION
For Oceania
1
1
4
TIRE INFORMATION
Cold tire normal pressure should be set as
follows.
FRONT : 100kPa, {1.00kgf/cm2}, 15psi
REAR : 100kPa, {1.00kgf/cm2}, 15psi
3RV-21668-A0
2
Before you operate this vehicle, read the owner’s manual.
Prima di usare il veicolo, leggete il manuale di istruzioni.
Lire le manuel du propriétaire avant d’utiliser ce véhicule.
Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.
Antes de conducir este vehículo, lea el Manual del Propietario.
5PA-21568-00
1-11
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
DESCRIPTION
EAU10410
Left view
2
1.
2.
3.
4.
5.
6.
7.
Radiator cap (page 6-10)
Fuel cock (page 3-5)
Shock absorber assembly spring preload adjusting nut (page 3-9)
Air filter element (page 6-12)
Seat (page 3-6)
Shift pedal (page 3-1)
Starter (choke) knob (page 3-6)
2-1
U5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM
DESCRIPTION
EAU10420
Right view
2
9. Transmission oil drain bolt (page 6-9)
10.Brake pedal (page 3-2)
11.Shock absorber assembly rebound damping force adjusting screw
(page 3-9)
1. Shock absorber assembly compression damping force adjusting screw
(page 3-9)
2. Kickstarter (page 3-6)
3. Front fork rebound damping force adjusting screw (page 3-7)
4. Bleed screw (page 3-8)
5. Front fork compression damping force adjusting screw (page 3-7)
6. Spark plug cap (page 6-8)
7. Oil filler cap (page 6-9)
8. Coolant drain bolt (page 6-11)
2-2
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM
DESCRIPTION
EAU10430
Controls and instruments
2
1.
2.
3.
4.
5.
Clutch lever (page 3-1)
Left handlebar switch (page 3-1)
Brake lever (page 3-2)
Throttle grip (page 6-14)
Fuel tank cap (page 3-3)
2-3
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU40660
EAU12850
EAU12870
Handlebar switch
Clutch lever
Shift pedal
1. Engine stop button “ENGINE STOP”
1. Clutch lever
1. Shift pedal
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handlebar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 6-speed constant-mesh transmission equipped on
this motorcycle.
3
EAU12670
“ENGINE STOP” button
Hold this button pushed until the engine
stops in case of an emergency, such as
when the vehicle overturns or when the
throttle cable is stuck.
3-1
U5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU41261
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
2. While holding the lever pushed
away from the handlebar grip, turn
the adjusting bolt in direction (a) to
increase the distance, and in direction (b) to decrease it.
Distance between the brake lever
and the handlebar grip:
Minimum (shortest):
76 mm (2.99 in)
Standard:
95 mm (3.74 in)
Maximum (longest):
97 mm (3.82 in)
3. Tighten the locknut.
1.
2.
3.
4.
Brake lever
Locknut
Adjusting bolt
Distance between brake lever and handlebar
grip
The brake lever is equipped with a position adjusting bolt. Adjust the distance
between the brake lever and the handlebar grip as follows.
1. Loosen the locknut.
3-2
EAU12941
Brake pedal
3
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU13180
Fuel tank cap
EAU41831
Fuel
This motorcycle has been designed to
use a premixed fuel of gasoline and 2stroke engine oil. Always mix the gasoline and oil in a clean container before
filling the fuel tank.
ECA15601
CAUTION:
3
Always use fresh gasoline, and fill
the fuel tank with a fresh mix just before riding. Do not use premixed fuel
that is more than a few hours old.
1. Fuel tank cap
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it clockwise.
EWA11090
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
Mixing gasoline and 2-stroke engine
oil
Pour 2-stroke engine oil into a clean
container, and then add gasoline. To
mix the fuel thoroughly, shake the container from side to side.
1. 2-stroke engine oil
2. Gasoline
3. Container
Recommended fuel:
Premium unleaded gasoline only
Recommended 2-stroke engine oil:
See page 8-1.
Fuel tank capacity:
5.0 L (1.32 US gal) (1.10 Imp.gal)
Mixing ratios (gasoline to oil):
Break-in period: 15:1
After break-in: 30:1
ECA15590
CAUTION:
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the piston rings as well as to
the exhaust system.
3-3
U5PA85E0.book Page 4 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number
[(R+M)/2] of 91 or higher, or a research
octane number of 95 or higher. If
knocking (or pinging) occurs, use a
gasoline of a different brand.
If the recommended 2-stroke engine oil
is not available, use an equivalent oil.
Filling the fuel tank
ECA10070
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
3
ECA15551
CAUTION:
Never mix two brands of 2-stroke engine oil in the same batch. Always
use the same type of oil to ensure
maximum engine performance.
Should it be necessary to use a different oil brand, be sure to drain the
fuel tank and the carburetor float
chamber of the old premixed fuel
prior to filling with the new type.
1. Fuel level
2. Fuel tank filler tube
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EWA10880
WARNING
●
●
Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot engine.
3-4
U5PA85E0.book Page 5 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU41360
Fuel tank breather hose
EAU41280
Fuel cock
ON
The fuel cock supplies fuel from the
tank to the carburetor while filtering it also.
The fuel cock has two positions:
OFF
3
1. Arrow mark positioned over “ON”
1. Fuel tank breather hose
2. One-way valve
Before operating the motorcycle:
● Check the fuel tank breather hose
connection.
● Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.
● Make sure that the end of the fuel
tank breather hose is not blocked,
and clean it if necessary.
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
1. Arrow mark positioned over “OFF”
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
NOTE:
If the fuel tank breather hose falls out,
reinstall it on the fuel tank cap with the
arrow mark on the one-way valve pointed downward as shown.
3-5
U5PA85E0.book Page 6 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU13640
Starter (choke) knob
EAU13650
Kickstarter
EAU13960
Seat
To remove the seat
Remove the bolts, and then pull the
seat off.
3
1. Starter (choke) knob
1. Kickstarter lever
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the knob in direction (a) to turn on
the starter (choke).
Move the knob in direction (b) to turn off
the starter (choke).
To start the engine, fold out the kickstarter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but forcefully. This model is equipped with a primary kickstarter, allowing the engine to
be started in any gear if the clutch is
disengaged. However, shifting the
transmission into the neutral position
before starting is recommended.
3-6
1. Bolt
To install the seat
1. Insert the projections on the front
of the seat into the seat holders as
shown.
U5PA85E0.book Page 7 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU41470
Adjusting the front fork
This front fork is equipped with rebound
damping force adjusting screws and
compression damping force adjusting
screws.
EWA10180
WARNING
3
1. Projection
2. Seat holder
2. Place the seat in the original position, and then tighten the bolts.
Always adjust both fork legs equally, otherwise poor handling and loss
of stability may result.
Rebound damping force
soften the rebound damping, turn the
adjusting screw on each fork leg in direction (b).
Rebound damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard:
7 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
Compression damping force
NOTE:
Make sure that the seat is properly secured before riding.
1. Rebound damping force adjusting screw
To increase the rebound damping force
and thereby harden the rebound damping, turn the adjusting screw on each
fork leg in direction (a). To decrease the
rebound damping force and thereby
3-7
1. Rubber cap
2. Compression damping force adjusting screw
1. Remove the rubber cap by pulling
it out of the front fork leg.
U5PA85E0.book Page 8 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
2. To increase the compression
damping force and thereby harden
the compression damping, turn the
adjusting screw on each fork leg in
direction (a). To decrease the
compression damping force and
thereby soften the compression
damping, turn the adjusting screw
on each fork leg in direction (b).
Compression damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard:
YZ85(W)/YZ85W1: 10 click(s) in
direction (b)*
YZ85LW(W): 9 click(s) in direction
(b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
EAU14790
NOTE:
Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above specifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the
specifications as necessary.
Front fork bleeding
3
1. Bleed screw
When riding in extremely rough conditions, the air temperature and pressure
in the front fork will rise. This will increase the spring preload and harden
the front suspension. If this occurs,
bleed the front fork as follows.
1. Elevate the front wheel by placing
a suitable stand under the engine.
3. Install the rubber cap.
NOTE:
When bleeding the front fork, there
should be no weight on the front end of
the vehicle.
ECA10100
CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum or
minimum settings.
2. Remove the bleed screws and allow all of the air to escape from
each fork leg.
3-8
U5PA85E0.book Page 9 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
EWA10200
WARNING
Always bleed both fork legs, otherwise poor handling and loss of stability may result.
3. Install the bleed screws.
EAU41330
Adjusting the shock absorber
assembly
This shock absorber assembly is
equipped with a spring preload adjusting nut, a rebound damping force adjusting screw and a compression
damping force adjusting screw.
3
ECA10100
CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum or
minimum settings.
Spring preload
Adjust the spring preload as follows.
1. Loosen the locknut.
1. Locknut
2. Spring preload adjusting nut
3-9
2. To increase the spring preload and
thereby harden the suspension,
turn the adjusting nut in direction
(a). To decrease the spring preload and thereby soften the suspension, turn the adjusting nut in
direction (b).
NOTE:
● A special wrench can be obtained
at a Yamaha dealer to make this
adjustment.
● The spring preload setting is determined by measuring distance A,
shown in the illustration. The longer distance A is, the lower the
spring preload; the shorter distance A is, the higher the spring
preload. With each complete turn
of the adjusting nut, distance A is
changed by 1.5 mm (0.06 in).
U5PA85E0.book Page 10 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
ECA10120
CAUTION:
Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
1. Distance A
Spring preload:
Minimum (soft):
Distance A = 218.5 mm (8.60 in)
Standard: YZ85(W)/YZ85W1
Distance A = 215.0 mm (8.46 in)
For Europe only: Distance A =
212.0 mm (8.35 in)
Standard: YZ85LW(W)
Distance A = 207.0 mm (8.15 in)
For Europe only: Distance A =
212.0 mm (8.35 in)
Maximum (hard):
Distance A = 202.5 mm (7.97 in)
3. Tighten the locknut to the specified
torque.
Rebound damping force
To increase the rebound damping force
and thereby harden the rebound damping, turn the adjusting screw in direction
(a). To decrease the rebound damping
force and thereby soften the rebound
damping, turn the adjusting screw in direction (b).
Rebound damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard: YZ85(W)/YZ85W1
6 click(s) in direction (b)*
For Europe only: 12 click(s) in direction (b)*
Standard: YZ85LW(W)
7 click(s) in direction (b)*
For Europe only: 12 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
Compression damping force
To increase the compression damping
force and thereby harden the compression damping, turn the adjusting screw
in direction (a). To decrease the compression damping force and thereby
soften the compression damping, turn
the adjusting screw in direction (b).
1. Rebound damping force adjusting screw
Tightening torque:
Locknut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
3-10
3
U5PA85E0.book Page 11 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
ifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the
specifications as necessary.
3
EWA10220
1. Compression damping force adjusting screw
Compression damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard: YZ85(W)/YZ85W1
9 click(s) in direction (b)*
For Europe only: 12 click(s) in direction (b)*
Standard: YZ85LW(W)
7 click(s) in direction (b)*
For Europe only: 12 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
NOTE:
Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above spec-
WARNING
This shock absorber contains highly
pressurized nitrogen gas. For proper handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held responsible for property damage or
personal injury that may result from
improper handling.
● Do not tamper with or attempt to
open the gas cylinder.
● Do not subject the shock absorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
3-11
●
●
Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping performance.
Always have a Yamaha dealer
service the shock absorber.
U5PA85E0.book Page 12 Thursday, April 13, 2006 3:06 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU41381
Removable sidestand
3
1. Sidestand
This motorcycle is equipped with a removable sidestand.
NOTE:
Make sure that the sidestand is properly secured when the motorcycle is being supported or is being transported.
EWA14601
WARNING
●
●
Never apply force on the motorcycle while it is on the sidestand.
Always remove the sidestand
before starting out.
3-12
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
PRE-OPERATION CHECKS
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
4
EWA11150
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
4-1
U5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM
PRE-OPERATION CHECKS
EAU15605
Pre-operation check list
ITEM
CHECKS
PAGE
Fuel
• Check fuel level in fuel tank.
• Always use a fresh mixture of gasoline and oil.
• Check fuel line for leakage.
3-3
Transmission oil
• Check oil level in transmission case.
• If necessary, add recommended oil to specified level.
6-9
Coolant
• Check coolant level.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
6-10
Front brake
•
•
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-18, 6-19
Rear brake
•
•
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-18, 6-19
Clutch
•
•
•
•
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
Throttle grip
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
4
6-17
4-2
6-14, 6-22
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM
PRE-OPERATION CHECKS
ITEM
4
CHECKS
PAGE
Drive chain
•
•
•
•
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
6-20, 6-21
Wheels and tires
•
•
•
•
•
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Check for loose spokes and tighten if necessary.
6-15, 6-17
Shift pedal
• Make sure that operation is smooth.
• Correct if necessary.
6-23
Brake pedal
• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.
6-23
Steering
• Check that the handlebar can be turned smoothly and has no excessive play.
6-25
Front fork and rear shock absorber assembly
• Check that they operate smoothly and there is no oil leakage.
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
Moving parts and cables
• Check that the control cables move smoothly.
• Check that the control cables are not caught when the handlebars are turned or
when the front forks travel up and down.
• Lubricate moving parts and cables if necessary.
Exhaust system
• Check that the exhaust pipe is tightly mounted and has no cracks.
• Check for leakage.
—
Ignition system
• Check that all leads and cables are properly connected.
6-8
4-3
3-7, 3-8, 3-9, 6-24
—
6-22, 6-23, 6-24, 6-24
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
OPERATION AND IMPORTANT RIDING POINTS
EAU41400
EWA14610
WARNING
●
●
●
This model is designed for offroad use only. Become thoroughly familiar with all operating controls and their functions
before riding. Consult a Yamaha
dealer regarding any control or
function that you do not thoroughly understand.
Never start the engine or operate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
Before starting out, make sure
that the sidestand is removed. If
the sidestand is not removed, it
will contact the ground, which
could distract the operator or affect the balance of the motorcycle, resulting in a possible
loss of control.
EAU41300
Starting and warming up a
cold engine
1. Turn the fuel cock lever to “ON”.
2. Shift the transmission into the neutral position.
3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-6.)
4. Start the engine by pushing the
kickstarter lever down.
ECA11130
CAUTION:
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
5. When the engine is warm, turn the
starter (choke) off.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
5-1
EAU16660
Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm. Instead, start
the engine with the throttle slightly
open.
NOTE:
If the engine does not start after several
kicks, try again with the throttle 1/4 to
1/2 open.
5
U5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM
OPERATION AND IMPORTANT RIDING POINTS
EAU16671
Shifting
ECA10260
CAUTION:
●
5
1. Shift pedal
2. Neutral position
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the illustration.
●
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid damaging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16690
NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
To start out and accelerate
1. Pull the clutch lever to disengage
the clutch.
2. Shift the transmission into first
gear.
3. Open the throttle gradually and simultaneously release the clutch lever slowly.
5-2
4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle, and at the
same time, quickly pull the clutch
lever in.
5. Shift the transmission into second
gear. (Make sure not to shift the
transmission into the neutral position.)
6. Open the throttle halfway and
gradually release the clutch lever.
7. Follow the same procedure when
shifting to the next gear.
EAU16710
To decelerate
1. Close the throttle and apply both
the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and
shift the transmission into the neutral position when the motorcycle
is almost completely stopped.
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM
OPERATION AND IMPORTANT RIDING POINTS
EAU41502
Engine break-in
1. Before starting the engine, fill the
fuel tank with a break-in oil-fuel
mixture as follows.
Recommended 2-stroke engine oil:
See page 8-1.
Mixing ratio (gasoline to oil):
15:1
2. Start and warm up the engine.
Check the operation of the controls
and the engine stop button. (See
page 3-1.)
3. Operate the motorcycle in the lower gears at moderate throttle openings for five to eight minutes. Stop
the engine and check the spark
plug condition (see page 6-8); it
will show a rich condition during
break-in.
4. Allow the engine to cool. Restart
the engine and operate the motorcycle as in the step above for five
minutes. Then, very briefly shift to
the higher gears and check the
full-throttle response. Stop the engine and check the spark plug.
5. After again allowing the engine to
cool, restart and run the motorcycle for five more minutes. Full
throttle and the higher gears may
be used, but sustained full-throttle
operation should be avoided. Stop
the engine and check the spark
plug again.
6. Allow the engine to cool, remove
the cylinder head and cylinder, and
inspect the piston and cylinder.
Remove any high spots on the piston with #600-grit wet sandpaper.
Clean all components and carefully reassemble the cylinder head
and cylinder.
EWA10320
WARNING
If you are not familiar with maintenance work, have a Yamaha dealer
do it for you.
7. Drain the break-in oil-fuel mixture
from the fuel tank and refill with the
specified mix. (See page 3-3.)
8. Start the engine and check the operation of the motorcycle throughout its entire operating range. Stop
the engine and check the spark
5-3
plug condition. Restart the motorcycle and ride it for about 10 to 15
more minutes. The motorcycle will
now be ready to ride normally.
After the engine break-in period, thoroughly check the motorcycle for loose
parts, oil leakage and any other problems. Be sure to inspect and make adjustments thoroughly, especially cable
and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tighten if necessary.
ECA15560
CAUTION:
●
When any of the following parts
have been replaced, they must
be broken in.
Cylinder or crankshaft:
About one hour of break-in operation is necessary.
Piston, rings or transmission
gears:
These parts require about 30
minutes of break-in operation at
half-throttle or less. Observe the
condition of the engine carefully
during operation.
5
U5PA85E0.book Page 4 Thursday, April 13, 2006 3:06 PM
OPERATION AND IMPORTANT RIDING POINTS
●
If any engine trouble should occur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.
EAU17190
Parking
When parking, stop the engine, and
then turn the fuel cock lever to “OFF”.
EWA10310
WARNING
●
●
5
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
5-4
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17240
Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a general guide under normal riding conditions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED.
6
EWA10320
WARNING
If you are not familiar with maintenance work, have a Yamaha dealer
do it for you.
6-1
U5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41794
Periodic maintenance and lubrication chart
The following chart is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather,
terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are in
doubt as to what intervals to follow in maintaining and lubricating your motorcycle, consult your Yamaha dealer.
NOTE:
● From the seventh race, repeat the maintenance intervals starting from “Every race”.
● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO.
ROUTINE
After
break-in
Every
race
• Check piston for carbon deposits and cracks or damage.
• Clean.
√
√
√
√
ITEM
1 * Piston
6
Every
Every
third race fifth race
√
• Replace.
2 * Piston rings
3 *
Piston pin and small
end bearing
4 * Cylinder head
• Check piston ring end gap and rings for damage.
√
• Replace.
As
required
√
√
√
• Check piston pin and small end bearing for damage.
√
• Replace.
• Check cylinder head for carbon deposits.
• Clean.
√
√
• Check cylinder head gasket for damage.
• Tighten cylinder head bolts if necessary.
√
√
√
• Replace cylinder head gasket.
6-2
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
ITEM
5 * Cylinder
After
break-in
ROUTINE
• Check cylinder for score marks or wear.
• Clean.
√
Every
race
Every
Every
third race fifth race
√
√
• Replace.
6 * Clutch
• Check clutch housing, friction plates, clutch plates
and clutch springs for wear or damage.
• Adjust.
√
√
√
• Replace.
√
• Change the transmission oil.
7 * Transmission
• Check transmission for damage.
√
√
√
Shift forks, guide bars,
shift cam
• Check all parts for wear and damage.
• Replace if necessary.
9 *
Rotor nut
(flywheel magneto)
• Tighten.
11 * Exhaust system
12 * Crankshaft
√
• Replace bearings.
8 *
10 * Kickstarter system
As
required
√
6
√
• Check idle gear for damage.
• Replace if necessary.
√
• Check exhaust pipe and muffler for carbon deposits.
√
√
• Clean.
√
• Check crankshaft for carbon deposits and damage.
√
√
• Clean.
√
√
6-3
U5PA85E0.book Page 4 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
ITEM
13 * Carburetor
14
Spark plug
ROUTINE
After
break-in
Every
race
• Check carburetor settings and for obstructions.
√
√
• Adjust and clean.
√
√
• Check condition.
• Clean and regap.
√
√
Every
Every
third race fifth race
√
• Replace.
15
Drive chain
• Check chain slack, alignment and condition.
• Adjust and thoroughly lubricate chain with Yamaha
chain and cable lube or equivalent.
√
√
√
• Replace.
√
• Check coolant level and for leakage.
16 * Cooling system
6
√
√
• Check hoses for cracks or damage.
√
• Check radiator cap spring operation.
• Change coolant.
17 * Chassis fasteners
As
required
Every 2 years
• Check all chassis fitting and 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.
√
6-4
√
√
U5PA85E0.book Page 5 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
ROUTINE
After
break-in
Every
race
Adjust lever position and pedal height.
Lubricate pivot points.
Check brake disk surface.
Check fluid level and for leakage.
Tighten brake disk bolts, caliper bolts, master cylinder
bolts and union bolts.
√
√
ITEM
21 * Brakes
•
•
•
•
•
Every
Every
third race fifth race
√
• Replace brake pads.
• Replace brake fluid.
22 * Front fork
As
required
√
Every year
• Check operation and for oil leakage.
• Adjust if necessary.
• Clean dust seal and lubricate with lithium-soap-based
grease.
√
• Replace fork oil.
√
√
√
√
• Replace oil seals.
• Check operation and adjust.
√
• Tighten if necessary.
Shock absorber assem23 *
bly
• Lubricate with molybdenum disulfide grease.
6-5
√
√
√
(After
washing
the
motorcycle
or riding in
the rain)
6
U5PA85E0.book Page 6 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
24 *
ITEM
Drive chain roller and
support guide
25 * Rear suspension
26 * Steering head
After
break-in
ROUTINE
Every
race
Every
Every
third race fifth race
• Check for wear or damage.
• Replace if necessary.
√
• Check operation and tighten if necessary.
√
√
• Lubricate with molybdenum disulfide grease.
√
√
• Check operation, free play, and tighten if necessary.
√
√
√
• Clean and lubricate with lithium-soap-based grease.
√
• Replace bearings.
27 * Tires and wheels
6
• Check tire air pressure, wheel runout, spokes for
looseness, and tires for wear.
√
√
• Tighten sprocket bolts if necessary.
√
√
• Check wheel bearings for looseness.
√
• Lubricate wheel bearings with lithium-soap-based
grease.
√
√
• Replace wheel bearings.
Moving parts and ca28 *
bles
29 *
Throttle grip housing
and cable
As
required
• Lubricate.
√
√
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
√
√
EAU42010
NOTE:
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
6-6
U5PA85E0.book Page 7 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
• 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.
6
6-7
U5PA85E0.book Page 8 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
EAU19612
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
6
1. Spark plug cap
2. Remove the spark plug as shown,
with a spark plug wrench available
at a Yamaha dealer.
Specified spark plug:
NGK/BR10EG
1. Spark plug wrench
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:
If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to
diagnose such problems yourself. Instead, have a Yamaha dealer check
the vehicle.
6-8
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
1. Spark plug gap
Spark plug gap:
0.5–0.6 mm (0.020–0.024 in)
chapter6 Page 9 Tuesday, April 18, 2006 10:03 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
Tightening torque:
Spark plug:
20 Nm (2.0 m·kgf, 14 ft·lbf)
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
4. Install the spark plug cap.
EAU41441
Transmission oil
The transmission oil must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha dealer check and repair the motorcycle. In
addition, the transmission oil must be
changed at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place the motorcycle on a level
surface and hold it in an upright position.
3. Place an oil pan under the transmission to collect the used oil.
4. Remove the oil filler cap and drain
bolt to drain the oil from the transmission.
1. Oil filler cap
2. Transmission oil drain bolt
5. Install the transmission oil drain
bolt, and then tighten it to the specified torque.
6
Tightening torque:
Transmission oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
6. Add the specified amount of the
recommended transmission oil,
and then install and tighten the oil
filler cap.
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0.50 L (0.53 US qt) (0.44 Imp.qt)
6-9
chapter6 Page 10 Tuesday, April 18, 2006 10:03 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10452
CAUTION:
In order to prevent clutch slippage (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign material enters the transmission.
The coolant level should be checked
before each ride. In addition, the coolant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
7. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
Never attempt to remove the radiator
cap when the engine is hot.
●
●
6
EAU20070
Coolant
EAUM1291
To check the coolant level
1. Place the vehicle on a level surface and hold it in an upright position.
EWA10380
WARNING
2. Remove the radiator cap and
check the coolant level in the radiator.
1. Radiator cap
NOTE:
● The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
● Make sure that the vehicle is positioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
NOTE:
The coolant should be at the brim of the
radiator filler. The level will change with
variation of engine temperature.
6-10
chapter6 Page 11 Tuesday, April 18, 2006 10:03 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10380
WARNING
Never attempt to remove the radiator
cap when the engine is hot.
3. Remove the radiator cap.
5. After the coolant is completely
drained, thoroughly flush the cooling system with clean tap water.
6. Install the coolant drain bolt, and
then tighten it to the specified
torque.
NOTE:
Check the washer for damage and replace it if necessary.
1. Correct coolant level
3. If the coolant is below this level,
add coolant, and then install the
radiator cap.
NOTE:
If the engine overheats, see page 6-30
for further instructions.
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
7. Pour the recommended coolant
into the radiator until it is full.
1. Radiator cap
4. Remove the coolant drain bolt to
drain the cooling system.
EAUM1311
To change the coolant
1. Place the vehicle on a level surface and let the engine cool if necessary.
2. Place a container under the engine
to collect the used coolant.
1. Coolant drain bolt
6-11
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol antifreeze containing corrosion inhibitors
for aluminum engines
Coolant quantity:
Radiator capacity (including all
routes):
0.54 L (0.57 US qt) (0.48 Imp.qt)
6
chapter6 Page 12 Tuesday, April 18, 2006 10:03 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10471
CAUTION:
●
●
●
6
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not
be protected against frost and
corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
10. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
8. Install the radiator cap, start the
engine, let it idle for several minutes, and then turn it off.
9. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radiator, and then install the radiator
cap.
EAU41431
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more frequently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-6.)
2. Remove the air filter case cover as
shown.
1. Air filter case cover
6-12
U5PA85E0.book Page 13 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
The sponge material should be wet but
not dripping.
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
3. Remove the air filter element by
removing the wing bolt and washer.
1. Sponge material
2. Air filter element frame
5. Clean the sponge material with
solvent, and then squeeze the remaining solvent out.
7. Pull the sponge material over the
air filter element frame.
8. Insert the air filter element into the
air filter case with the projection
facing upward, and then install the
washer and wing bolt.
6
1. Wing bolt
2. Washer
3. Sponge material
4. Remove the sponge material from
the air filter element frame.
6. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the excess oil out.
6-13
1. Sponge material
2. Projection
U5PA85E0.book Page 14 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10480
CAUTION:
●
●
Make sure that the air filter element is properly seated in the
air filter case.
The engine should never be operated without the air filter element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
9. Install the air filter case cover in the
original position as shown.
EAU39930
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the
following section, however, may be serviced by the owner as part of routine
maintenance.
ECA10550
1. Throttle cable free play
CAUTION:
The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings
without sufficient technical knowledge may result in poor performance of or damage to the engine.
6
EAU21370
Adjusting the throttle cable
free play
10. Install the seat.
The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, adjust it as follows.
NOTE:
The engine idling speed must be correctly adjusted before checking and adjusting the throttle cable free play.
1. Loosen the locknut.
6-14
U5PA85E0.book Page 15 Friday, April 21, 2006 4:22 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
2. To increase the throttle cable free
play, turn the adjusting nut in direction (a). To decrease the throttle
cable free play, turn the adjusting
nut in direction (b).
EAU41820
Tires
Tire inspection
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
EWA14380
WARNING
●
1. Locknut
2. Throttle cable free play adjusting nut
3. Tighten the locknut.
●
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be adjusted in accordance with the
weight of the rider, the riding
speed, and the riding conditions.
Standard tire air pressure:
Front:
100 kPa (15 psi) (1.00 kgf/cm²)
Rear:
100 kPa (15 psi) (1.00 kgf/cm²)
6-15
2
1
1. Tire sidewall
2. Tire tread depth
The tires must be checked before each
ride.
ECA15580
CAUTION:
●
●
Be sure the bead stoppers are
tightened. Loose bead stoppers
will cause the tire to slip off the
rim if tire pressure is too low.
Be sure the valve stem is positioned straight. A tilted valve
stem indicates that the tire has
slipped from its original position on the rim. Rotate the tire
so that the valve stem is positioned straight.
6
U5PA85E0.book Page 16 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
If the center tread depth reaches the
specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer replace the tire immediately.
Minimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
EWA10460
WARNING
6
●
●
The front and rear tires should
be of the same make and design, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.
After extensive tests, only the
tires listed below have been approved for this model by
Yamaha Motor Co., Ltd.
Front tire:
Size:
YZ85 70/100-17 40M
YZ85LW 70/100-19 42M
YZ85LWW 70/100-19 42M
YZ85W 70/100-17 40M
YZ85W1 70/100-17 40M
Manufacturer/model:
YZ85 DUNLOP/D739FA (ZAF)
YZ85 DUNLOP/D756F
(AUT)(BEL)(CHE)(DEU)(DNK)(ES
P)(FIN)(FRA)(GBR)(GRC)(IRL)(N
LD)(NOR)(PRT)(SWE)
YZ85LW DUNLOP/D756F
YZ85LWW DUNLOP/D756F
YZ85W DUNLOP/D756F
YZ85W1 DUNLOP/D756F
Rear tire:
Size:
YZ85 90/100-14 49M
YZ85LW 90/100-16 52M
YZ85LWW 90/100-16 52M
YZ85W 90/100-14 49M
YZ85W1 90/100-14 49M
Manufacturer/model:
DUNLOP/D756
EWA14390
WARNING
●
Have a Yamaha dealer replace
excessively worn tires. Operating the motorcycle with exces6-16
●
●
sively worn tires decreases
riding stability and can lead to
loss of control.
The replacement of all wheeland brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
It is not recommended to patch
a punctured tube. If unavoidable, however, patch the tube
very carefully and replace it as
soon as possible with a highquality product.
U5PA85E0.book Page 17 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21940
Spoke wheels
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or damage before each ride. If any damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.
● The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse handling characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it
to develop its optimal characteristics.
EAU40431
Accessories and replacement
parts
EAU22031
Adjusting the clutch lever free
play
EWA14481
WARNING
The accessories or replacement
parts you choose for your vehicle
should be designed specifically for
this model, and they must be securely mounted to maintain the inherent stability of the original
design. Genuine Yamaha Parts and
Accessories are designed and tested to be compatible with your vehicle. Yamaha recommends the use of
Genuine Yamaha Parts and Accessories before making a purchase.
Use of non-Yamaha-approved accessories or replacement parts may
cause loss of handling stability and
riding safety. Since Yamaha cannot
control the quality of accessories or
parts manufactured by other companies, Yamaha cannot be held liable
for any consequences caused by
the use of items which have not
been approved by Yamaha.
6-17
1. Clutch lever free play
2. Locknut (clutch lever)
3. Adjusting bolt
The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch lever free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in direction (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
6
U5PA85E0.book Page 18 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
3. If the specified clutch lever free
play could be obtained as described above, tighten the locknut
and skip the rest of the procedure,
otherwise, proceed as follows.
4. Fully turn the adjusting bolt in direction (a) to loosen the clutch cable.
5. Loosen the locknut further down
the clutch cable.
EAU22390
Checking the front and rear
brake pads
EAU22500
Rear brake pads
The front and rear brake pads must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart.
EAU22400
Front brake pads
1. Lining thickness
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 1.0 mm (0.04 in),
have a Yamaha dealer replace the
brake pads as a set.
6
1. Lining thickness
1. Locknut (clutch cable)
2. Adjusting nut
6. To increase the clutch lever free
play, turn the adjusting nut in direction (a). To decrease the clutch lever free play, turn the adjusting nut
in direction (b).
7. Tighten both locknuts.
Check each front brake pad for damage and measure the lining thickness. If
a brake pad is damaged or if the lining
thickness is less than 0.8 mm (0.03 in),
have a Yamaha dealer replace the
brake pads as a set.
6-18
U5PA85E0.book Page 19 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22580
Checking the brake fluid level
Front brake
1. Minimum level mark
Rear brake
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:
● When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
● Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
Recommended brake fluid:
DOT 4
●
1. Minimum level mark
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it to become ineffective.
6-19
●
●
●
Be careful that water does not enter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
6
U5PA85E0.book Page 20 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22730
6
EAU22760
Changing the brake fluid
Drive chain slack
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic maintenance and lubrication chart. In addition,
have the oil seals of the master cylinders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
● Oil seals: Replace every two
years.
● Brake hoses: Replace every four
years.
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU41410
To check the drive chain slack
1. Install the removable sidestand
and place the motorcycle on it.
NOTE:
When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into the neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tightest portion of the drive chain, and
then measure the drive chain slack
as shown.
Drive chain slack:
35.0–45.0 mm (1.38–1.77 in)
6-20
1. Drive chain slack
4. If the drive chain slack is incorrect,
adjust it as follows.
EAU41480
To adjust the drive chain slack
1. Loosen the axle nut and the locknut on each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction (a). To loosen the drive chain, turn the adjusting bolt on each side of the
swingarm in direction (b), and then
push the rear wheel forward.
U5PA85E0.book Page 21 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Using the alignment marks on each
chain puller, make sure that both chain
pullers are in the same position for
proper wheel alignment.
3. Tighten both locknuts and the axle
nut to the specified torques.
Tightening torques:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
EAU23013
Cleaning and lubricating the
drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
ECA10581
CAUTION:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1.
2.
3.
4.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
Axle nut
Locknut
Drive chain slack adjusting bolt
Alignment marks
NOTE:
For a thorough cleaning, have a
Yamaha dealer remove the drive chain
and soak it in solvent.
ECA10570
CAUTION:
Improper drive chain slack will overload the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,
6-21
6
U5PA85E0.book Page 22 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
making sure that all side plates
and rollers have been sufficiently
oiled.
EAU41840
Checking and lubricating the
throttle grip and cable
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil SAE 10W-30 (API SE)
EWA10710
6
EAU23111
Checking and lubricating the
cables
WARNING
Damage to the outer housing of cables may result in internal rusting
and cause interference with cable
movement. Replace damaged cables as soon as possible to prevent
unsafe conditions.
6-22
U5PA85E0.book Page 23 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23131
Checking and lubricating the
brake and shift pedals
EAU23140
Checking and lubricating the
brake and clutch levers
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
Brake lever
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lubricated if necessary.
Clutch lever
6
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubricated if necessary.
6-23
U5PA85E0.book Page 24 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAUM1650
Lubricating the swingarm pivots
EAU23250
Lubricating the rear suspension
EAU23271
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
EWA10750
WARNING
Securely support the vehicle so that
there is no danger of it falling over.
6
The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
The pivoting points of the rear suspension must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
6-24
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level surface and hold it in an upright position.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
U5PA85E0.book Page 25 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23280
Checking the steering
ECA10590
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
EWA10750
WARNING
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
6-25
6
U5PA85E0.book Page 26 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23290
6
EAU24350
Checking the wheel bearings
Supporting the motorcycle
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand upright. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack under the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motorcycle stand is not available, by placing
6-26
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
U5PA85E0.book Page 27 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24360
Front wheel
4. Pull the wheel axle out, and then
remove the wheel.
EAU25080
Rear wheel
EAU41340
EAU41310
To remove the front wheel
To remove the rear wheel
EWA10820
EWA10820
WARNING
●
●
WARNING
●
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motorcycle so that there is no danger
of it falling over.
1. Loosen the axle nut.
●
1. Wheel axle
EAU41420
1. Washer
2. Axle nut
2. Lift the front wheel off the ground
according to the procedure on
page 6-26.
3. Remove the axle nut and washer.
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle from the right
side.
3. Lower the front wheel so that it is
on the ground.
4. Install the washer and axle nut,
and then tighten the axle nut to the
specified torque.
Tightening torque:
Axle nut:
70 Nm (7.0 m·kgf, 50 ft·lbf)
6-27
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motorcycle so that there is no danger
of it falling over.
1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-26.
3. Loosen the locknut and drive chain
adjusting bolt on each side of the
swingarm.
4. Remove the axle nut and washer.
6
U5PA85E0.book Page 28 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
● Make sure that the retainer on the
swingarm is inserted into the slot in
the brake caliper bracket.
● Make sure that there is enough
space between the brake pads before installing the wheel.
1.
2.
3.
4.
6
Axle nut
Washer
Locknut
Drive chain slack adjusting bolt
5. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:
● If the drive chain is difficult to remove, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
● The drive chain cannot be disassembled.
6. While supporting the brake caliper
and slightly lifting the wheel, pull
the wheel axle out.
1. Wheel axle
NOTE:
A rubber mallet may be useful to tap the
wheel axle out.
7. Remove the wheel.
ECA11070
CAUTION:
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU41320
To install the rear wheel
1. Install the wheel and the brake caliper bracket by inserting the wheel
axle from the right-hand side.
6-28
1. Retainer
2. Slot
2. Install the drive chain onto the rear
sprocket.
3. Install the washer and axle nut,
and then lower the rear wheel so
that it is on the ground.
4. Adjust the drive chain slack. (See
page 6-20.)
5. Tighten the axle nut to the specified torque.
U5PA85E0.book Page 29 Thursday, April 13, 2006 3:06 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25870
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like
Yamaha parts, but they are often inferior, have a shorter service life and can
lead to expensive repair bills.
6-29
6
chapter6 Page 30 Tuesday, April 18, 2006 10:09 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41491
Troubleshooting charts
Starting problems or poor engine performance
EWA10840
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
Check the fuel level in
the fuel tank.
There is
enough fuel.
Check the compression.
There is
no fuel.
Supply fuel.
The engine does not start.
Check the compression.
6
2. Compression
There is compression.
Check the ignition.
There is
no compression.
Have a Yamaha dealer
check the vehicle.
Operate the kickstarter.
3. Ignition
Wet
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Open the throttle halfway and operate
the kickstarter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer check the vehicle.
Remove the spark plug
and check the electrodes.
6-30
chapter6 Page 31 Tuesday, April 18, 2006 10:09 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EWAT1040
WARNING
●
●
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap
while turning it counterclockwise, and then remove the cap.
The coolant level is low.
Check the cooling system
for leakage.
Wait until the
engine has cooled.
Check the coolant level in the
radiator.
The coolant level
is OK.
There is
leakage.
There is
no leakage.
Have a Yamaha dealer check
and repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
6-31
6
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
MOTORCYCLE CARE AND STORAGE
ucts onto seals, gaskets, sprockets, the drive chain and wheel
axles. Always rinse the dirt and degreaser off with water.
EAU41351
Care
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a motorcycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
7
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
●
Cleaning
ECA10770
CAUTION:
●
●
●
Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a corrosion protection spray.
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
7-1
●
cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors,
instruments,
switches and lights), breather
hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning compounds for plastic may leave
scratches on the windshield.
Test the product on a small hidden part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing
compound
after
washing.
U5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM
MOTORCYCLE CARE AND STORAGE
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain or near the sea
Since sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold water and a mild detergent, after the
engine has cooled down.
ECA10790
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
5. Use spray oil as a universal cleaner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA11130
WARNING
●
Make sure that there is no oil or
wax on the brakes or tires.
7-2
●
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cornering behavior.
ECA10800
CAUTION:
●
●
●
Apply spray oil and wax sparingly and make sure to wipe off
any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
7
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM
MOTORCYCLE CARE AND STORAGE
EAU41511
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10810
CAUTION:
●
●
7
Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your motorcycle for several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” position: Turn the fuel cock lever to
“OFF”.
3. Drain the fuel tank and fuel lines,
and the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up.
4. Perform the following steps to protect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit sparking during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
7-3
EWA10950
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
5. Lubricate all control cables and the
pivoting points of all levers and
pedals.
6. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
7. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
NOTE:
Make any necessary repairs before
storing the motorcycle.
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
SPECIFICATIONS
Dimensions:
Overall length:
YZ85 1818 mm (71.6 in)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)(
FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)(
SWE)
YZ85 1821 mm (71.7 in) (ZAF)
YZ85LW 1903 mm (74.9 in)
YZ85LWW 1903 mm (74.9 in)
YZ85W 1818 mm (71.6 in)
YZ85W1 1818 mm (71.6 in)
Overall width:
758 mm (29.8 in)
Overall height:
YZ85 1161 mm (45.7 in)
YZ85LW 1205 mm (47.4 in)
YZ85LWW 1205 mm (47.4 in)
YZ85W 1161 mm (45.7 in)
YZ85W1 1161 mm (45.7 in)
Seat height:
YZ85 864 mm (34.0 in)
YZ85LW 904 mm (35.6 in)
YZ85LWW 904 mm (35.6 in)
YZ85W 864 mm (34.0 in)
YZ85W1 864 mm (34.0 in)
Wheelbase:
YZ85 1255 mm (49.4 in)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)(
FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)(
SWE)
YZ85 1258 mm (49.5 in) (ZAF)
YZ85LW 1286 mm (50.6 in)
YZ85LWW 1286 mm (50.6 in)
YZ85W 1255 mm (49.4 in)
YZ85W1 1255 mm (49.4 in)
Ground clearance:
YZ85 351 mm (13.82 in)
YZ85LW 393 mm (15.47 in)
YZ85LWW 393 mm (15.47 in)
YZ85W 351 mm (13.82 in)
YZ85W1 351 mm (13.82 in)
Weight:
Transmission oil:
Type:
YAMALUBE 4 (10W30) or SAE10W30 type
SE motor oil
Oil change quantity:
0.50 L (0.53 US qt) (0.44 Imp.qt)
Cooling system:
Radiator capacity (including all routes):
0.54 L (0.57 US qt) (0.48 Imp.qt)
Air filter:
With oil and fuel:
YZ85 71.0 kg (157 lb)
YZ85LW 73.9 kg (163 lb)
YZ85LWW 73.9 kg (163 lb)
YZ85W 71.0 kg (157 lb)
YZ85W1 71.0 kg (157 lb)
Engine:
Engine type:
Liquid cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
84.7 cm³ (5.17 cu.in)
Bore × stroke:
47.5 × 47.8 mm (1.87 × 1.88 in)
Compression ratio:
8.20 :1
Starting system:
Kickstarter
Lubrication system:
Premix
Engine oil:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
5.0 L (1.32 US gal) (1.10 Imp.gal)
Carburetor:
Manufacturer:
KEIHIN
Type × quantity:
PWK28 x 1
Spark plug (s):
Manufacturer/model:
NGK/BR10EG
Spark plug gap:
0.5–0.6 mm (0.020–0.024 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Spur gear
Type:
YAMALUBE 2-R
8-1
8
U5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM
SPECIFICATIONS
8
Primary reduction ratio:
65/18 (3.611)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
YZ85 47/14 (3.357) (ZAF)
YZ85 48/14 (3.428)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)(
FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)(
SWE)
YZ85LW 52/14 (3.714)
YZ85LWW 52/14 (3.714)
YZ85W 47/14 (3.357)
YZ85W1 48/14 (3.428)
Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
Gear ratio:
1st:
27/11 (2.454)
2nd:
32/17 (1.882)
3rd:
26/17 (1.529)
4th:
22/17 (1.294)
5th:
26/23 (1.130)
6th:
25/25 (1.000)
Chassis:
Frame type:
Semi double cradle
Caster angle:
YZ85 26.30 °
YZ85LW 26.90 °
YZ85LWW 26.90 °
YZ85W 26.30 °
YZ85W1 26.30 °
Trail:
YZ85 88.0 mm (3.46 in)
YZ85LW 105.5 mm (4.15 in)
YZ85LWW 105.5 mm (4.15 in)
YZ85W 88.0 mm (3.46 in)
YZ85W1 88.0 mm (3.46 in)
Front tire:
Type:
With tube
Size:
YZ85 70/100-17 40M
YZ85LW 70/100-19 42M
YZ85LWW 70/100-19 42M
YZ85W 70/100-17 40M
YZ85W1 70/100-17 40M
Manufacturer/model:
YZ85 DUNLOP/D739FA (ZAF)
YZ85 DUNLOP/D756F
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)(
FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)(
SWE)
YZ85LW DUNLOP/D756F
YZ85LWW DUNLOP/D756F
YZ85W DUNLOP/D756F
YZ85W1 DUNLOP/D756F
Rear tire:
Type:
With tube
8-2
Size:
YZ85 90/100-14 49M
YZ85LW 90/100-16 52M
YZ85LWW 90/100-16 52M
YZ85W 90/100-14 49M
YZ85W1 90/100-14 49M
Manufacturer/model:
DUNLOP/D756
Tire air pressure (measured on cold
tires):
Front:
100 kPa (15 psi) (1.00 kgf/cm²)
Rear:
100 kPa (15 psi) (1.00 kgf/cm²)
Front wheel:
Wheel type:
Spoke wheel
Rim size:
YZ85 17x1.40
YZ85LW 19x1.40
YZ85LWW 19x1.40
YZ85W 17x1.40
YZ85W1 17x1.40
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
YZ85 14x1.60
YZ85LW 16x1.85
YZ85LWW 16x1.85
YZ85W 14x1.60
YZ85W1 14x1.60
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM
SPECIFICATIONS
Front brake:
Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Electrical system:
Ignition system:
CDI
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
275.0 mm (10.83 in)
Rear suspension:
Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
YZ85 282.0 mm (11.10 in)
YZ85LW 287.0 mm (11.30 in)
YZ85LWW 287.0 mm (11.30 in)
YZ85W 282.0 mm (11.10 in)
YZ85W1 282.0 mm (11.10 in)
8
8-3
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
CONSUMER INFORMATION
EAU40790
Identification numbers
EAU26400
EAU26460
Vehicle identification number
Model label
1. Vehicle identification number
1. Model label
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
The model label is affixed to the location shown. Record the information on
this label in the space provided. This information will be needed when ordering
spare parts from a Yamaha dealer.
Record the vehicle identification number and model label information in the
spaces provided below for assistance
when ordering spare parts from a
Yamaha dealer or for reference in case
the vehicle is stolen.
VEHICLE IDENTIFICATION
NUMBER:
MODEL LABEL INFORMATION:
9
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in your
area.
9-1
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
INDEX
A
Accessories and replacement parts ..... 6-17
Air filter element, cleaning .................... 6-12
B
Brake and clutch levers, checking
and lubricating .................................... 6-23
Brake and shift pedals, checking
and lubricating .................................... 6-23
Brake fluid, changing ............................ 6-20
Brake fluid level, checking .................... 6-19
Brake lever ............................................. 3-2
Brake pedal ............................................ 3-2
C
Cables, checking and lubricating.......... 6-22
Carburetor, adjusting ............................ 6-14
Care........................................................ 7-1
Clutch lever............................................. 3-1
Clutch lever free play, adjusting ........... 6-17
Coolant ................................................. 6-10
D
Drive chain, cleaning and lubricating.... 6-21
Drive chain slack .................................. 6-20
E
Engine break-in ...................................... 5-3
Engine, starting a warm.......................... 5-1
Engine stop button.................................. 3-1
F
Front and rear brake pads, checking.... 6-18
Front fork, adjusting................................ 3-7
Front fork, bleeding................................. 3-8
Front fork, checking .............................. 6-24
Fuel......................................................... 3-3
Fuel cock ................................................ 3-5
Fuel tank breather hose.......................... 3-5
Swingarm pivots, lubricating ................. 6-24
Fuel tank cap...........................................3-3
H
Handlebar switch.....................................3-1
I
Identification numbers .............................9-1
K
Kickstarter ...............................................3-6
L
Labels, location of ...................................1-4
M
Model label..............................................9-1
P
Parking ....................................................5-4
Part locations ..........................................2-1
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list...........................4-2
R
Rear suspension, lubricating.................6-24
S
Safety information ...................................1-1
Seat.........................................................3-6
Shifting ....................................................5-2
Shift pedal ...............................................3-1
Shock absorber assembly, adjusting ......3-9
Sidestand ..............................................3-12
Spark plug, checking...............................6-8
Specifications ..........................................8-1
Starter (choke) knob................................3-6
Starting and warming up a cold
engine ...................................................5-1
Steering, checking.................................6-25
Storage....................................................7-3
Supporting the motorcycle ....................6-26
T
Throttle cable free play, adjusting......... 6-14
Throttle grip and cable, checking
and lubricating .................................... 6-22
Tires...................................................... 6-15
Transmission oil...................................... 6-9
Troubleshooting .................................... 6-29
Troubleshooting charts ......................... 6-30
V
Vehicle identification number.................. 9-1
W
Wheel bearings, checking..................... 6-26
Wheel (front) ......................................... 6-27
Wheel (rear).......................................... 6-27
Wheels.................................................. 6-17
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2006.04-1.4×1 CR
(E)