YZ85 (2002) - Motorcycle YAMAHA - Free user manual and instructions

Brand	Yamaha
Model	YZ85 (2002)
Product type	Off-road motorcycle (dirt bike)
Category	Motorcycle
Year	2002
Engine	Single-cylinder 2-stroke, 84.7 cm³
Fuel system	Mikuni VM24SS carburetor
Fuel tank capacity	5.5 L
Transmission	6-speed, chain
Front suspension	36 mm inverted telescopic fork
Rear suspension	Adjustable mono-shock
Front brakes	190 mm disc
Rear brakes	190 mm disc
Length	1,925 mm
Width	755 mm
Height	1,120 mm
Wheelbase	1,285 mm
Seat height	840 mm
Dry weight	68 kg
Curb weight	72 kg
Front tires	70/100-19
Rear tires	90/100-16
Engine oil (premix)	Semi-synthetic or synthetic 2-stroke oil
Spark plug	NGK BR10EG or equivalent
Routine maintenance	Oil change, air filter, chain, suspension
Spare parts	Available at Yamaha dealerships or online

Frequently Asked Questions - YZ85 (2002) YAMAHA

What type of oil should I use for the mixture?

Use a quality semi-synthetic or synthetic 2-stroke oil, mixed at 25:1 (for example 40 ml of oil per 1 liter of gasoline) or according to the manual's recommendations.

What spark plug do you recommend?

The recommended spark plug is an NGK BR10EG or equivalent. Tighten it to a torque of 20 N·m.

What tire pressure for the motorcycle?

Front tires: 1.0 bar (15 psi); rear tires: 1.0 to 1.2 bar (15-18 psi) depending on terrain. Adjust according to your weight and conditions.

How to adjust the chain?

Loosen the rear wheel axle and tension nuts, tighten the chain to have a vertical slack of 35-45 mm in the middle, then retighten.

What is the routine maintenance schedule?

Oil change and air filter every 5 hours, suspension and brake check every 20 hours, and chain lubrication after each ride.

The motorcycle has trouble starting, what should I do?

Check the spark plug, fuel supply, choke, and air filter. Make sure the oil-gas mixture is correct. Clean the carburetor if necessary.

What type of gasoline should I use?

Use unleaded gasoline with 95 or 98 octane. Avoid fuels with a high proportion of ethanol.

How to maintain the air filter?

Clean the foam air filter with a mild detergent or a special cleaner, lightly oil it after drying. Replace it every 20 to 30 hours.

Where to find spare parts?

At any Yamaha dealership or on specialized motorcycle parts websites. Use the part number indicated in the manual.

How to check the transmission oil level?

The YZ85 does not have a separate transmission oil reservoir; the oil is mixed with the gasoline. Instead, check the fork oil and shock absorber oil levels.

USER MANUAL YZ85 (2002) YAMAHA

OWNER'S SERVICE MANUAL

MANUEL D'ATELIER DU

PROPRIETAIRE

FAHRER- UND

WARTUNGS-HANDBUCH

YZ85(R)/LC

YZ85L W(R)

5PA-28199-81

YZ85(R)/LC

YZ85LW(R)

OWNER'S SERVICE MANUAL

©2002 by Yamaha Motor Co., Ltd.

1st Edition, April 2002

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

YZ85(R)/LC

YZ85LW(R)

MANUEL D'ATELIER

DU PROPRIETAIRE

©2002 Yamaha Motor Co., Ltd.

Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha's vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.

This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.

NOTE:

As improvements are made on this model, some data in this manual may become outdated. If you have any questions, please consult your Yamaha dealer.

WARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

INTRODUCTION

THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.

SAFETY INFORMATION

1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY.

Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.

1. THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.

Do not carry passengers on this machine.

1. ALWAYS WEAR PROTECTIVE APPAREL.

When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine.

1. ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.

For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident.

1. GASOLINE IS HIGHLY FLAMMABLE.

Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.

NOTICE IMPORTANTE

If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.

7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILA-TION.

Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.

8. PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.

Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over.

9. THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN.

Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.

10. PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.

When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

1. L'ESSENCE PEUT CAUSER DES BLES- SURES.

This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.

NOTE:

This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.

EC060000

NOTICE

Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer.

AU NOUVEAU PROPRIETAIRE

HOW TO USE THIS MANUAL

EC081000

PARTICULARLY IMPORTANT INFORMATION

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 machine operator, a bystander, or a person inspecting or repairing the machine.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters; "General information", "Specifications", "Regular inspection and adjustments", "Engine", "Chassis", "Electrical" and "Tuning".

2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

COMMENT UTILISER CE MANUEL

INFORMATIONS PARTICULIE- REMENT IMPORTANTES

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,

- Bearings

Pitting/damage → Replace.

EC084002

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1. An easy-to-see exploded diagram ① is provided for removal and disassembly jobs.
2. Numbers ② are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks ③. The meanings of the symbol marks are given on the next page.
4. A job instruction chart ④ accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
5. Extent of removal ⑤ is provided in the job instruction chart to save the trouble of an unnecessary removal job.
6. For jobs requiring more information, the step-by-step format supplements ⑥ are given in addition to the exploded diagram and job instruction chart.

FORMAT DU MANUEL

ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols ① to ⑦ are designed as thumb tabs to indicate the chapter's number and content.

① General information
② Specifications
③ Regular inspection and adjustments
④ Engine
⑤ Chassis
⑥ Electrical
⑦ Tuning

Illustrated symbols ⑧ to ⑭ are used to identify the specifications appearing in the text.

⑧ With engine mounted
⑨ Special tool
⑩ Filling fluid
⑪ Lubricant
⑫ Tightening
⑬ Specified value, Service limit
⑭ Resistance (Ω), Voltage (V), Electric current (A)

Illustrated symbols ⑮ to ⑲ in the exploded diagrams indicate grade of lubricant and location of lubrication point.

⑮ Apply transmission oil
⑯ Apply engine oil
⑰ Apply molybdenum disulfide oil
⑱ Apply lightweight lithium-soap base grease
⑲ Apply molybdenum disulfide grease

Illustrated symbols ⑳ to ㉑ in the exploded diagrams indicate where to apply a locking agent and where to install new parts.

⑳ Apply locking agent (LOCTITE®)
②1 Use new one

SYMBOLES GRAPHIQUES (Voir l'illustration)

CHECKING OF CONNECTION ....1-6

SPECIAL TOOLS 1-7

CONTROL FUNCTIONS....1-9

FUEL AND ENGINE MIXING OIL....1-12

STARTING AND BREAK-IN....1-13

TORQUE-CHECK POINTS....1-16

CLEANING AND STORAGE 1-17

CHAPTER 2 SPECIFICATIONS

GENERAL SPECIFICATIONS....2-1

MAINTENANCE SPECIFICATIONS....2-4

ENGINE 2-4

CHASSIS....2-8

YZ85 2-8

YZ85LW....2-10

ELECTRICAL 2-14

GENERAL TORQUE

SPECIFICATIONS 2-15

DEFINITION OF UNITS ......2-15

CABLE ROUTING DIAGRAM 2-16

TABLES DES MATIERES

CHAPITRE 1 RENSEIGNEMENTS GENERAUX

DESCRIPTION.... 1-1

IDENTIFICATION DE LA MOTO.... 1-2

INFORMATIONS IMPORTANTES ...... 1-3

VERIFICATION DES CONNEXIONS ..... 1-6

OUTILS SPECIAUX 1-7

FONCTIONS DES COMMANDES ...... 1-9

MELANGE CARBURANT

ET HUILE MOTEUR.... 1-12

MISE EN MARCHE ET RODAGE.... 1-13

POINTS DE VERIFICATION

DE COUPLE DE SERRAGE.... 1-16

NETTOYAGE ET REMISAGE 1-17

CHAPITRE 2 CARACTERISTIQUES

CARACTERISTIQUES GENERALES...... 2-1

CARACTERISTIQUES D'ENTRETIEN..... 2-4

MOTEUR.... 2-4

CHASSIS.... 2-8

YZ85 2-8

YZ85LW 2-10

PARTIE ELECTRIQUE.... 2-14

CARACTERISTIQUES GENERALES DE

COUPLE 2-15

DEFINITION DES UNITES.... 2-15

CHEMINEMENT DES CABLES...... 2-16

INHALT

CARBURETOR AND REED VALVE .....4-6

CYLINDER HEAD, CYLINDER

AND PISTON 4-15

CLUTCH AND PRIMARY

DRIVEN GEAR 4-26

KICK SHAFT, SHIFT SHAFT

AND PRIMARY DRIVE GEAR....4-33

WATER PUMP 4-41

CDI MAGNETO 4-45

ENGINE REMOVAL....4-49

CRANKCASE AND CRANKSHAFT .....4-53

TRANSMISSION, SHIFT CAM

AND SHIFT FORK....4-59

CHAPITRE 3 CONTROLES ET REGLAGES PERIODIQUES

PROGRAMME D'ENTRETIEN.... 3-1

CONTROLE ET ENTRETIEN

AVANT UTILISATION 3-4

MOTEUR.... 3-5

CHASSIS.... 3-16

PARTIE ELECTRIQUE 3-36

CHAPITRE 4 MOTEUR

SELLE, RESERVOIR DE CARBURANT

FOURCHE AVANT.... 5-27

GUIDON 5-41

DIRECTION.... 5-46

BRAS OSCILLANT.... 5-51

AMORTISSEUR ARRIERE.... 5-59

KAPITEL 5 FAHRWERK

VORDER- UND HINTERRAD ....5-1

VORDER- UND

HINTERRADBREMSE 5-9

TELESKOPGABEL 5-27

LENKER DEMONTIEREN ....5-41

LENKKOPF 5-46

SCHWINGE 5-51

FEDERBEIN 5-59

CHAPITRE 6 PARTIE ELECTRIQUE

COMPOSANTS ELECTRIQUES

CHAPITRE 7 MISE AU POINT

MOTEUR....7-1

CHASSIS.... 7-10

①Clutch lever
②Engine stop switch
③Front brake lever
④Throttle grip
⑤Fuel tank cap
⑥Radiator cap
⑦Kickstarter crank
⑧Fuel tank
⑨Coolant drain bolt
⑩Rear brake pedal
⑪Radiator
⑫Valve joint
⑬Fuel cock
⑭Air filter
⑮Drive chain
⑯Shift pedal
⑰Starter knob
⑱Front fork

NOTE:

• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.

RENSEIGNEMENTS GENERAUX DESCRIPTION

There are two significant reasons for knowing the serial number of your machine:

1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own.
2. If your machine is stolen, the authorities will need the number to search for and identify your machine.

EC121001

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number ① is stamped on the right of the steering head pipe.

Technical line drawing of a mechanical assembly with labeled components (no readable text or symbols)

EC123001

ENGINE SERIAL NUMBER

The engine serial number ① is stamped into the elevated part of the right-side of the engine.

EC124000

MODEL LABEL

The model label ① is affixed to the frame under the rider's seat. This information will be needed to order spare parts.

IDENTIFICATION DE LA MOTO

Illustration of a person cleaning a motorcycle with mechanical components and cleaning steps (no text or symbols)

EC130000

IMPORTANT INFORMATION

EC131010

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts follows.

2. Silencer exhaust port

3. Side cover air intake port
   • Crankcase cover hole at the bottom
   • Water pump housing hole at the bottom

Cartoon illustration of a mechanic working on a motorcycle with tools (no text or symbols)

1. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS" section.

Cartoon illustration of a smiling worker using a power tool (no text or symbols)

1. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.

Cartoon illustration of a man sitting on the floor surrounded by stacks of money and a question mark above his head (no text or symbols)

1. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

2. Keep away from fire.

INFORMATIONS IMPORTANTES PREPARATION A LA DEPOSE ET AU DEMONTAGE

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

EC133000

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

EC134000

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock washers/plates ① and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

EC135001

BEARINGS AND OIL SEALS

1. Install the bearing(s) ① and oil seal(s) ② with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

CAUTION:

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

PIECES DE RECHANGE

EC136000

CIRCLIPS

1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip ①, make sure that the sharp-edged corner ② is positioned opposite to the thrust ③ it receives. See the sectional view.

④ Shaft

CIRCLIPS

Two-panel line drawing showing a hand holding a tool, with no text or symbols present.

Pure electrical circuit lines without any symbols

Diagram of a multimeter connected to two cables with wires, no text or symbols present

EC1C0001

CHECKING OF CONNECTION

Dealing with stains, rust, moisture, etc. on the connector.

1. Disconnect:

- Connector

1. Dry each terminal with an air blower.

2. Connect and disconnect the connector two or three times.

3. Pull the lead to check that it will not come off.

4. If the terminal comes off, bend up the pin ① and reinsert the terminal into the connector.

5. Connect:

- Connector

NOTE:

The two connectors "click" together.

1. Check for continuity with a tester.

NOTE:

- If there in no continuity, clean the terminals.

- Be sure to perform the steps 1 to 7 listed above when checking the wireharness.

- For a field remedy, use a contact revitalizer available on the market.

- Use the tester on the connector as shown.

VERIFICATION DES CONNEXIONS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

NOTE:

• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".
• For others, use part number starting with "90890-".

Part number Tool	name/How to use Illustration
YU-1135-A, 90890-01135 Crankcase separating toolThis tool is used to split the crankcase as well as remove the crankshaft from either case.		YU-1135-A 90890-01135
YM-1189, 90890-01189 Flywheel pullerThis tool is used to remove the flywheel magneto.		YM-1189 90890-01189
YU-1235, 90890-01235 Rotor holding toolThis tool is used when loosening or tightening the fly-wheel magneto securing nut.		YU-1235 90890-01235
YU-3097, 90890-01252 YU-1256	Dial gauge and standStandThese tools are used to check each part for runout or bent.	YU-3097YU-1256	90890-01252
YU-90050, 90890-01274 YU-90050, 90890-01275 YM-1277, 90890-01277	Crankshaft installing toolCrankshaft installing potCrankshaft installing boltAdapter (M10)These tools are used to install the crankshaft.	YU-90050YM-1277	90890-0127490890-0127590890-01277
YU-1304, 90890-01304 Piston pin puller setThis tool is used to remove the piston pin.		YU-1304 90890-01304
YU-24460-01, 90890-01325 YU-33984, 90890-01352	Radiator cap testerRadiator cap tester adapterThese tools are used for checking the cooling sys-tem.	YU-24460-01YU-33984	90890-0132590890-01352
YU-33975, 90890-01403 Steering nut wrenchThis tool is used when tighten the steering ring nut to specification.		YU-33975 90890-01403
YM-01434, 90890-01434 Rod holderThis tool is used to hold the fork spring.		YM-01434 90890-01434
YM-01437, 90890-01437 90890-01436	Rod pullerRod puller attachment (M10)These tools are used to pull up the fork damper rod.	YM-01437 90890-01437	9089
YM-01442, 90890-01442 Fork seal driverThis tool is used when install the fork oil seal.		YM-01442 90890-01442
YM-01454, 90890-01454 Damper rod holderUse this tool to remove and install the damper rod.		YM-01454	90890-01454
YU-3112-C, 90890-03112 Pocket testerUse this tool to inspect the coil resistance, output voltage and amperage.		YU-3112-C 90890-03112
YM-91042, 90890-04086 Clutch holding toolThis tool is used to hold the clutch when removing or installing the clutch boss securing nut.		YM-91042 90890-04086
YM-34487 90890-06754	Dynamic spark testerIgnition checkerThis instrument is necessary for checking the ignition system components.	YM-34487 90890-06754
ACC-QUICK-GS-KT 90890-85505	Quick gasket®YAMAHA Bond No. 1215This sealant (Bond) is used for crankcase mating surface, etc.	ACC-QUICK-GS-KT 90890-85505

OUTILS SPECIAUX

Technical line drawing of a mechanical assembly with labeled component (1), no readable text or symbols present

Mechanical assembly diagram showing a lever mechanism with labeled component (1), no text or symbols present

EC150000

CONTROL FUNCTIONS

ENGINE STOP SWITCH

The engine stop switch ① is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop.

EC152000

CLUTCH LEVER

The clutch lever ① is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.

EC153000

SHIFT PEDAL

The gear ratios of the constant-mesh 6 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal ① on the left side of the engine.

KICKSTARTER CRANK

Rotate the kickstarter crank ① away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.

EC155001

THROTTLE GRIP

The throttle grip ① is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.

FONCTIONS DES COMMANDES

COUPE-CIRCUIT DU MOTEUR

Technical line drawing of a mechanical lever assembly (no text or symbols)

Technical line drawing of a mechanical assembly with labeled component (no text or symbols present)

EC156000

FRONT BRAKE LEVER

The front brake lever ① is located on the right handlebar. Pull it toward the handlebar to activate the front brake.

EC157000

REAR BRAKE PEDAL

The rear brake pedal ① is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.

EC158001

FUEL COCK

The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the two positions:

OFF: With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.

ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

EC159000

STARTER KNOB (CHOKE)

When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is controlled by the starter knob ①, supplies this mixture. Pull the starter knob out to open the circuit for starting. When the engine has warmed up, push it in to close the circuit.

LEVIER DE FREIN AVANT

EC15F000

VALVE JOINT

This valve joint ① prevents fuel from flowing out and is installed to the fuel tank breather hose.

CAUTION:

In this installation, make sure the arrow faces the fuel tank and also downward.

EC15R001

DETACHABLE SIDESTAND

This sidestand ① is used to support only the machine when standing or transporting it.

WARNING

• Never apply additional force to the side-stand.
• Remove this sidestand before starting out.

NIPPLE WRENCH

This nipple wrench ① is used to tighten the spoke.

AIR FILTER CASE COVER

In order to prevent water from entering the carburetor while the machine is operated in the rain, attach the air filter case cover ① to the rear frame.

• Air filter case cover installation
1. Set the air filter case cover as shown, and install it to the seat rail of the rear frame while rotating air filter case cover in the direction of the arrow.
2. Using a conventional screwdriver, hold up the front of the air filter case cover.

Then engage the groove ⓐ in the cover over the air filter case edge ⓑ.

FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION

CLAPET DE RENIFLARD

CLE A EMBOUTS DE RAYONS

Mix oil with the gas at the ratio specified below. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old.

Recommended fuel:

Except for ZA:

Premium unleaded gasoline only with a research octane number of 95 or higher.

For ZA:

Premium gasoline

NOTE:

If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.

CAUTION:

Never mix two types of oil in the same batch; clotting of the oil could result. If you wish to change oil types, be sure to drain the fuel tank and the carburetor float bowl of old premix prior to filling with the new type.

Fuel tank capacity:

5 L (1.10 Imp gal, 1.32 US gal)

Mixing oil

Recommended oil:

Yamalube "2-R"

(Yamalube racing 2-cycle oil)

Mixing ratio: 30 : 1

If unavailable, use an equivalent type of oil.

MELANGE CARBURANT ET HUILE MOTEUR

Before starting the machine, perform the checks in the pre-operation check list.

WARNING

Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area.

STARTING A COLD ENGINE

1. Shift the transmission into neutral.
2. Turn the fuel cock to "ON" and full open the starter knob (CHOKE).
3. With the throttle completely closed start the engine by kicking the kickstarter crank forthly with firm stroke.
4. Run the engine at idle or slightly higher until it warms up: this usually takes about one or two minutes.
5. The engine is warmed up when it responds normally to the throttle with the starter knob (CHOKE) turned off.

CAUTION:

Do not warm up the engine for extended periods.

STARTING A WARM ENGINE

Do not operate the starter knob (CHOKE). Open the throttle slightly and start the engine by kicking the kickstarter crank forcefully with firm stroke.

CAUTION:

Observe the following break-in procedures during initial operation to ensure optimum performance and avoid engine damage.

1. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows.

Mixing oil: Yamalube “2-R” Mixing ratio: 15 : 1

1. Perform the pre-operation checks on the machine.
2. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch.
3. Operate the machine in the lower gears at moderate throttle openings for five to eight minutes. Stop and check the spark plug condition; it will show a rich condition during break-in.
4. Allow the engine to cool. Restart the engine and operate the machine as in the step above for five minutes. Then, very briefly shift to the higher gears and check full-throttle response. Stop and check the spark plug.
5. After again allowing the engine to cool, restart and run the machine for five more minutes. Full throttle and the higher gears may be used, but sustained full-throttle operation should be avoided. Check the spark plug condition.
6. Allow the engine to cool, remove the top end, 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 top end.
7. Drain the break-in oil-fuel mixture from the fuel tank and refill with the specified mix.
8. Restart the engine and check the operation of the machine throughout its entire operating range. Stop and check the spark plug condition. Restart the machine and operate it for about 10 to 15 more minutes. The machine will now be ready to race.

PROCEDURE DE RODAGE

- After the break-in or before each race, you must check the entire machine for loose fittings and fasteners as per "TORQUE-CHECK POINTS".

Tighten all such fasteners as required.

- When any of the following parts have been replaced, they must be broken in. CYLINDER AND CRANKSHAFT:

About one hour of break-in operation is necessary.

PISTON, RING AND 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.

ATTENTION:

Frame construction ____ Frame to rear frame Combined seat and fuel tank ____ Fuel tank to frame

Engine mounting ____ Frame to engine

Steering Steering stem to handlebar Steering stem to upper bracket Upper bracket to handlebar

Suspension Front Steering stem to front fork Front fork to upper bracket Front fork to lower bracket Rear For link type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Rear Installation of rear shock absorber Rear shock absorber to frame Rear Installation of swing-garm Tightening of pivot shaft

Wheel Installation of wheel Front Tightening of wheel axle Rear Tightening of wheel axle Wheel to rear wheel sprocket

Brake Front Brake caliper to front fork Brake disc to wheel Tightening of union bolt Brake master cylinder to handlebar Tightening of bleed screw Rear Brake caliper to bracket Brake disc to wheel Tightening of union bolt Brake master cylinder to frame Tightening of bleed screw

Fuel system ____ Fuel tank to fuel cock

NOTE: ____

Concerning the tightening torque, refer to "MAINTENANCE SPECIFICATIONS" section in the CHAPTER 2.

POINTS DE VERIFICATION DE COUPLE DE SERRAGE

CLEANING AND STORAGE

EC1B1000

CLEANING

Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components.

1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a garden hose; use only enough pressure to do the job.

CAUTION:

Excessive hose pressure may cause water seepage and contamination of wheel bearings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers.

1. After the majority of the dirt has been hosed off, wash all surfaces with warm water and a mild detergent. Use an old toothbrush to clean hard-to-reach places.
2. Rinse the machine off immediately with clean water, and dry all surfaces with a soft towel or cloth.
3. Immediately after washing, remove excess water from the chain with a paper towel and lubricate the chain to prevent rust.
4. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.
5. Automotive wax may be applied to all painted or chromed surfaces. Avoid combination cleaner-waxes, as they may contain abrasives.
6. After completing the above, start the engine and allow it to idle for several minutes.

NETTOYAGE ET REMISAGE

NETTOYAGE

If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows:

1. Drain the fuel tank, fuel lines, and the carburetor float bowl.
2. Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil.
3. Remove the drive chain, clean it thoroughly with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off the ground.
6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.
7. If the machine is to be stored in a humid or salt-air environment, coat all exposed metal surfaces with a film of light oil. Do not apply oil to rubber parts or the seat cover.

NOTE:

Make any necessary repairs before the machine is stored.

REMISAGE

Model name: YZ85 YZ85LW
	YZ85R (USA)YZ85LC (EUROPE)YZ85(R)(CDN, AUS, NZ, ZA)	YZ85LW (EUROPE)YZ85LWR (AUS, NZ)
Model code number: YZ85 YZ85LW
	5PA4(USA, CDN, EUROPE,NZ, ZA)5PA5(AUS)	5SH4(EUROPE, NZ)5SH5(AUS)
Dimensions: YZ85 YZ85LW
Overall length 1,821 mm (71.7 in) 1,903 mm (74.9 in)Overall width 758 mm (28.9 in)←Overall height 1,161 mm (45.7 in) 1,205 mm (47.4 in)Seat height 864 mm (34.0 in) 904 mm (35.6 in)Wheelbase 1,258 mm (49.5 in) 1,286 mm (50.6 in)Minimum ground clearance 351 mm (13.8 in) 393 mm (15.5 in)	(USA, S, NZ, ZA)1,818 mm (71.6 in)(F, D, I, GB, E, CDN,AUS)(USA, S, NZ, ZA)1,255 mm (49.4 in)(F, D, I, GB, E, CDN,AUS)
Basic weight: YZ85 YZ85LW
With oil and full fuel tank 71 kg (156.5 lb) 73.9	kg (162.9 lb)
Engine:Engine type Liquid cooled 2-stroke, gasolineCylinder arrangementDisplacementBore × strokeCompression ratioStarting system	Single cylinder, forward inclined 84.7 cm3 (2.98 Imp oz, 2.86 US oz) 47.5 × 47.8 mm ( 1.870 × 1.882 in )8.2 : 1Kickstarter
Lubrication system:	Premix (30 : 1) (Yamalube 2-R)
Oil type or grade (2-cycle):Transmission oilPeriodic oil changeTotal amount	Yamalube 4 (10W-30) or SAE 10W-30 type SEMotor oil0.50 L (0.44 Imp qt, 0.52 US qt)0.55 L (0.48 Imp qt, 0.58 US qt)
Coolant capacity (including all routes):	0.54 L (0.48 Imp qt, 0.57 US qt)
Air filter:	Wet type element
Fuel:Type Premium unleaded gasoline only with aTank capacity 5.0 L (1.10 Imp gal, 1.32 US gal)	research octane number of 95 or higher.(Except for ZA)Premium gasoline (For ZA)
Carburetor:Type/manufacturer PWK28/KEIHIN
Spark plug:Type/manufacturer BR10EG/NGK (resistancetype)Gap 0.5 ~ 0.6 mm (0.020 ~ 0.024 in)
Clutch type: Wet, multiple-disc
Transmission: YZ85 YZ85LWPrimary reduction system Gear←Primary reduction ratio 65/18 (3.611)←Secondary reduction system Chain drive←Secondary reduction ratio 47/14 (3.357) 52/14Transmission type Constant mesh,Operation Left foot operation ←Gear ratio: 1st2nd3rd4th5th6th	(3.714)(USA, S, NZ, ZA)48/14 (3.429)(F, D, I, GB, E, CDN,AUS)6-speed27/11 (2.454)←32/17 (1.882)←26/17 (1.529)←22/17 (1.294)←26/23 (1.130)←25/25 (1.000)←	←
Chassis:Frame typeCaster angleTrail	YZ85 YZ85LW
	Semi double cradle26.3°88 mm (3.46 in)	←26.9°105.5 mm (4.15 in)
Tire:Type With tube ←Size (front)Size (rear)Tire pressure (front and rear)	YZ85 YZ85LW
	70/100-17 40M90/100-14 49M100 kPa(1.0 kgf/cm2, 15 psi)	70/100-19 42M90/100-16 52M←
Brake:Front brake typeOperation Right hand operationRear brake typeOperation Right foot operation	Single disc brakeSingle disc brake
Suspension:Front suspension Telescopic forkRear suspension Swingarm (link type monocross suspension)
Shock absorber:Front shock absorber Coil spring/air, oil damperRear shock absorber Coil spring/gas, oil damper
Wheel travel: YZ85 YZ85LW
Front wheel travel 275 mm (10.8 in) ←Rear wheel travel 282 mm (11.1 in) 287 mm (11.3 in)
Electrical:Ignition system CDI magneto

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit
Cylinder head:Combustion chamber capacity 7.14 cmWarp limit ---- 0.03 mm	3 (0.25 Imp oz, 0.24 US oz)	----(0.0012 in)
Cylinder:Bore size 47.500 ~ 47.514 mmTaper limit ---- 0.05 mmOut of round limit ---- 0.01 mm	(1.8701 ~ 1.8706 in)	47.6 mm(1.8740 in)(0.0020 in)(0.0004 in)
Piston:Piston to cylinder clearance 0.040 ~ 0.045 mmPiston size “D”Measuring point “H”Piston off-set 1.0 mm (0.039 in)/EX-side ----Piston pin bore inside diameter 14.004 ~ 14.015 mmPiston pin outside diameter	(0.0016 ~ 0.0018 in)47.457 ~ 47.472 mm(1.8684 ~ 1.8690 in)20 mm (0.79 in)15 mm(0.5513 ~ 0.5518 in)13.996 ~ 14.000 mm(0.5510 ~ 0.5512 in)	0.1 mm(0.004 in)----14.040 mm(0.5528 in)13.975 mm(0.5502 in)
Piston ring:TypeDimensions (B × T)End gap (installed)Side clearance (installed)	Plain0.8 × 2.0 mm (0.031 × 0.079 in)0.30 ~ 0.45 mm(0.012 ~ 0.018 in)0.030 ~ 0.065 mm(0.001 ~ 0.003 in)	----0.80 mm(0.031 in)0.1 mm(0.004 in)
Item	Standard Limit
Crankshaft:
Crank width “A” 44.90 ~ 44.95 ---- -	(1.768 ~ 1.770 in)	----
Runout limit “C” 0.03 mm (0. n	0.20 ~ 0.70 mm(0.008 ~ 0.028 in)	(0.003 in)
Big end side clearance “D”		----
Small end free play “F”	0.5 ~ 1.2 mm(0.020 ~ 0.047 in)	2.0 mm(0.08 in)
Clutch:
Friction plate thickness 2.9 ~ 3.1 mm	(0.114 ~ 0.122 in)	2.7 mm(0.106 in)
Quantity 7 ----
Clutch plate thickness 1.8 ~ 2.2 mm (0.071 ~ 0.087 in) ----
Quantity 6 ----
Warp limit ---- 0.1 mm		(0.004 in)
Clutch spring free length 34.0 mm (1.34 in) 32.0 mm		(1.26 in)
Quantity 5 ----
Clutch housing thrust clearance 0.10 ~ 0.35 mm	(0.0039 ~ 0.0138 in)	----
Clutch housing radial clearance 0.022 ~ 0.051 mm	(0.0009 ~ 0.0020 in)	----
Clutch release method	Inner push, cam push	----
Shifter:
Shifter type	Cam drum and guide bar	----
Guide bar bending limit	---- 0.05 mm	(0.002 in)
Kickstarter:
Type	Kick and mesh type	----
Carburetor:
Type/manufacturer	PWK28/ KEIHIN	----
I. D. mark	5PA1 00	----
Main jet (M.J)	#138	----
Jet needle-clip position (J.N)	NBKF-2	----
Main nozzle (N.J)	ø3.4	----
Cutaway (C.A)	3.0	----
Pilot jet (P.J)	#45	----
Pilot air screw (example) (P.A.S)	2 ----
Starter jet (G.S)	#62	----
Float height (F.H)	18 ~ 20 mm (0.71 ~ 0.79 in)	----
Item	Standard	Limit
Reed valve:Thickness “T” 0.42 mm (0.017 in) ---Valve stopper height 7.4 ~ 7.8 mm (0.291 ~ 0.307 in) ----Valve bending limit ---- 0.2 mm		(0.008 in)
Cooling:Radiator core sizeWidth 117.8 mm (4.64 in) ----Height 240 mm (9.45 in) ----Thickness 32 mm (1.26 in) ----Radiator cap opening pressure 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm 2 ,13.5 ~ 17.8 psi)Radiator capacity 0.32 L (0.28 Imp qt, 0.34 US qt) ----Water pumpType Single-suction centrifugal pump ----		----

Part to be tightened Thread size Qty			Tightening torque
			Nm m·kg ft·lb
Spark plug M14 × 1.25 1 20 2.0 14Cylinder head (nut) M8 × 1.25 4 30 3.0 22(stud bolt) M8 × 1.25 4 13 1.3 9.4Cylinder (nut) M8 × 1.25 4 28 2.8 20(stud bolt) M8 × 1.25 4 13 1.3 9.4Impeller M8 × 1.25 1 14 1.4 10Coolant drain boltWater pump housingAir filter elementCarburetor jointReed valveExhaust pipeExhaust pipe staySilencerFiber (silencer)CrankcaseLeft crankcase coverRight crankcase coverRight crankcase coverClutch coverTransmission oil drain boltKickstarter crankPrimary drive gearClutch bossClutch springDrive sprocketCrankcase bearing stopperCrankcase oil seal holderShift pedal	M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M6 × 1.0M12 × 1.0M12 × 1.0M5 × 0.8M16 × 1.0M6 × 1.0M8 × 1.25M16 × 1.0M6 × 1.0M8 × 1.25M6 × 1.0	121442112122114444444444444444444444444444444444444444444444444444444444444444444444444444444444444444444444444444	101028112121212885555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555	1.01.00.20.80.11.21.21.21.21.20.80.51.01.07.97.00.66.00.82.01.0	7.27.21.45.80.78.78.78.78.75.83.67.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.27.2

CHASSIS

YZ85

Item Standard Limit
Steering system:Steering bearing type Taper roller bearing ----
Front suspension:Front fork travel 275 mm (10.8 in) ----Fork spring free length 430 mm (16.9 in) 425 mm (16.7 in)Spring rate, STD K = 2.84 N/mm(0.29 kg/mm, 16.2 lb/in)----Optional spring Yes ----Oil capacity 318 cm3(11.2 Imp oz, 10.8 US oz)----Oil level 90 mm (3.54 in) ----<Min.~Max.>(From top of outer tube with inner tube and damper rod fully compressed without spring.)80 ~ 120 mm (3.15 ~ 4.72 in) ----Oil gradeInner tube outer diameterSuspension oil “01”----Front fork top end36 mm (1.42 in) ----24 mm (0.94 in) --------
Rear suspension:Shock absorber travelSpring free lengthFitting length<Min.~Max.>Spring rate, STD K = 49.0 N/mmShock absorber travelSpring free lengthFitting length<Min.~Max.>Spring rate, STD K = 49.0 N/mmSpring absorber travelSpring free lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthFitting lengthsK = 45.0 N/mm----(5.00 kg/mm,280.0 lb/in)(4.60 kg/mm,257.6 lb/in)----Yes←----1,000 kPa←----(10 kg/cm2,142 psi)--------	USA, CDN,AUS, NZ, ZA	EUROPE
	102 mm (4.02 in)220 mm (8.66 in)215 mm (8.46 in)202.5 ~ 218.5 mm(7.97 ~ 8.60 in)K = 45.0 N/mm----(5.00 kg/mm,280.0 lb/in)(4.60 kg/mm,257.6 lb/in)----Yes←----1,000 kPa←----(10 kg/cm2,142 psi)----	←←212 mm (8.35 in)←----K = 45.0 N/mm----(4.60 kg/mm,257.6 lb/in)←----
Swingarm:Swingarm free play limitEnd	----		1.0 mm (0.04 in)
Item	Standard		Limit
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 17 × 1.40/Aluminum ----
Rear rim size/material 14 × 1.60/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428DS/DAIDO ----
Number of links 117 links + joint ----
Chain slack 35 ~ 45 mm (1.4 ~ 1.8 in) ----
Chain length (10 links) ----			122.1 mm (4.81 in)
Front disc brake:
Disc outside dia. × Thickness	220 × 3.0 mm (8.66 × 0.12 in)		220 × 2.5 mm(8.66 × 0.10 in)
Deflection limit	----		0.15 mm (0.006 in)
Pad thickness	4.0 mm (0.16 in)		0.8 mm (0.03 in)
Master cylinder inside dia.	11.0 mm (0.433 in)		----
Caliper cylinder inside dia.	22.22 mm (0.875 in) × 2		----
Brake fluid type	DOT #4		----
Rear disc brake:
Disc outside dia. × Thickness	190 × 3.0 mm (7.84 × 0.12 in)		190 × 2.5 mm(7.84 × 0.12 in)
Deflection limit	----		0.15 mm (0.006 in)
Pad thickness	3.7 mm (0.15 in)		1.0 mm (0.04 in)
Master cylinder inside dia.	12.7 mm (0.500 in)		----
Caliper cylinder inside dia.	27.0 mm (1.063 in) × 1		----
Brake fluid type	DOT #4		----
Brake lever and brake pedal:
Brake lever position	95 mm (3.74 in)		----
Brake pedal height(vertical height above footrest top)	4 ~ 10 mm (0.16 ~ 0.39 in)		----
Clutch lever free play (lever end)	10 ~ 15 mm (0.39 ~ 0.59 in)		----
Throttle grip free play	3 ~ 5 mm (0.12 ~ 0.20 in) ----

YZ85LW

Item Standard Limit
Steering system:Steering bearing type Taper roller bearing ----
Front suspension:Front fork travel 275 mm (10.8 in) ----Fork spring free length 430 mm (16.9 in) 425 mm (16.7 in)Spring rate, STD K = 2.94 N/mm(0.30 kg/mm, 16.8 lb/in)----Optional spring Yes ----Oil capacity 318 cm3(11.2 Imp oz, 10.8 US oz)----Oil level 90 mm (3.54 in) ----(From top of outer tube with inner tube and damper rod fully compressed without spring.)80 ~ 120 mm (3.15 ~ 4.72 in) ----Oil gradeSuspension oil “01”----Inner tube outer diameter36 mm (1.42 in) ----Front fork top endZero mm (Zero in)----
Rear suspension:Shock absorber travelSpring free lengthFitting length<Min.~Max.>Spring rate, STD K = 51.0 N/mm(5.20 kg/mm, 291.2 lb/in)K = 47.0 N/mm(4.80 kg/mm, 268.8 lb/in)----Optional springEnclosed gas pressureYes←----1,000 kPa(10 kg/cm2, 142 psi)←----Swingarm:Swingarm free play limitEnd----1.0 mm (0.04 in)		AUS, NZ	EUROPE
		102 mm (4.02 in)	←
		220 mm (8.66 in)	←
		207 mm (8.15 in)	212 mm (8.35 in)
		202.5 ~ 218.5 mm(7.97 ~ 8.60 in)	←
		(5.20 kg/mm, 291.2 lb/in)	K = 47.0 N/mm(4.80 kg/mm, 268.8 lb/in)----
		Yes	←
		1,000 kPa(10 kg/cm2, 142 psi)	←
Swingarm:Swingarm free play limitEnd		----

Item		Standard	Limit
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 19 × 1.40/Aluminum ----
Rear rim size/material 16 × 1.85/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428DS/DAIDO ----
Number of links 123 links + joint ----
Chain slack 35 ~ 45 mm (1.4 ~ 1.8 in) ----
Chain length (10 links) ----			122.1 mm (4.81 in)
Front disc brake:
Disc outside dia. × Thickness		220 × 3.0 mm (8.66 × 0.12 in)	220 × 2.5 mm(8.66 × 0.10 in)
Deflection limit		----	0.15 mm (0.006 in)
Pad thickness		4.0 mm (0.16 in)	0.8 mm (0.03 in)
Master cylinder inside dia.		11.0 mm (0.433 in)	----
Caliper cylinder inside dia.		22.22 mm (0.875 in) × 2	----
Brake fluid type		DOT #4	----
Rear disc brake:
Disc outside dia. × Thickness		190 × 3.0 mm (7.84 × 0.12 in)	190 × 2.5 mm(7.84 × 0.12 in)
Deflection limit		----	0.15 mm (0.006 in)
Pad thickness		3.7 mm (0.15 in)	1.0 mm (0.04 in)
Master cylinder inside dia.		12.7 mm (0.500 in)	----
Caliper cylinder inside dia.		27.0 mm (1.063 in) × 1	----
Brake fluid type		DOT #4	----
Brake lever and brake pedal:
Brake lever position		95 mm (3.74 in)	----
Brake pedal height(vertical height above footrest top)		4 ~ 10 mm (0.16 ~ 0.39 in)	----
Clutch lever free play (lever end)		10 ~ 15 mm (0.39 ~ 0.59 in)	----
Throttle grip free play		3 ~ 5 mm (0.12 ~ 0.20 in) ----
Part to be tightened Thread size Q'ty			Tightening torque
			Nm m·kg ft·lb
Upper bracket and outer tube M8 × 1.25 2 22 2.2 16
Lower bracket and outer tube M8 × 1.25 4 20 2.0 14
Upper bracket and steering stem M22 × 1.0 1 125 12.5 90
Handlebar holder and upper bracket M8 × 1.25 4 27 2.7 19
Steering stem and steering ring nut	M25 × 1.0	1	Refer to NOTE.
Front fork and front fork cap bolt	M40 × 1.0	2	28	2.8	20
Front fork and base valve	M22 × 1.0	2	55	5.5	40
Front fork cap bolt and damper rod	M10 × 1.0	2	15	1.5	11
Front fork bleed screw and front fork cap bolt	M5 × 0.8	2	1	0.1	0.7
Front fork and front fork protector	M6 × 1.0	6	7	0.7	5.1
Front fork and brake hose guide	M5 × 0.8	1	4	0.4	2.2
Front fork and brake hose holder	M6 × 1.0	1	10	1.0	7.2
Throttle grip cap	M5 × 0.8	2	4	0.4	2.2
Throttle cable cap	M4 × 0.7	2	1	0.1	0.7
Front brake master cylinder	M6 × 1.0	2	9	0.9	6.5
Brake lever mounting bolt	M6 × 1.0	1	6	0.6	4.3
Brake lever mounting nut	M6 × 1.0	1	6	0.6	4.3
Brake lever position locknut	M6 × 1.0	1	5	0.5	3.6
Clutch lever holder	M5 × 0.8	2	4	0.4	2.2
Front brake master cylinder cap	M4 × 0.7	2	2	0.2	1.4
Front brake hose union bolt	M10 × 1.25	2	26	2.6	19
Front fork and brake caliper bracket	M8 × 1.25 2 30 3.0 22
Brake caliper support bolt	M8 × 1.25	1	23	2.3	17
Front brake caliper and bleed screw	M7 × 1.0	1	6	0.6	4.3
Rear brake caliper and brake caliper bracket	M8 × 1.25	2	23	2.3	17
Rear brake caliper and pad pin	M10 × 1.0	2	18	1.8	13
Rear brake caliper and bleed screw	M8 × 1.25	1	6	0.6	4.3
Front wheel axle and axle nut	M12 × 1.25	1	70	7.0	50
Front brake disc	M6 × 1.0	3	12	1.2	8.7
Rear brake disc	M6 × 1.0	4	12	1.2	8.7
Rear brake master cylinder	M6 × 1.0	2	10	1.0	7.2
Rear brake reservoir tank	M6 × 1.0	1	10	1.0	7.2
Rear brake hose union bolt	M10 × 1.25	2	26	2.6	19
Rear wheel axle and axle nut	M14 × 1.5	1	90	9.0	65

NOTE:

1. First, tighten the steering nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the steering nut wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 4 Nm (0.4 m • kg, 2.9 ft • lb).

Part to be tightened Thread size Q'ty			Tightening torque
			Nm m·kg ft·lb
Nipple (spoke) — 64 3 0.3 2.2
Rear wheel sprocket M8 × 1.25 4 42 4.2 30
Rear brake caliper protector M6 × 1.0 1 10 1.0 7.2
Engine mounting:
Engine and frame (front) M10 × 1.25 1 69 6.9 50
Engine and frame (lower)	M10 × 1.25	1 69 6.9	50
Pivot shaft and nut	M12 × 1.25	1 63 6.3	45
Relay arm and frame	M10 × 1.25	1 54 5.4	39
Relay arm and connecting rod	M12 × 1.25	1	53	5.3	38
Connecting rod and swingarm	M12 × 1.25	1 53 5.3	38
Rear shock absorber and frame	M10 × 1.25	1	36	3.6	25
Rear shock absorber and relay arm	M10 × 1.25	1	36	3.6	25
Rear frame (upper)	M8 × 1.25	1	26	2.6	19
Rear frame (lower)	M8 × 1.25	2	16	1.6	11
Swingarm and brake hose holder	M5 × 0.8	4	1	0.1	0.7
Drive chain tensioner (upper)	M8 × 1.25	1	23	2.3	17
Drive chain tensioner (lower)	M6 × 1.0	1	10	1.0	7.2
Drive chain support	M8 × 1.25	2	16	1.6	11
Drive chain support cover	M6 × 1.0	1	7	0.7	5.1
Seal guard and swingarm	M6 × 1.0	2	10	1.0	7.2
Fuel tank	M6 × 1.0	2	7	0.7	5.1
Fuel cock	M6 × 1.0	2	4	0.4	2.9
Fuel tank bracket and fuel tank	M6 × 1.0	4	7	0.7	5.1
Seat set bracket and fuel tank	M6 × 1.0	1	7	0.7	5.1
Radiator cover	M6 × 1.0	3	4	0.4	2.9
Front fender	M6 × 1.0	4	7	0.7	5.1
Rear fender	M6 × 1.0	4	7	0.7	5.1
Flap guard	M6 × 1.0	2	7	0.7	5.1
Side cover	M6 × 1.0	2	7	0.7	5.1
Seat	M6 × 1.0	2	7	0.7	5.1
Number plate	M6 × 1.0	1	7	0.7	5.1

NOTE:
△- marked portion shall be checked for torque tightening after break-in or before each race.

EC212300

ELECTRICAL

Item Standard Limit
Ignition system:Ignition timing (B.T.D.C.) 0.9 mm (0.035 in) ----Advancer type Electrical ----
CDI:Magneto-model (stator)/manufacturerCharging coil 1 resistance (color)Charging coil 2 resistance (color)Pickup coil resistance (color)CDI unit-model/manufacturer 5PA-00/YAMAHA ----	5PA-00/YAMAHA ----720 ~ 1,080 Ω at 20 °C (68 °F)(Green/White – Black/Red)44 ~ 66 Ω at 20 °C (68 °F)(Black – Green/Blue)248 ~ 372 Ω at 20 °C (68 °F)(White/Blue – White/Red)	------------
Ignition coil:Model/manufacturer 5PA-00/YAMAHA ----Minimum spark gap 6 mm (0.24 in) ----Primary coil resistanceSecondary coil resistance	0.18 ~ 0.28 Ω at 20 °C (68 °F)6.3 ~ 9.5 kΩ at 20 °C (68 °F)	--------
Spark plug cap:Resistance	4 ~ 6 kΩ at 20 °C (68 °F)	----

Part to be tightened	Thread size	Q'ty	Tightening torque
			Nm	m·kg	ft·lb
Stator	M6 × 1.0	2	8	0.8	5.8
Rotor	M10 × 1.25	1	33	3.3	24
Ignition coil	M6 × 1.0	2	7	0.7	5.1

EC220001

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.

A(Nut)	B(Bolt)	TORQUE SPECIFICATION
		Nm	m•kg	ft•lb
10 mm	6 mm	6	0.6	4.3
12 mm	8 mm	15	1.5	11
14 mm	10 mm	30	3.0	22
17 mm	12 mm	55	5.5	40
19 mm	14 mm	85	8.5	61
22 mm	16 mm	130	13	94

A: Distance between flats
B: Outside thread diameter

EC230000

DEFINITION OF UNITS

Unit Read Definition Measure
mmcm	millimetercentimeter	10-3 meter 10-2 meter	LengthLength
kg kilogram 10		3 gram Weight
N Newton 1 kg		× m/sec2	Force
Nm m • kg	Newton meterMeter kilogram	N × mm × kg	TorqueTorque
Pa Pascal N/m		2	Pressure
N/mm Newton per millimeter N/mm		Spring rate
L cm 3	LiterCubic centimeter	——	Volume or capacityVolume or capacity
r/min	Revolution per minute	—	Engine speed

CARACTERISTIQUES

CARACTERISTIQUES GENERALES

① Hose guide
② Brake hose
③ Throttle cable
④ Fuel tank breather hose
⑤ Engine stop switch lead
⑥ CDI magneto lead
⑦ Clamp
⑧ Carburetor breather hose
⑨ Carburetor overflow hose
⑩ Transmission oil breather hose
⑪ Radiator breather hose
⑫ Clutch cable
⑬ Spark plug lead

⑭ Cable guide
⑮ Brake hose holder

A Pass the fuel tank breather hose between the handlebar and tension bar, then insert its end into the hole of the steering stem.
B Fasten the ground lead together with the ignition coil.
☐ Clamp the brake hose with the brake hose holder.
D Fit the brake hose into the guides of the protector.

CHEMINEMENT DES CABLES

①Guide de durit

②Durit de frein

③Câble des gaz

① Sub-wire harness
② CDI unit
③ Ignition coil
④ Clutch cable
⑤ Cable guide
⑥ Transmission oil breather hose
⑦ CDI unit band
⑧ Clamp
⑨ Brake hose
⑩ Brake hose holder
⑪ Hose guide
⑫ Reservoir hose
⑬ Reservoir tank
⑭ Brake master cylinder

A Pass the transmission oil breather hose through the hose guide.
B Clamp the sub-wire harness at the tape on it within the arrow mark.
C Pass the sub-wire harness on the left of the CDI unit.
D Pass the reservoir hose between the brake hose and swingarm bracket.
E Pass the reservoir hose through the hose guides.
F Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake master cylinder.

① Throttle cable
② Clutch cable
③ Clamp
④ Engine stop switch lead
⑤ Brake hose
⑥ Hose guide

A Fasten the engine stop switch lead to the handlebar with the plastic band.
B Pass the brake hose in front of the number plate.
C Cross the clutch cable and throttle cable over the number plate boss.

The following schedule 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 a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.

Item	After break-in	Every race	Every third race	Every fifth race	As required	Remarks
PISTONInspect and cleanReplace	●	●		●	●	Inspect crackInspect carbon deposits and eliminate them
PISTON RINGInspectReplace	●	●	●		●	Check ring end gap
PISTON PIN, SMALL END BEARINGInspectReplace		●			●
CYLINDER HEADInspect and cleanRetighten	●●●	●●				Inspect carbon deposits and eliminate themCheck gasket
CYLINDERInspect and cleanReplace	●	●			●	Inspect score marksInspect wear
CLUTCHInspect and adjustReplace	●	●			●	Inspect housing, friction plate, clutch plate and spring
TRANSMISSIONReplace oilInspectReplace bearing	●			●	●●●	Yamalube 4 (10W-30) or SAE 10W-30 SE motor oil
SHIFT FORK, SHIFT CAM, GUIDE BARInspect					●	Inspect wear
ROTOR NUTRetighten	●			●
KICK SHAFTInspect idle gearReplace					●●
EXHAUST PIPE, SILENCERInspectClean	●	●		●
CRANKInspect and clean				●	●
CARBURETORInspect, adjust and clean	●	●
SPARK PLUGInspect and cleanReplace	●	●			●
DRIVE CHAINLubricate, slack, alignmentReplace	●	●			●	Chain slack: 35 ~ 45 mm(1.4 ~ 1.8 in)
COOLING SYSTEMCheck coolant level and leakageCheck radiator cap operationReplace coolantInspect hoses	●	●			●●	Every two years
		●			●
OUTSIDE NUTS AND BOLTSRetighten	●	●
AIR FILTERClean and lubricateReplace	●	●			●	Use foam air-filter oil
FRAMEClean and inspect	●	●
FUEL TANK, COCKClean and inspect	●		●
BRAKESAdjust lever position and pedal heightLubricate pivot pointCheck brake disc surfaceCheck fluid level and leakageRetighten brake disc bolts, caliperbolts, master cylinder bolts and unionboltsReplace padsReplace brake fluid	●●●●●●	●●●●●●			●●	Every one year
FRONT FORKSInspect and adjustReplace oilReplace oil seal	●●	●		●	●	Suspension oil “01”
FRONT FORK OIL SEAL AND DUSTSEALClean and lube	●	●				Lithium base grease
REAR SHOCK ABSORBERInspect and adjustLubeRetighten	●●	●●	●		(After rain ride)●	Molybdenum disulfide grease
DRIVE CHAIN GUIDE, ROLLERS AND SUPPORTInspect					●
SWINGARIMspect and retightenLube	●●	●●				Molybdenum disulfide grease
RELAY ARM, CONNECTING RODInspect and retightenLube	●●	●●				Molybdenum disulfide grease
STEERING HEADInspect free play and retightenClean and lubeReplace bearing	●	●		●	●	Lithium base grease
Item	After break-in	Every race	Every third race	Every fifth race	As re-quired	Remarks
TIRE, WHEELS
Inspect air pressure, wheel run-out,tire wear and spoke looseness	●	●
Retighten sprocket bolt	●	●
Inspect bearings			●
Replace bearings					●
Lubricate			●			Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection	●	●				Yamaha cable lube or SAE 10W-30 motor oil
Inspect and Lubricate	●	●

CONTROLES ET REGLAGES PERIODIQUES

PROGRAMME D'ENTRETIEN

Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition.

Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page
Coolant	Check that coolant is filled up to the radiator cap.Check the cooling system for leakage.	P.3-5 ~ 9
Fuel	Check that a fresh mixture of oil and gasoline is filled in the fuel tank. Check the fuel line for leakage.	P.1-12
Transmission oil	Check that the oil level is correct. Check the crankcase for leakage.	P.3-12 ~ 13
Gear shifter and clutch	Check that gears can be shifted correctly in order and that the clutch operates smoothly.	P.3-9
Throttle grip/Housing	Check that the throttle grip operation and free play are correctly adjusted. Lubricate the throttle grip and housing, if necessary.	P.3-10
Brakes Check the play of front brake and effect of front and rear brake. P.3-16 ~ 21
Drive chain	Check drive chain slack and alignment. Check that the drive chain is lubricated properly.	P.3-22 ~ 24
Wheels	Check for excessive wear and tire pressure. Check for loose spokes and have no excessive play.	P.3-31 ~ 32
Steering	Check that the handlebar can be turned smoothly and have no excessive play.	P.3-32 ~ 34
Front forks and rear shock absorber	Check that they operate smoothly and there is no oil leakage. P.3-24 ~ 30
Cables (wires)	Check that the clutch and throttle cables move smoothly. Check that they are not caught when the handlebars are turned or when the front forks travel up and down.	—
Exhaust pipe and silencer	Check that the exhaust pipe is tightly mounted and has no cracks.	P.4-2
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-22
Lubrication Check for smooth operation. Lubricate if necessary. P.3-35
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-16
Lead connectors	Check that the CDI magneto, CDI unit, and ignition coil are connected tightly.	P.1-6
Settings	Is the machine set suitably for the condition of the racing course and weather or by taking into account the results of test runs before racing? Are inspection and maintenance completely done?	P.7-1 ~ 19

CONTROLE ET ENTRETIEN AVANT UTILISATION

EC350000

ENGINE

COOLANT LEVEL INSPECTION

WARNING

Do not remove the radiator cap ①, drain bolt and hoses when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.

When the engine has cooled, place a thick towel over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.

CAUTION:

Hard water or salt water is harmful to the engine parts. You may use distilled water, if you can't get soft water.

1. Place the machine on a level place, and hold it in an upright position.
2. Remove:

- Radiator cap

1. Check:
2. Coolant level

Coolant level ⓐ low → Add coolant.

① Radiator

MOTEUR

CONTROLE DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT

AVERTISSEMENT

Do not remove the radiator cap when the engine is hot.

CAUTION:

Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water.

Mechanical assembly diagram showing a linkage mechanism with no visible text or symbols

1. Place a container under the engine.

2. Remove:

3. Coolant drain bolt ①

4. Remove:
5. Radiator cap

Drain the coolant completely.

1. Clean:

- Cooling system

Thoroughly flush the cooling system with clean tap water.

1. Install:

- Copper washer

- Coolant drain bolt

10 Nm (1.0 m · kg, 7.2 ft · lb)

1. Fill:

2. Radiator

3. Engine

To specified level.

Recommended coolant: High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine

Coolant ① and water (soft water) ②

mixing ratio:

50 %/50 %

Coolant capacity:

0.54 L (0.48 Imp qt, 0.57 US qt)

CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT

AVERTISSEMENT

• Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engine.
• Do not use water containing impurities or oil.

Handling notes of coolant:

The coolant is harmful so it should be handled with special care.

WARNING

• When coolant splashes to your eye.
  Thoroughly wash your eye with water and see your doctor.
• When coolant splashes to your clothes. Quickly wash it away with water and then with soap.
• When coolant is swallowed.
  Quickly make him vomit and take him to a doctor.

7. Install:

• Radiator cap
  Start the engine and warm it up for a several minutes.

8. Check:

• Coolant level
  Coolant level low → Add coolant.

EC355000

RADIATOR CAP INSPECTION

1. Inspect:

• Seal (radiator cap) ①
• Valve and valve seat ②
  Crack/damage → Replace.
  Exist fur deposits ③ → Clean or replace.

ATTENTION:

RADIATOR CAP OPENING PRESSURE INSPECTION

1. Attach:

2. Radiator cap tester ①

3. Radiator cap tester adapter ②

Radiator cap tester: YU-24460-01/90890-01325

Radiator cap tester adapter: YU-33984/90890-01352

NOTE:

Apply water on the radiator cap seal.

③ Radiator cap

1. Apply the specified pressure.

Radiator cap opening pressure: 95 \~ 125 kPa (0.95 \~ 1.25 kg/cm², 13.5 \~ 17.8 psi)

1. Inspect:

- Pressure

Impossible to maintain the specified pressure for 10 seconds → Replace.

COOLING SYSTEM INSPECTION

1. Inspect:

- Coolant level

1. Attach:

2. Radiator cap tester ①

3. Radiator cap tester adapter ②

Radiator cap tester: YU-24460-01/90890-01325 Radiator cap tester adapter: YU-33984/90890-01352

1. Apply the specified pressure.

Standard pressure: 180 kPa (1.8 kg/cm², 25.6 psi)

CONTROLE DE LA PRESSION D'OUVERTURE DU BOUCHON DE RADIATEUR

1. Fixer:

• Do not apply pressure more than specified pressure.
• Radiator should be filled fully.

1. Inspect:

2. Pressure
   Impossible to maintain the specified pressure for 10 seconds → Repair.

3. Radiator ①
4. Radiator hose joint ②
   Coolant leakage → Repair or replace.
5. Radiator hose ③
   Swelling → Replace.

CLUTCH ADJUSTMENT

1. Check:

- Clutch lever free play @

Out of specification → Adjust.

Clutch lever free play ⓐ: 10 \~ 15 mm (0.39 \~ 0.59 in)

1. Adjust:

- Clutch lever free play

Clutch lever free play adjustment steps:

• Loosen the locknut ①.
• Turn the adjuster ② until free play ⓐ is within the specified limits.
• Tighten the locknut.

NOTE:

• Make minute adjustment on the lever side.
• After adjustment, check proper operation of clutch lever.

ATTENTION:

Line drawing of a hand gripping a mechanical component with a knob and handle (no text or symbols)

EC35A001

THROTTLE CABLE ADJUSTMENT

1. Check:

- Throttle grip free play @ Out of specification → Adjust.

Throttle grip free play ⓐ: 3 \~ 5 mm (0.12 \~ 0.20 in)

2. Adjust:

- Throttle grip free play

Throttle grip free play adjustment steps:

• Loosen the locknut ①.
• Turn the adjuster ② until the specified free play is obtained.
• Tighten the locknut.

NOTE:

Before adjusting the throttle cable free play, the engine idle speed should be adjusted.

WARNING

After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster.

THROTTLE LUBRICATION

1. Remove:

- Throttle cable cap ①

2. Apply:

- Lithium soap base grease On the throttle cable end ① and tube guide cable winding portion ②.

3. Install:

- Throttle grip cap

1 Nm (0.1 m · kg, 0.7 ft · lb)

REGLAGE DU CABLE DES GAZ

1. Contrôler:

Proper air filter maintenance is the biggest key to preventing premature engine wear and damage.

CAUTION:

Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.

Illustration showing three steps of a hand holding a small object, with arrows indicating motion (no text or symbols)

1. Remove:

• Seat
• Fitting bolt ①
• Washer ②
• Air filter element ③
• Air filter guide ④

2. Clean:

• Air filter element
  Clean them with solvent.

NOTE:

After cleaning, remove the remaining solvent by squeezing the element.

CAUTION:

• Do not twist the element when squeezing the element.
  • Leaving too much of solvent in the element may result in poor starting.

3. Inspect:

• Air filter element
  Damage → Replace.

4. Apply:

- Foam-air-filter oil or engine mixing oil To the element.

NOTE:

Squeeze out the excess oil. Element should be wet but not dripping.

NETTOYAGE DU FILTRE A AIR

N.B.:

5. Install:

- Air filter guide ① To air filter element ②.

6. Apply:

- Lithium soap base grease On the matching surface @ on air filter element.

7. Install:

- Air filter element ① - Washer - Fitting bolt

2 Nm (0.2 m · kg, 1.4 ft · lb)

NOTE:

Install the air filter element with its projection Ⓐ facing upward.

TRANSMISSION OIL REPLACEMENT

1. Start the engine and warm it up for several minutes, and then turn off the engine and wait for five minute.
2. Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine.
3. Place a suitable container under the engine.

4. Remove:

• Oil drain bolt ①
• Oil filler cap ②
  Drain the transmission oil.

CHANGEMENT DE L'HUILE DE BOITE DE VITESSES GETRIEBEÖL WECHSEL

INSP ADJ

5. Monter:

- Transmission oil capacity Out of specification → Adjust.

Oil capacity (periodic oil change): 0.50 L (0.44 Imp qt, 0.52 US qt)

Technical line drawing of a mechanical component with no visible text or symbols

6. Install:

• Copper washer
- Oil drain bolt ①

10 Nm (1.0 m · kg, 7.2 ft · lb)

7. Fill:

- Transmission oil

Recommended oil: Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil Oil capacity (periodic oil change): 0.50 L (0.44 Imp qt, 0.52 US qt)

Technical line drawing of a mechanical component with no visible text or symbols

8. Check:

- Oil leakage

9. Install:

- Oil filter cap ①

CHANGEMENT DE L'HUILE DE BOITE DE VITESSES GETRIEBEÖL WECHSEL

INSP ADJ

5. Mesurer:

PILOT AIR SCREW ADJUSTMENT/ENGINE IDLING SPEED ADJUSTMENT/EXHAUST PIPE INSPECTION

INSP ADJ

Technical line drawing of a mechanical assembly with springs and components (no text or symbols)

PILOT AIR SCREW ADJUSTMENT

1. Adjust:

- Pilot air screw ①

Adjustment steps:

NOTE:

To optimize the fuel flow at a smaller throttle opening, each machine's pilot air screw has been individually set at the factory. Before adjusting the pilot air screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out.

• Turn in the pilot air screw until it is lightly seated.
• Turn out the pilot air screw by the specified number of turns.

Pilot air screw: 2 turns out (example)

ENGINE IDLING SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it up.
2. Adjust:

- Engine idling speed

Adjustment steps:

- Turn the throttle stop screw ① until the engine runs at the lowest possible speed.

To increase idle speed → Turn the throttle stop screw ① in ⓐ.

To decrease idle speed → Turn the throttle stop screw ① out ⑥.

EXHAUST PIPE INSPECTION

1. Inspect:

- O-ring ①

Damage → Replace.

NOTE:

Install the O-rings with their depressed ⓐ facing inward.

SILENCER FIBER REPLACEMENT

1. Remove:

2. Seat

3. Right side cover
4. Bolt (silencer) ①
5. Silencer ②
6. Bolt (fiber) ③

7. Washer

8. Remove:

- Inner pipe ①

1. Replace:

- Fiber ②

1. Install:

- Inner pipe

NOTE:

Fully apply Quick gasket® (Yamaha bond No.1215) or equivalent as shown.

Quick gasket®:

ACC-QUICK-GS-KT

YAMAHA Bond No.1215:

90890-85505

1. Install:

2. Washer

3. Bolt (fiber) ①

12 Nm (1.2 m · kg, 8.7 ft · lb)

- Silencer ②

- Bolt (silencer) ③

12 Nm (1.2 m · kg, 8.7 ft · lb)

- Right side cover

	7 Nm (0.7 m · kg, 5.1 ft · lb)
	7 Nm (0.7 m · kg, 5.1 ft · lb)

REMPLACEMENT DES FIBRES DU SILENCIEUX

1. Déposer:

Bleed the brake system if:

• The system has been disassembled.
- A brake hose has been loosened or removed.
• The brake fluid is very low.
• The brake operation is faulty.

A dangerous loss of braking performance may occur if the brake system is not properly bleed.

1. Remove:

2. Reservoir cap
   • Diaphragm

3. Bleed:

- Brake fluid

A Front

B Rear

Air bleeding steps:

a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow.
c. Connect the clear plastic tube ② tightly to the caliper bleed screw ①.
d. Place the other end of the tube into a container.
e. Slowly apply the brake lever or pedal several times.
f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position.
g. Loosen the bleed screw and allow the lever or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever or pedal limit has been reached; then release the lever or pedal.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb)

i. Repeat steps (e) to (h) until of the air bubbles have been removed from the system.

CHASSIS

PURGE D'AIR DU CIRCUIT DE FREINAGE

AVERTISSEMENT

If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.

j. Add brake fluid to the level line on the reservoir.

WARNING

Check the operation of the brake after bleeding the brake system.

3. Install:

• Diaphragm
- Reservoir cap

Technical line drawing of a mechanical lever assembly with labeled parts (a), showing no text or symbols beyond basic technical lines and annotations.

EC362040

- Brake lever position @

Standard brake lever position: 95 mm (3.74 in)

Extent of adjustment: 76 \~ 97 mm (2.99 \~ 3.82 in)

2. Remove:

- Lever cover

3. Adjust:

- Brake lever position

Brake lever position adjustment steps:

• Loosen the locknut ①.
• Turn the adjusting bolt ② until the lever position ⓐ is within specified position.
• Tighten the locknut.

Locknut: 5 Nm (0.5 m • kg, 3.6 ft • lb)

CAUTION:

Be sure to tighten the locknut, as it will cause poor brake performance.

4. Install:

- Lever cover

EC364002

- Brake pedal height ⓐ Out of specification → Adjust.

Brake pedal height ⓐ: 4 \~ 10 mm (0.16 \~ 0.39 in)

2. Adjust:

- Brake pedal height

Pedal height adjustment steps:

• Loosen the locknut ①.
• Turn the adjusting nut ② until the pedal height @ is within specified height.
• Tighten the locknut.

WARNING

• Adjust the pedal height between the maximum A and the minimum B as shown. (In this adjustment the bolt ③ end ⑥ should protrude out of the lower adjusting nut ④ but not be less than 2 mm (0.08 in) © away from the brake pedal ⑤).
  • After the pedal height adjustment, make sure that the rear brake does not drag.

FRONT BRAKE PAD INSPECTION AND REPLACEMENT

1. Remove:

- Rubber cap

2. Inspect:

- Brake pad thickness ⓐ Out of limit → Replace as a set.

Brake pad thickness: 4.0 mm (0.16 in) : 0.8 mm (0.03 in)

REGLAGE DU FREIN ARRIERE

1. Contrôler:

Technical line drawing of a mechanical assembly with hands operating a bracket (no text or symbols present)

3. Replace:

- Brake pad

Brake pad replacement steps:

• Remove the brake caliper support bolt ①.
• Turn the brake caliper ② counterclockwise @.
• Replace the brake pads ③.
• Connect the transparent hose ④ to the bleed screw ⑤ and place the suitable container under its end.
• Loosen the bleed screw and push the brake caliper piston in.

CAUTION:

Do not reuse the drained brake fluid.

- Tighten the bleed screw.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb)

- Install the brake caliper ⑥ and brake caliper support bolt ⑦.

NOTE:

Apply the lithium soap base grease on the brake caliper support bolt.

Brake caliper support bolt: 30 Nm (3.0 m • kg, 22 ft • lb)

4. Inspect:

- Brake fluid level

Refer to "BRAKE FLUID LEVEL INSPECTION" section.

5. Check:

- Brake lever operation

A softly or spongy feeling → Bleed brake system.

Refer to "BRAKE SYSTEM AIR BLEEDING" section.

CONTROLE ET REMPLACEMENT DES PLAQUETTES DE FREIN AVANT VORDERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN

3. Remplacer:

REAR BRAKE PAD INSPECTION AND REPLACEMENT

1. Inspect:

- Brake pad thickness ⓐ Out of limit → Replace as a set.

Brake pad thickness: 3.7 mm (0.15 in) : 1.0 mm (0.04 in)

2. Replace:

- Brake pad

Brake pad replacement steps:

- Loosen the pad pins ① and remove the brake caliper ②.

NOTE:

Before removing the brake caliper from the swingarm, loosen the pad pins.

- Remove the pad pins ③ and brake pads ④. - Connect the transparent hose ⑤ to the bleed screw ⑥ and place the suitable container under its end. - Loosen the bleed screw and push the brake caliper piston in.

CAUTION:

Do not reuse the drained brake fluid.

• Tighten the bleed screw.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb)

• Install the brake pads ⑦ and pad pins ⑧.

NOTE:

Install the brake pad fitted with the brake pad shim ⑨ on the brake caliper piston side.

CONTROLE ET REMPLACEMENT DES PLAQUETTES DE FREIN ARRIERE

1. Contrôler:

• Install the brake caliper ⑩ and tighten the pad pins ⑪.

Bolt (brake caliper): 23 Nm (2.3 m • kg, 17 ft • lb) Pad pin: 18 Nm (1.8 m • kg, 13 ft • lb)

NOTE: Apply the LOCTITE® on the bolt (brake caliper rear side).

3. Inspect:

- Brake fluid level Refer to "BRAKE FLUID LEVEL INSPECTION" section.

4. Check:

- Brake pedal operation A softly or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section.

1. Place the brake master cylinder (reservoir tank) so that its top is in a horizontal position.

2. Inspect:

- Brake fluid level Fluid at lower level ⓐ → Fill up.

A Front
B Rear

Recommended brake fluid: DOT #4

WARNING

• Use only designated quality brake fluid to avoid poor brake performance.
• Refill with same type and brand of brake fluid; mixing fluids could result in poor brake performance.
• Be sure that water or other contaminants do not enter master cylinder when refilling.
• Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts.

CONTROLE DU NIVEAU DU LIQUIDE DE FREIN BREMSFLÜSSIGKEITSTAND KONTROLLIEREN

INSP ADJ

Illustration of a hand using a tool to brush a chain link onto a plate, with no text or symbols present.

SPROCKETS INSPECTION

1. Inspect:

- Sprocket teeth ⓐ Excessive wear → Replace.

NOTE: Replace the drive sprocket, rear wheel sprocket and drive chain as a set.

EC369002 DRIVE CHAIN INSPECTION

1. Remove:

• Master link clip
• Joint ①
• Drive chain ②

2. Clean:

- Drive chain

Place it in kerosene, and brush off as much dirt as possible. Then remove the chain from the kerosene and dry the chain.

3. Measure:

- Drive chain length (10 links) ⓐ Out of limit → Replace.

Drive chain length (10 links): : 122.1 mm (4.81 in)

4. Check:

- Drive chain stiffness @ Clean and oil the chain and hold as illustrated. Stiff → Replace drive chain.

CONTROLE DES PIGNONS

1. Contrôler:

• Dents de pignon ⓐ
Usure excessive → Remplacer.

N.B.:

Illustration of a hand using a tool to adjust a chain gear mechanism (no text or symbols present)

5. Install:

• Drive chain ①
• Joint ②
• Master link clip ③

New

CAUTION:

Be sure to install the master link clip to the direction as shown.

① Turning direction

6. Lubricate:

- Drive chain

EC36A060

DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine.

2. Check:

- Drive chain slack @

In the center between the drive axle and rear wheel axle.

Out of specification → Adjust.

NOTE:

Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point. Check and/or adjust chain slack with rear wheel in this "tight chain" position.

REGLAGE DU JEU DE LA CHAINE DE TRANSMISSION ANTRIEBSKETTENDURCHHANG EINSTELLEN

INSP ADJ

5. Monter:

3. Adjust:

- Drive chain slack

Drive chain slack adjustment steps:Loosen the axle nut 1 and locknuts 2.Adjust chain slack by turning the adjusters 3.
To tighten → Turn adjuster 3 clockwise.To loosen → Turn adjuster 3 counterclockwise and push wheel forward.
Turn each adjuster exactly the sameamount to maintain correct axle alignment.(There are marks @ on each side of chainpuller alignment.)NOTE:Turn the adjuster so that the chain is in linewith the sprocket, as viewed from the rear.CAUTION:Too small chain slack will overload theengine and other vital parts; keep theslack within the specified limits.Tighten the axle nut while pushing downthe drive chain.
	Axle nut:90 Nm (9.0 m • kg, 65 ft • lb)
Tighten the locknuts.

DRIVE CHAIN SUPPORT INSPECTION

1. Inspect:

- Drive chain support wear limit Limit reaches indicator @ → Replace. Refer to “SWINGARM” section in the CHAPTER 5.

Mechanical diagram showing a hand operating a vehicle tire with a brake and suspension mechanism (no text or symbols)

EC36C000

FRONT FORK INSPECTION

1. Inspect:

- Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or replace.

3. Régler:

Technical line drawing of a mechanical assembly with no visible text or symbols

EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING

1. Remove:

2. Protector ①

3. Dust seal ②

NOTE:

Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.

1. Clean:

2. Dust seal ⓐ

3. Oil seal ⓑ

NOTE:

• Clean the dust seal and oil seal after every run.
• Apply the lithium soap base grease on the inner tube.

FRONT FORK INTERNAL PRESSURE BLEEDING

NOTE:

If the front fork initial movement feels stiff during a run, bleed the front fork internal pressure.

1. Elevate the front wheel by placing a suitable stand under the engine.
2. Remove the air bleed screw ① and release the internal pressure from the front fork.
3. Install:
   • Air bleed screw

1 Nm (0.1 m · kg, 0.7 ft · lb)

EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT

1. Adjust:

2. Rebound damping force By turning the adjuster ①.

Stiffer ⓐ → Increase the rebound damping force. (Turn the adjuster ① in.) Softer ⑥ → Decrease the rebound damping force. (Turn the adjuster ① out.)

NETTOYAGE DE LA BAGUE D'ETANCHEITE ET DU JOINT ANTIPOUSSIERE DE FOURCHE AVANT

1. Déposer:

2. Protection ①

3. Joint antipoussière ②

N.B.:

	Extent of adjustment
Maximum Minimum		um
Fully turned in position		20 clicks out (from maximum position)

• STANDARD POSITION:

This is the position which is back by the specific number of clicks from the fully turned-in position.

Standard position:7 clicks out

CAUTION:

Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

WARNING

Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT

1. Remove:
2. Rubber cap
3. Adjust:
4. Compression damping force By turning the adjuster ①.

Stiffer ⓐ → Increase the compression damping force. (Turn the adjuster ① in.)

Softer ⑥ → Decrease the compression damping force. (Turn the adjuster ① out.)

	Extent of adjustment
Maximum Minimum		um
Fully turned in position		20 clicks out (from maximum position)

• STANDARD POSITION:

This is the position which is back by the specific number of clicks from the fully turned-in position.

Standard position:YZ85: 10 clicks outYZ85LW: 9 clicks out

CAUTION:

Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

WARNING

Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

1. Install:

- Rubber cap

Mechanical diagram showing a hand operating a tire with a gear mechanism, no text or symbols present

EC36K000 REAR SHOCK ABSORBER INSPECTION

1. Inspect:

- Swingarm smooth action Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points. Damage/oil leakage → Replace.

CONTROLE DE L'AMORTISSEUR ARRIÈRE HINTEREN STOSSDÄMPFER KONTROLLIEREN

Technical illustration of a mechanical spring assembly with dimension label 'a' (no text or symbols beyond the label)

REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine.
2. Remove:

- Rear frame

1. Loosen:
2. Locknut ①
3. Adjust:
4. Spring preload By turning the adjuster ②.

Stiffer → Increase the spring preload. (Turn the adjuster ② in.)

Softer → Decrease the spring preload. (Turn the adjuster ② out.)

Spring length (installed) ⓐ:

YZ85: 215 mm (8.46 in)

*212 mm (8.35 in)

YZ85LW: 207 mm (8.15 in)

*212 mm (8.35 in)

Extent of adjustment:

202.5 \~ 218.5 mm

(7.97 \~ 8.60 in)

* For EUROPE

NOTE:

• Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment.
• The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster.

CAUTION:

Never attempt to turn the adjuster beyond the maximum or minimum setting.

1. Tighten:

- Locknut

1. Install:

- Rear frame (upper)

26 Nm (2.6 m · kg, 19 ft · lb)

- Rear frame (lower)

16 Nm (1.6 m · kg, 11 ft · lb)

REGLAGE DE LA PRECONTRAINTE DE RESSORT DE L'AMORTISSEUR ARRIERE

REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT

1. Adjust:

- Rebound damping force By turning the adjuster ①.

Stiffer → Increase the rebound damping force. (Turn the adjuster 1 in.)

Softer → Decrease the rebound damping force. (Turn the adjuster 1 out.)

	Extent of adjustment
Maximum Minimum		um
Fully turned in position		20 clicks out (from maximum position)

• STANDARD POSITION:

This is the position which is back by the specific number of clicks from the fully turned-in position.

Standard position:YZ85: 6 clicks out*12 clicks outYZ85LW: 7 clicks out*12 clicks out

* For EUROPE

CAUTION:

Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

REGLAGE DE LA FORCE

D'AMORTISSEMENT DE DETENTE DE

REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT

1. Adjust:

- Compression damping force By turning the adjuster ①.

Stiffer ① → Increase the compression damping force. (Turn the adjuster 1 in.)

Softer ⑥ → Decrease the compression damping force. (Turn the adjuster 1 out.)

	Extent of adjustment
Maximum Minimum
Fully turned in position		20 clicks out (from maximum position)

• STANDARD POSITION:

This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark ⓐ on the adjuster with the punch mark ⓑ on the bracket.)

Standard position:

YZ85: About 9 clicks out

*About 12 clicks out

YZ85LW: About 7 clicks out

*About 12 clicks out

* For EUROPE

CAUTION:

Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

REGLAGE DE LA FORCE D'AMORTISSEMENT DE COMPRESSION DE L'AMORTISSEUR ARRIERE

1. Régler:

Illustration of hands adjusting a pressure gauge with a tool (no text or symbols)

EC36Q000

TIRE PRESSURE CHECK

1. Measure:

- Tire pressure

Out of specification → Adjust.

Standard tire pressure: 100 kPa (1.0 kgf/cm², 15 psi)

NOTE:

• Check the tire while it is cold.
• Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
• A tilted tire valve stem indicates that the tire slips off its position on the rim.
• If the tire valve stem is found tilted, the tire is considered to be slipping off its position. Correct the tire position.

EC36S002

SPOKES INSPECTION AND TIGHTENING

1. Inspect:

• Spokes ①
  Bend/damage → Replace.
  Loose spoke → Retighten.

2. Retighten:

- Spokes

3 Nm (0.3 m · kg, 2.2 ft · lb)

NOTE:

Be sure to retighten these spokes before and after break-in. After a practice or a race check spokes for looseness.

CONTROLE DE LA PRESSION DES PNEUS

1. Mesurer:

WHEEL INSPECTION/ STEERING HEAD INSPECTION AND ADJUSTMENT

Diagram of a hand operating a tire with a brake caliper and wheel (no text or symbols)

Diagram of a car tire and brake system with hand motion arrows indicating rotational direction (no text or labels)

EC36T000 WHEEL INSPECTION

1. Inspect:

- Wheel runout Elevate the wheel and turn it. Abnormal runout → Replace.

2. Inspect:

- Bearing free play Exist play → Replace.

Mechanical diagram showing a car wheel and brake system with motion arrows (no text or symbols)

Technical line drawing of a mechanical device with bidirectional arrows indicating rotation (no text or symbols)

STEERING HEAD INSPECTION AND ADJUSTMENT

1. Elevate the front wheel by placing a suitable stand under the engine.

2. Check:

- Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play → Adjust steering head.

3. Check:

- Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut.

CONTROLE DES ROUES

1. Contrôler:

4. Adjust:

- Steering ring nut

Steering ring nut adjustment steps:Remove the number plate.Remove the handlebar and handlebar upper bracket.Loosen the steering ring nut 1 using the steering nut wrench 2.
	Steering nut wrench: YU-33975/90890-01403
Tighten the steering ring nut 3 using steering nut wrench 4.NOTE:Install the steering ring nut with its larger chamfered side @ downward.Set the torque wrench to the steering nut wrench so that they form a right angle.
	Steering nut wrench: YU-33975/90890-01403
	Steering ring nut (initial tightening): 38 Nm (3.8 m • kg, 27 ft • lb)
Loosen the steering ring nut one turn.Retighten the steering ring nut using the steering nut wrench.AVoid over-tightening.
	Steering ring nut (final tightening): 4 Nm (0.4 m • kg, 2.9 ft • lb)

- Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings. - Install the upper bracket 5, washer, steering stem nut 6, handlebar 7, handlebar upper holder 8 and number plate 9.

NOTE:

• The upper handlebar holder should be installed with the punched mark @ forward.
• Insert the end of fuel breather hose 0 into the hole of the steering stem.

CAUTION:

First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.

Steering stem nut: 125 Nm (12.5 m • kg, 90 ft • lb)

Handlebar upper holder: 27 Nm (2.7 m • kg, 19 ft • lb)

Pinch bolt (upper bracket): 22 Nm (2.2 m • kg, 16 ft • lb)

Number plate: 7 Nm (0.7 m • kg, 5.1 ft • lb)

To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race.

① All control cable
② Clutch lever pivot
③ Shift pedal pivot
④ Footrest pivot
⑤ Throttle-to-handlebar contact
⑥ Drive chain
⑦ Tube guide cable winding portion
⑧ Throttle cable end
⑨ Clutch cable end

A Use Yamaha cable lube or equivalent on these areas.
B Use SAE 10W-30 motor oil or suitable chain lubricants.
C Lubricate the following areas with high quality, lightweight lithium-soap base grease.

CAUTION:

Wipe off any excess grease, and avoid getting grease on the brake discs.

LUBRIFICATION

EC370000

ELECTRICAL

EC371001

SPARK PLUG INSPECTION

1. Remove:

- Spark plug

1. Inspect:

- Electrode ①

Wear/damage → Replace.

- Insulator color ②

Normal condition is a medium to light tan color.

Distinctly different color → Check the engine condition.

NOTE:

When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition.

1. Measure:

- Plug gap ⓐ

Use a wire gauge or thickness gauge.

Out of specification → Regap.

Spark plug gap: 0.5 \~ 0.6 mm (0.020 \~ 0.024 in)

1. Clean the plug with a spark plug cleaner if necessary.

1. Tighten:

- Spark plug

20 Nm (2.0 m · kg, 1.4 ft · lb)

NOTE:

• Before installing a spark plug, clean the gasket surface and plug surface.
• Finger-tighten ⓐ the spark plug before torquing to specification ⓑ.

PARTIE ELECTRIQUE

CONTROLE DE LA BOUGIE

1. Déposer:

- Bougie

2. Contrôler:

- Electrode ①

IGNITION TIMING CHECK

1. Remove:

2. Air scoop

3. Spark plug

4. Left crankcase cover

5. Attach:

6. Dial gauge ①

7. Dial gauge stand ②

Dial gauge and stand: YU-3097/90890-01252

Stand: YU-1256

Technical line drawing of a mechanical gear assembly with no visible text or symbols

1. Rotate the rotor ① until the piston reaches top dead center (TDC). When this happens, the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direction.

2. Set the dial gauge to zero at TDC.

3. From TDC, rotate the rotor clockwise until the dial gauge indicates that the piston is at a specified distance from TDC.

Ignition timing (B.T.D.C.): 0.9 mm (0.035 in)

1. Check:

2. Ignition timing Punch mark ⓐ on rotor should be aligned with punch mark ⓑ on stator. Not aligned → Adjust.

CONTROLE DE L'AVANCE A L'ALLUMAGE

1. Déposer:

7. Adjust:

- Ignition timing

Adjustment steps:

• Loosen the screws (stator) ①.
• Align the punch mark on the rotor with punch mark on stator ② by moving stator.
• Tighten the screws (stator).

Screw (stator): 8 Nm (0.8 m • kg, 5.8 ft • lb)

8. Check:

- Ignition timing

Re-check the ignition timing.

CONTROLE DE L'AVANCE A L'ALLUMAGE ZÜNDZEITPUNKT KONTROLLIEREN

7. Régler:

③ Side covers removal

④ Number plate removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		SEAT, FUEL TANK AND SIDE COVERS REMOVALTurn the fuel cock to “OFF”.Disconnect the fuel hose.
1↓3↓2↓3↓4↓	1 2 Air scoop 13 Bolt (fuel tank) 24 Fuel tank 15 Left side cover 16 Right side cover 17 Number plate 1

MOTEUR

SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX

② Exhaust pipe removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal			EXHAUST PIPE AND SILENCER REMOVALRight side cover		Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.
[48SA]	[75CO]	1 Bolt (silencer) 12 Silencer 13 Exhaust pipe spring 24 Bolt (exhaust pipe) 25 Exhaust pipe	1

TUYAU D'ECHAPPEMENT ET SILENCIEUX

Extent of removal:

① Radiator removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		RADIATOR REMOVALDrain the coolant.Air scoop Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.
	1 Radiator guard 12 Radiator hose clamp 4 Only loosening.3 Radiator hose 1 14 Radiator hose 2 15 R a d i a t o r6 Radiator breather hose 1		1

RADIATEUR

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.

When the engine has cooled, open the radiator cap by the following procedure:

Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.

EC454000

INSPECTION

Radiator

1. Inspect:

- Radiator core ① Obstruction → Blow out with compressed air through rear of the radiator. Bent fin → Repair or replace.

EC455000

ASSEMBLY AND INSTALLATION

Radiator

1. Install:

- Radiator breather hose ① To radiator ②.

1. Install:

2. Radiator ①

3. Bolt (radiator) ②

REMARQUES CONCERNANT LA MANIPULATION

AVERTISSEMENT

3. Install:

• Radiator hose 1 ①
• Radiator hose 2 ②

Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

4. Tighten:

- Radiator hose clamp

5. Install:

• Radiator guard ①
• Bolt (radiator guard) ②

NOTE:

Fit the hooks ⓐ on the inner side first into the radiator.

3. Monter:

CARBURETOR AND REED VALVE

Extent of removal:

① Carburetor removal

② Reed valve removal

Extent of removal Order Part name Q'ty Remarks
		CARBURETOR AND REEDVALVE REMOVAL1 Clamp (air filter joint) 1 Loosen the screw (air filter joint).2 Clamp (carburetor joint) 1 Loosen the screw (carburetor joint).3 Carburetor assembly 14 Carburetor joint 15 Reed valve assembly 16 Reed valve stopper 27 Reed valve 2

CARBURATEUR ET SOUPAPE FLEXIBLE

Extent of removal:

① Carburetor disassembly

Extent of removal Order Part name Q'ty Remarks
1	12345678910111213	CARBURETOR DISASSEMBLYMixing chamber top 1Throttle valveJet needle 1Float chamber 1Float pin 1Float 1Main jet 1Main nozzle holder 1Main nozzle 1Pilot jet 1Starter plunger 1Throttle stop screwPilot air screw	1	Refer to “REMOVAL POINTS”.
			1
			1
			1

CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND REED-VENTIL

ENG

DEMONTAGE DU CARBURATEUR

HANDLING NOTE

CAUTION:

Do not disassemble the venturi block ① because it will cause a drop in carburetor performance.

EC463000

REMOVAL POINTS

EC463110

Throttle valve

1. Remove:

2. Throttle valve ①

3. Ring ②
4. Spring (throttle valve) ③
5. Mixing chamber top ④
6. Throttle cable ⑤

NOTE:

While compressing the spring (throttle valve), disconnect the throttle cable.

Mechanical assembly diagram showing a valve and adjustment tool (no text or labels)

Illustration of a hand holding an Air Gun tool next to a device (no text or symbols on the diagram itself)

INSPECTION

Pilot air screw

1. Remove:

- Pilot air screw ①

NOTE:

To optimize the fuel flow at a small throttle opening, each machine's pilot air screw has been individually set at the factory. Before removing the pilot air screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out.

Carburetor

1. Inspect:

- Carburetor body Contamination → Clean.

NOTE:

• Use a petroleum based solvent for cleaning. Blow out all passages with compressed air.
• Never use a wire.

REMARQUES CONCERNANT LA MANIPULATION

ATTENTION:

2. Inspect:

• Main jet ①
• Main nozzle ②
• Main nozzle holder ③
• Pilot jet ④ Contamination → Clean.

NOTE:

• Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air.
• Never use a wire.

Needle valve

1. Inspect:

• Needle valve ①
• Valve seat ②
  Grooved wear ⓐ → Replace.
  Dust ⓑ → Clean.

EC464301

Throttle valve

1. Check:

• Free movement
  Stick → Repair or replace.

NOTE:

Insert the throttle valve ① into the carburetor body, and check for free movement.

EC464401

Jet needle

1. Inspect:

• Jet needle ①
  Bends/wear → Replace.
• Clip groove
  Free play exists/wear → Replace.
• Clip position

Standard clip position: No.2 Groove

CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND REED-VENTIL

ENG

2. Contrôler:

Technical line drawing of a mechanical assembly with two cylindrical components and a bracket (no text or symbols)

Technical line drawing of a mechanical assembly with labeled component 'a' (no text or symbols beyond label)

Float height

1. Measure:

- Float height ⓐ

Out of specification → Adjust.

Float height: 18 \~ 20 mm (0.71 \~ 0.79 in)

Measurement and adjustment steps:

• Hold the carburetor in an upside down position.
• Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers.

NOTE:

The float arm should be resting on the needle valve, but not compressing the needle valve.

• If the float height is not within specification, inspect the valve seat and needle valve.
• If either is worn, replace them both.
• If both are fine, adjust the float height by bending the float tab ⑥ on the float.
• Recheck the float height.

EC464600

Float

1. Inspect:

- Float ①

Damage → Replace.

EC464701

Reed valve

1. Measure:

• Reed valve bending ⓐ
  Out of limit → Replace.

Reed valve bending limit: 0.2 mm (0.008 in)

Hauteur du flotteur

1. Mesurer:

Technical line drawing of a mechanical bracket or support structure with no visible text or symbols

- Valve stopper height ⑥ Out of specification → Replace.

Valve stopper height: 7.4 \~ 7.8 mm (0.291 \~ 0.307 in)

EC465000 ASSEMBLY AND INSTALLATION Reed valve

1. Install:

2. Reed valve ①

3. Reed valve stopper ②
4. Screw (reed valve) ③

1 Nm (0.1 m · kg, 0.7 ft · lb)

NOTE:

• Install the reed valve with the reed valve bending as shown.
- Note the cut ⓐ in the lower corner of the reed valve and stopper.

CAUTION:

Tighten each screw gradually to avoid warping.

1. Install:

- Reed valve assembly ①

NOTE:

Install the reed valve assembly with its projection @ facing upward.

1. Install:

2. Carburetor joint ①

3. Bolt (carburetor joint) ②

8 Nm (0.8 m · kg, 5.8 ft · lb)

CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND REED-VENTIL

ENG

- Ensemble soupape flexible ①

N.B.:

Carburetor

1. Install:

• Pilot air screw ①
• Throttle stop screw ②

Note the following installation points:

• Turn in the pilot air screw until it is lightly seated.
• Turn out the pilot air screw by the number of turns recorded before removing.

Pilot air screw: 2 turns out (example)

2. Install:

- Starter plunger ①

3. Install:

• Pilot jet ①
• Main nozzle ②
• Main nozzle holder ③
• Main jet ④

NOTE:

Install the main nozzle with its chamfered side @ facing the carburetor.

4. Install:

• Needle valve ①
• Float ②
• Float pin ③

NOTE:

• After installing the needle valve to the float, install them to the carburetor.
• Check the float for smooth movement.

Carburateur

1. Monter:

5. Install:

• Float chamber ①
• Hose holder (carburetor breather hose) ②
• Screw (float chamber) ③

6. Install:

• Carburetor breather hose ①
- Overflow hose ②
- Clamp ③

7. Install:

• Jet needle ①
  To throttle valve ②.

8. Install:

• Throttle cable ①
• Mixing chamber top ②
• Spring (throttle valve) ③
• Ring ④
• Throttle valve ⑤

NOTE:

• While compressing the spring, connect the throttle cable.
• Align the cut ⓐ in the ring with the throttle cable.

CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND REED-VENTIL

ENG

5. Monter:

9. Install:

• Mixing chamber top ①
• Screw (mixing chamber top) ②

To carburetor ③.

NOTE:

• Pass the throttle cable in front of the carburetor breather hoses.
• After installing, check the throttle grip for smooth movement.

Carburetor installation

1. Install:

- Carburetor ①

NOTE:

Install the projection between the carburetor joint slots.

2. Tighten:

• Screw (air filter joint) ①
• Screw (carburetor joint) ②

3. Clamp:

• Carburetor breather hose ①
- Overflow hose ②
Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

4. Adjust:

• Engine idling speed
  Refer to "ENGINE IDLING SPEED ADJUSTMENT" section in the CHAPTER 3.

CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND REED-VENTIL

ENG

9. Monter:

① Cylinder head removal

② Cylinder removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal				CYLINDER HEAD AND CYLIN-DER REMOVALSeat and fuel tankExhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER” section.Radiator hose 1 Disconnect at cylinder head side.Radiator hose 2 Disconnect at radiator side.	Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.
			1 Spark plug 12 Nut (cylinder head) 4 Loosen each nut3 Cylinder head 14 Nut (cylinder) 45 Cylinder 1	1/4 turn,	and remove them after all nuts are loosened.

CULASSE, CYLINDRE ET PISTON

CULASSE ET CYLINDRE

Extent of removal:
① Piston and piston ring removal

Extent of removal Order Part name Q'ty Remarks
		PISTON REMOVAL1 Piston pin clip 22 Piston pin 13 Piston4 Small end bearing 15 Piston ring 1	1	Refer to “REMOVAL POINTS”.

Technical illustration of a hand using a tool to adjust the piston component (no text or symbols present)

EC473000

REMOVAL POINTS

Piston and piston ring

1. Remove:

- Piston pin clip ①

NOTE:

Before removing piston pin clip, cover the crankcase with a clean rag to prevent piston pin clip from falling into the crankcase cavity.

1. Remove:

2. Piston pin ①

3. Piston ②
4. Small end bearing ③

NOTE:

Before removing the piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and piston pin is still difficult to remove, use the piston pin puller set ④.

Piston pin puller set: YU-1304/90890-01304

CAUTION:

Do not use a hammer to drive the piston pin out.

Technical diagram of a mechanical component with a tool inserted, showing internal structure and part outline (no text or symbols)

1. Remove:

- Piston ring ①

NOTE:

Take care not to scratch the piston and damage the piston ring.

INSPECTION

Cylinder head

1. Eliminate:

- Carbon deposits

Use a rounded scraper ①.

NOTE:

Take care to avoid damaging the spark plug threads. Do not use a sharp instrument. Avoid scratching the aluminum.

2. Inspect:

• Cylinder head water jacket Crust of minerals/rust → Remove.
• Cylinder head warpage Out of specification → Re-surface.

Warpage measurement and resurfacing steps:

• Attach a straightedge ① and a thickness gauge ② on the cylinder head.
  • Measure the warpage.

Warpage limit: 0.03 mm (0.012 in)

• If the warpage is out of specification, resurface the cylinder head.
• Place # 400 \~ 600 grit wet sandpaper ③ on the surface plate, and re-surface the head ④ using a figure-eight sanding pattern.

NOTE: Rotate the cylinder head several times to avoid removing too much material from one side.

Illustration of hands assembling a mechanical component (no text or symbols visible)

Cylinder

1. Eliminate:

• Carbon deposits
  Use a rounded scraper ①.

NOTE:

Do not use a sharp instrument. Avoid scratching the aluminum.

2. Inspect:

• Cylinder inner surface
  Use # 400 \~ 600 grit wet sandpaper. Score marks → Repair or replace.

CAUTION:

Do not rebore the cylinder.

Technical line drawing of two mechanical components: a cylindrical roller and a hollow cylindrical roller (no text or symbols)

3. Measure:

- Cylinder bore "C" Use cylinder gauge ①. Out of limit → Replace.

NOTE:

Measure the cylinder bore "C" in parallel (A, B, C) to and at right angles to the crankshaft (a, b). Then, find the average of the measurements.

	Standard Wear	limit
Cylinder bore “C”	47.500 ~ 47.514 mm(1.8701 ~ 1.8706 in)	47.6 mm(1.8740 in)
Taper “T”	-	0.05 mm(0.0020 in)
C = Maximum Aa ~ CbT = (Maximum Aa, or Ab) –(Maximum Ba, or Bb)

Piston

1. Eliminate:

- Carbon deposits From the piston crown ⓐ and ring groove ⑥.

2. Inspect:

- Piston wall Score marks → Replace.

3. Measure:

- Piston skirt diameter Use micrometer ①. Measure the specific distance ② from the bottom edge. Out of specification → Replace.

Piston dia.: 47.457 \~ 47.472 mm (1.8684 \~ 1.8690 in) Distance ⓐ: 20 mm (0.79 in)

Piston pin and small end bearing

1. Inspect:

- Piston pin - Small end bearing Signs of heat discoloration → Replace.

2. Measure:

- Piston pin outside diameter Use micrometer ①. Out of limit → Replace.

Piston pin outside diameter: 13.996 \~ 14.000 mm (0.5510 \~ 0.5512 in) : 13.975 mm (0.5502 in)

3. Check:

- Free play (when the piston pin ① is in place in the piston ②) There should be no noticeable for the play. Free play exists → Replace piston pin and/or piston.

4. Install:

• Small end bearing
• Piston pin Into the small end of connecting rod.

Illustration of a hand turning a mechanical component with arrows indicating rotation (no text or symbols)

5. Check:

- Free play There should be no noticeable free play. Free play exists/unsmooth revolution → Inspect the connecting rod for wear/replace the pin and/or connecting rod as required.

Technical line drawing of a mechanical component with a tool inserted, no visible text or symbols

Piston ring

1. Install:

- Piston ring

Into the cylinder.

Push the ring with the piston crown.

2. Measure:

- End gap

Use a thickness gauge ①.

Out of limit → Replace.

Ring end gap (installed):

0.30 \~ 0.45 mm

(0.012 \~ 0.018 in)

: 0.80 mm (0.031 in)

Illustration of hands using a tool to adjust or install a circular component, no text or symbols present

3. Measure:

- Side clearance

Use a thickness gauge ①.

Out of limit → Replace piston and/or ring.

Side clearance:

0.030 \~ 0.065 mm

(0.001 \~ 0.003 in)

: 0.1 mm (0.004 in)

NOTE:

Check at several points.

Piston clearance

1. Calculate:

- Piston clearance

Out of limit → Replace piston, and piston ring and/or cylinder.

Refer to "Cylinder" and "Piston".

Segment

1. Monter:

Combination of piston and cylinder

1. Check:

- Cylinder mark ⓐ

Cylinder mark ⓐCylinder size
A	47.500 ~ 47.502 mm(1.8701 ~ 1.8702 in)
B	47.504 ~ 47.506 mm(1.8702 ~ 1.8703 in)
C	47.508 ~ 47.510 mm(1.8704 ~ 1.8705 in)
D	47.512 ~ 47.514 mm(1.8706 ~ 1.8706 in)

2. Check:

- Piston mark ⓐ

Piston mark ⓐ (color)	Piston size
A (red)	47.457 ~ 47.460 mm(1.8684 ~ 1.8685 in)
B (orange)	47.461 ~ 47.464 mm(1.8685 ~ 1.8687 in)
C (green)	47.465 ~ 47.468 mm(1.8687 ~ 1.8688 in)
D (purple)	47.469 ~ 47.472 mm(1.8689 ~ 1.8690 in)

3. Combination:

- Combine the piston and cylinder by the following chart.

Cylinder mark Piston mark (color)
A	A
B B (orange)
C C (green)
D D (purple)

Jeu du piston:

0,040 à 0,045 mm

Zylinderkennung aZylindergröße

A 47,500–47,502 mm

B 47,504–47,506 mm

C 47,508–47,510 mm

D 47,512–47,514 mm

2. Kontrollieren:

When you purchase a cylinder, you cannot designate its size. Choose the piston that matches the above chart.

ASSEMBLY AND INSTALLATION

Piston ring and piston

1. Install:

- Piston ring ①

NOTE:

• Take care not to scratch the piston or damage the piston ring.
• Align the piston ring gap with the pin ②.
• After installing the piston ring, check the smooth movement of it.

2. Install:

• Gasket (cylinder) ①
• Small end bearing ②
• Dowel pin ③

NOTE:

• Apply the engine oil on the bearing (crankshaft and connecting rod) and connecting rod big end washers.
  • Install the gasket with the seal print side toward the crankcase.

N.B.:

Technical line drawing of a mechanical assembly with hands and tools (no visible text or symbols)

Technical line drawing of a mechanical assembly with no visible text or symbols

3. Install:

- Piston ①

- Piston pin ②

- Piston pin clip ③

NOTE:

- The arrow ⓐ on the piston dome must point to exhaust side.

- Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase cavity.

CAUTION:

Do not allow the clip open ends to meet the piston pin slot ⓑ.

Cylinder head and cylinder

1. Apply:

- Engine oil

To piston ①, piston ring ② and cylinder surface.

2. Install:

- Cylinder ①

CAUTION:

Make sure the piston ring is properly positioned. Install the cylinder with one hand while compressing the piston ring with the other hand.

NOTE:

After installing, check the smooth movement of the piston.

3. Install:

- Nut (cylinder) ①

4. Install:

- O-ring ① New

NOTE:

Apply the lithium soap base grease on the O-rings.

5. Install:

• Cylinder head ①
• Copper washer ②
• Nut (cylinder head) ③

30 Nm (3.0 m · kg, 22 ft · lb)

NOTE:

Tighten the nuts (cylinder head) in stage, using a crisscross pattern.

6. Install:

- Spark plug ①

• Spark plug cap ②
• Radiator hose 1 ③
• Radiator hose 2 ④

CLUTCH AND PRIMARY DRIVEN GEAR

EC498000

CLUTCH PLATE AND FRICTION PLATE

Extent of removal:

① Clutch plate and friction plate removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		CLUTCH PLATE AND FRIC-TION PLATE REMOVALDrain the transmission oil.Clutch cable Disconnect at engine side.	Refer to “TRANSMISSION OIL REPLACEMENT” section in the CHAP-TER 3.
	1 Clutch cover 12 Bolt (clutch spring) 53 Clutch spring 54 Pressure plate 15 Friction plate 76 Clutch plate 6

EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

EMBRAYAGE ET PIGNON MENE PRIMAIRE

DISQUE D'EMBRAYAGE ET DISQUE DE FRICTION

① Push rod and push lever shaft removal

② Primary driven gear removal

Extent of removal Order Part name Q'ty Remarks
	PRIMARY DRIVEN GEAR,PUSH ROD AND PUSH LEVERSHAFT REMOVAL1 Push rod 1 12 B a l l 13 Push rod 2 14 Nut (clutch boss) 15 Conical washer 16 Clutch boss 17 Washer 18 Primary driven gear 19 S p a c e r 110 Washer 111 Push lever shaft	1	Use special tool.Refer to “REMOVAL POINTS”.

EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

PIGNON MENE PRIMAIRE, TIGE DE POUSSEE ET ARBRE DE LEVIER DE POUSSEE

Technical line drawings of two mechanical clamps labeled A and B, showing different clamp configurations (no text or symbols present)

Illustration of hands assembling a mechanical gear assembly (no text or symbols)

Line drawing of a hand using a caliper to adjust a spring component (no text or symbols present)

REMOVAL POINTS

Clutch boss

1. Remove:

2. Nut (clutch boss) ①

3. Conical washer ②
4. Clutch boss ③

NOTE:

Use the clutch holding tool ④ to hold the clutch boss.

Clutch holding tool: YM-91042/90890-04086

A For USA and CDN
B Except for USA and CDN

EC494000

INSPECTION

EC484100

Clutch housing and boss

1. Inspect:

2. Clutch housing ①
   Cracks/wear/damage → Replace.

3. Clutch boss ②
   Scoring/wear/damage → Replace.

EC484201

Primary driven gear

1. Check:

2. Circumferential play
   Free play exists → Replace.

3. Gear teeth ⓐ
   Wear/damage → Replace.

Clutch spring

1. Measure:

2. Clutch spring free length ⓐ
   Out of limit → Replace springs as a set.

EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

POINTS DE DEPOSE

Noix d'embrayage

1. Déposer:

Line drawing of hands using a tool to cut a gear component (no text or symbols)

Friction plate

1. Measure:

- Friction plate thickness Out of limit → Replace friction plate as a set. Measure at all four points.

Friction plate thickness:

2.9 \~ 3.1 mm

(0.114 \~ 0.122 in)

: 2.7 mm (0.106 in)

EC484600

Clutch plate

1. Measure:

- Clutch plate warpage Out of limit → Replace clutch plate as a set. Use a surface plate ① and thickness gauge ②.

Warp limit: 0.1 mm (0.004 in)

Technical line drawing of a mechanical tool or clamp component (no text or symbols)

Push lever shaft

1. Inspect:

- Push lever shaft ① Wear/damage → Replace.

Push rod

1. Inspect:

• Push rod 1 ①
• Ball ②
• Push rod 2 ③

Wear/damage/bend → Replace.

EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

Disque de friction

1. Mesurer:

ASSEMBLY AND INSTALLATION

Push lever shaft

1. Install:

- Push lever shaft ①

NOTE:

• Apply the lithium soap base grease on the oil seal lip and push lever shaft end.
• Apply the transmission oil on the push lever shaft.

Clutch

1. Install:

2. Washer [thickness 2 mm (0.08 in)] ①

3. Spacer ②
   • Primary driven gear ③

NOTE:

Apply the transmission oil on the washer, spacer and primary driven gear inner circumference.

1. Install:

2. Washer [thickness 4 mm (0.16 in)] ①

3. Clutch boss ②

4. Install:

- Conical washer ①

NOTE:

Install the conical washer to the main axle ② as shown in the illustration.

EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

ASSEMBLAGE ET MONTAGE

Two technical line drawings of metal clamps, labeled A and B, showing different angles and mounting points (no text or symbols present)

4. Install:

- Nut (clutch boss) ①

70 Nm (7.0 m · kg, 50 ft · lb)

NOTE:

Use the clutch holding tool ② to hold the clutch boss.

Clutch holding tool: YM-91042/90890-04086

A For USA and CDN

B Except for USA and CDN

5. Install:

• Friction plate 1 ①
• Clutch plate ②
• Friction plate 2 ③

NOTE:

• Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.
- Use the friction plates 1 for the first and final while paying attention to the difference in surface pattern.
- Apply the transmission oil on the friction plates and clutch plates.

6. Install:

• Push rod 2 ①
• Ball ②
• Push rod 1 ③

NOTE:

Apply the transmission oil on the push rod 1, 2 and ball.

EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

4. Monter:

CLUTCH AND PRIMARY DRIVEN GEAR

ENG

7. Install:

- Pressure plate ①

NOTE:

Align the punch mark ⓐ on the pressure plate with the punch mark ⓑ on the clutch boss.

8. Install:

- Clutch spring ①

- Bolt (clutch spring) ②

6 Nm (0.6 m · kg, 4.3 ft · lb)

NOTE:

Tighten the bolts (clutch spring) in stage, using a crisscross pattern.

9. Install:

- Dowel pin ①

• Gasket (clutch cover) ②

New

10. Install:

- Clutch cover ①

- Bolt (clutch cover) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Tighten the bolts in stage, using a crisscross pattern.

EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

7. Monter:

KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR

ENG

KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR

Extent of removal:
① Primary drive gear removal

Extent of removal Order Part name Q'ty Remarks
		PRIMARY DRIVE GEAR REMOVALDrain the transmission oil. Refer to “TRANSMISSION OIL REPLACEMENT” section in the CHAPTER 3.Brake pedalRadiator hose 2 Disconnect at water pump side.
1	1 Kickstarter crank 12 Right crankcase cover 13 Nut (primary drive gear) 1 Only loosening.4 Primary driven gear 1 Refer to “CLUTCH AND PRIMARYDRIVEN GEAR” section.		Refer to “REMOVAL POINTS”.

ARBRE DE KICK, ARBRE DE SELECTEUR ET PIGNON DE

TRANSMISSION PRIMAIRE

PIGNON DE TRANSMISSION PRIMAIRE

KICK SHAFT AND SHIFT SHAFT

Extent of removal:
① Kick shaft and kick idle gear removal
② Shift shaft and stopper lever removal

Extent of removal Order Part name Q'ty Remarks
(HCV)2	1 Kick idle gear 12 Kick shaft assembly3 Shift pedal 14 Shift shaft 15 Stopper lever assembly 16 Torsion spring 17 Circlip 18 Washer 19 Stopper lever 110 Collar 1	KICK SHAFT AND SHIFT SHAFT REMOVAL	1	Refer to “REMOVAL POINTS”.

REMOVAL POINTS

Primary drive gear

1. Loosen:

- Nut (primary drive gear) ①

NOTE:

Place an aluminum plate ① between the teeth of the primary drive gear ② and driven gear ③.

Kick shaft assembly

1. Remove:

- Kick shaft assembly ①

NOTE:

Unhook the torsion spring ② from the hole ④ in the crankcase.

INSPECTION

Kick shaft and kick gear

1. Check:

- Kick gear smooth movement Unsmooth movement → Replace.

1. Inspect:

- Kick shaft ① Wear/damage → Replace.

Kick gear, kick idle gear

1. Inspect:

2. Kick gear ①

3. Kick idle gear ②

- Gear teeth ⓐ Wear/damage → Replace.

Kick gear clip

1. Measure:

- Kick clip friction force Out of specification → Replace. Use a spring gauge ①.

Kick clip friction force: 0.6 \~ 1.5 kg (1.3 \~ 3.3 lb)

POINTS DE DEPOSE

Pignon de transmission primaire

1. Desserrer:

EC4B4400

Shift shaft

1. Inspect:

• Shift shaft ①
  Bend/damage → Replace.
• Spring ②
  Broken → Replace.

EC4B4500

Stopper lever

1. Inspect:

• Stopper lever ①
  Wear/damage → Replace.
• Torsion spring ②
  Broken → Replace.

EC484300

Primary drive gear and primary driven gear

1. Inspect:

• Primary drive gear ①
  • Primary driven gear ②
  Wear/damage → Replace.

ASSEMBLY AND INSTALLATION

Stopper lever assembly

1. Install:

• Stopper lever ①
• Washer ②
• Circlip ③ New
• Torsion spring ④
  To collar ⑤.

NOTE:

Install the torsion spring with its shorter end ⓐ aligning with the stopper Ⓑ.

Arbre de sélecteur

1. Contrôler:

Technical line drawing of a mechanical component with no visible text or symbols

Mechanical assembly diagram showing a linkage mechanism with no visible text or symbols

2. Install:

- Stopper lever assembly ① To shift shaft ②.

NOTE:

Apply the transmission oil on the stopper lever assembly.

Shift shaft

1. Install:

- Shift shaft ①

NOTE:

• Apply transmission oil on the shift shaft.
• When installing the shift shaft, align the stopper lever roller with the slot on segment.
• When installing the shift shaft, make sure that the torsion spring ② is in the position as shown.

2. Check:

- Shift lever ① position Gaps ④ and ⑥ are not equal except in neutral → Replace the shift shaft.

Kick shaft assembly

1. Install:

• Kick gear ①
• Washer ②
• Torsion spring ③ To kick shaft ④.

NOTE:

Make sure the stopper ⓐ of the torsion spring fits into the hole Ⓒ in the other side of the stopper ⓑ of the kick shaft.

2. Monter:

KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR

ENG

2. Install:

- Spring guide ①

NOTE:

Slide the spring guide into the kick shaft, make sure the groove ⓐ in the spring guide fits on the stopper of the torsion spring.

3. Install:

- Kick shaft assembly ①

NOTE:

• Apply the transmission oil on the kick shaft.
• Apply the lithium soap base grease on the kick shaft stopper.
• Slide the kick shaft assembly into the crank-case, make sure the clip ② and kick shaft stopper a fit into their home positions b, c.

4. Hook:

- Torsion spring ①

NOTE:

Turn the torsion spring clockwise and hook into the proper hole @ in the crankcase.

Kick idle gear

1. Install:

• Washer ①
• Kick idle gear ②
• Circlip ③ New

NOTE:

• Apply the transmission oil on the kick idle gear inner circumference.
  • Install the kick idle gear with its groove @ facing the engine.

2. Monter:

- Guide de ressort ①

N.B.:

Primary drive gear

1. Install:

- Straight key ①

2. Install:

• Primary drive gear ①
- Conical washer ②
- Nut (primary drive gear) ③

NOTE:

• Temporarily tighten the nut at this point.
- Install the conical washer to the crankshaft ④ as shown in the illustration.

3. Install:

• Primary driven gear

Refer to "CLUTCH AND PRIMARY DRIVEN GEAR" section.

4. Tighten:

- Nut (primary drive gear) ①

79 Nm (7.9 m · kg, 57 ft · lb)

NOTE:

Place an aluminum plate ⓐ between the teeth of the primary drive gear ② and driven gear ③.

5. Install:

• Dowel pin ①
  • Gasket (right crankcase cover) ②

New

Pignon de transmission primaire

1. Monter:

- Clavette droite ①

KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR

ENG

6. Install:

• Right crankcase cover ①

NOTE:

Mesh the impeller shaft gear ② with primary drive gear ③.

7. Install:

- Bolt (right crankcase cover) ①

10 Nm (1.0 m · kg, 7.2 ft · lb)

• Copper washer (oil drain bolt) ②

New

- Oil drain bolt ③

10 Nm (1.0 m · kg, 7.2 ft · lb)

• Copper washer (coolant drain bolt)

④ New

- Coolant drain bolt ⑤

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Tighten the bolts in stage, using a crisscross pattern.

8. Install:

- Kickstarter crank ①

- Washer ②

- Bolt (kickstarter crank) ③

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Install the kickstarter crank closest to but not contacting the pillar tube ④ and exhaust pipe ⑤.

9. Install:

- Shift pedal ①

- Bolt (shift pedal) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Install the shift pedal with the bottom of the pedal outer diameter ⑧ as close to the center of the engine mounting bolt ③ as possible.

6. Monter:

① Impeller shaft removal

② Oil seal removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		WATER PUMP DISASSEMBLYRight crankcase cover		Refer to “KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR” section.
↓	1 Water pump housing 12 Impeller 13 Washer4 Impeller shaft 15 Bearing 16 Oil seal 2	1	Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.

POMPE A EAU

REMOVAL POINTS

Impeller shaft

1. Remove:

2. Impeller ①

3. Washer ②
4. Impeller shaft ③

NOTE:

Hold the impeller shaft on its width across the flats ⓐ with spanners, etc. and remove the impeller.

Technical line drawing of a mechanical component with no visible text or symbols

EC4G3210

Oil seal

NOTE:

• It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil.
• Replace the oil seal whenever it is removaled.

1. Remove:
2. Bearing ①
3. Remove:
4. Oil seal ①

Technical line drawing of a mechanical gear assembly with threaded shaft and central hub (no text or symbols)

INSPECTION

EC444200

Impeller shaft

1. Inspect:

- Impeller shaft ①

Bend/wear/damage → Replace.

Fur deposits → Clean.

POINTS DE DEPOSE

Arbre de rotor

Technical line drawing of a mechanical gear assembly with threaded shaft and central hub (no text or symbols)

Technical line drawing of a mechanical component with cross-sectional and side views (no text or symbols)

EC444300

Impeller shaft gear

1. Inspect:

- Gear teeth @ Wear/damage → Replace.

EC4H4600

Bearing

1. Inspect:

- Bearing Rotate inner race with a finger. Rough spot/seizure → Replace.

EC444400

Oil seal

1. Inspect:

- Oil seal ① Wear/damage → Replace.

ASSEMBLY AND INSTALLATION

Oil seal

1. Install:

- Oil seal ① New

NOTE:

• Apply the lithium soap base grease on the oil seal lip.
• Install the oil seal with its manufacture's marks or numbers facing the right crankcase cover ②.

Technical line drawing of a mechanical component with no visible text or symbols

2. Install:

- Bearing ①

NOTE:

Install the bearing by pressing its outer race parallel.

Impeller shaft

1. Install:

• Impeller shaft ①
• Washer ②
  • Impeller ③ 14 Nm (1.4 m · kg, 10 ft · lb)

NOTE:

• Take care so that the oil seal lip is not damaged or the spring does not slip off its position.
• When installing the impeller shaft, apply the lithium soap base grease on the oil seal lip and impeller shaft. And install the shaft while turning it.
• Hold the impeller shaft on its width across the flats @ with spanners, etc. and install the impeller.

2. Install:

• Gasket (water pump housing) ①

3. Install:

• Water pump housing ①
- Bolt (water pump housing) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

• Copper washer (coolant drain bolt)

③ New

- Coolant drain bolt ④

10 Nm (1.0 m · kg, 7.2 ft · lb)

POMPE A EAU WASSERPUMPE

ENG

2. Monter:

- Roulement ①

N.B.:

Extent of removal:
① CDI magneto removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		CDI MAGNETO REMOVALSeat and fuel tankDisconnect the CDI magneto lead.		Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.
1	1 Left crankcase cover 12 Nut (rotor) 1 Use special tool.3 Rotor 14 Stator 15 Woodruff key		1	Refer to “REMOVAL POINTS”.

VOLANT MAGNETIQUE CDI

Technical line drawing of a mechanical assembly with numbered components (no text or symbols)

EC4L3000

REMOVAL POINTS

Rotor

1. Remove:

2. Nut (rotor) ①

3. Washer ②

Use the rotor holding tool ③.

Rotor holding tool: YU-1235/90890-01235

1. Remove:

- Rotor ①

Use the flywheel puller ②.

Flywheel puller: YM-1189/90890-01189

NOTE:

When installing the flywheel puller, turn it counterclockwise.

Technical line drawing of a mechanical assembly with no visible text or symbols

EC4L4000

INSPECTION

EC4L4101

CDI magneto

1. Inspect:

2. Rotor inner surface @

3. Stator outer surface ⓑ

Damage → Inspect the crankshaft runout and crankshaft bearing.

If necessary, replace CDI magneto and/or stator.

EC4L4200

Woodruff key

1. Inspect:

- Woodruff key ①

Damage → Replace.

POINTS DE DEPOSE

Rotor

1. Déposer:

• Ecrou (rotor) ①
  • Rondelle ②

EC4L5000

ASSEMBLY AND INSTALLATION CDI magneto

1. Install:

2. Stator ①

3. Screw (stator) ②

NOTE:

Temporarily tighten the screw (stator) at this point.

1. Install:

2. Woodruff key ①

3. Rotor ②

NOTE:

• Clean the tapered portions of the crankshaft and rotor.
• When installing the woodruff key, make sure that its flat surface ① is in parallel with the crankshaft center line ⑥.
• When installing the rotor, align the keyway © of the rotor with the woodruff key.

Technical line drawing of a mechanical assembly with numbered components (no text or symbols)

1. Install:

2. Washer ①

3. Nut (rotor) ②

Ignition timing (B.T.D.C.): 0.9 mm (0.035 in)

Refer to "IGNITION TIMING CHECK" section in the CHAPTER 3.

• Stator ①
• Vis (stator) ②

N.B.:

Serrer provisoirement la vis (stator).

2. Monter:

• Stator ①
  • Schraube (Stator) ②

HINWEIS:

Technical line drawing of a mechanical gear assembly with no visible text or symbols

Technical line drawing of a mechanical assembly with gears and components (no text or symbols)

5. Tighten:

- Screw (stator) ①

8 Nm (0.8 m · kg, 5.8 ft · lb)

6. Check:

- Ignition timing

Re-check the ignition timing.

7. Connect:

- CDI magneto lead ①

Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

8. Install:

• Gasket (left crankcase cover)

New

- Left crankcase cover ①

- Screw (left crankcase cover) ②

5 Nm (0.5 m · kg, 3.6 ft · lb)

NOTE:

Tighten the screws in stage, using a crisscross pattern.

Extent of removal Order Part name Q'ty Remarks
Preparation for removal Hold the ENGINE REMOVALmachine by placing the suitable stand under the frame.Drain the coolant.Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDECOVERS” section.Carburetor Refer to “CARBURETOR AND REEDVALVE” section.Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER” section.Clutch cable Disconnect at engine side.Radiator hose 1 Disconnect at cylinder head side.Radiator hose 2 Disconnect at water pump side.Spark plug capDisconnect the CDI magneto lead.		WARNINGSupport the machine securely so there is no danger of it falling over.Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3.

DEPOSE DU MOTEUR

Extent of removal:
① Engine removal

Extent of removal Order Part name Q'ty Remarks
1	1 Left crankcase cover 12 Nut (drive sprocket) 13 Lock washer4 Drive sprocket 15 Engine mounting bolt 26 Pivot shaft 17 E n g i n e	1	Refer to “REMOVAL POINTS”.
			Refer to “REMOVAL POINTS”.

DEPOSE DU MOTEUR MOTOR DEMONTIEREN

ENG

Technical line drawing of an engine assembly with no visible text or symbols

EC4M3000

REMOVAL POINTS

EC4F3100

Drive sprocket

1. Remove:

2. Nut (drive sprocket) ①

3. Lock washer ②

NOTE:

• Straighten the lock washer tab.

• Loosen the nut while applying the rear brake.

• Remove:

• Drive sprocket ①

• Drive chain ②

NOTE:

Remove the drive sprocket together with the drive chain.

EC4M3301

Engine removal

1. Remove:

- Pivot shaft ①

NOTE:

If the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it.

1. Remove:

- Engine ①

From right side.

NOTE:

Make sure that the couplers, hoses and cables are disconnected.

POINTS DE DEPOSE

EC4M5000

ASSEMBLY AND INSTALLATION Engine installation

1. Install:

2. Engine ① Install the engine from right side.

3. Pivot shaft ② 63 Nm (6.3 m · kg, 45 ft · lb)
4. Engine mounting bolt (front) ③ 69 Nm (6.9 m · kg, 50 ft · lb)
5. Engine mounting bolt (lower) ④ 69 Nm (6.9 m · kg, 50 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the pivot shaft.

Drive sprocket

1. Install:

2. Drive sprocket ①

3. Drive chain ②

NOTE:

Install the drive sprocket together with the drive chain.

1. Install:

2. Lock washer ① New

3. Nut (drive sprocket) ②

60 Nm (6.0 m · kg, 43 ft · lb)

NOTE:

Tighten the nut while applying the rear brake.

1. Bend the lock washer tab to lock the nut.

2. Install:

• Gasket (left crankcase cover) New
- Left crankcase cover ①
- Screw (left crankcase cover) ②

5 Nm (0.5 m · kg, 3.6 ft · lb)

NOTE:

Tighten the screws in stage, using a crisscross pattern.

ASSEMBLAGE ET MONTAGE

Montage du moteur

1. Monter:

CRANKCASE AND CRANKSHAFT

Extent of removal:
① Crankcase separation
② Crankshaft removal
③ Crankshaft bearing removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		CRANKCASE AND CRANK-SHAFT REMOVALEnginePiston Refer to “CYLINDER HEAD, CYLINDERPrimary drive gearKick idle gearStopper lever assemblyRotor and stator		Refer to “ENGINE REMOVAL” section.AND PISTON” section.Refer to “KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR” section.Refer to “CDI MAGNETO” section.
↓	1 Screw (crankcase) 112 Crankcase oil seal holder 13 Right crankcase 14 Left crankcase 15 Crankshaft 1 Use special tool.6 Oil seal 27 Bearing			Use special tool.Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.

Mechanical gear assembly diagram showing meshing gears and mounting holes (no text or labels)

REMOVAL POINTS

Crankcase

1. Remove:

• Right crankcase ①

Use the crankcase separating tool ②.

Crankcase separating tool: YU-1135-A/90890-01135

NOTE:

- Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case. If necessary, one screw may be backed out slightly to level tool body.

- As pressure is applied, alternately tap on the front engine mounting boss and transmission shafts.

CAUTION:

• Turn the segment ③ to the position shown in the figure so that it does not contact the crankcase.
• Use soft hammer to tap on the case half. Tap only on reinforced portions of case. Do not tap on gasket mating surface. Work slowly and carefully. Make sure the case halves separate evenly. If one end "hangs up", take pressure off the push screw, realign, and start over. If the cases do not separate, check for a remaining case screw or fitting. Do not force.

EC4N3301

Crankshaft

1. Remove:

- Crankshaft ①

Use the crankcase separating tool ②.

Crankcase separating tool: YU-1135-A/90890-01135

NOTE:

Make appropriate bolts ③ as shown available by yourself and attach the tool with them.

CAUTION:

Do not use a hammer to drive out the crankshaft.

Technical line drawing of two mechanical components labeled a and b, showing internal cavities and housing (no text or symbols beyond labels)

Technical line drawing of a mechanical component with no visible text or symbols

EC4N3401

Crankshaft bearing

1. Remove:

- Bearing ①

NOTE:

• Remove the bearing from the crankcase by pressing its inner race as shown in A.
• If the bearing is removed together with the crankshaft, remove the bearing using a general bearing puller ② as shown in B.
• Do not use the removed bearing.

EC4N4000

INSPECTION

Crankcase

1. Inspect:

2. Contacting surface ⓐ Scratches → Replace.

3. Engine mounting boss ⑥, crankcase Cracks/damage → Replace.

4. Inspect:

- Bearing ① Rotate inner race with a finger. Rough spot/seizure → Replace.

1. Inspect:

- Oil seal ① Damage → Replace.

Crankshaft

1. Measure:

• Runout limit ⓐ
• Small end free play limit ⑥
• Connecting rod big end side clearance ©
• Crank width ⓓ

Out of limit → Replace.

Use the dial gauge and a thickness gauge.

Dial gauge and stand: YU-3097/90890-01252

	Standard
Runout limit:	0.03 mm(0.0012 in)	0.08 mm(0.003 in)
Small end free play:	0.5 ~ 1.2 mm(0.020 ~ 0.047 in)	2.0 mm(0.08 in)
Side clearance:	0.20 ~ 0.70 mm(0.008 ~ 0.028 in)	—
Crack width:	44.90 ~ 44.95 mm(1.768 ~ 1.770 in)	—

EC4N5000

ASSEMBLY AND INSTALLATION

Crankshaft bearing

1. Install:

• Bearing ①
  To left and right crankcase.

NOTE:

Install the bearing by pressing its outer race parallel.

Oil seal

1. Install:

- Oil seal ①

NOTE:

• Apply the lithium soap base grease on the oil seal lip.
• Install the oil seal with its manufacture's marks or numbers facing outward as shown.

Vilebrequin

Crankshaft

1. Install:

- Crankshaft ① Use the crankshaft installing tool ②, ③, ④.

Crankshaft installing pot ②:

YU-90050/90890-01274

Crankshaft installing bolt ③:

YU-90050/90890-01275

Adapter (M10) ④:

YM-1277/90890-01277

A For USA and CDN

B Except for USA and CDN

NOTE:

• Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing.
• Before installing the crankshaft, clean the contacting surface of crankcase.
• Apply the lithium soap base grease on the oil seal lip.

CAUTION:

Do not use a hammer to drive in the crankshaft.

Mechanical assembly diagram showing hands operating a gear and shaft assembly (no text or labels)

2. Check:

• Shifter operation
  • Transmission operation
  Unsmooth operation → Repair.

3. Apply:

- Sealant On the right crankcase ①.

Quick gasket®:

ACC-QUICK-GS-KT

YAMAHA Bond No. 1215:

90890-85505

NOTE:

Clean the contacting surface of left and right crankcase before applying the sealant.

Vilebrequin

1. Monter:

Technical line drawing of a mechanical gear assembly with no visible text or symbols

4. Install:

• Dowel pin ①
• Right crankcase ②

To left crankcase ③.

NOTE:

• Turn the shift cam ④ to the position shown in the figure so that it does not contact the crankcase when installing the crankcase.
• Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer.
• When installing the crankcase, the connecting rod should be positioned at TDC (top dead center).

5. Install:

• Clamp ①
• Screw (crankcase) ②

8 Nm (0.8 m · kg, 5.8 ft · lb)

NOTE:

Tighten the crankcase tightening screws in stage, using a crisscross pattern.

6. Install:

• Crankcase oil seal holder ①
- Bolt (crankcase oil seal holder) ②

Forced out on the cylinder mating surface.

8. Apply:

- Engine oil

To the crank pin, bearing, oil delivery hole and connecting rod end washer.

9. Check:

- Crankshaft and transmission operation Unsmooth operation → Repair.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

graph TD
    A[" gears"] --> B[" M "]
    B --> C[" New "]
    C --> D[" G "]
    D --> E[" 7 "]
    E --> F[" G "]
    F --> G[" M "]
    G --> H[" G "]
    H --> I[" 8 "]
    I --> J[" M "]
    J --> K[" New "]
    K --> L[" G "]
    L --> M[" 9 "]
    M --> N[" G "]
    N --> O[" 2 "]
    O --> P[" G "]
    P --> Q[" 6 "]
    Q --> R[" G "]
    R --> S[" 3 "]
    S --> T[" 4 "]
    T --> U[" New "]
    U --> V[" 1 "]
    V --> W[" G "]
    W --> X[" 5 "]

Extent of removal:

① Shift cam and shift fork removal

② Main axle and drive axle removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVALEngineSeparate the crankcase. Refer to “CRANKCASE AND CRANK-SHAFT” section.
	1 Guide bar (long) 12 Guide bar (short) 13 S h i f t c a m4 Shift fork 3 15 Shift fork 1 16 Shift fork 2 17 Main axle 18 Drive axle9 Collar		Refer to “REMOVAL POINTS”.

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION

EC4H3000

REMOVAL POINTS

Transmission

1. Remove:

2. Main axle ①

3. Drive axle ②

NOTE:

• Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks.
• Remove the main axle and drive axle by tapping lightly on the transmission drive axle with a soft hammer.

EC4H4000

INSPECTION

EC4H4200

Gears

1. Inspect:

2. Matching dog ⓐ

3. Gear teeth ⑥
4. Shift fork groove ©

Wear/damage → Replace.

Technical line drawing of a mechanical gear assembly (no text or symbols)

1. Check:

- Gears movement Unsmooth movement → Disassemble, and then repair or replace.

EC4H4600

Bearing

1. Inspect:

- Bearing ①

Rotate inner race with a finger.

Rough spot/seizure → Replace.

POINTS DE DEPOSE

Boîte de vitesses

1. Déposer:

Diagram of a hand gripping a cylindrical object with two arrows indicating motion or force (no text or symbols)

Shift fork, shift cam and segment

1. Inspect:

• Shift fork ① Wear/damage/scratches → Replace.
• Straight pin ② Wear/damage → Replace.

2. Inspect:

• Shift cam ①
• Guide bar ② Bend/wear/damage → Replace.

3. Check:

• Shift fork movement
  On its guide bar.
  Unsmooth operation → Replace shift fork and/or guide bar.

NOTE:

For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adjacent to the shift fork.

EC4H5000

ASSEMBLY AND INSTALLATION

Transmission

1. Install:

• 5th pinion gear (23T) ①
  • 3rd/4th pinion gear (17T/17T) ②
• 6th pinion gear (25T) ③
• 2nd pinion gear (17T) ④
  To main axle ⑤.

NOTE:

• Apply the molybdenum disulfide oil on the 5th and 6th pinion gears inner circumference and on the end surface.
• Apply the transmission oil on the 3rd/4th and 2nd pinion gears inner circumference.

2. Install:

• 2nd wheel gear (32T) ①
• 6th wheel gear (25T) ②
• 3rd wheel gear (26T) ③
  • 4th wheel gear (22T) ④
• 5th wheel gear (26T) ⑤
• 1st wheel gear (27T) ⑥
  To drive axle ⑦.

NOTE:

• Apply the molybdenum disulfide oil on the 1st, 2nd, 3rd and 4th wheel gears inner circumference and on the end surface.
• Apply the transmission oil on the 5th and 6th wheel gears inner circumference.

3. Install:

• Washer ①
• Circlip ② New

NOTE:

• Be sure the circlip sharp-edged corner ⓐ is positioned opposite side to the washer and gear ⓑ.
• Be sure the circlip end © is positioned at axle spline groove ⓐ.

Technical line drawing of a gear assembly (left) and a mechanical component with labeled parts (right), no text or symbols present.

4. Install:

- Collar ①

NOTE:

• Apply the lithium soap base grease on the oil seal lip.
• When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip.

2. Monter:

Mechanical assembly diagram showing gear and shaft components with no visible text or symbols

5. Install:

• Main axle ①
• Drive axle ②
  To left crankcase.

Shift cam and shift fork

1. Install:

• Shift fork 1 (L) ①
• Shift fork 2 ②
• Shift fork 3 (R) ③
• Straight pin ④

NOTE:

• Mesh the shift fork #1 (L) with the 6th wheel gear ⑤ and #3 (R) with the 5th wheel gear ⑦ on the drive axle.
• Mesh the shift fork #2 with the 3rd/4th pinion gear ⑥ on the main axle.

2. Install:

- Shift cam ①

NOTE:

Apply the transmission oil on the shift cam.

5. Monter:

Mechanical assembly diagram showing hands operating a gear and shaft assembly (no text or labels)

3. Install:

• Guide bar (long) ①
• Guide bar (short) ②

NOTE:

• Apply the transmission oil on the guide bars.
• Be sure the long bar is inserted into the shift forks #1 and #3 and the short one into #2.

4. Check:

• Shifter operation
  • Transmission operation
  Unsmooth operation → Repair.

3. Monter:

• Barre de guidage (longue) ①
• Barre de guidage (courte) ②

N.B.:

Extent of removal:
① Front wheel removal
③ Brake disc removal

② Wheel bearing removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal			FRONT WHEEL REMOVALHold the machine by placing the suitable stand under the engine.
		1 Nut (front wheel axle) 12 Front wheel axle 13 Front wheel 14 Collar 25 Oil seal 26 Bearing7 Brake disc 1	2	Refer to “REMOVAL POINTS”.

CHASSIS

ROUE AVANT ET ROUE ARRIERE

ROUE AVANT

① Rear wheel removal

② Wheel bearing removal

③ Brake disc removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		REAR WHEEL REMOVALHold the machine by placing the suitable stand under the engine.		WARNINGSupport the machine securely so there is no danger of it falling over.
	1 Nut (rear wheel axle) 12 Rear wheel axle 13 Drive chain puller 24 Rear wheel5 Collar 26 Rear wheel sprocket 17 Oil seal 28 Circlip 19 Bearing10 Brake disc	1	Refer to “REMOVAL POINTS”.21	Refer to “REMOVAL POINTS”.

ROUE ARRIERE

Technical line drawing of two mechanical components with dimension arrows, no text or symbols present

EC593000

REMOVAL POINTS

EC523101

Rear wheel

1. Remove:

- Wheel ①

NOTE:

Push the wheel forward and remove the drive chain ②.

EC513201

Wheel bearing (if necessary)

1. Remove:

- Bearing ①

NOTE:

Remove the bearing using a general bearing puller ②.

EC594000

INSPECTION

EC514100

Wheel

1. Measure:

- Wheel runout

Out of limit → Repair or replace.

Wheel runout limit:

Radial ①: 2.0 mm (0.08 in)

Lateral ②: 2.0 mm (0.08 in)

1. Inspect:

- Bearing

Rotate inner race with a finger.

Rough spot/seizure → Replace.

NOTE:

Replace the bearings, oil seal and wheel collar as a set.

POINTS DE DEPOSE

Roue arrière

1. Déposer:

- Roue ①

N.B.:

EC514200

Wheel axle

1. Measure:

- Wheel axle bends

Out of specification → Replace.

Use the dial gauge ①.

Wheel axle bending limit: 0.5 mm (0.020 in)

NOTE:

The bending value is shown by one half of the dial gauge reading.

WARNING

Do not attempt to straighten a bent axle.

Brake disc

1. Measure:

- Brake disc deflection

Use the dial gauge ①.

Out of specification → Inspect wheel runout.

If wheel runout is in good condition, replace the brake disc.

Brake disc deflection limit: 0.15 mm (0.006 in)

2. Measure:

- Brake disc thickness ⓐ

Out of limit → Replace.

Brake disc thickness:

3.0 mm (0.12 in)

: 2.5 mm (0.10 in)

Axe de roue

1. Mesurer:

EC595000

ASSEMBLY AND INSTALLATION

Front wheel

1. Install:

2. Bearing (left) ①

3. Spacer ②
4. Bearing (right) ③
5. Oil seal ④ New

NOTE:

• Apply the lithium soap base grease on the bearing and oil seal lip when installing.
• Use a socket that matches the outside diameter of the race of the bearing.
• Left side of bearing shall be installed first.
• Install the oil seal with its manufacture's marks or numbers facing outward.

CAUTION:

Do not strike the inner race of the bearing. Contact should be made only with the outer race.

1. Install:

2. Brake disc ①

3. Bolt (brake disc) ②

1. Install:

- Collar ①

NOTE:

Apply the lithium soap base grease on the oil seal lip.

1. Install:

- Wheel

NOTE:

Install the brake disc ① between the brake pads ② correctly.

MONTAGE ET REMONTAGE

Roue avant

1. Monter:

5. Install:

• Washer ①
• Wheel axle ②

NOTE:

Apply the lithium soap base grease on the wheel axle.

6. Install:

• Washer ①
• Nut (wheel axle) ②

70 Nm (7.0 m · kg, 50 ft · lb)

Rear wheel

1. Install:

• Bearing (left) ①
• Circlip ② New
• Spacer ③
• Bearing (right) ④
• Oil seal ⑤
  New

NOTE:

• Apply the lithium soap base grease on the bearing and oil seal lip when installing.
  • Install the bearing with seal facing outward.
• Use a socket that matches the outside diameter of the race of the bearing.
  • Left side of bearing shall be installed first.
• Install the oil seal with its manufacture's marks or numbers facing outward.

CAUTION:

Do not strike the inner race of the bearing. Contact should be made only with the outer race.

5. Monter:

2. Install:

• Brake disc ①
• Bolt (brake disc) ②

12 Nm (1.2 m · kg, 8.7 ft · lb)

NOTE:

Tighten the bolts (brake disc) in stage, using a crisscross pattern.

3. Install:

• Rear wheel sprocket ①
• Bolt (rear wheel sprocket) ②
• Washer (rear wheel sprocket) ③
• Nut (rear wheel sprocket) ④

42 Nm (4.2 m · kg, 30 ft · lb)

NOTE:

Tighten the nuts (rear wheel sprocket) in stage, using a crisscross pattern.

4. Install:

- Collar ①

NOTE:

Apply the lithium soap base grease on the oil seal lip.

5. Install:

- Wheel

NOTE:

Install the brake disc ① between the brake pads ② correctly.

6. Install:

- Drive chain ①

NOTE:

Push the wheel ② forward and install the drive chain.

2. Monter:

7. Install:

• Right drive chain puller ①
- Left drive chain puller ②
- Washer ③
- Wheel axle ④

NOTE:

• Apply the lithium soap base grease on the wheel axle.
• Insert the wheel axle from right side.

8. Install:

• Washer ①
• Nut (wheel axle) ②

NOTE:

Temporarily tighten the nut (wheel axle) at this point.

9. Adjust:

- Drive chain slack ⓐ

Refer to "DRIVE CHAIN SLACK ADJUSTMENT" section in the CHAPTER 3.

10. Tighten:

- Nut (wheel axle) ①

90 Nm (9.0 m · kg, 65 ft · lb)

- Locknut ②

7. Monter:

① Brake hose removal

② Brake caliper removal

③ Brake master cylinder removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		FRONT BRAKE REMOVALHold the machine by placing the suitable stand under the engine.Drain the brake fluid.		WARNINGSupport the machine securely so there is no danger of it falling over.Refer to “REMOVAL POINTS”.
		1 Protector 12 Brake hose holder 13 Union bolt 24 Brake hose 15 Brake caliper support bolt 16 Brake caliper7 Br a k e l8 Brake master cylinder bracket9 Brake master cylinder	1e v11	Refer to “REMOVAL POINTS”.e r 1

FREIN AVANT ET FREIN ARRIERE

FREIN AVANT

① Brake caliper removal

② Brake hose removal

③ Brake master cylinder removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		REAR BRAKE REMOVALHold the machine by placing the suitable stand under the engine.Drain the brake fluid.
1Protector 12 Pad pin 2 Loosen when disassembling the caliper.3 Brake caliper 14 Brake hose holder 25 Union bolt 26 Brake hose 17 Brake pedal 18 Reservoir tank9 Reservoir hose10 Brake master cylinder	1 Protector 12 Pad pin 2 Loosen when disassembling the caliper.3 Brake caliper 14 Brake hose holder 25 Union bolt 26 Brake hose 17 Brake pedal 18 Reservoir tank9 Reservoir hose10 Brake master cylinder	1	WARNINGSupport the machine securely so there is no danger of it falling over.Refer to “REMOVAL POINTS”.

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE

FREIN ARRIERE

A Front
B Rear
Extent of removal:
① Front brake caliper disassembly
② Rear brake caliper disassembly

Extent of removal Order Part name Q'ty Remarks
12	123456789101112	BRAKE CALIPER DISASSEMBLYBrake pad 2Brake caliper bracket 1Brake caliper pistonDust seal 2Piston seal 2Pin boot 1Sleeve boot 1Pad pin 2Brake pad 2Brake caliper pistonDust seal 1Piston seal	2	Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.
			1	Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.

DEMONTAGE DE L'ETRIER DE FREIN

AAvant
BArrière

A Front
B Rear
Extent of removal:
① Front brake master cylinder disassembly
② Rear brake master cylinder disassembly

Extent of removal Order Part name Q'ty Remarks
1	1 Brake master cylinder cap 12 Diaphragm 13 Brake master cylinder boot 14 Circlip 1 Use a long nose circlip pliers.5 Washer 16 Push rod 17 Brake master cylinder kit	BRAKE MASTER CYLINDER DISASSEMBLY

DEMONTAGE DU MAITRE-CYLINDRE DE FREIN

AAvant
BArrière

• Brake master cylinder cap ①
  [Rear]
• Reservoir tank cap ①

NOTE:

Do not remove the diaphragm.

A Front

B Rear

1. Connect the transparent hose ② to the bleed screw ① and place a suitable container under its end.

A Front

B Rear

1. Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal.

CAUTION:

• Do not reuse the drained brake fluid.
- Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

Front brake caliper

1. Remove:

- Brake caliper ①

NOTE:

Turn the brake caliper counterclockwise and pull out it from the guide pin ② on the brake caliper bracket.

POINTS DE DEPOSE

Liquide de frein

1. Déposer:

[Avant]

Line drawing of a hand holding a tool, with no visible text or symbols

Line drawing of a mechanical device with a lever and cylindrical components (no text or symbols)

Brake caliper piston

1. Remove:

- Brake caliper piston Use compressed air and proceed carefully.

WARNING

• Cover piston with rag and use extreme caution when expelling piston from cylinder.
• Never attempt to pry out piston.

Caliper piston removal steps:

• Insert a piece of rag into the brake caliper to lock one brake caliper.
• Carefully force the piston out of the brake caliper cylinder with compressed air.

A Front
B Rear

Brake caliper piston seal kit

1. Remove:

2. Dust seal ①

3. Piston seal ②

NOTE:

Remove the piston seals and dust seals by pushing them with a finger.

CAUTION:

Never attempt to pry out piston seals and dust seals.

WARNING

Replace the piston seals and dust seals whenever a caliper is disassembled.

A Front
B Rear

Technical drawing of a mechanical component with sectional views (A and B), no visible text or symbols

Technical line drawings of two mechanical components labeled A and B, showing cross-sectional views with no text or symbols beyond labels.

EC5A4000

INSPECTION

Brake master cylinder

1. Inspect:

- Brake master cylinder inner surface @ Wear/scratches → Replace master cylinder assembly. Stains → Clean.

WARNING

Use only new brake fluid.

A Front

B Rear

2. Inspect:

- Diaphragm ① Crack/damage → Replace.

A Front

B Rear

3. Inspect:

- Brake master cylinder piston ① - Brake master cylinder cup ② Wear/damage/score marks → Replace brake master cylinder kit.

A Front

B Rear

Brake caliper

1. Inspect:

- Brake caliper cylinder inner surface ⓐ Wear/score marks → Replace brake caliper assembly.

A Front

B Rear

2. Inspect:

- Brake caliper piston ① Wear/score marks → Replace brake caliper piston assembly.

WARNING

Replace the piston seals and dust seals ② whenever a caliper is disassembled.

CONTROLE

Technical line drawing of a bolt with threaded shaft and nut (no text or symbols)

Diagram of a curved mechanical or electrical component with labeled parts (no text or symbols present)

1. Inspect: (only front brake caliper)

2. Brake caliper bracket ①
   Cranks/damage → Replace the brake caliper assembly.

3. Guide pin ②
   Rust/damage → Replace the brake caliper assembly.
4. Sleeve boot ③

5. Pin boot ④
   Wear/damage → Replace.

6. Inspect: (only front brake caliper)

- Brake caliper support bolt ①

Scorches/rust/damage → Replace.

EC534301

Brake hose

1. Inspect:

2. Brake hose ①
   Crack/damage → Replace.

EC5A5000

ASSEMBLY AND INSTALLATION

WARNING

• All internal parts should be cleaned in new brake fluid only.
• Internal parts should be lubricated with brake fluid when installed.
• Replace the piston seals and dust seals whenever a caliper is disassembled.

Brake caliper piston

1. Install:

- Piston seal ①

New

- Dust seal ②

New

WARNING

Always use new piston seals and dust seals.

NOTE:

Fit the piston seals and dust seals onto the slot on brake caliper correctly.

A Front

B Rear

1. Install:

- Brake caliper piston ①

NOTE:

Apply the brake fluid on the brake caliper piston wall.

CAUTION:

- For the front brake caliper, install the piston with its shallow depressed side ① facing the caliper. For the rear brake caliper, install the piston with its depressed side ⑥ facing the brake caliper.

- Never force to insert.

A Front

B Rear

Front brake caliper

1. Install:

- Sleeve boot ①

On brake caliper bracket ②.

2. Monter:

- Joint de piston ①

New

• Joint antipoussière

② New

⚠ AVERTISSEMENT

2. Install:

- Pin boot ①

On brake caliper ②.

NOTE:

Apply the lithium soap base grease on the pin boot inner surface.

3. Install:

- Brake caliper bracket ①

- Bolt (brake caliper bracket) ②

30 Nm (3.0 m · kg, 22 ft · lb)

- Brake pad ③

4. Install:

- Brake caliper ①

NOTE:

- Apply the lithium soap base grease on the guide pin ②.

• Install the brake caliper into the guide pin and turn it clockwise.

5. Install:

- Brake caliper support bolt ①

23 Nm (2.3 m · kg, 17 ft · lb)

NOTE:

Apply the lithium soap base grease on the brake caliper support bolt.

Rear brake caliper

1. Install:

• Pad support ①
• Brake pad ②
• Pad pin ③

NOTE:

• Install the brake pad fitted with brake pad shim ④ on the brake caliper piston side.
• Temporarily tighten the pad pins at this point.

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE

2. Monter:

2. Install:

• Brake caliper ①
• Bolt (brake caliper front side) ②

23 Nm (2.3 m · kg, 17 ft · lb)

- Bolt (brake caliper rear side) ③

23 Nm (2.3 m · kg, 17 ft · lb)

• Plate
• Protector ④
• Bolt (protector) ⑤

10 Nm (1.0 m · kg, 7.2 ft · lb)

3. Tighten

- Pad pin ⑥

18 Nm (1.8 m · kg, 13 ft · lb)

Brake master cylinder kit

1. Clean:

• Brake master cylinder
• Brake master cylinder kit Clean them with brake fluid.

2. Install:

• Brake master cylinder cup (primary) ①
• Brake master cylinder cup (secondary) ② To brake master cylinder piston ③.

NOTE:

Apply the brake fluid on the brake master cylinder cup.

WARNING

After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake performance.

A Front
B Rear

3. Install:

- Spring ① To brake master cylinder piston ②.

NOTE:

Install the spring at the smaller dia. side.

A Front
B Rear

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE

2. Monter:

• Plaque
• Protection ④
  • Boulon (protection) ⑤

10 Nm (1,0 m · kg, 7,2 ft · lb)

3. Serrer

4. Install:

[Front]

• Brake master cylinder kit ①
• Washer ②
• Circlip ③
• Brake master cylinder boot ④ To brake master cylinder ⑤. [Rear]

- Brake master cylinder kit ①

- Push rod ②

- Circlip ③

- Brake master cylinder boot ④ To brake master cylinder ⑤.

NOTE:

• Apply the brake fluid on the brake master cylinder kit.
• Apply the lithium soap base grease on the tip of the push rod.
• When installing the circlip, use a long nose circlip pliers.

A Front
B Rear

Front brake master cylinder

1. Install:

• Brake master cylinder ①
• Brake master cylinder bracket ②
• Bolt (brake master cylinder bracket) ③

9 Nm (0.9 m · kg, 6.5 ft · lb)

NOTE:

• Install the bracket so that the arrow mark ⓐ face upward.
• First tighten the bolts on the upper side of the brake master cylinder bracket, and then tighten the bolts on the lower side.

4. Monter:

[Avant]

2. Install:

• Brake lever ①
• Bolt (brake lever) ②

6 Nm (0.6 m · kg, 4.3 ft · lb)

- Nut (brake lever) ③

6 Nm (0.6 m · kg, 4.3 ft · lb)

NOTE:

Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the brake master cylinder piston.

Rear brake master cylinder

1. Install:

• Reservoir hose ①
• Reservoir tank ②

2. Install:

• Brake master cylinder ①
• Bolt (brake master cylinder) ②

10 Nm (1.0 m · kg, 7.2 ft · lb

3. Install:

• Brake pedal ①
• Spring ②
• O-ring ③ New
• Washer ④
• Cotter pin ⑤ New

NOTE:

Apply the lithium soap base grease on the brake pedal shaft and O-rings.

4. Install:

• Pin ①
• Washer ②
• Cotter pin ③

New

NOTE:

After installing, check the brake pedal height. Refer to "REAR BRAKE ADJUSTMENT" section in the CHAPTER 3.

2. Monter:

Front brake hose

1. Install:

- Copper washer ①

- Brake hose ②

- Union bolt ③

30 Nm (3.0 m · kg, 22 ft · lb)

WARNING

Always use new copper washers.

CAUTION:

Install the brake hose so that its pipe portion ⓐ directs as shown and lightly touches the projection Ⓑ on the brake master cylinder.

2. Install:

- Protector ①

- Bolt (protector) ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:

Fit the brake hose into the guides ⓐ of the protector.

3. Install:

- Brake hose holder ①

- Bolt (brake hose holder) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

- Align the brake hose holder with the projection @ on the front fork and clamp the brake hose.

- Pass the brake hose behind the rib ⑥ on the front fork.

4. Install:

• Copper washer ①
• Brake hose ②
• Union bolt ③

26 Nm (2.6 m · kg, 19 ft · lb)

WARNING

Always use new copper washers.

CAUTION:

Install the brake hose so that its pipe portion ⓐ lightly touches the projection Ⓑ on the brake caliper.

Rear brake hose

1. Install:

• Copper washer ①
• Brake hose ②
• Union bolt ③

26 Nm (2.6 m · kg, 19 ft · lb)

WARNING

Always use new copper washers.

CAUTION:

Install the brake hose so that its pipe portion ⓐ directs as shown and lightly touches the projection ⓑ on the brake master cylinder.

4. Monter:

2. Install:

• Copper washer ①
• Brake hose ②
• Union bolt ③

26 Nm (2.6 m · kg, 19 ft · lb)

WARNING

Always use new copper washers.

CAUTION:

Install the brake hose so that its pipe portion ⓐ lightly touches the projection Ⓑ on the brake caliper.

3. Install:

• Brake hose holder ①
• Screw (brake hose holder) ②

1 Nm (0.1 m · kg, 0.7 ft · lb)

2. Monter:

- Brake fluid Until the fluid level reaches "LOWER" level line ⓐ.

Recommended brake fluid: DOT #4

WARNING

• Use only the designated quality brake fluid:
  otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
• Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor performance.
• Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

CAUTION:

Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

A Front

B Rear

2. Air bleed:

- Brake system Refer to "BRAKE SYSTEM AIR BLEEDING" section in the CHAPTER 3.

3. Inspect:

- Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPEC-TION” section in the CHAPTER 3.

Liquide de frein

1. Remplir:

- Screw (brake master cylinder cap) ②

2 Nm (0.2 m · kg, 1.4 ft · lb)

[Rear]

• Diaphragm
• Reservoir tank cap ①
• Bolt (reservoir tank) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

CAUTION:

After installation, while pulling the brake lever in or pushing down on the brake pedal, check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper.

A Front
B Rear

4. Monter:

[Avant]

① Front fork removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		FRONT FORK REMOVALHold the machine by placing the suitable stand under the engine.Front wheel Refer to “FRONT WHEEL AND REAR Front brake caliperNumber plateHandlebar	WARNINGSupport the machine securely so there is no danger of it falling over.WHEEL” section.Refer to “FRONT BRAKE AND REAR BRAKE” section.Refer to “HANDLEBAR” section.
	1 Protector 12 Brake hose holder 13 Pinch bolt (upper bracket) 1 Only loosening.4 Cap bolt 1 Loosen when disassembling the front fork.5 Pinch bolt (lower bracket) 2 Only loosening.6 Front fork	1

FOURCHE AVANT

Extent of removal:
① Oil seal removal
② Damper rod removal

Extent of removal Order Part name Q'ty Remarks
↓	FRONT FORK DISASSEMBLY1 Front fork cap bolt 1 Use special tool.2 Fork spring 1 Drain the fork oil.3 Dust seal 14 Stopper ring 15 Inner tube 16 Outer tube 17 Piston metal 18 Slide metal 19 Oil seal washer 110 Oil seal11 Spring guide12 Base valve13 Damper rod	1	Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.1 Use special tool.1 Refer to “REMOVAL POINTS”.

DEMONTAGE DE LA FOURCHE AVANT

The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers.

CAUTION:

To prevent an accidental explosion of air, the following instructions should be observed:

• The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
  Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled.
• Before removing the cap bolts or front forks, be sure to extract the air from the air chamber completely.

EC553000

REMOVAL POINTS

Front fork cap bolt

1. Remove:

- Front fork cap bolt ①

From the outer tube.

NOTE:

Before removing the front fork from the machine, loosen the front fork cap bolt.

1. Remove:

- Front fork cap bolt ①

NOTE:

• Set the rod holder ② between the locknut ③ and washer ④.
• Hold the locknut and remove the front fork cap bolt.

Rod holder:

YM-01434/90890-01434

REMARQUES CONCERNANT LA MANIPULATION

N.B.:

Technical line drawing of a mechanical component with labeled part (1), no text or symbols present

EC553201

Inner tube

1. Remove:

2. Dust seal ①

3. Stopper ring ②

Using slotted-head screwdriver.

CAUTION:

Take care not to scratch the inner tube.

1. Remove:

- Inner tube ①

Oil seal removal steps:

• Push in slowly @ the inner tube just before it bottoms out and then pull it back quickly ⑥.
• Repeat this step until the inner tube can be pulled out from the outer tube.

EC553311

Damper rod

1. Remove:

2. Base valve ①

3. Damper rod ②

NOTE:

Use a damper rod holder ③ to lock the damper rod.

Damper rod holder: YM-01454/90890-01454

EC554000

INSPECTION

EC554100

Damper rod

1. Inspect:

- Damper rod ① Bend/damage → Replace damper rod.

CAUTION:

The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.

Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled.

Tube plongeur

1. Déposer:

Diagram of a coiled spring with labeled dimension 'a' (no text or symbols beyond label)

Technical line drawing of a cylindrical pipe fitting with a labeled end (no text or symbols present)

EC554200

Base valve

1. Inspect:

• Valve assembly ①
  Wear/damage → Replace.
• O-ring ②
  Damage → Replace.

EC554400

Fork spring

1. Measure:

• Fork spring free length ⓐ
  Out of specification → Replace.

Fork spring free length:

430 mm (16.9 in)

: 425 mm (16.7 in)

EC554502

Inner tube

1. Inspect:

• Inner tube surface ⓐ
  Score marks → Repair or replace.
  Use #1,000 grit wet sandpaper.
  Damaged oil lock piece → Replace.
• Inner tube bends
  Out of specification → Replace.
  Use the dial gauge ①.

Inner tube bending limit:

0.2 mm (0.008 in)

NOTE:

The bending value is shown by one half of the dial gauge reading.

WARNING

Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube.

EC554600

Outer tube

1. Inspect:

• Outer tube ①
  Score marks/wear/damage → Replace.

Soupape de base

1. Contrôler:

• Ensemble de soupape ① Usure/endommagement → Remplacer.
• Joint torque ② Endommagement → Remplacer.

Luftventil

1. Kontrollieren:

Front fork cap bolt

1. Inspect:

2. Front fork cap bolt ①

3. O-ring ②
4. Air bleed screw ③

Wear/damage → Replace.

EC555000

ASSEMBLY AND INSTALLATION

Front fork assembly

1. Wash the all parts in a clean solvent.

1. Install:

- Damper rod ①

To inner tube ②.

CAUTION:

To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper rod may fall into it, damaging the valve inside.

1. Install:

2. Copper washer ①

3. O-ring ②
4. Base valve ③

To inner tube ④.

1. Tighten:

- Base valve ①

55 Nm (5.5 m · kg, 40 ft · lb)

NOTE:

Use a damper rod holder ② to lock the damper rod ③.

Damper rod holder: YM-01454/90890-01454

Bouchon de fourche

1. Contrôler:

5. Install:

• Spring guide ①
• Locknut ②

To damper rod ③.

NOTE:

Install the spring guide with its cut @ facing downward.

6. Install:

• Dust seal ①
• Stopper ring ②
• Oil seal ③ New
• Oil seal washer ④
• Slide metal ⑤ New To inner tube ⑥.

NOTE:

• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat ⓐ with fork oil applied to protect the oil seal lip.
• Install the oil seal with its manufacture's marks or number facing the axle holder side.

7. Install:

- Piston metal ①

NOTE:

Install the piston metal onto the slot on inner tube.

8. Install:

- Outer tube ①

To inner tube ②.

5. Monter:

Illustration of a hand holding a mechanical component with a numbered label (3), no text or symbols present.

Technical line drawing of a mechanical joint or pipe connection (no text or symbols)

9. Install:

• Slide metal ①
• Oil seal washer ②
  To outer tube slot.

NOTE: Press the slide metal into the outer tube with fork seal driver ③.

Fork seal driver: YM-01442/90890-01442

1. Install: • Oil seal ①

NOTE: ____ Press the oil seal into the outer tube with fork seal driver ②.

Fork seal driver: YM-01442/90890-01442

1. Install: • Stopper ring ①

NOTE: Fit the stopper ring correctly in the groove in the outer tube.

1. Install: • Dust seal ①

NOTE: ____ Apply the lithium soap base grease on the inner tube.

FOURCHE AVANT TELESKOPGABEL

9. Monter:

Illustration of a hand holding a mechanical component with directional arrows indicating motion (no text or symbols)

1. Check:

- Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12.

1. Compress the front fork fully.

2. Fill:

- Front fork oil Until outer tube top surface with recommended fork oil ①.

Recommended oil: Suspension oil "01"

CAUTION:

• Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance.
• Never allow foreign materials to enter the front fork.

1. After filling, pump the damper rod ① slowly up and down more than 10 times to distribute the fork oil.

2. Fill:

- Front fork oil Until outer tube top surface with recommended fork oil once more.

1. After filling, pump the outer tube ① slowly up and down (about 150 mm (5.9 in) stroke) to distribute the fork oil once more.

NOTE:

Be careful not to excessive full stroke. A stroke of 150 mm (5.9 in) or more will cause air to enter. In this case, repeat the steps 15 to 18.

13. Contrôler:

1. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level.

NOTE:

Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level.

Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks.

1. Measure:

- Oil level (left and right) ⓐ Out of specification → Adjust.

Standard oil level: 90 mm (3.54 in)

Extent of adjustment: 80 \~ 120 mm (3.15 \~ 4.72 in) From top of outer tube with inner tube and damper rod ① fully compressed without spring.

NOTE:

Be sure to install the spring guide ② when checking the oil level.

WARNING

Never fail to make the oil level adjustment between the maximum and minimum level and always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

1. Install:

2. Fork spring ①

3. Washer ②

4. Attach:

5. Rod puller ①

6. Rod puller attachment ②
7. Rod holder ③

NOTE:

• Pull up the damper rod with rod puller and rod puller attachment.
• Set the rod holder between the locknut ④ and washer.

Rod puller:

YM-01437/90890-01437

Rod puller attachment (M10):

90890-01436

Rod holder:

YM-01434/90890-01434

1. Measure:

- Distance ⓐ

Out of specification → Turn into the lock-nut.

Distance ⓐ:

18 mm (0.71 in) or more

Between damper rod ① top and locknut ② top.

Illustration of a hand using a screwdriver to adjust a bolt, with no text or symbols present.

1. Install:

- Push rod ①

21. Monter:

• Ressort de fourche ①
• Rondelle ②

21. Montieren:

• Gabelfeder ①
- Scheibe ②

22. Fixer:

1. Loosen:

- Rebound damping adjuster ①

NOTE:

• Loosen the rebound damping adjuster finger tight.

• Record the set position of the adjuster (the amount of turning out the fully turned in position).

• Install:

- Front fork cap bolt ①

Fully tighten the front fork cap bolt onto the damper rod by hand.

NOTE:

Make sure that there is a clearance ⓐ of Zero \~ 1 mm (Zero \~ 0.04 in) between the front fork cap bolt and locknut ②.

1. Tighten:

- Front fork cap bolt (locknut) ①

Hold the locknut ② and tighten the front fork cap bolt with specified torque.

1. Install:

- Front fork cap bolt ①

To outer tube.

NOTE:

Temporarily tighten the cap bolt.

1. Install:

- Protector guide ①

FOURCHE AVANT TELESKOPGABEL

1. Desserrer:

Front fork installation

1. Install:

- Front fork ①

NOTE:

• Temporarily tighten the pinch bolts (lower bracket).

• Do not tighten the pinch bolts (upper bracket) yet.

• Tighten:

- Front fork cap bolt ①

- Front fork top end @

Front fork top end (standard) ⓐ:

YZ85: 24 mm (0.94 in)

YZ85LW: Zero mm (Zero in)

1. Tighten:

2. Pinch bolt (upper bracket) ①
   22 Nm (2.2 m · kg, 16 ft · lb)

3. Pinch bolt (lower bracket) ②
   20 Nm (2.0 m · kg, 14 ft · lb)

CAUTION:

Tighten the lower bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.

1. Install:

2. Protector ①

3. Bolt (protector) ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:

Fit the brake hose into the guides ⓐ of the protector.

• Protection ①
• Boulon (protection) ②

7 Nm (0,7 m · kg, 5,1 ft · lb)

N.B.:

1. Install:

2. Brake hose holder ①

3. Bolt (brake hose holder) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

• Align the brake hose holder with the projection @ on the front fork and clamp the brake hose.
• Pass the brake hose behind the rib ⑥ on the front fork.

1. Adjust:

- Rebound damping force

NOTE:

Turn in the damping adjuster ① finger-tight and then turn out to the originally set position.

FOURCHE AVANT TELESKOPGABEL

6. Monter:

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		HANDLEBAR REMOVALNumber plate Remove the clamp portion only.
1	1 Clutch cable 1 Disconnect at the lever side.2 Clutch lever holder 13 Engine stop switch 14 Brake master cylinder5 Throttle cable cap 16 Grip cap (lower) 17 Grip cap (upper) 18 Throttle cable 1 Disconnect at the throttle side.9 Right grip10 Tube guide11 Collar12 Left grip13 Handlebar upper holder14 Handlebar	1	Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.

GUIDON

REMOVAL POINTS

Brake master cylinder

1. Remove:

2. Brake master cylinder bracket ①

3. Brake master cylinder ②

CAUTION:

• Do not let the brake master cylinder hang on the brake hose.
• Keep the brake master cylinder cap side horizontal to prevent air from coming in.

Illustration of a hand using a tool to adjust or install a mechanical component (no text or symbols visible)

EC5B3200

Grip

1. Remove:

- Grip ①

NOTE:

Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose.

Line drawing of a bent tool or blade with a labeled point (1) on the end, no text or symbols present.

EC5B4000

INSPECTION

EC5B4100

Handlebar

1. Inspect:

- Handlebar ① Bends/cracks/damage → Replace.

WARNING

Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.

POINTS DE DEPOSE

EC5B5000

ASSEMBLY AND INSTALLATION Handlebar

1. Install:

2. Handlebar ①

3. Handlebar upper holder ②
4. Bolt (handlebar upper holder) ③

27 Nm (2.7 m · kg, 19 ft · lb)

NOTE:

• The handlebar upper holder should be installed with the punched mark @ forward.

• First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side.

• Install:

- Left grip ①

Apply the adhesive to the handlebar ②.

NOTE:

• Before applying the adhesive, wipe off grease or oil on the handlebar surface @ with a lacquer thinner.
  • Install the left grip to the handlebar so that the arrow mark (L) faces straight upward.

• Install:

- Right grip ①

Apply the adhesive on the tube guide ②.

NOTE:

• Before applying the adhesive, wipe off grease or oil on the tube guide surface @ with a lacquer thinner.
• Locate the mating mark ⑥ on the grip as shown.

ASSEMBLAGE ET MONTAGE

Guidon

1. Monter:

Technical diagram of a mechanical clamp or connector with labeled parts (no text or symbols present)

4. Install:

• Collar ①
• Tube guide ②
• Grip cap (upper) ③
• Throttle cable ④

NOTE:

Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion.

5. Install:

• Throttle cable cap ①
• Screw (throttle cable cap) ②

1 Nm (0.1 m · kg, 0.7 ft · lb)

• Grip cap (lower) ③
• Screw (grip cap) ④

4 Nm (0.4 m · kg, 2.9 ft · lb)

- Cover (grip cap) ⑤

WARNING

After tightening the screws, check that the throttle grip ⑥ moves smoothly. If it does not, retighten the screws (grip cap) for adjustment.

6. Install:

• Brake master cylinder ①
• Brake master cylinder bracket ②
• Bolt (brake master cylinder bracket) ③

9 Nm (0.9 m · kg, 6.5 ft · lb)

NOTE:

• Install the bracket so that the arrow mark ⓐ face upward.
• First tighten the bolts on the upper side of the brake master cylinder bracket, and then tighten the bolts on the lower side.

4. Monter:

7. Install:

• Engine stop switch ①
• Clutch lever holder ②
• Bolts (clutch lever holder) ③

4 Nm (0.4 m · kg, 2.9 ft · lb)

- Clamp ④

NOTE:

The engine stop switch and clutch lever holder should be installed according to the dimensions shown.

8. Install:

- Clutch cable ①

NOTE:

Apply the lithium soap base grease on the clutch cable end.

9. Adjust:

- Clutch lever free play Refer to "CLUTCH ADJUSTMENT" section in the CHAPTER 3.

1. Clamp the clamp portion ⓐ of the number plate to the handlebar.
2. Insert the end of the fuel tank breather hose ① into the hole of the steering stem.

7. Monter:

① Lower bracket removal

② Bearing removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal	Hold the	STEERING REMOVALmachine by placing the suitable stand under the engine.Number plateHandlebarCable guideFront fender		WARNINGSupport the machine securely so there is no danger of it falling over.Refer to “HANDLEBAR” section.
	1 Steering stem nut 12 Front fork3 Upper bracket 14 Steering ring nut 1 Use special tool.5 Lower bracket 16 Ball race cover 17 Upper bearing 18 Lower bearing9 Ball race	2	Refer to “FRONT FORK” section.Refer to “REMOVAL POINTS”.12	Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.

DIRECTION

Organisation de la dépose	Ordre	Nom de la pièce	Qté	Remarques
Préparation à la dépose		DEPOSE DE LA DIRECTIONCaler la moto en plaçant un support adéquat sous le moteur.Plaque de numéroGuidonGuide de câbleGarde-boue avant		⚠ AVERTISSEMENTBien caler la moto afin qu'elle ne risque pas de bascu-ler.Se reporter à la section “GUIDON”.
	1 Écrou de blocage de la direction 12 Fourche avant3 T é supérieur 14 Écrou de blocage de la direction5 T é inférieur 16 Couvercle de cage à billes7 Roulement supérieur8 Roulement inférieur9 Cage à billes	2 1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111	Se reporter à la section “FOURCHE AVANT”.Utiliser l’outil spécial.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporter à “POINTS DE DEPOSE”.Se reporting à “POINTS DE DEPOSE”.Se reporting à “POINTS DE DEPOSE”.Se reporting à “POINTS DE DEPOSE”.Se reporting à “POINTS DE DEPOSE”.Se reporting à “POINTS DE DEPOSE”.Se reporting à “POINTS DE DEPOSE”.Se reporting à “POINTS DE 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ETAPES DE SERRAGE:

EC563000

REMOVAL POINTS

Steering ring nut

1. Remove:

- Steering ring nut ① Use the steering nut wrench ②.

Steering nut wrench: YU-33975/90890-01403

WARNING

Support the steering stem so that it may not fall down.

Lower bearing

1. Remove:

- Lower bearing ① Use the floor chisel ②.

CAUTION:

Take care not to damage the steering shaft thread.

EC563400

Ball race

1. Remove:

- Ball race ① Remove the ball race using long rod ② and the hammer.

EC564000

INSPECTION

Steering stem

1. Inspect:

- Steering stem ① Bend/damage → Replace.

POINTS DE DEPOSE

Hand holding a ball bearing with a rotating arrow indicating motion (no text or symbols)

EC564101

Bearing and ball race

1. Wash the bearings and ball races with a solvent.

2. Inspect:

3. Bearing ①

4. Ball race

Pitting/damage → Replace bearings and ball races as a set.

Install the bearing in the ball races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the ball races, replace bearings and ball races as a set.

EC565000

ASSEMBLY AND INSTALLATION

Lower bracket

1. Install:

- Lower bearing ①

NOTE:

Apply the lithium soap base grease on the bearing inner circumference.

1. Install:

2. Ball race
   • Upper bearing ①

NOTE:

Apply the lithium soap base grease on the bearing.

1. Install:

- Lower bracket ①

NOTE:

Apply the lithium soap base grease on the bearing.

Line drawing of a hand adjusting a mechanical component with an arrow indicating rotational motion (no text or symbols)

4. Install:

• Washer ①
• Ball race cover ②

5. Install:

- Steering ring nut ①

4 Nm (0.4 m · kg, 2.9 ft · lb)

Tighten the steering ring nut using the steering nut wrench ②.

Refer to "STEERING HEAD INSPECTION AND ADJUSTMENT" section in the CHAPTER 3.

1. Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings.

7. Install:

• Front fork ①
  • Upper bracket ②

NOTE:

• Temporarily tighten the pinch bolts (lower bracket).
• Do not tighten the pinch bolts (upper bracket) yet.

8. Install:

• Washer ①
• Steering stem nut ②

125 Nm (12.5 m · kg, 90 ft · lb)

4. Monter:

• Scheibe ①

• Lenkkopfmutter ② 125 Nm (12,5 m · kg)

• After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little.

1. Adjust:

- Front fork top end ⓐ

Front fork top end (standard) @: YZ85: 24 mm (0.94 in) YZ85LW: Zero mm (Zero in)

1. Tighten:

- Pinch bolt (upper bracket) ①

22 Nm (2.2 m · kg, 16 ft · lb)

- Pinch bolt (lower bracket) ②

Tighten the lower bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.

Extent of removal Order Part name Q'ty Remarks
Preparation for removal	Hold theSWINGARM REMOVALmachine by placing the suitable stand under the engine.Real wheel Refer to “FRONT WHEEL AND REAR Brake hose holderRear brake caliperDrive chain		WARNINGSupport the machine securely so there is no danger of it falling over.____D REARWHEEL” section.Refer to “FRONT BRAKE AND REAR BRAKE” section.
	1 Drive chain support 12 Bolt (connecting rod) 1 Hold the swingarm.3 Bolt (rear shock absorber-relay arm)4 Pivot shaft 15 Swingarm 1	1

BRAS OSCILLANT

② Connecting rod removal and disassembly

③ Relay arm removal and disassembly

Extent of removal Order Part name Q'ty Remarks
	123456789	SWINGARM DISASSEMBLYRelay arm 1Connecting rod 1Cover 2Dust seal 2Collar 5Bushing 4Oil seal 8Bearing 9Bushing (swingarm)	2	Refer to “REMOVAL POINTS”.

DEMONTAGE DU BRAS OSCILLANT

Technical line drawing of a mechanical assembly with no visible text or symbols

EC573000

REMOVAL POINTS

Bearing and bushing

1. Remove:

2. Bearing ①

3. Bushing (swingarm) ②
   From swingarm.

NOTE:

Remove the bushing by pressing.

1. Remove:

2. Bearing ①
   From relay arm and connecting rod.

NOTE:

Remove the bearing by pressing its outer race.

INSPECTION

Wash the bearings, bushings, collars, and covers in a solvent.

Swingarm

1. Inspect:

2. Bearing ①

3. Bushing ②

4. Collar ③
   Free play exists/unsmooth revolution/rust → Replace bearing, bushing and collar as a set.

5. Inspect:

6. Oil seal ④
   Damage → Replace.

POINTS DE DEPOSE

Roulement et bague

1. Déposer:

• Roulement ①
• Bague (bras oscillant) ②
  Du bras oscillant.

N.B.:

Relay arm

1. Inspect:

2. Bearing ①

3. Bearing (polylube bearing) ②
4. Bushing ③

Free play exists/unsmooth revolution/rust → Replace bearing and bushing as a set.

1. Inspect:

2. Bearing (polylube bearing) ②
   Loss of solid lubrication → Replace.

3. Oil seal ④
   Damage → Replace.

NOTE:

Polylube bearings, with solid lubrication, have been adopted with the intent to make the needle bearings, used in this model, maintenance free. With polylube bearings, no grease nipple and regular lubrication is necessary. However, grease should be applied to all oil seals and collars when removed or installed.

Connecting rod

1. Inspect:

2. Bearing ①

3. Bushing ②
   Free play exists/unsmooth revolution/rust → Replace bearing and bushing as a set.

4. Inspect:

5. Oil seal ③
   Damage → Replace.

EC575000

ASSEMBLY AND INSTALLATION

Bearing, bushing and oil seal

1. Install:

2. Bearing ①

3. Bushing (swingarm) ②
4. Oil seal ③
   To swingarm.

NOTE:

• Apply the molybdenum disulfide grease on the bearing and bushing when installing.
• Install the bearing by pressing it on the side having the manufacture's marks or numbers.
• First install the bushing and then the bearing to a specified depth from inside.

Installed depth of bearings and bushings:

Bearing ⓐ: 4.5 mm (0.18 in)

Bushing ⓑ:4.5 mm (0.18 in)

Bras relais

1. Contrôler:

2. Install:

• Bearing ①
• Oil seal ②

To relay arm.

NOTE:

• Apply the molybdenum disulfide grease on the bearing when installing.
• Install the bearing by pressing it on the side having the manufacture's marks or numbers.

Installed depth of bearings:

Depth ⓐ: 4.5 mm (0.18 in)

Depth ⓑ: 0.5 mm (0.02 in)

Depth ©: 4.0 mm (0.16 in)

3. Install:

• Bearing ①
• Oil seal ②
  To connecting rod.

NOTE:

• Apply the molybdenum disulfide grease on the bearing when installing.
• Install the bearing by pressing it on the side having the manufacture's marks or numbers.

Installed depth of bearings ⓐ: 6.5 mm (0.26 in)

Swingarm

1. Install:

• Collar ①
  To swingarm ②.

NOTE:

Apply the molybdenum disulfide grease on the collars, bearings, bushings and oil seal lips.

2. Monter:

2. Install:

• Bushing ①
• Collar ②
• Dust seal ③
• Cover ④

To relay arm ⑤.

NOTE:

Apply the molybdenum disulfide grease on the bushings, dust seals, collars, cover lips, bearings and oil seal lips.

3. Install:

- Bushing ①

To connecting rod ②.

NOTE:

Apply the molybdenum disulfide grease on the bushings, bearings and oil seal lips.

4. Install:

• Connecting rod ①
• Washer ②
• Bolt (connecting rod) ③
• Nut (connecting rod) ④

53 Nm (5.3 m · kg, 38 ft · lb)

To swingarm ⑤.

NOTE:

Apply the molybdenum disulfide grease on the bolt.

5. Install:

• Relay arm ①
• Bolt (relay arm) ②
• Nut (relay arm) ③

54 Nm (5.4 m · kg, 39 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt.

2. Monter:

• Bague ①
• Collerette ②
  • Joint antipoussière ③
• Cache ④
  Sur le bras relais ⑤.

N.B.:

6. Install:

• Swingarm ①
• Pivot shaft ②
• Washer ③
• Nut (pivot shaft) ④

63 Nm (6.3 m · kg, 45 ft · lb)

NOTE:

• Apply the molybdenum disulfide grease on the pivot shaft.
• Insert the pivot shaft from right side.

7. Check:

• Swingarm side play @ Free play exists → Replace collars.
• Swingarm up and down movement ⑥ Unsmooth movement/binding/rough spots → Grease or replace bearings, bushings and collars.

8. Install:

- Washer ① - Bolt (rear shock absorber-relay arm) ②

36 Nm (3.6 m · kg, 25 ft · lb)

NOTE:

• Apply the molybdenum disulfide grease on the bolt.
• Insert the bolt from left side.

9. Install:

• Bolt (connecting rod) ①
• Nut (connecting rod) ②

53 Nm (5.3 m · kg, 38 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt.

10. Install:

• Drive chain support ①
• Drive chain support cover ②
• Bolt (drive chain support cover) ③
• Nut (drive chain support cover) ④

7 Nm (0.7 m · kg, 5.1 ft · lb)

• Bolt (drive chain support) ⑤
• Nut (drive chain support) ⑥

16 Nm (1.6 m · kg, 11 ft · lb)

6. Monter:

① Rear shock absorber removal

② Rear shock absorber disassembly

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		REAR SHOCK ABSORBER REMOVALHold the machine by placing the suitable stand under the engine.Seat Refer to “SEAT, FUEL TANKSilencer Refer to “EXHAUST PIPE AND SIDECOVERS” section in the CHAPTER 4.SILENCER” section in the CHAPTER 4.	WARNINGSupport the machine securely so there is no danger of it falling over.
↓	1 Clamp (air cleaner joint) 1 Only loosening.2 R e a r f r3 Bolt (rear shock absorber-relay arm)4 Bolt (rear shock absorber-frame) 15 Rear shock absorber 16 Locknut 1 Only loosening.7 Adjuster8 Spring guide9 Spring (rear shock absorber)	a m 1 Hold the swingarm.1 Only loosening.	e 1

AMORTISSEUR ARRIERE

This rear shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber.

The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling.

1. Never tamper or attempt to disassemble the cylinder or the tank.
2. Never throw the rear shock absorber into an open flame or other high heat. The rear shock absorber may explode as a result of nitrogen gas expansion and/or damage to the hose.
3. Be careful not to damage any part of the gas tank. A damaged gas tank will impair the damping performance or cause a malfunction.
4. Take care not to scratch the contact surface of the piston rod with the cylinder; or oil could leak out.
5. Never attempt to remove the plug at the bottom of the nitrogen gas tank. It is very dangerous to remove the plug.
6. When scrapping the rear shock absorber, follow the instructions on disposal.

Technical illustration of a mechanical assembly with coiled spring and housing (no text or symbols)

NOTES ON DISPOSAL (YAMAHA DEALERS ONLY)

Before disposing the rear shock absorber, be sure to extract the nitrogen gas from valve ①. Wear eye protection to prevent eye damage from escaping gas and/or metal chips.

WARNING

To dispose of a damaged or worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure.

REMARQUES CONCERNANT LA MANIPULATION

AVERTISSEMENT

EC584000

INSPECTION

Rear shock absorber

1. Inspect:

- Damper rod ① Bends/damage → Replace rear shock absorber assembly.

- Shock absorber ② Oil leaks → Replace rear shock absorber assembly. Gas leaks → Replace rear shock absorber assembly.

- Spring ③ Damage → Replace spring. Fatigue → Replace spring. Move spring up and down.

- Spring guide ④ Wear/damage → Replace spring guide.

EC585000

ASSEMBLY AND INSTALLATION

Spring (rear shock absorber)

1. Install:

• Spring ①
• Spring guide ②

Technical illustration of a mechanical spring assembly with labeled component (1), no text or symbols present

2. Tighten:

- Adjuster ①

CONTROLE

Amortisseur arrière

1. Contrôler:

Technical line drawing of a mechanical spring assembly with dimension label (a), no text or symbols present

Technical illustration of a mechanical spring assembly with labeled component (1), no text or symbols present

3. Adjust:

- Spring length (installed) ⓐ

Spring length (installed) ⓐ:

YZ85: 215 mm (8.46 in)

*212 mm (8.35 in)

YZ85LW: 207 mm (8.15 in)

*212 mm (8.35 in)

Extent of adjustment

202.5 \~ 218.5 mm

(7.97 \~ 8.60 in)

* For EUROPE

NOTE:

The length of the spring (installed) changes

1.5 mm (0.06 in) per turn of the adjuster.

CAUTION:

Never attempt to turn the adjuster beyond the maximum or minimum setting.

4. Tighten:

- Locknut ①

Rear shock absorber

1. Install:

- Rear shock absorber

2. Install:

- Bolt (rear shock absorber-frame) ①

- Washer ②

- Nut (rear shock absorber-frame) ③

36 Nm (3.6 m · kg, 25 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt.

3. Install:

- Washer ①

- Bolt (rear shock absorber-relay arm) ②

36 Nm (3.6 m · kg, 25 ft · lb)

NOTE:

- Apply the molybdenum disulfide grease on the bolt.

- Insert the bolt from left side.

3. Régler:

Technical line drawing of a mechanical assembly with labeled parts (no readable text or symbols)

4. Install:

• Rear frame ①
• Bolt [rear frame (upper)] ②

26 Nm (2.6 m · kg, 19 ft · lb)

- Bolt [rear frame (lower)] ③

16 Nm (1.6 m · kg, 11 ft · lb)

5. Tighten:

- Screw (air filter joint) ①

4. Monter:

① Engine stop switch
② Ignition coil
③ CDI unit
④ CDI magneto
⑤ Spark plug

COLOR CODE

B..... Black G/L..... Green/Blue
O....Orange G/W....Green/White
B/R .... Black/Red W/L .... White/Blue
B/W .... Black/White W/R .... White/Red

EC612000

WIRING DIAGRAM

graph TD
    A["③"] --> B["①"]
    A --> C["④"]
    A --> D["⑤"]
    B --> E["B/W"]
    B --> F["B/W"]
    B --> G["B"]
    C --> H["G/L"]
    C --> I["W/L"]
    D --> J["B/R"]
    D --> K["W/R"]
    D --> L["B/W"]
    E --> M["B/W"]
    F --> N["B/W"]
    G --> O["B/W"]
    H --> P["G/L"]
    I --> Q["W/L"]
    J --> R["B/R"]
    K --> S["W/R"]
    L --> T["B/W"]
    M --> U["B/W"]
    N --> V["B/W"]
    O --> W["B/W"]
    P --> X["B/W"]
    Q --> Y["B/W"]
    R --> Z["B/W"]
    S --> AA["B/W"]
    T --> AB["B/W"]
    U --> AC["B/W"]
    V --> AD["B/W"]
    W --> AE["B/W"]
    X --> AF["B/W"]
    Y --> AG["B/W"]
    Z --> AH["B/W"]

PARTIE ELECTRIQUE COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE COMPOSANTS ELECTRIQUES

Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark.

graph TD
    A["Spark gap test"] -->|No spark| B["Check entire ignition system for connection."]
    B -->|OK| C["Check engine stop switch. Replace."]
    C -->|OK| D["Check ignition coil. Primary coil Replace."]
    D -->|No good| E["Secondary coil Replace."]
    E -->|No good| F["Check spark plug cap. Replace."]
    F -->|No good| G["Check CDI magneto. Pickup coil Replace."]
    G -->|No good| H["Charging coil Replace."]
    H -->|No good| I["Replace CDI unit."]
    A -->|Spark| J["*Clean or replace spark plug."]
    B -->|No good| K["Repair or replace."]
    C -->|No good| L[" "]
    D -->|No good| M[" "]
    F -->|No good| N[" "]
    G -->|No good| O[" "]
    H -->|No good| P[" "]
    I -->|No good| Q[" "]

*marked: Only when the ignition checker is used.

NOTE:

• Remove the following parts before inspection.
  1) Seat
  2) Fuel tank
• Use the following special tools in this inspection.

Dynamic spark tester:

YM-34487

Ignition checker:

90890-06754

Pocket tester:

YU-3112-C/90890-03112

SYSTEME D'ALLUMAGE

ETAPES DU CONTROLE

SPARK GAP TEST

1. Disconnect the spark plug cap from spark plug.

2. Connect the dynamic spark tester ① (ignition checker ②) as shown.

3. Spark plug cap ③

4. Spark plug ④

A For USA and CDN
B Except for USA and CDN

1. Kick the kickstarter crank.
2. Check the ignition spark gap.
3. Start engine, and increase spark gap until misfire occurs. (for USA and CDN only)

Minimum spark gap: 6.0 mm (0.24 in)

EC624000

COUPLERS AND LEADS CONNECTION INSPECTION

1. Check:

- Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

ENGINE STOP SWITCH INSPECTION

1. Inspect:

• Engine stop switch conduct

Tester (+) lead → Black/White lead 1

Tester (−) lead → Black lead 2

		B/W1	B2	Tester selec-tor position
	PUSH IN	○	○	Ω×1
	FREE

No continuous while being pushed → Replace. Continuous while being freed → Replace.

TEST DE LA LONGUEUR D'ETINCELLE

Diagram of a mechanical device with directional arrows indicating motion or force (no text or symbols)

EC626002

IGNITION COIL INSPECTION

1. Inspect:

- Primary coil resistance Out of specification → Replace.

Tester (+) lead → Orange lead 1

Tester (−) lead → Black lead 2

	Primary coil resistance	Tester selector position
	0.18 ~ 0.28 Ω at 20 °C (68 °F)	Ω × 1

2. Inspect:

- Secondary coil resistance Out of specification → Replace.

Tester (+) lead → Spark plug lead 1

Tester (−) lead → Orange lead 2

	Secondary coil resistance	Tester selector position
	6.3 ~ 9.5 kΩ at 20 °C (68 °F)	kΩ×1

NOTE:

• Remove the spark plug cap by turning it counterclockwise and inspect.
• Install the spark plug cap by turning it clockwise until it is tight.

SPARK PLUG CAP INSPECTION

1. Inspect:

• Spark plug cap Loose connection → Tighten. Deteriorated/Damaged → Replace.
• Spark plug cap resistance Out of specification → Replace.

Tester (+) lead → Spark plug lead terminal 1 Tester (−) lead → Spark plug terminal 2

	Spark plug cap resistance	Tester selector position
	4 ~ 6 kΩ at 20 °C (68 °F)	kΩ×1

CONTROLE DE LA BOBINE D'ALLUMAGE

1. Contrôler:

- Pickup coil resistance Out of specification → Replace.

Tester (+) lead → White/Red lead 1

Tester (−) lead → White/Blue lead 2

	Pickup coil resistance	Tester selector position
	248 ~ 372 Ω at 20 °C (68 °F)	Ω × 100

2. Inspect:

- Charging coil 1 resistance Out of specification → Replace.

Tester (+) lead → Black/Red lead 1

Tester (−) lead → Green/White lead 2

	Charging coil 1 resistance	Tester selector position
	720 ~ 1,080 Ω at 20 °C (68 °F)	Ω × 100

3. Inspect:

- Charging coil 2 resistance Out of specification → Replace.

Tester (+) lead → Green/Blue lead 1

Tester (−) lead → Black lead 2

	Charging coil 2 resistance	Tester selector position
	44 ~ 66 Ω at 20 °C (68 °F)	Ω × 10

EC628000

CDI UNIT INSPECTION

Check all electrical components. If no fault is found, replace the CDI unit. Then check the electrical components again.

CONTROLE DU VOLANT MAGNETIQUE CDI

1. Contrôler:

- The role of fuel is to cool the engine, and in the case of a 2-stroke engine, to lubricate the engine in addition to power generation. Accordingly, if a mixture of air and fuel is too lean, abnormal combustion will occur, and engine seizure may result. If the mixture is too rich, spark plugs will get wet with oil, thus making it impossible to bring the engine into full play or if the worst comes to the worst, the engine may stall.

• The richness of the air-fuel mixture required for the engine will vary with atmospheric conditions of the day and therefore, the settings of the carburetor must be properly suited to the atmospheric conditions (air pressure, humidity and temperature).
• Finally, the rider himself must make a test run and check his machine for conditions (pick-up of engine speed, road surface conditions) and for the discoloration of the spark plug(s).

After taking these into consideration, he must select the best possible carburetor settings.

* It is advisable to make a note of settings, atmospheric conditions, road surface condition, lap-time, etc. so that the memorandum can be used as a reference useful for future.

Atmospheric conditions and carburetor settings

Air temp. Humidity		Air pressure (altitude)	Mixture Setting
High High Low (high)		Richer Leaner
Low Low High (low) Leaner Richer

The air density (i.e., concentration of oxygen in the air) determines the richness or leanness of the air/fuel mixture. Therefore, refer to the above table for mixture settings.

MISE AU POINT MOTEUR

• Higher temperature expands the air with its resultant reduced density.
• Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air.
• Lower atmospheric pressure (at a high altitude) reduces the density of the air.

Close-up of a mechanical spark plug with threaded end and central bore (no text or symbols visible)

Close-up of a mechanical screw with a curved head and central bore (no text or symbols visible)

Close-up of a black-and-white photo of a spark plug (no text or symbols visible)

Test run

After warming up the engine equipped with the standard type carburetor(s) and spark plug(s), run two or three laps of the circuit and check the smooth operation of the engine and discoloration of spark plug(s).

Discoloration Condition of spark plug
Normal	Insulator is dry and burnt brown.
Over burned (too lean)	Insulator is whitish.
Oil fouled (too rich)	Insulator is sooty and wet.

A Normal
B Over burned (too lean)
© Oil fouled (too rich)

Effects of the setting parts on the throttle valve opening

Setting part		Throttle valve opening
		Full-closed1/4 1/2 3/4 Full-open
Pilot jetPilot air screw
Jet needle	Diameter of straight por-tion
	Clip position
Main jet

① Throttle valve opening
② Full-open
③ Full-closed

Technical line drawing of a mechanical assembly with labeled component (1), no readable text or symbols present

Main jet adjustment

The richness of air-fuel mixture with 3/4 \~ 4/4 throttle can be set by changing the main jet ①.

Standard main jet #138

1. Spark plug is too hot.

Select a main jet having higher calibrating No. than standard. (To be enriched)

1. Spark plug is wet.

Select a main jet having lower calibrating No. than standard. (To be leaned out)

Technical line drawing of a mechanical assembly with springs and levers (no text or symbols)

Pilot air screw adjustment

The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot air screw ①.

Turning in the pilot air screw will make the mixture enrich at low speeds, and turning it out will lean it.

Standard pilot air screw position

2 turns out (example)

Pilot jet adjustment

The richness of air-fuel mixture with the throttle fully closed to 1/2 open can be set by turning the pilot jet ①. It is changed when adjustment cannot be made by the pilot air screw alone.

A larger size jet results in a richer mixture at low speeds, and a smaller size in a leaner mixture.

Standard pilot jet #45

Line drawing of a rod with a flanged end and labeled point 1 (no text or symbols beyond label)

Jet needle adjustment

The richness of air-fuel mixture with 1/4 \~ 3/4 throttle can be set by changing the jet needle ①.

A smaller diameter jet needle results in a richer mixture at middle speeds, and a larger diameter in a leaner mixture.

Standard jet needle NBKF

Jet needle groove position adjustment

Should the engine be hard to run smoothly at intermediate speeds, the jet needle ① must be adjusted. If the mixture is too rich or too lean at intermediate speed operation, irregular engine operation and poor acceleration will result. Whether or not the richness of the mixture is proper is hard to be determined by means of the spark plug and therefore, it should be judged from your feeling of actual engine operation.

Standard clip position No.2 groove

1. Too rich at intermediate speeds

Rough engine operation is felt and the engine will not pick up speed smoothly.

In this case, step up the jet needle clip by one groove and move down the needle to lean out the mixture.

1. Too lean at intermediate speeds

The engine breathes hard and will not pick up speed quickly.

In this case, step down the jet needle clip by one groove and move up the needle to enrich the mixture.

EC71Q000

Carburetor setting parts

Part name Size		Part number
Main jet 1	Rich	#148	4MX-14943-87
		#145	4MX-14943-36
		#142	4MX-14943-86
		#140	4MX-14943-35
	(STD)	#138	4MX-14943-85
		#135	4MX-14943-34
		#132	4MX-14943-84
Pilot jet 2	Rich	#48	4MX-14948-06
	(STD)	#45	4MX-14948-05
		#42	4MX-14948-04
Jet needle 3Refer to the following table about the change in the air-fuel mixture ratio due to a different jet needle.		NBLE	5PA-14916-LE
		NBLF	5PA-14916-LF
		NBLG	5PA-14916-LG
		NBKE	5PA-14916-KE
		NBKF	5PA-14916-KF
		NBKG	5PA-14916-KG

Clip position\Diameter of straight portion		Rich Lean→
		φ 2.405 mm (0.0947 in)	φ 2.415 mm (0.0951 in)	φ 2.425 mm (0.0955 in)
Rich Lean	1 richer NBKE	E-3rd groove NBKF-3rd groove	NBLG-3rd groove
	0.5 richer NBL	E-2nd groove NBLF-2nd groove	NBLG-2nd groove
	STD NBKE	2nd groove NBKF-2nd groove (STD)	NBLG-2nd groove
	0.5 leaner NBL	E-1st groove NBLF-1st groove	NBLG-1st groove
	1 leaner	NBKE-1st groove	NBLF-1st groove	NBLG-1st groove

Road condition and examples of carburetor setting

Parts\Conditions	General condition Sandy condition
	Under 10 °C(50 °F)(Winter)	15 ~ 25 °C(59 ~ 77 °F)(Spring, Autumn)	Over 30 °C(86 °F)(Summer)	Under 10 °C(50 °F)(Winter)	15 ~ 25 °C(59 ~ 77 °F)(Spring, Autumn)	Over 30 °C(86 °F)(Summer)
Main jet #140	#138 #135 ~	#138 #142 #142	#142
Jet needle NBKF-2 NBKF-2 NBKF-2 NBKF-2 NBKF-2 NBKF-2
Pilot jet #45 #45 #45 #48 #48
Pilot air screw	Zero	Zero	+1/4	-1/2	-1/2	Zero ~ +1/2

NOTE:

Optimum pilot air screw setting can be obtained by adding the ex-factory number of the same screw back-out turns to any required value provided in the chart.

For example, if the ex-factory number is "2", add "2" to the value chosen in the chart.

Examples of carburetor setting depending on symptom

Symptom	Setting	Checking
At full throttle Stall at high speeds *Hard breathing Shearing noise Whitish spark plug↓Lean mixture	Increase main jet calibration no. (Gradually)	Discoloration of spark plug →If tan color, it is in good condition.If cannot be corrected:Clogged float valve seatClogged fuel hoseClogged fuel cock
At full throttle Speed pick-up stops Slow speed pick-up Slow response Sooty spark plug↓Rich mixture	Decrease main jet calibration no. (Gradually)*In case of racing slight enrichment of mixture reduces engine trouble.	Discoloration of spark plug →If tan color, it is in good condition.If cannot be corrected:Clogged air filterFuel overflow from carburetor
Lean mixture	Use jet needle with a smaller diameter, or NBLF.Lower jet needle clip position.	Leaner↑(Standard)↓RicherThe clip position is the jet needle groove on which the clip is installed. The positions are numbered from the top.
Rich mixture	Use jet needle with a larger diameter, or NBKG.Raise jet needle clip position.
1/4 ~ 3/4 throttle*Hard breathing Lack of speed	Use jet needle with a smaller diameter, or NBLF.Lower jet needle clip position.
1/4 ~ 1/2 throttle Slow speed pick-up White smoke Poor acceleration	Use jet needle with a larger diameter, or NBKG.Raise jet needle clip position.
Closed to 1/4 throttle*Hard breathing Speed down	Use jet needle with a smaller diameter.Turn out pilot air screw.
Symptom Setting	Checking
Closed to 1/4 throttlePoor accelerationWhite smoke	Use jet needle with a larger diameter.Turn in pilot air screw.
Unstable at low speedsPinking noise	Lower jet needle clip position.(1 groove down)Turn in pilot air screw.
Poor response at extremely low speed	Reduce pilot jet calibration No.Turn out pilot air screw.If not effect, reverse the above procedures.	Dragging brakeOverflow from carburetor
Poor response in the low to intermediate speeds	Raise jet needle clip position.If this has no effect, lower the jet needle clip position.
Poor response when throttle is opened quickly	Check overall settings.Use main jet with a lower calibration no.Raise jet needle clip position.Use jet needle with a larger diameter.If these have no effect, use a main jet with a higher calibration no.and lower the jet needle clip position.	Check air filter for fouling.
Poor engine operation Turn in pilot air screw.Adjust the throttle stop screw.		Check throttle valve operation.

* marked: In case of hard breathing, check the carburetor breather hoses for clogging.

This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine and discoloration of spark plugs.

Normally, carburetor setting is made by means of the main jet, jet needle clip position, pilot jet and pilot air screw.

Technical line drawing of a spark plug (no text or symbols)

Change of the heat range of spark plugs

Judging from the discoloration of spark plugs, if they are found improper, it can be corrected by the following two methods; changing carburetor settings and changing the heat range of spark plug.

Standard spark plug

BR10EG/NGK (resistance type)

• In principle, it is advisable to first use spark plugs of standard heat range, and judging from the discoloration of spark plugs, adjust carburetor settings.
• If the calibration No. of the main jet must be changed by ± 30 , it is advisable to change the heat range of spark plugs and newly select the proper main jet.

NOTE:

• When checking the discoloration of spark plugs, be sure to stop the engine immediately after a run and check.
• Avoid racing.
• When changing the heat range of spark plugs, never attempt to change it more than ± 1 rank.
• When using a spark plug other than standard, check its heat range against the standard and check that it is a resistance type.
• Note that even if the discoloration seems proper, it may slightly vary with the spark plug maker and oil in use.

Selection of the secondary reduction ratio (Sprocket)

Secondary reduction ratio = of rear wheel sprocket teethNumber of drive sprocket teeth

Standard secondary reduction ratio

YZ85:47/14 (3.357)(USA, S, NZ, ZA)48/14 (3.429)(F, D, I, GB, E, CDN, AUS)YZ85LW:52/14 (3.714)

• It is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners. Actually, however, as the speed depends on the ground condition of the day of the race, be sure to run through the circuit to set the machine suitable for the entire course.
• In actuality, it is very difficult to achieve settings suitable for the entire course and some settings may be sacrificed. Thus, the settings should be matched to the portion of the course that has the greatest effect on the race result. In such a case, run through the entire course while making notes of lap times to find the best balance; then, determine the secondary reduction ratio.
• If a course has a long straight portion where a machine can run at maximum speed, the machine is generally set such that it can develop its maximum revolutions toward the end of the straight line, with care taken to avoid the engine over-revving.

NOTE:

Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine. Therefore, do not imitate other rider's settings from the beginning but choose your own setting according to the level of your riding technique.

CHASSIS

EC72N000

Drive and driven sprockets setting parts

YZ85:

Part name Size	Part number
Drive (STD)	14T	9382A-14227
Sprocket 1	15T	9382A-15228
Real wheel	46T	5PA-25446-00
sprocket 2*(STD)	47T	4ES-25447-10
** (STD)	48T	5PA-25448-00
	49T	5PA-25449-00

**For F, D, I, GB, E, CDN and AUS

YZ85LW:

Part name Size	Part number
Drive (STD)	14T	9382A-14227
sprocket 1	15T	9382A-15228
Real wheel	51T	5PA-25451-00
sprocket 2(STD)	52T	5PA-25452-00
	53T	5PA-25453-00

EC721002

Tire pressure

Tire pressure should be adjust to suit the road surface condition of the circuit.

Standard tire pressure: 100 kPa (1.0 kgf/cm², 15 psi)

- Under a rainy, muddy, sandy, or slippery condition, the tire pressure should be lower for a larger area of contact with the road surface.

Extent of adjustment: 60 \~ 80 kPa (0.6 \~ 0.8 kgf/cm², 9.0 \~ 12 psi)

- Under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire.

Extent of adjustment: 100 \~ 120 kPa (1.0 \~ 1.2 kgf/cm², 15 \~ 18 psi)

**F, D, I, GB, E, CDN, et AUS

YZ85LW:

The front fork setting should be made depending on the rider's feeling of an actual run and the circuit conditions.

The front fork setting includes the following three factors:

1. Setting of air spring characteristics
2. Change the fork oil level.
3. Setting of spring preload
4. Change the spring.
5. Setting of damping force
6. Change the compression damping.
7. Change the rebound damping.
   The spring acts on the load and the damping force acts on the cushion travel speed.

EC723001

Change in level and characteristics of fork oil

Damping characteristic near the final stroke can be changed by changing the fork oil amount.

CAUTION:

Adjust the oil level in 5 mm (0.2 in) increments or decrements. Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body. Alternatively, too high oil level will develop unexpectedly early oil lock with the consequent shorter front fork travel and deteriorated performance an characteristics. Therefore, adjust the front fork within the specified range.

Standard oil level:

90 mm (3.54 in)

Extent of adjustment:

80 \~ 120 mm (3.15 \~ 4.72 in)

From top of outer tube with inner tube and damper rod fully compressed without spring.

A Air spring characteristics in relation to oil level change
B Load
C Stroke
① Max. oil level
② Standard oil level
③ Min. oil level

Setting of spring after replacement

As the front fork setting can be easily affected by rear suspension, take care so that the machine front and rear are balanced (in position, etc.) when setting the front fork.

1. Use of soft spring

Generally a soft spring gives a soft riding feeling. Rebound damping tends to become stronger and the front fork may sink deeply over a series of gaps.

To set a soft spring:

• Change the rebound damping.
  Turn out one or two clicks.
• Change the compression damping.
  Turn in one or two clicks.

2. Use of stiff spring

Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar.

To set a stiff spring:

• Change the rebound damping.
  Turn in one or two clicks.
• Change the compression damping.
  Turn out one or two clicks.

graph TD
    A["Group ①"] --> B["Group ②"]
    B --> C["Group ③"]
    style A fill:#f9f,stroke:#333
    style B fill:#bbf,stroke:#333
    style C fill:#dfd,stroke:#333

A Coverage of spring by weight

B Rider weight

① Soft
② Standard
③ Stiff

Front fork setting parts

- Front fork spring ①

YZ85

TYPE	SPRING RATE	SPRING PART NUMBER	I.D. MARK (slits)
SOFT	0.280 4ES	-23141-50 I
STD	0.290 4ES	-23141-40 –
STIFF	0.300 4ES	-23141-60 II

YZ85LW

TYPE	SPRING RATE	SPRING PART NUMBER	I.D. MARK (slits)
SOFT	0.290 4ES	-23141-40 –
STD	0.300 4LB	-23141-10 –
STIFF	0.310 4ES	-23141-70 III

NOTE:

The I.D. mark (slits) ⓐ is proved on the end of the spring.

EC72B000

Rear suspension setting

The rear suspension setting should be made depending on the rider's feeling of an actual run and the circuit conditions.

The rear suspension setting includes the following two factors:

1. Setting of spring preload

2. Change the set length of the spring.

3. Change the spring.

4. Setting of damping force

5. Change the rebound damping.

6. Change the compression damping.

EC72C001

Choosing set length

1. Place a stand or block under the engine to put the rear wheel above the floor, and measure the length ⓐ between the rear wheel axle center and the rear fender holding bolt.
2. Remove the stand or block from the engine and with a rider astride the seat, measure the sunken length ⑥ between the rear wheel axle center and the rear fender holding bolt.
3. Loosen the locknut ① and make adjustment by turning the spring adjuster ② to achieve the standard figure from the subtraction of the length ⑥ from the length ⑧.

Standard figure: 75 \~ 85 mm (3.0 \~ 3.3 in)

NOTE:

• If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re-evaluation.
• If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make re-adjustment.

Setting of spring after replacement

After replacement, be sure to adjust the spring to the set length [sunken length 75 \~ 85 mm (3.0 \~ 3.3 in)] and set it.

1. Use of soft spring

- Set the soft spring for less rebound damping to compensate for its less spring load. Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference.

2. Use of stiff spring

- Set the soft spring for more rebound damping to compensate for its greater spring load. Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference.

* Adjusting the rebound damping will be followed more or less by a change in the compression damping. For correction, turn the compression damping adjuster on the softer side.

Technical line drawing of a mechanical spring assembly with dimension lines (no text or symbols)

graph TD
    A["80 kg"] --> B["(176 lb)"]
    C["70 kg"] --> D["(154 lb)"]
    E["60 kg"] --> F["(132 lb)"]
    G["50 kg"] --> H["(110 lb)"]
    I["40 kg"] --> J["(88 lb)"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#cfc,stroke:#333
    style H fill:#fcc,stroke:#333
    style I fill:#cfc,stroke:#333
    style J fill:#fcc,stroke:#333

CAUTION:

When using a rear shock absorber other than currently installed, use the one whose overall length ⓐ does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard.

Length ⓐ of standard shock: 403.5 mm (15.89 in)

A Coverage of spring by weight
B Rider weight
① Soft
② Standard
③ Stiff

Rear shock absorber setting parts

- Rear shock spring ①

YZ85

For USA, CDN, AUS, NZ and ZA

TYPE	SPRING RATE	SPRING PART NUMBER	I.D. COLOR
SOFT	4.8 4ES-22	212-G0 Red
STD	5.0 4ES-22	212-F0 –
STIFF	5.2 4ES-22	2212-H0 Blue

For EUROPE

TYPE	SPRING RATE	SPRING PART NUMBER	I.D. COLOR
SOFT	4.4 4ES-22	212-M0 Brown
STD	4.6 4ES-22	212-K0 Green
STIFF	4.8 4ES-22	2212-G0 Red

YZ85LW

For AUS and NZ

TYPE	SPRING RATE	SPRING PART NUMBER	I.D. COLOR
SOFT	5.0 4ES-22	212-F0 –
STD	5.2 4ES-22	212-H0 Blue
STIFF	5.4 4ES-22	2212-J0 Black

For EUROPE

TYPE	SPRING RATE	SPRING PART NUMBER	I.D. COLOR
SOFT	4.6 4ES-22	212-K0 Green
STD	4.8 4ES-22	212-G0 Red
STIFF	5.0 4ES-22	2212-F0 –

NOTE:

The I.D. color ⓐ is marked at the end of the spring.

• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 75 \~ 85 mm (3.0 \~ 3.3 in).

Symptom	Section				Check Adjust
	Jump	Large gap	Medium gap	Small gap
Stiff over entire range	○	○	○		Compression dampingOil level (oil amount)Spring	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).Replace with soft spring.
Unsmooth movement over entire range	○	○	○	○	Outer tubeInner tubeUnder bracket tightening torque	Check for any bends, dents, and other noticeable scars, etc. If any, replace affected parts.Retighten to specified torque.
Poor initial movement				○	Rebound dampingOil seal	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Apply grease in oil seal wall.
Soft over entire range, bottoming out	○	○			Compression dampingOil level (oil amount)Spring	Turn adjuster clockwise (about 2 clicks) to increase damping.Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).Replace with stiff spring.
Stiff toward stroke end	○				Oil level (oil amount)	Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke end, bottoming out	○	Oil level	(oil amount)	Increase oil level by about 5 mm (0.2 in).
Stiff initial movement ○	○	○	○	Compression damping		Turn adjuster counterclockwise (about 2 clicks) to decrease damping.
Low front, tending to lower front posture			○	○	Compression dampingRebound dampingBalance with rear endOil level (oil amount)	Turn adjuster clockwise (about 2 clicks) to increase damping.Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Set sunken length for 80 ~ 85 mm (3.1 ~ 3.3 in) when one passenger is astride seat (lower rear posture).Increase oil level by about 5 mm (0.2 in).
“Obtrusive” front, tending to upper front posture			○	○	Compression dampingBalance with rear endSpringOil level (oil amount)	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in) when one passenger is astride seat (upper rear posture).Replace with soft spring.Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).

- Rear shock absorber

NOTE:

• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Adjust the damping in 2-click increments or decrements.

Symptom	Section				Check Adjust
	Jump	Large gap	Medium gap	Small gap
Stiff, tending to sink			○	○	Rebound dampingSpring set length	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in) when one passenger is astride seat.
Spongy and unstable ○	○				Rebound dampingSpring	Turn adjuster clockwise (about 2 clicks) to increase damping.Replace with stiff spring.
Heavy and dragging ○	○				Rebound dampingSpring	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Replace with soft spring.
Poor road gripping ○					Rebound dampingCompression dampingSpring set lengthSpring	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Turn adjuster clockwise (about 2 clicks) to increase damping.Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in) when one passenger is astride seat.Replace with soft spring.
Bottoming out ○	○				Compression dampingSpring set lengthSpring	Turn adjuster clockwise (about 2 clicks) to increase damping.Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in) when one passenger in astride seat.Replace with stiff spring.
Bouncing ○ ○					Rebound dampingSpring	Turn adjuster clockwise (about 2 clicks) to increase damping.Replace with soft spring.
Stiff travel ○ ○					Compression dampingSpring set lengthSpring	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Set sunken length for 80 ~ 85 mm (3.1 ~ 3.3 in) when one passenger is astride seat.Replace with soft spring.