Yamaha YZ85W1 User manual

2007

YZ85W1

5PA-28197-E0

SERVICE MANUAL

YZ85(W)

YZ85LW(W)

YZ85W1/YZ85 (W)/YZ85LW (W)

SERVICE MANUAL

First edition, April 2006

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EAS00000

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the

vehicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

TE:

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death

to the vehicle operator, a bystander or a person checking or repairing the

vehicle.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the vehicle.

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

WARNING

CAUTION:

NOTE:

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)

appears.

Sub-section titles appear in smaller print than the section title.

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

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SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols to indicate the subject of each

chapter.

General information

Specifications

Periodic checks and adjustments

Chassis

Engine

Cooling system

Carburetor(s)

Electrical system

Tuning

Troubleshooting

Symbols to indicate the following.

Serviceable with engine mounted

Filling fluid

Lubricant

Special tool

Tightening torque

Wear limit, clearance

Engine speed

Electrical data

Symbols to in the exploded diagrams

indicate the types of lubricants and lubrication

points.

Engine oil

Gear oil

Molybdenum-disulfide oil

Wheel-bearing grease

Lithium-soap- based grease

Molybdenum-disulfide grease

Symbols to in the exploded diagrams

indicate the following.

Apply locking agent (LOCTITE®)

Replace the part with a new one.

EAS00010

TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

ADJ 3

CHASSIS CHAS 4

ENGINE ENG 5

COOLING SYSTEM COOL 6

CARBURETOR CARB 7

ELECTRICAL SYSTEM ELEC 8

TUNING TUN 9

TROUBLESHOOTING TRBL

SHTG 10

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . 1-1

MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1-2

REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

GASKETS, OIL SEALS AND O-RINGS. . . . . . . . . . . . . . . . . . . . . . . 1-2

LOCK WASHERS/PLATES AND COTTER PINS. . . . . . . . . . . . . . . 1-3

BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

FUEL AND ENGINE MIXING OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

GEN

INFO

1-1

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GENERAL INFORMATION

VEHICLE IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is

stamped into the right side of the steering

head pipe.

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MODEL LABEL

The model label is affixed to the frame. This

information will be needed to order spare

parts.

VEHICLE IDENTIFICATION

GEN

INFO

1-2

EAS00020

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1. Before removal and disassembly, remove

all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to the “SPECIAL TOOLS”.

3. When disassembling, always keep mated

parts together. This includes gears, cylin-

ders, pistons and other parts that have

been “mated” through normal wear. Mated

parts must always be reused or replaced as

an assembly.

4. During disassembly, clean all of the parts

and place them in trays in the order of dis-

assembly. This will speed up assembly and

allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EAS00021

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace-

ments. Use oil and grease recommended by

Yamaha for all lubrication jobs. Other brands

may be similar in function and appearance, but

inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-

faces, oil seal lips and O-rings must be

cleaned.

2. During reassembly, properly oil all mating

parts and bearings and lubricate the oil seal

lips with grease.

lip

oil

lip

spring

grease

IMPORTANT INFORMATION

GEN

INFO

1-3

EAS00023

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

and cotter pins. After the bolt or nut has

been tightened to specification, bend the lock

tabs along a flat of the bolt or nut.

EAS00024

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-

facturer’s marks or numbers are visible. When

installing oil seals, lubricate the oil seal lips

with a light coat of lithium-soap-based grease.

Oil bearings liberally when installing, if appro-

priate.

Oil seal

CAUTION:

Do not spin the bearing with compressed

air because this will damage the bearing

surfaces.

Bearing

EAS00025

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips.

Always replace piston pin clips after one use.

When installing a circlip , make sure the

sharp-edged corner is positioned opposite

the thrust that the circlip receives.

Shaft

IMPORTANT INFORMATION

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