2002 YAMAHA YZ85 transmission oil

3 - 12
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
5. Install:
lAir filter guide 1
To air filter element 2.
5PA30170
6. Apply:
lLithium soap base grease
On the matching surface a on air filter ele-
ment.
5PA30180
7. Install:
lAir filter element 1
lWasher
lFitting bolt
NOTE:
Install the air filter element with its projection
a facing upward.
5PA30190
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
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:
lOil drain bolt 1
lOil filler cap 2
Drain the transmission oil.
5PA30200

3 - 13
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
5. Measure:
lTransmission oil capacity
Out of specification ® Adjust.
Oil capacity (periodic oil change):
0.50 L (0.44 Imp qt, 0.52 US qt)
6. Install:
lCopper washer
lOil drain bolt 1
5PA30210
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Fill:
lTransmission 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)
8. Check:
lOil leakage
9. Install:
lOil filter cap 1
5PA30220

4 - 26
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC490000
CLUTCH AND PRIMARY DRIVEN GEAR
EC498000
CLUTCH PLATE AND FRICTION PLATE
5PA40720
Extent of removal:
1 Clutch plate and friction plate removal
Extent of removal Order Part name Q’ty Remarks
CLUTCH PLATE AND FRIC-
TION PLATE REMOVAL
Preparation for removal Drain the transmission oil. Refer to “TRANSMISSION OIL
REPLACEMENT” section in the CHAP-
TER 3.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Bolt (clutch spring) 5
3 Clutch spring 5
4 Pressure plate 1
5 Friction plate 7
6 Clutch plate 6
1

4 - 30
ENG
ASSEMBLY AND INSTALLATION
Push lever shaft
1. Install:
lPush lever shaft 1
NOTE:
lApply the lithium soap base grease on the oil
seal lip and push lever shaft end.
lApply the transmission oil on the push lever
shaft.5PA40830
Clutch
1. Install:
lWasher [thickness 2 mm (0.08 in)] 1
lSpacer 2
lPrimary driven gear 3
NOTE:
Apply the transmission oil on the washer,
spacer and primary driven gear inner circum-
ference.
2. Install:
lWasher [thickness 4 mm (0.16 in)] 1
lClutch boss 2
5PA40840
5PA40850
3. Install:
lConical washer 1
NOTE:
Install the conical washer to the main axle 2
as shown in the illustration.
5PA40860
CLUTCH AND PRIMARY DRIVEN GEAR

4 - 31
ENG
4. Install:
lNut (clutch boss) 1
NOTE:
Use the clutch holding tool 2 to hold the clutch
boss.
ÈFor USA and CDN
ÉExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-040865PA40870
T R..70 Nm (7.0 m · kg, 50 ft · lb)
È€É
5PA40880
5. Install:
lFriction plate 1 1
lClutch plate 2
lFriction plate 2 3
NOTE:
lInstall the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
lUse the friction plates 1 for the first and final
while paying attention to the difference in
surface pattern.
lApply the transmission oil on the friction
plates and clutch plates.
5PA40890
5PA40900
6. Install:
lPush rod 2 1
lBall 2
lPush rod 1 3
NOTE:
Apply the transmission oil on the push rod 1, 2
and ball.
5PA40910
CLUTCH AND PRIMARY DRIVEN GEAR

4 - 33
ENGKICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
PRIMARY DRIVE GEAR
5PA40960
Extent of removal:
1 Primary drive gear removal
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVE GEAR
REMOVAL
Drain the transmission oil. Refer to “TRANSMISSION OIL
REPLACEMENT” section in the CHAP-
TER 3.
Brake pedal
Radiator hose 2 Disconnect at water pump side.
1 Kickstarter crank 1
2 Right crankcase cover 1
3 Nut (primary drive gear) 1 Only loosening.
Refer to “REMOVAL POINTS”.
4 Primary driven gear 1 Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
5 Primary drive gear 1
1

4 - 37
ENG
2. Install:
lStopper lever assembly 1
To shift shaft 2.
NOTE:
Apply the transmission oil on the stopper lever
assembly.
5PA41070
Shift shaft
1. Install:
lShift shaft 1
NOTE:
lApply transmission oil on the shift shaft.
lWhen installing the shift shaft, align the stop-
per lever roller with the slot on segment.
lWhen installing the shift shaft, make sure
that the torsion spring 2 is in the position as
shown.
5PA41080
5PA41090
2. Check:
lShift lever 1 position
Gaps a and b are not equal except in
neutral ® Replace the shift shaft.
5PA41100
Kick shaft assembly
1. Install:
lKick gear 1
lWasher 2
lTorsion spring 3
To kick shaft 4.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole c in the other side of the
stopper b of the kick shaft.
5PA41110
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR

4 - 38
ENG
2. Install:
lSpring guide 1
NOTE:
Slide the spring guide into the kick shaft, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
5PA41120
3. Install:
lKick shaft assembly 1
NOTE:
lApply the transmission oil on the kick shaft.
lApply the lithium soap base grease on the
kick shaft stopper.
lSlide 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.5PA41130
4. Hook:
lTorsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
5PA41140
Kick idle gear
1. Install:
lWasher 1
lKick idle gear 2
lCirclip 3
NOTE:
lApply the transmission oil on the kick idle
gear inner circumference.
lInstall the kick idle gear with its groove a
facing the engine.
5PA41150
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR