2002 YAMAHA YZ85 brake

5 - 18
CHAS
2. Install:
lPin boot 1
On brake caliper 2.
NOTE:
Apply the lithium soap base grease on the pin
boot inner surface.
5PA50500
3. Install:
lBrake caliper bracket 1
lBolt (brake caliper bracket) 2
lBrake pad 3
5PA50510
T R..30 Nm (3.0 m · kg, 22 ft · lb)
4. Install:
lBrake caliper 1
NOTE:
lApply the lithium soap base grease on the
guide pin 2.
lInstall the brake caliper into the guide pin
and turn it clockwise.
5PA50520
5. Install:
lBrake caliper support bolt 1
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
Rear brake caliper
1. Install:
lPad support 1
lBrake pad 2
lPad pin 3
NOTE:
lInstall the brake pad fitted with brake pad
shim 4 on the brake caliper piston side.
lTemporarily tighten the pad pins at this point.
5PA50530
T R..23 Nm (2.3 m · kg, 17 ft · lb)
5PA50540
FRONT BRAKE AND REAR BRAKE

5 - 19
CHAS
2. Install:
lBrake caliper 1
lBolt (brake caliper front side) 2
lBolt (brake caliper rear side) 3
lPlate
lProtector 4
lBolt (protector) 5
3. Tighten
lPad pin 6
Brake master cylinder kit
1. Clean:
lBrake master cylinder
lBrake master cylinder kit
Clean them with brake fluid.
5PA50550
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..18 Nm (1.8 m · kg, 13 ft · lb)
2. Install:
lBrake master cylinder cup (primary) 1
lBrake master cylinder cup (secondary) 2
To brake master cylinder piston 3.
NOTE:
Apply the brake fluid on the brake master cylin-
der cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
ÈFront
ÉRear
ÈÉ
5PA50560
ÈÉ
5PA50570
3. Install:
lSpring 1
To brake master cylinder piston 2.
NOTE:
Install the spring at the smaller dia. side.
ÈFront
ÉRear
ÈÉ
5PA50580
FRONT BRAKE AND REAR BRAKE

5 - 20
CHAS
4. Install:
[Front]
lBrake master cylinder kit 1
lWasher 2
lCirclip 3
lBrake master cylinder boot 4
To brake master cylinder 5.
[Rear]
lBrake master cylinder kit 1
lPush rod 2
lCirclip 3
lBrake master cylinder boot 4
To brake master cylinder 5.
NOTE:
lApply the brake fluid on the brake master cyl-
inder kit.
lApply the lithium soap base grease on the tip
of the push rod.
lWhen installing the circlip, use a long nose
circlip pliers.
ÈFront
ÉRear
È
5PA50590
É
5PA50600
Front brake master cylinder
1. Install:
lBrake master cylinder 1
lBrake master cylinder bracket 2
lBolt (brake master cylinder bracket) 3
NOTE:
lInstall the bracket so that the arrow mark
a
face upward.
lFirst tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
5PA50610
FRONT BRAKE AND REAR BRAKE

5 - 21
CHAS
2. Install:
lBrake lever 1
lBolt (brake lever) 2
lNut (brake lever) 3
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:
lReservoir hose 1
lReservoir tank 2
5PA50620
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
5PA50630
2. Install:
lBrake master cylinder 1
lBolt (brake master cylinder) 2
5PA50640
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
lBrake pedal 1
lSpring 2
lO-ring 3
lWasher 4
lCotter pin 5
NOTE:
Apply the lithium soap base grease on the
brake pedal shaft and O-rings.5PA50650
4. Install:
lPin 1
lWasher 2
lCotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTER 3.
5PA50655
FRONT BRAKE AND REAR BRAKE

5 - 22
CHAS
Front brake hose
1. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the brake master cylin-
der.
5PA50660
T R..30 Nm (3.0 m · kg, 22 ft · lb)
5PA50670
2. Install:
lProtector 1
lBolt (protector) 2
NOTE:
Fit the brake hose into the guides a of the pro-
tector.
5PA50680
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
lBrake hose holder 1
lBolt (brake hose holder) 2
NOTE:
lAlign the brake hose holder with the projec-
tion a on the front fork and clamp the brake
hose.
lPass the brake hose behind the rib b on the
front fork.
5PA50690
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 23
CHAS
4. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a lightly touches the projection b on
the brake caliper.
5PA50700
5PA50710
T R..26 Nm (2.6 m · kg, 19 ft · lb)
Rear brake hose
1. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the brake master cylin-
der.
5PA50720
5PA50730
T R..26 Nm (2.6 m · kg, 19 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 24
CHAS
2. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a lightly touches the projection b on
the brake caliper.
5PA50740
5PA50750
T R..26 Nm (2.6 m · kg, 19 ft · lb)
3. Install:
lBrake hose holder 1
lScrew (brake hose holder) 2
5PA50760
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 25
CHAS
Brake fluid
1. Fill:
lBrake fluid
Until the fluid level reaches “LOWER” level
line a.
WARNING
lUse only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
lRefill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor perfor-
mance.
lBe 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.
ÈFront
ÉRear
2. Air bleed:
lBrake system
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section in the CHAPTER 3.
Recommended brake fluid:
DOT #4
È
5PA50770
É
5PA50780
3. Inspect:
lBrake fluid level
Fluid at lower level ® Fill up.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section in the CHAPTER 3.
FRONT BRAKE AND REAR BRAKE