2002 YAMAHA YZ85 transmission

4 - 59
ENG
EC4H0000
TRANSMISSION, SHIFT CAM AND SHIFT FORK
5PA41790
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
TRANSMISSION, SHIFT CAM
AND SHIFT FORK REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Separate the crankcase. Refer to “CRANKCASE AND CRANK-
SHAFT” section.
1 Guide bar (long) 1
2 Guide bar (short) 1
3Shift cam 1
4 Shift fork 3 1
5 Shift fork 1 1
6 Shift fork 2 1
7 Main axle 1
Refer to “REMOVAL POINTS”.
8 Drive axle 1
9 Collar 1
1
2
TRANSMISSION, SHIFT CAM AND SHIFT FORK

4 - 60
ENG
EC4H3000
REMOVAL POINTS
Transmission
1. Remove:
lMain axle 1
lDrive axle 2
NOTE:
lRemove assembly carefully. Note the posi-
tion of each part. Pay particular attention to
the location and direction of shift forks.
lRemove the main axle and drive axle by tap-
ping lightly on the transmission drive axle
with a soft hammer.
5PA41800
EC4H4000
INSPECTION
EC4H4200
Gears
1. Inspect:
lMatching dog a
lGear teeth b
lShift fork groove c
Wear/damage ® Replace.
5PA41810
2. Check:
lGears movement
Unsmooth movement ® Disassemble, and
then repair or replace.
5PA41820
EC4H4600
Bearing
1. Inspect:
lBearing 1
Rotate inner race with a finger.
Rough spot/seizure ® Replace.
5PA41830
TRANSMISSION, SHIFT CAM AND SHIFT FORK

4 - 61
ENG
Shift fork, shift cam and segment
1. Inspect:
lShift fork 1
Wear/damage/scratches ® Replace.
lStraight pin 2
Wear/damage ® Replace.
5PA41840
2. Inspect:
lShift cam 1
lGuide bar 2
Bend/wear/damage ® Replace.
5PA41850
3. Check:
lShift 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 adja-
cent to the shift fork.5PA41860
EC4H5000
ASSEMBLY AND INSTALLATION
Transmission
1. Install:
l5th pinion gear (23T) 1
l3rd/4th pinion gear (17T/17T) 2
l6th pinion gear (25T) 3
l2nd pinion gear (17T) 4
To main axle 5.
NOTE:
lApply the molybdenum disulfide oil on the
5th and 6th pinion gears inner circumference
and on the end surface.
lApply the transmission oil on the 3rd/4th and
2nd pinion gears inner circumference.
5PA41870
TRANSMISSION, SHIFT CAM AND SHIFT FORK

4 - 62
ENG
2. Install:
l2nd wheel gear (32T) 1
l6th wheel gear (25T) 2
l3rd wheel gear (26T) 3
l4th wheel gear (22T) 4
l5th wheel gear (26T) 5
l1st wheel gear (27T) 6
To drive axle 7.
NOTE:
lApply the molybdenum disulfide oil on the
1st, 2nd, 3rd and 4th wheel gears inner cir-
cumference and on the end surface.
lApply the transmission oil on the 5th and 6th
wheel gears inner circumference.
5PA41880
3. Install:
lWasher 1
lCirclip 2
NOTE:
lBe sure the circlip sharp-edged corner a is
positioned opposite side to the washer and
gear b.
lBe sure the circlip end c is positioned at
axle spline groove d.
5PA41900
5PA41890
4. Install:
lCollar 1
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lWhen installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
5PA41910
TRANSMISSION, SHIFT CAM AND SHIFT FORK

4 - 63
ENG
5. Install:
lMain axle 1
lDrive axle 2
To left crankcase.
5PA41920
Shift cam and shift fork
1. Install:
lShift fork 1 (L) 1
lShift fork 2 2
lShift fork 3 (R) 3
lStraight pin 4
NOTE:
lMesh the shift fork #1 (L) with the 6th wheel
gear 5 and #3 (R) with the 5th wheel gear 7
on the drive axle.
lMesh the shift fork #2 with the 3rd/4th pinion
gear 6 on the main axle.
5PA41930
5PA41940
2. Install:
lShift cam 1
NOTE:
Apply the transmission oil on the shift cam.
5PA41950
TRANSMISSION, SHIFT CAM AND SHIFT FORK

4 - 64
ENG
3. Install:
lGuide bar (long) 1
lGuide bar (short) 2
NOTE:
lApply the transmission oil on the guide bars.
lBe sure the long bar is inserted into the shift
forks #1 and #3 and the short one into #2.
5PA41960
4. Check:
lShifter operation
lTransmission operation
Unsmooth operation ® Repair.
5PA41970
TRANSMISSION, SHIFT CAM AND SHIFT FORK

5 - 2
CHAS
ROUE ARRIERE
Organisation de la dépose:1 Dépose de la roue arrière2 Dépose du roulement de roue
3 Dépose du disque de frein
Organisation de la dépose Ordre Nom de la pièce Qté Remarques
Préparation à la déposeDEPOSE DE LA ROUE
ARRIERE
Caler la moto en plaçant un support
adéquat sous le moteur.
AVERTISSEMENT
Bien caler la moto afin qu’elle ne risque pas de bascu-ler.
1 Ecrou (axe de roue arrière) 1
2 Axe de roue arrière 1
3 Tendeur de chaîne de transmission 2
4 Roue arrière 1 Se reporter à “POINTS DE DEPOSE”.
5Collerette 2
6 Couronne arrière 1
7 Bague d’étanchéité 2
8Circlip 1
9 Roulement 2 Se reporter à “POINTS DE DEPOSE”.
10Disque de frein
1
2
31
3
ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
HINTERRAD
Demontage-Arbeiten:
1 Hinterrad demontieren
2 Radlager ausbauen
3 Bremsscheibe ausbauen
Demontage-Arbeiten
Reihen-
folgeBezeichnung Wahl Bemerkungen
Vorbereitung für den
AusbauHINTERRAD DEMONTIEREN
Das Motorrad auf einem geeigne-
ten Ständer unter den Motor auf-
bocken.
WARNUNG
Das Motorrad gegen Umfallen sichern.
1 Mutter (Hinterachse) 1
2 Hinterradachse 1
3 Kettenspanner 2
4 Hinterrad 1 Siehe unter “DEMONTAGE-ARBEITEN”.
5 Hülse 2
6 Kettenrad 1
7Dichtring 2
8 Sicherungsring 1
9 Lager 2 Siehe unter “DEMONTAGE-ARBEITEN”.
10Bremsscheibe
1
2
31
3

5 - 3
CHAS
POINTS DE DEPOSE
Roue arrière
1. Déposer:
lRoue 1
N.B.:
Pousser la roue vers l’avant et déposer la chaîne de
transmission 2.
Roulement de roue (si nécessaire)
1. Déposer:
lRoulement 1
N.B.:
Déposer le roulement à l’aide d’un arrache-roule-
ment courant 2.
CONTROLE
Roue
1. Mesurer:
lVoile de roue
Hors spécifications ® Réparer ou remplacer.
2. Contrôler:
lRoulement
Faire tourner la bague intérieure avec le doigt.
Rugosité/grippage ® Remplacer.
N.B.:
Remplacer ensemble les roulements, la bague
d’étanchéité et la collerette de roue.
Limite de voile de roue:
Radial 1: 2,0 mm (0,08 in)
Latéral 2: 2,0 mm (0,08 in)
ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
DEMONTAGE-ARBEITEN
Hinterrad
1. Ausbauen:
lRad 1
HINWEIS:
Das Rad vorwärts drehen und die Antriebs-
kette abnehmen 2.
Radlager (falls erforderlich)
1. Ausbauen:
lLager 1
HINWEIS:
Lager mit einem Lageraustreiber anziehen 2.
PRÜFUNG
Rad
1. Messen:
lFelgenschlag
Unvorschriftsmäßig ® instand setzen oder
erneuern.
2. Kontrollieren:
lLager
Inneren Laufring mit dem Finger drehen.
Schwergängigkeit/Freßspuren ® erneuern
HINWEIS:
Lager, Dichtungen und Distanzhülse komplett
erneuern.
Max. Felgenschlag
Höhenschlag
1: 2,0 mm
Seitenschlag
2: 2,0 mm