2002 YAMAHA YZ85 engine

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

5 - 1
CHAS
EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1 Front wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
1 Nut (front wheel axle) 1
2 Front wheel axle 1
3 Front wheel 1
4 Collar 2
5 Oil seal 2
6 Bearing 2 Refer to “REMOVAL POINTS”.
7 Brake disc 1
2
31
3
5PA50010




5

5 - 2
CHAS
EC598100
REAR WHEEL
5PA50020
Extent of removal:
1 Rear wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10Brake disc
1
2
31
3
FRONT WHEEL AND REAR WHEEL

5 - 9
CHASFRONT BRAKE AND REAR BRAKE
EC5A0000
FRONT BRAKE AND REAR BRAKE
EC5A8000
FRONT BRAKE
5PA50250
Extent of removal:
1 Brake hose removal
2 Brake caliper removal
3 Brake master cylinder removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Protector 1
2 Brake hose holder 1
3 Union bolt 2
4 Brake hose 1
5 Brake caliper support bolt 1
6 Brake caliper 1 Refer to “REMOVAL POINTS”.
7Brake lever 1
8 Brake master cylinder bracket 1
9 Brake master cylinder 1
2
3
132

5 - 10
CHAS
EC5A8100
REAR BRAKE
5PA50260
Extent of removal:
1 Brake caliper removal
2 Brake hose removal
3 Brake master cylinder removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Protector 1
2 Pad pin 2 Loosen when disassembling the caliper.
3 Brake caliper 1
4 Brake hose holder 2
5 Union bolt 2
6 Brake hose 1
7 Brake pedal 1
8 Reservoir tank 1
9 Reservoir hose 1
10 Brake master cylinder 1
3
1
321
FRONT BRAKE AND REAR BRAKE

5 - 27
CHASFRONT FORK
EC550000
FRONT FORK
5PA50820
Extent of removal:
1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front brake caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Number plate
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Brake hose holder 1
3 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
1

5 - 41
CHAS
EC5B0000
HANDLEBAR
5PA51290
Extent of removal:
1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Number plate Remove the clamp portion only.
1 Clutch cable 1 Disconnect at the lever side.
2 Clutch lever holder 1
3 Engine stop switch 1
4 Brake master cylinder 1 Refer to “REMOVAL POINTS”.
5 Throttle cable cap 1
6 Grip cap (lower) 1
7 Grip cap (upper) 1
8 Throttle cable 1 Disconnect at the throttle side.
9 Right grip 1 Refer to “REMOVAL POINTS”.
10 Tube guide 1
11 Collar 1
12 Left grip 1 Refer to “REMOVAL POINTS”.
13 Handlebar upper holder 2
14 Handlebar 1
1
HANDLEBAR

5 - 45
CHAS
7. Install:
lEngine stop switch 1
lClutch lever holder 2
lBolts (clutch lever holder) 3
lClamp 4
NOTE:
The engine stop switch and clutch lever holder
should be installed according to the dimen-
sions shown.
5PA51420
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
5PA51430
8. Install:
lClutch cable 1
NOTE:
Apply the lithium soap base grease on the
clutch cable end.
5PA51440
9. Adjust:
lClutch lever free play
Refer to “CLUTCH ADJUSTMENT” section
in the CHAPTER 3.
10. Clamp the clamp portion a of the number
plate to the handlebar.
11. Insert the end of the fuel tank breather
hose 1 into the hole of the steering stem.
5PA51450
HANDLEBAR