2002 YAMAHA YZ85 brake pads

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses
ll
ll
l
Every two years
OUTSIDE NUTS AND BOLTS
Retighten
ll
AIR FILTER
Clean and lubricate
Replace
ll
lUse foam air-filter oil
FRAME
Clean and inspect
ll
FUEL TANK, COCK
Clean and inspect
ll
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid
l
l
l
l
ll
l
l
l
l
l
l
Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal
l
ll
l
l
Suspension oil “01”
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube
llLithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten
l
ll
ll(After
rain ride)
l
Molybdenum disulfide
grease
CHAIN GUARD AND ROLLERS
Inspect
l
SWINGARM
Inspect and retighten
Lube
l
ll
l
Molybdenum disulfide
grease
RELAY ARM, CONNECTING ROD
Inspect and retighten
Lube
l
ll
l
Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing
ll
l
l
Lithium base grease ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks


3

3 - 19
INSP
ADJ
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
3. Replace:
lBrake pad
4. Inspect:
lBrake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section.
5. Check:
lBrake lever operation
A softy or spongy feeling ® Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section. Brake pad replacement steps:
lRemove the brake caliper support bolt 1.
lTurn the brake caliper 2 counterclockwise
a.
lReplace the brake pads 3.
lConnect the transparent hose 4 to the
bleed screw 5 and place the suitable con-
tainer under its end.
lLoosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
lTighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
lInstall the brake caliper 6 and brake cali-
per support bolt 7.
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
T R..
Brake caliper support bolt:
30 Nm (3.0 m • kg, 22 ft • lb)
5PA30370
5PA30380
5PA30390
5PA30400

3 - 20
INSP
ADJ
REAR BRAKE PAD INSPECTION AND REPLACEMENT
REAR BRAKE PAD INSPECTION AND
REPLACEMENT
1. Inspect:
lBrake pad thickness a
Out of limit ® Replace as a set.
Brake pad thickness:
3.7 mm (0.15 in)
: 1.0 mm (0.04 in)
5PA30410
2. Replace:
lBrake pad
Brake pad replacement steps:
lLoosen the pad pins 1 and remove the
brake caliper 2.
NOTE:
Before removing the brake caliper from the
swingarm, loosen the pad pins.
lRemove the pad pins 3 and brake pads
4.
lConnect the transparent hose 5 to the
bleed screw 6 and place the suitable con-
tainer under its end.
lLoosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
lTighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
lInstall the brake pads 7 and pad pins 8.
NOTE:
Install the brake pad fitted with the brake
pad shim 9 on the brake caliper piston side.
5PA30420
5PA30430
5PA30440
5PA30450

5 - 5
CHAS
EC595000
ASSEMBLY AND INSTALLATION
Front wheel
1. Install:
lBearing (left) 1
lSpacer 2
lBearing (right) 3
lOil seal 4
NOTE:
lApply the lithium soap base grease on the
bearing and oil seal lip when installing.
lUse a socket that matches the outside diam-
eter of the race of the bearing.
lLeft side of bearing shall be installed first.
lInstall the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
lBrake disc 1
lBolt (brake disc) 2
5PA50090
5PA50100
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
lCollar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5PA50110
4. Install:
lWheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
5PA50120
FRONT WHEEL AND REAR WHEEL

5 - 7
CHAS
2. Install:
lBrake disc 1
lBolt (brake disc) 2
NOTE:
Tighten the bolts (brake disc) in stage, using a
crisscross pattern.
5PA50160
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
lRear wheel sprocket 1
lBolt (rear wheel sprocket) 2
lWasher (rear wheel sprocket) 3
lNut (rear wheel sprocket) 4
NOTE:
Tighten the nuts (rear wheel sprocket) in
stage, using a crisscross pattern.5PA50170
T R..42 Nm (4.2 m · kg, 30 ft · lb)
4. Install:
lCollar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5PA50180
5. Install:
lWheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
5PA50190
6. Install:
lDrive chain 1
NOTE:
Push the wheel 2 forward and install the drive
chain.
5PA50200
FRONT WHEEL AND REAR WHEEL