2002 YAMAHA YZ85 height adjustment

3 - 18
INSP
ADJREAR BRAKE ADJUSTMENT/
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
EC364002
REAR BRAKE ADJUSTMENT
1. Check:
lBrake pedal height a
Out of specification ® Adjust.
Brake pedal height
a:
7 mm (0.28 in)
5PA30330
2. Adjust:
lBrake pedal height
Pedal height adjustment steps:
lLoosen the locknut 1.
lTurn the adjusting nut 2 until the pedal
height a is within specified height.
lTighten the locknut.
WARNING
lAdjust the pedal height between the
maximum
È and the minimum
É as
shown. (In this adjustment the bolt
3
end
b should protrude out of the lower
adjusting nut
4 but not be less than
2 mm (0.08 in)
c away from the brake
pedal
5).
lAfter the pedal height adjustment, make
sure that the rear brake does not drag.
5PA30340
ÈÉ
5PA30350
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT
1. Remove:
lRubber cap
2. Inspect:
lBrake pad thickness a
Out of limit ® Replace as a set.
Brake pad thickness:
4.0 mm (0.16 in)
: 0.8 mm (0.03 in)5PA30360

4 - 10
ENGCARBURETOR AND REED VALVE
Float height
1. Measure:
lFloat height a
Out of specification ® Adjust.
Float height:
18 ~ 20 mm (0.71 ~ 0.79 in)
Measurement and adjustment steps:
lHold the carburetor in an upside down
position.
lMeasure the distance between the mating
surface of the float chamber and top of the
float using a vernier calipers.
NOTE:
The float arm should be resting on the nee-
dle valve, but not compressing the needle
valve.
lIf the float height is not within specification,
inspect the valve seat and needle valve.
lIf either is worn, replace them both.
lIf both are fine, adjust the float height by
bending the float tab b on the float.
lRecheck the float height.
5PA40180
5PA40190
EC464600
Float
1. Inspect:
lFloat 1
Damage ® Replace.
5PA40200
EC464701
Reed valve
1. Measure:
lReed valve bending a
Out of limit ® Replace.
Reed valve bending limit:
0.2 mm (0.008 in)
5PA40210

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