2002 YAMAHA YZ85 wheel

3 - 25
INSP
ADJFRONT FORK INTERNAL PRESSURE BLEEDING/FRONT
FORK REBOUND DAMPING FORCE ADJUSTMENT
2. Clean:
lDust seal a
lOil seal b
NOTE:
lClean the dust seal and oil seal after every
run.
lApply the lithium soap base grease on the
inner tube.
5PA30590
FRONT FORK INTERNAL PRESSURE
BLEEDING
NOTE:
If the front fork initial movement feels stiff dur-
ing a run, bleed the front fork internal pressure.
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Remove the air bleed screw 1 and release
the internal pressure from the front fork.
3. Install:
lAir bleed screw
5PA30590
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)
EC36H002
FRONT FORK REBOUND DAMPING FORCE
ADJUSTMENT
1. Adjust:
lRebound damping force
By turning the adjuster 1.
Stiffer
a
® Increase the rebound damp-
ing force. (Turn the adjuster
1 in.)
Softer
b
® Decrease the rebound damp-
ing force. (Turn the adjuster
1 out.)
Extent of adjustment
Maximum Minimum
Fully turned in
position20 clicks out (from
maximum position)
5PA30600

3 - 28
INSP
ADJREAR SHOCK ABSORBER SPRING PRELOAD
ADJUSTMENT
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT
1. Elevate the rear wheel by placing the suit-
able stand under the engine.
2. Remove:
lRear frame
3. Loosen:
lLocknut 1
4. Adjust:
lSpring preload
By turning the adjuster 2.
* For EUROPE
NOTE:
lBe sure to remove all dirt and mud from
around the locknut and adjuster before
adjustment.
lThe length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
CAUTION:
Never attempt to turn the adjuster beyond
the maximum or minimum setting.
5. Tighten:
lLocknut
6. Install:
lRear frame (upper)
lRear frame (lower) Stiffer
®Increase the spring preload.
(Turn the adjuster
2 in.)
Softer
®Decrease the spring preload.
(Turn the adjuster
2 out.)
Spring length (installed)
a:
YZ85: 215 mm (8.46 in)
*212 mm (8.35 in)
YZ85LW: 207 mm (8.15 in)
*212 mm (8.35 in)
Extent of adjustment:
202.5 ~ 218.5 mm
(7.97 ~ 8.60 in)
5PA30630
5PA30640
T R..26 Nm (2.6 m · kg, 19 ft · lb)
T R..16 Nm (1.6 m · kg, 11 ft · lb)

3 - 31
INSP
ADJTIRE PRESSURE CHECK/SPOKES INSPECTION AND
TIGHTENING/WHEEL INSPECTION
EC36Q000
TIRE PRESSURE CHECK
1. Measure:
lTire pressure
Out of specification ® Adjust.
NOTE:
lCheck the tire while it is cold.
lLoose bead stoppers allow the tire to slip off
its position on the rim when the tire pressure
is low.
lA tilted tire valve stem indicates that the tire
slips off its position on the rim.
lIf the tire valve stem is found tilted, the tire is
considered to be slipping off its position. Cor-
rect the tire position.
Standard tire pressure:
100 kPa (1.0 kg/cm2, 15 psi)
5PA30680
EC36S002
SPOKES INSPECTION AND TIGHTENING
1. Inspect:
lSpokes 1
Bend/damage ® Replace.
Loose spoke ® Retighten.
2. Retighten:
lSpokes
NOTE:
Be sure to retighten these spokes before and
after break-in. After a practice or a race check
spokes for looseness.
5PA30690
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)
EC36T000
WHEEL INSPECTION
1. Inspect:
lWheel runout
Elevate the wheel and turn it.
Abnormal runout ® Replace.
5PA30700

3 - 32
INSP
ADJ
2. Inspect:
lBearing free play
Exist play ® Replace.
5PA30710
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
lSteering stem
Grasp the bottom of the forks and gently
rock the fork assembly back and forth.
Free play ® Adjust steering head.
3. Check:
lSteering smooth action
Turn the handlebar lock to lock.
Unsmooth action ® Adjust steering ring
nut.
5PA30720
5PA30730
4. Adjust:
lSteering ring nut
Steering ring nut adjustment steps:
lRemove the number plate.
lRemove the handlebar and handlebar
upper bracket.
lLoosen the steering ring nut 1 using the
steering nut wrench 2.
Steering nut wrench:
YU-33975/90890-01403
5PA30740
STEERING HEAD INSPECTION AND ADJUSTMENT

4 - 46
ENG
EC4L3000
REMOVAL POINTS
Rotor
1. Remove:
lNut (rotor) 1
lWasher 2
Use the rotor holding tool 3.
Rotor holding tool:
YU-1235/90890-01235
5PA41390
2. Remove:
lRotor 1
Use the flywheel puller 2.
NOTE:
When installing the flywheel puller, turn it
counterclockwise.
Flywheel puller:
YM-1189/90890-01189
5PA41400
EC4L4000
INSPECTION
EC4L4101
CDI magneto
1. Inspect:
lRotor inner surface a
lStator outer surface b
Damage ® Inspect the crankshaft runout
and crankshaft bearing.
If necessary, replace CDI magneto and/or
stator.
5PA41410
EC4L4200
Woodruff key
1. Inspect:
lWoodruff key 1
Damage ® Replace.
5PA41420
CDI MAGNETO

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

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




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