2002 YAMAHA YZ85 warning

5 - 16
CHAS
3. Inspect: (only front brake caliper)
lBrake caliper bracket 1
Cranks/damage ® Replace the brake cali-
per assembly.
lGuide pin 2
Rust/damage ® Replace the brake caliper
assembly.
lSleeve boot 3
lPin boot 4
Wear/damage ® Replace.5PA50420
4. Inspect: (only front brake caliper)
lBrake caliper support bolt 1
Scorches/rust/damage ® Replace.
5PA50430
EC534301
Brake hose
1. Inspect:
lBrake hose 1
Crack/damage ® Replace.
5PA50440
EC5A5000
ASSEMBLY AND INSTALLATION
WARNING
lAll internal parts should be cleaned in
new brake fluid only.
lInternal parts should be lubricated with
brake fluid when installed.
lReplace the piston seals and dust seals
whenever a caliper is disassembled.
Brake caliper piston
1. Clean:
lBrake caliper
lPiston seal
lDust seal
lBrake caliper piston
Clean them with brake fluid.
FRONT BRAKE AND REAR BRAKE

5 - 17
CHAS
2. Install:
lPiston seal 1
lDust seal 2
WARNING
Always use new piston seals and dust
seals.
NOTE:
Fit the piston seals and dust seals onto the slot
on brake caliper correctly.
ÈFront
ÉRear
È
5PA50450
É
5PA50460
3. Install:
lBrake caliper piston 1
NOTE:
Apply the brake fluid on the brake caliper pis-
ton wall.
CAUTION:
lFor the front brake caliper, install the pis-
ton with its shallow depressed side
a
facing the caliper. For the rear brake cali-
per, install the piston with its depressed
side
b facing the brake caliper.
lNever force to insert.
ÈFront
ÉRear
È
5PA50470
É
5PA50480
Front brake caliper
1. Install:
lSleeve boot 1
On brake caliper bracket 2.
5PA50490
FRONT BRAKE AND REAR BRAKE

5 - 19
CHAS
2. Install:
lBrake caliper 1
lBolt (brake caliper front side) 2
lBolt (brake caliper rear side) 3
lPlate
lProtector 4
lBolt (protector) 5
3. Tighten
lPad pin 6
Brake master cylinder kit
1. Clean:
lBrake master cylinder
lBrake master cylinder kit
Clean them with brake fluid.
5PA50550
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..18 Nm (1.8 m · kg, 13 ft · lb)
2. Install:
lBrake master cylinder cup (primary) 1
lBrake master cylinder cup (secondary) 2
To brake master cylinder piston 3.
NOTE:
Apply the brake fluid on the brake master cylin-
der cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
ÈFront
ÉRear
ÈÉ
5PA50560
ÈÉ
5PA50570
3. Install:
lSpring 1
To brake master cylinder piston 2.
NOTE:
Install the spring at the smaller dia. side.
ÈFront
ÉRear
ÈÉ
5PA50580
FRONT BRAKE AND REAR BRAKE

5 - 22
CHAS
Front brake hose
1. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the brake master cylin-
der.
5PA50660
T R..30 Nm (3.0 m · kg, 22 ft · lb)
5PA50670
2. Install:
lProtector 1
lBolt (protector) 2
NOTE:
Fit the brake hose into the guides a of the pro-
tector.
5PA50680
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
lBrake hose holder 1
lBolt (brake hose holder) 2
NOTE:
lAlign the brake hose holder with the projec-
tion a on the front fork and clamp the brake
hose.
lPass the brake hose behind the rib b on the
front fork.
5PA50690
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 23
CHAS
4. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a lightly touches the projection b on
the brake caliper.
5PA50700
5PA50710
T R..26 Nm (2.6 m · kg, 19 ft · lb)
Rear brake hose
1. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the brake master cylin-
der.
5PA50720
5PA50730
T R..26 Nm (2.6 m · kg, 19 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 24
CHAS
2. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a lightly touches the projection b on
the brake caliper.
5PA50740
5PA50750
T R..26 Nm (2.6 m · kg, 19 ft · lb)
3. Install:
lBrake hose holder 1
lScrew (brake hose holder) 2
5PA50760
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
FRONT BRAKE AND REAR BRAKE

5 - 25
CHAS
Brake fluid
1. Fill:
lBrake fluid
Until the fluid level reaches “LOWER” level
line a.
WARNING
lUse only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
lRefill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor perfor-
mance.
lBe careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
ÈFront
ÉRear
2. Air bleed:
lBrake system
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section in the CHAPTER 3.
Recommended brake fluid:
DOT #4
È
5PA50770
É
5PA50780
3. Inspect:
lBrake fluid level
Fluid at lower level ® Fill up.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section in the CHAPTER 3.
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