2002 YAMAHA YZ85 oil

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ENGKICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
PRIMARY DRIVE GEAR
5PA40960
Extent of removal:
1 Primary drive gear removal
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVE GEAR
REMOVAL
Drain the transmission oil. Refer to “TRANSMISSION OIL
REPLACEMENT” section in the CHAP-
TER 3.
Brake pedal
Radiator hose 2 Disconnect at water pump side.
1 Kickstarter crank 1
2 Right crankcase cover 1
3 Nut (primary drive gear) 1 Only loosening.
Refer to “REMOVAL POINTS”.
4 Primary driven gear 1 Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
5 Primary drive gear 1
1

4 - 37
ENG
2. Install:
lStopper lever assembly 1
To shift shaft 2.
NOTE:
Apply the transmission oil on the stopper lever
assembly.
5PA41070
Shift shaft
1. Install:
lShift shaft 1
NOTE:
lApply transmission oil on the shift shaft.
lWhen installing the shift shaft, align the stop-
per lever roller with the slot on segment.
lWhen installing the shift shaft, make sure
that the torsion spring 2 is in the position as
shown.
5PA41080
5PA41090
2. Check:
lShift lever 1 position
Gaps a and b are not equal except in
neutral ® Replace the shift shaft.
5PA41100
Kick shaft assembly
1. Install:
lKick gear 1
lWasher 2
lTorsion spring 3
To kick shaft 4.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole c in the other side of the
stopper b of the kick shaft.
5PA41110
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR

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ENG
2. Install:
lSpring guide 1
NOTE:
Slide the spring guide into the kick shaft, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
5PA41120
3. Install:
lKick shaft assembly 1
NOTE:
lApply the transmission oil on the kick shaft.
lApply the lithium soap base grease on the
kick shaft stopper.
lSlide the kick shaft assembly into the crank-
case, make sure the clip 2 and kick shaft
stopper a fit into their home positions b, c.5PA41130
4. Hook:
lTorsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
5PA41140
Kick idle gear
1. Install:
lWasher 1
lKick idle gear 2
lCirclip 3
NOTE:
lApply the transmission oil on the kick idle
gear inner circumference.
lInstall the kick idle gear with its groove a
facing the engine.
5PA41150
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR

4 - 40
ENG
6. Install:
lRight crankcase cover 1
NOTE:
Mesh the impeller shaft gear 2 with primary
drive gear 3.
5PA41200
7. Install:
lBolt (right crankcase cover) 1
lCopper washer (oil drain bolt) 2
lOil drain bolt 3
lCopper washer (coolant drain bolt)
4
lCoolant drain bolt 5
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
5PA41210
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
8. Install:
lKickstarter crank 1
lWasher 2
lBolt (kickstarter crank) 3
NOTE:
Install the kickstarter crank closest to but not con-
tacting the pillar tube 4 and exhaust pipe 5.
5PA41220
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
9. Install:
lShift pedal 1
lBolt (shift pedal) 2
NOTE:
Install the shift pedal with the bottom of the
pedal outer diameter a as close to the center
of the engine mounting bolt 3 as possible.
5PA41230
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR

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ENG
EC4G0000
WATER PUMP
5PA41240
Extent of removal:
1 Impeller shaft removal
2 Oil seal removal
Extent of removal Order Part name Q’ty Remarks
WATER PUMP DISASSEMBLY
Preparation for removal Right crankcase cover Refer to “KICK SHAFT, SHIFT SHAFT
AND PRIMARY DRIVE GEAR” section.
1 Water pump housing 1
2 Impeller 1
Refer to “REMOVAL POINTS”. 3 Washer 1
4 Impeller shaft 1
5 Bearing 1
Refer to “REMOVAL POINTS”.
6 Oil seal 2
1
2
WATER PUMP

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ENG
REMOVAL POINTS
Impeller shaft
1. Remove:
lImpeller 1
lWasher 2
lImpeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats a with spanners, etc. and remove the
impeller.
5PA41250
EC4G3210
Oil seal
NOTE:
lIt is not necessary to disassemble the water
pump, unless there is an abnormality such
as excessive change in coolant level, discol-
oration of coolant, or milky transmission oil.
lReplace the oil seal whenever it is remov-
aled.
1. Remove:
lBearing 1
2. Remove:
lOil seal 1
5PA41260
5PA41270
INSPECTION
EC444200
Impeller shaft
1. Inspect:
lImpeller shaft 1
Bend/wear/damage ® Replace.
Fur deposits ® Clean.
5PA41280
WATER PUMP

4 - 43
ENG
EC444300
Impeller shaft gear
1. Inspect:
lGear teeth a
Wear/damage ® Replace.
5PA41290
EC4H4600
Bearing
1. Inspect:
lBearing
Rotate inner race with a finger.
Rough spot/seizure ® Replace.
5PA41300
EC444400
Oil seal
1. Inspect:
lOil seal 1
Wear/damage ® Replace.
5PA41310
ASSEMBLY AND INSTALLATION
Oil seal
1. Install:
lOil seal 1
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lInstall the oil seal with its manufacture’s
marks or numbers facing the right crankcase
cover 2.
5PA41320
WATER PUMP

4 - 44
ENG
2. Install:
lBearing 1
NOTE:
Install the bearing by pressing its outer race
parallel.
5PA41330
Impeller shaft
1. Install:
lImpeller shaft 1
lWasher 2
lImpeller 3
NOTE:
lTake care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.
lWhen installing the impeller shaft, apply the
lithium soap base grease on the oil seal lip
and impeller shaft. And install the shaft while
turning it.
lHold the impeller shaft on its width across
the flats a with spanners, etc. and install the
impeller.
5PA41340
T R..14 Nm (1.4 m · kg, 10 ft · lb)
5PA41350
2. Install:
lGasket (water pump housing) 1
5PA41360
3. Install:
lWater pump housing 1
lBolt (water pump housing) 2
lCopper washer (coolant drain bolt)
3
lCoolant drain bolt 4
5PA41370
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
WATER PUMP