2003 YAMAHA YZ85 clock

5 - 18
CHAS
2. Install:

Pin boot 1
On brake caliper 2.
NOTE:
Apply the lithium soap base grease on the pin
boot inner surface.
5PA50500
3. Install:

Brake caliper bracket 1

Bolt (brake caliper bracket) 2

Brake pad 3
5PA50510
T R..30 Nm (3.0 m · kg, 22 ft · lb)
4. Install:

Brake caliper 1
NOTE:

Apply the lithium soap base grease on the
guide pin 2.

Install the brake caliper into the guide pin
and turn it clockwise.
5PA50520
5. Install:

Brake caliper support bolt 1
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
Rear brake caliper
1. Install:

Pad support 1

Brake pad 2

Pad pin 3
NOTE:

Install the brake pad fitted with brake pad
shim 4 on the brake caliper piston side.

Temporarily tighten the pad pins at this point.
5PA50530
T R..23 Nm (2.3 m · kg, 17 ft · lb)
5PA50540
FRONT BRAKE AND REAR BRAKE

6 - 4
–+ELECIGNITION SYSTEM
EC626002
IGNITION COIL INSPECTION
1. Inspect:

Primary coil resistance
Out of specification → Replace.
2. Inspect:

Secondary coil resistance
Out of specification → Replace.
NOTE:

Remove the spark plug cap by turning it
counterclockwise and inspect.

Install the spark plug cap by turning it clock-
wise until it is tight.
SPARK PLUG CAP INSPECTION
1. Inspect:

Spark plug cap
Loose connection → Tighten.
Deteriorated/Damaged → Replace.

Spark plug cap resistance
Out of specification → Replace. Tester (+) lead
→ Orange lead
1
Tester (–) lead
→ Black lead
2
Primary coil
resistanceTester selector
position
0.18 ~ 0.28
Ω at
20 °C (68 °F)Ω
× 1
Tester (+) lead
→ Spark plug lead
1
Tester (–) lead
→ Orange lead
2
Secondary coil
resistanceTester selector
position
6.3 ~ 9.5 k
Ω at
20 °C (68 °F)k
Ω
× 1
Tester (+) lead
→
Spark plug lead terminal
1
Tester (–) lead
→ Spark plug terminal
2
Spark plug cap
resistanceTester selector
position
4 ~ 6 k
Ω at
20 °C (68 °F)k
Ω
× 1
5PA60060
5PA60070
5PA60070
5PA60070
2
1

7 - 18
TUNSETTING
Suspension setting

Front fork
NOTE:

If any of the following symptoms is experienced with the standard position as the base, make
resetting by reference to the adjustment procedure given in the same chart.

Before any change, set the rear shock absorber sunken length to the standard figure 75 ~ 85 mm
(3.0 ~ 3.3 in).
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff over entire range
{{{Compression damping
Oil level (oil amount)
SpringTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with soft spring.
Unsmooth movement
over entire range{{{{Outer tube
Inner tube
Under bracket tightening
torqueCheck for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Retighten to specified torque.
Poor initial
movement{Rebound damping
Oil sealTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Apply grease in oil seal wall.
Soft over entire range,
bottoming out{{Compression damping
Oil level (oil amount)
SpringTurn adjuster clockwise (about 2 clicks) to increase
damping.
Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with stiff spring.
Stiff toward stroke end{Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke end,
bottoming out{Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
Stiff initial movement{{{{Compression dampingTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low front, tending to
lower front posture{{Compression damping
Rebound damping
Balance with rear end
Oil level (oil amount)Turn adjuster clockwise (about 2 clicks) to increase
damping.
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 80 ~ 85 mm (3.1 ~ 3.3 in) when
one passenger is astride seat (lower rear posture).
Increase oil level by about 5 mm (0.2 in).
“Obtrusive” front, tend-
ing to upper front pos-
ture{{Compression damping
Balance with rear end
Spring
Oil level (oil amount)Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in) when
one passenger is astride seat (upper rear posture).
Replace with soft spring.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).

7 - 19
TUNSETTING

Rear shock absorber
NOTE:

If any of the following symptoms is experienced with the standard position as the base, make
resetting by reference to the adjustment procedure given in the same chart.

Adjust the damping in 2-click increments or decrements.
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff, tending to sink
{{Rebound damping
Spring set lengthTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger is astride seat.
Spongy and unstable{{Rebound damping
SpringTurn adjuster clockwise (about 2 clicks) to increase
damping.
Replace with stiff spring.
Heavy and dragging{{Rebound damping
SpringTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Replace with soft spring.
Poor road gripping{Rebound damping
Compression damping
Spring set length
SpringTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Turn adjuster clockwise (about 2 clicks) to increase
damping.
Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger is astride seat.
Replace with soft spring.
Bottoming out{{Compression damping
Spring set length
SpringTurn adjuster clockwise (about 2 clicks) to increase
damping.
Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger in astride seat.
Replace with stiff spring.
Bouncing{{Rebound damping
SpringTurn adjuster clockwise (about 2 clicks) to increase
damping.
Replace with soft spring.
Stiff travel{{Compression damping
Spring set length
SpringTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 80 ~ 85 mm (3.1 ~ 3.3 in)
when one passenger is astride seat.
Replace with soft spring.