2003 YAMAHA YZ85 oil level

SPEC
2 - 8
MAINTENANCE SPECIFICATIONS
CHASSIS
YZ85
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension:
Front fork travel 275 mm (10.8 in) ----
Fork spring free length 430 mm (16.9 in) 425 mm (16.7 in)
Spring rate, STD K = 2.84 N/mm
(0.29 kg/mm, 16.2 lb/in)----
Optional spring Yes ----
Oil capacity318 cm
3
(11.2 Imp oz, 10.8 US oz) ----
Oil level 90 mm (3.54 in) ----

(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 120 mm (3.15 ~ 4.72 in) ----
Oil grade Suspension oil “01”----
Inner tube outer diameter 36 mm (1.42 in) ----
Front fork top end 24 mm (0.94 in) ----
Rear suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Shock absorber travel 102 mm (4.02 in)←----
Spring free length 220 mm (8.66 in)←----
Fitting length 215 mm (8.46 in) 212 mm (8.35 in) ----
202.5 ~ 218.5 mm
(7.97 ~ 8.60 in)←----
Spring rate, STD K = 49.0 N/mm
(5.00 kg/mm,
280.0 lb/in)K = 45.0 N/mm
(4.60 kg/mm,
257.6 lb/in)----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)←----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)

SPEC
2 - 10
MAINTENANCE SPECIFICATIONS
YZ85LW
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension:
Front fork travel 275 mm (10.8 in) ----
Fork spring free length 430 mm (16.9 in) 425 mm (16.7 in)
Spring rate, STD K = 2.94 N/mm
(0.30 kg/mm, 16.8 lb/in)----
Optional spring Yes ----
Oil capacity318 cm
3
(11.2 Imp oz, 10.8 US oz) ----
Oil level 90 mm (3.54 in) ----

(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 120 mm (3.15 ~ 4.72 in) ----
Oil grade Suspension oil “01”----
Inner tube outer diameter 36 mm (1.42 in) ----
Front fork top end Zero mm (Zero in) ----
Rear suspension: AUS, NZ EUROPE
Shock absorber travel 102 mm (4.02 in)←----
Spring free length 220 mm (8.66 in)←----
Fitting length 207 mm (8.15 in) 212 mm (8.35 in) ----
202.5 ~ 218.5 mm
(7.97 ~ 8.60 in)←----
Spring rate, STD K = 51.0 N/mm
(5.20 kg/mm,
291.2 lb/in)K = 47.0 N/mm
(4.80 kg/mm,
268.8 lb/in)----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)←----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses








Every two years
OUTSIDE NUTS AND BOLTS
Retighten



AIR FILTER
Clean and lubricate
Replace




Use foam air-filter oil
FRAME
Clean and inspect



FUEL TANK, COCK
Clean and inspect



BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid























Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal









Suspension oil “01”
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube


Lithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten







(After
rain ride)


Molybdenum disulfide
grease
DRIVE CHAIN GUIDE, ROLLERS AND
SUPPORT
Inspect


SWINGARM
Inspect and retighten
Lube







Molybdenum disulfide
grease
RELAY ARM, CONNECTING ROD
Inspect and retighten
Lube







Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing







Lithium base grease ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks


3

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh mixture of oil and gasoline is filled in the fuel
tank. Check the fuel line for leakage.P.1-12
Transmission oilCheck that the oil level is correct. Check the crankcase for leak-
age.P.3-12 ~ 13
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10
Brakes Check the play of front brake and effect of front and rear brake. P.3-16 ~ 21
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-22 ~ 24
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-31 ~ 32
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-32 ~ 34
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-24 ~ 30
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Exhaust pipe and silencerCheck that the exhaust pipe is tightly mounted and has no
cracks.P.4-2
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-22
Lubrication Check for smooth operation. Lubricate if necessary. P.3-35
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-16
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 19

3 - 7
INSP
ADJ
RADIATOR CAP INSPECTION
CAUTION:

Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.

Do not use water containing impurities or
oil.
7. Install:

Radiator cap
Start the engine and warm it up for a sev-
eral minutes.
8. Check:

Coolant level
Coolant level low → Add coolant. Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING

When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.

When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.

When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:

Seal (radiator cap) 1

Valve and valve seat 2
Crack/damage → Replace.
Exist fur deposits 3 → Clean or replace.
5PA30050

3 - 12
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
5. Install:

Air filter guide 1
To air filter element 2.
5PA30170
6. Apply:

Lithium soap base grease
On the matching surface a on air filter ele-
ment.
5PA30180
7. Install:

Air filter element 1

Washer

Fitting bolt
NOTE:
Install the air filter element with its projection
a facing upward.
5PA30190
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
TRANSMISSION OIL REPLACEMENT
1. Start the engine and warm it up for several
minutes, and then turn off the engine and
wait for five minute.
2. Place the machine on a level place and
hold it on upright position by placing the
suitable stand under the engine.
3. Place a suitable container under the
engine.
4. Remove:

Oil drain bolt 1

Oil filler cap 2
Drain the transmission oil.
5PA30200

4 - 42
ENG
REMOVAL POINTS
Impeller shaft
1. Remove:

Impeller 1

Washer 2

Impeller 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:

It 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.

Replace the oil seal whenever it is remov-
aled.
1. Remove:

Bearing 1
2. Remove:

Oil seal 1
5PA41260
5PA41270
INSPECTION
EC444200
Impeller shaft
1. Inspect:

Impeller shaft 1
Bend/wear/damage → Replace.
Fur deposits → Clean.
5PA41280
WATER PUMP

5 - 25
CHAS
Brake fluid
1. Fill:

Brake fluid
Until the fluid level reaches “LOWER” level
line a.
WARNING

Use only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.

Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor perfor-
mance.

Be 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:

Brake system
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section in the CHAPTER 3.
Recommended brake fluid:
DOT #4
È
5PA50770
É
5PA50780
3. Inspect:

Brake 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