2003 YAMAHA YZ85 torque

3 - 33
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
4. Adjust:

Steering ring nut
Steering ring nut adjustment steps:

Remove the number plate.

Remove the handlebar and handlebar
upper bracket.

Loosen the steering ring nut 1 using the
steering nut wrench 2.
Steering nut wrench:
YU-33975/90890-01403

Tighten the steering ring nut 3 using
steering nut wrench 4.
NOTE:

Install the steering ring nut with its larger
chamfered side a downward.

Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering nut wrench:
YU-33975/90890-01403
T R..
Steering ring nut (initial tighten-
ing):
38 Nm (3.8 m  kg, 27 ft  lb)

Loosen the steering ring nut one turn.

Retighten the steering ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Steering ring nut (final tighten-
ing):
4 Nm (0.4 m  kg, 2.9 ft  lb)
5PA30740
5PA30740

5 - 38
CHAS
25. Loosen:

Rebound damping adjuster 1
NOTE:

Loosen the rebound damping adjuster finger
tight.

Record the set position of the adjuster (the
amount of turning out the fully turned in posi-
tion).
5PA51170
26. Install:

Front fork cap bolt 1
Fully tighten the front fork cap bolt onto the
damper rod by hand.
NOTE:
Make sure that there is a clearance a of Zero
~ 1 mm (Zero ~ 0.04 in) between the front fork
cap bolt and locknut 2.
5PA51180
27. Tighten:

Front fork cap bolt (locknut) 1
NOTE:
Hold the locknut 2 and tighten the front fork
cap bolt with specified torque.
5PA51190
T R..15 Nm (1.5 m · kg, 11 ft · lb)
28. Install:

Front fork cap bolt 1
To outer tube.
NOTE:
Temporarily tighten the cap bolt.
5PA51200
29. Install:

Protector guide 1
5PA51210
FRONT FORK

5 - 39
CHAS
Front fork installation
1. Install:

Front fork 1
NOTE:

Temporarily tighten the pinch bolts (lower
bracket).

Do not tighten the pinch bolts (upper bracket)
yet.
5PA51220
2. Tighten:

Front fork cap bolt 1
3. Adjust:

Front fork top end a
Front fork top end (standard) a:
YZ85: 24 mm (0.94 in)
YZ85LW: Zero mm (Zero in)
T R..28 Nm (2.8 m · kg, 20 ft · lb)
5PA51230
4. Tighten:

Pinch bolt (upper bracket) 1

Pinch bolt (lower bracket) 2
CAUTION:
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.5PA51240
T R..22 Nm (2.2 m · kg, 16 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
5. Install:

Protector 1

Bolt (protector) 2
NOTE:
Fit the brake hose into the guides a of the pro-
tector.
5PA51260
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
FRONT FORK

5 - 50
CHAS
9. After tightening the nut, check the steering
for smooth movement. If not, adjust the
steering by loosening the steering ring nut
little by little.
10. Adjust:

Front fork top end a
Front fork top end (standard) a:
YZ85: 24 mm (0.94 in)
YZ85LW: Zero mm (Zero in)
5PA51600
11. Tighten:

Pinch bolt (upper bracket) 1

Pinch bolt (lower bracket) 2
CAUTION:
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.5PA51610
T R..22 Nm (2.2 m · kg, 16 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
STEERING

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).