2004 YAMAHA YZ85 oil

2 - 16
SPEC
EC240000
CABLE ROUTING DIAGRAM
1Hose guide
2Brake hose
3Throttle cable
4Fuel tank breather hose
5Engine stop switch lead
6CDI magneto lead
7Clamp
8Carburetor breather hose
9Carburetor overflow hose
0Transmission oil breather hose
ARadiator breather hose
BClutch cable
CSpark plug leadDCable guide
EBrake hose holder
ÈPass the fuel tank breather hose between the
handlebar and tension bar, then insert its end
into the hole of the steering stem.
ÉFasten the ground lead together with the ignition
coil.
ÊClamp the brake hose with the brake hose
holder.
ËFit the brake hose into the guides of the protec-
tor.
CABLE ROUTING DIAGRAM

2 - 17
SPEC
1Sub-wire harness
2CDI unit
3Ignition coil
4Clutch cable
5Cable guide
6Transmission oil breather hose
7CDI unit band
8Clamp
9Brake hose
0Brake hose holder
AHose guide
BReservoir hose
CReservoir tank
DBrake master cylinderÈPass the transmission oil breather hose through
the hose guide.
ÉClamp the sub-wire harness at the tape on it
within the arrow mark.
ÊPass the sub-wire harness on the left of the CDI
unit.
ËPass the reservoir hose between the brake hose
and swingarm bracket.
ÌPass the reservoir hose through the hose guides.
ÍInstall the brake hose so that its pipe portion
directs as shown and lightly touches the projec-
tion on the brake master cylinder.
CABLE ROUTING DIAGRAM

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks
PISTON
Inspect and clean
Replace







Inspect crack
Inspect carbon deposits
and eliminate them
PISTON RING
Inspect
Replace





Check ring end gap
PISTON PIN, SMALL END BEARING
Inspect
Replace




CYLINDER HEAD
Inspect and clean
Retighten







Inspect carbon deposits
and eliminate them
Check gasket
CYLINDER
Inspect and clean
Replace




Inspect score marks
Inspect wear
CLUTCH
Inspect and adjust
Replace





Inspect housing, friction
plate, clutch plate and
spring
TRANSMISSION
Replace oil
Inspect
Replace bearing






Yamalube 4 (10W-30) or
SAE 10W-30 SE motor oil
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect

Inspect wear
ROTOR NUT
Retighten




KICK SHAFT
Inspect idle gear
Replace




EXHAUST PIPE, SILENCER
Inspect
Clean





CRANK
Inspect and clean



CARBURETOR
Inspect, adjust and clean



SPARK PLUG
Inspect and clean
Replace





DRIVE CHAIN
Lubricate, slack, alignment
Replace




Chain slack: 35 ~ 45 mm
(1.4 ~ 1.8 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 or
equivalent 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 - 3
INSP
ADJ
MAINTENANCE INTERVALS
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate












Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection
Inspect and Lubricate






Yamaha cable lube or
SAE 10W-30 motor oil ItemAfter
break-inEvery
raceEvery
third
raceEvery
fifth
raceAs re-
quiredRemarks

INSP
ADJ
PROGRAMME D’ENTRETIEN
TETE DE FOURCHE
Contrôler le jeu et resserrer
Nettoyer et lubrifier
Remplacer le roulement







Graisse à base de lithium
PNEUS, ROUES
Contrôler la pression de gonflage, le
voile de roue, l’usure des pneus et la ten-
sion des rayons
Resserrer le boulon de la roue dentée
Contrôler les roulements
Remplacer les roulements
Lubrifier












Graisse à base de lithium
ACCELERATEUR, CABLE DE COM-
MANDE
Contrôler le cheminement et le raccorde-
ment
Contrôler et lubrifier






Lubrifiant pour câbles
Yamaha ou huile moteur
SAE 10W-30 ElémentAprès
rodageA cha-
que
courseToutes
les trois
coursesToutes
les cinq
coursesSi
néces-
saireRemarques
3 - 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