2004 YAMAHA YZ85 brake

5 - 26
CHAS
4. Install:
[Front]

Reservoir float

Diaphragm

Brake master cylinder cap 1

Screw (brake master cylinder cap) 2
[Rear]

Diaphragm

Reservoir tank cap 1

Bolt (reservoir tank) 2
CAUTION:
After installation, while pulling the brake
lever in or pushing down on the brake
pedal, check whether there is any brake
fluid leaking where the union bolts are
installed respectively at the brake master
cylinder and brake caliper.
ÈFront
ÉRear
È
5PA50800
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)É
5PA50810
FRONT BRAKE AND REAR BRAKE

5 - 27
CHASFRONT FORK
EC550000
FRONT FORK
5PA50820
Extent of removal:
1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front brake caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Number plate
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Brake hose holder 1
3 Pinch bolt (upper bracket) 1 Only loosening.
4 Cap bolt 1 Loosen when disassembling the front fork.
5 Pinch bolt (lower bracket) 2 Only loosening.
6 Front fork 1
1

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 - 40
CHAS
6. Install:

Brake hose holder 1

Bolt (brake hose holder) 2
NOTE:

Align the brake hose holder with the projec-
tion a on the front fork and clamp the brake
hose.

Pass the brake hose behind the rib b on the
front fork.
5PA51270
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Adjust:

Rebound damping force
NOTE:
Turn in the damping adjuster 1 finger-tight
and then turn out to the originally set position.
5PA51280
FRONT FORK

5 - 41
CHAS
EC5B0000
HANDLEBAR
5PA51290
Extent of removal:
1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Number plate Remove the clamp portion only.
1 Clutch cable 1 Disconnect at the lever side.
2 Clutch lever holder 1
3 Engine stop switch 1
4 Brake master cylinder 1 Refer to “REMOVAL POINTS”.
5 Throttle cable cap 1
6 Grip cap (lower) 1
7 Grip cap (upper) 1
8 Throttle cable 1 Disconnect at the throttle side.
9 Right grip 1 Refer to “REMOVAL POINTS”.
10 Tube guide 1
11 Collar 1
12 Left grip 1 Refer to “REMOVAL POINTS”.
13 Handlebar upper holder 2
14 Handlebar 1
1
HANDLEBAR

5 - 42
CHAS
REMOVAL POINTS
Brake master cylinder
1. Remove:

Brake master cylinder bracket 1

Brake master cylinder 2
CAUTION:

Do not let the brake master cylinder hang
on the brake hose.

Keep the brake master cylinder cap side
horizontal to prevent air from coming in.
5PA51300
EC5B3200
Grip
1. Remove:

Grip 1
NOTE:
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.
5PA51310
EC5B4000
INSPECTION
EC5B4100
Handlebar
1. Inspect:

Handlebar 1
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
5PA51320
HANDLEBAR

5 - 44
CHAS
4. Install:

Collar 1

Tube guide 2

Grip cap (upper) 3

Throttle cable 4
NOTE:
Apply the lithium soap base grease on the
throttle cable end and tube guide cable wind-
ing portion.5PA51380
5. Install:

Throttle cable cap 1

Screw (throttle cable cap) 2

Grip cap (lower) 3

Screw (grip cap) 4

Cover (grip cap) 5
WARNING
After tightening the screws, check that the
throttle grip 6 moves smoothly. If it does
not, retighten the screws (grip cap) for
adjustment.
5PA51390
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
5PA51400
6. Install:

Brake master cylinder 1

Brake master cylinder bracket 2

Bolt (brake master cylinder bracket) 3
NOTE:

Install the bracket so that the arrow mark a
face upward.

First tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
5PA51410
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
HANDLEBAR

5 - 51
CHASSWINGARM
EC570000
SWINGARM
5PAR0019
Extent of removal:
1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM REMOVAL
WARNING
Support the machine securely so there is no
danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Real wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Brake hose holder
Rear brake caliper
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
1 Drive chain support 1
2 Bolt (connecting rod) 1 Hold the swingarm.
3 Bolt (rear shock absorber-relay
arm)1
4 Pivot shaft 1
5 Swingarm 1
1