2004 YAMAHA YZ85 oil

4 - 64
ENG
3. Install:

Guide bar (long) 1

Guide bar (short) 2
NOTE:

Apply the transmission oil on the guide bars.

Be sure the long bar is inserted into the shift
forks #1 and #3 and the short one into #2.
5PA41960
4. Check:

Shifter operation

Transmission operation
Unsmooth operation → Repair.
5PA41970
TRANSMISSION, SHIFT CAM AND SHIFT FORK

5 - 1
CHAS
EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1 Front wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
1 Nut (front wheel axle) 1
2 Front wheel axle 1
3 Front wheel 1
4 Collar 2
5 Oil seal 2
6 Bearing 2 Refer to “REMOVAL POINTS”.
7 Brake disc 1
2
31
3
5PA50010

5 - 2
CHAS
EC598100
REAR WHEEL
5PAR0012
Extent of removal:
1 Rear wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR WHEEL 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.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10Brake disc
1
2
31
3
FRONT WHEEL AND REAR WHEEL

5 - 3
CHAS
EC593000
REMOVAL POINTS
EC523101
Rear wheel
1. Remove:

Wheel 1
NOTE:
Push the wheel forward and remove the drive
chain 2.
5PA50030
EC513201
Wheel bearing (if necessary)
1. Remove:

Bearing 1
NOTE:
Remove the bearing using a general bearing
puller 2.
5PA50040
EC594000
INSPECTION
EC514100
Wheel
1. Measure:

Wheel runout
Out of limit → Repair or replace.
2. Inspect:

Bearing
Rotate inner race with a finger.
Rough spot/seizure → Replace.
NOTE:
Replace the bearings, oil seal and wheel collar
as a set.
Wheel runout limit:
Radial 1: 2.0 mm (0.08 in)
Lateral 2: 2.0 mm (0.08 in)
5PA50050
5PA50060
FRONT WHEEL AND REAR WHEEL

5 - 3
CHAS
POINTS DE DEPOSE
Roue arrière
1. Déposer:

Roue 1
N.B.:
Pousser la roue vers l’avant et déposer la chaîne de
transmission 2.
Roulement de roue (si nécessaire)
1. Déposer:

Roulement 1
N.B.:
Déposer le roulement à l’aide d’un arrache-roule-
ment courant 2.
CONTROLE
Roue
1. Mesurer:

Voile de roue
Hors spécifications → Réparer ou remplacer.
2. Contrôler:

Roulement
Faire tourner la bague intérieure avec le doigt.
Rugosité/grippage → Remplacer.
N.B.:
Remplacer ensemble les roulements, la bague
d’étanchéité et la collerette de roue.
Limite de voile de roue:
Radial 1: 2,0 mm (0,08 in)
Latéral 2: 2,0 mm (0,08 in)
ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
DEMONTAGE-ARBEITEN
Hinterrad
1. Ausbauen:

Rad 1
HINWEIS:
Das Rad vorwärts drehen und die Antriebs-
kette abnehmen 2.
Radlager (falls erforderlich)
1. Ausbauen:

Lager 1
HINWEIS:
Lager mit einem Lageraustreiber anziehen 2.
PRÜFUNG
Rad
1. Messen:

Felgenschlag
Unvorschriftsmäßig → instand setzen oder
erneuern.
2. Kontrollieren:

Lager
Inneren Laufring mit dem Finger drehen.
Schwergängigkeit/Freßspuren → erneuern.
HINWEIS:
Lager, Dichtungen und Distanzhülse komplett
erneuern.
Max. Felgenschlag:
Höhenschlag
1: 2,0 mm (0,08 in)
Seitenschlag
2: 2,0 mm (0,08 in)

5 - 4
CHAS
Axe de roue
1. Mesurer:

Déformations de l’axe de roue
Hors spécifications → Remplacer.
Utiliser la jauge à cadran 1.
N.B.:
La valeur de flexion est égale à la moitié de la
valeur affichée sur la jauge à cadran.
AVERTISSEMENT
Ne pas tenter de redresser un axe déformé.
Limite de flexion d’axe de roue:
0,5 mm (0,020 in)
Disque de frein
1. Mesurer:

Déflexion du disque de frein
Utiliser la jauge à cadran 1.
Hors spécifications → Contrôler le voile de
roue.
Si le voile de roue est normal, remplacer le dis-
que de frein.
2. Mesurer:

Epaisseur du disque de frein a
Hors spécifications → Remplacer.
Limite de déflexion du disque de
frein:
0,15 mm (0,006 in)
Epaisseur du disque de frein:
3,0 mm (0,12 in)
: 2,5 mm (0,10 in)
ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
Radachse
1. Messen:

Radachsenbiegung
Unvorschriftsmäßig → erneuern.
Meßuhr verwenden 1.
HINWEIS:
Der Betrag der Biegung ist die Hälfte des an
der Meßuhr abgelesenen Wertes.
WARNUNG
Keinesfalls versuchen, eine verbogene
Achse zu richten.
Max. Radachsenbiegung:
0,5 mm (0,020 in)
Bremsscheibe
1. Messen:

Bremsscheibenschlag
Meßuhr verwenden 1.
Unvorschriftsmäßig → Felgenschlag über-
prüfen.
Falls im Sollbereich, Bremsscheibe erneu-
ern.
2. Messen:

Bremsscheibenstärke a
Unvorschriftsmäßig → erneuern.
Max. Bremsscheibenverzug:
0,15 mm (0,006 in)
Stärke des Bremsbelages:
3,0 mm (0,12 in)
: 2,5 mm (0,10 in)

5 - 5
CHAS
EC595000
ASSEMBLY AND INSTALLATION
Front wheel
1. Install:

Bearing (left) 1

Spacer 2

Bearing (right) 3

Oil seal 4
NOTE:

Apply the lithium soap base grease on the
bearing and oil seal lip when installing.

Use a socket that matches the outside diam-
eter of the race of the bearing.

Left side of bearing shall be installed first.

Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:

Brake disc 1

Bolt (brake disc) 2
5PA50090
5PA50100
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:

Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5PA50110
4. Install:

Wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
5PA50120
FRONT WHEEL AND REAR WHEEL

5 - 6
CHAS
5. Install:

Washer 1

Wheel axle 2
NOTE:
Apply the lithium soap base grease on the
wheel axle.
5PA50130
6. Install:

Washer 1

Nut (wheel axle) 2
5PA50140
T R..70 Nm (7.0 m · kg, 50 ft · lb)
Rear wheel
1. Install:

Bearing (left) 1

Circlip 2

Spacer 3

Bearing (right) 4

Oil seal 5
NOTE:

Apply the lithium soap base grease on the
bearing and oil seal lip when installing.

Install the bearing with seal facing outward.

Use a socket that matches the outside diam-
eter of the race of the bearing.

Left side of bearing shall be installed first.

Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
5PA50150
FRONT WHEEL AND REAR WHEEL