2004 YAMAHA YZ85 height adjustment

3 - 18
INSP
ADJREAR BRAKE ADJUSTMENT/
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
EC364002
REAR BRAKE ADJUSTMENT
1. Check:

Brake pedal height a
Out of specification → Adjust.
Brake pedal height
a:
4 ~ 10 mm (0.16 ~ 0.39 in)
5PA30330
2. Adjust:

Brake pedal height
Pedal height adjustment steps:

Loosen the locknut 1.

Turn the adjusting nut 2 until the pedal
height a is within specified height.

Tighten the locknut.
WARNING

Adjust the pedal height between the
maximum
È and the minimum
É as
shown. (In this adjustment, the bolt
3
end
b should protrude out of the lower
adjusting nut
4 but not be less than
2 mm (0.08 in)
c away from the brake
pedal
5).

After the pedal height adjustment, make
sure that the rear brake does not drag.
5PA30340
ÈÉ
5PA30350
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT
1. Remove:

Rubber cap
2. Inspect:

Brake pad thickness a
Out of limit → Replace as a set.
Brake pad thickness:
4.0 mm (0.16 in)
: 0.8 mm (0.03 in)5PA30360

4 - 10
ENGCARBURETOR AND REED VALVE
Float height
1. Measure:

Float height a
Out of specification → Adjust.
Float height:
18 ~ 20 mm (0.71 ~ 0.79 in)
Measurement and adjustment steps:

Hold the carburetor in an upside down
position.

Measure the distance between the mating
surface of the float chamber and top of the
float using a vernier calipers.
NOTE:
The float arm should be resting on the nee-
dle valve, but not compressing the needle
valve.

If the float height is not within specification,
inspect the valve seat and needle valve.

If either is worn, replace them both.

If both are fine, adjust the float height by
bending the float tab b on the float.

Recheck the float height.
5PA40180
5PA40190
EC464600
Float
1. Inspect:

Float 1
Damage → Replace.
5PA40200
EC464701
Reed valve
1. Measure:

Reed valve bending a
Out of limit → Replace.
Reed valve bending limit:
0.2 mm (0.008 in)
5PA40210

5 - 21
CHAS
2. Install:

Brake lever 1

Bolt (brake lever) 2

Nut (brake lever) 3
NOTE:
Apply the lithium soap base grease on the
brake lever sliding surface, bolt and contacting
surface of the brake master cylinder piston.
Rear brake master cylinder
1. Install:

Reservoir hose 1

Reservoir tank 2
5PA50620
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
5PA50630
2. Install:

Brake master cylinder 1

Bolt (brake master cylinder) 2
5PA50640
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:

Brake pedal 1

Spring 2

O-ring 3

Washer 4

Cotter pin 5
NOTE:
Apply the lithium soap base grease on the
brake pedal shaft and O-rings.5PA50650
4. Install:

Pin 1

Washer 2

Cotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTER 3.
5PA50655
FRONT BRAKE AND REAR BRAKE