2005 YAMAHA YZ85 radiator

4 - 5
ENGRADIATOR
3. Install:

Radiator hose 1 1

Radiator hose 2 2
Refer to “CABLE ROUTING DIAGRAM”
section in the CHAPTER 2.
4. Tighten:

Radiator hose clamp
5PA40070
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)
5. Install:

Radiator guard 1

Bolt (radiator guard) 2
NOTE:
Fit the hooks a on the inner side first into the
radiator.
5PA40080

4 - 15
ENGCYLINDER HEAD, CYLINDER AND PISTON
EC470000
CYLINDER HEAD, CYLINDER AND PISTON
EC478000
CYLINDER HEAD AND CYLINDER
5PA40390
Extent of removal:
1 Cylinder head removal
2 Cylinder removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD AND CYLIN-
DER REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Radiator hose 1 Disconnect at cylinder head side.
Radiator hose 2 Disconnect at radiator side.
1 Spark plug 1
2 Nut (cylinder head) 4 Loosen each nut 1/4 turn, and remove
them after all nuts are loosened.
3 Cylinder head 1
4 Nut (cylinder) 4
5 Cylinder 1
1
2

4 - 25
ENG
4. Install:

O-ring 1
NOTE:
Apply the lithium soap base grease on the O-
rings.
5PA40690
5. Install:

Cylinder head 1

Copper washer 2

Nut (cylinder head) 3
NOTE:
Tighten the nuts (cylinder head) in stage, using
a crisscross pattern.
5PA40700
T R..30 Nm (3.0 m · kg, 22 ft · lb)
6. Install:

Spark plug 1

Spark plug cap 2

Radiator hose 1 3

Radiator hose 2 4
5PA40710
T R..20 Nm (2.0 m · kg, 14 ft · lb)
CYLINDER HEAD, CYLINDER AND PISTON

4 - 33
ENGKICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
PRIMARY DRIVE GEAR
5PAR0008
Extent of removal:
1 Primary drive gear removal
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVE GEAR
REMOVAL
Drain the transmission oil. Refer to“TRANSMISSION OIL
REPLACEMENT” section in the CHAP-
TER 3.
Brake pedal
Radiator hose 2 Disconnect at water pump side.
1 Kickstarter crank 1
2 Right crankcase cover 1
3 Primary driven gear 1 Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
4 Nut (primary drive gear) 1 Refer to “REMOVAL POINTS”.
5Primary drive gear
1
1

4 - 49
ENG
EC4M0000
ENGINE REMOVAL
5PA41490
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
WARNING
Support the machine securely so there is no
danger of it falling over.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR AND REED
VALVE” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Clutch cable Disconnect at engine side.
Radiator hose 1 Disconnect at cylinder head side.
Radiator hose 2 Disconnect at water pump side.
Spark plug cap
Disconnect the CDI magneto
lead.
ENGINE REMOVAL