2006 YAMAHA YZ85 clock

3 - 5
INSP
ADJ
EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap
1, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:
Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
5PA30010
1. Place the machine on a level place, and
hold it in an upright position.
2. Remove:

Radiator cap
3. Check:

Coolant level
Coolant level a low → Add coolant.
1Radiator
5PA30020
ENGINE/COOLANT LEVEL INSPECTION

3 - 19
INSP
ADJ
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
3. Replace:

Brake pad
4. Inspect:

Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section.
5. Check:

Brake lever operation
A softy or spongy feeling → Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section. Brake pad replacement steps:

Remove the brake caliper support bolt 1.

Turn the brake caliper 2 counterclockwise
a.

Replace the brake pads 3.

Connect the transparent hose 4 to the
bleed screw 5 and place the suitable con-
tainer under its end.

Loosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.

Tighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m  kg, 4.3 ft  lb)

Install the brake caliper 6 and brake cali-
per support bolt 7.
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
T R..
Brake caliper support bolt:
23 Nm (2.3 m  kg, 17 ft  lb)
5PA30370
5PA30380
5PA30390
5PA30400

3 - 24
INSP
ADJDRIVE CHAIN SUPPORT INSPECTION/
FRONT FORK INSPECTION
3. Adjust:

Drive chain slack
DRIVE CHAIN SUPPORT INSPECTION
1. Inspect:

Drive chain support wear limit
Limit reaches indicator a → Replace.
Refer to “SWINGARM” section in the
CHAPTER 5. Drive chain slack adjustment steps:

Loosen the axle nut 1 and locknuts 2.

Adjust chain slack by turning the adjusters 3.
To tighten
→ Turn adjuster
3 clockwise.
To loosen
→ Turn adjuster
3 counter-
clockwise and push wheel forward.

Turn each adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks a on each side of chain
puller alignment.)
NOTE:
Turn the adjuster so that the chain is in line
with the sprocket, as viewed from the rear.
CAUTION:
Too small chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.

Tighten the axle nut while pushing down
the drive chain.
T R..
Axle nut:
90 Nm (9.0 m  kg, 65 ft  lb)

Tighten the locknuts.
T R..
Locknut:
16 Nm (1.6 m  kg, 11 ft  lb)
5PAR0004
5PAR0005
a a
EC36C000
FRONT FORK INSPECTION
1. Inspect:

Front fork smooth action
Operate the front brake and stroke the front
fork.
Unsmooth action/oil leakage → Repair or
replace.
5PA30570

3 - 37
INSP
ADJ
IGNITION TIMING CHECK
IGNITION TIMING CHECK
1. Remove:

Air scoop

Spark plug

Left crankcase cover
2. Attach:

Dial gauge 1

Dial gauge stand 2
Dial gauge and stand:
YU-3097/90890-01252
Stand:
YU-12565PA30870
3. Rotate the rotor 1 until the piston reaches
top dead center (TDC). When this hap-
pens, the needle on the dial gauge will stop
and reverse directions even though the
rotor is being turned in the same direction.
4. Set the dial gauge to zero at TDC.
5PA30880
5. From TDC, rotate the rotor clockwise until
the dial gauge indicates that the piston is at
a specified distance from TDC.
Ignition timing (B.T.D.C.):
0.9 mm (0.035 in)
6. Check:

Ignition timing
Punch mark a on rotor should be aligned
with punch mark b on stator.
Not aligned → Adjust.
5PA30890

4 - 4
ENGRADIATOR
EC456000
HANDLING NOTE
WARNING
Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury.
When the engine has cooled, open the radi-
ator cap by the following procedure:
Place a thick rag, like a towel, over the radi-
ator cap, slowly rotate the cap counter-
clockwise to the detent. This procedure
allows any residual pressure to escape.
When the hissing sound has stopped,
press down on the cap while turning coun-
terclockwise and remove it.
EC454000
INSPECTION
Radiator
1. Inspect:

Radiator core 1
Obstruction → Blow out with compressed
air through rear of the radiator.
Bent fin → Repair or replace.
5PA40040
EC455000
ASSEMBLY AND INSTALLATION
Radiator
1. Install:

Radiator breather hose 1
To radiator 2.
5PA40050
2. Install:

Radiator 1

Bolt (radiator) 2
5PA40060

4 - 38
ENG
2. Install:

Spring guide 1
NOTE:
Slide the spring guide into the kick shaft, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
5PA41120
3. Install:

Kick shaft assembly 1
NOTE:

Apply the transmission oil on the kick shaft.

Apply the lithium soap base grease on the
kick shaft stopper.

Slide the kick shaft assembly into the crank-
case, make sure the clip 2 and kick shaft
stopper a fit into their home positions b, c.5PA41130
4. Hook:

Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
5PA41140
Kick idle gear
1. Install:

Washer 1

Kick idle gear 2

Circlip 3
NOTE:

Apply the transmission oil on the kick idle
gear inner circumference.

Install the kick idle gear with its groove a
facing the engine.
5PA41150
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR

4 - 46
ENG
EC4L3000
REMOVAL POINTS
Rotor
1. Remove:

Nut (rotor) 1

Washer 2
Use the rotor holding tool 3.
Rotor holding tool:
YU-1235/90890-01235
5PA41390
2. Remove:

Rotor 1
Use the flywheel puller 2.
NOTE:
When installing the flywheel puller, turn it
counterclockwise.
Flywheel puller:
YM-1189/90890-01189
5PA41400
EC4L4000
INSPECTION
EC4L4101
CDI magneto
1. Inspect:

Rotor inner surface a

Stator outer surface b
Damage → Inspect the crankshaft runout
and crankshaft bearing.
If necessary, replace CDI magneto and/or
stator.
5PA41410
EC4L4200
Woodruff key
1. Inspect:

Woodruff key 1
Damage → Replace.
5PA41420
CDI MAGNETO

5 - 13
CHAS
EC5A3000
REMOVAL POINTS
Brake fluid
1. Remove:
[Front]

Brake master cylinder cap 1
[Rear]

Reservoir tank cap 1
NOTE:
Do not remove the diaphragm.
ÈFront
ÉRear
È
5PA50290
É
5PA50300
2. Connect the transparent hose 2 to the
bleed screw 1 and place a suitable con-
tainer under its end.
ÈFront
ÉRear
3. Loosen the bleed screw and drain the
brake fluid while pulling the lever in or
pushing down on the pedal.
CAUTION:

Do not reuse the drained brake fluid.

Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled
fluid immediately.
ÈÉ
5PA50310
Front brake caliper
1. Remove:

Brake caliper 1
NOTE:
Turn the brake caliper counterclockwise and
pull out it from the guide pin 2 on the brake
caliper bracket.
5PA50320
FRONT BRAKE AND REAR BRAKE