2007 YAMAHA YZ85 clutch

TABLE OF CONTENTS
SAFETY INFORMATION .................. 1-1
Location of important labels ........... 1-4
DESCRIPTION .................................. 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instruments ................2-3
INSTRUMENT AND CONTROL
FUNCTIONS....................................... 3-1
Handlebar switch ............................ 3-1
Clutch lever .................................... 3-1
Shift pedal ......................................3-1
Brake lever ..................................... 3-2
Brake pedal .................................... 3-2
Fuel tank cap .................................. 3-3
Fuel ................................................ 3-3
Fuel tank breather hose ................. 3-5
Fuel cock ........................................ 3-5
Starter (choke) knob ....................... 3-6
Kickstarter ......................................3-6
Seat ................................................ 3-6
Adjusting the front fork ................... 3-7
Front fork bleeding ......................... 3-8
Adjusting the shock absorber
assembly ..................................... 3-9
Removable sidestand ................... 3-12
PRE-OPERATION CHECKS.............. 4-1
Pre-operation check list .................. 4-2OPERATION AND IMPORTANT
RIDING POINTS................................ 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-1
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Checking the spark plug ................ 6-8
Transmission oil ............................. 6-9
Coolant ........................................ 6-10
Cleaning the air filter element ...... 6-12
Adjusting the carburetor ............... 6-14
Adjusting the throttle cable
free play .................................... 6-14
Tires ............................................. 6-15
Spoke wheels .............................. 6-17
Accessories and replacement
parts ......................................... 6-17
Adjusting the clutch lever
free play .................................... 6-17
Checking the front and rear brake
pads .......................................... 6-18
Checking the brake fluid level ...... 6-19
Changing the brake fluid .............. 6-20
Drive chain slack .......................... 6-20Cleaning and lubricating the
drive chain ................................ 6-21
Checking and lubricating the
cables ....................................... 6-22
Checking and lubricating the
throttle grip and cable ............... 6-22
Checking and lubricating the
brake and shift pedals ............... 6-23
Checking and lubricating the
brake and clutch levers ............. 6-23
Lubricating the swingarm pivots ... 6-24
Lubricating the rear suspension ... 6-24
Checking the front fork ................. 6-24
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-26
Supporting the motorcycle ........... 6-26
Front wheel .................................. 6-27
Rear wheel ................................... 6-27
Troubleshooting ........................... 6-29
Troubleshooting charts ................. 6-30
MOTORCYCLE CARE AND
STORAGE.......................................... 7-1
Care ............................................... 7-1
Storage ........................................... 7-3
SPECIFICATIONS ............................ 8-1
CONSUMER INFORMATION............ 9-1
Identification numbers .................... 9-1
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM

DESCRIPTION
2-3
2
EAU10430
Controls and instruments1. Clutch lever (page 3-1)
2. Left handlebar switch (page 3-1)
3. Brake lever (page 3-2)
4. Throttle grip (page 6-14)
5. Fuel tank cap (page 3-3)
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-1
3
EAU40660
Handlebar switch
EAU12670
“ENGINE STOP” button
Hold this button pushed until the engine
stops in case of an emergency, such as
when the vehicle overturns or when the
throttle cable is stuck.
EAU12850
Clutch lever The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
EAU12870
Shift pedal The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
1. Engine stop button “ENGINE STOP”
1. Clutch lever
1. Shift pedal
U5PA85E0.book Page 1 Thursday, April 13, 2006 3:06 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-6
3
EAU13640
Starter (choke) knob Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the knob in direction (a) to turn on
the starter (choke).
Move the knob in direction (b) to turn off
the starter (choke).
EAU13650
Kickstarter To start the engine, fold out the kick-
starter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but force-
fully. This model is equipped with a pri-
mary kickstarter, allowing the engine to
be started in any gear if the clutch is
disengaged. However, shifting the
transmission into the neutral position
before starting is recommended.
EAU13960
Seat To remove the seat
Remove the bolts, and then pull the
seat off.
To install the seat
1. Insert the projections on the front
of the seat into the seat holders as
shown.
1. Starter (choke) knob
1. Kickstarter lever
1. Bolt
U5PA85E0.book Page 6 Thursday, April 13, 2006 3:06 PM

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Always use a fresh mixture of gasoline and oil.
Check fuel line for leakage.3-3
Transmission oilCheck oil level in transmission case.
If necessary, add recommended oil to specified level.6-9
CoolantCheck coolant level.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-10
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-18, 6-19
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-18, 6-19
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-17
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-14, 6-22
U5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM

OPERATION AND IMPORTANT RIDING POINTS
5-2
5
EAU16671
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.NOTE:To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of itstravel, and then slightly raise it.
CAUTION:
ECA10260


Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand theshock of forced shifting.
EAU16690
To start out and accelerate
1. Pull the clutch lever to disengage
the clutch.
2. Shift the transmission into first
gear.
3. Open the throttle gradually and si-
multaneously release the clutch le-
ver slowly.4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle, and at the
same time, quickly pull the clutch
lever in.
5. Shift the transmission into second
gear. (Make sure not to shift the
transmission into the neutral posi-
tion.)
6. Open the throttle halfway and
gradually release the clutch lever.
7. Follow the same procedure when
shifting to the next gear.
EAU16710
To decelerate
1. Close the throttle and apply both
the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and
shift the transmission into the neu-
tral position when the motorcycle
is almost completely stopped.
1. Shift pedal
2. Neutral positionU5PA85E0.book Page 2 Thursday, April 13, 2006 3:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
√
5
*CylinderCheck cylinder for score marks or wear.
Clean.√
Replace.√ NO. ITEM ROUTINEAfter
break-inEvery
raceEvery
third raceEvery
fifth raceAs
required
6*ClutchCheck clutch housing, friction plates, clutch plates
and clutch springs for wear or damage.
Adjust.√ √
Replace.√
7*TransmissionChange the transmission oil.√
Check transmission for damage.√
Replace bearings.√
8*Shift forks, guide bars,
shift cam Replace if necessary. Check all parts for wear and damage.
√
9*Rotor nut
(flywheel magneto)Tighten.√√√
10*Kickstarter systemCheck idle gear for damage.
√
Replace if necessary.
11*Exhaust system Check exhaust pipe and muffler for carbon deposits.√ √
Clean.√
√
√ √
√ 12*CrankshaftCheck crankshaft for carbon deposits and damage.
Clean.
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
CAUTION:
ECA10452


In order to prevent clutch slip-
page (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the transmission.
7. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUM1291
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
2. Remove the radiator cap and
check the coolant level in the radi-
ator.
NOTE:

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
NOTE:The coolant should be at the brim of the
radiator filler. The level will change withvariation of engine temperature.1. Radiator cap
chapter6 Page 10 Tuesday, April 18, 2006 10:03 AM