2008 YAMAHA YZ85 air filter

TABLE OF CONTENTS
SAFETY INFORMATION .................. 1-1
Safe riding ....................................... 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 engine idling
speed ........................................ 6-14
Adjusting the throttle cable free
play ........................................... 6-15
Tires ............................................. 6-15
Spoke wheels .............................. 6-17
Accessories and replacement
parts ......................................... 6-17
Adjusting the clutch lever free
play ........................................... 6-18
Checking the front brake lever
free play .................................... 6-18Checking the front and rear
brake pads ................................ 6-19
Checking the brake fluid level ...... 6-20
Changing the brake fluid .............. 6-21
Drive chain slack .......................... 6-21
Cleaning and lubricating the
drive chain ................................ 6-22
Checking and lubricating the
cables ....................................... 6-23
Checking and lubricating the
throttle grip and cable ............... 6-23
Checking and lubricating the
brake and shift pedals ............... 6-24
Checking and lubricating the
brake and clutch levers ............. 6-24
Lubricating the swingarm pivots ... 6-25
Lubricating the rear suspension ... 6-25
Checking the front fork ................. 6-25
Checking the steering .................. 6-26
Checking the wheel bearings ....... 6-27
Supporting the motorcycle ........... 6-27
Front wheel .................................. 6-28
Rear wheel ................................... 6-28
Troubleshooting ........................... 6-30
Troubleshooting charts ................. 6-31
MOTORCYCLE CARE AND
STORAGE.......................................... 7-1
Matte color caution ......................... 7-1
Care ............................................... 7-1
Storage ........................................... 7-3
U5PA86E0.book Page 1 Monday, April 9, 2007 3:16 PM

DESCRIPTION
2-1
2
EAU10410
Left view1. Radiator cap (page 6-10)
2. Fuel cock (page 3-5)
3. Shock absorber assembly spring preload adjusting nut (page 3-9)
4. Air filter element (page 6-12)
5. Seat (page 3-6)
6. Shift pedal (page 3-1)
7. Throttle stop screw (page 6-14)
8. Starter (choke) knob (page 3-6)
U5PA86E0.book Page 1 Monday, April 9, 2007 3:16 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
NO. ITEM ROUTINEAfter
break-inEvery
raceEvery
third raceEvery
fifth raceAs
required
√
√
√ 13*CarburetorCheck carburetor settings and for obstructions.√
Adjust and clean.√
14 Spark plugCheck condition.
Clean and regap.√
Replace.√
15 Drive chainCheck chain slack, alignment and condition.
Adjust and thoroughly lubricate chain with Yamaha
chain and cable lube or equivalent.√
√
√
√ √
Replace.√
16* *
Cooling systemCheck coolant level and for leakage.√ √
Check hoses for cracks or damage.√
Check radiator cap spring operation.√
Change coolant. Every 2 years√
17*Chassis fastenersCheck all chassis fitting and fasteners.
Correct or tighten if necessary.√
18*Air filter elementClean.
√
Replace.√
19*FrameClean and check for damage.√
20*Fuel line Clean and check for leakage.√√
U5PA86E0.book Page 4 Monday, April 9, 2007 3:16 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
CAUTION:
ECA10471


If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the cooling system will not
be protected against frost and
corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness ofthe coolant will be reduced.
7. Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
8. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the bottom of the
radiator filler neck, and then install
the radiator cap.9. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
EAU41431
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-6.)
2. Remove the air filter case cover as
shown.1. Air filter case cover
U5PA86E0.book Page 12 Monday, April 9, 2007 3:16 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6 3. Remove the air filter element by
removing the wing bolt and wash-
er.
4. Remove the sponge material from
the air filter element frame.5. Clean the sponge material with
solvent, and then squeeze the re-
maining solvent out.
6. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.
NOTE:The sponge material should be wet butnot dripping.
7. Pull the sponge material over the
air filter element frame.
8. Insert the air filter element into the
air filter case with the projection
facing upward, and then install the
washer and wing bolt.
1. Wing bolt
2. Washer
3. Sponge material
1. Sponge material
2. Air filter element frame
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
1. Sponge material
2. Projection
U5PA86E0.book Page 13 Monday, April 9, 2007 3:16 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
CAUTION:
ECA10480


Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) maybecome excessively worn.
9. Install the air filter case cover in the
original position as shown.
10. Install the seat.
EAU39930
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in the
following section, however, may be ser-
viced by the owner as part of routine
maintenance.CAUTION:
ECA10550
The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-mance of or damage to the engine.
EAU44390
Adjusting the engine idling
speed The engine idling speed must be ad-
justed when necessary.
1. Start the engine and thoroughly
warm it up.
2. Turn the throttle stop screw until
the engine runs at the lowest pos-
sible speed.
3. To increase the engine idling
speed, turn the throttle stop screw
in direction (a). To decrease the
engine idling speed, turn the throt-
tle stop screw in direction (b).1. Throttle stop screw
U5PA86E0.book Page 14 Monday, April 9, 2007 3:16 PM

SPECIFICATIONS
8-1
8
Dimensions:Overall length:
YZ85 1818 mm (71.6 in)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)
YZ85 1821 mm (71.7 in) (ZAF)
YZ85LW 1903 mm (74.9 in)
YZ85LWX 1903 mm (74.9 in)
YZ85X 1818 mm (71.6 in)
Overall width:
758 mm (29.8 in)
Overall height:
YZ85 1161 mm (45.7 in)
YZ85LW 1205 mm (47.4 in)
YZ85LWX 1205 mm (47.4 in)
YZ85X 1161 mm (45.7 in)
Seat height:
YZ85 864 mm (34.0 in)
YZ85LW 904 mm (35.6 in)
YZ85LWX 904 mm (35.6 in)
YZ85X 864 mm (34.0 in)
Wheelbase:
YZ85 1255 mm (49.4 in)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)
YZ85 1258 mm (49.5 in) (ZAF)
YZ85LW 1286 mm (50.6 in)
YZ85LWX 1286 mm (50.6 in)
YZ85X 1255 mm (49.4 in)Ground clearance:
YZ85 351 mm (13.82 in)
YZ85LW 393 mm (15.47 in)
YZ85LWX 393 mm (15.47 in)
YZ85X 351 mm (13.82 in)
Weight:With oil and fuel:
YZ85 71.0 kg (157 lb)
YZ85LW 73.9 kg (163 lb)
YZ85LWX 73.9 kg (163 lb)
YZ85X 71.0 kg (157 lb)Engine:Engine type:
Liquid cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
84.7 cm³
Bore × stroke:
47.5 × 47.8 mm (1.87 × 1.88 in)
Compression ratio:
8.20 :1
Starting system:
Kickstarter
Lubrication system:
PremixEngine oil:Type:
YAMALUBE 2-RTransmission oil:Type:
YAMALUBE 4 (10W30) or SAE 10W30
type SE motor oilOil change quantity:
0.50 L (0.53 US qt) (0.44 Imp.qt)
Cooling system:Radiator capacity (including all routes):
0.54 L (0.57 US qt) (0.48 Imp.qt)Air filter:Air filter element:
Wet elementFuel:Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
5.0 L (1.32 US gal) (1.10 Imp.gal)Carburetor:Manufacturer:
KEIHIN
Type × quantity:
PWK28 x 1Spark plug (s):Manufacturer/model:
NGK/BR10EG
Spark plug gap:
0.5–0.6 mm (0.020–0.024 in)Clutch:Clutch type:
Wet, multiple-discTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
65/18 (3.611)
Secondary reduction system:
Chain drive
U5PA86E0.book Page 1 Monday, April 9, 2007 3:16 PM

INDEX
AAccessories and replacement parts ..... 6-17
Air filter element, cleaning .................... 6-12BBrake and clutch levers, checking
and lubricating .................................... 6-24
Brake and shift pedals, checking
and lubricating .................................... 6-24
Brake fluid, changing ............................ 6-21
Brake fluid level, checking .................... 6-20
Brake lever ............................................. 3-2
Brake pedal ............................................ 3-2CCables, checking and lubricating .......... 6-23
Carburetor, adjusting ............................ 6-14
Care ........................................................ 7-1
Clutch lever............................................. 3-1
Clutch lever free play, adjusting ........... 6-18
Coolant ................................................. 6-10DDrive chain, cleaning and lubricating .... 6-22
Drive chain slack .................................. 6-21EEngine break-in ...................................... 5-3
Engine idling speed .............................. 6-14
Engine, starting a warm .......................... 5-1
Engine stop button.................................. 3-1FFront and rear brake pads, checking .... 6-19
Front brake lever free play, checking ... 6-18
Front fork, adjusting ................................ 3-7
Front fork, bleeding................................. 3-8
Front fork, checking .............................. 6-25
Fuel......................................................... 3-3Fuel cock ................................................. 3-5
Fuel tank breather hose .......................... 3-5
Fuel tank cap........................................... 3-3
HHandlebar switch..................................... 3-1IIdentification numbers ............................. 9-1KKickstarter ............................................... 3-6LLabels, location of ...................................1-4MMatte color, caution .................................7-1
Model label .............................................. 9-1PParking ....................................................5-4
Part locations .......................................... 2-1
Periodic maintenance and
lubrication chart.....................................6-2
Pre-operation check list........................... 4-2RRear suspension, lubricating ................. 6-25SSafety information ...................................1-1
Seat ......................................................... 3-6
Shifting ....................................................5-2
Shift pedal ............................................... 3-1
Shock absorber assembly, adjusting ...... 3-9
Sidestand .............................................. 3-12
Spark plug, checking ...............................6-8
Specifications .......................................... 8-1
Starter (choke) knob................................ 3-6
Starting and warming up a cold
engine ................................................... 5-1Steering, checking ................................ 6-26
Storage ................................................... 7-3
Supporting the motorcycle .................... 6-27
Swingarm pivots, lubricating ................. 6-25
TThrottle cable free play, adjusting ......... 6-15
Throttle grip and cable, checking
and lubricating .................................... 6-23
Tires ...................................................... 6-15
Transmission oil ...................................... 6-9
Troubleshooting .................................... 6-30
Troubleshooting charts ......................... 6-31VVehicle identification number .................. 9-1WWheel bearings, checking..................... 6-27
Wheel (front) ......................................... 6-28
Wheel (rear) .......................................... 6-28
Wheels .................................................. 6-17
U5PA86E0.book Page 1 Monday, April 9, 2007 3:16 PM