2012 YAMAHA YZ85 brake fluid

TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS ............................................1-1
SAFETY INFORMATION .................. 2-1
DESCRIPTION .................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................3-3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 4-1
Handlebar switch ............................ 4-1
Clutch lever .................................... 4-1
Shift pedal ......................................4-1
Brake lever ..................................... 4-2
Brake pedal .................................... 4-2
Fuel tank cap .................................. 4-3
Fuel ................................................ 4-3
Fuel tank breather hose ................. 4-5
Fuel cock ........................................ 4-5
Starter (choke) knob ....................... 4-6
Kickstarter ......................................4-6
Seat ................................................ 4-7
Adjusting the front fork ................... 4-7
Front fork bleeding ......................... 4-9
Adjusting the shock absorber assembly ..................................... 4-9
Removable sidestand ................... 4-12 FOR YOUR SAFETY
–
PRE-OPERATION CHECKS ............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS ................................ 6-1
Starting and warming up a cold engine .............................. 6-1
Starting a warm engine .................. 6-1
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 7-1
Periodic maintenance and lubrication chart .......................... 7-2
Checking the spark plug ................ 7-8
Transmission oil ............................. 7-9
Coolant ........................................ 7-10
Cleaning the air filter element ...... 7-12
Adjusting the carburetor ............... 7-14
Adjusting the engine idling speed ........................................ 7-14
Adjusting the throttle grip free play ........................................... 7-15
Tires ............................................. 7-15
Spoke wheels .............................. 7-17
Adjusting the clutch lever free play ........................................... 7-17
Checking the brake lever free play ........................................... 7-18 Checking the shift pedal ............... 7-19
Checking the front and
rear brake pads ......................... 7-19
Checking the brake fluid level ...... 7-20
Changing the brake fluid .............. 7-21
Drive chain slack .......................... 7-22
Cleaning and lubricating the drive chain .......................... 7-23
Checking and lubricating the cables ................................. 7-23
Checking and lubricating
the throttle grip and cable ......... 7-24
Checking and lubricating the brake and clutch levers ....... 7-24
Checking and lubricating the brake pedal ......................... 7-25
Lubricating the swingarm pivots ... 7-25
Lubricating the rear suspension ... 7-25
Checking the front fork ................. 7-26
Checking the steering .................. 7-26
Checking the wheel bearings ....... 7-27
Supporting the motorcycle ........... 7-27
Front wheel .................................. 7-28
Rear wheel ................................... 7-29
Troubleshooting ........................... 7-30
Troubleshooting charts ................. 7-32
MOTORCYCLE CARE AND
STORAGE .......................................... 8-1
Matte color caution ......................... 8-1
Care ............................................... 8-1
U1SN80E0.book Page 1 Thursday, June 9, 2011 11:24 AM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner ’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel 
Check fuel level in fuel tank.
 Always use a fresh mixture of gasoline and oil.
 Check fuel line for leakage.
 Check fuel tank breather hose for obstructions, cracks or damage, and check
hose connection. 4-3, 4-5
Transmission oil 
Check oil level in transmission case.
 If necessary, add recommended oil to specified level. 7-9
Coolant 
Check coolant level.
 If necessary, add recommended coolant to specified level.
 Check cooling system for leakage. 7-10
Front brake 
Check 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 specified brake fluid to specified level.
 Check hydraulic system for leakage. 7-19, 7-20
U1SN80E0.book Page 1 Thursday, June 9, 2011 11:24 AM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-2
5
Rear brake 
Check 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 specified brake fluid to specified level.
 Check hydraulic system for leakage. 7-19, 7-20
Clutch 
Check operation.
 Lubricate cable if necessary.
 Check lever free play.
 Adjust if necessary. 7-17
Throttle grip 
Make sure that operation is smooth.
 Check throttle grip free play.
 If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable
and grip housing. 7-15, 7-24
Drive chain 
Check chain slack.
 Adjust if necessary.
 Check chain condition.
 Lubricate if necessary. 7-22, 7-23
Wheels and tires 
Check for damage.
 Check tire condition and tread depth.
 Check air pressure.
 Correct if necessary.
 Check for loose spokes and tighten if necessary. 7-15, 7-17
Shift pedal 
Make sure that operation is smooth.
 Correct if necessary. 7-19
Brake pedal 
Make sure that operation is smooth.
 Lubricate pedal pivoting point if necessary. 7-25
Brake and clutch levers 
Make sure that operation is smooth.
 Lubricate lever pivoting points if necessary. 7-24
Steering Check that the handlebar can be turned smoothly and has no excessive play. 7-26
ITEM CHECKS PAGE
U1SN80E0.book Page 2 Thursday, June 9, 2011 11:24 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-5
7
√ √
21 *Brakes 
Adjust lever position and pedal height.
 Lubricate pivot points.
 Check brake disk surface.
 Check fluid level and for leakage.
 Tighten brake disk bolts, caliper bolts, master cylinder
bolts and union bolts. √
 Replace brake pads. √
 Replace brake fluid. Every year√
22 *Front fork
Replace oil seals.

Replace fork oil.

Clean dust seal and lubricate with lithium-soap-based
grease.
Adjust if necessary.

Check operation and for oil leakage.
√
√√√
NO. ITEM ROUTINE
After
break-in Every
race Every
third race Every
fifth race As
required
√
√
√
23 *Shock absorber assem-
bly 
Check operation and adjust.
 Tighten if necessary.
 Lubricate with
lithium-soap-based grease
. √(After
washing the
motorcycle or riding in the rain)
U1SN80E0.book Page 5 Thursday, June 9, 2011 11:24 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-6
7
EAU42011
TIP

Hydraulic brake service Regularly check and, if necessary, correct the brake fluid levels.
√
√√
√
24
*Drive chain roller and
support guide

Replace if necessary.

Check for wear or damage.
√
25 *Rear suspension 
Check operation and tighten if necessary.
 Lubricate with
lithium-soap-based grease
.
NO. ITEM ROUTINEAfter
break-in Every
race Every
third race Every
fifth race As
required
√ √√
√
√ √
√
√ √
√
√
√ √
√
√
26
*Steering head 
Check operation, free play, and tighten if necessary.
 Clean and lubricate with lithium-soap-based grease.
 Replace bearings.
27 *Tires and wheels 
Check tire air pressure, wheel runout, spokes for
looseness, and tires for wear.
 Tighten sprocket bolts if necessary.
 Check wheel bearings for looseness.
 Lubricate wheel bearings with lithium-soap-based
grease.
 Replace wheel bearings.
28 *Moving parts and ca-
bles 
Lubricate.
29 *Throttle grip 
Check operation.
 Check throttle grip free play, and adjust if necessary.
 Lubricate cable and grip housing.
U1SN80E0.book Page 6 Thursday, June 9, 2011 11:24 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-7
7

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
 Replace the brake hoses every four years and if cracked or damaged.
U1SN80E0.book Page 7 Thursday, June 9, 2011 11:24 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
7point that the wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU46291
Rear brake pads
Each rear brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that a wear
indicator groove almost appears, have
a Yamaha dealer replace the brake
pads as a set.
EAU22581
Checking the brake fluid level Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
Rear brake
WARNING
EWA15990
Improper maintenance can result in
loss of braking ability. Observe
these precautions:

Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.


Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
1. Brake pad wear indicator groove
1. Minimum level mark
1. Minimum level markSpecified brake fluid:
DOT 4
U1SN80E0.book Page 20 Thursday, June 9, 2011 11:24 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
7


Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.


Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.


Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
NOTICE
ECA17640
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brakefluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
EAU22731
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.

Oil seals: Replace every two
years.


Brake hoses: Replace every four
years.
U1SN80E0.book Page 21 Thursday, June 9, 2011 11:24 AM