2013 YAMAHA YZ85 maintenance

PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
7
√
5 *Cylinder Check cylinder for score marks or wear.
Clean.
√
Replace. √
NO. ITEM ROUTINE
After
break-in Every
race Every
third race Every
fifth race As
required
6 *Clutch Check clutch housing, friction plates, clutch plates
and clutch springs for wear or damage.
Adjust. √
√
Replace. √
7 *Transmission Change 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 system Check idle gear for damage.
√
Replace if necessary.
11 *Exhaust system Check exhaust pipe and muffler for carbon deposits.
√
√
Clean. √
√
√
√
√
12
*Crankshaft Check crankshaft for carbon deposits and damage.
Clean.
U1SN81E0.book Page 3 Tuesday, June 12, 2012 3:17 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
7
NO.ITEM ROUTINEAfter
break-in Every
race Every
third race Every
fifth race As
required
√
√
√
13
*Carburetor Check carburetor settings and for obstructions.
√
Adjust and clean. √
14 Spark plug Check condition.
Clean and regap.
√
Replace. √
15 Drive chain Check chain slack, alignment and condition.
Adjust and thoroughly lubricate chain with Yamaha
chain and cable lube or equivalent. √
√
√
√
√
Replace. √
16 * *
Cooling system Check coolant level and for leakage.
√
√
Check hoses for cracks or damage. √
Check radiator cap spring operation. √
Change coolant. Every 2 years√
17 *Chassis fasteners Check all chassis fitting and fasteners.
Correct or tighten if necessary. √
18 Air filter element Clean.
√
Replace. √
19 *Frame Clean and check for damage. √
20 *Fuel line Clean and check for leakage. √√
U1SN81E0.book Page 4 Tuesday, June 12, 2012 3:17 PM

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)
U1SN81E0.book Page 5 Tuesday, June 12, 2012 3:17 PM

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.
U1SN81E0.book Page 6 Tuesday, June 12, 2012 3:17 PM

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.
U1SN81E0.book Page 7 Tuesday, June 12, 2012 3:17 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
7
EAU19613
Checking the spark plug The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug1. Remove the spark plug cap.
2. Remove the spark plug as shown, with a spark plug wrench available
at a Yamaha dealer. To check the spark plug
1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
TIPIf the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electrodeerosion and excessive carbon or
other deposits, and replace it if
necessary.
3. Measure the spark plug gap with a wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
1. Spark plug cap
1. Spark plug wrench
Specified spark plug:NGK/BR10EG
1. Spark plug gap
Spark plug gap:0.5–0.6 mm (0.020–0.024 in)
U1SN81E0.book Page 8 Tuesday, June 12, 2012 3:17 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-9
7To install the spark plug
1. Clean the surface of the spark plug gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
2. Install the spark plug with the spark plug wrench, and then tight-
en it to the specified torque.
TIPIf a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.3. Install the spark plug cap.
EAU41448
Transmission oil The transmission must be checked for
oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the transmission oil must be
changed at the intervals specified in the
periodic maintenance and lubrication
chart.1. Start the engine, warm it up for several minutes, and then turn it
off.
2. Place the motorcycle on a level surface and hold it in an upright po-
sition.
3. Place an oil pan under the trans- mission case to collect the used
oil.
4. Remove the oil filler cap, the trans- mission oil drain bolt and its gasket
to drain the oil from the transmis-
sion. 5. Install the drain bolt and its new
gasket, and then tighten the bolt to
the specified torque.
6. Refill with the specified amount of the recommended transmission
oil, and then install and tighten the
oil filler cap.
Tightening torque:Spark plug:20 Nm (2.0 m·kgf, 14 ft·lbf)
1. Transmission oil filler cap
2. Transmission oil drain bolt
3. GasketTightening torque:Transmission oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Recommended transmission oil: See page 9-1.
Oil change quantity: 0.50 L (0.53 US qt, 0.44 Imp.qt)
1
2
3
U1SN81E0.book Page 9 Tuesday, June 12, 2012 3:17 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-10
7
NOTICE
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 idlefor several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately 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.
EAUM1295
To check the coolant level1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion.TIP●
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 the
side can result in a false reading.
2. Remove the radiator cap andcheck the coolant level in the radi-
ator. WARNING! Never attempt
to remove the radiator cap when
the engine is hot.
[EWA10381]
TIPThe coolant should be at the bottom of
the radiator filler neck. The level will
change with variation of engine temper-
ature.1. Radiator cap
1. Correct coolant level
U1SN81E0.book Page 10 Tuesday, June 12, 2012 3:17 PM