2015 YAMAHA YZ85 transmission oil

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 .......................................4-2
Brake lever ......................................4-2
Brake pedal .....................................4-3
Fuel tank cap ...................................4-3
Fuel ..................................................4-3
Fuel tank breather hose...................4-5
Fuel cock .........................................4-6
Starter (choke) knob ........................4-6
Kickstarter .......................................4-7
Seat .................................................4-7
Adjusting the front fork ....................4-8
Front fork bleeding ..........................4-9
Adjusting the shock absorber assembly ....................................4-10
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 ............................................ 7-18
Checking the brake lever free play ............................................ 7-19 Checking the shift pedal ............... 7-19
Checking the front and rear brake
pads ........................................... 7-20
Checking the brake fluid level ....... 7-20
Changing the brake fluid ............... 7-22
Drive chain slack ........................... 7-22
Cleaning and lubricating the drive chain .......................................... 7-23
Checking and lubricating the cables ........................................ 7-24
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 rear suspension.... 7-25
Lubricating the swingarm pivots ... 7-26
Checking the front fork ................. 7-26
Checking the steering ................... 7-27
Checking the wheel bearings ........ 7-27
Supporting the motorcycle ........... 7-28
Front wheel ................................... 7-28
Rear wheel .................................... 7-29
Troubleshooting ............................ 7-31
Troubleshooting charts ................. 7-32
MOTORCYCLE CARE AND
STORAGE .......................................... 8-1
Matte color caution ......................... 8-1
Care................................................. 8-1
U1SN83E0.book Page 1 Monday, September 8, 2014 2:36 PM

DESCRIPTION
3-2
3
EAU10421
Right view
1
9
81011
6
7
5
2 3,4
1. Shock absorber assembly compression damping force adjusting
screw (page 4-10)
2. Kickstarter (page 4-7)
3. Front fork rebound damping force adjusting screw (page 4-8)
4. Bleed screw (page 4-9)
5. Front fork compression damping force adjusting screw (page 4-8)
6. Spark plug cap (page 7-8)
7. Transmission oil filler cap (page 7-9)
8. Coolant drain bolt (page 7-11) 9. Brake pedal (page 4-3)
10.Transmission oil drain bolt (page 7-9)
11.Shock absorber assembly rebound damping force adjusting screw
(page 4-10)
U1SN83E0.book Page 2 Monday, September 8, 2014 2:36 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
EAU15598
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
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an acci dent or equipment damag e.
Do not operate the vehicle if you fin d any pro blem. If a pro blem cannot be corrected b y the proce dures provi ded in
this manual, have the vehicle inspecte d b y 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 for leakage. 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. 7-20, 7-20
U1SN83E0.book Page 1 Monday, September 8, 2014 2:36 PM

OPERATION AND IMPORTANT RIDING POINTS
6-3
6
EAU41505
Engine break-in
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or death durin g
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.1. Before starting the engine, fill the fuel tank with a break-in oil-fuel
mixture as follows.
2. Start and warm up the engine. Check the operation of the con-
trols and the engine stop switch.
(See page 4-1.)
3. Operate the motorcycle in the lower gears at moderate throttle
openings for five to eight minutes.
Stop the engine and check the spark plug condition (see page
7-8); it will show a rich condition
during break-in.
4. Allow the engine to cool. Restart the engine and operate the motor-
cycle as in the step above for five
minutes. Then, very briefly shift to
the higher gears and check the
full-throttle response. Stop the en-
gine and check the spark plug.
5. After again allowing the engine to cool, restart and run the motorcy-
cle for five more minutes. Full
throttle and the higher gears may
be used, but sustained full-throttle
operation should be avoided.
Stop the engine and check the
spark plug again.
6. Allow the engine to cool, remove the cylinder head and cylinder,
and inspect the piston and cylin-
der. Remove any high spots on
the piston with #600-grit wet
sandpaper. Clean all components
and carefully reassemble the cyl-
inder head and cylinder.
7. Drain the break-in oil-fuel mixture from the fuel tank and refill with
the specified mix. (See page 4-3.) 8. Start the engine and check the op-
eration of the motorcycle through-
out its entire operating range.
Stop the engine and check the
spark plug condition. Restart the
motorcycle and ride it for about 10
to 15 more minutes. The motorcy-
cle will now be ready to ride nor-
mally.
After the engine break-in period, thor-
oughly check the motorcycle for loose
parts, oil leakage and any other prob-
lems. Be sure to inspect and make ad-
justments thoroughly, especially cable
and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tight-
en if necessary.
NOTICE
ECA15561
 When any of the followin g parts
have been replaced , they must
b e broken in.
Cylin der or crankshaft:
A bout one hour of b reak-in op-
eration is necessary.
Piston, rin gs or transmission
g ears:
Recommen ded 2-stroke en gine oil:
See page 9-1.
Mixin g ratio ( gasoline to oil):
15:1
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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.
U1SN83E0.book Page 3 Monday, September 8, 2014 2:36 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-9
7To install the spark plu
g
1. Clean the surface of the spark plug gasket and its mating sur-
face, 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
specified torque as soon as possible.3. Install the spark plug cap.
EAU41449
Transmission oilThe 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 lubrica-
tion 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
position.
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 gas-
ket to drain the oil from the
transmission. 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.
Tightenin g torque:
Spark plug: 20 Nm (2.0 m·kgf, 14 ft·lbf)
1. Transmission oil filler cap
2. Transmission oil drain bolt
3. GasketTightenin g torque:
Transmission oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Recommen ded transmission oil:
See page 9-1.
Oil chan ge quantity:
0.50 L (0.53 US qt, 0.44 Imp.qt)
1
2
3
U1SN83E0.book Page 9 Monday, September 8, 2014 2:36 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-10
7
NOTICE
ECA10453
In or der to prevent clutch slip-
pa ge (since the transmission oil
also lu bricates the clutch), do
not mix any chemical additives.
Do not use oils with a d iesel
specification of “CD” or oils of a
hi gher quality than specifie d. In
a ddition, do not use oils lab eled
“ENERGY CONSERVING II” or
hi gher.
 Make sure that no forei gn mate-
rial enters the transmission.7. Start the engine, and then let it idle for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
EAU20071
CoolantThe 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.
EAUM1296
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 tem-
perature.
 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 and
check the coolant level in the radi-
ator. WARNING! Never attempt
to remove the ra diator cap
when the en gine is hot.
[EWA10382]
TIPThe coolant should be at the bottom of
the radiator filler neck. The level will
change with variation of engine tem-
perature.1. Radiator cap
1. Correct coolant level
1
1
U1SN83E0.book Page 10 Monday, September 8, 2014 2:36 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
7
EAU51721
Changin g the brake flui dHave a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the master cylinders and calipers as
well as the brake hoses replaced at the
intervals listed below or whenever they
are damaged or leaking.
 Oil seals: Replace every two
years.
 Brake hoses: Replace every four
years.
EAU22762
Drive chain slackThe drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU41413
To check the drive chain slack
1. Install the removable sidestand and place the motorcycle on it.TIPWhen checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.2. Shift the transmission into theneutral position.
3. Measure the drive chain slack as shown. 4. If the drive chain slack is incorrect,
adjust it as follows.
EAU41484
To a djust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack. 1. Loosen the axle nut and the lock- nut on each side of the swingarm.
2. To tighten the drive chain, turn the drive chain slack adjusting bolt on
each side of the swingarm in di-
rection (a). To loosen the drive
chain, turn the adjusting bolt on
each side of the swingarm in di-
rection (b), and then push the rear
wheel forward. NOTICE: Improp-
er drive chain slack will over-
Drive chain slack:
35.0–45.0 mm (1.38–1.77 in)
1. Drive chain slack
U1SN83E0.book Page 22 Monday, September 8, 2014 2:36 PM