2019 YAMAHA YZ85 air filter

Table of contents
Location of important la bels ........... 1-1
Safety information ............................ 2-1
Description ....................................... 3-1
Left view ......................................... 3-1
Right view ....................................... 3-2
Controls and instruments ............... 3-3
Instrument an d 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 ................................................. 4-4
Fuel tank breather hose.................. 4-6
Fuel cock ........................................ 4-6
Starter (choke) knob ....................... 4-7
Kickstarter ...................................... 4-7
Seat ................................................ 4-8
Adjusting the front fork ................... 4-8
Front fork bleeding ....................... 4-10
Adjusting the shock absorber assembly ................................... 4-11
Removable sidestand ................... 4-14
YPVS system ................................ 4-15
For your safety – pre-operation
checks ............................................... 5-1
Operation an d important ri din g
points ................................................ 6-1
Starting and warming up a cold
engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-5
Perio dic maintenance an d
a d justment ........................................ 7-1
Periodic maintenance and lubrication chart .......................... 7-2
Checking the spark plug ................ 7-6 Transmission oil .............................. 7-7
Coolant ............................................ 7-8
Cleaning the air filter element ....... 7-10
Adjusting the carburetor ............... 7-12
Adjusting the engine idling
speed ......................................... 7-13
Adjusting the throttle grip free play ............................................ 7-13
Tires .............................................. 7-14
Spoke wheels ................................ 7-16
Adjusting the clutch lever free play ............................................ 7-17
Checking the brake lever free play ............................................ 7-18
Checking the shift pedal ............... 7-18
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 ........................... 7-21
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 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 an d stora ge .......... 8-1
Matte color caution ......................... 8-1
Care................................................. 8-1
Storage............................................ 8-3
UB4B80E0.book Page 1 Tuesday, March 27, 2018 1:39 PM

Description
3-1
3
EAU63371
Left view
6745231
8910
1. Rebound damping force adjuster (page 4-8)
2. Radiator cap (page 7-8)
3. Fuel tank cap (page 4-3)
4. Fuel cock (page 4-6)
5. Starter (choke) knob (page 4-7)
6. Air filter element (page 7-10)
7. Seat (page 4-8)
8. Throttle stop screw (page 7-13)
9. Shift pedal (page 4-2)
10.Compression damping force adjuster (page 4-8)
UB4B80E0.book Page 1 Tuesday, March 27, 2018 1:39 PM

Instrument and control functions
4-12
4
4. Loosen the locknut.
5. To increase the spring preload
and thereby harden the suspen-
sion, turn the adjusting nut in di-
rection (a). To decrease the spring
preload and thereby soften the
suspension, turn the adjusting nut
in direction (b).
 A special wrench can be ob-
tained at a Yamaha dealer to
make this adjustment.
 The spring preload setting is
determined by measuring
distance A, shown in the illus-
tration. The longer distance A
is, the lower the spring pre-
load; the shorter distance A
is, the higher the spring pre- load. With each complete
turn of the adjusting nut, dis-
tance A is changed by 1.5
mm (0.06 in).
6. Tighten the locknut to the speci- fied torque. NOTICE: Always
ti ghten the locknut ag ainst the
a d justin g nut, and then tighten
the locknut to the specifie d
torque.
[ECA10122]
7. Install the air filter joint in its origi- nal position, and then tighten the
clamp screw and clamp bolt.
TIP
Align the projection on the air filter joint
with the projection on the frame guide.
1. Clamp bolt
2. Clamp screw
3. Air filter joint
1. Locknut
2. Spring preload adjusting nut
1 2
3
1 2
(a)
(b)
1. Distance A
Sprin
g preloa d:
Minimum (soft): Distance A = 218.5 mm (8.60 in)
Standard: Distance A = 210.0 mm (8.27 in)
(YZ85LW, YZ85LWK)
215.0 mm (8.46 in) (YZ85, YZ85K)
Maximum (hard): Distance A = 202.0 mm (7.95 in)
Ti ghtenin g torque:
Locknut:
30 N·m (3.0 kgf·m, 22 lb·ft)
1
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Instrument and control functions
4-13
4
8. Place the left side panel in its orig-
inal position, and then install the
bolt.
9. Install the seat.
Re boun d d ampin g force
To increase the rebound damping for-
ce and thereby harden the rebound
damping, turn the adjusting screw in
direction (a). To decrease the rebound
damping force and thereby soften the
rebound damping, turn the adjusting
screw in direction (b).
TIP
Although a damping force adjuster
may click beyond the stated minimum
settings, such adjustments are ineffec-
tive and may damage the suspension.
Compression dampin g force
To increase the compression damping
force and thereby harden the com-
pression damping, turn the adjusting
screw in direction (a). To decrease the
compression damping force and there-
by soften the compression damping,
turn the adjusting screw in direction (b).
1. Frame guide
2. Air filter joint
3. Projection
1. Rebound damping force adjusting screw
1
3
2
1
(a)
(b)
Re boun d d ampin g settin g:
Minimum (soft): 20 click(s) in direction (b)*
Standard:
10 (YZ85LW, YZ85LWK)
6 (YZ85, YZ85K) click(s) in direc-
tion (b)*
Maximum (hard): 1 click(s) in direction (b)*
* With the adjusting screw fully
turned in direction (a)
1. Compression damping force adjusting
screw
(b)(a)
1
UB4B80E0.book Page 13 Tuesday, March 27, 2018 1:39 PM

Operation and important ri din g points
6-3
6
an
d d rive train, which are not
d esi gne d to withstan d the
shock of force d shifting .
EAU16691To start out an d 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
lever 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.
EAU16711To 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.
EAU41506
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.
TIP
Before starting the engine for the first
time, the air filter must be lubricated.
(See page 7-10.)
En gine break-in proce dure
1. 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 low- er gears at moderate throttle
openings for 5 to 8 minutes. Stop
the engine and check the spark
plug condition (see page 7-6); 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 5 mi-
nutes. Then, very briefly shift to
Recommen ded 2-stroke en gine oil:
YAMALUBE 2R
Mixin g ratio ( gasoline to oil):
15:1
UB4B80E0.book Page 3 Tuesday, March 27, 2018 1:39 PM

Periodic maintenance an d a djustment
7-4
7
23 *Front fork Check operation and for oil leakage.
Adjust if necessary.
 Clean dust seal and lubricate with
lithium-soap-based grease.
Replace fork oil.
 Replace oil seals.
NO. ITEM ROUTINE
After
break-in
Everyrace
Every
third race
Every
fifth race
As
required
Check coolant level and for leakage.
17 *
Cooling system Check hoses for cracks or damage. Check radiator cap spring operation. Change coolant.
Every 2 years
Every 2 years Check all chassis fitting and fasteners.
18
*Chassis fasteners
Correct or tighten if necessary.
19Air filter element Clean. Replace.
20 *Frame Clean and check for damage.

21
*Fuel line Clean and check for leakage.
22 *
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.
UB4B80E0.book Page 4 Tuesday, March 27, 2018 1:39 PM

Periodic maintenance an d a djustment
7-10
7
6. Pour the recommended coolant
into the radiator until it is full.
7. Install the radiator cap, start the engine, let it idle for several minu-
tes, 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.
EAU48393
Cleanin g the air filter element
The air filter element should be cleaned
or replaced at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean or, if necessary, re-
place the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 4-8.)
2. Remove the air filter case cover as shown.
3. Remove the air filter element by removing the wing bolt and its
washer.
Antifreeze/water mixture ratio:1:1
Recommen ded antifreeze:
High-quality ethylene glycol anti-
freeze containing corrosion inhibi-
tors for aluminum engines
Coolant quantity:
Radiator (including all routes):0.55 L (0.58 US qt, 0.48 Imp.qt)
1. Air filter case cover
UB4B80E0.book Page 10 Tuesday, March 27, 2018 1:39 PM

Periodic maintenance an d a djustment
7-11
7 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 excess oil out.
TIP
The sponge material should be wet but
not dripping.
7. Pull the sponge material over theair filter element frame.
8. Insert the air filter element into the air filter case with the projection
facing upward, and then install the
wing bolt and its washer.
NOTICE: Make sure that the air
filter element is properly seate d
in the air filter case. The en gine
shoul d never b e operated with-
out the air filter element in-
stalle d, otherwise the piston(s)
an d/or cylin der(s) may become
excessively worn.
[ECA10482]
NOTICE: Be sure to install the
washer with its curve d si de fac-
in g outwar d as shown.
[ECA16692]
1. Wing bolt
2. Washer
3. Air filter element
1. Sponge material
2. Air filter element frame
1
2
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
1. Air filter element
2. Projection
UB4B80E0.book Page 11 Tuesday, March 27, 2018 1:39 PM