2022 YAMAHA YZ65 maintenance

Introduction
EAU84170
Congratulations on your purchase of the Yamaha YZ65 / YZ65N. This model is the
result of Yamaha’s vast experience in the production of fine sporting, touring, and
pacesetting racing machines. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions concerning the opera-
tion or maintenance of your motorcycle, please consult a Yamaha dealer.
Yamaha continually seeks advancements in product design and quality. There- fore, while this manual contains the most current product information available at
the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If there is any question concerning this manual, please consult a
Yamaha dealer.
WARNING
EWA10032
Please read this manual carefully and completely before operating this mo-
torcycle.
WARNING
EWA14352
This motorcycle is designed and manufactured for off-road use only. It is il-
legal to operate this motorcycle on any public street, road or highway. Such
use is prohibited by law. This motorcycle complies with almost all state off-
highway noise level and spark arrester laws and regulations. Please check
your local riding laws and regulations before operating this motorcycle.
AN IMPORTANT SAFETY MESSAGE:  Read this manual completely before operating your motorcycle. Make sure
you understand all instructions.
 Pay close attention to the warning and notice labels on the motorcycle.
 Never operate a motorcycle without proper training or instruction.
 Weight of the rider should not exceed 50.0 kg (110 lb).
AN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you
should understand the instructions and warnings in this Owner’s Manual. Then be
sure your child understands and will follow them. Children differ in skills, physical
abilities, and judgment. Some children may not be able to operate a motorcycle
safely. Parents should supervise their child’s use of the motorcycle at all times.
Parents should permit continued use only if they determine that the child has the
ability to operate the motorcycle safely.
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Introduction
Motorcycles are sin gle track vehicles. Their safe use an d operation are d e-
pen dent upon the use of proper rid ing techniques as well as the expertise of
the operator. Every operator shoul d know the followin g requirements before
ri din g this motorcycle.
He or she should:  Obtain thorough instructions from a competent source on all aspects of mo-
torcycle operation.
 Observe the warnings and maintenance requirements in this Owner’s Manu-
al.
 Obtain qualified training in safe and proper riding techniques.
 Obtain professional technical service as indicated in this Owner’s Manual
and/or when made necessary by mechanical conditions.
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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 ........................................ 4-7
Starter (choke) knob ....................... 4-7
Kickstarter ...................................... 4-8
Seat ................................................ 4-8
Adjusting the front fork ................... 4-9
Front fork bleeding ....................... 4-11
Adjusting the shock absorber assembly ................................... 4-12
Removable sidestand ................... 4-16
YPVS system ................................ 4-17
For your safety – pre-operation
checks ............................................... 5-1
Operation an d important ri din g
points ................................................ 6-1
Engine break-in .............................. 6-1
Starting and warming up a cold
engine ......................................... 6-3
Starting a warm engine .................. 6-3
Shifting ........................................... 6-4
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 ......................................... 7-12
Adjusting the throttle grip free play ............................................ 7-13
Tires .............................................. 7-14
Spoke wheels ................................ 7-16
Adjusting the clutch lever free play ............................................ 7-16
Checking the brake lever free play ............................................ 7-17
Checking the shift pedal ............... 7-18
Checking the front and rear brake pads ................................. 7-18
Checking the brake fluid level ....... 7-19
Changing the brake fluid ............... 7-20
Drive chain slack ........................... 7-21
Cleaning and lubricating the drive chain ................................. 7-22
Checking and lubricating the
cables ........................................ 7-23
Checking and lubricating the throttle grip and cable ............... 7-23
Checking and lubricating the brake and clutch levers ............. 7-24
Checking and lubricating the
brake pedal ................................ 7-24
Lubricating the rear suspension.... 7-25
Lubricating the swingarm pivots ... 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 chart ................... 7-31
Motorcycle care an d stora ge .......... 8-1
Matte color caution ......................... 8-1
Care................................................. 8-1
Storage............................................ 8-4
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Safety information
2-2
2sic motorcycle maintenance.
Certain maintenance can only
be carried out by certified staff.
 Many accidents involve inexperi-
enced operators.
• Make sure that you are qualified and that you only lend your mo-
torcycle to other qualified oper-
ators.
• Know your skills and limits. Staying within your limits may
help you to avoid an accident.
• We recommend that you prac- tice riding your motorcycle until
you have become thoroughly
familiar with the motorcycle and
all of its controls.
 Many accidents have been
caused by error of the motorcycle
operator. A typical error made by
the operator is veering wide on a
turn due to excessive speed or un-
dercornering (insufficient lean an-
gle for the speed). Never travel
faster than warranted by condi-
tions.
 Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.
 The posture of the operator is im-
portant for proper control. The op-
erator should keep both hands on
the handlebar and both feet on the
operator footrests during opera-
tion to maintain control of the mo-
torcycle.
 Never ride under the influence of
alcohol or other drugs.
 Be sure the transmission is in neu-
tral before starting the engine. Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the pre-
vention or reduction of head injuries.
 Always wear an approved helmet.
 Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
 The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abra-
sions or lacerations.
 Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
 Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause
burns.
Avoi d Car bon Monoxi de Poisonin g
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause head-
aches, dizziness, drowsiness, nausea,
confusion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pres-
ent even if you do not see or smell any
engine exhaust. Deadly levels of car-
bon monoxide can collect rapidly and
you can quickly be overcome and un-
able to save yourself. Also, deadly lev-
els of carbon monoxide can linger for
hours or days in enclosed or poorly
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For your safety – pre-operation checks
5-1
5
EAU63441
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating 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 d amage. Do not operate the vehicle if you fin d
any pro blem. If a pro blem cannot be correcte d 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 CHECKSPAGE
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. 4-4, 4-6
Transmission oil • Check for leakage. 7-7
Coolant • Check coolant level.
• If necessary, add recommended coolant to specified
level.
• Check cooling system for leakage. 7-8
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. 7-18,
7-19
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. 7-18,
7-19
Clutch • Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary. 7-16
Throttle grip • Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, adjust throttle grip free play. 7-13,
7-23
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Operation and important rid ing points
6-1
6
EAU15952
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10272
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which coul d cause an acci dent
or injury.
EAU41506
En gine 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 during
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 proced ure
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
minutes. Then, very briefly shift to
Recommen ded 2-stroke en gine oil:
YA M A L U B E 2 R
Mixin g ratio ( gasoline to oil):
15:1
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Periodic maintenance an d a djustment
7-1
7
EAU42074
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.
WARNING
EWA15123
Turn off the en gine when performin g
maintenance unless otherwise
specified .
 A runnin g en gine has movin g
parts that can catch on body
parts or clothin g an d electrical
parts that can cause shocks or
fires.
 Runnin g the en gine while ser-
vicin g can lead to eye injury,
b urns, fire, or car bon monoxi de
poisonin g – possi bly lea din g to d
eath. See pag e 2-2 for more in-
formation a bout car bon monox-
i d e.
WARNING
EWA15461
Brake discs, calipers, drums, an d
linin gs can b ecome very hot durin g
use. To avoi d possi ble burns, let
b rake components cool before
touching them.
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Periodic maintenance an d a djustment
7-2
7
EAU84193
Perio dic maintenance an d lu brication chart
The following chart is intended as a general guide to maintenance and lubrication.
Bear in mind that such factors as weather, terrain, geographical location, and in-
dividual usage will alter the required maintenance and lubrication intervals. If you
are in doubt as to what intervals to follow in maintaining and lubricating your mo-
torcycle, consult your Yamaha dealer.
TIP
Items marked with an asterisk should be performed by a Yamaha dealer as they
require special tools, data and technical skills.
NO. ITEM ROUTINEAfter
break-in
Everyrace
Every
third race
Every
fifth race
As
required
1 *Piston Check piston for carbon deposits and
cracks or damage. Clean.
Replace.

2 *
Piston rings Check piston ring end gap and rings
for damage.
Replace.
3 *
Piston pin and small
end bearing Check piston pin and small end
bearing for damage.
Replace.
4 *
Cylinder head Check cylinder head for carbon
deposits.
 Clean.
Check cylinder head gasket fordamage.
 Tighten cylinder head bolts ifnecessary.
Replace cylinder head gasket.

5 *
Cylinder
6*YPVS Check cylinder for score marks or
wear.


 Clean.
Replace.
Check YPVS for carbon deposits andcracks or damage.
Clean.

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