2024 Yamaha YZ85 Service & Repair Manual

Repair&ServiceManual Le) .7 “;7_—oe-— a Vvpon a’ si% <7-:._-_ we

EAs20003 IMPORTANT ThismanualwasproducedbytheYamahaMotorCompany,Ltd.primarilyforusebyYamahadealers andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanual.Therefore,anyonewhousesthisbooktoperformmaintenanceandrepairsonYamahavehicles shouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles. Pleasereferto“BASICINFORMATION?”(separatevolume,YOA-28197-10*)forbasicinstructionsthat mustbeobservedduringservicing.Repairandmaintenanceworkattemptedbyanyonewithoutthis knowledgeislikelytorenderthevehicleunsafeandunfitforuse. Thismodelhasbeendesignedandmanufacturedtoperformwithincertainspecificationsinregardto performanceandemissions.Properservicewiththecorrecttoolsisnecessarytoensurethatthevehiclewilloperateasdesigned.Ifthereisanyquestionaboutaserviceprocedure,itisimperativethatyou contactaYamahadealerforanyserviceinformationchangesthatapplytothismodel.Thispolicyisintendedtoprovidethecustomerwiththemostsatisfactionfromtheirvehicleandtoconformtofederal environmentalqualityobjectives. YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallofitsmodels.Modificationsandsig- nificantchangesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealersand willappearinfutureeditionsofthismanualwhereapplicable. TIP. ¢*Ifthecontentsofthemanualarerevised,thelastdigitofthemanualnumberwillbeincreasedby one. ¢Designsandspecificationsaresubjecttochangewithoutnotice. AS30001 IMPORTANTMANUALINFORMATION Particularlyimportantinformationisdistinguishedinthismanualbythefollowingnotations. Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonal injuryhazards.Obeyallsafetymessagesthatfollowthissymboltoavoid ig possibleinjuryordeath. AWARNINGindicatesahazardoussituationwhich,ifnotavoided,could AyWARNINGresultindeathorseriousinjury. ANOTICEindicatesspecialprecautionsthatmustbetakentoavoid NOTICEdamagetothevehicleorotherproperty. TIPATIPprovideskeyinformationtomakeprocedureseasierorclearer. YZ85N/YZ85LWN SERVICEMANUAL ©2022byYamahaMotorCorporation,U.S.A. Firstedition,October2021 Allrightsreserved. Anyreproductionorunauthorizeduse withoutthewrittenpermissionof YamahaMotorCorporation,U.S.A. isexpresslyprohibited. PrintedinU.S.A. P/NLIT-11616-35-53

AS20004 HOWTOUSETHISMANUAL Thismanualisintendedasahandy,easy-to-readreferencebookforthemechanic.Comprehensiveex- planationsofallinstallation,removal,disassembly,assembly,repairandcheckproceduresarelaidout withtheindividualstepsinsequentialorder. ¢Themanualisdividedintochaptersandeachchapterisdividedintosections.Thecurrentsectiontitle “1”isshownatthetopofeachpage. ¢Sub-sectiontitles“2”appearinsmallerprintthanthesectiontitle. *Tohelpidentifypartsandclarifyproceduresteps,thereareexplodeddiagrams“3”atthestartofeach removalanddisassemblysection. *Numbers“4”aregivenintheorderofthejobsintheexplodeddiagram.Anumberindicatesaremoval oradisassemblystep. ¢Symbols“5”indicatepartstobelubricatedorreplaced. Referto“SYMBOLS”. Ajobinstructionchart“6”accompaniestheexplodeddiagram,providingtheorderofjobs,namesof parts,notesinjobs,etc.Thisstepexplainsremovalanddisassemblyprocedureonly.Forinstallation andassemblyprocedure,reversethesteps. ¢Jobs“7”requiringmoreinformation(suchasspecialtoolsandtechnicaldata)aredescribedsequen- tially. 1 1 CLUTCHCLUTCH ‘REVIOVINGTHECLUTCHw. 1RaroveRemewotheacerarebeahomthenin ‘Ofainer‘slathonmoveheolpurevechanom Fife1o"O1LPUNT”onpage5:58,‘halpunpavonencendtenrorrene Watepurethasitehhousingwoparpavochaneen PetertoWATERPUMP"onpage6-12, +Pistonlass *Clutchpiss Beasemavenpatna anease thepostonofschpalaothat jadnatorgraleaten 1Staightanthe cih boseeb Zonememenonpares2 fhoconnypescasplonaho engi Peete 2Loosen2 +Cluchbossat"“Teterpistemines aaGutespectication-»Replocetecon lehelingheceaaee“7'wlenorploa Escuishnder“®"coeentnevehbeesnitpp saretetionplateatfourpaces [7]eaegenecornoce Univers!tehnokiorFiltonptemnerness<17 :22-3bemm016-0.921bn) ‘aaots“ate "20mm(0.01) GFL ‘SicxnomecusreHPLATES Thofobsningrocodwppivsatie lushples 5-46550 G088877

AS20005 SYMBOLS Thefollowingsymbolsareusedinthismanualforeasierunderstanding. TIP. Thefollowingsymbolsarenotrelevanttoeveryvehicle. SYMBOLDEFINITIONSYMBOLDEFINITION oi.)ServiceablewithenginemountedAGearoil NPFillingfluidAMolybdenumdisulfideoil em||LubricantABrakefluid (6) &Specialtoola)YWheelbearinggrease Y,Tighteningtorque=PLithium-soap-basedgrease aWearlimit,clearance=aMolybdenumdisulfidegrease oyEnginespeed=asPySiliconegrease Ty. ealElectricaldataAApplylockingagent(LOCTITE®). AEngineoilNewReplacethepartwithanewone.

TABLEOFCONTENTS |GENERALINFORMATION1 SPECIFICATIONS2 PERIODICCHECKSAND ADJUSTMENTS CHASSIS |COOLINGSYSTEM6 FUELSYSTEM7 |ELECTRICALSYSTEM8 TUNING

IDENTIFICATION VEHICLEIDENTIFICATIONNUMBER... FUELANDENGINEMIXINGOIL.........::ssssssssesesesensessssssenenensnsanensetseeaeenenenes1-1 SPECIALTOOLS.......s.s:scssssssssesessessseseesensarsnseeseneareneneneatenenensonsnseeneneaeaneneneaeenes1-2

AS20007 IDENTIFICATION FUELANDENGINEMIXINGOIL Mixoilwiththegasattheratiospecifiedbelow. Alwaysusefresh,name-brandgasoline,and mixtheoilandgasthedayoftherace.Donot usepremixthatismorethanafewhoursold. Recommendedfuel Premiumunleadedgasoline (E10acceptable) Minimumresearchoctane 98 TIP. Ifknockingorpingingoccurs,useadifferent brandofgasolineorhigheroctanegrade. Ecaze2so NOTICE Nevermixtwotypesofoilinthesamebatch; clottingoftheoilcouldresult.Ifyouwishto changeoiltypes,besuretodrainthefuel tankandthecarburetorfloatbowlofoldpremixpriortofillingwiththenewtype. SFueltankcapacity 5.0L(1.3USgal,1.1Imp.gal) Engineoil YAMALUBE2R Lubricationsystem Premixlubrication *Ifunavailable,useanequivalenttypeof oil. 1-1 IDENTIFICATION YAMALUBE“2-R”

2024 Yamaha YZ85 Service & Repair Manual

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