YAMAHA YZ85W1 Manuals

Manuals and User Guides for YAMAHA YZ85W1. We have 2 YAMAHA YZ85W1 manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha YZ85W1 Service Manual

Yamaha YZ85W1 Service Manual (255 pages)

Brand: Yamaha | Category: Motorcycle | Size: 9.61 MB

Table of Contents

Gen Info

7
- Table of Contents
  7
- General Information
  8
- Vehicle Identification
  8
- Vehicle Identification Number
  8
- Model Label
  8
- Important Information
  9
- Preparation for Removal and Disassembly
  9
- Replacement Parts
  9
- Gaskets, Oil Seals and O-Rings
  9
- Lock Washers / Plates and Cotter Pins
  10
- Bearings and Oil Seals
  10
- Circlips
  10
- Fuel and Engine Mixing Oil
  11
- Checking the Connections
  12
- Special Tools
  13
Table of Contents

16
- General Specifications
  17
- Specifications
  17
- Engine Specifications
  18
- Chassis Specifications
  23
- Electrical Specifications
  27
- Conversion Table
  28
- General Tightening Torque Specifications
  28
- Engine Tightening Torques
  29
- Tightening Torques
  29
- Chassis Tightening Torques
  30
- Chassis
  32
- Engine
  32
- Lubrication Points and Lubricant Types
  32
- Cable Routing
  33
Chapter 3 Periodic Checks and Adjustments

38
Table of Contents

71
- Front Wheel and Brake Disc
  73
- Checking the Front Wheel
  75
- Removing the Front Wheel
  75
- Checking the Brake Discs
  78
- Installing the Front Wheel
  79
- Rear Wheel
  80
- Rear Wheel and Brake Disc
  80
- Rear Brake Disc and Rear Wheel Sprocket
  82
- Removing the Rear Wheel
  84
- Checking and Replacing the Rear Wheel Sprocket
  85
- Checking the Rear Wheel
  85
- Installing the Rear Wheel
  86
- Front and Rear Brakes
  87
- Front Brake Pads
  87
- Rear Brake Pads
  88
- Replacing the Front Brake Pads
  89
- Replacing the Rear Brake Pads
  91
- Front Brake Master Cylinder
  93
- Rear Brake Master Cylinder
  95
- Disassembling the Front Brake Master Cylinder
  97
- Disassembling the Rear Brake Master Cylinder
  97
- Checking the Front and Rear Brake Master
  98
- Cylinders
  98
- Assembling and Installing the Front Brake Master
  99
- Assembling the Rear Brake Master Cylinder
  101
- Cylinder
  101
- Front Brake Caliper
  103
- Rear Brake Caliper
  105
- Disassembling the Rear Brake Caliper
  106
- Checking the Front and Rear Brake Calipers
  108
- Assembling and Installing the Front Brake Caliper
  109
- Assembling and Installing the Rear Brake Caliper
  111
- Front Fork
  114
- Front Fork Legs
  114
- Removing the Front Fork Legs
  117
- Disassembling the Front Fork Legs
  118
- Checking the Front Fork Legs
  119
- Assembling the Front Fork Legs
  120
- Installing the Front Fork Legs
  126
- Handlebar
  127
- Checking the Handlebar
  129
- Installing the Handlebar
  129
- Removing the Handlebar
  129
- Steering Head
  133
- Under Bracket
  133
- Checking the Steering Head
  134
- Removing the Lower Bracket
  134
- Installing the Steering Head
  135
- Rear Shock Absorber Assembly
  137
- Disposing of a Rear Shock Absorber and Gas
  138
- Handling the Rear Shock Absorber and Gas
  138
- Removing the Rear Shock Absorber Assembly
  139
- Checking the Rear Shock Absorber Assembly and Gas Cylinder
  140
- Installing the Rear Shock Absorber Assembly
  140
- Swingarm and Drive Chain
  142
- Removing the Swingarm
  144
- Checking the Swingarm
  145
- Removing the Drive Chain
  145
- Checking the Drive Chain
  146
- Checking the Drive Chain Support
  148
- Installing the Swingarm
  148
- Installing the Drive Chain
  150
Chapter 5 Engine

152
- Drive Sprocket
  154
- Engine
  154
- Exhaust Pipe
  155
- Engine
  156
- Silencer Fiber Replacement
  156
- Installing the Engine
  159
- Cylinder Head
  160
- Cylinder Head, Cylinder and Piston
  160
- Checking the Cylinder Head
  161
- Removing the Cylinder Head
  161
- Installing the Cylinder Head
  162
- Cylinder and Piston
  163
- Checking the Cylinder and Piston
  164
- Removing the Cylinder and Piston
  164
- Combination of Piston and Cylinder
  166
- Checking the Piston Pin
  167
- Checking the Piston Ring
  167
- Checking the Small End Bearing
  168
- Installing the Piston and Cylinder
  169
- Clutch
  171
- Removing the Clutch
  173
- Checking the Clutch Plates
  174
- Checking the Friction Plates
  174
- Checking the Clutch Boss
  175
- Checking the Clutch Housing
  175
- Checking the Clutch Springs
  175
- Checking the Pressure Plate
  175
- Checking the Clutch Push Rods
  176
- Checking the Push Lever Shaft
  176
- Installing the Clutch
  176
- Kick Starter and Shift Shaft
  179
- Primary Drive Gear
  179
- Checking the Kick Starter
  183
- Removing the Kick Shaft Assembly
  183
- Removing the Primary Drive Gear
  183
- Checking the Primary Drive Gear and Primary
  184
- Checking the Shift Shaft
  184
- Checking the Stopper Lever
  184
- Driven Gear
  184
- Installing the Shift Shaft
  184
- Installing the Kick Idle Gear
  186
- Installing the Kick Starter Shaft Assembly
  186
- Installing the Primary Drive Gear
  187
- CDI Magneto
  189
- Checking the CDI Magneto
  190
- Checking the Woodruff Key
  190
- Removing the Rotor
  190
- Installing the CDI Magneto
  191
- Crankcase and Crankshaft
  193
- Dissassembling the Crankcase
  194
- Removing the Crankshaft Assembly
  194
- Checking the Crankshaft and Connecting Rod
  195
- Removing the Crankshaft Bearing
  195
- Checking the Bearings and Oil Seals
  196
- Checking the Crankcase
  196
- Assembling the Crankcase
  197
- Installing the Crankshaft
  197
- Transmission
  199
- Checking the Shift Forks
  202
- Removing the Transmission
  202
- Checking the Shift Drum Assembly
  203
- Checking the Transmission
  203
- Installing the Transmission
  204
Radiator/Water Pump

207
- Cooling System
  208
- Radiator
  208
- Checking the Radiator
  209
- Installing the Radiator
  209
- Water Pump
  211
- Checking the Water Pump
  212
- Installing the Water Pump
  212
Table of Contents

214
- Carburetor and Reed Valve
  215
- Checking the Carburetor
  218
- Checking the Reed Valve
  219
- Assembling the Carburetor
  220
- Assembly the Reed Valve
  220
- Installing the Carburetor
  222
- Installing the Reed Valve
  222
- Checking the Fuel Cock
  223
- Measuring and Adjusting the Fuel Level
  223
Table of Contents

224
- Electrical Components
  225
- Electrical System
  225
- Checking Switch Continuity
  226
- Ignition System
  227
- Troubleshooting
  227
Chapter 9 Tuning

231
- Atmospheric Conditions and Carburetor Settings
  232
- Carburetor Setting
  232
- Engine
  232
- Effects of the Setting Parts on the Throttle Valve
  233
- Test Run
  233
- Jet Needle Adjustment
  234
- Main Jet Adjustment
  234
- Pilot Air Screw Adjustment
  234
- Pilot Jet Adjustment
  234
- Carburetor Setting Parts
  235
- Jet Needle Groove Position Adjustment
  235
- Examples of Carburetor Setting Depending on
  236
- Road Condition and Examples of Carburetor
  236
- Setting
  236
- Symptom
  236
- Change of the Heat Range of Spark Plugs
  237
- Chassis
  238
- Selection of the Secondary Reduction Ratio
  238
- Drive and Driven Sprockets Setting Parts
  239
- Sprocket
  239
- Front Fork Setting
  240
- Tire Pressure
  240
- Change in Level and Characteristics of Fork Oil
  241
- Setting of Spring after Replacement
  241
- Front Fork Setting Parts
  242
- Choosing Set Length
  243
- Rear Suspension Setting
  243
- Setting of Spring after Replacement
  244
- Rear Shock Absorber Setting Parts
  245
- Suspension Setting
  246
Trbl Shtg

248
- Electrical Systems
  249
- Engine
  249
- Fuel System
  249
- Starting Failures
  249
- Troubleshooting
  249
- Electrical Systems
  250
- Engine
  250
- Faulty Gear Shifting
  250
- Fuel System
  250
- Incorrect Engine Idling Speed
  250
- Jumps out of Gear
  250
- Poor Medium-And-High-Speed Performance
  250
- Shift Pedal Does Not Move
  250
- Shifting Is Difficult
  250
- Chassis
  251
- Clutch Drags
  251
- Clutch Slips
  251
- Cooling System
  251
- Electrical Systems
  251
- Engine
  251
- Faulty Clutch
  251
- Fuel System
  251
- Overheating
  251
- Faulty Front Fork Legs
  252
- Leaking Oil
  252
- Malfunction
  252
- Poor Braking Performance
  252
- Unstable Handling
  252

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YAMAHA YZ85W1 Owner's Manual

YAMAHA YZ85W1 Owner's Manual (82 pages)

Brand: YAMAHA | Category: Motorcycle | Size: 3.92 MB

Table of Contents

Important Manual Information
6
Table of Contents
9
Safety Information

10
- Location of Important Labels
  13
Description

21
- Left View
  21
- Right View
  22
- Controls and Instruments
  23
Instrument and Control Functions

24
- Handlebar Switch
  24
- Clutch Lever
  24
- Shift Pedal
  24
- Brake Lever
  25
- Brake Pedal
  25
- Fuel Tank Cap
  26
- Fuel
  26
- Fuel Tank Breather Hose
  28
- Fuel Cock
  28
- Starter (Choke) Knob
  29
- Kickstarter
  29
- Seat
  29
- Adjusting the Front Fork
  30
- Front Fork Bleeding
  31
- Specifications
  31
- Adjusting the Shock Absorber Assembly
  32
- Removable Sidestand
  35
Pre-Operation Checks

36
- Pre-Operation Check List
  37
Operation and Important Riding Points

39
- Starting and Warming up a Cold Engine
  39
- Starting a Warm Engine
  39
- Shifting
  40
- Engine Break-In
  41
- Parking
  42
Periodic Maintenance and Minor Repair

43
- Periodic Maintenance and Lubrication Chart
  44
- Checking the Spark Plug
  50
- Transmission Oil
  51
- Coolant
  52
- Cleaning the Air Filter Element
  54
- Adjusting the Carburetor
  56
- Adjusting the Throttle Cable Free Play
  56
- Tires
  57
- Spoke Wheels
  59
- Accessories and Replacement Parts
  59
- Adjusting the Clutch Lever Free Play
  59
- Checking the Front and Rear Brake Pads
  60
- Checking the Brake Fluid Level
  61
- Changing the Brake Fluid
  62
- Drive Chain Slack
  62
- Cleaning and Lubricating the Drive Chain
  63
- Checking and Lubricating the Cables
  64
- Checking and Lubricating the Throttle Grip and Cable
  64
- Checking and Lubricating the Brake and Shift Pedals
  65
- Checking and Lubricating the Brake and Clutch Levers
  65
- Lubricating the Swingarm Pivots
  66
- Lubricating the Rear Suspension
  66
- Checking the Front Fork
  66
- Checking the Steering
  67
- Checking the Wheel Bearings
  68
- Supporting the Motorcycle
  68
- Front Wheel
  69
- Rear Wheel
  69
- Troubleshooting
  71
- Troubleshooting Charts
  72
Motorcycle Care and Storage

74
- Care
  74
- Storage
  76
Specifications

77
Consumer Information

80
- Identification Numbers
  80

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