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Yamaha YZ85-2006

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P0ldy 2:35pm on Sunday, October 17th, 2010 
Versatility is the name of the game for me when it comes to buying a bike. It must be able to do many things if it wants to find a spot in my garage.

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Documents

doc0

EWA10030

WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

EWA14350

WARNING THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL 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. *Product and specifications are subject to change without notice.
U5PA85E0.book Page 3 Thursday, April 13, 2006 3:06 PM

EAU10200

YZ85(W)/YZ85W1/YZ85LW(W) OWNERS MANUAL 2006 by Yamaha Motor Co., Ltd. 1st edition, March 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

TABLE OF CONTENTS

SAFETY INFORMATION.1-1 Location of important labels.1-4 DESCRIPTION..2-1 Left view..2-1 Right view..2-2 Controls and instruments.2-3 INSTRUMENT AND CONTROL FUNCTIONS..3-1 Handlebar switch..3-1 Clutch lever.3-1 Shift pedal..3-1 Brake lever..3-2 Brake pedal.3-2 Fuel tank cap..3-3 Fuel..3-3 Fuel tank breather hose..3-5 Fuel cock..3-5 Starter (choke) knob..3-6 Kickstarter..3-6 Seat..3-6 Adjusting the front fork.3-7 Front fork bleeding..3-8 Adjusting the shock absorber assembly..3-9 Removable sidestand.3-12 PRE-OPERATION CHECKS.4-1 Pre-operation check list.4-2 OPERATION AND IMPORTANT RIDING POINTS.. 5-1 Starting and warming up a cold engine... 5-1 Starting a warm engine. 5-1 Shifting.. 5-2 Engine break-in.. 5-3 Parking.. 5-4 PERIODIC MAINTENANCE AND MINOR REPAIR.. 6-1 Periodic maintenance and lubrication chart. 6-2 Checking the spark plug. 6-8 Transmission oil.. 6-9 Coolant.. 6-10 Cleaning the air filter element. 6-12 Adjusting the carburetor.. 6-14 Adjusting the throttle cable free play. 6-14 Tires.. 6-15 Spoke wheels.. 6-17 Accessories and replacement parts... 6-17 Adjusting the clutch lever free play. 6-17 Checking the front and rear brake pads.. 6-18 Checking the brake fluid level. 6-19 Changing the brake fluid. 6-20 Drive chain slack. 6-20 Cleaning and lubricating the drive chain.. 6-21 Checking and lubricating the cables.. 6-22 Checking and lubricating the throttle grip and cable.. 6-22 Checking and lubricating the brake and shift pedals.. 6-23 Checking and lubricating the brake and clutch levers. 6-23 Lubricating the swingarm pivots. 6-24 Lubricating the rear suspension. 6-24 Checking the front fork.. 6-24 Checking the steering. 6-25 Checking the wheel bearings. 6-26 Supporting the motorcycle. 6-26 Front wheel.. 6-27 Rear wheel.. 6-27 Troubleshooting.. 6-29 Troubleshooting charts.. 6-30 MOTORCYCLE CARE AND STORAGE.. 7-1 Care.. 7-1 Storage.. 7-3 SPECIFICATIONS.. 8-1 CONSUMER INFORMATION. 9-1 Identification numbers.. 9-1

front fork area, they must be as lightweight as possible and should be kept to a minimum. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycles electrical system an electric failure could result, which could cause a dangerous loss of engine power.
Gasoline and exhaust gas G GASOLINE IS HIGHLY FLAMMABLE: Be sure to always use a fresh mixture of oil and gasoline. Always turn the engine off when refueling. Take care not to spill any gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking or in the vicinity of an open flame. G Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. G Always turn the engine off before leaving the motorcycle unattended. When parking the motorcycle, note the following: The engine and exhaust pipe/muffler may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. When transporting the motorcycle in another vehicle, make sure that it is kept upright and that the fuel cock is turned to OFF. If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.
U5PA85E0.book Page 4 Thursday, April 13, 2006 3:06 PM

EAU41851

Location of important labels
Please read the following important labels carefully before operating this vehicle. YZ85(W)/YZ85W1 1
U5PA85E0.book Page 5 Thursday, April 13, 2006 3:06 PM

For Canada

CAUTION
Use premium unleaded gasoline/oil premix only.

3XJ-2415E-A0

Rinding as a passenger can cause the vehicle to go out of control. Loss of control can cause a collision or rollover, which can result in severe injury or death. NEVER ride as a passenger.

EWA10880

Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. Avoid spilling fuel on the hot engine.

EAU41360 EAU41280

Fuel tank breather hose

Fuel cock

The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has two positions: OFF
1. Arrow mark positioned over ON 1. Fuel tank breather hose 2. One-way valve
Before operating the motorcycle: G Check the fuel tank breather hose connection. G Check the fuel tank breather hose for cracks or damage, and replace it if damaged. G Make sure that the end of the fuel tank breather hose is not blocked, and clean it if necessary. NOTE: If the fuel tank breather hose falls out, reinstall it on the fuel tank cap with the arrow mark on the one-way valve pointed downward as shown.
With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.
1. Arrow mark positioned over OFF
With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.
EAU13640 EAU13650 EAU13960

Starter (choke) knob

Kickstarter
To remove the seat Remove the bolts, and then pull the seat off.

1. Starter (choke) knob

1. Kickstarter lever
Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction (a) to turn on the starter (choke). Move the knob in direction (b) to turn off the starter (choke).
To start the engine, fold out the kickstarter lever, move it down lightly with your foot until the gears engage, and then push it down smoothly but forcefully. This model is equipped with a primary kickstarter, allowing the engine to be started in any gear if the clutch is disengaged. However, shifting the transmission into the neutral position before starting is recommended.

1. Bolt

To install the seat 1. Insert the projections on the front of the seat into the seat holders as shown.

EAU41470

Adjusting the front fork
This front fork is equipped with rebound damping force adjusting screws and compression damping force adjusting screws.

EWA10180

soften the rebound damping, turn the adjusting screw on each fork leg in direction (b).

3. Install the rubber cap.

ECA10100

CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.

EWA10200 EAU41330

WARNING Always bleed both fork legs, otherwise poor handling and loss of stability may result. 3. Install the bleed screws. 3
Adjusting the shock absorber assembly
This shock absorber assembly is equipped with a spring preload adjusting nut, a rebound damping force adjusting screw and a compression damping force adjusting screw.
2. To increase the spring preload and thereby harden the suspension, turn the adjusting nut in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting nut in direction (b). NOTE: G A special wrench can be obtained at a Yamaha dealer to make this adjustment. G The spring preload setting is determined by measuring distance A, shown in the illustration. The longer distance A is, the lower the spring preload; the shorter distance A is, the higher the spring preload. With each complete turn of the adjusting nut, distance A is changed by 1.5 mm (0.06 in).
CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. Spring preload Adjust the spring preload as follows. 1. Loosen the locknut.
1. Locknut 2. Spring preload adjusting nut 3-9

ECA10120

CAUTION: Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. Rebound damping force To increase the rebound damping force 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).

1. Distance A

Spring preload: Minimum (soft): Distance A = 218.5 mm (8.60 in) Standard: YZ85(W)/YZ85W1 Distance A = 215.0 mm (8.46 in) For Europe only: Distance A = 212.0 mm (8.35 in) Standard: YZ85LW(W) Distance A = 207.0 mm (8.15 in) For Europe only: Distance A = 212.0 mm (8.35 in) Maximum (hard): Distance A = 202.5 mm (7.97 in)
Rebound damping setting: Minimum (soft): 20 click(s) in direction (b)* Standard: YZ85(W)/YZ85Wclick(s) in direction (b)* For Europe only: 12 click(s) in direction (b)* Standard: YZ85LW(W) 7 click(s) in direction (b)* For Europe only: 12 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in direction (a)
Compression damping force To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b).

1. Turn the fuel cock lever to ON. 2. Shift the transmission into the neutral position. 3. Turn the starter (choke) on and completely close the throttle. (See page 3-6.) 4. Start the engine by pushing the kickstarter lever down.

ECA11130

Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. NOTE: If the engine does not start after several kicks, try again with the throttle 1/4 to 1/2 open. 5
This model is designed for offroad use only. Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation. Before starting out, make sure that the sidestand is removed. If the sidestand is not removed, it will contact the ground, which could distract the operator or affect the balance of the motorcycle, resulting in a possible loss of control.
CAUTION: For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! 5. When the engine is warm, turn the starter (choke) off. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off.

EAU16671 ECA10260

Shifting

CAUTION:

1. Shift pedal 2. Neutral position
Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. NOTE: To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it.
Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission. Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.

ECA15560

WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you. 7. Drain the break-in oil-fuel mixture from the fuel tank and refill with the specified mix. (See page 3-3.) 8. Start the engine and check the operation of the motorcycle throughout its entire operating range. Stop the engine and check the spark
When any of the following parts have been replaced, they must be broken in. Cylinder or crankshaft: About one hour of break-in operation is necessary. Piston, rings or transmission gears: These parts require about 30 minutes of break-in operation at half-throttle or less. Observe the condition of the engine carefully during operation.
If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.

EAU17190

Parking
When parking, stop the engine, and then turn the fuel cock lever to OFF.

EWA10310

Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn.
PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17240

Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED.
WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you.

EAU41794

Periodic maintenance and lubrication 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 individual 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 motorcycle, consult your Yamaha dealer. NOTE: G From the seventh race, repeat the maintenance intervals starting from Every race. G Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

21 * Brakes

Replace brake pads. Replace brake fluid. 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. Check operation and adjust. Tighten if necessary. Shock absorber assem23 * bly Lubricate with molybdenum disulfide grease. Every year

22 * Front fork

(After washing the motorcycle or riding in the rain)
NO. ITEM Drive chain roller and support guide ROUTINE Check for wear or damage. Replace if necessary. Check operation and tighten if necessary. Lubricate with molybdenum disulfide grease. Check operation, free play, and tighten if necessary. 26 * Steering head Clean and lubricate with lithium-soap-based grease. Replace bearings. Check tire air pressure, wheel runout, spokes for looseness, and tires for wear. Tighten sprocket bolts if necessary. 27 * Tires and wheels Check wheel bearings for looseness. Lubricate wheel bearings with lithium-soap-based grease. Replace wheel bearings. Moving parts and ca28 * bles 29 * Throttle grip housing and cable Lubricate. Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. After break-in Every race Every Every third race fifth race As required

25 * Rear suspension

EAU42010
NOTE: G Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.

EAU19612

Checking the spark plug
The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine. To remove the spark plug 1. Remove the spark plug cap. 6
2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

EWA14390

Tire information This motorcycle is equipped with spoke wheels and tube tires.

EWA10460

WARNING 6
sively worn tires decreases riding stability and can lead to loss of control. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. It is not recommended to patch a punctured tube. If unavoidable, however, patch the tube very carefully and replace it as soon as possible with a highquality product.
The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle cannot be guaranteed. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.
Have a Yamaha dealer replace excessively worn tires. Operating the motorcycle with exces6-16
U5PA85E0.book Page 17 Thursday, April 13, 2006 3:06 PM
EAU21940 EAU40431 EAU22031

Spoke wheels

To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. G The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or damage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced. G The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life. G Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics.
Accessories and replacement parts

EWA14481

Adjusting the clutch lever free play
WARNING The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your vehicle. Yamaha recommends the use of Genuine Yamaha Parts and Accessories before making a purchase. Use of non-Yamaha-approved accessories or replacement parts may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of accessories or parts manufactured by other companies, Yamaha cannot be held liable for any consequences caused by the use of items which have not been approved by Yamaha.
1. Clutch lever free play 2. Locknut (clutch lever) 3. Adjusting bolt

Recommended brake fluid: DOT 4
Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.
Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.
U5PA85E0.book Page 20 Thursday, April 13, 2006 3:06 PM

EAU22730 EAU22760

Changing the brake fluid
Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication 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. G Oil seals: Replace every two years. G Brake hoses: Replace every four years. 6

Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary.

EAU41410

To check the drive chain slack 1. Install the removable sidestand and place the motorcycle on it. NOTE: When checking and adjusting the drive chain slack, there should be no weight on the motorcycle. 2. Shift the transmission into the neutral position. 3. Move the rear wheel by pushing the motorcycle to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown.
Drive chain slack: 35.045.0 mm (1.381.77 in)

1. Drive chain slack

4. If the drive chain slack is incorrect, adjust it as follows.

EAU41480

To adjust the drive chain slack 1. Loosen the axle nut and the locknut on each side of the swingarm. 2. To tighten the drive chain, turn the adjusting bolt on each side of the swingarm in direction (a). To loosen the drive chain, turn the adjusting bolt on each side of the swingarm in direction (b), and then push the rear wheel forward.
U5PA85E0.book Page 21 Thursday, April 13, 2006 3:06 PM
NOTE: Using the alignment marks on each chain puller, make sure that both chain pullers are in the same position for proper wheel alignment. 3. Tighten both locknuts and the axle nut to the specified torques.

Cleaning

ECA10770
Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray. Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive
cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents. For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield. Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.
After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning. After riding in the rain or near the sea Since sea salt is extremely corrosive, carry out the following steps after each ride in the rain or near the sea. 1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down.

ECA10790

CAUTION: Do not use warm water since it increases the corrosive action of the salt. 2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion.
After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 5. Use spray oil as a universal cleaner to remove any remaining dirt. 6. Touch up minor paint damage caused by stones, etc. 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing or covering it.

EWA11130

If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent. Before riding at higher speeds, test the motorcycles braking performance and cornering behavior.

ECA10800

Apply spray oil and wax sparingly and make sure to wipe off any excess. Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint.
NOTE: Consult a Yamaha dealer for advice on what products to use.
Make sure that there is no oil or wax on the brakes or tires.

EAU41511

Storage
Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.

ECA10810

Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust. To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.
Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the Care section of this chapter. 2. For motorcycles equipped with a fuel cock that has an OFF position: Turn the fuel cock lever to OFF.
3. Drain the fuel tank and fuel lines, and the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. 4. Perform the following steps to protect the cylinder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark plug. b. Pour a teaspoonful of engine oil into the spark plug bore. c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap.

EWA10950

WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. 5. Lubricate all control cables and the pivoting points of all levers and pedals. 6. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 7. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. NOTE: Make any necessary repairs before storing the motorcycle.

SPECIFICATIONS

Dimensions:
Overall length: YZmm (71.6 in) (AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)( FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)( SWE) YZmm (71.7 in) (ZAF) YZ85LW 1903 mm (74.9 in) YZ85LWW 1903 mm (74.9 in) YZ85W 1818 mm (71.6 in) YZ85Wmm (71.6 in) Overall width: 758 mm (29.8 in) Overall height: YZmm (45.7 in) YZ85LW 1205 mm (47.4 in) YZ85LWW 1205 mm (47.4 in) YZ85W 1161 mm (45.7 in) YZ85Wmm (45.7 in) Seat height: YZmm (34.0 in) YZ85LW 904 mm (35.6 in) YZ85LWW 904 mm (35.6 in) YZ85W 864 mm (34.0 in) YZ85Wmm (34.0 in) Wheelbase: YZmm (49.4 in) (AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)( FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)( SWE) YZmm (49.5 in) (ZAF) YZ85LW 1286 mm (50.6 in) YZ85LWW 1286 mm (50.6 in) YZ85W 1255 mm (49.4 in) YZ85Wmm (49.4 in) Ground clearance: YZmm (13.82 in) YZ85LW 393 mm (15.47 in) YZ85LWW 393 mm (15.47 in) YZ85W 351 mm (13.82 in) YZ85Wmm (13.82 in)

Transmission oil:

Type: YAMALUBE 4 (10W30) or SAE10W30 type SE motor oil Oil change quantity: 0.50 L (0.53 US qt) (0.44 Imp.qt)

Cooling system:

Radiator capacity (including all routes): 0.54 L (0.57 US qt) (0.48 Imp.qt)

Weight:

With oil and fuel: YZ85 71.0 kg (157 lb) YZ85LW 73.9 kg (163 lb) YZ85LWW 73.9 kg (163 lb) YZ85W 71.0 kg (157 lb) YZ85W1 71.0 kg (157 lb)

Air filter:

Air filter element: Wet element
Recommended fuel: Premium unleaded gasoline only Fuel tank capacity: 5.0 L (1.32 US gal) (1.10 Imp.gal)

Engine:

Engine type: Liquid cooled 2-stroke Cylinder arrangement: Forward-inclined single cylinder Displacement: 84.7 cm (5.17 cu.in) Bore stroke: 47.5 47.8 mm (1.87 1.88 in) Compression ratio: 8.20 :1 Starting system: Kickstarter Lubrication system: Premix

Carburetor:

Manufacturer: KEIHIN Type quantity: PWK28 x 1

Spark plug (s):

Manufacturer/model: NGK/BR10EG Spark plug gap: 0.50.6 mm (0.0200.024 in)

Clutch:

Clutch type: Wet, multiple-disc

Engine oil:

Type: YAMALUBE 2-R 8-1

Transmission:

Primary reduction system: Spur gear
Primary reduction ratio: 65/18 (3.611) Secondary reduction system: Chain drive Secondary reduction ratio: YZ85 47/14 (3.357) (ZAF) YZ85 48/14 (3.428) (AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)( FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)( SWE) YZ85LW 52/14 (3.714) YZ85LWW 52/14 (3.714) YZ85W 47/14 (3.357) YZ85W1 48/14 (3.428) Transmission type: Constant mesh 6-speed Operation: Left foot operation Gear ratio: 1st: 27/11 (2.454) 2nd: 32/17 (1.882) 3rd: 26/17 (1.529) 4th: 22/17 (1.294) 5th: 26/23 (1.130) 6th: 25/25 (1.000) Caster angle: YZ85 26.30 YZ85LW 26.90 YZ85LWW 26.90 YZ85W 26.30 YZ85W1 26.30 Trail: YZ85 88.0 mm (3.46 in) YZ85LW 105.5 mm (4.15 in) YZ85LWW 105.5 mm (4.15 in) YZ85W 88.0 mm (3.46 in) YZ85W1 88.0 mm (3.46 in) Size: YZ85 90/100-14 49M YZ85LW 90/100-16 52M YZ85LWW 90/100-16 52M YZ85W 90/100-14 49M YZ85W1 90/100-14 49M Manufacturer/model: DUNLOP/D756
Tire air pressure (measured on cold tires):
Front: 100 kPa (15 psi) (1.00 kgf/cm) Rear: 100 kPa (15 psi) (1.00 kgf/cm)

Front tire:

Type: With tube Size: YZ85 70/100-17 40M YZ85LW 70/100-19 42M YZ85LWW 70/100-19 42M YZ85W 70/100-17 40M YZ85W1 70/100-17 40M Manufacturer/model: YZ85 DUNLOP/D739FA (ZAF) YZ85 DUNLOP/D756F (AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)( FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)( SWE) YZ85LW DUNLOP/D756F YZ85LWW DUNLOP/D756F YZ85W DUNLOP/D756F YZ85W1 DUNLOP/D756F

Front wheel:

Wheel type: Spoke wheel Rim size: YZ85 17x1.40 YZ85LW 19x1.40 YZ85LWW 19x1.40 YZ85W 17x1.40 YZ85W1 17x1.40

Rear wheel:

Wheel type: Spoke wheel Rim size: YZ85 14x1.60 YZ85LW 16x1.85 YZ85LWW 16x1.85 YZ85W 14x1.60 YZ85W1 14x1.60

Chassis:

Frame type: Semi double cradle

Rear tire:

Type: With tube 8-2

Front brake:

Type: Single disc brake Operation: Right hand operation Recommended fluid: DOT 4

Electrical system:

Ignition system: CDI

Rear brake:

Type: Single disc brake Operation: Right foot operation Recommended fluid: DOT 4

Front suspension:

Type: Telescopic fork Spring/shock absorber type: Coil spring/oil damper Wheel travel: 275.0 mm (10.83 in)

Rear suspension:

Type: Swingarm (link suspension) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: YZ85 282.0 mm (11.10 in) YZ85LW 287.0 mm (11.30 in) YZ85LWW 287.0 mm (11.30 in) YZ85W 282.0 mm (11.10 in) YZ85W1 282.0 mm (11.10 in)

CONSUMER INFORMATION

EAU40790 EAU26400 EAU26460

Identification numbers

Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. VEHICLE IDENTIFICATION NUMBER:
Vehicle identification number

Model label

1. Vehicle identification number

1. Model label

MODEL LABEL INFORMATION:
The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided. NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area.
The model label is affixed to the location shown. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
Accessories and replacement parts.. 6-17 Air filter element, cleaning.. 6-12 Fuel tank cap..3-3 Swingarm pivots, lubricating.. 6-24

Handlebar switch..3-1

Throttle cable free play, adjusting. 6-14 Throttle grip and cable, checking and lubricating. 6-22 Tires.. 6-15 Transmission oil.. 6-9 Troubleshooting. 6-29 Troubleshooting charts.. 6-30
Brake and clutch levers, checking and lubricating. 6-23 Brake and shift pedals, checking and lubricating. 6-23 Brake fluid, changing.. 6-20 Brake fluid level, checking.. 6-19 Brake lever.. 3-2 Brake pedal.. 3-2
Identification numbers..9-1

Kickstarter..3-6

Labels, location of..1-4

Model label...9-1

Vehicle identification number. 9-1
Cables, checking and lubricating.. 6-22 Carburetor, adjusting.. 6-14 Care... 7-1 Clutch lever.. 3-1 Clutch lever free play, adjusting. 6-17 Coolant.. 6-10
Parking..5-4 Part locations..2-1 Periodic maintenance and lubrication chart..6-2 Pre-operation check list..4-2
Wheel bearings, checking. 6-26 Wheel (front)... 6-27 Wheel (rear).. 6-27 Wheels.. 6-17

doc1

by Technical Touch

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RACING PARTS CATALOGUE

KYB Worldtitels

Year 2007 2008 2009
Class GP 500 MX 125 MX 250 MX 125 MX 250 MX 250 MX 500 GP 250 MX 250 MX 500 MX 125 MX 250 MX 500 MX 250 MX1 MX1 MX1 MX1 MX3 MXW MX1 MX85cc EMX2
Name Kevin Schwantz Pedro Tragter Stefan Everts Sebastian Tortelli Stefan Everts Sebastian Tortelli Andrea Bartolini Olivier Jacque Mickael Pichon Stefan Everts Mickael Maschio Mickael Pichon Stefan Everts Stefan Everts Stefan Everts Stefan Everts Stefan Everts Steve Ramon Yves Demaria Kathrin Prumm David Philippaerts Jeffrey Herlings
Make Suzuki Suzuki Kawasaki Kawasaki Honda Kawasaki Yamaha Yamaha Suzuki Yamaha Kawasaki Suzuki Yamaha Yamaha Yamaha Yamaha Yamaha Suzuki Yamaha Kawasaki Yamaha Suzuki
Model RSV 500 RM125WS KX-SR250 KX-SR125 CR250 KX-SR250 YZM400F YZR250 RM250WS YZM500F KX-SR125 RM250WS YZM500F YZM450F YZM450F YZM450F YZM450F RM-Z450WS YZ480F KX250F YZM450F RM85 YZ250F
Christophe Charlier Yamaha

Content

INTRODUCTION SEMI-FACTORY KIT 2009 SEMI-FACTORY KIT - MINICROSS 3. SEMI-FACTORY KIT FRONT FORK 85cc 4. SEMI-FACTORY KIT REAR SHOCK 85cc 5. WORKS KIT - FORK INSERT 1. SEMI-FACTORY KIT FRONT FORK 2. SEMI-FACTORY KIT REAR SHOCK
RACING ACCESSOIRES - FORK RACING ACCESSOIRES - SHOCK MERCHANDISE WORKSHOP 12. PRELOAD ADJUSTER 13. BUMP RUBBER KIT REAR SHOCK 14. TITANIUM SPRING 15. Cylinder CAP 16. ADJUSTER CASE 17. VALVE CAP 6. COATED INNERTUBE 7. TRIPLE CLAMP 8. Compression unit for WR 9. CARBON FIBER PROTECTION 10. SPRING COLLAR 11. COLOURED TOP CAP 15 16
Introduction Technical Touch
Welcome to the KYB By Technical Touch catalogue
Not only for World champions ! Since 1991, Technical Touch is the official provider of assistance, set-up, development and maintenance of the KYB factory suspensions. We support the factory teams competing in the MX-worldchampionships, such as Team Yamaha Rinaldi, Team Suzuki Geboers, and Kawasaki Racing Team. Side by side we fight to achieve the next world title. In the past as in the present, we are proud to cooperate with many legendary riders : David Philippaerts, Steve Ramon, Ken De Dycker, Joshua Coppins, Tanel Leok, Kevin Strijbos, Yves Demaria, Stefan Everts, Sebastien Tortelli, Mike Brown, Michael Pichon, Jol Smets and many others. Based on this experiences and great test-work, a line of official KYB racing parts labelled as KYB By Technical Touch is born. All these parts are especially designed, developed, assembled and tested to improve performance, and to personalize your suspension ! Are you ready to take your suspensions to the next level ?
Benvenuti nel catalogo KYB By Technical Touch
Non solo per Campioni del mondo ! Dal 1991 Technical Touch il partner ufficiale per il servizio, set-up, sviluppo e manutenzione delle sospensiono ufficiali KYB. Sosteniamo i team ufficiali che partecipano alle gare del mondiale MX. Come il Team Yamaha Rinaldi, Team Suzuki Geboers, e il Kawasaki Racing Team. Fianco a fianco combattiamo per il prossimo titolo. Siamo fieri, ieri come oggi, di collaborare con dei leggendari piloti come : David Philippaerts, Steve Ramon, Ken De Dycker, Joshua Coppins, Tanel Leok, Kevin Strijbos, Yves Demaria, Stefan Everts, Sebastien Tortelli, Mike Brown, Michael Pichon, Jol Smets e molti altri. Basata sulla nostra esperienza insieme a tanto lavoro di testing, una linea ufficiale di ricambi KYB racing nata con il marchio KYB By Technical Touch. Tutti questi ricambi sono specialmente concepiti, sviluppati, costruiti e provati per migliorare le prestazione e per personalizzare le vostre sospensioni. Siete pronti per sospensioni ad alto livello ?

Constancy

5. Works Kit - Fork Insert

Reacdey ra

Make Yamaha

Model YZ85

2002-2002-2010 160060001102
Kawasaki KX85 Honda Suzuki
CR85 2002-2008 160060001002* CRF150R 2007-2010 160060001002* RM85 2002-2010 160060001002*
* can only be mounted with optional KYB springs

Hydraulic Anti-Bottoming

Optional Springs
Rate 2,6 N 2,7 N 2,8 N 2,9 N 3,0 N 3,1 N
Reference 110053600501 110053600601
Racing Accessoires - Fork

6. Coated Innertube

Reference LeftReference Right 160174801501
Yamaha YZ125 2008-YZ250 2008-YZ250F 2008-YZ450F 2008-Honda CRF450R 2009-2010 160174801601
Available from February 2009
Bil-aFcrkiction t AnCoating

Improved Durability

7. Triple Clamp

Rouubnbteerd M

2 Off-Set positions 6 Handle Bar Clamp positions 3 Handle Bar Clamp Height positions 3 Damping Rubber possibilities (optional) Make Model Year Reference
Yamaha YZ85 2002-2010 XT040280801YA YZ250F 2007-2009 XT040270424YA YZ250F 2010 XT0402100424YA YZ450F 2007 XT040270524YA YZ450F 2008-2009 XT040280524YA YZ450F 2010 XT0402100521YA Kawasaki KX85 2002-2010 XT040280801KA KX250F 2006-2009 XT040270423KA KX250F 2006-2009 XT040270523KA* KX450F 2006-2008 XT040270523KA KX450F 2009-2010 XT040290522KA Honda CRF250R 2005-2007 XT040270623HO CRF250R 2008-2009 XT040280623HO CRF250R 2008-2009 XT041180623HO* CRF250R 2010 XT040290623HO CRF450R 2005-2007 XT040270623HO CRF450R 2008 XT040280623HO CRF450R 2008 XT041180623HO* CRF450R 2009-2010 XT040290623HO RM85 2005-2010 XT040290801SU Suzuki RMZ250 2007-2009 XT040270619SU RMZ250 2008-2009 XT041170619SU* RMZXT040270619SU RMZ450 2008-2009 XT040280519SU RMZ450 2008-2009 XT041180519SU*
* adapted to fit KYB forks
8. Compression unit for WR
Compression unit with real shim-valving Fully controlled compression damping Make Yamaha Model Year Reference
WR250F 2005 -2010110890000802 WR450F 2005-2010 110890000802
9. Carbon Fiber Protection

ect Fit Perf

Yamaha YZ125 2004-YZ250 2004-YZ250F 2004-YZ450F 2004-Kawasaki KX125 2002-KX250 2002-KX250F 2004-KX450F 2006-Honda CRF450R 2009-Suzuki RMZ250 2004-HusqvarnaCR160150000201 TC160150000201 TC160150000201 TE160150000201 TE160150000201 TE160150000201 TE160150000201 TXC160150000201 TXC160150000201 TXC160150000201 WR160150000201 WR160150000201 WR160150000201

10. Spring Collar

Improves bottoming out resistance Maintains comfort feeling Make Model Year Reference
Yamaha YZ125 2006-YZ250 2006-YZ250F 2006-YZ450F 2006-Kawasaki KX450F 2007-Honda CRF450R 2009-HusqvarnaCR160190000101 TC160190000101 TC160190000101 TE160190000101 TE160190000101 TE160190000101 TE160190000101 TXC160190000101 TXC160190000101 TXC160190000101 WR160190000101 WR160190000101 WR160190000101

11. Coloured Top Cap

Make Model Year Reference Yamaha YZ125 2006-YZ250 2006-YZ250F 2006-YZ450F 2006-Kawasaki KX450F 2008-Honda CRF450R 2009-HusqvarnaCR110060000601 TC110060000601 TC110060000601 TE110060000601 TE110060000601 TE110060000601 TE110060000601 TXC110060000601 TXC110060000601 TXC110060000601 WR110060000601 WR110060000601 WR110060000601

y look Factor

Racing Accessoires - Shock

12. Preload Adjuster

Mechanical transmission Use the complete thread of the shock absorber Easy handling Adjust the preload very quickly Low weight Dirt insensible
Yamaha YZ125 2006-2010 XT100280601YA YZ250 2006-2010 XT100280601YA YZ250F 2006-2009 XT100280601YA YZ250F 2010 XT1002100401YA YZ450F 2006-2009 XT100280601YA YZ450F 2010 XT1002100501YA Kawasaki KX450F 2009 - 2010 T100290501KA X Honda CRF450R 2009 - 2010 T100290501HO X
13. Bump Rubber Kit Rear Shock

ry look Facto

Yamaha YZ125 2006-YZ250 2006-YZ250F 2006-YZ450F 2006-Kawasaki KX450F 2006-2008 160021600101

14. Titanium Spring

EXTRA 30% WEIGHT PROFIT

lt Qunaiuimy High ita T

53 N 160134600401 160134600401
Yamaha YZ125 2000-YZ250 2000-YZ250F 2000-YZ450F 2000-Kawasaki KX125 2000-KX250 2000-KX250F 2004-KX450F 2006-Suzuki RM250 2001-RMZ250 2004-160134600201 160134600301

15. Cylinder Cap Black

Make Model Year Reference Colour black black gold black gold black gold black gold black black black black Yamaha YZ85 2002-YZ125 2006-YZ125 2006-YZ250 2006-YZ250 2006-YZ250F 2006-YZ250F 2006-YZ450F 2006-YZ450F 2006-YZ450F Kawasaki KX450F 2007 - 1 KX450F 2009 - 1 Honda CRF450R 2009 - 1

16. Adjuster Case

Make Model Year Reference

y look actor F

Yamaha YZ125 2006-YZ250 2006-YZ250F 2006-YZ450F 2006-Kawasaki KX450F 2007-Honda CRF450R 2009-2010 120060003301

17. Valve Cap

Make Model Year Reference Kawasaki KX80 1999-KX85 2002-KX125 1991-KX125 1994-KX120140000201 KX125 2000-KX250 1991-KX250 1994-KX160030000201 KX250 2000-KX250F 2004-KX450F 2006-KX500 1991-KLX160030000201 Honda CR125 1991-CR125 1993-CR160030000201 CR250 1995- CRF450R 2009-CR500 1991-CR500 1995-2002 160030000201
Yamaha YZ250 1991-YZ160030000201 YZ160030000201 YZ250 1996-YZ250F 2001-YZ400F YZ426F 2000-YZ450F 2003-WR250F 2003-WR450F 2003-Suzuki RM250 2001-RM-Z250 2004-

Merchandising

Size all Reference 170060000101
Size all Reference 170040000101

Sweater

Size S M L XL XXL Reference 170080000501

Fleece

Size M L XL Reference 170070000401

T-shirt

Size S M L XL
Reference 170050000301 170050000401
Suspension Tuning & Service
ssionTaulning Profseion Suspefnor everyone
Suspension Revalve Suspension Maintenance All Replacement Parts from Stock
n Workshop Form Send your standard KYB suspensiothis info with

General Information

Company Name :.... Contactperson :....
Invoice Adress Street & number :...... City :..... Phone :..... Postal code :...
Country :..... Fax :.....
E-mail :......... Delivery Adress Street & number :...... City :..... Postal code :...

Country :.....

Rider Information
First name :.... Wheight :....kg (without gear) Rider level : Motorcycle : Model : Type of use : Type of track : Last name :.... Height :....cm Class :....
recreation amator Yamaha MX hard

expert

Kawasaki Honda Suzuki Order Information.. 2-stroke 4-stroke Year :.... SX ENDURO SUPERM desert BEACH RAID FMX intermed. sand

Remarks :.........

Requested
Revalve : Service : Oil Seal Change : Spring Change : Front Fork Rear Shock Rear Shock + Bleed Hole
SETTINGMXFF SERVICEMXFF SPRING CHANGE
SETTINGMXRCU SERVICEMXRCU STEEL SPRING Option List
SETTINGMXBBRCU SERVICEMXBBRCU TITANIUM SPRING

OILSEALCHANGE

........ ........ ........ ........

Quantity

.......

Fill in and SEND TO

Technical Touch IZ Maatheide Lommel - Belgium Tel: 96 Fax: 97 E-mail : info@technical-touch.com
Please contact us about workshop availability
Technical Touch bvba IZ Kristalpark Ondernemersstraat Lommel - Belgium T 96 - F 97 info@technical-touch.com www.technical-touch.com

 

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