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Yamaha YZ85LWW Manuals
Manuals and User Guides for Yamaha YZ85LWW. We have
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Yamaha YZ85LWW manual available for free PDF download: Service Manual
Yamaha YZ85LWW 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
Introduction
39
Periodic Checks and Adjustments
39
Periodic Maintenance and Lubrication Intervals
39
Seat, Side Covers and Fuel Tank
41
Adjusting the Engine Idling Speed
43
Adjusting the Pilot Air Screw
43
Engine
43
Adjusting the Throttle Cable Free Play
44
Checking the Spark Plug
45
Checking the Ignition Timing
46
Changing the Transmission Oil
47
Adjusting the Clutch Cable Free Play
48
Cleaning the Air Filter Element
48
Checking the Carburetor Joint
50
Checking the Hoses
50
Checking the Crankcase Breather Hose
51
Checking the Exhaust System
51
Checking the Coolant Level
52
Changing the Coolant
53
Checking the Cooling System
53
Adjusting the Front Brake
55
Chassis
55
Adjusting the Rear Brake
56
Checking the Brake Fluid Level
57
Checking the Front and Rear Brake Hoses
58
Checking the Front and Rear Brake Pads
58
Bleeding the Hydraulic Brake System
59
Adjusting the Drive Chain Slack
60
Adjusting the Shift Pedal
60
Checking and Adjusting the Steering Head
62
Lubricating the Drive Chain
62
Checking the Front Fork
63
Adjusting the Front Fork Legs
64
Adjusting the Rear Shock Absorber Assembly
66
Checking the Tires
68
Checking and Tightening the Spokes
70
Lubricating the Levers and Pedals
70
Lubricating the Rear Suspension
70
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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