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Yamaha YZ85W1 User Manual

Yamaha YZ85W1
255 pages
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2007
YZ85W1
5PA-28197-E0
SERVICE MANUAL
YZ85(W)
YZ85LW(W)

Table of Contents

Questions and Answers:

Yamaha YZ85W1 Specifications

General IconGeneral
BrandYamaha
ModelYZ85W1
CategoryMotorcycle
LanguageEnglish

Summary

Yamaha YZ85W1 Service Manual 2007

Notice and Important Information

Important notices and distinctions for manual information, including safety alerts.

How to Use This Manual

Guidance on the structure and conventions used within the service manual.

Symbols Explained

Explanation of symbols used in the manual for chapters, procedures, and parts.

Chapter 1: General Information

Vehicle Identification

Information on identifying the vehicle, including VIN and model label locations.

Important Maintenance Information

Details on preparation, parts, seals, and fasteners for maintenance.

Fuel and Engine Mixing Oil

Specifications and guidelines for fuel and oil mixture for the engine.

Checking Electrical Connections

Procedure for inspecting and ensuring proper continuity of electrical connections.

Special Tools Required

List of essential special tools with part numbers for servicing the vehicle.

Chapter 2: Specifications

General Vehicle Specifications

Key overall dimensions, weights, and model codes for the vehicle.

Engine Specifications and Data

Detailed technical specifications for the engine, including displacement and components.

Chassis Specifications and Dimensions

Technical data related to the frame, wheels, brakes, and suspension systems.

Electrical System Specifications

Specifications for ignition system, coils, and spark plug components.

Tightening Torque Specifications

Torque values for engine and chassis fasteners to ensure proper assembly.

Lubrication Points and Lubricant Types

Identification of lubrication points and recommended lubricant types for engine and chassis.

Cable Routing Guide

Diagrams and instructions for proper routing of cables and hoses on the vehicle.

Chapter 3: Periodic Checks and Adjustments

Periodic Maintenance Schedule

Recommended maintenance intervals and tasks for ensuring vehicle reliability.

Engine Checks and Adjustments

Procedures for adjusting pilot air screw, idling speed, and throttle cable free play.

Chassis Checks and Adjustments

Procedures for adjusting brakes, checking fluid, and inspecting suspension components.

Front Fork Adjustments

Guidance on checking and adjusting front fork legs, including oil levels and damping.

Rear Suspension Setting

Procedures for adjusting rear shock absorber spring preload and damping.

Chapter 4: Chassis

Front Wheel and Brake Disc Service

Procedures for removing, checking, and installing the front wheel and brake disc.

Rear Wheel and Brake Disc Service

Procedures for removing, checking, and installing the rear wheel and sprocket.

Front and Rear Brakes Service

Procedures for replacing brake pads, servicing master cylinders and calipers.

Front Fork Service

Procedures for removing, disassembling, checking, and installing front fork legs.

Handlebar Service

Procedures for removing, checking, and installing the handlebar and related components.

Steering Head Service

Procedures for removing, checking, and installing the steering head and bearings.

Rear Shock Absorber Assembly Service

Procedures for handling, removing, checking, and installing the rear shock absorber.

Swingarm and Drive Chain Service

Procedures for removing, checking, and installing the swingarm and drive chain.

Chapter 5: Engine

Engine Components Service

Procedures for servicing engine drive sprocket and exhaust pipe.

Cylinder Head, Cylinder, and Piston Service

Procedures for cylinder head, cylinder, and piston removal, checking, and installation.

Clutch Service

Procedures for clutch removal, checking friction plates, springs, and installation.

Kick Starter and Shift Shaft Service

Procedures for servicing kick starter, shift shaft, and related gears.

CDI Magneto Service

Procedures for removing, checking, and installing the CDI magneto and rotor.

Crankcase and Crankshaft Service

Procedures for crankcase and crankshaft disassembly, checking, and assembly.

Transmission Service

Procedures for transmission removal, checking, and installation of gears and shafts.

Chapter 6: Cooling System

Radiator Service

Procedures for removing, checking, and installing the radiator and cap.

Water Pump Service

Procedures for removing, checking, and installing the water pump components.

Chapter 7: Carburetor

Carburetor and Reed Valve Service

Procedures for carburetor and reed valve removal, disassembly, and checking.

Fuel Level Measurement and Adjustment

Procedures for measuring and adjusting the carburetor fuel level.

Chapter 8: Electrical System

Electrical Components Identification

Identification of key electrical components like ignition coil, CDI unit, and spark plug.

Checking Switch Continuity

Method for testing switch continuity using a pocket tester.

Ignition System Troubleshooting

Troubleshooting steps for ignition system failures, including spark plug and coil checks.

Chapter 9: Tuning

Engine Tuning: Carburetor Settings

Guidance on adjusting carburetor settings based on atmospheric conditions and symptoms.

Chassis Tuning Adjustments

Adjustments for sprockets, tire pressure, front fork, and rear suspension settings.

Chapter 10: Troubleshooting

Starting Failures Troubleshooting

Common causes and checks for engine starting failures.

Incorrect Engine Idling Speed

Troubleshooting steps for incorrect engine idling speed and performance issues.

Faulty Clutch and Overheating Issues

Diagnosis and solutions for clutch problems and engine overheating.

Braking and Handling Problems

Troubleshooting guides for poor braking performance, faulty front forks, and unstable handling.

2007 Wiring Diagram

Electrical Components Overview

Diagram showing the location of key electrical components on the motorcycle.

Color Code for Wiring

Key to understanding wire colors used in the wiring diagram.

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