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Yamaha YZ85 Workshop Repair Manual All 2004-2005 ModelS COVERED
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🏷️ Basic Information Identification Make: Yamaha Model: YZ85 Model Variant: Motocross Competition Bike Covered Years: 2004, 2005 Codes Vin Code Model Year Identifier: 4 (2004), 5 (2005) 👋 Introduction Market...
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类型: Motorcycle
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YZ85
Model Variant:
Motocross Competition Bike
Covered Years:
2004, 2005
Codes
Vin Code Model Year Identifier:
4 (2004), 5 (2005)
👋 Introduction
Market Position
Category:
Entry-level to intermediate motocross competition
Target Audience:
Young motocross racers, mechanics, hobbyists
Competitive Analysis
Key Competitors:
KTM 85 SX, Honda CR85R, Kawasaki KX85, Suzuki RM85
Segment Strength:
Known for its strong engine performance and reliable chassis for its class
Key Features Vehicle
Engine Type:
Liquid-cooled, 2-stroke, reed valve, single-cylinder
Key Features Manual
Value Proposition:
Comprehensive guide for all maintenance, repair, and troubleshooting needs
Benefit To Owner:
Empowers owners to perform DIY maintenance and repairs, saving time and money
📋 Manual Details
Coverage Areas
Engine:
Complete overhaul, tuning, carburetor, cooling system, ignition
Transmission:
Clutch, gearbox, shifting mechanism, lubrication
Chassis:
Frame, subframe, suspension (forks, shock absorber), steering, wheels, tires
Brakes:
Front and rear disc brake systems, hydraulic lines, calipers, master cylinders
Electrical System:
Ignition system, lighting (if applicable for competition), wiring diagrams, battery (if applicable)
Bodywork:
Fairings, seat, fenders, handlebars, footpegs
Troubleshooting:
Diagnostic procedures for common faults and performance issues
Page Count
Estimated Pages:
300-400 (typical for comprehensive workshop manuals of this type)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Internals:
Cylinder, piston, rings, connecting rod, crankshaft, bearings, seals
Fuel Delivery:
Carburetor disassembly, cleaning, adjustment, jetting, fuel tank, petcock
Cooling System:
Radiator, coolant hoses, water pump, thermostat (if applicable)
Exhaust System:
Expansion chamber, silencer inspection and repair
Ignition System:
CDI unit, ignition coil, spark plug, stator, flywheel
Transmission Internals:
Gearbox components, shift drum, shift forks, clutch basket, plates, springs
Suspension Front:
KYB (Kayaba) forks, seal replacement, oil change, damping adjustments, spring rates
Suspension Rear:
Monoshock absorber, linkage system, bearing service, oil and gas pressure (if applicable)
Wheel Assembly:
Hubs, spokes, rims, bearings, tire mounting/disassembly
Brake Hydraulics:
Master cylinder rebuild, caliper service, bleeding procedure, fluid specifications
Electrical Harness:
Wiring diagrams, component identification, troubleshooting electrical faults
Procedures Included
Routine Maintenance:
Pre-ride checks, air filter cleaning/replacement, chain adjustment, lubrication
Engine Rebuild:
Top-end rebuild (piston, rings, cylinder), bottom-end rebuild (crankshaft, bearings)
Carburetor Tuning:
Jetting adjustments for altitude and temperature, idle speed setting
Suspension Service:
Fork seal replacement, fork oil level and type, shock absorber servicing
Clutch Service:
Clutch plate replacement, spring replacement, adjustment
Brake System Maintenance:
Pad replacement, rotor inspection, fluid flush and replacement, bleeding
Wheel Truing:
Spoke tension adjustment, wheel balancing
Troubleshooting Guides:
Step-by-step diagnostics for ignition, fueling, and mechanical issues
Technical Depth
Diagnostic Capability:
Advanced diagnostic procedures, component testing, fault code interpretation (if applicable)
Rebuild Comprehensiveness:
Full engine and transmission disassembly and reassembly, including torque specifications
Suspension Tuning:
Detailed instructions on adjusting damping and spring preload for various track conditions
Electrical Diagnostics:
Comprehensive wiring diagrams and troubleshooting charts for electrical system issues
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Text-searchable (allows quick finding of specific information)
Printability:
Printable pages for convenient workshop use
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity
Diagram Detail:
Detailed exploded views and line drawings
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, reed valve induction
Displacement:
84.7 cc (5.17 cu. in.)
Bore X Stroke:
47.5 mm x 47.8 mm (1.87 in. x 1.88 in.)
Compression Ratio:
8.1:1 (approximate, competition spec)
Carburetor:
Mikuni VM28, flat-slide
Ignition:
Digital CDI (Capacitor Discharge Ignition)
Lubrication:
Pre-mix (2-stroke oil mixed with gasoline)
Performance
Horsepower Estimated:
25-28 HP (at crankshaft, estimated)
Torque Estimated:
14-16 lb-ft (at crankshaft, estimated)
Fuel System
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Mixture Ratio:
Typically 40:1 or 50:1 (verify with manual for specific oil type)
Cooling System
Type:
Liquid-cooled
Coolant Type:
Permanent type anti-freeze coolant (50/50 mix with distilled water)
🔧 Transmission
Standard
Type:
6-speed, constant mesh
Clutch Type:
Wet, multi-plate
Final Drive:
Chain drive
Optional
Transmission Options:
None (standard configuration)
Features
Gear Ratios:
Specific ratios detailed within the manual (e.g., 1st: 2.462, 2nd: 1.706, etc.)
Transmission Oil Type:
Yamalube 10W-30 API SG or higher (or equivalent SAE 10W-30 API SE classification)
Transmission Oil Capacity:
0.70 Liters (0.74 US qt, 0.62 Imp qt)
📐 Dimensions
Exterior
Overall Length:
1840 mm (72.4 in.)
Overall Width:
780 mm (30.7 in.)
Overall Height:
1165 mm (45.9 in.)
Seat Height:
845 mm (33.3 in.)
Wheelbase:
1275 mm (50.2 in.)
Ground Clearance:
330 mm (13.0 in.)
Weights
Dry Weight:
72 kg (158.7 lbs)
Wet Weight Estimated:
78 kg (171.9 lbs)
Fuel Tank Capacity:
5.0 Liters (1.3 US gal, 1.1 Imp gal)
🛡️ Safety Features
Ratings
Safety Certification:
N/A (Competition Off-Road Vehicle)
Active Features
Brakes:
Hydraulic disc brakes front and rear
Suspension:
High-performance KYB suspension for optimal control and stability
Passive Features
Ergonomics:
Designed for rider control and balance during aggressive riding
💡 Technology Features
Infotainment
Infotainment System:
N/A (Pure Motocross Competition Bike)
Driver Assistance
Assistance Features:
N/A (Pure Motocross Competition Bike)
Connectivity
Connectivity Features:
N/A (Pure Motocross Competition Bike)
🔧 Maintenance
Service Intervals
Oil Change Transmission:
Every 10-15 hours of riding or annually (whichever comes first)
Air Filter Cleaning:
After every few rides or as needed based on dust conditions
Spark Plug Replacement:
Every 20-30 hours of riding or as recommended
Piston Ring Replacement:
Every 40-50 hours of riding (top-end inspection/rebuild)
Top End Rebuild:
Every 60-80 hours of riding (piston, rings, cylinder inspection)
Fork Oil Change:
Every 20-30 hours of riding or annually
Fluid Specifications
Two Stroke Oil:
Yamalube 2R, or other premium JASO FD/API TC certified 2-stroke racing oil
Fork Oil:
Kayaba Fork Oil (KHL 15-10) or equivalent SAE 10W fork oil (check manual for exact weight)
Brake Fluid:
DOT 4 Brake Fluid
Known Issues
Clutch Wear:
Clutch plates can wear prematurely with aggressive riding; regular inspection and replacement are key.
Carburetor Jetting:
Requires careful jetting based on altitude, temperature, and humidity for optimal performance.
Suspension Seals:
Fork seals can sometimes leak, requiring replacement to maintain suspension performance.
Power Valve Cleaning:
The power valve mechanism can accumulate carbon deposits, necessitating periodic cleaning for proper engine operation.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha has a long and storied history in motorcycle racing, particularly in off-road disciplines.
Model Evolution
Yz Lineage:
The YZ85 is part of Yamaha's highly successful YZ line, which has consistently evolved to meet the demands of motocross competition.
Yz85 Development:
The YZ85 has seen significant development in its chassis, suspension, and engine performance over the years to remain competitive in its class.
Production
Manufacturing Location:
Japan
Production Years Yz85:
Continuous production since its introduction, with model updates.
🏆 Awards & Recognition
Recognitions
Motocross Awards:
The YZ85 platform has historically been a dominant force in 85cc motocross racing classes, earning numerous class wins and championships across various racing series.
Ratings
Magazine Reviews:
Consistently praised by motocross publications for its strong engine, capable chassis, and user-friendly maintenance.