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Yamaha DT125R 1989, Manual

The Yamaha DT125R 1989 Manual is available for free download on our website. This comprehensive user manual provides detailed instructions and essential information to keep your Yamaha DT125R running smoothly. Take advantage of this opportunity to download the manual from manualshive.com and enhance your riding experience.

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DT200R WIRING  DIAGRAM 

(Except for  Oceania) 

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COLOR CODE 

Ignition coil 

B ....... Black 

COi  unit 

Br ...... Brown 

COi  magneto 

Ch  ..... Chocolate 

Rectifier/ Regulator 

Dg  ...•. Dark green 

Servomotor 

G  ....•. Green 

Ignition  control unit 

L ....... Blue 

Battery 

O  ...... Orange 

Rear flasher light  (R) 

P .•..•.. Pink 

Tail/Brake light 

R ...•... Red 

Sidestand  switch 

Sb  ..... Sky blue 

Rear brake switch 

W .•.... White 

Flasher relay 

Y .....•. Yellow 

Themo unit 

G/W  ... Green/White 

Oil level gauge 

W/L .... White/Blue 

"LIGHTS"  (Dimmer) switch  LIB  .... Blue/Black 

"TURN" switch 

B/R .... Black/Red 

"HORN" switch 

B/W .••. Black/White 

"LIGHTS"  switch 

B/Y .... Black/Yellow 

Main  switch 

Br/W ... Brown/White 

Front flasher light (L) 

G/R .••. Green/Red 

Auxiliary light 

G/Y .... Green/Yellow 

Headlight 

L/R  .... Blue/Red 

"HIGH BEAM" indicator light L/Y  .... Blue/Yellow 

"OIL"  indicator light 

W /R .... White/Red 

"TURN"  indicator light 

Y /R .•.. Yellow/Red 

"NEUTRAL"  indicator light 

Meter light 

Temperature  gauge 

"ENGINE  STOP" switch 

Front brake switch 

Front flasher light (R) 

Rear flasher light  ( L) 

Summary of Contents for DT125R 1989

Page 1: ... YAMAHA 2YY AE1 SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ... f r ...

Page 3: ...Supplemen tary Service Manual together with following manual DT125R Service Manual 3BN ME1 DT200R W SUPPLEMENTARY SERVICE MANUAL TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO LTD 1988 by Yamaha Motor Co Ltd 1st Edition September 1988 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ANT INFORMATION This material is distinguished by the following notation NOTE A NOTE provides key information to make procedures easier or clearer A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle __ __WARNING A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motor...

Page 5: ...ooling system Carburetion Chassis Electrical Troubleshooting Illustrated symbols to are used to identify the specifications appearing in the text Filling fluid Lubricant Special tool Tightening Wear limit clearance Engine speed 0 V A Illustrated symbols to in the exploded dia gram indicate grade of lubricant and location of lubrication point I Apply engine oil Apply gear oil Apply molybdenum disul...

Page 6: ...SIS M 16 FRONT FORK ADJUSTMENT M 16 REAR SHOCK ABSORBER ADJUSTMENT A 1 RECOMMENDED COMBINATIONS OF FRONT FORK AND REAR SHOCK ABSORBER SETTING A 2 COOLING SYSTEM A 2 THERMOSTATIC VALVE AND RADIATOR A 2 REMOVAL A 3 INSTALLATION A 4 CARBURETION A 5 CARBURETOR A 5 REMOVAL A 5 DISASSEMBLY A 6 INSPECTION A 6 ASSEMBLY A 7 INSTALLATION A 8 ADJUSTMENT A 9 CHASSIS A 9 FRONT FORK A 9 REAR SHOCK ABSORBER A 10...

Page 7: ...he frame serial number G is stamped on the right of the steering head pipe Starting Serial Number 2YY 020101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the elevated part of the left rear section of the engine NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting serial number FOR OCEANIA 3CJ 002...

Page 8: ...ne Engine Type Liquid cooled 2 stroke gasoline Induction System Reed valve Cylinder Arrangement Single cylinder Forward inclined Displacement 195 cm3 Bore x Stroke 66 x 57 mm 2 598 x 2 244 in Compression Ratio 6 4 1 Starting System Kick starter Lubrication System Separate lubrication Yamaha Autolube Engine Oil Type Yamaha oil 2T or air cooled 2 stroke engine oil Capacity 1 2 L 1 1 Imp qt 1 3 US qt...

Page 9: ...Left foot operation Gear Ratio 1st 33 12 2 750 2nd 30 16 1 875 3rd 24 17 1 412 4th 24 21 1 143 5th 22 23 0 957 6th 18 22 0 818 Chassis Frame Type Semi double cradle Caster Angle 27 5 Trail 113 mm 4 45 in Tire Type With tube Size Front 3 00 21 4PR Rear 4 60 18 4PR Maximum Load Front 47 kg 104 lb Rear 134 kg 295 lb Cold Tire Pressure Front Rear Up to 90 kg 198 lb Load 130 kPa 150 kPa 1 3 kg cm2 18 p...

Page 10: ...il and gas spring Oil damper Wheel Travel Front Wheel Travel 270 mm 10 6 in Rear Wheel Travel 270 mm 10 6 in Electrical Ignition System CDI Generator System Flywheel magneto Battery Type GM3 3B FB3L B Capacity 12V 3AH Headlight Type Bulb type Bulb Wattage Quantity Headlight 12V 00W 55W 12V 35W 36 5W Ocl Tail Brake Light 12V 5W 21W Flasher Light 12V 21W 4 pcs 12V 10W 4 pcs Oc Auxiliary Light 12V 4W...

Page 11: ... I I T 2nd Ring cJ a I I T Top Ring 2nd Ring Top Ring 2nd Ring DT200R W 0 03 mm 0 0012 in Lines indicate straightedge measurement 66 00 66 02 mm 2 598 2 599 in 0 05 mm 0 002 in 0 01 mm 0 0004 in 65 94 66 00 mm 2 596 2 598 in 10 mm 0 4 in 0 mm 0 in 0 055 0 060 mm 0 0022 0 0024 in 0 1 mm 0 004 in 66 25 mm 2 61 in 66 50 mm 2 62 in Keystone type B 1 2 mm 0 047 in T 2 8 mm 0 110 in Plain type B 1 2 mm ...

Page 12: ...ear limit 2 7 mm 0 106 in Clutch Plate Thickness 1 05 1 35 mm 0 041 0 053 in Quantity 6 pcs Warpage limit 0 05 mm 0 002 in Clutch Spring Free Length 34 5 mm 1 358 in Quantity 5 pcs Minimum Free Length 32 0 mm 1 260 in Clutch Release Method Inner push Cam push Push Rod Bending limit 0 15 mm 0 006 in Transmission Main Axle Runout Limit 0 08 mm 0 003 in Drive Axle Runout Limit 0 08 mm 0 003 in Shifte...

Page 13: ... P O P J B P 1 V S G S PW J F L F H Radiator Core Thickness Radiator Cap Opening Pressure Reservoir Tank Capacity Water Pump Type Thermostatic Valve Opening Temperature Full Open Temperature Lift 2YYOO 150 c 0 5 5J10 4 P 2 2 5 c 0 6 25 c 1 6 c 2 8 25 65 DT200R W 2 5 4 5 mm 0 10 0 18 in 20 21 mm 0 79 0 83 in 1 300 1 400 r min 0 4 mm 0 02 in 6 8 mm 0 27 in 0 5 mm 0 02 in White 0 20 0 25 mm 0 008 0 0...

Page 14: ...M 6 x 1 0 8 0 8 5 8 Drain Bolt Housing Cover 1 M 6 x 1 0 10 1 0 7 2 Radiator Bolt 2 M 6 x 1 0 8 0 8 5 8 Warm Water Hose Carburetor Bolt 2 M 6 x 1 0 8 0 8 5 8 Radiator Cap Stopper Screw 1 M 5 x 0 8 5 0 5 3 6 Oil Pump Screw 2 M 5 x 0 8 5 0 5 3 6 Carburetor Joint Bolt 4 M 6 x 1 0 8 0 8 5 8 Air Filter Bolt 2 M 6 x 1 0 5 0 5 3 6 Exhaust Pipe Nut 2 M 8 x 1 25 18 1 8 13 l Stud Bolt 2 M 8 x 1 25 10 1 0 7 ...

Page 15: ... 65 6 5 47 Primary Drive Gear Nut 1 M12 x 1 0 80 8 0 58 Clutch Boss Nut 1 M12 x 1 0 70 7 0 51 Clutch Spring Bolt 5 M 5 x 0 8 6 0 6 4 3 Plate Cover Screw 2 M 6 x 1 0 10 1 0 7 2 Drive Sprocket Nut 1 M16x 1 0 60 0 6 43 Tachometer Housing Bolt 1 M 6 x 1 0 5 0 5 3 6 Stopper Lever a Bolt 1 M 6 x 1 0 14 1 4 10 Change Pedal Bolt 1 M 6 x 1 0 15 1 5 11 Thermo Unit 1 15 1 5 11 Rotor Nut 1 M12 x 1 25 80 8 0 5...

Page 16: ... Runout limit Vertical Lateral Rear Wheel Type Rim Size Rim Material Rim Runout limit Vertical lateral DT200R W Ball bearing Taper roller bearing 3 16 in 22 pcs 270 mm 10 6 in 548 mm 21 6 in 543 mm 21 4 in 3 5 N mm 0 35 kg mm 20 lb in 0 270 mm 0 10 6 in No 512 cm3 18 1 Imp oz 17 3 US oz 140 mm 5 51 in From top of inner tube fully compressed without spring Fork oil 10W or equivalent 99 mm 3 90 in 2...

Page 17: ... No 3 can be used Rear Disc Brake Type Single Disc Outside Diameter 220 mm 8 66 in Disc Thickness 4 5 mm 0 18 in Pad Thickness 6 mm 0 24 in Limit 0 8 mm 0 03 in Master Cylinder Inside Diameter 12 7 mm 0 5 in Caliper Cylinder Inside Diameter 30 2 mm 1 19 in Brake Fluid Type DOT No 4 If DOT No 4 is not available DOT No 3 can be used Brake Lever and Brake Pedal Brake Lever Free Play 2 5 mm 0 08 0 20 ...

Page 18: ...cting Rod M14 x 1 5 58 5 8 42 Relay Arm and Frame M10 x 1 25 58 5 8 42 Rear Shock Absorber and Frame M10 x 1 25 33 3 3 24 Rear Arm and Rear Shock Absorber M10 x 1 25 33 3 3 24 Chain Cover M 6 x 1 0 4 0 4 2 9 Swingarm End Bolt M 6 x 1 0 3 0 3 2 2 Fuel Tank Seat Rear Fender License Bracket and Stay M 6 x 1 0 5 0 5 3 6 Wheels Front Wheel Axle M14 x 1 5 58 5 8 42 Rear Wheel Axle and Nut M18 x 1 5 90 9...

Page 19: ...2 850 r min 50 70 1 5 19 250 min C El 0 2 4 6 8 10 12 Engine Speed x 1 000 r min C 0 1 Magneto Model Manufacturer F3ET YAMAHA C 0 1 Unit Model Manufacturer 3ET YAMAHA Pickup Coil Resistance Color 280 4200 at 20 C 68 F White Red White Bluel Source Coil Resistance Color 192 2880 at 20 c 68 Fl Black Red Green White Ignition Coil Model Manufacturer 2JN YAMAHA Minimum Spark Gap 6 mm 0 24 in Primary Coi...

Page 20: ... White Black Standard Output 12V 1 1A at 2 500 r min When LIGHT switch is turned to OFF 2 0 I C o I u I C 0 _ 2 3 4 5 6 7 8 9 Engine Speed x 1 000 r min Voltage Regulator Type Semi conductor Short circuit type Rectifier Model Manufacturer EHU01TR23 MATSUSHITA Capacity 12A Battery Specific Gravity 1 280 Horn Type Plane type Quantity 1 pc Model Manufacturer YF 12 NIKKO Maximum Amperage 2 5A 14 ...

Page 21: ...er FZ249SD NIPPON DENSO Self Cancelling Device No Flasher Frequency 60 120 cycle min Wattage 21W x 2 3 4W Ignition Control Unit Model Manufacturer 4Y3 YAMAHA Oil Level Switch Model Manufacturer 4Ul STANLEY Thermo Unit Model Manufacturer 11H NIPPON SEIKI Circuit Breaker Type Fuse Circuit Fuse MAIN 10A 1 pc 15 ...

Page 22: ...n dry threads Components should be at room tem perature A Distance across flats B Outside thread diameter DEFINITION OF UNITS Unit Read A Nut 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm Definition mm millimeter 10 3 meter cm centimeter 10 2 meter kg kilogram 103 gram N Newton 1 kg x m sec2 Nm Newton meter N x m m kg Meter kilogram m x kg Pa Pascal N m2 N mm Newton per millimeter N mm L Liter cm3 Cubic cen...

Page 23: ...r pump Crankcase cover Crankcase Bypass hole Thermostatic valve Outlet hose Radiator 1t11 1 Coolant is cooled Less than 65 C 149 F l 2 Coolant is hot 65 C 149 F or more 17 Cylinder head 2 Thermostatic valve Carburetor warmer Inlet hose Carburetor body Carburetor warmer Outlet hose ...

Page 24: ...Connecting rod Main axle bearings Drive axle bearings C l Push lever bearing a Crank pins m Piston rings piston pins and pistons a Power valve holders Impeller shaft Water pump 1 Worm shaft Autolube pump a Kick idle gear am Kick axle am Primary driven gear Clutch housing am Push rod Gl Push lever axle am Sliding gear Transmission 9 Free movement gear Transmission 9 Guide bar Shift forks am Crankca...

Page 25: ...ngarm Oil seal lip Swingarm Steering shaft Relay arm Bearing Swingarm 3 Collar Swingarm Bush Relay arm Connecting rod Collar Relay arm Connecting rod Bearing Relay arm Bolt Relay arm and frame Bearing oil seal lip Rear shock absorber Lower Throttle grip inner surface Lever pivots and cable end Oil seal lip Wheels Speedometer gear Rear brake pedal boss Sidestand pivot 19 ...

Page 26: ...ING ISPEC I1 f I Speedometer cable IA Pass the flasher light lead in front Headlight stay of stay Flasher light left lead ID Pass the cables and leads Brake hose between meter and handlebar Wireharness crown Headlight Cl Pass the front brake hose inside Flasher light right lead of throttle cable 20 Q Clamp the couplers between the speedometer cable and headlight stay ...

Page 27: ...tch lead Throttle cable ENGINE STOP switch lead Band Handlebar switch Left lead Clutch cable Metr light lead Flasher light lead Flasher relay Speedometer cable Rubber boot Tachometer cable IA Pass the cables and leads between meter and handlebar crown Bl Pass the front brake hose inside of throttle cable ...

Page 28: ...UTING ISPEC I 7I IA Clamp the COi magneto lead BJ Pass the COi unit lead between the main pipe and tension pipe Q Pass the earth lead inside of throttle cable and secure with screw Ignition coil OJ Pass the sub tank hose on the left side of rear shock absorber If Pass the COi magneto lead out side of sub tank hose 22 El Clamp the brake hose while pull ing it up ...

Page 29: ...i Rectifier Regulator Flasher light right lead Flasher light left lead White tape for wireharness locating 18J Pass the radiator overflow hose between main pipe and tension pipe CJ Pass the wireharness under the tension pipe 23 0 20 mm 0 0 8 in 3 ...

Page 30: ...OUTING ISPEC I 071 Speedometer cable Spark plug cap Spark plug lead Oil hose Autolube pump cable Oil delivery hose Rear brake switch Reservoir tank hose Carburetor overflow hose 24 Crankcase breather hose Battery breather hose Cable guide Master cylinder Rear brake Rear brake hose Fuse holder Battery negative lead Silencer drain hose CDI magneto lead ...

Page 31: ... __________ c_A_e_LE_R_o_u_T_1N_G_ ISPEC 1 71 IA Pass the flasher light leads between headlight cowl and stay la Keep clearance 1 2 mm 0 04 0 08 in IC Pass the horn lead in front of the radiator 25 ...

Page 32: ...rcycle Remove the valve cap Using the air check gauge G check and ad just the air pressure Stiffer Increase the air pressure Use an air pump or pressurized air supply Softer Decrease the air pressure Release the air by pushing the valve Standard air pressure Zero kPa Zero kg cm2 Zero psi Maximum air pressure 40 kPa 0 4 kg cm2 5 7 psi Never exceed the maximum pressure or oil seal damage may occur _...

Page 33: ...ame or other high heat source This may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylinder In any way Cylinder damage will result in poor damping performance 1 Adjust Spring preload Adjustment steps Elevate the rear wheel by placing the suita ble stand loosen the locknut G Adjust the spring preload NOTE The length ofthe spring Installed changes 1 0 mm 0 04 ...

Page 34: ...5 Nm 5 5 m kg 40 ft lb 2 Adjust Rebound damping force Adjustment steps Adjust the rebound damping force by turn ing the adjuster G Slower Increase the rebound damping force Tum the adjuster j in Faster Decrease the rebound damp ing force Turn the adjuster j out Adjusting Position Hard 5 4 STD Soft 3 2 1 Do not turn out In the adjuster from the damping force minimum maximum setting ...

Page 35: ...otorcycle load conditions Front fork Rear shock absorber Loading condition Wrth With Air pressure Spring length Damping Solo rider With accessories and accessories adjuster passenger equipment equipment and passenger 0 kPa 250 mm 1 0 kg cm2 9 8 in 1 3 0 0 psi 0 kPa 250 245 mm 2 0 kg cm2 9 8 9 6 in 3 5 0 0 psi 0 kPa 250 mm 3 0 kg cm2 9 8 in 1 3 0 0 psi 0 40 kPa 250 240 mm 4 0 0 4 kg cm2 9 8 9 4 in ...

Page 36: ...ipe Copper washer Clip Gasket Thermostatic valve Hose Carburetor warmer Inlet Hose Carburetor warmer Outlet RADIATOR CAP OPENING PRESSURE COOLANT CAPACITY A 75 105 kPa 0 75 1 05 kg cm2 10 14 psi B 1 20 L 1 06 Imp qt 1 27 US qt Including all routes THERMOSTATIC VALVE OPENING A C TEMPERATURE 63 67 C 146 153 F D USE NEW ONE 8 Nm 0 8 m kg 5 8 ft lb 8 Nm 0 8 m kg 5 8 ft lb 8 Nm 0 8 m kg 4 3 ft lbl 30 ...

Page 37: ...h it away with water _ WARNING Do not remove the radiator cap drain bolts and hoses especially when the engine and radiator are hot Scalding hot fluid and steam may be blown out under pressure which could cause serious injury When the engine has cooled place a thick rag like a towel over the radiator cap slowly rotate the cap coun terclockwise to the detent This procedure allows any residual press...

Page 38: ... 32 4 Remove Radiator hose CD Radiator hose Radiator hose Radiator breather hose 5 Remove Radiator hose CD 6 Remove Panel CD Radiator left 7 Remove Radiator hose CD Radiator right 8 Remove Thermostatic valve cover CD Gasket Thermostatic valve 0 ring ...

Page 39: ... the fol lowing points 1 Install 0 ring G Thermostatic valve Gasket Thermostatic valve cover WARNING Always use new 0 ring and gasket 33 Screw thermostatic valve cover 8 Nm 0 8 m kg 5 8 ft lb 2 Install Radiators G Panel Bolt radiator 8 Nm 0 8 m kg 5 8 ft lb 3 Apply the grease to the 0 ring G 4 Install 0 ring G Water outlet pipe IA Right la Left ...

Page 40: ...r Reservoir tank radiator Refer to the COOLANT REPLACEMENT section in the CHAPTER 3 6 Inspect Cooling system Decrease of pressure leaks Repair as re quired Inspection steps Attach the Cooling System Tester G to the radiator Cooling system tester 90890 01325 Apply 100 kPa 1 0 kg cm2 14psi pressure Measure the indicated pressure with the gauge ...

Page 41: ...Main jet Needle valve assembly Float 1 Drain screw USE NEW ONE 35 SPECIFICATIONS MAIN JET M J 150 MAIN AIR JET M A J 0 5 JET NEEDLE J N 5J10 4 NEEDLE JET N J P 2 PILOT JET P J 25 POWER JET PW J 65 FLOAT HEIGHT 20 21 mm F H 0 79 0 83 in ENGINE IDLING SPEED 1 300 1 400 r min A FUEL LEVEL 2 5 4 5 mm 0 10 0 18 in 4 6 6 mm mm I L____ t A USE NEW ONE 8 POWER JET Power jet is fixed type ...

Page 42: ...embly Throttle valve Starter plunger 1 Remove Side covers Seat Radiator covers Fuel tank 2 Remove YEIS chamber G Sub tank rear shock absorber i 3 Disconnect Hose carburetor warmer inlet G Hose carburetor warmer outlet i 4 Loosen Screws carburetor clamp G i 5 Remove Carburetor 6 Remove Carburetor top G ...

Page 43: ...ISASSEMBLY 1 Remove Starter lever CD Starter plunger 2 Remove Hose CD Float chamber Fuel hose 3 Remove Float pin CD Float Needle valve 4 Remove Main jet CD Needle jet Pilot jet Valve seat 5 Remove Throttle stop screw CD Pilot air jet ...

Page 44: ...hamber body Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with compressed air 2 Inspect Main jet D Needle jet Pilot jet Pilot air jet Throttle stop screw Contamination Blow out passage of jets with compressed air Damage Replace 3 Inspect Valve seat D Needle valve WearIDamage Replace ...

Page 45: ... Inspect Throttle valve G WearIDamage Replace Jet needle Bends Wear Replace 7 Check Free movement Stick Replace Insert the throttle valve into the carburetor body and check for free movement 8 Inspect Starter plunger WearIContamination Replace ASSEMBLY Reverse the DISASSEMBLY procedures Note the following points Before reassembling wash the all parts with a clean gasoline 39 ...

Page 46: ...0 21 mm 0 79 0 83 in Measurement and adjustment steps Hold the carburetor in an upside down po sition Measure the distance from the mating surface of the float chamber gasket removed to the top of the float NOTE The float arm should be resting on the needle valve but not compressing the needle valve If the float height is not within specification inspect the valve seat and needle valve If either i...

Page 47: ...lunger G Spring O ring _ _WARNING Always use a new O ring 6 Install Starter plunger G Vacuum hose Nut starter plunger 3 Nm 0 3 m kg 2 2 ft lb 7 Install Jet needle G Throttle valve Joint Spring Ring Throttle cable NOTE Hook the throttle cable end to the joint while com pressing the spring 8 Install Throttle valve G Gasket _ _WARNING Always use a new O ring 41 ...

Page 48: ... Screws carburetor clamp Z 3 Adjust Idle speed Refer to the IDLE SPEED ADJUSTMENT section in the CHAPTER 3 Engine idle speed 1 300 1 400 r min 4 Adjust Throttle cable free play Refer to the THROTTLE CABLE FREE PLAY ADJUSTMENT section in the CHAPTER 3 Throttle cable free play 2 5 mm 0 08 0 20 in 5 Adjust Carburetor cable free play Refer to the CARBURETOR CABLE FREE PLAY ADJUSTMENT section in the CH...

Page 49: ...e jack under the engine to ensure that the carburetor is positioned vertically Connect the Fuel Level Gauge CDto the drain pipe I Fuel level gauge 90890 01312 Loosen the drain screw and warm up the engine for several minutes Measure the fuel level with the gauge If the fuel level is incorrect adjust the fuel level Remove the carburetor Inspect the valve seat and needle valve If either is worn repl...

Page 50: ...lide metal FORK OIL CAPACITY 512 cm3 18 1 Imp oz 17 3 US oz GRAD A FORK OIL 10W OR EQUIVALENT OIL LEVEL 140 mm 5 51 in Bellow the top of Inner Tube fully rebounded without Fork Spring 10 Nm 1 0 m kg 7 2 ft lb I Outer tube Drain screw Gasket Axle holder I Front fork boot Under bracket Gasket FORK SPRING B MINIMUM FREE LENGTH 543 mm 21 4 in 23 Nm 2 3 m kg 17 ft lb o C USE NEW ONE 62 Nm 6 2 m kg 45 f...

Page 51: ...i Rear shock absorber Bush Collar Damper Band SPRING PRELOAD INSTALLED STANDARD LENGTH 250 mm 9 8 in A MINIMUM LENGTH 236 mm 9 3 In MAXIMUM LENGTH 255 mm 10 0 in 33 Nm 3 3 m kg ZJ ft lb REAR sHocK ABSORBER icHAslb0 I IA 45 ...

Page 52: ...e the unit to explode due to excessive W gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out When scrapping the shock absorber refer to the NOTES ON DISPOSAL section NOTES ON DISPOSAL Shock absorber disposal steps Gas pressure must...

Page 53: ...itable stand under the engine __WARNING Securely support the motorcycle so there is no danger of it falling over 3 Remove Bolt connecting arm swingarm CD from swingarm side 4 Remove Bolt shock absorber lower CD WARNING When removing the bolt G hold the swing arm so that it does not drop downwards when the lower bolt removed 5 Remove Chain tensioner CD Relay arm i ...

Page 54: ...k absorber rod Bends Damage Replace the shock absorb er assembly Shock absorber Oil leaks Gas leaks Replace the shock ab sorber assembly Spring Wear Damage Replace the shock absorb er assembly Bushings CD 48 Dust seals Wear Damage Replace Bolts WearIBends Damage Replace INSTALLATION Rear Shock Absorber Reverse the REMOVAL procedure Note the following points 1 Apply Lithium soap base grease To bear...

Page 55: ... lb 3 Tighten Nut shock absorber upper D Nut shock absorber upper 33 Nm 3 3 m kg 24 ft lb 4 Tighten Nut shock absorber lower D Nut shock absorber lower 33 Nm 3 3 m kg 24 ft lb 5 Tighten Nut connecting arm swingarm D Nut connecting arm swingarm 58 Nm 5 8 m kg 42 ft lb 6 Adjust Rear shock absorber Refer to the REAR SHOCK ABSORBER ADJUSTMENT section in the CHAPTER 3 ...

Page 56: ...________ RE_A_R_S_H_O_C_K_A_BS_O_R_B_E_R ICHASIAl I 50 1 ...

Page 57: ...3 I IA ELECTRICAL DT200R W CIRCUIT DIAGRAM I I 7 y R 8 R J_ T B Y R I I I I I I I I R I I Br L I I Br Br I L i tl I OFF Br I POS iO I I ON I I L________ 7 I f ____ y G I I I I L_ HI I LO J I L R y I I b I y Br Br Br G R____ L L Y Sb B B ...

Page 58: ...E B Black R Red 0 Orange L Blue p Pink y Yellow G Green w White Ch Dg Sb Br L Y B Y B W B R Chocolate Dark green Sky blue Brown Blue Yellow Black Yellow Black White Black Red 52 Flasher relay TURN switch TURN indicator light Flasher light Right Flasher light Left Horn HORN switch OIL indicator light Oil level switch Diode Neutral switch NEUTRAL indicator light Temperature gauge Thermo unit Front b...

Page 59: ...Y y l y I 7 IJ j l l Hom Ignition coil COi unit Flywheel magneto Rectifier Regulator YPVS Control unit Battery Rear flasher light L Tail Brake light Sidestand switch Brake switch Flasher relay Thermo switch Oil level gauge LIGHTS Dimmer switch TURN switch HORN switch Main switch Front flasher light R Headlight HIGH BEAM indicator light OIL indicator light TURN indicator light NEUTRAL indicator lig...

Page 60: ...unit COi magneto Rectifier Regulator Servomotor Ignition control unit Battery Rear flasher light RI Tail Brake light Sidestand switch Rear brake switch Flasher relay Themo unit Oil level gauge LIGHTS Dimmer switch TURN switch HORN switch LIGHTS switch Main switch Front flasher light LI Headlight HIGH BEAM indicator light OIL indicator light TURN indicator light NEUTRAL indicator light Coolant temp...

Page 61: ...ODE Ignition coil B Black COi unit Br Brown COi magneto Ch Chocolate Rectifier Regulator Dg Dark green Servomotor G Green Ignition control unit L Blue Battery O Orange Rear flasher light R P Pink Tail Brake light R Red Sidestand switch Sb Sky blue Rear brake switch W White Flasher relay Y Yellow Themo unit G W Green White Oil level gauge W L White Blue LIGHTS Dimmer switch LIB Blue Black TURN swit...

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