Yamaha DT125R Owner'S Manual Download Page 60

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6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00694

Adjusting the clutch lever
free play

The clutch lever free play should
measure 10–15 mm as shown.
Periodically check the clutch lever
free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the clutch

lever.

2. To increase the clutch lever free

play, turn the adjusting bolt in
direction

. To decrease the

clutch lever free play, turn the
adjusting bolt in direction

1 2

Locknut (Clutch lever)

Adjusting bolt

Free play

5. Loosen the locknut at the

crankcase.

6. To increase the clutch lever free

play, turn the adjusting nut in
direction

. To decrease the

clutch lever free play, turn the
adjusting nut in direction

7. Tighten the locknut at the clutch

lever and the crankcase.

Locknut (Crankcase)

Adjusting nut

3. If the specified clutch lever free

play could be obtained as
described above, tighten the
locknut and skip the rest of the
procedure, otherwise proceed as
follows.

4. Fully turn the adjusting bolt at the

clutch lever in direction

loosen the clutch cable.

3MB-9-E8 6/13/01 10:55 AM Page 59

Summary of Contents for DT125R

Page 1: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 6 0 3 1 E OWNER S MANUAL 3MB 28199 E8 DT125R YAMAHA MOTOR CO LTD ...

Page 2: ...ly so as to enjoy all advantages of your DT125R The owner s manual does not only instruct you in how to operate inspect and maintain your motorcy cle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Ya...

Page 3: ...aken to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product in...

Page 4: ...IMPORTANT MANUAL INFORMATION EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 3MB 9 E8 6 13 01 10 55 AM Page 3 ...

Page 5: ...Yamaha Motor Co Ltd 1st Edition May 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU03337 3MB 9 E8 6 13 01 10 55 AM Page 4 ...

Page 6: ...stria 3 6 Catalytic converter for Switzerland and Austria 3 7 2 stroke engine oil 3 8 Fuel cock 3 9 Starter choke lever 3 10 Kickstarter 3 10 Steering lock 3 10 Seat 3 11 Helmet holder 3 12 Adjusting the shock absorber assembly 3 12 Carrier 3 14 YEIS handling precautions 3 14 YPVS 3 14 Sidestand 3 15 Ignition circuit cut off system 3 16 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATI...

Page 7: ...ng the brake fluid level 6 25 Changing the brake fluid 6 26 Drive chain slack 6 27 Lubricating the drive chain 6 28 Checking and lubricating the cables 6 29 Checking and lubricating the throttle grip and cable 6 29 Adjusting the Autolube pump 6 30 Checking and lubricating the brake and shift pedals 6 30 Checking and lubricating the brake and clutch levers 6 30 Checking and lubricating the sidestan...

Page 8: ...TENTS SPECIFICATIONS 8 1 Conversion table 8 5 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 9 8 3MB 9 E8 6 13 01 10 55 AM Page 7 ...

Page 9: ...uence of even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen gers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum pro tective wear how...

Page 10: ...3MB 9 E8 6 13 01 10 55 AM Page 9 ...

Page 11: ...4 3 Fuel cock page 3 9 4 Air filter element page 6 16 5 Coolant reservoir tank page 6 12 6 Helmet holder page 3 12 7 Starter choke lever page 3 10 8 Shift pedal page 3 4 5 2 9 YEIS page 3 14 10 YPVS page 3 14 1 2 3 4 5 6 7 8 9 10 Left view 3MB 9 E8 6 13 01 10 55 AM Page 10 ...

Page 12: ...it page 6 1 12 Fuse page 6 35 13 Battery page 6 33 14 2 stroke engine oil tank page 3 8 15 Brake pedal page 3 5 6 23 16 Shock absorber spring preload adjusting nut page 3 12 11 12 14 15 16 13 Right view 3MB 9 E8 6 13 01 10 55 AM Page 11 ...

Page 13: ...r unit page 3 2 4 Coolant temperature gauge page 3 3 5 Tachometer page 3 2 6 Right handlebar switch page 3 4 7 Brake lever page 3 5 6 23 8 Throttle grip page 6 18 6 29 9 Fuel tank cap page 3 5 10 Main switch page 3 1 1 2 3 4 5 6 7 8 9 10 Controls and instruments 3MB 9 E8 6 13 01 10 55 AM Page 12 ...

Page 14: ...ecked according to the following procedure 1 Turn the key to ON 2 Shift the transmission into the neutral position 3 If the warning light does not come on have a Yamaha dealer check the electrical circuit NOTE Even if the 2 stroke engine oil level is sufficient the warning light may flick er when riding on a slope or during sudden acceleration or deceleration but this is not a malfunction ON OFF E...

Page 15: ... This information will enable you to plan future fuel stops NOTE Only for the German model equipped with a speed limiter The speed limiter prevents the motor cycle from exceeding a riding speed of 80 km h INSTRUMENT AND CONTROL FUNCTIONS 3 4 2 3 1 1 Speedometer unit 2 Odometer 3 Tripmeter 4 Reset knob EAU00102 Tachometer The tachometer allows the rider to monitor the engine speed and keep it withi...

Page 16: ... signal a left hand turn push this switch to 4 When released the switch returns to the center position To cancel the turn signal lights push the switch in after it has returned to the center position EAU00129 Horn switch Press this switch to sound the horn 1 2 1 Coolant temperature gauge 2 Red zone EAU00118 Handlebar switches EAU03898 Light switch 9 Set this switch to to turn on the auxiliary ligh...

Page 17: ...is located at the left handlebar grip To disengage the clutch pull the lever toward the han dlebar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation 1 1 Clutch lever EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of th...

Page 18: ...U00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 1 Brake pedal EAU00177 Fuel tank cap To remove the fuel tank cap 1 Insert the key into the lock and turn it 1 4 turn counterclockwise 2 Turn the fuel tank cap 1 3 turn counterclockwise and pull it off 3 1 2 1 Fuel tank cap 2 Unlock 3 Open 3MB 9 E8 6 13 01 10 55 AM Page ...

Page 19: ...EAU03753 Fuel except for Switzerland and Austria Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown EW000130 w 8 Do not overfill the fuel tank otherwise it may overflow when the fuel warms up and expands 8 Avoid spilling fuel on the hot engine 2 1 1 Filler tube 2 Fuel level EAU03754 Fuel for Switzerland and Austria Make sure that there ...

Page 20: ... octane num ber of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce mainte nance costs EAU01084 Catalytic converter for Switzerland and Austria This motorcycle is equipped with a catalytic converter in the exhaust chamber EW000128 w The exhaust system is hot after operation Make sure ...

Page 21: ...as grass or other materi als that easily burn 8 Do not allow the engine to idle too long EAU03750 2 stroke engine oil Make sure that there is sufficient oil in the 2 stroke engine oil tank Add the recommended 2 stroke engine oil if necessary NOTE Make sure that the 2 stroke engine oil tank cap is properly installed 2 1 1 2 stroke engine oil tank cap 2 Stopper Recommended oil Yamalube 2 or equivale...

Page 22: ...st opportunity Be sure to set the lever back to ON after refueling OFF ON FUEL RES 1 RES 1 Arrow mark positioned over RES EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not running RES ON FUEL OF...

Page 23: ...orce fully This model is equipped with a primary kickstarter allowing the engine to be started in any gear if the clutch is disengaged However shift ing the transmission into the neutral position before starting is recom mended 1 1 Kickstarter EAU02934 Steering lock To lock the steering 1 Turn the handlebar all the way to the right 2 Open the steering lock cover and then insert the key 3 Turn the ...

Page 24: ... To remove the seat 1 Remove panels A and B See page 6 8 for panel removal and installation procedures 2 Remove the bolts and pull the seat off 1 1 Bolt 2 To install the seat 1 Insert the projections on the front of the seat into the seat holders as shown 2 Place the seat in the original position and then tighten the bolts 3 Install the panels NOTE Make sure that the seat is properly secured befor...

Page 25: ...acci dent 1 1 Open EAU03591 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut EC000015 cC Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings b a 2 1 1 Locknut 2 Adjusting nut Adjust the spring preload as follows 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspen sion t...

Page 26: ...th or attempt to open the gas cylinder 8 Do not subject the shock absorber to an open flame or other high heat sources other wise it may explode due to excessive gas pressure 8 Do not deform or damage the gas cylinder in any way as this will result in poor damp ing performance 8 Always have a Yamaha dealer service the shock absorber NOTE The spring preload setting is deter mined by measuring dista...

Page 27: ...eplace any cracked or damaged parts EC000022 cC Do not attempt to modify the YEIS in any way 1 2 1 YEIS air chamber 2 Air chamber hose EAU00326 YPVS This model is equipped with the YPVS Yamaha Power Valve System This system boosts engine performance and efficiency by means of a variable valve in the exhaust port The YPVS valve is constantly adjusted in accordance with the engine speed by a compute...

Page 28: ...while holding the motorcycle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situ ations See further down for an explanation of the ignition circuit cut off system EW000044 w The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up otherwise the sidestan...

Page 29: ...on is in gear and the sidestand is still down 8 It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000045 w If a malfunction is noted have a Yamaha dealer check the system before riding INSTRUMENT AND CONTROL FUNCTIONS 3 3MB 9 E8 6 13 01 10 55 AM P...

Page 30: ... The motorcycle should not be ridden until checked by a Yamaha dealer With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer NO NOTE This check is most reliable if performed with a...

Page 31: ...dd recommended oil to specified level Check vehicle for oil leakage 3 8 Transmission oil Check oil level in transmission case If necessary add recommended oil to specified level 6 10 6 12 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 12 6 15 Front brake Check operation If soft or spongy have Yamaha dealer bleed h...

Page 32: ...ndition Lubricate if necessary 6 7 6 28 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 19 6 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 30 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 30 Sidestand Make sure th...

Page 33: ... operation check list is not working properly have it inspected and repaired before operat ing the motorcycle Instruments lights signals and switches Check operation Correct if necessary 3 1 3 4 6 36 6 38 Sidestand switch Check operation of ignition circuit cut off system If system is defective have Yamaha dealer check vehicle 3 15 3 17 Battery Check fluid level Fill with distilled water if necess...

Page 34: ...e loss of control EAU01177 Starting a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met 8 The transmission is in the neutral position 8 The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 w 8 Before starting the engine check the function of the igni tion circuit cut off system according to ...

Page 35: ...mally to the throttle with the starter choke turned off EAU01258 Starting a warm engine Follow the same procedure as for starting a cold engine with the excep tion that the starter choke is not required when the engine is warm EAU00423 Shifting 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 i...

Page 36: ... are shown in the table below NOTE When shifting down two gears at a time reduce the speed accordingly e g down to 35 km h when shifting from 5th to 3rd gear EAU00424 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the follow ing tips to reduce fuel consumption 8 Thoroughly warm up the engine 8 Turn the starter choke off as soon as possible 8 Shift...

Page 37: ...U00453 0 500 km 8 Avoid prolonged operation above 6 000 r min 8 After every hour of operation stop the engine and then let it cool for five to ten minutes 8 Vary the engine speed from time to time Do not operate the engine at one set throttle posi tion 500 1 000 km 8 Avoid prolonged operation above 7 000 r min 8 Rev the engine freely through the gears but do not use full throttle at any time EC000...

Page 38: ...F EW000058 w 8 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them 8 Do not park on a slope or on soft ground otherwise the motorcycle may overturn EC000062 cC Never park in an area where there are fire hazards such as grass or other flammable materials 3MB 9 E8 6 13 01 10 55 AM Page 37 ...

Page 39: ...with motor cycle maintenance work have a Yamaha dealer do it for you EAU01175 Owner s tool kit The owner s tool kit is located behind panel B See page 6 8 for panel removal and installation procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of pre ventive maintenance and minor repairs However addit...

Page 40: ...Replace brake pads Whenever worn to the limit 7 Rear brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit 8 Brake hoses Check for cracks or damage Replace See NOTE on page 6 4 Every 4 years EAU03686 Periodic maintenance and lubrication chart NOTE 8 The annual checks must be performed every year except if a kilometer base...

Page 41: ...cycle or riding in the rain 14 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 24 000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assembly Check opera...

Page 42: ...ke hoses every four years and if cracked or damaged 21 Carburetor Check starter choke operation Adjust engine idling speed 22 Autolube pump Check operation Bleed if necessary 23 Transmission oil Check oil level Change 24 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Li...

Page 43: ... perform some of the maintenance jobs described in this chapter 2 1 1 Cowling A 2 Cowling B EAU01534 Cowling A To remove the cowling Remove the cowling screws and then pull the cowling off as shown 1 1 Screw 2 Refer to this section each time a cowling needs to be removed and installed 1 1 Cowling C 3MB 9 E8 6 13 01 10 55 AM Page 42 ...

Page 44: ...original posi tion and then install the screws To install the cowling Place the cowling in the original posi tion and then install the screws EAU01534 Cowling B To remove the cowling Remove the cowling screws and then pull the cowling off as shown 1 1 Screw 3 3MB 9 E8 6 13 01 10 55 AM Page 43 ...

Page 45: ... the cowling off as shown 1 1 Screw 3 EAU01122 Removing and installing panels The panels shown above need to be removed to perform some of the maintenance jobs described in this chapter 1 1 Panel A To install the cowling Place the cowling in the original posi tion and then install the screws 3MB 9 E8 6 13 01 10 55 AM Page 44 ...

Page 46: ...ed and installed 1 1 Panel B To install the panel Place the panel in the original posi tion and then install the screw 1 2 1 Screw 2 Panel B EAU04003 Panels A and B To remove one of the panels Remove the screw and then pull the panel off as shown 1 2 1 Screw 2 Panel A 3MB 9 E8 6 13 01 10 55 AM Page 45 ...

Page 47: ...heck the spark plug 1 Check that the porcelain insula tor around the center electrode of the spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally NOTE If the spark plug shows a distinctly different color the engine could be defective Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle 2 Check the spark plug for e...

Page 48: ...intervals specified in the peri odic maintenance and lubrication chart To check the transmission oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make sure that the motorcycle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off ...

Page 49: ...ransmission oil level check window 2 Minimum level mark 4 Install the transmission oil drain bolt and then tighten it to the specified torque 5 Add the specified amount of the recommended transmission oil and then install and tighten the oil filler cap 1 1 Transmission oil drain bolt To change the transmission oil 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oi...

Page 50: ...ycle on a level surface and hold it in an upright position NOTE 8 The coolant level must be checked on a cold engine since the level varies with engine tem perature 8 Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 2 Remove panel A See page 6 8 for panel removal and installation procedures 3 Check the c...

Page 51: ...ailable use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine 8 If water has been used instead of coolant replace it with coolant as soon as possible otherwise the engine may not be sufficiently cooled and the cooling system will not be pro tected against frost and corro sion 8 If water has been added to the coolant have a Yamaha dealer...

Page 52: ...ap 5 Disconnect the reservoir tank hose on the reservoir tank side and drain the coolant from the reservoir tank 6 After draining the coolant thor oughly flush the cooling system with clean tap water 7 Replace the coolant drain bolt washer if it is damaged and tight en the coolant drain bolt to the specified torque 1 1 Reservoir tank hose 4 Place a container under the engine and remove the coolant...

Page 53: ...d the panel EC000080 cC 8 If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine 8 If water has been used instead of coolant replace it with coolant as soon as possible otherwise the engine may not be sufficiently cooled and the cooling system will not be pro tected against frost and corro sion 8 If water has ...

Page 54: ...ase cover by removing the screws 1 2 1 Screw 3 2 Air filter case cover 4 Remove the wing nut and then separate the air filter element from the guide 5 Remove the sponge material from the frame clean it with sol vent and then squeeze the remaining solvent out 6 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the excess oil out NOTE The sponge material...

Page 55: ...ngine and warm it up for several minutes at 1 000 2 000 r min while occasionally revving it to 4 000 5 000 r min NOTE The engine is warm when it quickly responds to the throttle 2 Check the engine idling speed and if necessary adjust it to specification by turning the throt tle stop screw EAU00629 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisti...

Page 56: ...able free play should measure 3 5 mm at the throttle grip Periodically check the throttle cable free play and if necessary adjust it as follows NOTE The engine idling speed must be cor rectly adjusted before checking and adjusting the throttle cable free play a a Free play Engine idling speed 1 250 1 450 r min 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting nut i...

Page 57: ... cargo and accessories does not exceed the specified maximum load for the vehicle 8 Do not carry along loosely packed items which can shift during a ride 8 Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides 8 Adjust the suspension and tire air pressure with regard to the load 8 Check the tire condition and air pressure before each ...

Page 58: ...cement of all wheel and brake related parts including the tires should be left to a Yamaha dealer who has the necessary profession al knowledge and experience 8 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 high quality product Tire information This motorcycle is equipped with tube tires EW000078 w 8 T...

Page 59: ...mage 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 8 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 8 Ride at moderate speeds after changing a ti...

Page 60: ... c 1 Locknut Clutch lever 2 Adjusting bolt c Free play 5 Loosen the locknut at the crankcase 6 To increase the clutch lever free play turn the adjusting nut in direction a To decrease the clutch lever free play turn the adjusting nut in direction b 7 Tighten the locknut at the clutch lever and the crankcase a 2 1 b 1 Locknut Crankcase 2 Adjusting nut 3 If the specified clutch lever free play could...

Page 61: ...the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an accident EAU00696 Adjusting the brake lever free play The brake lever free play should measure 2 5 mm as shown Periodically check the brake lever free play and ...

Page 62: ...s must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EAU00713 Adjusting the rear brake light switch The rear brake light switch which is activated by the brake pedal is prop erly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rea...

Page 63: ... become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake system for leak age 1 1 Minimum level mark EAU00728 Rear brake pads Each rear brake pad is provided with a wear indica...

Page 64: ...t the intervals listed below or whenever they are damaged or leaking 8 Oil seals Replace every two years 8 Brake hoses Replace every four years 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking perfor mance 8 Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boi...

Page 65: ...adjust the drive chain slack 1 Loosen the axle nut 2 To tighten the drive chain turn the adjusting plate on each side of the swingarm in direction a To loosen the drive chain turn the adjusting plate on each side of the swingarm in direction b and then push the rear wheel for ward a b 2 1 1 Axle nut 2 Adjusting plate 2 Shift the transmission into the neutral position 3 Move the rear wheel by pushi...

Page 66: ...oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings EAU03006 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows EC000097 cC Th...

Page 67: ...g the cables The operation of all control cables and the condition of the cables should be checked before each ride and the cables and cable ends should be lubricated if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000112 w Damage to the outer sheath may interfere with proper cable opera tion and will cause the inner cable to rust Replace a d...

Page 68: ...e and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary Recommended lubricant Lithium soap based grease al...

Page 69: ...an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and rebounds smoothly EC000098 cC If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or repair it EAU03165 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and th...

Page 70: ...lubrication chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the opera tion of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrica tion chart 1 Place a stand under the engine to r...

Page 71: ...tained battery will cor rode and discharge quickly The elec trolyte level battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrication chart To check the electrolyte level 1 Place the motorcycle on a level surface and hold it in an upright position 1 2 1 Battery 2 Battery breather hose 3 If the elec...

Page 72: ... 8 KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN EC000100 cC Use only distilled water as tap water contains minerals that are harmful to the battery 4 Check and if necessary tighten the battery lead connections and correct the breather hose rout ing EW000117 w 8 Electrolyte is poisonous and dangerous since it contains sulfuric acid which causes severe burns Avoid any con tact with skin...

Page 73: ... system EAU01307 Replacing the fuse The fuse holder is located behind panel B See page 6 8 for panel removal and installation procedures If the fuse is blown replace it as fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 1 Fuse EC000099 cC If the breather hose is positioned in such a way that the fra...

Page 74: ...nect the headlight cou pler and then remove the head light bulb cover 1 2 1 Headlight coupler 2 Headlight bulb cover EAU01158 Replacing the headlight bulb If the headlight bulb burns out replace it as follows 1 Remove cowling A See page 6 5 for cowling removal and installation procedures 2 Remove the headlight unit by removing the bolts 1 1 Bolt 2 3MB 9 E8 6 13 01 10 55 AM Page 73 ...

Page 75: ... by installing the screw 1 2 3 1 Screw 2 Lens 3 Bulb 7 Install the headlight unit by installing the bolts 8 Install the cowling 9 Have a Yamaha dealer adjust the headlight beam if necessary EW000119 w Headlight bulbs get very hot Therefore keep flammable prod ucts away from a lit headlight bulb and do not touch the bulb until it has cooled down 5 Place a new bulb into position and then secure it w...

Page 76: ...ke light lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws 1 2 3 1 Screw 2 2 Lens 3 Bulb ECA00065 cC Do not overtighten the screw oth erwise the lens may break 3MB 9 E8 6 13 01 10 55 AM Page 75 ...

Page 77: ...l or under each side of the swingarm EAU01579 Supporting the motorcycle Since this model is not equipped with a centerstand follow these precau tions when removing the front and rear wheel or performing other main tenance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the...

Page 78: ...he front wheel off the ground according to the procedure on page 6 39 4 Loosen the wheel axle holder nuts 5 Pull the wheel axle out and then remove the wheel 3 2 1 1 Speedometer cable 2 Axle holder nut 4 3 Wheel axle EAU03555 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots 2 Lift the wheel up between the fork legs 1 1 Sp...

Page 79: ...nes When tightened in this sequence there should be a gap formed at the bottom of the axle holder NOTE Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Install the wheel axle 4 Lower the front wheel so that it is on the ground 5 Tighten the wheel axle to the specified ...

Page 80: ... axle nut 2 Lift the rear wheel off the ground according to the procedure on page 6 39 3 Remove the swingarm end bolts 2 2 1 1 Axle nut 2 Swingarm end bolt 2 4 Turn the drive chain adjusting plate on each side of the swingarm fully in direction a 5 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove ...

Page 81: ... properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills EAU01806 To install the rear wheel 1 Install the drive chain onto the rear sprocket and then insert the wheel axle from the left side NOTE Make sure that there is enough space between the brake pads before ins...

Page 82: ... Ask a Yamaha dealer to Remove spark plug 3 Ignition Wet Dry Wipe clean with dry cloth and correct Ask a Yamaha dealer to inspect Engine doesn t start ask a Yamaha Open throttle half way and start in the fuel tank and check electrodes spark gap or replace spark plug the engine dealer to inspect inspect EAU03108 Troubleshooting charts EW000125 w Keep away open flames and do not smoke while checking...

Page 83: ...e engine and radiator are hot Scalding hot fluid and steam may be blown out under pressure which could cause serious injury Be sure to wait until the engine has cooled 8 After removing the radiator cap retaining bolt place a thick rag like a towel over the radiator cap and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape When the hissing sound has ...

Page 84: ... as all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 cC 8 Avoid using strong acidic wheel clean...

Page 85: ...ot 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 bottle brush 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...

Page 86: ... minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry complete ly before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or tires 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 8 Before operating the motorcy cle te...

Page 87: ...lt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 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 spa...

Page 88: ...a little every month in order to pre vent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C or more than 30 C For more informa tion on storing the ba...

Page 89: ...nder arrangement Forward inclined single cylinder Displacement 124 cm3 Bore Stroke 56 0 50 7 mm Compression ratio 6 7 1 Starting system Kickstarter Lubrication system Separate lubrication Yamaha Autolube Engine oil 2 cycle Type 2 stroke engine oil Capacity Total amount 1 2 L Transmission oil Type SAE 10W30 type SE motor oil Capacity Periodic oil change 0 75 L Total amount 0 8 L Cooling system capa...

Page 90: ...procket teeth rear front 57 16 Transmission type Constant mesh 6 speed Operation Left foot operation Gear ratio 1st 2 833 2nd 1 875 3rd 1 412 4th 1 143 5th 0 957 6th 0 818 Chassis Frame type Semi double cradle Caster angle 27 30 Trail 113 mm Tire Front Type With tube Size 2 75 21 45P Manufacturer BRIDGESTONE TW25 model Rear Type With tube Size 4 10 18 59P Manufacturer BRIDGESTONE TW44 model Maximu...

Page 91: ...1 Rear Type Spoke wheel Size 1 85 18 Brakes Front Type Single disc brake Operation Right hand operation Fluid DOT 4 Rear Type Single disc brake Operation Right foot operation Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspension Shock absorber Front Coil spring oil damper Rear Coil gas spring oil damper Wheel travel Front 270 mm Rear 260 mm Electrical Ignition system C D I Cha...

Page 92: ...Tail brake light 12 V 5 21 W 1 Front turn signal light 12 V 21 W 2 Rear turn signal light 12 V 21 W 2 Auxiliary light 12 V 4 W 1 12 V 3 4 W 1 GB only Meter lighting 12 V 3 4 W 2 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Oil level indicator light 12 V 3 4 W 1 Turn indicator light 12 V 3 4 W 1 Fuse 10 A 3MB 9 E8 6 13 01 10 55 AM Page 91 ...

Page 93: ... unit Multiplier Imperial unit m kgf 7 233 ft lb Torque m kgf 86 794 in lb cm kgf 0 0723 ft lb cm kgf 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km hr 0 6214 mph km 0 6214 mi m 3 281 ft Distance m 1 094 yd cm 0 3937 in mm 0 03937 in cc cm3 0 03527 oz IMP liq Volume cc cm3 0 06102 cu in capacity L liter 0 8799 qt IMP liq L liter 0 2199 gal IMP liq kgf mm 55 997 lb in Misc kgf cm2 14 2234 ps...

Page 94: ...1042 Key identification number The key identification number is stamped into the key Record this number in the space pro vided and use it for reference when ordering a new key 1 1 Key identification number EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number i...

Page 95: ...label The model label is affixed to the loca tion shown Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 1 Model label 3MB 9 E8 6 13 01 10 55 AM Page 94 ...

Page 96: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 6 0 3 1 E OWNER S MANUAL 3MB 28199 E8 DT125R YAMAHA MOTOR CO LTD ...

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Yamaha DT125R, Owner'S Manual

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