OWNER’S MANUAL DT125R YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000·12–0.
3MB-9-E7 12/27/00 2:52 PM Page 1 INTRODUCTION EAU00001 Welcome to the Yamaha world of motorcycling! 1 As the owner of a DT125R, you are benefiting from Yamaha’s vast experience in and newest technology for the design and the manufacture of high-quality products, which have earned Yamaha a reputation for dependability. 2 Please take the time to read this manual thoroughly, so as to enjoy all your DT125R’s advantages.
MB-9-E7 12/27/00 2:52 PM Page 2 IMPORTANT MANUAL INFORMATION EAU00005 Particularly important information is distinguished in this manual by the following notations: 1 The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Q 2 3 4 w Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
3MB-9-E7 12/27/00 2:52 PM Page 3 IMPORTANT MANUAL INFORMATION w EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
3MB-9-E7 12/27/00 2:52 PM Page 4 1 2 3 4 5 6 7 8 9 EAU03337 DT125R OWNER’S MANUAL © 2000 by Yamaha Motor Co., Ltd. 1st Edition, December 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
3MB-9-E7 12/27/00 2:52 PM Page 5 EAU00009 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY..................1-1 2 DESCRIPTION ....................................................2-1 Left view............................................................2-1 Right view .........................................................2-2 Controls/Instruments.........................................2-3 3 INSTRUMENT AND CONTROL FUNCTIONS ....3-1 Main switch .......................................................
3MB-9-E7 12/27/00 2:52 PM Page 6 TABLE OF CONTENTS 6 1 2 3 4 5 6 7 8 9 PERIODIC MAINTENANCE AND MINOR REPAIR................................................................6-1 Tool kit ..............................................................6-1 Periodic maintenance and lubrication chart ......6-3 Cowling removal and installation ......................6-6 Cowling A..........................................................6-6 Cowling B..........................................................
3MB-9-E7 12/27/00 2:52 PM Page 7 TABLE OF CONTENTS 7 MOTORCYCLE CARE AND STORAGE .............7-1 Care ..................................................................7-1 Storage .............................................................7-4 8 SPECIFICATIONS ...............................................8-1 How to use the conversion table.......................8-5 9 CONSUMER INFORMATION..............................9-1 Identification number records ...........................
3MB-9-E7 12/27/00 2:52 PM Page 8 Q GIVE SAFETY THE RIGHT OF WAY 1 2 3 4 EAU00021 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving your motorcycle’s value and operating condition.
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3MB-9-E7 12/27/00 2:52 PM Page 10 EAU00026 DESCRIPTION Left view 1 1 23 4 5 6 2 3 4 5 6 7 10 9 8 7 8 9 1. 2. 3. 4. 5. 6. Headlight Radiator cap Fuel cock Air filter Coolant reservoir tank Helmet holder (page 6-33) (page 6-13) (page 3-9) (page 6-15) (page 6-13) (page 3-12) 7. 8. 9. 10. 2-1 Starter (choke) Shift pedal Y.E.I.S. Y.P.V.S.
3MB-9-E7 12/27/00 2:52 PM Page 11 DESCRIPTION Right view 11 12 13 1 2 3 4 5 6 7 15 14 8 11. 12. 13. 14. 15.
3MB-9-E7 12/27/00 2:52 PM Page 12 DESCRIPTION Controls/Instruments 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 25 16. 17. 18. 19. 20. Clutch lever Left handlebar switches Speedometer Coolant temperature gauge Tachometer (page 3-5, 6-21) (page 3-4) (page 3-3) (page 3-4) (page 3-3) 24 21. 22. 23. 24. 25.
3MB-9-E7 12/27/00 2:52 PM Page 13 EAU00027 INSTRUMENT AND CONTROL FUNCTIONS EAU00063 ON High beam indicator light “&” This indicator comes on when the headlight high beam is used. 4 OFF 1 2 3 EAU00028 Main switch The main switch controls the ignition and lighting systems. Its operation is described below. EAU00036 1. 2. 3. 4. EAU01313 Oil level indicator light “7” This indicator comes on when the oil level is low. This light circuit can be checked by the procedure on page 32.
3MB-9-E7 12/27/00 2:52 PM Page 14 INSTRUMENT AND CONTROL FUNCTIONS EAU00075 Oil level indicator circuit check 1 Turn the main switch to “ON”. 2 Put the transmission in neutral. 3 4 Oil level indicator light does not come on. Oil level indicator light comes on. 5 Shift into gear. 6 7 Oil level indicator light does not come on. Oil level indicator light comes on. Engine oil level and electrical circuit are OK. Go ahead with riding. Supply engine oil.
3MB-9-E7 12/27/00 2:52 PM Page 15 INSTRUMENT AND CONTROL FUNCTIONS 4 1. 2. 3. 4. 1 NOTE: (for German model equipped with speed limiter only) This motorcycle is equipped with a speed limiter which prevents it from exceeding a top speed of 80 km/h. 2 1 1 2 2 3 3 Speedometer Odometer Trip odometer Reset knob 1. Tachometer 2. Red zone 4 EAU00102 Tachometer EAU01087 This model is equipped with a tachometer so the rider can monitor the engine speed and keep it within the ideal power range.
3MB-9-E7 12/27/00 2:52 PM Page 16 INSTRUMENT AND CONTROL FUNCTIONS EAU00127 1 2 1 Turn signal switch To signal a right-hand turn, push the switch to “6”. To signal a left-hand turn, push the switch to “4”. Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position. 2 1 2 3 4 4 1. Coolant temperature gauge 2.
3MB-9-E7 12/27/00 2:52 PM Page 17 INSTRUMENT AND CONTROL FUNCTIONS 1 6 5 4 3 2 N 1 1 2 1 1 1. Engine stop switch 1. Clutch lever EAU00138 Engine stop switch The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to “#” to start the engine. In case of emergency, turn the switch to “$” to stop the engine. EAU00155 Clutch lever 3 1. Shift pedal N.
3MB-9-E7 12/27/00 2:52 PM Page 18 INSTRUMENT AND CONTROL FUNCTIONS 1 2 1 1 1 2 3 3 4 5 6 1. Front brake lever 1. Rear brake pedal EAU00158 EAU00162 Front brake lever Rear brake pedal The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake. 7 8 1. Fuel tank cap 2. Unlock 3.
3MB-9-E7 12/27/00 2:52 PM Page 19 INSTRUMENT AND CONTROL FUNCTIONS NOTE: The tank cap cannot be reinstalled unless it is unlocked. The key must remain in the cap until the cap is properly installed and locked onto the fuel tank. w 2 1 1 2 4 3 1 2 3 EW000023 Be sure the cap is properly installed and locked in place before riding the motorcycle. 1. Filler tube 2. Fuel level EAU01183 Fuel (except for Switzerland and Austria) Make sure there is sufficient fuel in the tank.
3MB-9-E7 12/27/00 2:52 PM Page 20 INSTRUMENT AND CONTROL FUNCTIONS w 1 2 3 4 5 6 EW000130 EAU01084 Catalyzer Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube or it may overflow when the fuel heats up later and expands. cC EAU00191 EAU00185 Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts.
3MB-9-E7 12/27/00 2:52 PM Page 21 INSTRUMENT AND CONTROL FUNCTIONS cC EC000114 The following must be observed to prevent a fire hazard or other damages. 8 Use only unleaded gasoline. Use of leaded gasoline will cause unrepairable damage to the catalytic converter. 8 Never park this motorcycle in an area that would cause a fire hazard such as grass or other materials that may easily burn. 8 Do not allow the engine to idle for very long. OFF: closed position 1 RES 2 1 OFF ON 2 FUEL 1 1.
3MB-9-E7 12/27/00 2:52 PM Page 22 INSTRUMENT AND CONTROL FUNCTIONS ON: normal position RES: reserve position RES RES 1 a RES OFF 2 ON 3 4 5 6 ON OFF FUEL 1 ON FUEL 1 1. Arrow mark positioned “ON” 1. Arrow mark positioned “RES” ON With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity.
3MB-9-E7 12/27/00 2:52 PM Page 23 INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering Insert the key, push it in and turn it 1/8 turn counterclockwise so that it moves out. Then, release and remove the key. 1 1 1 2 3 1. Kick starter 1. Steering lock EAU00212 EAU02934 Kick starter Steering lock Rotate the kick starter away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine.
3MB-9-E7 12/27/00 2:52 PM Page 24 INSTRUMENT AND CONTROL FUNCTIONS 1 1 2 1 3 4 1. Bolt (×2) 1. Open EAU01648 Seat 5 6 7 8 To remove 1. Remove panels D and E. (See page 6-9 for panel removal and installation procedures.) 2. Remove the seat bolts and lift the seat upward. To install 1. Insert the projections on the front of the seat into the holders, then tighten the seat bolts. 2. Install the panels. NOTE: Make sure that the seat is securely fitted.
3MB-9-E7 12/27/00 2:52 PM Page 25 INSTRUMENT AND CONTROL FUNCTIONS 3. Tighten the locknut to the specified torque. b “A” 1 Tightening torque: Locknut: 55 Nm (5.5 m0kg) a 2 1 cC Rear shock absorber adjustment This shock absorber is equipped with a spring preload adjuster. Adjust spring preload as follows. 1. Loosen the locknut. 2. Turn the adjusting nut in direction a to increase spring preload and in direction b to decrease spring preload. The spring preload is determined by the spring set length.
3MB-9-E7 12/27/00 2:52 PM Page 26 INSTRUMENT AND CONTROL FUNCTIONS w 1 2 3 4 5 6 7 8 9 EAU00315 This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. 8 Do not tamper with or attempt to open the cylinder assembly. 8 Do not subject the shock absorber to an open flame or other high heat source.
3MB-9-E7 12/27/00 2:52 PM Page 27 INSTRUMENT AND CONTROL FUNCTIONS EC000023 cC 1 The Y.P.V.S. was set at the Yamaha factory after many tests. If the settings are disturbed by someone without sufficient technical knowledge, poor engine performance and damage may result. 1. Y.P.V.S. EAU00326 Y.P.V.S. (Yamaha Power Valve System) The Y.P.V.S. is a vital part of the engine and requires very sophisticated adjustment.
3MB-9-E7 12/27/00 2:52 PM Page 28 INSTRUMENT AND CONTROL FUNCTIONS w 1 2 3 4 5 6 7 EW000044 This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand.
3MB-9-E7 12/27/00 2:52 PM Page 29 EAU01114 PRE-OPERATION CHECKS Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual inspection, you check the following points before each ride.
3MB-9-E7 12/27/00 2:52 PM Page 30 PRE-OPERATION CHECKS ITEM 1 2 3 4 5 6 9 Brake and shift pedal shafts 9 9 Brake and clutch lever pivots 9 9 Sidestand pivot 9 9 Chassis fasteners 9 9 Fuel tank 9 Lights, signals and 9 switches 9 Battery 9 CHECKS Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check fuel level.
3MB-9-E7 12/27/00 2:52 PM Page 31 EAU00372 OPERATION AND IMPORTANT RIDING POINTS w EAU00373 8 Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. 8 Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time.
3MB-9-E7 12/27/00 2:52 PM Page 32 OPERATION AND IMPORTANT RIDING POINTS TURN THE MAIN SWITCH TO "ON" AND THE ENGINE STOP SWITCH TO “#”. 1 2 3 IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN, IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP, KICK THE KICK STARTER. ENGINE WILL START. APPLY THE CLUTCH LEVER AND KICK THE KICK STARTER. ENGINE WILL START. 4 5 6 RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR. MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.
3MB-9-E7 12/27/00 2:52 PM Page 33 OPERATION AND IMPORTANT RIDING POINTS 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “#”. 3. Shift the transmission into neutral. NOTE: When the transmission is in neutral, the neutral indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect it. NOTE: For maximum engine life, never accelerate hard with a cold engine! 7. After the engine is warm, turn off the starter (choke) completely.
3MB-9-E7 12/27/00 2:52 PM Page 34 OPERATION AND IMPORTANT RIDING POINTS EC000048 cC 1 2 6 5 4 3 2 N 1 1 3 4 N. Neutral 1. Shift pedal EAU00423 5 6 7 8 9 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the shift pedal is shown in the illustration. To shift into neutral, depress the shift pedal repeatedly until it reaches the end of its travel, then raise the pedal slightly.
3MB-9-E7 12/27/00 2:52 PM Page 35 OPERATION AND IMPORTANT RIDING POINTS EAU00424 Tips for reducing fuel consumption Your motorcycle’s fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption: 8 Warm up the engine before riding. 8 Turn off the starter (choke) as soon as possible. 8 Shift up swiftly and avoid high engine speeds during acceleration.
3MB-9-E7 12/27/00 2:52 PM Page 36 OPERATION AND IMPORTANT RIDING POINTS EAU00458 1,000 km and beyond Parking Full throttle can be used. 1 2 3 4 5 6 7 8 9 cC EC000053 8 Never let engine speeds enter the red zone. 8 If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to “OFF” whenever stopping the engine. EW000058 w The exhaust system is hot.
3MB-9-E7 12/27/00 2:52 PM Page 37 EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00464 Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals.
3MB-9-E7 12/27/00 2:52 PM Page 38 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 NOTE: If you do not have necessary tools required during a service operation, take your motorcycle to a Yamaha dealer for service. w EW000063 Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes.
3MB-9-E7 12/27/00 2:52 PM Page 39 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03686 Periodic maintenance and lubrication chart NOTE: 8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. 8 From 30,000 km, repeat the maintenance intervals starting from 6,000 km. 8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. 1 2 3 NO.
3MB-9-E7 12/27/00 2:52 PM Page 40 PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM √ √ √ √ √ √ √ √ Wheel bearings • Check bearing for looseness or damage. √ √ √ √ Swingarm • Check operation and for excessive play. √ √ √ √ 9 * Wheels 2 10 * Tires 11 * * 12 ODOMETER READING (× 1,000 km) 1 6 12 18 24 • Check runout, spoke tightness and for damage. • Tighten spokes if necessary. • Check tread depth and for damage. • Replace if necessary. • Check air pressure.
3MB-9-E7 12/27/00 2:52 PM Page 41 PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM 21 * Carburetor 22 * Autolube pump 23 Transmission oil 24 * Cooling system 25 * Front and rear brake switches 26 27 CHECK OR MAINTENANCE JOB ODOMETER READING (× 1,000 km) 1 6 12 18 24 • Check starter (choke) operation. • Adjust engine idling speed. • Check operation. • Bleed if necessary. √ • Check oil level. • Change. • Check coolant level and vehicle for coolant leakage. • Change.
3MB-9-E7 12/27/00 2:52 PM Page 42 PERIODIC MAINTENANCE AND MINOR REPAIR 2 1 1 1 1 2 3 4 1. Cowling A 2. Cowling B 1. Cowling C 1. Screw (×2) EAU01534* Cowling A EAU01065 5 6 7 8 Cowling removal and installation To remove Remove the screws and pull outward as shown. The cowlings indicated in the illustration need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a cowling has to be removed or reinstalled.
3MB-9-E7 12/27/00 2:52 PM Page 43 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1. Screw (×3) To install Place in the original position and install the screws. EAU01534* Cowling B To remove Remove the screws and pull outward as shown. 6-7 To install Place in the original position and install the screws.
3MB-9-E7 12/27/00 2:52 PM Page 44 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 2 3 4 1. Screw (×3) 1. Panel D EAU01534* Cowling C 5 6 To remove Remove the screws and pull outward as shown. To install Place in the original position and install the screws. 7 8 9 6-8 EAU01122 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter.
3MB-9-E7 12/27/00 2:52 PM Page 45 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 1 2 3 1. Panel E Refer to this section each time a panel has to be removed or reinstalled. 1. Screw 1. Screw EAU01535* EAU01535* 4 Panel D Panel E To remove Remove the screw and pull outward as shown. To remove Remove the screw and pull outward as shown. 5 To install Place the panel in the original position and install the screw. To install Place the panel in the original position and install the screw.
3MB-9-E7 12/27/00 2:52 PM Page 46 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 2 3 4 1. Spark plug cap 1. Spark plug wrench EAU01833 Spark plug 5 Removal 1. Remove the spark plug cap. 2. Use the spark plug wrench in the tool kit to remove the spark plug as shown. 6 7 8 9 Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine.
3MB-9-E7 12/27/00 2:52 PM Page 47 PERIODIC MAINTENANCE AND MINOR REPAIR 1 NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. 2 1 2 3 1 3 1. Spark plug gap 4. Install the spark plug cap. Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 1.
3MB-9-E7 12/27/00 2:52 PM Page 48 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 Recommended oil: See page 8-1. Oil quantity: Total amount: 0.8 L Periodic oil change: 0.75 L 2 3 4 5 6 7 1. Oil filler cap 2. With the engine stopped, check the oil level through the level window located at the right side crankcase cover. NOTE: Wait a few minutes until the oil level settles before checking. 8 9 3. The oil level should be between the maximum and minimum level on the level window.
3MB-9-E7 12/27/00 2:52 PM Page 49 PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the panel. Reservoir tank capacity: 0.35 L 1 3 1. Stopper bolt 2. Radiator cap 1. Remove panel D. (See page 6-9 for panel removal and installation procedures.) 2. Check the coolant level in the reservoir tank when the engine is cold as the coolant level will vary with engine temperature. The coolant level should be between the maximum and minimum marks. 3.
3MB-9-E7 12/27/00 2:52 PM Page 50 PERIODIC MAINTENANCE AND MINOR REPAIR 8. Install the reservoir tank hose. 9. Pour the recommended coolant into the radiator until it is full. 1 2 2 1 1 3 4 5 6 7 8 9 3 1. Drain bolt 4. Place a container under the engine and remove the coolant drain bolt. 1. Reservoir tank hose 2. Maximum level mark 3. Minimum level mark 5. Disconnect the reservoir tank hose on the reservoir tank side and drain the coolant from the reservoir tank. 6.
3MB-9-E7 12/27/00 2:52 PM Page 51 PERIODIC MAINTENANCE AND MINOR REPAIR cC EC000080 1 Hard water or salt water is harmful to the engine. You may use distilled water if you can’t get soft water. 10. Install the radiator cap. 11. Run the engine several minutes. Stop the engine and recheck the coolant level in the radiator. If it is low, add more coolant until it reaches the top of the radiator. 12. Install the radiator cap stopper bolt. 13. Fill the reservoir tank with coolant up to maximum level. 14.
3MB-9-E7 12/27/00 2:52 PM Page 52 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 1 6. Insert the air filter guide into the air filter and install it in the case. 7. Install the air filter case cover and panel by installing the screws. 2 3 4 5 6 7 8 9 EC000082 cC 1. Guide 2. Filter element 4. Remove the air filter element from its guide and clean it with solvent. After cleaning, remove the remaining solvent by squeezing the element. 5.
3MB-9-E7 12/27/00 2:52 PM Page 53 PERIODIC MAINTENANCE AND MINOR REPAIR Standard idle speed: 1,250 ~ 1,450 r/min 1 NOTE: If the specified idle speed cannot be obtained by performing the above adjustment, consult a Yamaha dealer. a b a 1 1. Throttle stop screw 2 3 a. Free play EAU00632 EAU00634 Idle speed adjustment Throttle cable free play adjustment 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min.
3MB-9-E7 12/27/00 2:52 PM Page 54 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00652 2 1 Tires 1 b a 2 3 4 5 6 7 8 9 1. Locknut 2. Adjusting nut 1. Loosen the locknut. 2. Turn the adjusting nut in direction a to increase free play and in direction b to decrease free play. 3. Tighten the locknut. Maximum load* To ensure maximum performance, long service and safe operation, note the following: Tire air pressure Always check and adjust the tire pressure before operating the motorcycle.
3MB-9-E7 12/27/00 2:52 PM Page 55 PERIODIC MAINTENANCE AND MINOR REPAIR w EW000083 Proper loading of your motorcycle is important for several characteristics of your motorcycle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcycle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires.
3MB-9-E7 12/27/00 2:52 PM Page 56 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 NOTE: These limits may be different by regulation from country to country. If so, conform to the limits specified by the regulations of your own country. EAU00681 w EAU00685 Wheels 8 Operating the motorcycle with excessively worn tires decrease riding stability and can lead to loss of control. Have excessively worn tires replaced by a Yamaha dealer immediately.
3MB-9-E7 12/27/00 2:52 PM Page 57 PERIODIC MAINTENANCE AND MINOR REPAIR 3 3 2 1 a a b 1 a b b 1 1 2 2 2 3 1. Locknut 2. Adjusting bolt 3. Free play 1. Locknut 2. Adjusting nut EAU00694 Clutch lever free play adjustment The clutch lever free play should be adjusted to 10 ~ 15 mm. 1. Loosen the locknut at the clutch lever. 2. Turn the adjusting bolt at the clutch lever in direction a to increase free play or in direction b to decrease free play. 3. Tighten the locknut at the clutch lever.
3MB-9-E7 12/27/00 2:52 PM Page 58 PERIODIC MAINTENANCE AND MINOR REPAIR w 1 2 3 4 5 6 7 EW000099 8 Check the brake lever free play. Be sure the brake is working properly. 8 A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident.
3MB-9-E7 12/27/00 2:52 PM Page 59 PERIODIC MAINTENANCE AND MINOR REPAIR FRONT REAR 1 1 1 2 a 1 2 b 3 1. Brake light switch 2. Adjusting nut 1. Wear limit: 0.8 mm 1. Wear limit: 0.8 mm EAU00717 EAU00713 Brake light switch adjustment The rear brake light switch is activated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect. To adjust the rear brake light switch, hold the switch body so it does not rotate while turning the adjusting nut.
3MB-9-E7 12/27/00 2:52 PM Page 60 PERIODIC MAINTENANCE AND MINOR REPAIR FRONT REAR 1 2 1 1 3 4 5 6 7 8 9 1. Minimum level mark 1. Minimum level mark EAU00732 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level and fill when necessary.
3MB-9-E7 12/27/00 2:52 PM Page 61 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00742 To check the chain slack the motorcycle must be held straight up with both wheels on the ground and without rider. Check the slack at the position shown in the illustration. Normal slack is approximately 25 ~ 40 mm. If the slack exceeds 40 mm, adjust it. Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel.
3MB-9-E7 12/27/00 2:52 PM Page 62 PERIODIC MAINTENANCE AND MINOR REPAIR 2 1 b 2 a 1 3. Tighten the wheel axle nut to the specified torque. 1. Wheel axle nut 2. Chain adjusting plate EAU01533* 5 6 7 8 9 Drive chain slack adjustment 1. Loosen the wheel axle nut. 2. To tighten the chain, turn the chain adjusting plates in direction a. To loosen the chain, turn the chain adjusting plates in direction b and push the wheel forward.
3MB-9-E7 12/27/00 2:52 PM Page 63 PERIODIC MAINTENANCE AND MINOR REPAIR cC EC000097 Be sure to oil the chain after washing the motorcycle or riding in the rain. EAU02962 EW000112 w Damage to the outer housing of cables may lead to internal rusting and interfere with the cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions. Lubricate the cables and cable ends. If a cable does not operate smoothly, ask a Yamaha dealer to replace it.
3MB-9-E7 12/27/00 2:52 PM Page 64 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00774 Autolube pump adjustment 1 2 3 The autolube pump is a vital part of the engine and requires very sophisticated adjustment. Adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. EAU02984 EAU02985 Brake and shift pedal lubrication Brake and clutch lever lubrication Lubricate the pivoting parts. Lubricate the pivoting parts.
3MB-9-E7 12/27/00 2:52 PM Page 65 PERIODIC MAINTENANCE AND MINOR REPAIR EAU02986 EAU02939 Sidestand lubrication Front fork inspection Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly. Visual check Recommended lubricant: Engine oil w EW000113 If the sidestand does not move smoothly, consult a Yamaha dealer. EW000115 1 Securely support the motorcycle so there is no danger of it falling over.
3MB-9-E7 12/27/00 2:52 PM Page 66 PERIODIC MAINTENANCE AND MINOR REPAIR EW000115 w Securely support the motorcycle so there is no danger of it falling over. 1 2 3 4 EAU00794 Steering inspection 5 6 7 8 9 EAU01144 Wheel bearings Periodically inspect the condition of the steering. Worn out or loose steering bearings may be dangerous. Place a stand under the engine to raise the front wheel off the ground. Hold the lower end of the front forks and try to move them forward and backward.
3MB-9-E7 12/27/00 2:52 PM Page 67 PERIODIC MAINTENANCE AND MINOR REPAIR EC000099 cC 1 When inspecting the battery, be sure the breather hose is routed correctly. If the breather hose is positioned in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmetic damage to the motorcycle can occur. 2 1. Battery 2. Battery breather hose EAU01071 Battery Check the level of the battery electrolyte and make sure that the terminals are tight.
3MB-9-E7 12/27/00 2:52 PM Page 68 PERIODIC MAINTENANCE AND MINOR REPAIR EC000100 cC 1 1 2 2 3 4 5 6 7 8 Normal tap water contains minerals which are harmful to a battery; therefore, refill only with distilled water. EW000117 w 1. Maximum level mark 2. Minimum level mark Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly. The battery fluid should be checked at least once a month. The level should be between the minimum level and maximum level marks.
3MB-9-E7 12/27/00 2:52 PM Page 69 PERIODIC MAINTENANCE AND MINOR REPAIR 1 EC000103 cC Do not use fuses of higher amperage rating than those recommended. Substitution of a fuse of improper rating can cause extensive electrical system damage and possibly a fire. 1. Fuse EAU00804 Fuse replacement Specified fuse: 10 A If the fuse is blown, turn off the main switch and the switch of the circuit in question. Install a new fuse of specified amperage.
3MB-9-E7 12/27/00 2:52 PM Page 70 PERIODIC MAINTENANCE AND MINOR REPAIR 6. Install the bulb holder cover, connector and headlight unit. 7. Install the cowling. 8. If the headlight beam adjustment is necessary, ask a Yamaha dealer to make that adjustment. 1 1 1 2 2 3 4 5 6 7 8 9 1. Bulb holder cover 2. Connector 3. Remove the headlight connector and the bulb holder cover. 1. Bulb holder 4. Turn the bulb holder counterclockwise to remove it and then remove the defective bulb.
3MB-9-E7 12/27/00 2:52 PM Page 71 PERIODIC MAINTENANCE AND MINOR REPAIR 1 cC EC000108 Do not over-tighten the screws as the lens may break. 1 3 3 2 1 2 2 3 1. Screw 2. Lens 3. Bulb 1. Screw (×2) 2. Lens 3. Bulb 4 EAU01095 Turn signal light bulb replacement 1. Remove the screw and the lens. 2. Remove the defective bulb by pushing it inward and turning it counterclockwise. 3. Install a new bulb by pushing it inward and turning it clockwise. 4. Install the lens and tighten the screw.
3MB-9-E7 12/27/00 2:52 PM Page 72 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle 1 2 3 4 5 6 7 8 9 Since the Yamaha DT125R has no centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright. Check that the motorcycle is in a stable and level position before starting any maintenance. A strong wooden box can be placed under the engine for added stability.
3MB-9-E7 12/27/00 2:52 PM Page 73 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 2 3 2 3 1. Speedometer cable 2. Axle holder nut (×4) 3. Wheel axle 3. Elevate the front wheel by placing a suitable stand under the engine. 4. Loosen the wheel axle holder nuts. 5. Remove the wheel axle and the front wheel. Make sure the motorcycle is properly supported. NOTE: Do not depress the brake lever when the disc and caliper are separated. EAU03104 Front wheel installation 1.
3MB-9-E7 12/27/00 2:52 PM Page 74 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 1 1 2 1 1 3 4 5 6 7 8 1. Gap 6. Tighten the axle holder nuts to the specified tightening torque. Tighten the upper nuts first and then lower ones. When tightened in this sequence, there should be a gap formed at the bottom of the axle holder. Tightening torque: Axle holder nut: 10 Nm (1.0 m0kg) 9 7. After tightening the holder nuts, push down on the handlebars several times and check if the fork rebounds smoothly. 1.
3MB-9-E7 12/27/00 2:52 PM Page 75 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03106 Rear wheel installation 1. Install the rear wheel and chain. Guide the brake disc between the brake pads. Make sure there is enough gap between the brake pads before inserting the brake disc. 2. Make sure the wheel axle is inserted from the left side and that the chain adjusting plates are installed with the punched side outward. 3. Install the swingarm end bolts. 4. Adjust the drive chain. 5.
3MB-9-E7 12/27/00 2:52 PM Page 76 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03108 Troubleshooting charts 1 EW000125 w Never check the fuel system while smoking or in the vicinity of an open flame. 2 3 4 1. Fuel Enough fuel. Go to compression check. No fuel. Supply fuel. Check if there is fuel in the fuel tank. Engine doesn’t start, go to compression check. 5 2. Compression 6 There is compression. Go to ignition check. No compression. Ask a Yamaha dealer to inspect. Use kick starter.
3MB-9-E7 12/27/00 2:52 PM Page 77 PERIODIC MAINTENANCE AND MINOR REPAIR 4. Engine overheating EW000070 w Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap and slowly rotate the cap counterclockwise to the detent.
3MB-9-E7 12/27/00 2:52 PM Page 78 EAU01518 MOTORCYCLE CARE AND STORAGE Care 1 2 3 4 5 6 7 The exposure of its technology makes a motorcycle charming but also vulnerable. Although high-quality components are used, they are not all rust-resistant. While a rusty exhaust pipe may remain unnoticed on a car, it does look unattractive on a motorcycle. Frequent and proper care, however, will keep your motorcycle looking good, extend its life and maintain its performance.
3MB-9-E7 12/27/00 2:52 PM Page 79 MOTORCYCLE CARE AND STORAGE 8 Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. 8 Do not use any harsh chemical products on plastic parts.
3MB-9-E7 12/27/00 2:52 PM Page 80 MOTORCYCLE CARE AND STORAGE 1 2 3 4 5 6 7 8 9 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 4.
3MB-9-E7 12/27/00 2:52 PM Page 81 MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. cC ECA00014 8 Storing the motorcycle in a poorly ventilated room or covering it with a tarp while it is still wet will allow water and humidity to seep in and cause rust. 8 To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.
3MB-9-E7 12/27/00 2:52 PM Page 82 MOTORCYCLE CARE AND STORAGE 1 2 3 4 5 6 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7. Check and, if necessary, correct the tire air pressure, then raise the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8.
3MB-9-E7 12/27/00 2:52 PM Page 83 EAU01038 SPECIFICATIONS Specifications Model DT125R Dimensions Overall length Overall width Overall height 2,170 mm 2,235 mm (N, S, SF, CH, A only) 830 mm 885 mm Wheel base 1,415 mm Ground clearance Minimum turning radius Basic weight (with oil and full fuel tank) 6.7:1 Starting system Kick starter Lubrication system Separate lubrication (Yamaha autolube) 2 2 stroke engine oil 3 1.2 L 4 SAE 10W30 type SE motor oil 5 Periodic oil change 0.
3MB-9-E7 12/27/00 2:52 PM Page 84 SPECIFICATIONS 1 2 Carburetor Chassis Type × quantity TM28SS × 1 Manufacturer MIKUNI Frame type Spark plug 3 4 Manufacturer / type NGK / BR9ES NGK / BR8ES (CH, A only) Spark plug gap 0.7 ~ 0.8 mm Clutch type Caster angle 27°30’ Trail 113 mm Tire Type 6 7 8 9 With tube Front Wet, multiple-disc Transmission 5 Semi double cradle Size 2.
3MB-9-E7 12/27/00 2:52 PM Page 85 SPECIFICATIONS Rear 90 kg load ~ maximum load* Front 150 kPa (1.50 kg/cm2, 1.50 bar) Rear 175 kPa (1.75 kg/cm2, 1.75 bar) Off-road riding 1 Type Single disc brake Operation Right foot operation Fluid DOT 3 or DOT 4 Suspension Front 125 kPa (1.25 kg/cm2, 1.25 bar) Rear 150 kPa (1.50 kg/cm2, 1.50 bar) * Load is total weight of cargo, rider, passenger and accessories. Front Type Spoke wheel Size 1.60 × 21 Type Spoke wheel Size 1.
3MB-9-E7 12/27/00 2:52 PM Page 86 SPECIFICATIONS 1 Battery 2 Type GM3-3B Voltage, capacity 12 V, 3 AH Headlight type 3 4 5 6 7 8 9 Conventional incandescent bulb Bulb voltage, wattage × quantity Headlight 12 V, 45/40 W × 1 Tail / Brake light 12 V, 5/21 W × 1 Front flasher light 12 V, 21 W × 2 Rear flasher light 12 V, 21 W × 2 Auxiliary light 12 V, 4 W × 1 Meter light 12 V, 3.4 W × 2 12 V, 3.4 W × 1 (GB only) Neutral indicator light 12 V, 3.
3MB-9-E7 12/27/00 2:52 PM Page 87 SPECIFICATIONS EAU01064 HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC ** mm 2 mm MULTIPLIER × × 0.03937 0.03937 CONVERSION TABLE METRIC TO IMPERIAL Metric unit ** in 0.08 in Imperial unit 1 Torque 7.233 86.794 0.0723 0.8679 ft • lb in• lb ft • lb in • lb 2 Weight kg g 2.205 0.03527 lb oz 3 Speed km/hr 0.
3MB-9-E7 12/27/00 2:52 PM Page 88 EAU01039 CONSUMER INFORMATION EAU02944 Identification number records 1 2 3 4 5 Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1 1. Key identification number 1. Vehicle identification number EAU01042 1. KEY IDENTIFICATION NUMBER: 6 7 1 2.
3MB-9-E7 12/27/00 2:52 PM Page 89 CONSUMER INFORMATION 1 1 2 3 1. Model label 4 EAU01049 Model label The model label is affixed to the location shown in the figure. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
OWNER’S MANUAL DT125R YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000·12–0.
