Yamaha DT125X- User Manual

SPEC 2 SPECIFICATIONS CHK ADJ 3 PERIODIC CHECKS ANDADJUSTMENTS CHAS 4 CHASSIS ENG 5 ENGINE COOL 6 COOLING SYSTEM CARB 7 CARBURETOR ELEC 8 ELECTRICAL SYSTEM EAS00010 TABLE OF CONTENTS TRBL SHTG 9 TROUBLESHOOTING GENERAL INFORMATION GEN INFO 1

GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ……………………………………………1-1 FRAME SERIAL NUMBER ……………………………………………………1-1ENGINE SERIAL NUMBER……………………………………………………1-1 IMPORTANT INFORMATION …………………………………………………1-2 PREPARATION FOR REMOVAL ……………………………………………1-2 ALL REPLACEMENT PARTS ………………………………………...

GEN INFO MOTORCYCLE IDENTIFICATIONS 1-1 EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame IDENTIFICATION number is stamped onto the steering head pipe. NOTE: The frame serial number is used to identify themotorcycle and therefore it can be used for theenrollment in...

GEN INFO IMPORTANT INFORMATION 1-2 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment.Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep ma...

GEN INFO CHECKING THE CONNECTIONS 1-4 EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect: • lead• coupler• connector 2. Check: • lead• coupler• connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several ...

SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS …………………………………………………2-1 ENGINE SPECIFICATIONS ……………………………………………………2-4CHASSIS SPECIFICATIONS …………………………………………………2-6ELECTRICAL SPECIFICATIONS ……………………………………………2-8 CONVERSION TABLE …………………………………………………………2-10 GENERAL TIGHTENING TORQUE SPECIFICATIONS ……...

SPEC GENERAL SPECIFICATIONS 2-1 SPECIFICATIONS GENERAL SPECIFICATIONS Model DT125RE DT125X Model code 1D01/1D02 2C81 Dimensions: Overall lenght 2210mm 2139mm Overall width 795mm 1121mm Overall height 1200mm 1200mm Seatheight 900mm 886mm Wheelbase 1415mm 1396mm Minimum ground clearance 300mm 271 mm M...

SPEC CONVERSION TABLE / GENERAL TIGHTENING TORQUES SPECIFICATIONS 2-10 EAS00028 CONVERSION TABLE All specification data in this manual are listedin SI and METRIC UNITS.Use this table to convert METRIC unit data toIMPERIAL unit data. Ex. METRIC MULTIPLIER IMPERIAL ** mm x 0.03937 = ** in 2 mm x 0.039...

SPEC DEFINITION OF UNITS 2-11 TIGHTENING TORQUES ENGINE Tightening Thread torque Part to be tightened Q’ty size Nm m•kg Remarks Spark plug 1 M14x1.25 20 2,0 Cylinder head Nut 5 M8x1.25 22 2,2 Cylinder Stud bolt 9 M8X1.25 13 1,3 LOCTITE screw glue Nut 4 M8x1.25 28 2,8 Power valve holder, Valve cover ...

SPEC COOLANT FLOW CHART 2-13 COOLANT FLOW CHART Water pump Crankcase cover Crankcase Cylinder Cylinder head Bypass hose Thermostatic valve (Thermostatic valve) Outlet hose Radiator Inlet hose Coolant cold (Less than 65°C (149°F))Coolant hot (165°(149°F) or more)

SPEC LUBRICATION POINTS AND LUBRICANT TYPES 2-14 EAS00031 ENGINE Lubrication points (part name) Lubricant Type Oil seal lips (All) Apply lightweight lithium-soap base grease O-Rings (All) Apply lightweight lithium-soap base grease Bearing retainer Crankshaft bearings (Left and center) Apply engine o...

SPEC CABLE ROUTING 2-16 CABLE ROUTING Clutch wire Right turn signal lead Left turn signal lead Throttle cable Indicator light wire lead Meter wire lead Headlight bulb wire Handle wire lead (right) A Cover with cap after connecting wires. B Route the installation between lower brac- ket and headlight...

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION …………………3-1 ENGINE ……………………………………………………………………………3-2 Y.P.V.S. CABLE ADJUSTMENT ………………………………………………3-2IDLE SPEED ADJUSTMENT …………………………………………………3-3THROTTLE CABLE FREE PLAY ADJUSTMENT……………………………3-4CARBURETOR CABLE FREE...

CHK ADJ INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS 3-1 PERIODIC CHECKS AND ADJUSTMENTS NOTE: • The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. • From 30000 km, repeat the maintenance intervals starting from 6000 km. • Items ...

CHK ADJ IDLE SPEED ADJUSTMENT 3-3 IDLE SPEED ADJUSTMENT 1. Adjust: • engine idle speed EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, theair filter element should be clean, and the engi-ne should have adequate compression. 1. Start the engine and let it ...

CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY 3-4 EAS00058 ADJUSTING THE THROTTLE CABLE FREEPLAY NOTE: Prior to adjusting the throttle cable free play,the engine idling speed and carburetor synch-ronization should be adjusted properly. 1. Check: • throttle cable free play a Out of specification Adj...

CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY/ CARBURETOR CABLE FREE PLAY ADJUSTMEN 3-5 CARBURETOR CABLE FREE PLAYADJUSTMENT NOTE: Before adjusting carburetor cable, throttlecable free play should be adjusted. 1. Pull back the adjuster cover. 2. Check: • carburetor cable free play a Out of specific...

CHK ADJ AUTOLUBE PUMP STROKE ADJUSTMEN/ AUTOLUBE PUMP AIR BLEEDING 3-6 AUTOLUBE PUMP STROKE ADJUSTMENT 1. Remove: • Autolube pump cover 2. Adjusting mark Not aligned Adjust the Autolube Pump 3. Adjust • Autolube pump The adjusting marks a and b has to match when the throttle cable free play ends. Ad...

CHK ADJ AUTOLUBE PUMP AIR BLEEDING/ CHECKING THE SPARK PLUG 3-7 3. Air blled: • pump case and/or oil pipe Air bleeding steps • Remove the bleed cap • Start the engine.• Keep the oil running out until air bubbles dissapear. • Keep the engine running at about 2.000r/min for two minutes or so • When ai...

CHK ADJ CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 3-8 6. Measure: • spark plug gap a (with a wire Thickness gauge)Out of specification Regap. 7. Install: • spark plug NOTE: Before installing the spark plug, clean thespark plug and gasket surface. 8. Connect: • spark plug cap EAS00064 CHE...

CHK ADJ CHECKING THE IGNITION TIMING/ ENGINE OIL LEVEL INSPECTION 3-9 3. Check: • ignition timing a. Start the engine, warm it up for several minutes, and then let it run at the specifiedengine idling speed. b. Check that the stationary pointer is within the firing range on the generator rotor.Incor...

CHK ADJ ENGINE OIL LEVEL INSPECTION 3-10 0 km/h 4 0 6 0 8 0 1 0 0 1 2 0 1 3 0 2 0 y 0 0 0 0 1 5 0 0 0 8 b j z N CAUTION Always use the same type of engine oil;mixing oils may result in a harmful chemicalreaction and lead to poor performance. “OIL” Indicator light OIL WARNING LIGHT CHECKING METHOD Ma...

CHK ADJ TRANSMISSION OIL LEVEL INSPECTION/ TRANSMISSION OIL REPLACEMENT 3-11 TRANSMISSION OIL LEVEL INSPECTION 1. Inspect: • transmission oil level Oil level low Add sufficient oil Transmission oil level steps: • Place the machine on a level surface.• Warm up the engine for several minutes and stop ...

CHK ADJ TRANSMISSION OIL REPLACEMENT/ ADJUSTING THE CLUTCH CABLE FREE PLAY 3-12 5. Install: • Drain plug 6. Fill: • Crankcase CAUTION • Do not add any chemical additives. Transmission oil also lubricates theclutch and additives could cause clutchslippage. • Be sure no foreign materials enters the cr...

CHK ADJ ADJUSTING THE CLUTCH CABLE FREE PLAY 3-13 c. Tighten the locknut. NOTE: If the specified clutch cable free play cannotbe obtained on the handlebar side of thecable, use the adjusting nut on the engineside. Engine side a. Loosen the locknuts . b. Turn the adjusting bolt in direction a or b un...

CHK ADJ ADJUSTING THE CLUTCH CABLE FREE PLAY/ CLEANING THE AIR FILTER ELEMENT 3-16 20. Air bleeding: • Autolube pump Refer to the “AUTOLUBE PUMP AIR BLEE-DING section. 21. Install: • Autolube pump cover EAS00089 CLEANING THE AIR FILTER ELEMENT NOTE: On the bottom of the air filter case is a checkhos...

CHK ADJ CARBURETOR JOINT INSPECTIONS /FUEL LINE INSPECTION/CHECKING THE CRANKCASE BREATHER HOSE 3-18 CARBURETOR JOINT INSPECTION 1. Inspect: • Carburetor joint Crack-damage Replace Refer to the “REED VALVE” section in chap-ter 7 for replacement 2. Check the tightening torque of the carbure- tor join...

CHK ADJ EXHAUST SYSTEM INSPECTION/ENGINE OIL LINE INSPECTION/ COOLANT LEVEL INSPECTION 3-19 FULL LOW EXHAUST SYSTEM INSPECTION 1 .Inspect: • Gasket (exhaust pipe) • Joint (Silencer) Damage Replace Exhaust gas leakage Repair • Exhaust pipe • Silencer Cracked/Dent/Damage Repair or replace 2. Tighten: ...

CHK ADJ COOLANT LEVEL INSPECTION/ CHANGING THE COOLANT 3-20 s s WARNING Do not remove the radiator cap when theengine is hot. CAUTION Hard water or salt water is harmful to theengine parts; use boiled or distilled water ifyou can’t get soft water. 4. Add: • Soft water (tap water) Until the coolant l...

CHK ADJ CHANGING THE COOLANT 3-21 tor cap and slowly turn the radiator capcounterclockwise toward the detent toallow any residual pressure to escape.When the hissing sound has stopped, pressdown on the radiator cap and turn it coun-terclockwise to remove. The following procedure applies to all of th...

CHK ADJ ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE 3-24 EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play Out of specification Adjust. 2. Adjust: • brake lever free play a. Loosen the locknut . b. Turn the adjusting bolt in direction a or b until the specified bra...

CHK ADJ ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3-25 2. Adjust: • brake pedal position a. Loosen the locknut . b. Turn the adjusting bolt in direction a or b until the specified brake pedal position is obtained. s s WARNING After adjusting the brake pedal position,check that the end...

3-26 2. Check: • brake fluid level Below the minimum level mark Add the recommended brake fluid to the properlevel. A Front brake B Rear brake s s WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubberseals to deteriorate, causing leakageand poor brake performance. • ...

CHK ADJ CHECKING THE FRONT AND REAR BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-27 EAS00119 CHECKING THE FRONT AND REAR BRAKEPADS The following procedure applies to all of thebrake pads.1. Remove: • Rubber plug 2. Operate the brake.3. Check: • front brake pad• rear brake pad Wear indicators ...

CHK ADJ CHECKING THE FRONT AND REAR BRAKE HOSES/ ADJUSTING THE DRIVE CHAIN SLACK 3-28 EAS00131 CHECKING THE FRONT AND REAR BRAKEHOSES The following procedure applies to all of thebrake hoses and brake hose clamps.1. Check: • brake hose Cracks/damage/wear Replace. 2. Check: • brake hose clamp Loose T...

CHK ADJ LUBRICATING THE DRIVE CHAIN/ CHEEKING AND ADJUSTING THE STEERING HEAD 3-30 09*92/61 *0139 VTLD E0610 0000000 5 83 dB (A ) - 4000 m in- 1 EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interactingparts. If the drive chain is not maintained pro-perly, it will wear out qu...

CHK ADJ CHEEKING AND ADJUSTING THE STEERING HEAD 3-31 a. Remove the lock washer , the upper ring nut , and the rubber washer . b. Loosen the lower ring nut and then tigh- ten it to specification with a steering nutwrench. c. Loosen the lower ring nut completely, then tighten it to specification. s s...

CHK ADJ CHEEKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK 3-32 6. Measure: • steering head tension NOTE: Make sure all of the cables and wires are pro-perly routed. a. Point the front wheel straight ahead.b. Install a plastic locking tie loosely around the end of the handlebar as sho...

CHK ADJ CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-33 2. Check: • inner tube Damage/scratches Replace. • oil seal Oil leakage Replace. 3. Hold the motorcycle upright and apply the front brake. 4. Check: • front fork operation Push down hard on the handlebar severaltimes and...

CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES 3-34 2. Tighten: • Tighten the locknut EAS00164 CHECKING THE TIRES The following procedure applies to both of thetires.1. Check: • tire pressure Out of specification Regulate. s s WARNING • The tire pressure should only be checked...

CHK ADJ CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES 3-36 s s WARNING • New tires have a relatively low grip on the road surface until they have beenslightly worn. Therefore, approximately100 km should be traveled at normalspeed before any high-speed riding isdone. • After a tire has been ...

CHK ADJ CHECKING AND TIGHTENING THE SPOKES/ CHECKING AND LUBRICATING THE CABLES 3-37 2. Tighten: • spoke (with a spoke wrench) NOTE: Be sure to tighten the spokes before and afterbreak-in. EAS00170 CHECKING AND LUBRICATING THECABLES The following procedure applies to all of theinner and outer cables...

CHK ADJ LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE SIDESTAND/LUBRICANTING THE REAR SUSPENSION 3-38 EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point ...

CHK ADJ ELECTRICAL SYSTEM 3-39 EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THEBATTERY s s WARNING Batteries generate explosive hydrogen gasand contain electrolyte which is made ofpoisonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures: • Wear protective eye ...

CHK ADJ CHECKING AND CHARGING THE BATTERY 3-40 NOTE: Since MF batteries are sealed, it is not possi-ble to check the charge state of the battery bymeasuring the specific gravity of the electroly-te. Therefore, the charge of the battery has tobe checked by measuring the voltage at thebattery terminal...

CHK ADJ CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 3-42 CAUTION First, connect the positive battery lead , and then the negative battery lead . 8. Check: • battery terminals Dirt Clean with a wire brush. Loose connection Connect properly. 9. Lubricate: • battery terminals 10. Install: • B...

CHK ADJ CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB 3-43 3. Replace: • blown fuse a. Set the main switch to “OFF”.b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the el...

CHK ADJ REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 3-44 5. Install: • headlight bulbNew Secure the new headlight bulb with theheadlight bulb holder. CAUTION Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life...

CHAS FRONT WHEEL 4-1 CHASSIS FRONT WHEEL Hub Bearing Collar Oil Seal Rim Spoke Cap Collar Dust cover 10 Wheel axle 11 Cap 12 Gear unit (speedometer) 58 Nm (5,8 m • kg, 42ft•lb) DT125RE A Tire Size: 80/90-21 48P B Rim Size: 21x1.60 C Rim Runout Limit: Vertical: 1,0 mm (0,08 in) Lateral: 0,5 mm (0,02 ...

CHAS CHECKING THE FRONT WHEEL/ INSTALLING THE FRONT WHEEL 4-5 CAUTION Do not contact the wheel bearing inner raceor balls. Contact should be made only withthe outer race. NOTE: Use a socket that matches the diameter of the wheel bearing outer race and oil seal. EAS00542 INSTALLING THE FRONT WHEEL 1....

CHAS REAR WHEEL 4-7 REAR WHEEL Hub Collar Bearing Oil Seal Rim Spoke Cap Driven Sprocket Bolt 10 Nut 11 Collar 12 Dust Cover 13 Collar 14 Oil Seal 15 Chain puller 16 Chain puller 17 Wheel axle 18 Washer 19 Nut 20 Drive chain 90 Nm (9,0 m • kg,65ft•lb) DT125RE A Tire Size: 110/80-18 58P B Rim Size: 1...

CHAS INSPECTING THE REAR WHEEL/ INSTALLING THE REAR WHEEL 4-9 INSPECTING THE REAR WHEEL 1. Inspect: • Rear wheel axle Refer to the “FRONT WHEEL - INSPEC-TION” section. 2. Inspect: • Wheel hub • Dust covers (Bearings) • Wheel Refer to the “FRONT WHEEL - INSPEC-TION” section. 3. Measure: • Wheel runou...

CHAS INSTALLING THE REAR WHEEL 4-10 2. Adjust: • Drive chain slack a • Refer to the “DRIVE CHAIN SLACK ADJUSTMENT” section in CHAPTER 3. 3. Tighten: • wheel axle nut • bolts (swingarm end) Drive chain slack: DT125RE 40~55mm (1,77~2,16in.)DT125X 25~40mm (0,98~1,58 in.) Recommended lubricant Lithium-s...

CHAS FRONT AND REAR BRAKE 4-11 FRONT AND REAR BRAKE Master cylinder cap Diaphragm Master cylinder kit Master cylinder Brake hose Brake caliper Pad spring Piston Piston seal 10 Dust seal 11 Brake pad 12 Brake disc 26 Nm (2,6 m • kg, 19ft•lb) D USE NEW ONE 6 Nm (0,6 m • kg,4,3ft•lb) 18 Nm (1,8 m • kg,...

CHAS REPLACING THE FRONT BRAKE PADS 4-13 EAS00579 CAUTION Disc brake components rarely requiredisassembly.Therefore, always follow these preventivemeasures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire...

CHAS REPLACING THE FRONT BRAKE PADS/ REPLACING THE REAR BRAKE PADS 4-15 6. Lubricate: • retaining bolt CAUTION • Do not allow grease to contact the brake pads. • Remove any excess grease. 7. Install: • retaining bolt 8. Check: • brake fluid level Below the minimum level mark a Add the recommended br...

CHAS REPLACING THE REAR BRAKE PADS 4-16 1. Remove: • Protector (caliper body) • Retaining bolt • Turn the caliper body counterclockwise 2. Remove: • brake pads • brake pad springs • Shim (brake pad) 3. Measure: • brake pad wear limit a Out of specification Replace the brake pads as a set. 4. Install...

CHAS DISASSEMBLING THE FRONT BRAKE CALIPER 4-18 EAS00618 DISASSEMBLING THE FRONT BRAKECALIPER NOTE: Before disassembling the brake caliper, drainthe brake fluid from the entire brake system. 1. Remove: • union bolt • copper washers • brake hose NOTE: Put the end of the brake hose into a containerand...

CHAS DISASSEMBLING THE FRONT BRAKE CALIPER/ DISASSEMBLING THE REAR BRAKE CALIPER 4-19 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper. s s WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when thepiston is exp...

CHAS DISASSEMBLING THE REAR BRAKE CALIPER 4-20 3. Disconnect the dust boot and then pull out the caliper body from the guide shaft on te caliper bracket . 4. Remove: • Rear wheel Refer to the “REAR WHEEL” section. • Caliper bracket 5. Remove: • Caliper piston • Dust seal • Piston seal a. Blow compre...

CHAS DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4-21 EAS00588 DISASSEMBLING THE FRONT BRAKEMASTER CYLINDER NOTE: Before disassembling the front brake mastercylinder, drain the brake fluid from the entirebrake system. 1. Remove: • Brake switch • Brake lever • Return spring (brake lever) NOTE: When...

CHAS DISASSEMBLING THE REAR BRAKE MASTER CYLINDER/CHECKING THE FRONT AND REAR BRAKE CALIPER 4-23 4. Remove: • Brake hoses • Reservoir tank • Circlip • Push rod• Master cylinder kit 5. Remove: • Cap (reservoir tank) • Inner cap (reservoir tank) • Diaphragm NOTE: To collect any remaining brake fluid, ...

CHAS CHECKING THE FRONT AND REAR BRAKE CALIPER 4-24 1. Check: • brake caliper piston Rust/scratches/wear Replace the brake caliper piston. • brake caliper cylinder Scratches/wear Replace the brake caliper assembly. • brake caliper body Cracks/damage Replace the brake caliper assembly. • brake fluid ...

CHAS ASSEMBLING AND INSTALLING THE FRONT AND REAR BRAKE CALIPER 4-27 ASSEMBLING AND INSTALLING THEFRONT AND REAR BRAKE CALIPER s s WARNING • Before installation, all internal brake components should be cleaned andlubricated with clean or new brake fluid. • Never use solvents on internal brake compon...

CHAS BLEEDING THE HYDRAULIC BRAKE SYSTEM 4-35 EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM s s WARNING Bleed the hydraulic brake system whene-ver:• the system is disassembled.• a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low.• brake operation is faulty. NOTE: ...

CHAS DISASSEMBLY/CHECKING THE FRONT FORK LEGS 4-40 7. Remove: • Inner fork tube a. Hold the front fork leg horizontally.b. Securely clamp the brake caliper bracket ina vise with soft jaws.c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but care-fully. CAUTION • Ex...

CHAS CHECKING THE FRONT FORK LEGS/ASSEMBLING THE FRONT FORK LEGS 4-41 3. Check: • damper rod • piston ring Damage/wear Replace. Obstruction Blow out all of the oil pas- sages with compressed air. • rebound spring Damage Replace. 4. Check: • cap bolt O-ring Damage/wear Replace. EAS00659 ASSEMBLING TH...

CHAS STEERING HEAD AND HANDLEBARS 4-45 STERING HEAD AND HADLEBARS Handlebar Handlebar grip (Right) Handlebar grip (Left) Handlebar holder (Upper) Handlebar crown Ring nut 10 Cover 11 Bearing race 12 Headlight stay A TIGHTENING STEPS•Tightening ring nut 35Nm to 40Nm (3.5 to 4.0 m•kg, 25.6 to 29.3 ft•...

CHAS INSPECTION/INSTALLATION 4-50 4. Inspect: • Handlebar Cracks/Bend/Damage Replace s s WARNING Do not attempt to straighten a bent handle-bar as this may dangerously weaken thehandlebar. Handlebar replacement steps: • Remove the hadlebar grip and handlebar switch (Left) and lever holder. • Install...

CHAS INSTALLATION 4-51 3. Install: • Ball race (Upper-Lower)• Bearing cover • Under bracket• Ring nut s s WARNING Hold the under bracket until its secured 4. Tighten: • Ring nut Tightening steps: • Tighten the ring nut using the Ring Nut Wrench NOTE: Set the torque wrench to the right nut wrenchso t...

CHAS HANDLING THE REAR SHOCK ABSORBER/DISPO- SING OF A REAR SHOCK ABSORBER/REMOVING 4-57 EAS00686 HANDLING THE REAR SHOCK ABSORBER s s WARNING This rear shock absorber contains highlycompressed nitrogen gas. Before handlingthe rear shock absorber, read and makesure you understand the following infor...

CHAS REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-58 NOTE: Place the motorcycle on a suitable stand sothat the rear wheel is elevated. 2. Remove: • Bolt (Connecting arm swingarm) (from swingarm side) 3. Remove: • Bolt (Shock absorber Lower) s s WARNING When removing the lower bolt hold the swingarm s...

CHAS CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-62 EAS00695 CHECKING THE REAR SHOCK ABSORBERASSEMBLY 1. Check: • rear shock absorber rod Bends/damage Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks Replace the rear shock absorber assembly. • spring Damage/wear Re...

CHAS CHECKING THE SWINGARM/INSTALLING THE SWINGARM 4-64 7. Check: • spacers Damage/scratches Replace. EAS00711 INSTALLING THE SWINGARM 1. Lubricate: • bearings• spacers• dust covers• pivot shaft 2. Install: • relay arm • connecting arms NOTE: Install the connecting arm front bolt from the right. 3. ...

CHAS REMOVING THE DRIVE CHAIN/CHECKING THE DRIVE CHAIN 4-68 8. Remove: • Chain guide rollers (Upper and lower) EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: • ten-link section a of the drive chain Out of specification Replace the drive chain. 2. Check: • drive chain Stiffness Clean and lubricate or ...

ENG ENGINE REMOVAL/ ENGINE DISASSEMBLY 5-6 2. Remove: • Bolt (Engine mount Rear lower) • Pivot shaft NOTE: The engine and swingarm are installed usingthe same pivot shaft. Therefore, take care sothat the pivot shaft is pulled, not entirely, out,but for enough to set the engine free. 3. Remove: • Eng...

ENG ENGINE DISASSEMBLY/ INSPECTION AND REPAIR 5-17 1. Remove:(ref. oilpump) • Circlip • Drive gear (autolube pump) • Circlip • Oil seal • Collar • Pin • Drive shaft (autolube pump) • O-Ring • Autolube pump EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a...

ENG ENGINE ASSEMBLY AND ADJUSTMENTS 5-31 AUTOLUBE PUMP 5 Nm (0.5 m • kg, 3.6ft•lb) Autolube pump End cap Hose Clip Adjusting bolt Washer Drive shaft Collar O-Ring 10 Screw 11 Oil seal 12 Autolube pump gear 13 Pin 14 Circlip

COOL WATER PUMP 6-1 COOLING SYSTEM WATER PUMP Impeller shaft Oil Seal Pin Impeller shaft gear Plain washer Circlip Water pump housing cover Gasket Dowel pin 10 Drain bolt 11 Gasket 8 Nm (0.8 m • kg, 5.8 ft•lb) A USE NEW ONE A USE NEW ONE

CARB CARBURETION 7-1 CARBURETION CARBURETOR Cap Throttle valve spring Starter plunger Throttle stop screw Pilot air screw Throttle valve Needle set Pilot jet Needle jet 10 Gasket 11 Main jet 12 Needle valve assembly 13 Float 14 Drain screw Main Jet (M.J.) #210 Main Air Jet (M.A.J.) ø 0.8 Jet Needle ...

ELEC DT125RE CIRCUIT DIAGRAM 8-1 ELECTRICAL DT125RE CIRCUIT DIAGRAM B Black R Red O Orange L Blue P Pink Y Yellow G Green W White Ch Chocolate Dg Dark green Sb Sky blue Br Brown L/Y Blue/Yellow B/Y Black/YellowB/W Black/WhiteB/R black/Red W/R White/RedW/L White/BlueY/R Yellow/RedG/R Green/RedG/Y Gre...

ELEC ELECTRICAL COMPONENTS 8-2 ELECTRICAL COMPONENTS(1) CDI Unit Servomotor Battery Fuse Neutral switch Thermo unit Rectifier/Regulator Ignition coil Main switch Ignition coil: Primary coil resistance: 0.23 Ω at 20 °C Secondary coil resistance: 7.9 k Ω at 20 °C

ELEC CHECKING SWITCH CONTINUTY 8-4 LOCK OPEN OFF CHECK ON GY Br R B a b B W / EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the poc-ket tester. If the continuity reading is incorrect,check the wiring connections and if necessary,replace the switch. CAUTION: Never insert t...

ELEC CHECKING THE SWITCHES 8-5 EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, properconnections, and also for continuity between theterminals. Refer to “CHECKING SWITCH CON-TINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity read...

ELEC IGNITION SYSTEM 8-6 IGNITION SYSTEM The circuit diagram showns the ignition system.

ELEC CHARGING SYSTEM 8-14 EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM Generator Rectifier/regulator Battery Main fuse

ELEC LIGHTING SYSTEM 8-16 EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM Magento-CDI Rectifier/regulator Main switch 21 “LIGHTS” switch 29 Headlight 34 Tail light 36 Meter lights

ELEC SIGNAL SYSTEM 8-26 EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM Main switch Main fuse Battery 15 Neutral switch 35 Engine oil level switch 37 Diode 20 Horn switch 25 Horn 22 Turn switch 26 Turn signal relay 34 Tail/brake light 28 Rear brake light switch 27 Front brake light switch

ELEC YAMAHA POWER VALVE SYSTEM 8-42 YAMAHA POWER VALVE SYSTEM CIRCUIT DIAGRAM 16 CDI Unit Main switch Main fuse Battery 18 Servomotor

ELEC MOTOR 8-43 TROUBLESHOOTING Check:1. fuse2. battery3. main switch4. servomotor operation5. wiring connections (Yamaha Power Valve System) 6. servomotor and tachometer operation NOTE: • Before troubleshooting, remove the follo- wing part(s):1. side covers (left and right)2. seat3. fuel tank4. hea...

ELEC METER ASSEMBLY 8-46 METER ASSEMBLY Speedometer Bulb Bulb socket Speedometer cable Meter cushion Meter bracket Stopper clip Washer Damper collar

CHAPTER 9 TROUBLESHOOTING STARTING FAILURE / HARD STARTING ……………………………………9-1 FUEL SYSTEM …………………………………………………………………9-1ELECTRICAL SYSTEM ………………………………………………………9-2 POOR IDLE SPEED PERFORMANCE ………………………………………9-3 POOR IDLE SPEED PERFORMANCE ………………………………………9-3 POOR MEDIUM AND HIGH SPEED PERFORMANCE …………………...

TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be help-ful, however, as a guide to troubleshooting. Refeer to the relative procedure in this manual for ins-pection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING F...