YAMAHA DT125R 2002 Manual PDF

6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the electrolyte level.2. Check the electrolyte level in the
battery.NOTE:
The electrolyte should be between
the minimum and maximum level
marks.
1
2
1. Maximum level mark
2. Minimum level mark
EAU01071
BatteryA poorly maintained 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.
12
1. Battery
2. Battery breather hose
3. If the electrolyte is at or below
the minimum level mark, add dis-
tilled water to raise it to the maxi-
mum level mark.
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6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To store the battery
1. If the motorcycle will not be used
for more than one month,
remove the battery, fully charge
it, and then place it in a cool, dry
place.
2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte
at least once a month and fully
charge the battery whenever
necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals and that the breather hose
is properly routed, in good condi-
tion, and not obstructed. 8Take care not to spill elec-
trolyte on the drive chain, as
this may weaken it, shorten
chain life and possibly result
in an accident.
8KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
EC000100
cCUse 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
w8Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
9EXTERNAL: Flush with plen-
ty of water.
9INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.
9EYES: Flush with water for
15 minutes and seek prompt
medical attention.
8Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes,
etc., away from the battery and
provide sufficient ventilation
when charging it in an
enclosed space.
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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000103
cCDo not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.3. Turn the key to “ON” and turn on
the electrical circuits to check if
the devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU01307
Replacing the fuseThe 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
cCIf the breather hose is positioned
in such a way that the frame is
exposed to electrolyte or gas
expelled from the battery, the
frame could suffer structural and
external damages.
Specified fuse:
10 A
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6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6 4. Remove the headlight bulb hold-
er by turning it counterclockwise,
and then remove the defective
bulb.
1
1. Headlight bulb holder
3. Disconnect 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 bulbIf 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)
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6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03497
Replacing a turn signal light
bulb1. Remove the turn signal light lens
by removing the screw.
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
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
wHeadlight 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 with the bulb
holder.
6. Install the bulb cover, and then
connect the coupler.
a
a. Do not touch this area.
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6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000108
cCDo not overtighten the screws,
otherwise the lens may break.
EAU01623
Replacing the tail/brake light
bulb1. Remove the tail/brake 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
cCDo not overtighten the screw, oth-
erwise the lens may break.
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6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00898
Front wheelTo remove the front wheel
EW000122
w8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.1. Remove the brake disc cover by
removing the screws.
122
1. Disc cover
2. Screw (×2)
To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.
EAU01579
Supporting the motorcycleSince 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 engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6
ECA00048
cCDo not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
2. Disconnect the speedometer
cable from the front wheel.
3. Lift the 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. Speedometer gear unit
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6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
67. After tightening the holder nuts,
while applying the front brake,
push down on the handlebars
several times to check if the front
fork compress and rebounds
smoothly.
8. Connect the speedometer cable.
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.
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 torque.
1
1. Retainer
Tightening torque:
Wheel axle:
58 Nm (5.8 m0kgf)Tightening torque:
Axle holder nut:
10 Nm (1.0 m0kgf)
a
a. Gap
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6-42
PERIODIC MAINTENANCE AND MINOR REPAIR
6
ECA00048
cCDo not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU04237
Rear wheelWheel (rear)
EW000122
w8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.1. Loosen the 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 and
install the rear wheel.6. Pull the wheel axle out from the
left-hand side, and then remove
the wheel by pulling it back.
1
a
1. Chain adjusting plate
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