YAMAHA DT125R 2005 Workshop Manual

EAU22960
To adjust the drive chain slack
1. Axle nut
2. Chain tensioner
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.
NOTE:
Make sure that both adjusting plates
are in the same position for proper
wheel alignment.
ECA10570
CAUTION
Improper drive chain slack will
overload the engine as well as
other vital parts of the motorcycle
and can lead to chain slippage or
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.
3. Tighten the axle nut to the speci-
fied torque.
Tightening torque:
Axle nut:
90 Nm (9,0 m•kgf)
EAU23021
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.
ECA10581
CAUTION
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Clean the drive chain with kero-
sene and a small soft brush.
ECA11120
CAUTION
To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA11110
CAUTION
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
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EAU23100
Checking and lubricating 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 repla-
ce it.
Recommended lubricant:
Engine oil
EWA10720
s s
WARNING
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
EAU23110
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated or replaced at the intervals spe-
cified in the periodic maintenance
chart.
EAU23120
Adjusting the Autolube pump
The Autolube pump is a vital and sop-
histicated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU23131
Checking and lubricating the
brake 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.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
EAU23140
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 (all-pur-
pose grease)
EAU23200
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
EWA10730
s s
WARNING
If the sidestand does not move up
and down smoothly, have a Yama-
ha dealer check or repair it.
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Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
EAU23271
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in 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.ECA10590
CAUTION
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU23280
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
raise the front wheel off the
ground.
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
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2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the stee-
ring.
EAU23290
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spe-
cified in the periodic maintenance and
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.
EAU23380
Battery
1. Battery
2. Battery ventilation pipe
The battery is located behind panel D.
(See page 6-6.)
This model is equipped with a sealed-
type (MF) battery, which does not
require any maintenance. There is no
need to check the electrolyte or to
add distilled water.
ECA10620
CAUTION
Never attempt to remove the bat-
tery cell seals, as this would per-
manently damage the battery.
EWA10760
s s
WARNING
Electrolyte 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.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
• Batteries produce explosive
hydrogen gas. Therefore,
keep sparks, flames, cigaret-
tes, etc., away from the bat-
tery and provide sufficient
ventilation when charging it
in an enclosed space.
KEEP THIS AND ALL BATTE-
RIES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it seems
to have discharged. Keep in mind that
the battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.
To store the battery
1. If the vehicle will not be used for
more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
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2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if 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.
ECA10630
CAUTION
Always keep the battery char-
ged. Storing a discharged bat-
tery can cause permanent bat-
tery damage.
To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a Yamaha
dealer charge your battery.
EAUS1180
Replacing the fuse
1. Fuse
2. Reserve fuse
The fuse holder is located beside the
battery case.
If the fuse is blown, replace it as
follows.
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.
Specified fuse:
15 A
ECA10640
CAUTION
Do not use a fuse of a higher ampe-
rage rating than recommended 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.
EAU23910
Replacing a headlight bulb
1. Couplers
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This model is equipped with quartz
bulb headlights. If a headlight bulb
burns out, replace it as follows.
1. Remove cowling A. (See page
6-5.)
2. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
3. Remove the headlight bulb hol-
der according to the following
illustration, and then remove the
defective bulb.
NOTE:
The removal procedure depends on
the type of bulb holder installed on
your vehicle.
EWA10790
s s
WARNING
Headlight bulbs get very hot. The-
refore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.
4. Place a new bulb into position,
and then secure it with the bulb
holder.
ECA10660
CAUTION
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be adver-
sely affected. Thoroughly clean off
any dirt and fingerprints on the
headlight bulb using a cloth mois-
tened with alcohol or thinner.
5. Install the bulb cover, and then
connect the coupler.
6. Install the cowling.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU24131
Replacing the tail/brake light
bulb
1. Screw (x2)
2. Lens
1. 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.6
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ECA10680
CAUTION
Do not overtighten the screws,
otherwise the lens may break.
EAU24201
Replacing a turn signal light
bulb
1. Screw
2. Lens
3. Bulb
1. 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.
ECA11190
CAUTION
Do not overtighten the screw,
otherwise the lens may break.
EAU24350
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
motorcycle is in a stable and level
position before starting any mainte-
nance. 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.
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.
EAU24360
Front wheel
EAU24640
To remove the front wheel
1. Speedometer cable
2. Axle retainer nut (x4)
3. Wheel axle
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3
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EWA10820
s s
WARNING
It is advisable to have a Yama-
ha dealer service the wheel.
Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Disconnect the speedometer
cable from the front wheel.
2. Loosen the wheel axle holder
nuts, then the wheel axle.
3. Lift the front wheel off the ground
according to the procedure on
page 6-26.
4. Pull the wheel axle out, and then
remove the wheel.
ECA11070
CAUTION
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU24950
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.
NOTE:
Make sure that there is enough space
between the brake pads before inser-
ting the brake disc and that the slot in
the speedometer gear unit fits over
the retainer on the fork leg.
3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle to the
specified torque.
Tightening torque:
Wheel axle:
55 Nm (5,5 m•kgf)
6. Tighten the axle holder nuts to
the specified tightening torque. Tigh-
ten the upper nuts first and then lower
ones. When tightened in this sequen-
ce, there should be a gap formed at
the bottom of the axle holder.
Tightening torque:
Axle holder nut:
10 Nm (1,0 m•kgf)
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1. Gap
7. After tightening the axle holder
nuts, push down hard on the
handlebars several times while
applying the front brake to check
if the front fork compresses and
rebounds smoothly.
8. Connect the speedometer cable.
EAU25080
Rear wheel
EAU25230
To remove the rear wheel
1. Axle retainer bolt
EWA10820
s s
WARNING
It is advisable to have a Yama-
ha dealer service the wheel.
Securely 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 6-26.
1. Axle nut
2. Chain tensioner
3. Remove the swingarm end bolts.
4. Turn the drive chain adjusting
plate on each side of the swin-
garm 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.
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ECA11070
CAUTION
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU25530
To install the rear wheel
1. Install the drive chain onto the
rear sprocket, and then insert the
wheel axle from the left-hand
side.
NOTE:
Make sure that there is enough space
between the brake pads before inser-
ting the brake disc between the brake
pads.
2. Install the drive chain adjusting
plates.
NOTE:
Make sure that the drive chain adjus-
ting plates are installed with the pun-
ched side facing to the outside.
3. Install the swingarm end bolts.4. Adjust the drive chain slack. (See
page 6-19.)
5. Tighten the axle nut and the
swingarm end bolts to the speci-
fied torques, and then install the
cotter pin.
EWA10700
s s
WARNING
Always use a new cotter pin for the
axle nut.
Tightening torque:
Axle nut:
90 Nm (9,0 m•kgf)
Swingarm end bolt:
3 Nm (0,3 m•kgf)
EAU25850
Troubleshooting
Although Yamaha motorcycles recei-
ve a thorough inspection before ship-
ment from the factory, trouble may
occur during operation. Any problem
in the fuel, compression, or ignition
systems, for example, can cause poor
starting and loss of power.The following troubleshooting chart
represents a quick and easy procedu-
re for checking these vital systems
yourself. However, should your
motorcycle require any repair, take it
to a Yamaha dealer, whose skilled
technicians have the necessary tools,
experience, and know-how to service
the motorcycle 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.
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