brake YAMAHA DT125R 2000 User Guide

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a
EAU00694
Clutch lever free play
adjustmentThe 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 ato
increase free play or in direction
bto decrease free play.
3.Tighten the locknut at the clutch
lever.
If the specified free play cannot be
obtained, proceed with the following
steps.1.Locknut
2.Adjusting bolt
3.Free play
ab 12
4.Loosen the locknut at the clutch
lever.
5.Turn the adjusting bolt at the
clutch lever in direction ato
loosen the cable.
6.Loosen the locknut at the
crankcase side.
7.Turn the adjusting nut at the
crankcase in direction ato
increase free play or in direction
bto decrease free play.
8.Tighten the locknut at the
crankcase and the clutch lever.1.Locknut
2.Adjusting nut
3
2
1b
a
EAU00696
Front brake lever free play
adjustmentThe free play at the front brake lever
should be 2 ~ 5 mm.
1.Loosen the locknut.
2.Turn the adjusting bolt in direc-
tion ato increase free play or in
direction bto decrease free
play.
3.After adjusting, tighten the lock-
nut.1.Locknut
2.Adjusting bolt
3.Free play
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EW000099
w8 8
Check the brake lever free
play. Be sure the brake is
working properly.
8 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. Have a Yamaha deal-
er inspect and bleed the sys-
tem if necessary.
a
1
EAU00712
Rear brake pedal height
adjustmentThe top of the brake pedal should be
positioned 15 mm below the top of
the footrest. If not, ask a Yamaha
dealer to adjust it.1.Footrest
a.Pedal height
EW000109
wA soft or spongy feeling in the
brake pedal can indicate the pres-
ence 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. Have a Yamaha dealer
inspect and bleed the system if
necessary.
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EAU00713
Brake light switch
adjustmentThe rear brake light switch is activat-
ed 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.
Turn the adjusting nut in direction a
to make the brake light come on earli-
er.
Turn the adjusting nut in direction b
to make the brake light come on
later.
b
a 1
2
1.Brake light switch
2.Adjusting nut
EAU00717
Checking the front and rear
brake padsCheck the brake pads for damage
and wear. If the thickness is less than
the specified value, have a Yamaha
dealer replace the pads.
1
1.Wear limit: 0.8 mm FRONT
1
1.Wear limit: 0.8 mmREAR
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98Use only the designated quality
brake fluid. Otherwise, the rub-
ber seals may deteriorate, caus-
ing leakage and poor brake per-
formance.
NOTE:
If DOT 4 is not available, DOT 3 can
be used.
EAU00732
Inspecting the brake fluid
levelInsufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef-
fective.
Before riding, check that the brake
fluid is above the minimum level and
fill when necessary.
Observe these precautions:
8When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.
1
1.Minimum level mark FRONT
1
1.Minimum level markREARRecommended brake fluid:
DOT 4
8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
8Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8Have a Yamaha dealer check
the cause if the brake fluid level
goes down.
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EAU00742
Brake fluid replacementThe brake fluid should be replaced
only by trained Yamaha service per-
sonnel. Have the Yamaha dealer
replace the following components
during periodic maintenance or when
they are damaged or leaking:
8oil seals (every two years)
8brake hoses (every four years)
EAU00744*
Drive chain slack checkNOTE:
Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while itÕs in this tightest position.
a
a.Chain slack
To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and with-
out rider. Check the slack at the posi-
tion shown in the illustration. Normal
slack is approximately 25 ~ 40 mm. If
the slack exceeds 40 mm, adjust it.
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EAU00774
Autolube pump adjustmentThe autolube pump is a vital part of
the engine and requires very sophisti-
cated adjustment.
Adjusting should be left to a Yamaha
dealer who has the professional
knowledge and experience to do so.
EAU02984
Brake and shift pedal
lubricationLubricate the pivoting parts.
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
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EAU02986
Sidestand lubricationLubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
wIf the sidestand does not move
smoothly, consult a Yamaha deal-
er.
Recommended lubricant:
Engine oil
EAU02939
Front fork inspectionVisual check
EW000115
wSecurely support the motorcycle
so there is no danger of it falling
over.Check for scratches or damage on
the inner tube and excessive oil leak-
age from the front fork.Operation check
1.Place the motorcycle on a level
place.
2.Hold the motorcycle in an upright
position and apply the front
brake.
3.Push down hard on the handle-
bars several times and check if
the fork rebounds smoothly.
EC000098
cCIf any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
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1.Screw (´2)
2.Lens
3.Bulb 1.Screw
2.Lens
3.Bulb
EAU01095
Turn signal light bulb
replacement1.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.
EAU01623*
Tail/brake light bulb
replacement1.Remove the screws 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
screws.
EC000108
cCDo not over-tighten the screws as
the lens may break.
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3.Elevate the front wheel by plac-
ing 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 installation1.Install the speedometer gear unit
housing into the wheel hub.
Make sure the speedometer gear
unit housing is installed with the
projections meshed into the
slots.
2.Lift up the wheel between the
front fork legs and guide the
brake disc between the brake
pads. Make sure there is enough
gap between the brake pads
before inserting the brake disc.
1.Speedometer cable
2.Axle holder nut (´4)
3.Wheel axle
3.Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork
outer tube.
4.Install the wheel axle and let the
motorcycle down.
5.Tighten the wheel axle the speci-
fied torque.
Tightening torque:
Wheel axle:
58 Nm (5.8 m
0kg)
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1.Swingarm end bolt (´2)
EAU03105
Rear wheel removal
EW000122
w8
8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.1.Loosen the rear axle nut.
2.Elevate the rear wheel by placing
a suitable stand under the
engine.
3.Remove the swingarm end bolts.4.Remove the axle nut.
5.Push the wheel forward and
remove the drive chain.
6.Pull out the rear axle and remove
the wheel assembly by pulling
backward.
NOTE:
8Do not depress the brake pedal
when the disc and caliper are
separated.
8You do not have to disassemble
the chain in order to remove or
install the rear wheel.
2
1
1.Axle nut
2.Chain adjusting plate
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.
7.After tightening the holder nuts,
push down on the handlebars
several times and check if the
fork rebounds smoothly. Tightening torque:
Axle holder nut:
10 Nm (1.0 m
0kg)1
1.Gap
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