brake YAMAHA DT125R 2000 Owners Manual

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TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9 GIVE SAFETY THE RIGHT OF WAY..................1-1
DESCRIPTION....................................................2-1
Left view............................................................2-1
Right view.........................................................2-2
Controls/Instruments.........................................2-3
INSTRUMENT AND CONTROL FUNCTIONS....3-1
Main switch.......................................................3-1
Indicator lights...................................................3-1
Oil level indicator circuit check..........................3-2
Speedometer....................................................3-3
Tachometer.......................................................3-3
Engine temperature gauge...............................3-4
Handlebar switches..........................................3-4
Clutch lever.......................................................3-5
Shift pedal.........................................................3-5
Front brake lever...............................................3-6
Rear brake pedal..............................................3-6
Fuel tank cap....................................................3-6
Fuel (except for Switzerland and Austria).........3-7
Fuel (for Switzerland and Austria)....................3-7
Catalyzer (for Switzerland and Austria)............3-8
Two-stroke engine oil........................................3-9
Fuel cock..........................................................3-9
Starter (choke) Ò
1Ó.........................................3-10Kick starter......................................................3-11
Steering lock...................................................3-11
Seat................................................................3-12
Helmet holder.................................................3-12
Rear shock absorber adjustment....................3-13
Rear carrier.....................................................3-14
Note on handling of the Yamaha Energy
Induction System (Y.E.I.S.).............................3-14
Y.P.V.S.
(Yamaha Power Valve System)......................3-15
Sidestand........................................................3-15
Sidestand switch operation check..................3-16
PRE-OPERATION CHECKS...............................4-1
Pre-operation check list....................................4-1
OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting the engine............................................5-1
Starting a warm engine.....................................5-3
Shifting..............................................................5-4
Recommended shift points
(for Switzerland only)........................................5-4
Tips for reducing fuel consumption...................5-5
Engine break-in.................................................5-5
Parking..............................................................5-6
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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..........................................................6-7
Cowling C.........................................................6-8
Panel removal and installation..........................6-8
Panel D.............................................................6-9
Panel E.............................................................6-9
Spark plug.......................................................6-10
Transmission oil..............................................6-11
Cooling system...............................................6-12
Changing the coolant......................................6-13
Air filter............................................................6-15
Carburetor adjustment....................................6-16
Idle speed adjustment.....................................6-17
Throttle cable free play adjustment.................6-17
Tires................................................................6-18
Wheels............................................................6-20
Clutch lever free play adjustment...................6-21
Front brake lever free play adjustment...........6-21
Rear brake pedal height adjustment...............6-22
Brake light switch adjustment.........................6-23
Checking the front and rear brake pads.........6-23Inspecting the brake fluid level.......................6-24
Brake fluid replacement..................................6-25
Drive chain slack check..................................6-25
Drive chain slack adjustment..........................6-26
Drive chain lubrication....................................6-26
Cable inspection and lubrication.....................6-27
Throttle cable and grip lubrication...................6-27
Autolube pump adjustment.............................6-28
Brake and shift pedal lubrication.....................6-28
Brake and clutch lever lubrication...................6-28
Sidestand lubrication......................................6-29
Front fork inspection.......................................6-29
Steering inspection.........................................6-30
Wheel bearings...............................................6-30
Battery............................................................6-31
Fuse replacement...........................................6-33
Headlight bulb replacement............................6-33
Turn signal light bulb replacement..................6-35
Tail/brake light bulb replacement....................6-35
Supporting the motorcycle..............................6-36
Front wheel removal.......................................6-36
Front wheel installation...................................6-37
Rear wheel removal........................................6-38
Rear wheel installation....................................6-39
Troubleshooting..............................................6-39
Troubleshooting chart.....................................6-40
TABLE OF CONTENTS
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3
4
5
6
7
8
9
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DESCRIPTION
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3
4
5
6
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9
2-2
111213
14 15
Right view11.Tool kit (page 6-1)
12.Fuse (page 6-33)
13.Engine oil tank (page 3-9)
14.Rear brake pedal (page 3-6, 6-22)
15.Rear shock absorber spring
preload adjusting nut (page 3-13)
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4
5
6
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9
DESCRIPTION
2-3
16.Clutch lever (page 3-5, 6-21)
17.Left handlebar switches (page 3-4)
18.Speedometer (page 3-3)
19.Coolant temperature gauge (page 3-4)
20.Tachometer (page 3-3)21.Right handlebar switches (page 3-5)
22.Front brake lever (page 3-6, 6-27)
23.Throttle grip (page 6-17, 6-27)
24.Fuel tank cap (page 3-6)
25.Main switch (page 3-1)
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23 24 25
Controls/Instruments
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3-6
INSTRUMENT AND CONTROL FUNCTIONS
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23
4
5
6
7
8
9
1
1.Front brake lever
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Front brake leverThe front brake lever is located on
the right handlebar. Pull it toward the
handlebar to apply the front brake.
1
1.Rear brake pedal
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Rear brake pedalThe rear brake pedal is on the right
side of the motorcycle. Press down
on the brake pedal to apply the rear
brake.
31
2
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Fuel tank capTo open
Insert the key and turn it 1/4 turn
counterclockwise. Turn the cap 1/3
turn counterclockwise and remove it
from the tank.
To close
Put the cap in the filler neck and turn
it 1/3 turn clockwise. Lock the cap by
turning the key 1/4 turn clockwise,
and remove the key.1.Fuel tank cap
2.Unlock
3.Open
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4-1
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PRE-OPERATION CHECKS
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2
34
5
6
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8
9 Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs 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 thor-
ough visual inspection, you check the following points before each ride.
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PRE-OPERATION CHECK LIST
ITEMCHECKSPAGE
Front brake9Check operation, free play, fluid level and vehicle for fluid leakage.
9Fill with DOT 4 (or DOT 3) brake fluid if necessary.
3-6, 6-21 ~ 6-25
Rear brake9Check operation, free play, fluid level and vehicle for fluid leakage.
9Fill with DOT 4 (or DOT 3) brake fluid if necessary.
Clutch9Check operation, condition and free play.
3-5, 6-21
9Adjust if necessary.
9Check for smooth operation.
Throttle grip and housing9Lubricate.6-17, 6-27
9Adjust throttle cable free play if necessary.
Engine oil9Check oil level.
3-9
9Fill with oil if necessary.
Transmission oil9Check oil level.
6-11 ~ 6-12
9Fill with oil if necessary.
Coolant9Check coolant level.
6-12
9Fill with coolant if necessary.
Drive chain9Check chain slack and condition.
6-26 ~ 6-27
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage and spoke tightness.
6-18 ~ 6-20
9Tighten spokes if necessary.
Control and meter cable9Check for smooth operation.
6-27
9Lubricate if necessary.
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4-2
PRE-OPERATION CHECKS
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2
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5
6
7
8
9
ITEMCHECKSPAGE
Brake and shift pedal shafts9Check for smooth operation.
6-28 9Lubricate if necessary.
Brake and clutch lever pivots9Check for smooth operation.
9Lubricate if necessary.
Sidestand pivot9Check for smooth operation.
6-29
9Lubricate if necessary.
Chassis fasteners9Make sure that all nuts, bolts and screws are properly tightened.
Ñ
9Tighten if necessary.
Fuel tank9Check fuel level.
3-6 ~ 3-8
9Fill with fuel if necessary.
Lights, signals and
9Check for proper operation.6-33 ~ 6-35
switches
Battery9Check fluid level.
6-31 ~ 6-32
9Fill with distilled water if necessary.
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a
very short time; and the added safety it assures is more than worth the time involved.wIf any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating
the motorcycle.
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
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2
3
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7
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9
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Periodic maintenance and lubrication chart
NOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
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1
*Fuel line¥Check fuel hoses for cracks or damage.ÖÖÖÖÖ
2Spark plug¥Replace.ÖÖÖÖÖ
3Air filter element¥Clean.ÖÖ
¥Replace.ÖÖ
4*Battery¥Check electrolyte level and specific gravity.
¥Make sure that the breather hose is properly routed.ÖÖÖÖÖ
5Clutch¥Check operation.
¥Adjust.ÖÖÖÖÖ
6*Front brake¥Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖÖ
¥Replace brake pads.Whenever worn to the limit
7*Rear brake¥Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖÖ
¥Replace brake pads.Whenever worn to the limit
8*Brake hoses¥Check for cracks or damage.ÖÖÖÖÖ
¥Replace. (See NOTE on page 6-5.)Every 4 years
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
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NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.21
*Carburetor¥Check starter (choke) operation.
¥Adjust engine idling speed.ÖÖÖÖÖÖ
22*Autolube pump¥Check operation.
¥Bleed if necessary.ÖÖÖÖ
23Transmission oil¥Check oil level.ÖÖÖÖÖÖ
¥Change.ÖÖ
24*Cooling system¥Check coolant level and vehicle for coolant leakage.ÖÖÖÖÖ
¥Change.Every 3 years
25*Front and rear brake
switches¥Check operation.ÖÖÖÖÖÖ
26Moving parts and cables¥Lubricate.ÖÖÖÖÖ
27*Lights, signals and
switches¥Check operation.
¥Adjust headlight beam.ÖÖÖÖÖÖ NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
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6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
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WheelsTo ensure maximum performance,
long service, and safe operation, note
the following:
8Always inspect the wheels
before a ride. Check for cracks,
bends or warpage of the wheel.
Be sure the spokes are tight and
undamaged. If any abnormal
condition exists in a wheel, con-
sult a Yamaha dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.
8Tires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can
result in poor performance,
adverse handling characteristics,
and shortened tire life.
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it
to develop its optimal character-
istics.
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w8 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. Brakes, tires, and
related wheel parts replace-
ment should be left to a
Yamaha Service Technician.
8 8
Patching a punctured tube is
not recommended. If it is
absolutely necessary to do so,
use great care and replace the
tube as soon as possible with
a good quality replacement.
NOTE:
These limits may be different by regu-
lation from country to country. If so,
conform to the limits specified by the
regulations of your own country.
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