service YAMAHA DT125R 2000 Owners Manual

3-14
INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
9
12
1.Air chamber
2.Hose
EAU00325
Note on handling of the
Yamaha Energy Induction
System (Y.E.I.S.)Handle the air chamber and hose
with special care. Improper installa-
tion or damaged parts will result in
poor performance. Replace any
cracked or damaged parts immedi-
ately. No modification of this system
in any form can be made.
EC000022
cCNever attempt to modify the
Yamaha Energy Induction System.
EAU00315
wThis shock absorber contains
highly pressurized nitrogen gas.
Read and understand the following
information before handling the
shock absorber. The manufacturer
cannot be held responsible for
property damage or personal
injury that may result from improp-
er handling.
8 8
Do not tamper with or attempt
to open the cylinder assembly.
8 8
Do not subject the shock
absorber to an open flame or
other high heat source. This
may cause the unit to explode
due to excessive gas pres-
sure.
8 8
Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
8 8
Take your shock absorber to a
Yamaha dealer for any service.
1
EAU00320
Rear carrier
EW000032
wDo not exceed the load limit of
2 kg.1.Rear carrier
3MB-9-E7 12/27/00 2:52 PM Page 26

6-1
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00464
Periodic inspection, adjustment and
lubrication will keep your motorcycle
in the safest and most efficient condi-
tion possible. Safety is an obligation
of the motorcycle owner. The mainte-
nance and lubrication schedule chart
should be considered strictly as a
guide to general maintenance and
lubrication intervals.
YOU MUST TAKE INTO CONSIDER-
ATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND
A VARIETY OF INDIVIDUAL USES
ALL TEND TO DEMAND THAT
EACH OWNER ALTER THIS TIME
SCHEDULE TO SHORTER INTER-
VALS TO MATCH THE ENVIRON-
MENT. The most important points of
motorcycle inspection, adjustment,
and lubrication are explained in the
following pages.
EW000060
wIf you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.
1
EAU00469
Tool kitThe service information included in
this manual is intended to provide
you, the owner, with the necessary
information for completing some of
your own preventive maintenance
and minor repairs.
The tools provided in the ownerÕs tool
kit are to assist you in the perfor-
mance of periodic maintenance.
However, some other tools such as a
torque wrench are also necessary to
perform the maintenance correctly.1.Tool kit
3MB-9-E7 12/27/00 2:52 PM Page 37

6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
NOTE:
If you do not have necessary tools
required during a service operation,
take your motorcycle to a Yamaha
dealer for service.
EW000063
wModifications to this motorcycle
not approved by Yamaha may
cause loss of performance, and
render it unsafe for use. Consult a
Yamaha dealer before attempting
any changes.
3MB-9-E7 12/27/00 2:52 PM Page 38

6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03884
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
16121824
3MB-9-E7 12/27/00 2:52 PM Page 41

6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
96.Insert the air filter guide into the
air filter and install it in the case.
7.Install the air filter case cover
and panel by installing the
screws.
EC000082
cC8
8
Make sure the air filter is prop-
erly seated in the air filter
case.
8 8
The engine should never be
run without the air filter
installed. Excessive piston
and/or cylinder wear may
result.
EAU00629
Carburetor adjustmentThe carburetor is a vital part of the
engine and requires very sophisticat-
ed adjustment. Most adjustments
should be left to a Yamaha dealer
who has the professional knowledge
and experience to do so. However,
the following may be serviced by the
owner as part of routine mainte-
nance.
EC000094
cCThe carburetor was set at the
Yamaha factory after many tests. If
the settings are changed, poor
engine performance and damage
may result.
4.Remove the air filter element
from its guide and clean it with
solvent. After cleaning, remove
the remaining solvent by squeez-
ing the element.
5.Apply recommended oil to the
entire surface of the element and
squeeze out the excess oil. It
should be wet but not dripping.
1
2
1.Guide
2.Filter element
Recommended oil:
Engine oil
3MB-9-E7 12/27/00 2:52 PM Page 52

6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00652
TiresTo ensure maximum performance,
long service and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire
pressure before operating the motor-
cycle.
EW000082
wTire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted
according to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if
approved for this model), and vehi-
cle speed.
*Load is the total weight of cargo, rider, passenger
and accessories. Maximum load*180 kg
178 kg (CH, A only)
Cold tire pressureFrontRear
125 kPa150 kPa
Up to 90 kg(1.25 kg/cm
2,(1.50 kg/cm
2,
1.25 bar)1.50 bar)
90 kg load ~150 kPa175 kPa
Maximum load*(1.50 kg/cm
2,(1.75 kg/cm
2,
1.50 bar) 1.75 bar)
125 kPa150 kPa
Off-road riding(1.25 kg/cm
2,(1.50 kg/cm
2,
1.25 bar)1.50 bar)
1.Loosen the locknut.
2.Turn the adjusting nut in direc-
tion ato increase free play and
in direction bto decrease free
play.
3.Tighten the locknut.
2
1
b
a
1.Locknut
2.Adjusting nut
3MB-9-E7 12/27/00 2:52 PM Page 54

6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00685
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.
EAU00681
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.
3MB-9-E7 12/27/00 2:52 PM Page 56

6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
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.
3MB-9-E7 12/27/00 2:52 PM Page 61

6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EC000096
cCToo little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.3.Tighten the wheel axle nut to the
specified torque.
EAU01533*
Drive chain slack adjustment1.Loosen the wheel axle nut.
2.To tighten the chain, turn the
chain adjusting plates in direction
a. To loosen the chain, turn the
chain adjusting plates in direction
band push the wheel forward.
Turn each chain adjusting plate
to exactly the same position to
maintain correct axle alignment.
a b
2
1
1.Wheel axle nut
2.Chain adjusting plate
Tightening torque:
Wheel axle nut:
90 Nm (9.0 m
0kg)
EAU03006
Drive chain lubricationThe chain consists of many parts
which work with each other. If the
chain is not maintained properly, it
will wear out quickly. Therefore, the
chain must be serviced regularly.
This service is especially necessary
when riding in dusty areas. This
motorcycle is equipped with a sealed
type chain. Steam cleaning, high-
pressure washers, and solvents can
damage the drive chain, so do not
use these for cleaning it. Use only
kerosene to clean the drive chain.
Wipe it dry, and thoroughly lubricate it
with SAE 30 ~ 50W motor oil. Do not
use any other lubricants on the drive
chain. They may contain solvents
that could damage the sealed chain.
3MB-9-E7 12/27/00 2:52 PM Page 62

6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
122
1.Disc cover
2.Screw (´2)
EAU00898
Front 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.Remove the disc cover.
2.Remove the speedometer cable
from the front wheel side.
EAU01579
Supporting the motorcycleSince the Yamaha DT125R has no
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance 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.
Front wheel service
To stabilize the rear of the motorcy-
cle, either use a motorcycle stand or
place a motorcycle jack under the
frame in front of the rear wheel to
prevent it from moving from side to
side. Then use a motorcycle stand to
elevate the front wheel off of the
ground.Rear wheel service
Use a motorcycle stand or motorcycle
jack to elevate the motorcycle so the
rear wheel is off the ground.
Alternatively, two jacks can be placed
under the frame or swingarm.
3MB-9-E7 12/27/00 2:52 PM Page 72