wheel YAMAHA DT125R 2000 Owners Manual

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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4-1
EAU01114
PRE-OPERATION CHECKS
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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.
EAU00340
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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*Wheels¥Check runout, spoke tightness and for damage.
¥Tighten spokes if necessary.ÖÖÖÖ
10*Tires¥Check tread depth and for damage.
Â¥Replace if necessary.
Â¥Check air pressure.
¥Correct if necessary.ÖÖÖÖ
11*Wheel bearings¥Check bearing for looseness or damage.ÖÖÖÖ
12*Swingarm¥Check operation and for excessive play.ÖÖÖÖ
13Drive chain¥Check chain slack.
Â¥Make sure that the rear wheel is properly aligned.
Â¥Clean and lubricate.Every 500 km and after washing
the motorcycle or riding in the rain.
14*Steering bearings¥Check bearing play and steering for roughness.ÖÖÖÖÖ
Â¥Lubricate with lithium-soap-based grease.Every 24,000 km
15*Chassis fasteners¥Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖÖ
16Sidestand¥Check operation.
¥Lubricate.ÖÖÖÖÖ
17*Sidestand switch¥Check operation.ÖÖÖÖÖÖ
18*Front fork¥Check operation and for oil leakage.ÖÖÖÖ
19*Shock absorber
assembly¥Check operation and shock absorber for oil leakage.ÖÖÖÖ
20*Rear suspension relay
arm and connecting arm
pivoting points¥Check operation.ÖÖÖÖ NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
16121824
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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.
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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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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.
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EAU00794
Steering inspectionPeriodically inspect the condition of
the steering. Worn out or loose steer-
ing bearings may be dangerous.
Place a stand under the engine to
raise the front wheel off the ground.
Hold the lower end of the front forks
and try to move them forward and
backward. If any free play can be felt,
ask a Yamaha dealer to inspect and
adjust the steering. Inspection is eas-
ier if the front wheel is removed.
EW000115
wSecurely support the motorcycle
so there is no danger of it falling
over.
EAU01144
Wheel bearingsIf there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
inspect the wheel bearings.
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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.
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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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