clutch YAMAHA DT125R 2006 User Guide

1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the trans-
mission to collect the used oil.
3. Remove the oil filler cap and
drain bolt to drain the oil from the
transmission.
4. Install the transmission oil drain
bolt, and then tighten it to the
specified torque.
Tightening torque:
Transmission oil drain bolt:
15 Nm (1,5 m•kgf)
5. Add the specified amount of the
recommended transmission oil,
and then install and tighten the oil
filler cap.
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0,8 L (0,85 US qt)
ECA10450
CAUTION
In order to prevent clutch slip-
page (since the transmission
oil also lubricates the clutch),
do not mix any chemical additi-
ves with the oil.
Make sure that no foreign
material enters the transmis-
sion.
6. Start the engine, and then let it
idle for several minutes while
checking the transmission for oil
leakage. If oil is leaking, imme-
diately turn off the engine and
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20170
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Remove panel D. (See page 6-6.)
3. Check the coolant level in the
coolant reservoir.
FULL
LOW
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EWA10570
s s
WARNING
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding
stability and can lead to loss of
control.
The replacement of all wheel-
and brake-related parts, inclu-
ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience.
It is not recommended to patch
a punctured tube. If unavoida-
ble, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
EAU21940
Spoke wheels
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
The wheel rims should be chec-
ked for cracks, bends or warpa-
ge, and the spokes for looseness
or damage before each ride. If
any damage is found, have a
Yamaha dealer replace the whe-
el. Do not attempt even the sma-
llest repair to the wheel. A defor-
med or cracked wheel must be
replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal characte-
ristics.
EAU22041
Adjusting the clutch lever
free play
1. Lock nut
2. Adjusting bolt
3. Free play
The clutch lever free play should mea-
sure 10-15 mm (0,34-0,59 in) as
shown. Periodically check the clutch
lever free play and, if necessary,
adjust it as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in
direction (a). To decrease the
clutch lever free play, turn the
adjusting bolt in direction (b).6
PERIODIC MAINTENANCE AND MINOR REPAIR
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NOTE:
If the specified clutch lever free play
could be obtained as described abo-
ve, tighten the locknut and skip the
rest of the procedure, otherwise pro-
ceed as follows.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loo-
sen the clutch cable.
1. Lock nut
2. Adjusting nut
4. Loosen the locknut at the crank-
case.
5. To increase the clutch lever free
play, turn the adjusting nut in
direction (a). To decrease the
clutch lever free play, turn the
adjusting nut in direction (b).6. Tighten the locknut at the clutch
lever and the crankcase.
EAU22092
Adjusting the brake lever
free play
1. Lock nut
2. Adjusting bolt
3. Free play
The brake lever free play should mea-
sure 2-5 mm (0,07 ~ 0,19 in) as
shown. Periodically check the brake
lever free play and, if necessary,
adjust it as follows.
1. Loosen the locknut at the brake
lever.2. To increase the brake lever free
play, turn the adjusting screw in
direction (a). To decrease the bra-
ke lever free play, turn the adjus-
ting screw in direction (b).
3. Tighten the locknut.
EWA10630
s s
WARNING
After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the
hydraulic system, have a
Yamaha dealer bleed the sys-
tem before operating the
motorcycle. Air in the hydraulic
system will diminish the bra-
king performance, which may
result in loss of control and an
accident.
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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.
6
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DimensionsOverall length
DT125RE 2210 mm
DT125X 2139 mm
Overall width
795 mm
Overall height
DT125RE 1200 mm
DT125X 1121 mm
Seat height
DT125RE 900 mm
DT125X 886 mm
Wheelbase
DT125RE 1415 mm
DT125X 1396 mm
Ground clearance
DT125RE 300 mm
DT125X 271 mm
Minimum turning radius
DT125RE 2100 mm
DT125X 2016 mm
WeightWith oil and fuel
DT125RE 126.0 kg
DT125X 134.0 kg
EngineEngine type
Liquid cooled 2-stroke
Cylinder arrangement
Forward-inclined single cylinder
Displacement
124.0 cm
3
Bore x stroke
56.0 x 50.7 mmCompression ratio
6.70 :1
Starting system
Electric starter
Lubrication system
Separate lubrication (Yamaha autolube)
Type
YAMALUBE 2-cycle oil or 2-stroke engine
oil (JASO FC g
Engine oil quantityQuantity
1.3 L
Transmission oilType
SAE10W30 type SE motor oil
Oil change quantity
0.75 L
Cooling systemCoolant reservoir capacity (up to the maxi-
mum leve
0.30 L
Radiator capacity (including all routes)
0.92 L
Air filterAir filter element
Wet element
FuelRecommended fuel
Regular unleaded gasoline only
Fuel tank capacity
10.7 L
Fuel reserve amount
1.8 L
CarburetorManufacturer
MIKUNI
Type x quantity
TM28-92 x1
Spark plug(s)Manufacturer/model
NGK/BR8ES
Spark plug gap
0.7-0.8 mm
Clutch type
Wet, multiple-disc
TransmissionPrimary reduction system
Helical gear
Primary reduction ratio
71/22 (3.227)
Secondary reduction system
Chain drive
Secondary reduction ratio
57/16 (3.563)
Transmission type
Constant mesh 6-speed
Operation
Left foot operation
Gear ratio1st
34/12 (2.833)
2nd
30/16 (1.875)
3rd
24/17 (1.412)
4th
24/21 (1.143)
8
SPECIFICATIONS
8-1
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AAdjusting the autolube pump ..................6-21
Adjusting the brake lever free play ..........6-16
Adjusting the brake pedal position and
free play .................................................6-17
Adjusting the clutch lever free play .........6-15
Adjusting the drive chain slack ................6-20
Adjusting the engine idling speed ...........6-12
Adjusting the rear brake light switch .......6-17
Ajusting the carburetor ............................6-11
Ajusting the throttle cable free play .........6-12
BBrake lever .................................................3-5
Brake pedal ................................................3-5
CCare............................................................7-1
Catalytic converter .....................................3-6
Changing the brake fluid..........................6-19
Checking and lubricating the brake and
shift pedals ............................................6-21
Checking and lubricating the breake and
clutch levers...........................................6-21
Checking and lubricating the cables .......6-21
Checking and lubricating the sidestand ..6-21
Checking and lubricating the throttle grip
and cable ...............................................6-21
Checking the drive chain slack ................6-19
Checking the front and rear brake
pads .......................................................6-18
Checking the front fork ............................6-22
Checking the spark plug ............................6-6
Checking the steering ..............................6-22
Checking the wheel bearings ..................6-23Cleaning the air filter element and check
hose .......................................................6-10
Clutch lever ................................................3-4
Controls and instruments ..........................2-3
Coolant.......................................................6-8
D2-stroke engine oil .....................................3-7
EEngine break-in ..........................................5-2
FFront wheel ..............................................6-26
Fuel cock....................................................3-7
Fuel tank cap .............................................3-5
H
Handlebar switches ...................................3-3
IIdentification numbers ...............................9-1
Ignition circuit cut-off system ..................3-10
Indicator and warning lights ......................3-2
LLeft view .....................................................2-1
Lubricating the drive chain ......................6-20
MMain switch/steering lock ..........................3-1
OOwner’s tool kit ..........................................6-1
PParking .......................................................5-3
Periodic maintenance and lubrication
chart .........................................................6-2
Pre-operation check list .............................4-2
RRear wheel ...............................................6-28Removing and installing cowlings and
panels ......................................................6-5
Replacing the fuse ...................................6-24
Replacing the headlight bulb ...................6-24
Replacing the tail/brake light bulb ...........6-25
Replacing the turn signal light bulb .........6-26
Right view ..................................................2-2
SSeat ............................................................3-8
Shift pedal ..................................................3-4
Shifting .......................................................5-2
Shock absorber..........................................3-9
Sidestand .................................................3-10
Specifications.............................................8-1
Speedometer unit ......................................3-3
Spoke wheels...........................................6-15
Starter (choke) lever ...................................3-8
Starting a cold engine ................................5-1
Starting a warm engine ..............................5-2
Storage.......................................................7-3
Supporting the motorcycle ......................6-26
TTires .........................................................6-13
Transmission oil .........................................6-7
Troubleshooting .......................................6-29
YYEIS handling precautions.........................3-9
YPVS ..........................................................3-9
INDEX
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