YAMAHA DT125R User Manual

OWNER’S MANUAL

DT125R

3MB-28199-E7

Welcome to the Yamaha world of motorcycling!

INTRODUCTION

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As the owner of a DT125R, you are benefiting from Yamaha’s vast experience in and newest tech­nology for the design and the manufacture of high-quality products, which have earned Yamaha a
reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all your DT125R’s advantages.
The owner's manual does not only instruct you in how to operate, inspect and maintain your motorcy­cle, but also in how to safeguard yourself and others from trouble and injury.

In addition, the many tips given in this manual will help to keep your motorcycle in the best possible
condition. If you have any further questions, do not hesitate to contact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

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IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

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NOTE:

NOTE:

8 This manual should be considered a permanent part of this motorcycle and should remain

8 Yamaha continually seeks advancements in product design and quality. Therefore, while this

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

with it even if the motorcycle is subsequently sold.

manual contains the most current product information available at the time of printing, there
may be minor discrepancies between your motorcycle and this manual. If there is any ques­tion concerning this manual, please consult your Yamaha dealer.

IMPORTANT MANUAL INFORMATION

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.

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DT125R

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OWNER’S MANUAL

© 2000 by Yamaha Motor Co., Ltd.

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1st Edition, December 2000

All rights reserved.

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Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in Japan.

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TABLE OF CONTENTS

GIVE SAFETY THE RIGHT OF WAY..................1-1

1

DESCRIPTION ....................................................2-1

2

Left view............................................................2-1

Right view .........................................................2-2

Controls/Instruments.........................................2-3

INSTRUMENT AND CONTROL FUNCTIONS....3-1

3

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) “

1”.........................................3-10

Kick 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

4

Pre-operation check list ....................................4-1

OPERATION AND IMPORTANT RIDING

5

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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TABLE OF CONTENTS

PERIODIC MAINTENANCE AND MINOR

6

REPAIR................................................................6-1

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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 .........6-23

Inspecting 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

MOTORCYCLE CARE AND STORAGE .............7-1

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Care..................................................................7-1

Storage .............................................................7-4

SPECIFICATIONS...............................................8-1

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How to use the conversion table.......................8-5

TABLE OF CONTENTS

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CONSUMER INFORMATION..............................9-1

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Identification number records ...........................9-1

Key identification number .................................9-1

Vehicle identification number............................9-1

Model label .......................................................9-2

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GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free­dom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.

Regular care and maintenance are essential for preserving your motorcycle’s value and operating
condition. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders - more than car drivers - must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.

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Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen­gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro­tective wear, however, should not encourage carelessness. Though full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively

- avoiding all dangers, including those caused by others.

Enjoy your ride!

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DESCRIPTION

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Left view

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1. Headlight (page 6-33)

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2. Radiator cap (page 6-13)

3. Fuel cock (page 3-9)

4. Air filter (page 6-15)

5. Coolant reservoir tank (page 6-13)

6. Helmet holder (page 3-12)

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7. Starter (choke) (page 3-10)

8. Shift pedal (page 3-5, 5-4)

9. Y.E.I.S. (page 3-14)

10. Y.P.V.S. (page 3-15)

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Right view

DESCRIPTION

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11. 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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2-2

DESCRIPTION

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Controls/Instruments

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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)

2-3

ON

OFF

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INSTRUMENT AND CONTROL FUNCTIONS

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High beam indicator light “&”

This indicator comes on when the
headlight high beam is used.

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Main switch

The main switch controls the ignition
and lighting systems. Its operation is
described below.

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ON

Electrical circuits are switched on.
The engine can be started. The key
cannot be removed in this position.

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OFF

All electrical circuits are switched off.
The key can be removed in this posi­tion.

1. Turn indicator light “5”

2. High beam indicator light “&”

3. Neutral indicator light “N”

4. Oil level indicator light “7”

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Indicator lights

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Turn indicator light “5”

This indicator flashes when the turn
switch is moved to the left or right.

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Neutral indicator light “N”

This indicator comes on when the
transmission is in neutral.

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Oil level indicator light “7”

This indicator comes on when the oil
level is low. This light circuit can be
checked by the procedure on page 3-

2.

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Do not run the motorcycle until
you know it has sufficient engine
oil.

NOTE

Even if the oil is filled to the specified
level, the indicator light may flicker
when riding on a slope or during sud­den acceleration or deceleration, but
this is normal.

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3-1

INSTRUMENT AND CONTROL FUNCTIONS

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Oil level indicator circuit check

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Turn the main switch to “ON”.

2

Put the transmission in neutral.

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Oil level indicator light
does not come on.

Ask a Yamaha dealer to
inspect electrical circuit.

Oil level indicator light
comes on.

Shift into gear.

Oil level indicator light
does not come on.

Engine oil level and
electrical circuit are OK.
Go ahead with riding.

3-2

Oil level indicator light
comes on.

Supply engine oil.

INSTRUMENT AND CONTROL FUNCTIONS

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NOTE:

(for German model equipped with
speed limiter only)
This motorcycle is equipped with a
speed limiter which prevents it from
exceeding a top speed of
80 km/h.

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1. Speedometer

2. Odometer

3. Trip odometer

4. Reset knob

Speedometer

The speedometer shows riding
speed. This speedometer is equipped
with an odometer and trip odometer.
The trip odometer can be reset to “0”
with the reset knob. Use the trip
odometer to estimate how far you
can ride on a tank of fuel. This infor­mation will enable you to plan fuel
stops in the future.

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3-3

1. Tachometer

2. Red zone

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Tachometer

This model is equipped with a
tachometer so the rider can monitor
the engine speed and keep it within
the ideal power range.

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Do not operate in the red zone.
Red zone: 10,500 r/min and above

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INSTRUMENT AND CONTROL FUNCTIONS

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1. Coolant temperature gauge

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2. Red zone

Coolant temperature gauge

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This gauge indicates the coolant tem­perature when the main switch is on.

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The engine operating temperature
will vary with changes in weather and

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engine load. If the needle points to
the red zone or higher, stop your

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motorcycle and let the engine cool.
(See page 6-13 for details.)

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When the engine is overheated, do
not continue riding.

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1. Lights switch

2. Dimmer switch

3. Turn signal switch

4. Horn switch “*”

Handlebar switches

Lights switch

Turning the light switch to “'”,
turns on the auxiliary light, meter
lights and taillight. Turning the light
switch to “:”, turns the headlight on
also.

Dimmer switch

Turn the switch to “&” for the high
beam and to “%” for the low beam.

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Turn signal switch

To signal a right-hand turn, push the
switch to “6”. To signal a left-hand
turn, push the switch to “4”. Once
the switch is released it will return to
the center position. To cancel the sig­nal, push the switch in after it has
returned to the center position.

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Horn switch “*”

Press the switch to sound the horn.

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INSTRUMENT AND CONTROL FUNCTIONS

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N

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1. Engine stop switch

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Engine stop switch

The engine stop switch is a safety
device for use in an emergency such
as when the motorcycle overturns or
if trouble occurs in the throttle sys­tem. Turn the switch to “#” to start
the engine. In case of emergency,
turn the switch to “$” to stop the
engine.

1. Clutch lever

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Clutch lever

The clutch lever is located on the left
handlebar. Pull the clutch lever to the
handlebar to disengage the clutch,
and release the lever to engage the
clutch. The lever should be pulled
rapidly and released slowly for
smooth clutch operation.

3-5

1. Shift pedal
N. Neutral

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Shift pedal

This motorcycle is equipped with a
constant-mesh 6-speed transmission.
The shift pedal is located on the left
side of the engine and is used in
combination with the clutch when
shifting.

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INSTRUMENT AND CONTROL FUNCTIONS

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1. Front brake lever

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Front brake lever

The front brake lever is located on

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the right handlebar. Pull it toward the
handlebar to apply the front brake.

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1. Rear brake pedal

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Rear brake pedal

The rear brake pedal is on the right
side of the motorcycle. Press down
on the brake pedal to apply the rear
brake.

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1. Fuel tank cap

2. Unlock

3. Open

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Fuel tank cap

To 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.

NOTE:

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The tank cap cannot be reinstalled
unless it is unlocked. The key must
remain in the cap until the cap is
properly installed and locked onto the
fuel tank.

INSTRUMENT AND CONTROL FUNCTIONS

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Be sure the cap is properly
installed and locked in place
before riding the motorcycle.

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1. Filler tube

2. Fuel level

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Fuel

(except for Switzerland and
Austria)

Make sure there is sufficient fuel in
the tank. Fill the fuel tank to the bot­tom of the filler tube as shown in the
illustration.

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Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do
not fill the fuel tank above the bot­tom of the filler tube or it may
overflow when the fuel heats up
later and expands.

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1. Filler tube

2. Filling nozzle

3. Leaf valve

4. Fuel level

EAU01184

Fuel

(for Switzerland and Austria)

Make sure there is sufficient fuel in
the tank. When refueling, be sure to
insert the filling nozzle into the filler
hole and fill the tank to the bottom of
the filler tube as shown in the illustra­tion.

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INSTRUMENT AND CONTROL FUNCTIONS

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Do not overfill the fuel tank. Avoid

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spilling fuel on the hot engine. Do
not fill the fuel tank above the bot-

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tom of the filler tube or it may
overflow when the fuel heats up
later and expands.

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Always wipe off spilled fuel imme-

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diately with a dry and clean soft
cloth. Fuel may deteriorate painted

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surfaces or plastic parts.

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Recommended fuel:

Regular unleaded gasoline
with a research octane
number of 91 or higher.

Fuel tank capacity:

Total:

10.0 L

Reserve:

1.8 L

NOTE:

If knocking or pinging occurs, use a
different brand of gasoline or higher
octane grade.

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Catalyzer

(for Switzerland and Austria)

This motorcycle is equipped with a
catalytic converter in the exhaust
chamber.

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The exhaust system is hot during
and directly after engine operation.
Make sure the exhaust system has
cooled down before making any
adjustment to or lubricating the
motorcycle.

3-8

INSTRUMENT AND CONTROL FUNCTIONS

RES

ON

FUEL

OFF

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The following must be observed to
prevent a fire hazard or other dam­ages.

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Use only unleaded gasoline.
Use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.

88

Never park this motorcycle in
an area that would cause a fire
hazard such as grass or other
materials that may easily burn.

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Do not allow the engine to idle
for very long.

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1. Oil tank cap

2. Stopper

EAU02956

Two-stroke engine oil

Make sure there is sufficient two­stroke engine oil in the oil tank. Add
the recommended oil as necessary.

Recommended oil:

Yamalube 2 or 2-stroke
engine oil (JASO FC grade or
ISO EG-C, EG-D grade)

Oil quantity:

1.2 L

3-9

OFF: closed position

1. Arrow mark positioned “OFF”

EAU03050

Fuel cock

The fuel cock supplies fuel from the
tank to the carburetor while filtering it
also.
The fuel cock has three positions:

OFF

With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.

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INSTRUMENT AND CONTROL FUNCTIONS

ON

FUEL

RES

OFF

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ON

OFF

ON

FUEL

RES

1

RES

ON: normal position

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1. Arrow mark positioned “ON”

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ON

With the lever in this position, fuel

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flows to the carburetor. Normal riding
is done with the lever in this position.

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RES: reserve position

1. Arrow mark positioned “RES”

RES

This indicates reserve. If you run out
of fuel while riding, move the lever to
this position. Fill the tank at the first
opportunity. Be sure to set the lever
back to “ON” after refueling!

3-10

a

b

1. Starter (choke) “1”

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EAU02976

Starter (choke) “1”

Starting a cold engine requires a rich­er air-fuel mixture. A separate starter
circuit supplies this mixture.
Move in direction a to turn on the
starter (choke).
Move in direction b to turn off the
starter (choke).

INSTRUMENT AND CONTROL FUNCTIONS

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1

To unlock the steering

Insert the key, push it in and turn it
1/8 turn counterclockwise so that it
moves out. Then, release and
remove the key.

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1. Kick starter

EAU00212

Kick starter

Rotate the kick starter away from the
engine. Push the starter down lightly
with your foot until the gears engage,
then kick smoothly and forcefully to
start the engine. This model has a
primary-coupled kick starter so the
engine can be started in any gear if
the clutch is disengaged. However,
shifting to neutral before starting is
recommended.

1. Steering lock

EAU02934

Steering lock

To lock the steering

Turn the handlebars all the way to
the right and open the steering lock
cover.
Insert the key and turn it 1/8 turn
counterclockwise. Then, push the key
in while turning the handlebars slight­ly to the left and turn the key 1/8 turn
clockwise.
Check that the steering is locked,
remove the key and close the lock
cover.

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INSTRUMENT AND CONTROL FUNCTIONS

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1

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3

1. Bolt (×2)

4

Seat

5

To remove

1. Remove panels D and E. (See

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page 6-9 for panel removal and
installation procedures.)

2. Remove the seat bolts and lift
the seat upward.

EAU01648

To install

1. Insert the projections on the front
of the seat into the holders, then
tighten the seat bolts.

2. Install the panels.

NOTE:

Make sure that the seat is securely
fitted.

3-12

1. Open

EAU00261

Helmet holder

To open the helmet holder, insert the
key in the lock and turn it as shown.
To lock the helmet holder, turn the
key to its original position.

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Never ride with a helmet in the hel­met holder. The helmet may hit
objects, causing loss of control
and possibly an accident.

INSTRUMENT AND CONTROL FUNCTIONS

b

a

2

1

“A”

3. Tighten the locknut to the speci­fied torque.

1. Locknut

2. Adjusting nut

EAU01650

Rear shock absorber
adjustment

This shock absorber is equipped with
a spring preload adjuster. Adjust
spring preload as follows.

1. Loosen the locknut.

2. Turn the adjusting nut in direc­tion a to increase spring preload
and in direction b to decrease
spring preload. The spring pre­load is determined by the spring
set length.
Shortening the spring set length
increases spring preload, length­ening the spring set length
decreases spring preload.

Spring preload:

Minimum (soft):

Distance “A” = 235 mm

Standard:

Distance “A” = 230 mm

Maximum (hard):

Distance “A” = 220 mm

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Never attempt to turn an adjuster
beyond the maximum or minimum
setting.

3-13

Tightening torque:

Locknut:

55 Nm (5.5 m0kg)

EC000018

cC

Always tighten the locknut against
the spring adjusting nut and tight­en the locknut to the specified
torque.

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INSTRUMENT AND CONTROL FUNCTIONS

1

2

1

EAU00315

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This shock absorber contains

1

highly pressurized nitrogen gas.
Read and understand the following

2

information before handling the
shock absorber. The manufacturer
cannot be held responsible for

3

property damage or personal
injury that may result from improp-

4

er handling.

88

5

6

Do not tamper with or attempt
to open the cylinder assembly.

88

Do not subject the shock
absorber to an open flame or
other high heat source. This

7

may cause the unit to explode
due to excessive gas pres-

8

9

sure.

88

Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.

88

Take your shock absorber to a
Yamaha dealer for any service.

1. Rear carrier

Rear carrier

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Do not exceed the load limit of
2 kg.

EAU00320

EW000032

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 installa­tion or damaged parts will result in
poor performance. Replace any
cracked or damaged parts immedi­ately. No modification of this system
in any form can be made.

EC000022

cC

Never attempt to modify the
Yamaha Energy Induction System.

3-14

INSTRUMENT AND CONTROL FUNCTIONS

1

1. Y.P.V.S.

EAU00326

Y.P.V.S. (Yamaha Power
Valve System)

The Y.P.V.S. is a vital part of the
engine and requires very sophisticat­ed adjustment. Adjustment should be
left to a Yamaha dealer who has the
professional knowledge and experi­ence to do so.

EC000023

cC

The Y.P.V.S. was set at the
Yamaha factory after many tests. If
the settings are disturbed by
someone without sufficient techni­cal knowledge, poor engine perfor­mance and damage may result.

The Y.P.V.S. operation can be heard
in the following instances:

8 When the main switch is turned

on and the engine is started.

8 When the engine stalls while the

main switch is on.

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If the Y.P.V.S. does not operate,
ask a Yamaha dealer to inspect the
vehicle.

EAU00330

Sidestand

This model is equipped with an igni­tion circuit cut-off system. The motor­cycle must not be ridden when the
sidestand is down. The sidestand is
located on the left side of the frame.
(Refer to page 5-1 for an explanation
of this system.)

1

2

3

4

5

6

7

8

9

3-15

INSTRUMENT AND CONTROL FUNCTIONS

w

This motorcycle must not be oper-

1

ated with the sidestand in the
down position. If the stand is not

2

properly retracted, it could contact
the ground and distract the opera­tor, resulting in a possible loss of

3

control. Yamaha has designed into
this motorcycle a lockout system

4

to assist the operator in fulfilling
the responsibility of retracting the

5

sidestand. Please check carefully
the operating instructions listed

6

below and if there is any indication
of a malfunction, return the motor-

7

cycle to a Yamaha dealer immedi­ately for repair.

8

9

EW000044

EAU00333

Sidestand switch operation
check

Check the operation of the sidestand
switch against the information below.

TURN THE MAIN SWITCH TO “ON” AND
THE ENGINE STOP SWITCH TO “#”.

TRANSMISSION IS IN NEUTRAL AND
SIDESTAND IS DOWN.

KICK THE KICK STARTER.

ENGINE WILL START.

PULL IN THE CLUTCH LEVER AND
PUT TRANSMISSION IN GEAR.

ENGINE WILL STALL.

SIDESTAND SWITCH IS OK.

EW000045

w

If improper operation is noted,
consult a Yamaha dealer immedi­ately.

3-16

EAU01114

PRE-OPERATION CHECKS

Owners are personally responsible for their vehicle’s condition. Your motorcycle’s 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 thor­ough visual inspection, you check the following points before each ride.

1

PRE-OPERATION CHECK LIST

ITEM CHECKS PAGE

Front brake

Rear brake

Clutch

Throttle grip and housing 9 Lubricate. 6-17, 6-27

Engine oil

Transmission oil

Coolant

Drive chain

Wheels and tires

Control and meter cable

9 Check operation, free play, fluid level and vehicle for fluid leakage.
9 Fill with DOT 4 (or DOT 3) brake fluid if necessary.

9 Check operation, free play, fluid level and vehicle for fluid leakage.
9 Fill with DOT 4 (or DOT 3) brake fluid if necessary.

9 Check operation, condition and free play.
9 Adjust if necessary.

9 Check for smooth operation.
9 Adjust throttle cable free play if necessary.

9 Check oil level.
9 Fill with oil if necessary.

9 Check oil level.
9 Fill with oil if necessary.

9 Check coolant level.
9 Fill with coolant if necessary.

9 Check chain slack and condition.
9 Adjust if necessary.

9 Check tire pressure, wear, damage and spoke tightness.
9 Tighten spokes if necessary.

9 Check for smooth operation.
9 Lubricate if necessary.

3-6, 6-21 ~ 6-25

3-5, 6-21

3-9

6-11 ~ 6-12

6-12

6-26 ~ 6-27

6-18 ~ 6-20

6-27

EAU00340

2

3

4

5

6

7

8

9

4-1

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

Brake and shift pedal shafts

1

Brake and clutch lever pivots

Sidestand pivot

2

Chassis fasteners

3

Fuel tank
Lights, signals and

4

switches
Battery

5

NOTE:

Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a

6

very short time; and the added safety it assures is more than worth the time involved.

7

w

8

If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating
the motorcycle.

9

9 Check for smooth operation.
9 Lubricate if necessary.

9 Check for smooth operation.
9 Lubricate if necessary.

9 Check for smooth operation.
9 Lubricate if necessary.

9 Make sure that all nuts, bolts and screws are properly tightened.
9 Tighten if necessary.

9 Check fuel level.
9 Fill with fuel if necessary.

9 Check for proper operation. 6-33 ~ 6-35
9 Check fluid level.

9 Fill with distilled water if necessary.

6-28

6-29

—

3-6 ~ 3-8

6-31 ~ 6-32

4-2

EAU00372

OPERATION AND IMPORTANT RIDING POINTS

w

88

Before riding this motorcycle,
become thoroughly familiar
with all operating controls and
their functions. Consult a
Yamaha dealer regarding any
control or function that you do
not thoroughly understand.

88

Never start your engine or let
it run for any length of time in
a closed area. The exhaust
fumes are poisonous and can
cause loss of consciousness
and death within a short time.
Always operate your motorcy­cle in an area with adequate
ventilation.

88

Before starting out, always be
sure the sidestand is up.
Failure to retract the sidestand
completely can result in a seri­ous accident when you try to
turn a corner.

EAU00373

EAU01177

Starting the engine

NOTE:

This motorcycle is equipped with an
ignition circuit cut-off system. The
engine can be started only under one
of the following conditions:

8 The transmission is in neutral.
8 The sidestand is up, the trans-

mission is in gear and the clutch

is disengaged.
The motorcycle must not be ridden
when the sidestand is down.

EW000056

w

Before going through the following
steps, check the function of the
sidestand switch. (Refer to page
3-16.)

1

2

3

4

5

6

7

8

9

5-1

OPERATION AND IMPORTANT RIDING POINTS

TURN THE MAIN SWITCH TO "ON" AND
THE ENGINE STOP SWITCH TO “#”.

1

2

3

IF TRANSMISSION IS IN NEUTRAL
AND SIDESTAND IS DOWN,

KICK THE KICK STARTER.
ENGINE WILL START.

4

RETRACT SIDESTAND AND PUT

5

TRANSMISSION IN GEAR.

6

IF TRANSMISSION IS IN GEAR
AND SIDESTAND IS UP,

APPLY THE CLUTCH LEVER AND KICK
THE KICK STARTER.
ENGINE WILL START.

MOTORCYCLE CAN BE RIDDEN.MOTORCYCLE CAN BE RIDDEN.

7

8

9

5-2

OPERATION AND IMPORTANT RIDING POINTS

1. Turn the fuel cock to “ON”.

2. Turn the main switch to “ON” and
the engine stop switch to “#”.

3. Shift the transmission into neu­tral.

NOTE:

When the transmission is in neutral,
the neutral indicator light should be
on. If the light does not come on, ask
a Yamaha dealer to inspect it.

4. Turn on the starter (choke) and
completely close the throttle grip.

5. Kick the kick starter to start the
engine.

6. After starting the engine, move
the starter (choke) to the halfway
position.

NOTE:

For maximum engine life, never
accelerate hard with a cold engine!

7. After the engine is warm, turn off
the starter (choke) completely.

NOTE:

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.

EAU01258

Starting a warm engine

The starter (choke) is not required
when the engine is warm.

EC000046

cC

See the “Engine break-in” section
prior to operating the motorcycle
for the first time.

1

2

3

4

5

6

7

8

9

5-3

OPERATION AND IMPORTANT RIDING POINTS

6
5
4
3
2

1

N

1

1

2

3

N. Neutral

4

1. Shift pedal

Shifting

5

The transmission lets you control the
amount of power you have available

6

at a given speed for starting, acceler­ating, climbing hills, etc. The use of

7

the shift pedal is shown in the illustra­tion.
To shift into neutral, depress the shift

8

pedal repeatedly until it reaches the
end of its travel, then raise the pedal

9

slightly.

EAU00423

cC

88

Do not coast for long periods
with the engine off, and do not
tow the motorcycle a long dis­tance. Even with gears in neu­tral, the transmission is only
properly lubricated when the
engine is running. Inadequate
lubrication may damage the
transmission.

88

Always use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.

5-4

EC000048

EAU02937

Recommended shift points
(for Switzerland only)

The recommended shift points are
shown in the table below.

Acceleration shift point

km/h

1st → 2nd 20
2nd → 3rd 30
3rd → 4th 40

4th → 5th 50
5th → 6th 60

NOTE:

When shifting two gears down from
5th to 3rd, bring your motorcycle to a
speed of 35 km/h.

OPERATION AND IMPORTANT RIDING POINTS

EAU00424

Tips for reducing fuel
consumption

Your motorcycle’s fuel consumption
depends to a large extent on your rid­ing style. The following tips can help
reduce fuel consumption:

8 Warm up the engine before rid-

ing.

8 Turn off the starter (choke) as

soon as possible.

8 Shift up swiftly and avoid high

engine speeds during accelera­tion.

8 Do not double-clutch or rev the

engine while shifting down and
avoid high engine speeds with
no load on the engine.

8 Turn off the engine instead of let-

ting it idle for an extended length
of time, i.e. in traffic jams, at traf­fic lights or railroad crossings.

EAU00436

Engine break-in

There is never a more important peri­od in the life of your motorcycle than
the period between zero and 1,000
km. For this reason we ask that you
carefully read the following material.
Because the engine is brand new,
you must not put an excessive load
on it for the first 1,000 km. The vari­ous parts in the engine wear and pol­ish themselves to the correct operat­ing clearances. During this period,
prolonged full throttle operation, or
any condition which might result in
excessive heating of the engine,
must be avoided.

EAU00453

0 ~ 500 km

Avoid operation above 6,000 r/min.
Stop the engine and let it cool for 5 to
10 minutes after every hour of opera­tion. Vary the speed of the motorcy­cle from time to time. Do not operate
it at one set throttle position.

500 ~ 1,000 km

Avoid prolonged operation above
7,000 r/min. Rev the motorcycle
freely through the gears, but do not
use full throttle at any time.

EC000060

cC

After 1,000 km of operation, be
sure to replace the transmission
oil.

1

2

3

4

5

6

7

8

9

5-5

OPERATION AND IMPORTANT RIDING POINTS

1,000 km and beyond

Full throttle can be used.

1

cC

88

2

3

Never let engine speeds enter
the red zone.

88

If any engine trouble should
occur during the break-in peri­od, consult a Yamaha dealer

4

immediately.

5

6

7

8

9

EC000053

EAU00458

Parking

When parking the motorcycle, stop
the engine and remove the ignition
key. Turn the fuel cock to “OFF”
whenever stopping the engine.

EW000058

w

The exhaust system is hot. Park
the motorcycle in a place where
pedestrians or children are not
likely to touch the motorcycle. Do
not park the motorcycle on a slope
or soft ground; the motorcycle
may overturn.

EC000062

cC

Never park this motorcycle in an
area that would cause a fire haz­zard such as grass or other materi­als that may easily burn.

5-6

EAU00462

1

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00464

Periodic inspection, adjustment and
lubrication will keep your motorcycle
in the safest and most efficient condi­tion possible. Safety is an obligation
of the motorcycle owner. The mainte­nance and lubrication schedule chart
should be considered strictly as a
guide to general maintenance and
lubrication intervals.
YOU MUST TAKE INTO CONSIDER­ATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND
A VARIETY OF INDIVIDUAL USES
ALL TEND TO DEMAND THAT
EACH OWNER ALTER THIS TIME
SCHEDULE TO SHORTER INTER­VALS TO MATCH THE ENVIRON­MENT. The most important points of
motorcycle inspection, adjustment,
and lubrication are explained in the
following pages.

EW000060

w

If you are not familiar with motor­cycle service, this work should be
done by a Yamaha dealer.

1. Tool kit

EAU00469

Tool kit

The 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 owner’s tool
kit are to assist you in the perfor­mance of periodic maintenance.
However, some other tools such as a
torque wrench are also necessary to
perform the maintenance correctly.

1

2

3

4

5

6

7

8

9

6-1

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

If you do not have necessary tools
required during a service operation,

1

take your motorcycle to a Yamaha
dealer for service.

2

EW000063

3

w

Modifications to this motorcycle

4

not approved by Yamaha may
cause loss of performance, and
render it unsafe for use. Consult a

5

Yamaha dealer before attempting
any changes.

6

7

8

9

6-2

PERIODIC MAINTENANCE AND MINOR REPAIR

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1,000 km)

ANNUAL

CHECK

1 6 12 18 24

1

*

Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √

2 Spark plug • Replace. √ √ √ √ √

3 Air filter element

• Clean. √ √

• Replace. √ √

4

*

Battery

• Check electrolyte level and specific gravity.

• Make sure that the breather hose is properly routed.

√ √ √ √ √

5 Clutch

• Check operation.

• Adjust.

√ √ √ √ √

6

*

Front brake

• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)

√ √ √ √ √ √

• 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.)

√ √ √ √ √ √

• Replace brake pads. Whenever worn to the limit

8

*

Brake hoses

• Check for cracks or damage. √ √ √ √ √

• Replace. (See NOTE on page 6-5.) Every 4 years

EAU03686

Periodic maintenance and lubrication chart

NOTE:

8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8 From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and

technical skills.

1

2

3

4

6-3

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

9*Wheels

• Check runout, spoke tightness and for damage.

• Tighten spokes if necessary.

√ √ √ √

10

*

Tires

• Check tread depth and for damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

√ √ √ √

11

*

Wheel bearings • Check bearing for looseness or damage. √ √ √ √

12*Swingarm • Check operation and for excessive play. √ √ √ √

13 Drive chain

• Check chain slack.

• Make sure that the rear wheel is properly aligned.

• 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. √ √ √ √ √

• Lubricate with lithium-soap-based grease. Every 24,000 km

15*Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √
16 Sidestand

• Check operation.

• Lubricate.

√ √ √ √ √

17

*

Sidestand switch • Check operation. √ √ √ √ √ √

18*Front fork • Check operation and for oil leakage. √ √ √ √
19

*

Shock absorber
assembly

• Check operation and shock absorber for oil leakage. √ √ √ √

20

*

Rear suspension relay
arm and connecting arm
pivoting points

• Check operation. √ √ √ √

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1,000 km)

ANNUAL

CHECK

1 6 12 18 24

1

2

3

4

5

6

7

8

9

6-4

PERIODIC MAINTENANCE AND MINOR REPAIR

21*Carburetor

• Check starter (choke) operation.

• Adjust engine idling speed.

√ √ √ √ √ √

22

*

Autolube pump

• Check operation.

• Bleed if necessary.

√ √ √ √

23 Transmission oil

• Check oil level. √ √ √ √ √ √

• Change. √ √

24

*

Cooling system

• Check coolant level and vehicle for coolant leakage. √ √ √ √ √

• Change. Every 3 years

25

*

Front and rear brake
switches

• Check operation. √ √ √ √ √ √

26 Moving parts and cables • Lubricate. √ √ √ √ √
27

*

Lights, signals and
switches

• Check operation.

• Adjust headlight beam.

√ √ √ √ √ √

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1,000 km)

ANNUAL

CHECK

1 6 12 18 24

1

2

3

4

5

NOTE:

8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8 Hydraulic brake service

9 Regularly check and, if necessary, correct the brake fluid level.
9 Every two years replace the internal components of the brake master cylinders and calipers, and change the

brake fluid.

9 Replace the brake hoses every four years and if cracked or damaged.

6-5

EAU03884

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1

2

3

1. Cowling A

4

2. Cowling B

Cowling removal and

5

installation

The cowlings indicated in the illustra-

6

tion need to be removed to perform
some of the maintenance described

7

in this chapter.
Refer to this section each time a
cowling has to be removed or rein-

8

stalled.

9

EAU01065

1

1. Cowling C 1. Screw (×2)

Cowling A

To remove

Remove the screws and pull outward
as shown.

1

EAU01534*

6-6

1

To install

Place in the original position and
install the screws.

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screw (×3)

EAU01534*

Cowling B

To remove

Remove the screws and pull outward
as shown.

To install

Place in the original position and
install the screws.

6

6-7

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

2

3

1. Screw (×3) 1. Panel D

4

Cowling C

To remove

5

Remove the screws and pull outward
as shown.

6

7

8

EAU01534*

To install

Place in the original position and
install the screws.

1

EAU01122

Panel removal and
installation

The panels illustrated need to be
removed to perform some of the
maintenance described in this chap­ter.

9

6-8

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

1

1

2

3

1. Panel E 1. Screw 1. Screw

Refer to this section each time a
panel has to be removed or rein­stalled.

Panel D

To remove

Remove the screw and pull outward
as shown.

To install

Place the panel in the original posi­tion and install the screw.

EAU01535*

Panel E

To remove

Remove the screw and pull outward
as shown.

To install

Place the panel in the original posi­tion and install the screw.

6-9

EAU01535*

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

2

3

1. Spark plug cap

4

Spark plug

5

Removal

1. Remove the spark plug cap.

6

7

8

9

EAU01833

1. Spark plug wrench

2. Use the spark plug wrench in the
tool kit to remove the spark plug
as shown.

Inspection

1

The spark plug is an important
engine component and is easy to
inspect. The condition of the spark
plug can indicate the condition of the
engine.
The ideal color on the white insulator
around the center electrode is a
medium-to-light tan color for a motor­cycle that is being ridden normally.
Do not attempt to diagnose such
problems yourself. Instead, take the
motorcycle to a Yamaha dealer. You
should periodically remove and
inspect the spark plug because heat
and deposits will cause any spark
plug to slowly break down and erode.
If electrode erosion becomes exces­sive, or if carbon and other deposits
are excessive, you should replace
the spark plug with the specified plug.

Specified spark plug:

BR9ES (NGK)
BR8ES (NGK) (CH, A only)

6-10

PERIODIC MAINTENANCE AND MINOR REPAIR

1

NOTE:

If a torque wrench is not available
when you are installing a spark plug,
a good estimate of the correct torque
is 1/4 to 1/2 turn past finger tight.
Have the spark plug tightened to the
specified torque as soon as possible.

2

3

1

1

2

3

1. Spark plug gap

Installation

1. Measure the electrode gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.

Spark plug gap:

0.7 ~ 0.8 mm

2. Clean the gasket surface. Wipe
off any grime from the threads.

3. Install the spark plug and tighten
it to the specified torque.

Tightening torque:

Spark plug:

20 Nm (2.0 m0kg)

4. Install the spark plug cap.

6-11

1. Level window

2. Maximum level

3. Minimum level

EAU03109

Transmission oil

Oil level inspection

1. Place the motorcycle on a level
place and hold it in an upright
position. Warm up the engine for
several minutes.

NOTE:

Be sure the motorcycle is positioned
straight up when checking the oil
level. A slight tilt toward the side can
result in false readings.

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

1

5. Fill the engine with sufficient oil
to reach the specified level.
Install the oil filler cap and tight­en it.

2

3

1. Oil filler cap

4

2. With the engine stopped, check

5

6

the oil level through the level
window located at the right side
crankcase cover.

NOTE:

7

Wait a few minutes until the oil level
settles before checking.

8

3. The oil level should be between

9

the maximum and minimum level
on the level window. If the level
is low, add sufficient oil to raise it
to the specified level.

1. Drain bolt

Transmission oil replacement

1. Warm up the engine for several
minutes.

2. Stop the engine. Place an oil pan
under the engine to catch the oil
and remove the oil filler cap.

3. Remove the drain bolt and drain
the oil.

4. Install the drain bolt and tighten it
to the specified torque.

Tightening torque:

Drain bolt:

15 Nm (1.5 m0kg)

6-12

Recommended oil:

See page 8-1.

Oil quantity:

Total amount: 0.8 L
Periodic oil change: 0.75 L

EC000079

cC

Do not put in any chemical addi­tives. Transmission oil also lubri­cates the clutch and additives
could cause clutch slippage.

6. Start the engine and warm up for
a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for
cause.

2

1

1. Maximum level mark

1

2

2. Minimum level mark

EAU01808

Cooling system

1. Remove panel D. (See page 6-9
for panel removal and installation
procedures.)

2. Check the coolant level in the
reservoir tank when the engine is
cold as the coolant level will vary
with engine temperature. The
coolant level should be between
the maximum and minimum
marks.

3. If the level is low, add coolant or
distilled water to raise it to the
specified level.

PERIODIC MAINTENANCE AND MINOR REPAIR

4. Install the panel.
Reservoir tank capacity:

0.35 L

EC000080

cC

Hard water or salt water is harmful
to the engine. You may use dis­tilled water if you can’t get soft
water.

NOTE:

If water is added, have a Yamaha
dealer check the antifreeze content of
the coolant as soon as possible.

If your motorcycle overheats, see
page 6-41 for details.

6-13

1. Stopper bolt

2. Radiator cap

EAU03101

Changing the coolant

1. Put the motorcycle on a level
place.

2. Remove cowling C and panel D.
(See page 6-8 ~ 6-9 for cowling
and panel removal and installa­tion procedures.)

3. Remove the radiator cap stopper
bolt and the radiator cap.

1

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

2

3

1. Drain bolt 1. Reservoir tank hose

4

4. Place a container under the

5

6

7

8

9

engine and remove the coolant
drain bolt.

2. Maximum level mark

3. Minimum level mark

5. Disconnect the reservoir tank
hose on the reservoir tank side
and drain the coolant from the
reservoir tank.

6. After draining the coolant, thor­oughly flush the cooling system
with clean tap water.

7. Replace the coolant drain bolt
washer if it is damaged and tight­en the coolant drain bolt to the
specified torque.

1

3

8. Install the reservoir tank hose.

9. Pour the recommended coolant
into the radiator until it is full.

2

Recommended antifreeze:

High quality ethylene glycol
antifreeze containing
corrosion inhibitors for
aluminum engines.

Antifreeze and water mixing ratio:

1:1

Total amount:

1.05 L

Reservoir tank capacity:

0.35 L

Tightening torque:

Coolant drain bolt:

10 Nm (1.0 m0kg)

6-14

EC000080

1

cC

Hard water or salt water is harmful
to the engine. You may use dis­tilled water if you can’t get soft
water.

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

10. Install the radiator cap.

11. Run the engine several minutes.
Stop the engine and recheck the
coolant level in the radiator. If it
is low, add more coolant until it
reaches the top of the radiator.

12. Install the radiator cap stopper
bolt.

13. Fill the reservoir tank with
coolant up to maximum level.

14. Install the reservoir tank cap and
check for coolant leakage.

NOTE:

If any leakage is found, ask a
Yamaha dealer to inspect the cooling
system.

15. Install the cowling and the panel.

1. Screw (×3)

EAU03107

Air filter

The air filter should be cleaned at the
specified intervals. It should be
cleaned more frequently when riding
in unusually wet or dusty areas.

1. Remove panel D. (See page 6-9
for panel removal and installation
procedures.)

2. Remove the air filter case by
removing the screws.

6-15

3. Remove the air filter from the
case.

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1

2

3

1. Guide

4

2. Filter element

4. Remove the air filter element

5

from its guide and clean it with
solvent. After cleaning, remove

6

the remaining solvent by squeez­ing the element.

5. Apply recommended oil to the

7

entire surface of the element and

8

9

squeeze out the excess oil. It
should be wet but not dripping.

Recommended oil:

Engine oil

6. 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

cC

88

Make sure the air filter is prop­erly seated in the air filter
case.

88

The engine should never be
run without the air filter
installed. Excessive piston
and/or cylinder wear may
result.

EAU00629

Carburetor adjustment

The carburetor is a vital part of the
engine and requires very sophisticat­ed 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 mainte­nance.

EC000094

cC

The carburetor was set at the
Yamaha factory after many tests. If
the settings are changed, poor
engine performance and damage
may result.

6-16

PERIODIC MAINTENANCE AND MINOR REPAIR

b

a

1

Standard idle speed:

1,250 ~ 1,450 r/min

NOTE:

If the specified idle speed cannot be
obtained by performing the above
adjustment, consult a Yamaha deal­er.

a

1

2

3

1. Throttle stop screw

EAU00632

Idle speed adjustment

1. Start the engine and warm it up
for a few minutes at approxi­mately 1,000 to 2,000 r/min.
Occasionally rev the engine to
4,000 to 5,000 r/min. The engine
is warm when it quickly responds
to the throttle.

2. Set the idle to the specified
engine speed by adjusting the
throttle stop screw. Turn the
screw in direction a to increase
engine speed and in direction b
to decrease engine speed.

6-17

a. Free play

EAU00634

Throttle cable free play
adjustment

NOTE:

Before checking the throttle cable
free play, the engine idling speed
should be adjusted.

Adjust the throttle cable by turning
the adjusting nut so that specified
free play at the throttle grip is
obtained.

Free play:

3 ~ 5 mm

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

2

1

b

a

1

2

3

1. Locknut

4

2. Adjusting nut

1. Loosen the locknut.

5

2. Turn the adjusting nut in direc­tion a to increase free play and

6

in direction b to decrease free
play.

3. Tighten the locknut.

7

8

9

EAU00652

Tires

To ensure maximum performance,
long service and safe operation, note
the following:

Tire air pressure

Always check and adjust the tire
pressure before operating the motor­cycle.

EW000082

w

Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla­tion pressure must be adjusted
according to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if
approved for this model), and vehi­cle speed.

Maximum load*
Cold tire pressure Front Rear

Up to 90 kg (1.25 kg/cm

90 kg load ~
Maximum load*

Off-road riding (1.25 kg/cm

* Load is the total weight of cargo, rider, passenger

and accessories.

(1.50 kg/cm

180 kg

178 kg (CH, A only)

125 kPa 150 kPa

1.25 bar) 1.50 bar)
150 kPa 175 kPa

1.50 bar) 1.75 bar)
125 kPa 150 kPa

1.25 bar) 1.50 bar)

2

, (1.50 kg/cm2,

2

, (1.75 kg/cm2,

2

, (1.50 kg/cm2,

6-18

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

EW000083

w

Proper loading of your motorcycle
is important for several character­istics of your motorcycle, such as
handling, braking, performance
and safety. Do not carry loosely
packed items that can shift.
Securely pack your heaviest items
close to the center of the motorcy­cle, and distribute the weight even­ly from side to side. Properly
adjust the suspension for your
load, and check the condition and
pressure of your tires. NEVER
OVERLOAD YOUR MOTORCYCLE.
Make sure the total weight of the
cargo, rider, passenger, and
accessories (fairing, saddlebags,
etc. if approved for this model)
does not exceed the maximum
load of the motorcycle. Operation
of an overloaded motorcycle could
cause tire damage, an accident, or
even injury.

1. Tread depth

2. Side wall

Tire inspection

Always check the tires before operat­ing the motorcycle. If center tread
depth reaches the limit as shown, if
the tire has a nail or glass fragments
in it, or if the side wall is cracked,
contact a Yamaha dealer immediate­ly and have the tire replaced.

EW000078

w

After extensive tests, the tires
mentioned below have been
approved by Yamaha Motor Co.,
Ltd. for this model. No guarantee
for handling characteristics can be
given if tire combinations other
than what is approved are used on
this motorcycle. The front and rear
tires should be of the same manu­facture and design.

FRONT

Manufacturer Size Type

BRIDGESTONE 2.75-21 45P TW25

REAR

Manufacturer Size Type

BRIDGESTONE 4.10-18 59P TW44

Minimum tire tread
depth (front and rear)

1.6 mm

1

2

3

4

5

6

7

8

9

6-19

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

These limits may be different by regu­lation from country to country. If so,

1

conform to the limits specified by the
regulations of your own country.

2

3

4

5

6

7

8

9

w

88

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 replace­ment should be left to a
Yamaha Service Technician.

88

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.

EAU00681

EAU00685

Wheels

To ensure maximum performance,
long service, and safe operation, note
the following:

8 Always 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, con­sult a Yamaha dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.

8 Tires 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.

8 Ride at moderate speeds after

changing a tire since the tire sur­face must first be broken in for it
to develop its optimal character­istics.

6-20

PERIODIC MAINTENANCE AND MINOR REPAIR

3

1 2

b

a

a

b

1

2

3

2

1

b

a

1

2

3

1. Locknut

2. Adjusting bolt

3. Free play

Clutch lever free play
adjustment

The 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 a to
increase free play or in direction
b to decrease free play.

3. Tighten the locknut at the clutch
lever.

If the specified free play cannot be
obtained, proceed with the following
steps.

EAU00694

1. Locknut

2. Adjusting nut

4. Loosen the locknut at the clutch
lever.

5. Turn the adjusting bolt at the
clutch lever in direction a to
loosen the cable.

6. Loosen the locknut at the
crankcase side.

7. Turn the adjusting nut at the
crankcase in direction a to
increase free play or in direction
b to decrease free play.

8. Tighten the locknut at the
crankcase and the clutch lever.

6-21

1. Locknut

2. Adjusting bolt

3. Free play

EAU00696

Front brake lever free play
adjustment

The free play at the front brake lever
should be 2 ~ 5 mm.

1. Loosen the locknut.

2. Turn the adjusting bolt in direc­tion a to increase free play or in
direction b to decrease free
play.

3. After adjusting, tighten the lock­nut.

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

a

1

w

88

1

2

88

3

4

5

6

7

8

9

EW000099

Check the brake lever free
play. Be sure the brake is
working properly.
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 deal­er inspect and bleed the sys­tem if necessary.

1. Footrest
a. Pedal height

EAU00712

Rear brake pedal height
adjustment

The 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.

EW000109

w

A soft or spongy feeling in the
brake pedal 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 dealer
inspect and bleed the system if
necessary.

6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

b

a

1

2

1

1

1. Brake light switch

2. Adjusting nut

EAU00713

Brake light switch
adjustment

The rear brake light switch is activat­ed 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 earli­er.
Turn the adjusting nut in direction b
to make the brake light come on
later.

FRONT

1. Wear limit: 0.8 mm

EAU00717

Checking the front and rear
brake pads

Check the brake pads for damage
and wear. If the thickness is less than
the specified value, have a Yamaha
dealer replace the pads.

6-23

REAR

1. Wear limit: 0.8 mm

1

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

FRONT

1

2

3

1. Minimum level mark

4

Inspecting the brake fluid
level

5

Insufficient brake fluid may let air
enter the brake system, possibly

6

causing the brakes to become inef­fective.

7

Before riding, check that the brake
fluid is above the minimum level and

8

fill when necessary.
Observe these precautions:

9

8 When checking the fluid level,

make sure the top of the master
cylinder is level by turning the
handlebars.

EAU00732

REAR

1

1. Minimum level mark

8 Use only the designated quality

brake fluid. Otherwise, the rub­ber seals may deteriorate, caus­ing leakage and poor brake per­formance.

Recommended brake fluid:

DOT 4

NOTE:

If DOT 4 is not available, DOT 3 can
be used.

8 Refill with the same type of brake

fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.

8 Be 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.

8 Brake fluid may deteriorate paint-

ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.

8 Have a Yamaha dealer check

the cause if the brake fluid level
goes down.

6-24

PERIODIC MAINTENANCE AND MINOR REPAIR

a

EAU00742

Brake fluid replacement

The brake fluid should be replaced
only by trained Yamaha service per­sonnel. Have the Yamaha dealer
replace the following components
during periodic maintenance or when
they are damaged or leaking:

8 oil seals (every two years)
8 brake hoses (every four years)

a. Chain slack

EAU00744*

Drive chain slack check

NOTE:

Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while it’s in this tightest position.

To check the chain slack the motor­cycle must be held straight up with
both wheels on the ground and with­out rider. Check the slack at the posi­tion shown in the illustration. Normal
slack is approximately 25 ~ 40 mm. If
the slack exceeds 40 mm, adjust it.

1

2

3

4

5

6

7

8

9

6-25

PERIODIC MAINTENANCE AND MINOR REPAIR

a

b

2

1

1

2

3

1. Wheel axle nut

4

2. Chain adjusting plate

Drive chain slack adjustment

5

1. Loosen the wheel axle nut.

2. To tighten the chain, turn the

6

chain adjusting plates in direction
a. To loosen the chain, turn the

7

chain adjusting plates in direction
b and push the wheel forward.

8

Turn each chain adjusting plate
to exactly the same position to

9

maintain correct axle alignment.

EAU01533*

EC000096

cC

Too 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.

Tightening torque:

Wheel axle nut:

90 Nm (9.0 m0kg)

EAU03006

Drive chain lubrication

The 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, high­pressure 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.

6-26

PERIODIC MAINTENANCE AND MINOR REPAIR

EC000097

cC

Be sure to oil the chain after wash­ing the motorcycle or riding in the
rain.

EAU02962

Cable inspection and
lubrication

EW000112

w

Damage to the outer housing of
cables may lead to internal rusting
and interfere with the cable move­ment. Replace damaged cables as
soon as possible to prevent unsafe
conditions.

Lubricate the cables and cable ends.
If a cable does not operate smoothly,
ask a Yamaha dealer to replace it.

Recommended lubricant:

Engine oil

EAU00773

Throttle cable and grip
lubrication

The throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the grip
must be removed to get at the end of
the throttle cable. After removing the
screws, hold the end of the cable up
in the air and put in several drops of
lubricant. With the throttle grip disas­sembled, coat the metal surface of
the grip assembly with a suitable all­purpose grease.

1

2

3

4

5

6

7

8

9

6-27

PERIODIC MAINTENANCE AND MINOR REPAIR

Autolube pump adjustment

The autolube pump is a vital part of

1

the engine and requires very sophisti­cated adjustment.
Adjusting should be left to a Yamaha

2

dealer who has the professional
knowledge and experience to do so.

3

4

5

6

7

8

9

EAU00774

Brake and shift pedal
lubrication

Lubricate the pivoting parts.

Recommended lubricant:

Engine oil

EAU02984

EAU02985

Brake and clutch lever
lubrication

Lubricate the pivoting parts.

Recommended lubricant:

Engine oil

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU02986

Sidestand lubrication

Lubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.

Recommended lubricant:

Engine oil

EW000113

w

If the sidestand does not move
smoothly, consult a Yamaha deal­er.

EAU02939

Front fork inspection

Visual check

EW000115

w

Securely support the motorcycle
so there is no danger of it falling
over.

Check for scratches or damage on
the inner tube and excessive oil leak­age 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 handle­bars several times and check if
the fork rebounds smoothly.

EC000098

cC

If any damage or unsmooth move­ment is found with the front fork,
consult a Yamaha dealer.

1

2

3

4

5

6

7

8

9

6-29

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

4

Steering inspection

Periodically inspect the condition of

5

the steering. Worn out or loose steer­ing bearings may be dangerous.

6

Place a stand under the engine to
raise the front wheel off the ground.

7

Hold the lower end of the front forks
and try to move them forward and

8

backward. If any free play can be felt,
ask a Yamaha dealer to inspect and

9

adjust the steering. Inspection is eas­ier if the front wheel is removed.

EAU00794

EW000115

w

Securely support the motorcycle
so there is no danger of it falling
over.

EAU01144

Wheel bearings

If 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.

6-30

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1. Battery

2. Battery breather hose

EAU01071

Battery

Check the level of the battery elec­trolyte and make sure that the termi­nals are tight.
Fill with distilled water if the elec­trolyte level is low.

EC000099

cC

When inspecting the battery, be
sure the breather hose is routed
correctly. If the breather hose is
positioned in such a way as to
cause battery electrolyte or gas to
exit onto the frame, structural and
cosmetic damage to the motorcy­cle can occur.

EW000116

w

Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes
or clothing.
ANTIDOTE:

88

EXTERNAL: Flush with water.

88

INTERNAL: Drink large quanti­ties of water or milk. Follow
with milk of magnesia, beaten
egg, or vegetable oil. Call a
physician immediately.

88

EYES: Flush with water for 15
minutes and get prompt med­ical attention.

Batteries produce explosive
gases. Keep sparks, flame, ciga­rettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHIL­DREN.

1

2

3

4

5

6

7

8

9

6-31

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1

2

3

1. Maximum level mark

4

2. Minimum level mark

Replenishing the battery fluid

5

A poorly maintained battery will cor­rode and discharge quickly. The bat­tery fluid should be checked at least

6

once a month. The level should be
between the minimum level and max-

7

imum level marks. Use only distilled
water if refilling is necessary.

8

9

EC000100

cC

Normal tap water contains miner­als which are harmful to a battery;
therefore, refill only with distilled
water.

EW000117

w

Take care not to spill battery fluid
on the chain.
Battery fluid may weaken the chain
causing shorter chain life and pos­sibly result in an accident.

Battery storage

8 When the motorcycle will not be

used for a month or longer,
remove the battery, fully charge
it and store it in a cool, dry place.
Completely recharge the battery
before reinstallation.

8 If the battery will be stored for

longer than two months, check
the specific gravity of the fluid at
least once a month and fully
recharge the battery when it is
too low.

8 Always make sure the connec-

tions are correct when putting
the battery back in the motorcy­cle. Make sure the breather hose
is properly connected and is not
damaged or obstructed.

6-32

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1. Fuse

EAU00804

Fuse replacement

If the fuse is blown, turn off the main
switch and the switch of the circuit in
question. Install a new fuse of speci­fied amperage. Turn on the switches
and see if the electrical device oper­ates. If the fuse immediately blows
again, consult a Yamaha dealer.

EC000103

cC

Do not use fuses of higher amper­age rating than those recommend­ed. Substitution of a fuse of
improper rating can cause exten­sive electrical system damage and
possibly a fire.

Specified fuse:

10 A

1

1. Bolt (×2)

EAU01158

Headlight bulb replacement

If the headlight bulb burns out,
replace the bulb as follows:

1. Remove cowling A. (See page
6-6 ~ 6-7 for removal and instal­lation procedures.)

2. Remove the headlight unit by
removing the bolts.

1

2

3

4

5

6

7

8

9

6-33

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1

1

2

3

6. Install the bulb holder cover, con­nector and headlight unit.

7. Install the cowling.

8. If the headlight beam adjustment
is necessary, ask a Yamaha
dealer to make that adjustment.

1. Bulb holder cover

4

2. Connector

3. Remove the headlight connector

5

and the bulb holder cover.

6

7

8

9

1. Bulb holder

4. Turn the bulb holder counter­clockwise to remove it and then
remove the defective bulb.

EW000119

w

Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.

5. Put a new bulb into position and
secure it in place with the bulb
holder.

6-34

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

EC000108

1

cC

Do not over-tighten the screws as
the lens may break.

1

1. Screw

2. Lens

3. Bulb

EAU01095

Turn signal light bulb
replacement

1. 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.

3

2

1. Screw (×2)

2. Lens

3. Bulb

EAU01623*

Tail/brake light bulb
replacement

1. 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.

6-35

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

2

Supporting the motorcycle

Since the Yamaha DT125R has no

1

centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-

2

nance requiring the motorcycle to
stand upright. Check that the motor-

3

cycle is in a stable and level position
before starting any maintenance. A

4

strong wooden box can be placed
under the engine for added stability.

5

Front wheel service

To stabilize the rear of the motorcy-

6

cle, either use a motorcycle stand or
place a motorcycle jack under the

7

frame in front of the rear wheel to
prevent it from moving from side to

8

side. Then use a motorcycle stand to
elevate the front wheel off of the

9

ground.

EAU01579

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.

1. Disc cover

2. Screw (×2)

EAU00898

Front wheel removal

EW000122

w

88

It is advisable to have a
Yamaha dealer service the
wheel.

88

Securely support the motorcy­cle so there is no danger of it
falling over.

1. Remove the disc cover.

2. Remove the speedometer cable
from the front wheel side.

6-36

PERIODIC MAINTENANCE AND MINOR REPAIR

3

2

1

1

2

3

1. Speedometer cable

2. Axle holder nut (×4)

3. Wheel axle

3. Elevate the front wheel by plac­ing 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 installation

1. 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.

6-37

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 speci­fied torque.

Tightening torque:

Wheel axle:

58 Nm (5.8 m0kg)

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

2

1

1

2

3

1. Gap

4

1

6. Tighten the axle holder nuts to

5

the specified tightening torque.
Tighten the upper nuts first and
then lower ones. When tightened

6

in this sequence, there should be
a gap formed at the bottom of

7

8

the axle holder.

Tightening torque:

Axle holder nut:

10 Nm (1.0 m0kg)

9

7. After tightening the holder nuts,
push down on the handlebars
several times and check if the
fork rebounds smoothly.

1. Swingarm end bolt (×2)

EAU03105

Rear wheel removal

EW000122

w

88

It is advisable to have a
Yamaha dealer service the
wheel.

88

Securely support the motorcy­cle 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.

6-38

1. Axle nut

2. Chain adjusting plate

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:

8 Do not depress the brake pedal

when the disc and caliper are
separated.

8 You do not have to disassemble

the chain in order to remove or
install the rear wheel.

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU03106

Rear wheel installation

1. Install the rear wheel and chain.
Guide the brake disc between
the brake pads. Make sure there
is enough gap between the
brake pads before inserting the
brake disc.

2. Make sure the wheel axle is
inserted from the left side and
that the chain adjusting plates
are installed with the punched
side outward.

3. Install the swingarm end bolts.

4. Adjust the drive chain.

5. Tighten the following parts to the
specified torques.

Tightening torque:

Axle nut:

90 Nm (9.0 m0kg)

Swingarm end bolt:

3 Nm (0.3 m0kg)

EAU01008

Troubleshooting

Although Yamaha motorcycles
receive a rigid inspection before ship­ment from the factory, trouble may
occur during operation.
Any problem in the fuel, compres­sion, or ignition systems can cause
poor starting and loss of power. The
troubleshooting chart describes a
quick, easy procedure for making
checks.
If your motorcycle requires any
repair, bring it to a Yamaha dealer.
The skilled technicians at a Yamaha
dealership have the tools, experi­ence, and know-how to properly ser­vice your motorcycle. Use only gen­uine Yamaha parts on your
motorcycle. Imitation parts may look
like Yamaha parts, but they are often
inferior. Consequently, they have a
shorter service life and can lead to
expensive repair bills.

1

2

3

4

5

6

7

8

9

6-39

PERIODIC MAINTENANCE AND MINOR REPAIR

Check if there is fuel

1. Fuel

Enough fuel.

No fuel.

Go to compression check.

Supply fuel.

Engine doesn’t start, go to compression check.

Use kick starter.

2. Compression

There is compression.

No compression.

Go to ignition check.

Ask a Yamaha dealer to

Remove spark plug

3. Ignition

Wet.

Dry.

Wipe clean with dry cloth and correct

Ask a Yamaha dealer to inspect.

Engine doesn’t start, ask a Yamaha

Open throttle half-way and start

in the fuel tank.

and check electrodes.

spark gap or replace spark plug. the engine.

dealer to inspect.

inspect.

Troubleshooting charts

w

1

Never check the fuel system while smoking or in the vicinity of an open flame.

2

3

4

5

6

7

8

EAU03108

EW000125

9

6-40

PERIODIC MAINTENANCE AND MINOR REPAIR

Wait until the Check the coolant level in the

Level is OK.

Level is low, check the

No

Leakage.

Ask a Yamaha dealer to inspect

Add coolant. (See NOTE.)

Restart the engine. If the engine overheats again, ask a

engine has cooled.

reservoir tank and/or radiator.

cooling system for leakage.

Yamaha dealer to inspect and repair the cooling system.

leakage.

and repair the cooling system.

4. Engine overheating

EW000070

w

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the
engine has cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over
the radiator cap and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual
pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclock­wise and remove it.

1

2

3

4

5

6

7

8

NOTE:

If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the rec­ommended coolant as soon as possible.

6-41

9

MOTORCYCLE CARE AND STORAGE

EAU01518

Care

The exposure of its technology
makes a motorcycle charming but

1

also vulnerable. Although high-quality
components are used, they are not

2

all rust-resistant. While a rusty
exhaust pipe may remain unnoticed

3

on a car, it does look unattractive on
a motorcycle. Frequent and proper
care, however, will keep your motor-

4

cycle looking good, extend its life and
maintain its performance. Moreover,

5

the warranty states that the vehicle
must be properly taken care of. For

6

all these reasons, it is recommended
that you observe the following clean-

7

ing and storing precautions.

8

9

Before cleaning

1. Cover up the muffler outlet with a
plastic bag.

2. Make sure that all caps and cov­ers as well as all electrical cou­plers and connectors, including
the spark plug cap, are tightly
installed.

3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such
products onto seals, gaskets,
sprockets, the drive chain and
wheel axles. Always rinse the dirt
and degreaser off with water.

Cleaning

After normal use
Remove dirt with warm water, a neu­tral detergent and a soft clean
sponge, then rinse with plenty of
clean water. Use a tooth or bottle
brush for hard-to-reach parts.
Tougher dirt and insects will come off
more easily if the area is covered with
a wet cloth for a few minutes before
cleaning.

ECA00010

cC

88

Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If you do use
such products for hard-to­remove dirt, do not leave it on
any longer than instructed,
then thoroughly rinse it off
with water, immediately dry
the area and apply a corrosion
protection spray.

7-1

MOTORCYCLE CARE AND STORAGE

88

Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.

88

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra­sive cleaning products, sol­vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec­trolyte.

88

Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep­age and deterioration in the
following areas: seals (of
wheel bearings, swingarm
bearings, forks and brakes),
electric components (cou­plers, connectors, instru­ments, switches and lights),
breather hoses and vents.

88

For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas­tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure they
do not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com­pound after washing.

After riding in the rain, near the sea
or on salt-sprayed roads
Since sea salt or salt sprayed on the
roads in the winter are extremely cor­rosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads. (Salt sprayed
in the winter may remain on the roads
well into spring.)

1. Clean your motorcycle with cold
water and soap after the engine
has cooled down.

ECA00012

cC

Do not use warm water since it
increases the corrosive action of
the salt.

2. Be sure to apply a corrosion pro­tection spray on all (even
chrome- and nickel-plated) metal
surfaces to prevent corrosion.

1

2

3

4

5

6

7

8

9

7-2

MOTORCYCLE CARE AND STORAGE

After cleaning

1. Dry the motorcycle with a
chamois or an absorbing cloth.

1

2. Immediately dry the drive chain
and lubricate it to prevent it from

2

rusting.

3. Use a chrome polish to shine

3

chrome, aluminum and stainless­steel parts, including the exhaust

4

system. (Even the thermally
induced discoloring of stainless­steel exhaust systems can be

5

removed through polishing.)

4. To prevent corrosion, it is recom-

6

mended to apply a corrosion pro­tection spray on all (even

7

chrome- and nickel-plated) metal
surfaces.

5. Use spray oil as a universal

8

cleaner to remove any remaining
dirt.

9

6. Touch up minor paint damage
caused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry complete­ly before storing it or covering it.

EWA00001

w

Make sure that there is no oil or
wax on the brakes and tires. If nec­essary, clean the brake discs and
linings with a regular brake disc
cleaner or acetone, and wash the
tires with warm water and mild
soap. Then, carefully test the
motorcycle for its braking perfor­mance and cornering behavior.

ECA00013

cC

88

Apply spray oil and wax spar­ingly and wipe off any excess.

88

Never apply oil or wax on rub­ber and plastic parts, but treat
them with a suitable care prod­uct.

88

Avoid using abrasive polish­ing compounds as they wear
away the paint.

NOTE:

Consult a Yamaha dealer for advice
on what products to use.

7-3

MOTORCYCLE CARE AND STORAGE

Storage

Short-term

Always store your motorcycle in a
cool, dry place and, if necessary, pro­tect it against dust with a porous
cover.

ECA00014

cC

88

Storing the motorcycle in a
poorly ventilated room or cov­ering it with a tarp while it is
still wet will allow water and
humidity to seep in and cause
rust.

88

To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi­cals are stored.

Long-term

Before storing your motorcycle for
several months:

1. Follow all the instructions in the
“Care” section of this chapter.

2. Drain the carburetor float cham­ber by loosening the drain bolt;
this will prevent fuel deposits
from building up. Pour the
drained fuel into the fuel tank.

3. Only for motorcycles equipped
with a fuel cock which has an
“OFF” position: Turn the fuel
cock to “OFF”.

4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.

5. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.

a. Remove the spark plug cap and

spark plug.

b. Pour a teaspoonful of engine oil

into the spark plug bore.

c. Install the spark plug cap onto

the spark plug and place the
spark plug on the cylinder head
so that the electrodes are
grounded. (This will limit spark­ing during the next step.)

d. Turn the engine over several

times with the starter. (This will
coat the cylinder wall with oil.)

e. Remove the spark plug cap from

the spark plug, install the spark
plug and then the spark plug
cap.

EWA00003

w

When turning the engine over, be
sure to ground the spark plug elec­trodes to prevent damage or injury
from sparking.

1

2

3

4

5

6

7

8

9

7-4

MOTORCYCLE CARE AND STORAGE

6. Lubricate all control cables and
the pivoting points of all levers

1

2

3

4

5

6

7

8

9

and pedals as well as of the
sidestand/centerstand.

7. Check and, if necessary, correct
the tire air pressure, then raise
the motorcycle so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to pre­vent the tires from becoming
degraded in one spot.

8. Cover up the muffler outlet with a
plastic bag to prevent moisture
from entering.

9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge it once a
month. Do not store the battery
in an excessively cold or warm
place (less than 0 °C or more
than 30 °C). For more informa­tion, see “Battery storage” in the
chapter “PERIODIC MAINTE­NANCE AND MINOR
REPAIRS”.

NOTE:

Make any necessary repairs before
storing the motorcycle.

7-5

EAU01038

Specifications

SPECIFICATIONS

Model DT125R
Dimensions

Overall length 2,170 mm

Overall width 830 mm
Overall height 1,255 mm
Seat height 885 mm
Wheel base 1,415 mm
Ground clearance 315 mm
Minimum turning radius 2,100 mm

Basic weight (with oil and
full fuel tank) 127 kg

Engine

Engine type Liquid-cooled 2-stroke
Cylinder arrangement Forward-inclined single

Displacement 124 cm
Bore × Stroke 56.0 × 50.7 mm

2,235 mm (N, S, SF, CH, A only)

129 kg (CH, A only)

cylinder

3

Compression ratio 6.7:1
Starting system Kick starter
Lubrication system Separate lubrication

(Yamaha autolube)

Engine oil (2-cycle)

Type 2 stroke engine oil
Capacity

Total amount 1.2 L

Transmission oil

Type SAE 10W30 type SE motor oil
Capacity

Periodic oil change 0.75 L
Total amount 0.8 L

Radiator capacity

(Including all routes) 0.92 L

Air filter Wet type element
Fuel

Type Regular unleaded gasoline
Fuel tank capacity 10 L
Reserve amount 1.8 L

1

2

3

4

5

6

7

8

9

8-1

SPECIFICATIONS

1

2

3

4

5

6

7

8

9

Carburetor

Type × quantity TM28SS × 1
Manufacturer MIKUNI

Spark plug

Manufacturer / type NGK / BR9ES

NGK / BR8ES (CH, A only)

Spark plug gap 0.7 ~ 0.8 mm

Clutch type Wet, multiple-disc
Transmission

Primary 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 ratio 1st 2.833

2nd 1.875
3rd 1.412
4th 1.143
5th 0.957
6th 0.818

Chassis

Frame type Semi double cradle
Caster angle 27°30’
Trail 113 mm

Tire

Type With tube
Front

Size 2.75-21 45P
Manufacturer/ BRIDGESTONE / TW25

model

Rear

Size 4.10-18 59P
Manufacturer/ BRIDGESTONE / TW44

model

Maximum load* 180 kg

178 kg (CH, A only)
Air pressure (cold tire)
up to 90 kg load*

Front 125 kPa (1.25 kg/cm2, 1.25 bar)
Rear 150 kPa (1.50 kg/cm2, 1.50 bar)

8-2

SPECIFICATIONS

90 kg load ~ maximum
load*

Front 150 kPa (1.50 kg/cm2, 1.50 bar)
Rear 175 kPa (1.75 kg/cm2, 1.75 bar)

Off-road riding

Front 125 kPa (1.25 kg/cm2, 1.25 bar)
Rear 150 kPa (1.50 kg/cm2, 1.50 bar)

* Load is total weight of cargo, rider, passenger and accessories.

Wheels

Front

Type Spoke wheel
Size 1.60 × 21

Rear

Type Spoke wheel
Size 1.85 × 18

Brakes

Front

Type Single disc brake
Operation Right hand operation
Fluid DOT 3 or DOT 4

Rear

Type Single disc brake
Operation Right foot operation
Fluid DOT 3 or DOT 4

Suspension

Front Telescopic fork
Rear Swingarm (link suspension)

Shock absorber

Front Coil spring/oil damper
Rear Coil-gas spring/oil damper

Wheel travel

Front 270 mm
Rear 260 mm

Electrical

Ignition system C.D.I.
Charging system

Type C.D.I. magneto

1

2

3

4

5

6

7

8

9

8-3

SPECIFICATIONS

1

2

3

4

5

6

7

8

9

Battery

Type GM3-3B
Voltage, capacity 12 V, 3 AH

Headlight type Conventional incandescent bulb
Bulb voltage, wattage × quantity

Headlight 12 V, 45/40 W × 1
Tail / Brake light 12 V, 5/21 W × 1
Front flasher light 12 V, 21 W × 2
Rear flasher light 12 V, 21 W × 2
Auxiliary light 12 V, 4 W × 1

12 V, 3.4 W × 1 (GB only)
Meter light 12 V, 3.4 W × 2
Neutral indicator light 12 V, 3.4 W × 1
High beam indicator light 12 V, 3.4 W × 1
Oil level indicator light 12 V, 3.4 W × 1
Turn indicator light 12 V, 3.4 W × 1

Fuse

Main 10 A

8-4

EAU01064

HOW TO USE THE CONVERSION TABLE

All specification data in this manual are listed in SI and
METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMPERIAL

** mm × 0.03937 = ** in

2 mm × 0.03937 = 0.08 in

SPECIFICATIONS

CONVERSION TABLE

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

m• kg 7.233 ft• lb

Torque

Weight
Speed km/hr 0.6214 mph

Distance m 1.094 yd

Volume/ cc (cm3) 0.06102 cu •in
Capacity lt (liter) 0.8799 qt (IMP liq.)

Misc. kg/cm2 14.2234 psi (lb/in2)

m• kg 86.794 in•lb
cm• kg 0.0723 ft•lb
cm• kg 0.8679 in•lb

kg 2.205 lb
g 0.03527 oz

km 0.6214 mi
m 3.281 ft

cm 0.3937 in
mm 0.03937 in

cc (cm3) 0.03527 oz (IMP liq.)

lt (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in

Centigrade(°C)

9/5 + 32

Fahrenheit(°F)

1

2

3

4

5

6

7

8

8-5

9

CONSUMER INFORMATION

1

EAU02944

Identification number
records

1

Record the key identification number,
vehicle identification number and
model label information in the spaces

2

provided for assistance when order­ing spare parts from a Yamaha deal-

3

er or for reference in case the vehicle
is stolen.

4

1. KEY IDENTIFICATION

5

6

7

8

9

NUMBER:

2. VEHICLE IDENTIFICATION
NUMBER:

3. MODEL LABEL INFORMATION:

1
6

1. Key identification number 1. Vehicle identification number

EAU01042

Key identification number

The key identification number is
stamped on the key.
Record this number in the space pro­vided and use it for reference when
obtaining a new key.

Vehicle identification
number

The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro­vided.

NOTE:

The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor­cycle with the licensing authority in
your state.

EAU01039

1

EAU01043

9-1

CONSUMER INFORMATION

1

1

2

3

1. Model label

EAU01049

Model label

The model label is affixed to the loca­tion shown in the figure. Record the
information on this label in the space
provided. This information will be
needed to order spare parts from
your Yamaha dealer.

4

5

6

7

8

9

9-2

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN
2000·12–0.4×1(E)

!