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DT125 3BN0-ME5 repair manual

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Page 1: DT125 3BN0-ME5 repair manual
Page 2: DT125 3BN0-ME5 repair manual
Page 3: DT125 3BN0-ME5 repair manual

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the DT125R’99. For complete information on service procedures, it is necessary to use this Supplementary ServiceManual together with following manual:

DT125R SERVICE MANUAL: 3BN-ME1DT125R/DT125R ELECTRIC SUPPLEMENTARY SERVICE MANUAL: 3MB-AE1

DT125R/DT125RE SUPPLEMENTARY SERVICE MANUAL: 3BN-AE2DT125R/DT125RE SUPPLEMENTARY SERVICE MANUAL: 3BN-AE3

DT125RSUPPLEMENTARYSERVICE MANUAL

1998 by Yamaha Motor Co., Ltd.1st Edition, October 1998

All rights reserved. Any reprinting orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Page 4: DT125 3BN0-ME5 repair manual

CAUTION:

NOTICEThis manual was written by Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and qualifiedmechanics. It is not possible to put an entire mechanic’s education into one manual, so persons using thisbook to perform maintenance and repairs on Yamaha motorcycles should have a basic understanding ofthe mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowl-edge, attempted repairs or service to the motorcycle may render it unfit to use and/or unsafe.Yamaha Motor Company Ltd. is continually striving to improve all models manufactured by Yamaha. Modifi-cations and significant changes in specifications or procedures will be forwarded to all Authorized Yamahadealers and will, where applicable, appear in future editions of this manual.

PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETYIS INVOLVED!

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

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

NOTE: A NOTE provides key information to make procedures easier or cleaer.

Page 5: DT125 3BN0-ME5 repair manual

HOW TO USE THIS MANUAL

CONSTRACTION OF THIS MANUALThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1 : This is a chapter with its symbol on the upper right of each page.

2nd title 2 : This title appears on the upper of each page on the left of the chapter symbol. (Forthe chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title 3 : This is a final title.

MANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The information hasbeen compiled to provide the mechanic with an easy to read, handy reference that contains comprehensiveexplanations of all disassembly, repair assembly, and inspections.A set of particularly important procedure 4 is placed between a line of asterisks “ ” with each procedurepreceded by “”.

IMPORTANT FEATURESData and a special tool are framed in a box preceded by a relevant symbol 5 .An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment

mark 7 , the others being indicated by an alphabetical letter in a box 8 .A condition of a faulty component will precede an arrow symbol and the course of action required the

symbol 9 .

EXPLODED DIAGRAMEach chapter provides exploded diagrams before each disassembly section for ease in identifying correctdisassembly and assembly procedures.

Page 6: DT125 3BN0-ME5 repair manual

ILLUSTRATED SYMBOLS(Refer to the illustration)

Illustrated symbols 1 to 9 are designed asthumb tabs to indicate the chapter’s number andcontent.

1 General information

2 Specifications

3 Periodic inspection and adjustment4 Engine

5 Cooling system6 Carburetion

7 Chassis8 Electrical

9 Troubleshooting

Illustrated symbols 10 to 16 are used to identifythe specifications appearing in the text.

10 Filling fluid

11 Lubricant

12 Special tool

13 Tightening

14 Wear limit, clearance

15 Engine speed

16 Ω, V, A

Illustrated symbols 17 to 23 in the exploded dia-gram indicate grade of lubricant and location of lu-brication point.

17 Apply engine oil

18 Apply gear oil

19 Apply molybdenum disulfide oil

20 Apply wheel bearing grease

21 Apply lightweight lithium-soap base grease

22 Apply molybdenum disulfide grease

23 Apply locking agent (LOCTITE )

Page 7: DT125 3BN0-ME5 repair manual

CONTENTS

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS

GENERAL SPECIFICATIONS E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS E-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE E-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL E-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION E-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE AND LUBRICATION E-7. . . . . . . . . . . . . . . . . . . . .

ENGINE E-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUTOLUBE PUMP AIR BLEEDING E-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

DT125R CIRCUIT DIAGRAM E-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COLOR CODE E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DT125R ’99 WIRING DIAGRAM

Page 8: DT125 3BN0-ME5 repair manual
Page 9: DT125 3BN0-ME5 repair manual

–1–

MOTORCYCLE IDENTIFICATIONGENINFO

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATIONFRAME SERIAL NUMBERThe frame serial number 1 is stamped into theright side of the steering head pipe.

MODEL LABELThe model label 1 is affixed to the frame.This information will be needed to order spareparts.

Page 10: DT125 3BN0-ME5 repair manual

–2–

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Model DT125R

Model Code Number 3RMF (F)3RMD (G)3RME(GB) (N) (S) (SF) (G) (B)

(SP) (P) (I) (GR)4DJ9 (H) (A)

DimensionsOverall length 2170 mm (3RMD) (3RME) (3RMF)

2235 mm (4DJ9)

Basic Weight:With Oil and Full Fuel Tank 127 kg (3RMD) (3RME) (3RMF)

129 kg (4DJ9)

Engine:Engine TypeInduction SystemCylinder ArrangementDisplacementBore StrokeCompression Ratio

Starting SystemLubrication System

Liquid cooled 2-stroke, gasolineReed valveSingle cylinder, Forward inclined124 cm3

56.0 50.7 mm6.7 : 1 (4DJ9)6.5 : 1 (3RMD) (3RME) (3RMF)Kick starterSeparate lubrication (Yamaha Autolube)

Carburetor:Type/QuantityManufacturer

TM28SS/1 pc.MIKUNI

Spark Plug:Type/Quantity

ManufacturerPlug Gap

BR8ES/1 pc. (4DJ9)BR9ES/1 pc. (3RMD) (3RME) (3RMF)NGK0.7 0.8 mm

Page 11: DT125 3BN0-ME5 repair manual

–3–

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONSENGINE

Carburetor:I.D. MarkMain Jet (M.J.)Air Jet (A.J.)Jet Needle-Position (J.N.)Needle Jet (N.J.)Cutaway (C.A.)Pilot Outlet (P.O.)Pilot Jet (P.J.)Air Screw (A.S.)Bypass 1 (B.P.1)Valve Seat Size (V.S.)Starter Jet (G.S.)Power Jet (PW.J.)Fuel Level (F.L.)Float Height (F.H.)Idling Speed

3RM02 (3RMD) (3RME) (3RMF) 4DJ02 (4DJ9)#210 (4DJ9) #240 (3RMD) (3RME) (3RMF)ø0.75J25-4 (3RMD-E-F) 5J25-3 (4DJ9)Q-22.50.6#17.5 (4DJ9) #25 (3RMD-E-F)1-1/4 (3RMD-E-F) 1-5/8 (4DJ9)ø1.6ø2.8#40#60 (4DJ9) #95 (3RMD-E-F)–0.5 +1.5 mm15.5 16.5 mm1,300 1,400 r/min

Lubrication System:Autolube Pump:

Color CodeMinimum StrokeMaximum StrokeMinimum OutputMaximum Output

Green (3RME-D) (4DJ9)0.20 0.241.35 1.49

0.38 0.46 cm3/200 stroke2.59 2.86 cm3/200 stroke

Red (3RMF)0.20 0.242.72 2.86

0.38 0.46 cm3/200 stroke5.23 5.5 cm3/200 stroke

Pulley Adjusting Mark Auto adjuster

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MAINTENANCE SPECIFICATIONS SPEC

ELECTRICAL

Model DT125R

CDI:Magneto Model/ManufacturerC.B.I. Unit Model/Manufacturer

Source Coil Resistance

F3RM/YAMAHA3RM-10/YAMAHA (3RMD)3RM-20/YAMAHA (3RME)3RM-30/YAMAHA (4DJ9) (3RMF)688 1,032 Ω at 20C(Blank/Red – Green/White)

Spark Plug Cap:TypeResistance

Resin type5 kΩ

Charging System: C.D.I. magneto

C.D.I. magneto:Model/Manufacturer F3RM/YAMAHA

Rectifier/RegulatorTypeModel/manufacturerCapacity

Semi-conductor-Short circuit typeSH671-12/SHINDENGEN8A

Flasher Relay:TypeModel/Manufacturer

Full transistor typeFE246BH/DENSO

Thermo Unit: 2YK/NIPPON SEKIModel/Manufacturer

Page 13: DT125 3BN0-ME5 repair manual

–5–

INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION

INSPADJ

PERIODIC INSPECTION AND ADJUSTMENTINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjustments.These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and alonger service life. The need for costly overhaul work will be greatly reduced. This information applies tovehicles already in service as well as new vehicles that are being prepared for sale. All serviced techniciansshould be familiar with this entire chapter.

PERIODIC MAINTENANCE AND LUBRICATIONEVERY

No. ITEM CHECKS AND MAINTENANCE JOBSInitial

(1,000 km)

6,000 kmor

6 months(Whichevercomes first)

12,000 kmor

12 months(Whichevercomes first)

1 * Fuel line Check fuel hoses for cracks or damage. Replace if necessary.

2 Spark plug Check condition. Clean, regap or replace if necessary.

3 Air filter Clean or replace if necessary.

4 * Battery Check electrolyte level and specific gravity. Correct or recharge if necessary. Make sure that the breather hose is properly routed.

5 Clutch Check operation. Adjust or replace cable.

6 * Front brake

Check operation, fluid level and vehicle for fluidleakage. (See NOTE)

Correct accordingly. Replace brake pads if necessary.

7 * Rear brake

Check operation, fluid level and vehicle for fluidleakage. (See NOTE)

Correct accordingly. Replace brake pads if necessary.

8 * Wheels Check balance, runout, spoke tightness and for

damage. Tighten spokes and rebalance, replace if necessary.

9 * Tires

Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

10 * Wheel bearings Check bearing for looseness or damage. Replace if necessary.

11 * Swingarm Check swingarm pivoting point for play. Correct if necessary.

12 Drive chain

Check chain slack. Adjust if necessary. Make sure that the rear wheel is

properly aligned Clean and lubricate.

Every 500 km and after washingthe motorcycle or riding in the rain

13 * Steering bearings

Check bearing play and steering for roughness. Correct accordingly. Lubricate with lithium soap base grease every 24,000

km or 24 months (whichever comes first).

14 * Chassis fasteners Make sure that all nuts, bolts and screws are properly

tightened. Tighten if necessary.

15 Sidestand Check operation. Lubricate and repair if necessary.

Page 14: DT125 3BN0-ME5 repair manual

–6–

PERIODIC MAINTENANCE AND LUBRICATIONINSPADJ

NOTE:

EVERY

No. ITEM CHECKS AND MAINTENANCE JOBSInitial

(1,000 km)

6,000 kmor

6 months(Whichevercomes first)

12,000 kmor

12 months(Whichevercomes first)

16 * Sidestand switch Check operation. Replace if necessary.

17 * Front fork Check operation and for oil leakage. Correct accordingly.

18 *Rear shock absorberassembly

Check operation and shock absorber for oil leakage. Replace shock absorber assembly if necessary.

19 *

Rear suspensionrelay arm andconnecting armpivoting points

Check operation. Correct if necessary.

20 * Carburetor Check engine idling speed and starter operation. Adjust if necessary.

21 * Autolube pump Check operation. Correct if necessary. Bleed if necessary.

22 Transmission oil

Check oil level and vehicle for oil leakage. Correct accordingly. Change oil at initial 1,000 km and thereafter every

24,000 km or 24 months (whichever comes first).

23 * Cooling system

Check coolant level and vehicle for coolant leakage. Correct if necessary. Change coolant every 24,000 km or 24 months

(whichever comes first).

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake systemWhen disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the

brake fluid level regularly and fill as required.Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.Replace the brake hoses every four years or if cracked or damaged.

Page 15: DT125 3BN0-ME5 repair manual

–7–

ENGINEINSPADJ

NOTE:

NOTE:

ENGINEAUTOLUBE PUMP AIR BLEEDING

The Autolube pump and delivery lines must bebled on the following occasions:Setting up a new motorcycle out of the create.Whenever the oil tank has run dry.Whenever any portion of the engine oil system is

disconnected.

1. Remove:Autolube pump cover

2. Fill:Oil tank 1

Yamaha Oil 2T or Air-Cooled2-Stroke Engine Oil

2 Oil tank filler cap

3. Air bleed:Pump case and/or oil pipe

Air bleeding steps:Remove the bleed screw 1 .Keep the oil running out until a bubbles disap-

pear.When air bubbles are expelled completely,

tighten the bleed screw.

Check the bleed screw gasket, and if dam-aged, replace with a new one.

Place a rag or oil pan under the autolubepump to catch oil.

Page 16: DT125 3BN0-ME5 repair manual

–8–

DT125R CIRCUIT DIAGRAM ELEC

ELECTRICALDT125R CIRCUIT DIAGRAM

Page 17: DT125 3BN0-ME5 repair manual

–9–

19 Turn indicator light20 Neutral relay21 Sidestand switch22 Oil level switch23 Rear brake switch24 Front brake switch25 Tail /brake light26 Flasher relay27 Horn28 Flasher light29 “Turn” switch30 “Horn” switch31 “Lights” (Dimmer) switch32 “Lights” switch33 Handlebar switches (left)34 Auxiliary light35 Headlight

1 CDI magneto2 Neutral switch3 Rectifier / regulator4 Fuse5 Battery6 Main switch7 “ENGINE STOP” switch8 Servomotor9 CDI unit10 Ignition coil11 Read switch12 Meter light13 Meter light14 Neutral indicator light15 Oil level indicator light16 High beam indicator light17 Engine temperature gauge18 Thermo unit

DT125R CIRCUIT DIAGRAM ELEC

COLOR CODE

B Black Ch Chocolate W/R White/Red

R Red Dg Dark green W/L White/Blue

O Orange Sb Sky blue Y/R Yellow/Red

L Blue Br Brown G/R Green/Red

P Pink L/Y Blue/Yellow G/Y Green/Yellow

Y Yellow B/Y Black/Yellow G/W Green/White

G Green B/W Black/White Br/W Brown/White

W White B/R Black/Red L/R Blue/Red

Page 18: DT125 3BN0-ME5 repair manual

–10–

IGNITION SYSTEM ELEC

Disconnect the sidestand switch leads fromthe wireharness.

Connect the Pocket Tester (Ω 1) to the side-stand switch.

1. Sidestand switch

GOODCONDITION

Replace “Sidestand” switch.

BAD CONDITION

Tester (+) Lead Black TerminalTester (–) Lead Black Terminal2

Move the sidestand to up position and downposition.

Check the sidestand switch for continuity.

Sidestandposition

Goodcondition

Bad condition

Up

Down

: Continuity : No continuity

1

IGNITION SYSTEMTROUBLESHOOTINGCheck:1. Sidestand switch2. Neutral switch3. Wiring connection (Ignition system)

Page 19: DT125 3BN0-ME5 repair manual

–11–

Shift the transmission in neutral and gear.Check the neutral switch for continuity.

GOODCONDITION

Transmissionposition

Goodcondition

Bad condition

Neutral

Gear

: Continuity : No continuity

Disconnect the Neutral relay coupler fromthe wireharness.

Connect the Pocket Tester (Ω 1) to the neu-tral switch lead.

2. Neutral switch

Replace neutral switch.

BAD CONDITION

Tester (+) Lead Sky blue leadTester (–) Lead Frame Ground

2

1

IGNITION SYSTEM ELEC

Page 20: DT125 3BN0-ME5 repair manual

–12–

Disconnect the neutral relay from the wirehar-ness.

Connect the pocket tester (Ω 1) and battery(12 V) to the neutral relay.

3. Neutral relay

Correct.

POOR CONNECTION

Check the neutral relay for continuity.

Check the entire ignition system for connec-tions.Refer to the “WIRING DIAGRAM” section.

4. Wiring connection

CONTINUITY

Neutral relay is faulty, replace it.

NO CONTINUITY

CORRECT

Replace ignition control unit.

IGNITION SYSTEM ELEC

Page 21: DT125 3BN0-ME5 repair manual

COLOR CODEB Black. . . . . . R Red. . . . . . O Orange. . . . . L Blue. . . . . .

P Pink. . . . . . Y Yellow. . . . . . G Green. . . . . W White. . . . .

Ch Chocolate. . . . Dg Dark green. . . . Sb Sky blue. . . . . Br Brown. . . . .

L /Y Blue/Yellow. . . . B/Y Black/Yellow. . . . B/W Black/White. . . B/R Black/Red. . . .

W/R White /Red. . . W/L White /Blue. . . Y/R Yellow/Red. . . . G/R Green/Red. . .

G/Y Green/Yellow. . . G/W Green/White. . . Br /W Brown/White. . L /R Blue/Red. . . .

1 CDI magneto2 Neutral switch3 Rectifier / regulator4 Fuse5 Battery6 Main switch7 “ENGINE STOP” switch8 Servomotor9 CDI unit10 Ignition coil11 Read switch12 Meter light13 Meter light14 Neutral indicator light15 Oil level indicator light16 High beam indicator light17 Engine temperature gauge18 Thermo unit19 Turn indicator light20 Neutral relay21 Sidestand switch22 Oil level switch23 Rear brake switch24 Front brake switch25 Tail /brake light26 Flasher relay27 Horn28 Flasher light29 “Turn” switch30 “Horn” switch31 “Lights” (Dimmer) switch32 “Lights” switch33 Handlebar switches (left)34 Auxiliary light35 Headlight

DT125R ’99 WIRING DIAGRAM