OWNER’S MANUAL - dt125.cz - web o motocyklu Yamaha · PDF filemanual does not only instruct you in how to operate, inspect and maintain your motorcycle, ... OWNER’S MANUAL ©2004

1D0-F8199-E2

DT125RDT125X

OWNER’S MANUAL

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EAU10100

Welcome to the Yamaha world of motorcycling!As the owner of the DT125R/X, you are benefiting from Yamaha’s vast experience and newest technology regarding thedesign and 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 advantages of your DT125R/X. The owner’smanual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safe-guard yourself and others from trouble and injury.In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you haveany 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!

INTRODUCTION

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EAU10150

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

IMPORTANT MANUAL INFORMATION

CAUTION 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 clearer.

NOTE:● This manual should be considered a permanent part of this motorcycle and should remain with it even if the

motorcycle is subsequently sold.● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the

most current product information available at the time of printing, there may be minor discrepancies between yourmotorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dea-ler.

EWA10030

ss WARNINGPLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

t

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EAUS1171

IMPORTANT MANUAL INFORMATION

DT125R/XOWNER’S MANUAL

©2004 by YAMAHA MOTOR SPAIN S.A.1st edition, July 2004

All rights reservedAny reprinting or unauthorized usewithout the written permission of

YAMAHA MOTOR SPAIN S.A.is expressly prohibited.

Printed in Spain.

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SAFETY INFORMATION .....................1-1

DESCRIPTION.....................................2-1Left view ...........................................2-1Right view .........................................2-2Controls and instruments .................2-3

INSTRUMENTS AND CONTROLFUNCTIONS ........................................3-1

Main switch/steering lock.................3-1Indicator and warning lights .............3-2Speedometer unit .............................3-3Handlebar switches ..........................3-3Clutch lever.......................................3-4Shift pedal.........................................3-4Brake lever........................................3-5Brake pedal.......................................3-5Fuel tank cap ....................................3-5Catalytic converter............................3-62-stroke engine oil ............................3-7Fuel cock ..........................................3-7Starter (choke) lever..........................3-8Seat...................................................3-8Shock absorber ................................3-9YEIS handling precautions ...............3-9YPVS.................................................3-9Sidestand........................................3-10Ignition circuit cut-off system.........3-10

PRE-OPERATION CHECKS ...............4-1Pre-operation check list....................4-2

OPERATION AND IMPORTANT RIDINGPOINTS ................................................5-1

Starting a cold engine ......................5-1Starting a warm engine ....................5-2Shifting..............................................5-2Engine break-in.................................5-2Parking..............................................5-3

PERIODIC MAINTENANCE ANDMINOR REPAIR...................................6-1

Owner’s tool kit.................................6-1Periodic maintenance and

lubrication chart ............................6-2Removing and installing cowlings

and panels.....................................6-5Checking the spark plug ..................6-6Transmission oil ................................6-7Coolant .............................................6-8Cleaning the air filter element

and check hose...........................6-10Ajusting the carburetor ...................6-11Adjusting the engine idling

speed...........................................6-12Ajusting the throttle cable free

play..............................................6-12Tires ................................................6-13Spoke wheels .................................6-15Adjusting the clutch lever free

play..............................................6-15Adjusting the brake lever free

play..............................................6-16

Adjusting the brake pedal position and free play................................6-17

Adjusting the rear brake light switch ..........................................6-17

Checking the front and rear brake pads ..................................6-18

Changing the brake fluid ................6-19Checking the drive chain slack ......6-19Adjusting the drive chain slack.......6-20Lubricating the drive chain .............6-20Checking and lubricating the

cables ..........................................6-21Checking and lubricating the

throttle grip and cable .................6-21Adjusting the autolube pump .........6-21Checking and lubricating the

brake and shift pedals.................6-21Checking and lubricating the

breake and clutch levers .............6-21Checking and lubricating the

sidestand.....................................6-21Checking the front fork...................6-22Checking the steering.....................6-22Checking the wheel bearings .........6-23Replacing the fuse..........................6-24Replacing the headlight bulb..........6-24Replacing the tail/brake light

bulb .............................................6-25Replacing the turn signal light

bulb .............................................6-26Supporting the motorcycle .............6-26

TABLE OF CONTENTS

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Front wheel .....................................6-26Rear wheel ......................................6-28Troubleshooting ..............................6-29

MOTORCYCLE CARE AND STORAGE ........................................7-1Care ..................................................7-1Storage .............................................7-3

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

CONSUMER INFORMATION .............9-1Identification numbers ......................9-1

TABLE OF CONTENTS

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EAU10310

MOTORCYCLES ARE SINGLETRACK VEHICLES. THEIR SAFE USEAND OPERATION ARE DEPENDENTUPON THE USE OF PROPER RIDINGTECHNIQUES AS WELL AS THEEXPERTISE OF THE OPERATOR.EVERY OPERATOR SHOULD KNOWTHE FOLLOWING REQUIREMENTSBEFORE RIDING THIS MOTORCY-CLE.HE OR SHE SHOULD:

● OBTAIN THOROUGH INSTRUC-TIONS FROM A COMPETENTSOURCE ON ALL ASPECTS OFMOTORCYCLE OPERATION.

● OBSERVE THE WARNINGS ANDMAINTENANCE REQUIRE-MENTS IN THE OWNER’SMANUAL.

● OBTAIN QUALIFIED TRAININGIN SAFE AND PROPER RIDINGTECHNIQUES.

● OBTAIN PROFESSIONAL TECH-NICAL SERVICE AS INDICATEDBY THE OWNER’S MANUALAND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-TIONS.

Safe riding● Always make pre-operation

checks. Careful checks may helpprevent an accident.

● This motorcycle is designed tocarry the operator and a passen-ger.

● The failure of motorists to detectand recognize motorcycles intraffic is the predominating causeof automobile/motorcycle acci-dents. Many accidents havebeen caused by an automobiledriver who did not see themotorcycle. Making yourselfconspicuous appears to be veryeffective in reducing the chanceof this type of accident.Therefore:• Wear a brightly colored jacket.• Use extra caution when appro-

aching and passing throughintersections, since intersec-tions are the most likely placesfor motorcycle accidents tooccur.

• Ride where other motorists cansee you. Avoid riding in anot-her motorist’s blind spot.

● Many accidents involve inexpe-rienced operators. In fact, manyoperators who have been invol-ved in accidents do not evenhave a current motorcycle licen-se.• Make sure that you are quali-

fied and that you only lend yourmotorcycle to other qualifiedoperators.

• Know your skills and limits.Staying within your limits mayhelp you to avoid an accident.

• We recommend that you prac-tice riding your motorcyclewhere there is no traffic untilyou have become thoroughlyfamiliar with the motorcycleand all of its controls.

● Many accidents have been cau-sed by error of the motorcycleoperator. A typical error made bythe operator is veering wide on aturn due to EXCESSIVE SPEEDor undercornering (insufficientlean angle for the speed).

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t SAFETY INFORMATION

1-1

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• Always obey the speed limitand never travel faster thanwarranted by road and trafficconditions.

• Always signal before turning orchanging lanes. Make sure thatother motorists can see you.

● The posture of the operator andpassenger is important for propercontrol.• The operator should keep both

hands on the handlebar andboth feet on the operator foo-trests during operation tomaintain control of themotorcycle.

• The passenger should alwayshold onto the operator, the seatstrap or grab bar, if equipped,with both hands and keep bothfeet on the passenger foo-trests.

• Never carry a passengerunless he or she can firmly pla-ce both feet on the passengerfootrests.

● Never ride under the influence ofalcohol or other drugs.

Protective apparelThe majority of fatalities frommotorcycle accidents are the result ofhead injuries. The use of a safety hel-met is the single most critical factor inthe prevention or reduction of headinjuries.

● Always wear an approved hel-met.

● Wear a face shield or goggles.Wind in your unprotected eyescould contribute to an impair-ment of vision that could delayseeing a hazard.

● The use of a jacket, heavy boots,trousers, gloves, etc., is effectivein preventing or reducing abra-sions or lacerations.

● Never wear loose-fitting clothes,otherwise they could catch onthe control levers, footrests, orwheels and cause injury or anaccident.

● Never touch the engine orexhaust system during or afteroperation. They become very hotand can cause burns. Alwayswear protective clothing thatcovers your legs, ankles, andfeet.

● Passengers should also observethe precautions mentioned abo-ve.

ModificationsModifications made to this motorcy-cle not approved by Yamaha, or theremoval of original equipment, mayrender the motorcycle unsafe for useand may cause severe personal injury.Modifications may also make yourmotorcycle illegal to use.

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SAFETY INFORMATION t

1-2

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Loading and accessoriesAdding accessories or cargo to yourmotorcycle can adversely affect sta-bility and handling if the weight distri-bution of the motorcycle is changed.To avoid the possibility of an acci-dent, use extreme caution whenadding cargo or accessories to yourmotorcycle. Use extra care whenriding a motorcycle that has addedcargo or accessories. Here are somegeneral guidelines to follow if loadingcargo or adding accessories to yourmotorcycle:LoadingThe total weight of the operator, pas-senger, accessories and cargo mustnot exceed the maximum load limit of178 kg (392 lb) DT125R, 180 kg (396lb) DT125X. When loading within thisweight limit, keep the following inmind:

● Cargo and accessory weightshould be kept as low and closeto the motorcycle as possible.Make sure to distribute theweight as evenly as possible onboth sides of the motorcycle tominimize imbalance or instability.

● Shifting weights can create asudden imbalance. Make surethat accessories and cargo aresecurely attached to themotorcycle before riding. Checkaccessory mounts and cargo res-traints frequently.

● Never attach any large or heavyitems to the handlebar, front fork,or front fender. These items,including such cargo as sleepingbags, duffel bags, or tents, cancreate unstable handling or aslow steering response.

AccessoriesGenuine Yamaha accessories havebeen specifically designed for use onthis motorcycle. Since Yamaha can-not test all other accessories that maybe available, you must personally beresponsible for the proper selection,installation and use of non-Yamahaaccessories. Use extreme cautionwhen selecting and installing anyaccessories.Keep the following guidelines in mind,as well as those provided under “Loa-ding” when mounting accessories.

● Never install accessories or carrycargo that would impair the per-formance of your motorcycle.Carefully inspect the accessorybefore using it to make sure thatit does not in any way reduceground clearance or corneringclearance, limit suspension tra-vel, steering travel or control ope-ration, or obscure lights or reflec-tors.• Accessories fitted to the hand-

lebar or the front fork area cancreate instability due to impro-per weight distribution oraerodynamic changes. Ifaccessories are added to thehandlebar or front fork area,they must be as lightweight aspossible and should be kept toa minimum.

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t SAFETY INFORMATION

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• Bulky or large accessories mayseriously affect the stability ofthe motorcycle due to aerody-namic effects. Wind mayattempt to lift the motorcycle,or the motorcycle may becomeunstable in cross winds. Theseaccessories may also causeinstability when passing orbeing passed by large vehicles.

• Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits the fre-edom of movement of the ope-rator and may limit control abi-lity, therefore, suchaccessories are not recom-mended.

● Use caution when adding electri-cal accessories. If electricalaccessories exceed the capacityof the motorcycle’s electrical sys-tem an electric failure couldresult, which could cause a dan-gerous loss of lights or enginepower.

Gasoline and exhaust gas● GASOLINE IS HIGHLY FLAMMA-

BLE:• Always turn the engine off

when refueling.• Take care not to spill any gaso-

line on the engine or exhaustsystem when refueling.

• Never refuel while smoking orin the vicinity of an open flame.

● Never start the engine or let it runfor any length of time in a closedarea. The exhaust fumes are poi-sonous and may cause loss ofconsciousness and death withina short time. Always operate yourmotorcycle in an area that hasadequate ventilation.

● Always turn the engine off beforeleaving the motorcycle unatten-ded and remove the key from themain switch. When parking themotorcycle, note the following:• The engine and exhaust sys-

tem may be hot, therefore,park the motorcycle in a placewhere pedestrians or childrenare not likely to touch these hotareas.

• Do not park the motorcycle ona slope or soft ground, other-wise it may fall over.

• Do not park the motorcyclenear a flammable source (e.g.,a kerosene heater, or near anopen flame), otherwise it couldcatch fire.

● When transporting the motorcy-cle in another vehicle, make surethat it is kept upright and that thefuel cock(s) are turned to “ON” or“RES” (for vacuum type)/”OFF”(for manual type). If the motorcy-cle should lean over, gasolinemay leak out of the carburetor orfuel tank.

● If you should swallow any gasoli-ne, inhale a lot of gasoline vapor,or allow gasoline to get into youreyes, see your doctor immedia-tely. If any gasoline spills on yourskin or clothing, immediatelywash the affected area with soapand water and change your clot-hes.

1

SAFETY INFORMATION t

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EAU10410

Left view

DESCRIPTION

2-1

2

1 7

2 8 5 6 3 4

9

1. Headlight (page 6-24)2. Radiator cover (page 6-5)3. Fuel cock (page 3-7)4. Air filter (page 6-10)5. Choke lever (page 3-8)6. Shift pedal (page 3-4)7. Y.E.I.S (page 3-9)8. Y.P.V.S. (page 3-9)9. Oil tank (page 3-7)

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EAU10420

Right view

DESCRIPTION

2-2

2

13 11

12 14

11. Tool kit (page 6-1)12. Fuse (page 6-24)13. Coolant tank (page 6-8)14. Rear brake pedal (page 3-5)

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EAU10430

Controls and instruments

DESCRIPCION

2-3

2

0

km/h

4060 80

100

120

130

20

y

0 0 0 0 1 5

0 0 0 8

16 17 18 19 20 22

232116. Clutch lever (page 3-4)17. Left handlevar swicht (page 3-3)18. Speedometer (Page 3-3)19. Coolant temperature warning lamp (page 3-3)20. Indicators (page 3-2)21. Right handlevar swicht (page 3-3)22. Front brake lever (page 3-5)23. Throttle grip (page 6-12)24. Fuel tank cap (page 3-5)25. Main Switch (page 3-1)

2524

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EAU10460

Main switch/steering lock

The main switch/steering lock con-trols the ignition and lighting systems,and is used to lock the steering. Thevarious positions are describedbelow.

EAU10550

ONAll electrical circuits are supplied withpower, the meter lighting, taillight,license plate light and auxiliary lightscome on, and the engine can be star-ted. The key cannot be removed.

NOTE:The headlights come on automaticallywhen the engine is started and stayon until the key is turned to “OFF”,even if the engine stalls.

EAU10660

OFFAll electrical systems are off. The keycan be removed.

EAU10680

LOCKThe steering is locked, and all electri-cal systems are off. The key can beremoved.To lock the steering

1. Turn the handlebars all the way tothe left.

2. Push the key in from the “OFF”position, and then turn it to“LOCK” while still pushing it.

3. Remove the key.To unlock the steeringPush the key in, and then turn it to“OFF” while still pushing it.

EWA10060

ss WARNINGNever turn the key to “OFF” or“LOCK” while the vehicle ismoving, otherwise the electricalsystems will be switched off, whichmay result in loss of control or anaccident. Make sure that the vehi-cle is stopped before turning thekey to “OFF” or “LOCK”.

ONOFF

PU

SH

LO

CK

IGNITION

3

INSTRUMENT AND CONTROL FUNCTIONS

3-1

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EAU11002

Indicator and warning lights

1. Turn signal indicator light “b”2. Dimmer indicator light “j”3. Neutral indicator light “N”4. Oil level warning light “z”

EAU11030

Turn signal indicator lights “c” and“d”The corresponding indicator light flas-hes when the turn signal switch ispushed to the left or right.

EAU11070

Neutral indicator light “N”This indicator light comes on whenthe transmission is in the neutral posi-tion.

EAU11080

High beam indicator light “j”This indicator light comes on whenthe high beam of the headlight is swit-ched on.

EAU11180

Oil level warning light “z”This warning light comes on when thekey is in the “ON” position or whenthe oil level in the 2-stroke engine oiltank is low during operation. If thewarning light comes on during opera-tion, stop immediately and fill the oiltank with Yamalube 2 or equivalent 2-stroke engine oil of either JASO grade“FC” or ISO grades “EG-C” or “EG-D”. The warning light should go offafter the 2-stroke engine oil tank hasbeen refilled.

NOTE:If the warning light does not come onwhen the key is in the “ON” positionor does not go off after the 2-strokeengine oil tank has been refilled, havea Yamaha dealer check the electricalcircuit.

ECA10010

CAUTIONDo not operate the vehicle until youknow that the engine oil level is suf-ficient.

EAU11430

Coolant temperature warning light“y”This warning light comes on when theengine overheats. When this occurs,stop the engine immediately andallow the engine to cool.

ECA10020

CAUTIONDo not operate the engine if it isoverheated.

0

km/h

4060 80

100

120

130

20

y

0 0 0 0 1 5

0 0 0 8

b j

z N

3


3-2

1

2 34

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EAU11640

Speedometer unit

1. Odometer2. Tripmeter3. Reset button4. Coolant temperature warning lamp

The speedometer unit is equippedwith a speedometer, an odometer anda tripmeter. The speedometer showsriding speed. The odometer showsthe total distance traveled. The trip-meter shows the distance traveledsince it was last set to zero with thereset knob. The tripmeter can be usedto estimate the distance that can betraveled with a full tank of fuel. Thisinformation will enable you to planfuture fuel stops.

NOTE:Only for the German model equippedwith a speed limiter:The speed limiter prevents the vehiclefrom exceeding a riding speed of 80km/h.

EAU12343

Handlebar switches

1. Dimmer switch “j/k”2. Horn switch “a”3. Turn signal switch “c/d”4. Hazard switch “ ”

EAU12400

Dimmer switch “j/k”Set this switch to “j” for the highbeam and to “k” for the low beam.

EAU12460

Turn signal switch “c/d”To signal a right-hand turn, push thisswitch to “d”. To signal a left-handturn, push this switch to “c”. Whenreleased, the switch returns to thecenter position. To cancel the turnsignal lights, push the switch in after ithas returned to the center position.

EAU12500

Horn switch “a”Press this switch to sound the horn.

EAU12660

Engine stop switch “f/e”

1. Stop switch “f/e”2. Start switch “g”

Set this switch to “f” before startingthe engine. Set this switch to “e” to

0

km/h

4060 80

100

120

130

20

y

0 0 0 0 1 5

0 0 0 8

b j

z N

3


3-3

1

23

4

1

2

4 1

3 2

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stop the engine in case of an emer-gency, such as when the motorcycleoverturns or when the throttle cable isstuck.

EAU12710

Start switch “g”Push this switch to crank the enginewith the starter.

ECA10050

CAUTIONSee page 5-1 for starting instruc-tions prior to starting the engine.

EAU12763

Hazard switch “ ”With the key in the “ON” position, turnthis switch to “ ” to turn on thehazard lights (simultaneous flashingof all turn signal lights).The hazard lights are used in case ofan emergency or to warn other driverswhen your vehicle is stopped where itmight be a traffic hazard.

ECA10060

CAUTIONDo not use the hazard light for anextended length of time, otherwi-sethe battery may discharge.

EAU12820

Clutch lever

1. Clutch lever

The clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the hand-lebar grip. To engage the clutch, rele-ase the lever. The lever should bepulled rapidly and released slowly forsmooth clutch operation.The clutch lever is equipped with aclutch switch, which is part of theignition circuit cut-off system. (Seepage 3-11.)

EAU12880

Shift pedal

N. Neutral1. Shift pedal

The shift pedal is located on the leftside of the engine and is used in com-bination with the clutch lever whenshifting the gears of the 6-speedconstant-mesh transmission equip-ped on this motorcycle.

NOTE:Use your toes or heel to shift up andyour toes to shift down.

3


3-4

1

1

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EAU12890

Brake lever

1. Brake lever

The brake lever is located at the righthandlebar grip. To apply the front bra-ke, pull the lever toward the handle-bar grip.

EAU12941

Brake pedal

1. Brake pedal

The brake pedal is on the right side ofthe motorcycle. To apply the rear bra-ke, press down on the brake pedal.

EAU13150

Fuel tank capTo remove the fuel tank cap

1. Insert the key into the lock andturn it 1/4 turn counterclockwise.

2. Turn the fuel tank cap 1/3 turncounterclockwise and pull it off.

1. Fuel tank cap2. Unlock3. Open

To install the fuel tank cap1. Insert the fuel tank cap into the

tank opening with the key inser-ted in the lock, and then turn thecap 1/3 turn clockwise.

2. Turn the key 1/4 turn clockwise,and then remove it.

3


3-5

1

1

2

3

1

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NOTE:The fuel tank cap cannot be installedunless the key is in the lock. In addi-tion, the key cannot be removed if thecap is not properly installed and loc-ked.

EWA10120

ss WARNINGMake sure that the fuel tank cap isproperly closed and locked beforeriding.

EAU13220

FuelMake sure that there is sufficient fuelin the tank. When refueling, be sure toinsert the pump nozzle into the fueltank filler hole and to fill the tank tothe bottom of the filler tube as shown.

1. Filing pipe2. Fuel level

EWA10880

ss WARNING● Do not overfill the fuel tank,

otherwise it may overflowwhen the fuel warms up andexpands.

● Avoid spilling fuel on the hotengine.

ECA10070

CAUTIONImmediately wipe off spilled fuelwith a clean, dry, soft cloth, sincefuel may deteriorate painted surfa-ces or plastic parts.

EAU13320

Recommended fuel:REGULAR UNLEADED GASOLINEONLY

Fuel tank capacity:10,7 L (2,82 US gal) (2,35 Imp.gal)

Fuel reserve amount:1,8 L (0,48 US gal) (0,40 Imp.gal)

ECA11400

CAUTIONUse only unleaded gasoline. Theuse of leaded gasoline will causesevere damage to internal engineparts, such as the valves and pistonrings, as well as to the exhaust sys-tem.

Your Yamaha engine has been desig-ned to use regular unleaded gasolinewith a research octane number of 91or higher. If knocking (or pinging)occurs, use a gasoline of a differentbrand or premium unleaded fuel. Useof unleaded fuel will extend sparkplug life and reduce maintenancecosts.

EAU13430

Catalytic converterThis model is equipped with a cataly-tic converter in the exhaust chamber.

EWA10860

ss WARNINGThe exhaust system is hot afteroperation. Make sure that theexhaust system has cooled downbefore doing any maintenancework.

3


3-6

1

2

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ECA10700

CAUTIONThe following precautions must beobserved to prevent a fire hazard orother damages.

● Use only unleaded gasoline.The use of leaded gasoline willcause unrepairable damage tothe catalytic converter.

● Never park the vehicle nearpossible fire hazards such asgrass or other materials thateasily burn.

● Do not allow the engine to idletoo long.

EAU13460

2-stroke engine oil

1. Oil tank cap2. Sensor

Make sure that there is sufficient oil inthe 2-stroke engine oil tank. Add therecommended 2-stroke engine oil ifnecessary.

NOTE:Make sure that the 2-stroke engine oiltank cap is properly installed.

Recommended oil:Yamalube 2 or equivalent 2-strokeengine oil (JASO grade “FC”, or ISOgrades “EG-C” or “EG-D”)

Oil quantity:1,3 L (1,37 US qt) (0,29 Imp.qt)

EAU13560

Fuel cockThe fuel cock supplies fuel from thetank to the carburetor while filtering italso.The fuel cock has three positions:

OFF

1. Arrow mark

With the lever in this position, fuel willnot flow. Always return the lever tothis position when the engine is notrunning.ON

With the lever in this position, fuelflows to the carburetor. Normal ridingis done with the lever in this position.

3


3-7

1

2 1

1

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RES

This indicates reserve. If you run outof fuel while riding, move the lever tothis position. Fill the tank at the firstopportunity. Be sure to set the leverback to “ON” after refueling!

EAU13590

Starter (choke) lever “q”

1. Choke lever

Starting a cold engine requires aricher air-fuel mixture, which is sup-plied by the starter (choke).Move the lever in direction (a) to turnon the starter (choke).Move the lever in direction (b) to turnoff the starter (choke).

EAU13960

SeatTo remove the seatRemove the bolts, and then pull theseat off.

1. Bolt (x2)

To install the seat1. Insert the projections on the front

of the seat into the seat holdersas shown.

2. Place the seat in the originalposition, and then tighten thebolts.

NOTE:Make sure that the seat is properlysecured before riding.

3


3-8

1

1

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EAU15090

Shock absorberEWA10220

ss WARNINGThis shock absorber containshighly pressurized nitrogen gas.For proper handling, read andunderstand the following informa-tion before handling the shockabsorber. The manufacturer cannotbe held responsible for propertydamage or personal injury that mayresult from improper handling.

● Do not tamper with or attemptto open the gas cylinder.

● Do not subject the shockabsorber to an open flame orother high heat sources, other-wise it may explode due toexcessive gas pressure.

● Do not deform or damage thegas cylinder in any way, as thiswill result in poor damping per-formance.

● Always have a Yamaha dealerservice the shock absorber.

EAU15250

YEIS handling precautions

1. YEIS

Improper installation of or damage toany part of the YEIS (Yamaha EnergyInduction System) will result in poorperformance. Therefore, handle theYEIS air chamber and air chamberhose with special care and immedia-tely replace any cracked or damagedparts.

ECA10140

CAUTIONDo not attempt to modify the YEISin any way.

EAU15260

YPVS

1. YPVS

This model is equipped with the YPVS(Yamaha Power Valve System). Thissystem boosts engine performanceand efficiency by means of a variablevalve in the exhaust port. The YPVSvalve is constantly adjusted in accor-dance with the engine speed by acomputer-controlled servomotor.Since the YPVS is an important partof the engine and requires very sop-histicated adjustment, have a Yamahadealer, who has the necessary profes-sional knowledge and experience,make this adjustment.

3


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1

1

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ECA10150

CAUTIONThe YPVS has been set and exten-sively tested at the Yamaha factory.Changing these settings withoutsufficient technical knowledge mayresult in poor performance of ordamage to the engine.

YPVS operation noises can be heardin the following instances:

● When the key is turned to “ON”and the engine is started.

● When the engine stalls with thekey in the “ON” position.

ECA10160

CAUTIONIf the YPVS does not operate, havea Yamaha dealer check it.

EAU15300

SidestandThe sidestand is located on the leftside of the frame. Raise the sidestandor lower it with your foot while holdingthe motorcycle upright.

NOTE:The built-in sidestand switch is part ofthe ignition circuit cut-off system,which cuts the ignition in certainsituations. (See further down for anexplanation of the ignition circuit cut-off system.)

EWA10240

ss WARNINGThe vehicle must not be ridden withthe sidestand down, or if the sides-tand cannot be properly moved up(or does not stay up), otherwise thesidestand could contact the groundand distract the operator, resultingin a possible loss of control. Yama-ha’s ignition circuit cut-off systemhas been designed to assist theoperator in fulfilling the responsibi-lity of raising the sidestand beforestarting off. Therefore, check thissystem regularly as describedbelow and have a Yamaha dealerrepair it if it does not function pro-perly.

EAU15311

Ignition circuit cut-offsystemThe ignition circuit cut-off system(comprising the sidestand switch,clutch switch and neutral switch) hasthe following functions.

● It prevents starting when thetransmission is in gear and thesidestand is up, but the clutchlever is not pulled.

● It prevents starting when thetransmission is in gear and theclutch lever is pulled, but thesidestand is still down.

● It cuts the running engine whenthe transmission is in gear andthe sidestand is moved down.

Periodically check the operation ofthe ignition circuit cut-off systemaccording to the following procedure.

EWA10250

ss WARNINGIf a malfunction is noted, have aYamaha dealer check the systembefore riding.

3


3-10

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NOTE:This check is most reliable if performed with a warmed-up engine.


3-11

3

With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is turned on.3. Turn the key on. 4. Shift the transmission into the neutral position.5. Push the start switch.Does the engine start?

With the engine still running:6. Move the sidestand up.7. Keep the clutch lever pulled.8. Shift the transmission into gear.9. Move the sidestand down.Does the engine stall?

After the engine has stalled:10. Move the sidestand up.11. Keep the clutch lever pulled.12. Push the start switch.Does the engine start?

The system is OK. The motorcycle can be ridden.

This check is most reliable if performed witha warmed-up engine.

The neutral switch may be defective.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

The sidestand switch may be defective.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

The clutch switch may be defective.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

YES NO

YES NO

YES NO

NOTE:

1D0-F8199-E2.qxd 20/9/04 11:32 Página 25

EAU15591

The condition of a vehicle is theowner’s responsibility. Vital compo-nents can start to deteriorate quicklyand unexpectedly, even if the vehicleremains unused (for example, as aresult of exposure to the elements).Any damage, fluid leakage or loss oftire air pressure could have seriousconsequences. Therefore, it is veryimportant, in addition to a thoroughvisual inspection, to check the follo-wing points before each ride.

NOTE:Pre-operation checks should bemade each time the vehicle is used.Such an inspection can be accom-plished in a very short time; and theadded safety it assures is more thanworth the time involved.

EWA11150

ss WARNINGIf any item in the Pre-operationcheck list is not working properly,have it inspected and repairedbefore operating the vehicle.

4

PRE-OPERATION CHECKS

4-1

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4-2

4

EAU15603

Pre-operation check list

ITEM CHECKS PAGE• Check fuel level in fuel tank.

Fuel • Refuel if necessary. 3-6• Check fuel line for leakage.• Check oil level in oil tank.

2-stroke engine oil • If necessary, add recommended oil to specified level. 3-7• Check vehicle for oil leakage.

Transmission oil• Check oil level in transmission case.

6-7• If necessary, add recommended oil to specified level.• Check coolant level in reservoir.

Coolant • If necessary, add recommended coolant to specified level. 6-8• Check cooling system for leakage.• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.

Front brake• Check brake pads for wear.

6-16/6-18• Replace if necessary.• Check fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.

Rear brake• Check brake pads for wear.

6-16/6-18• Replace if necessary.• Check fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.• Check operation.

Clutch• Lubricate cable if necessary.

6-15• Check lever free play.• Adjust if necessary.• Make sure that operation is smooth.

Throttle grip• Check cable free play.

6-12/6-21• If necessary, have Yamaha dealer adjust cable free play and lubricatecable andgrip housing.

1D0-F8199-E2.qxd 20/9/04 11:32 Página 25

Control cables• Make sure that operation is smooth.

6-21• Lubricate if necessary.• Check chain slack.

Drive chain• Adjust if necessary.

6-19/6-20• Check chain condition.• Lubricate if necessary.• Check for damage.

Wheels and tires• Check tire condition and tread depth.

6-13• Check air pressure.• Correct if necessary.

Brake and shift pedals • Make sure that operation is smooth.6-21• Lubricate pedal pivoting points if necessary.

Brake and clutch levers • Make sure that operation is smooth.6-21• Lubricate lever pivoting points if necessary.

Sidestand• Make sure that operation is smooth.

6-21• Lubricate pivot if necessary.

Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.

–• Tighten if necessary.Instruments, lights, • Check operation.

–signals and switches • Correct if necessary.Engine stop switch • Check operation. 3-3

Sidestand switch• Check operation of ignition circuit cut-off system.

3-11• If system is defective, have Yamaha dealer check vehicle.


4-3

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EAU15950EWA10270

ss WARNING● Become thoroughly familiar

with all operating controls andtheir functions before riding.Consult a Yamaha dealerregarding any control or func-tion that you do not thoroughlyunderstand.

● Never start the engine or ope-rate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of cons-ciousness and death within ashort time. Always make surethat there is adequate ventila-tion.

● Before starting out, make surethat the sidestand is up. If thesidestand is not raised comple-tely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.

EAU16060

Starting a cold engineIn order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:

● The transmission is in the neutralposition.

● The transmission is in gear withthe clutch lever pulled and thesidestand up.

EWA10290

ss WARNING● Before starting the engine,

check the function of the igni-tion circuit cut-off systemaccording to the proceduredescribed on page 3-11.

● Never ride with the sidestanddown.

1. Turn the fuel cock lever to “ON”.2. Turn the key to “ON” and make

sure that the engine stop switchis set to “f”.

3. Shift the transmission into theneutral position.

NOTE:When the transmission is in the neu-tral position, the neutral indicator lightshould be on, otherwise have aYamaha dealer check the electricalcircuit.

4. Turn the starter (choke) on andcompletely close the throttle.(See page 3-8.)

5. Start the engine by pushing thestart switch.

NOTE:If the engine fails to start, release thestart switch, wait a few seconds, andthen try again. Each starting attemptshould be as short as possible to pre-serve the battery. Do not crank theengine more than 10 seconds on anyone attempt.

6. After starting the engine, movethe starter (choke) back halfway.

ECA11040

CAUTIONFor maximum engine life, neveraccelerate hard when the engine iscold!

5

OPERATION AND IMPORTANT RIDING POINTS

5-1

1D0-F8199-E2.qxd 20/9/04 11:32 Página 29

7. When the engine is warm, turnthe starter (choke) off.

NOTE:The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off.

EAU16640

Starting a warm engineFollow the same procedure as forstarting a cold engine with the excep-tion that the starter (choke) is notrequired when the engine is warm.

EAU16671

ShiftingShifting gears lets you control theamount of engine power available forstarting off, accelerating, climbinghills, etc.The gear positions are shown in theillustration.

N. Neutral1. Shift pedal

NOTE:To shift the transmission into the neu-tral position, press the shift pedal downrepeatedly until it reaches the end of itstravel, and then slightly raise it.

ECA10260

CAUTION● Even with the transmission in

the neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for longdistances. The transmission isproperly lubricated only whenthe engine is running. Inade-quate lubrication may damagethe transmission.

● Always use the clutch whilechanging gears to avoid dama-ging the engine, transmission,and drive train, which are notdesigned to withstand theshock of forced shifting.

EAU16830

Engine break-inThere is never a more importantperiod in the life of your engine thanthe period between 0 and 1000 km(600 mi). For this reason, you shouldread the following material carefully.Since the engine is brand new, do notput an excessive load on it for the first1000 km (600 mi). The various parts inthe engine wear and polish themsel-ves to the correct operating clearan-ces. During this period, prolongedfull-throttle operation or any conditionthat might result in engine overhea-ting must be avoided.

EAU17150

0–150 km (0–90 mi)Avoid prolonged operation above 1/3throttle.

5


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After every hour of operation, stop theengine, and then let it cool for five toten minutes.Vary the engine speed from time totime. Do not operate the engine atone set throttle position.150–500 km (90–300 mi)Avoid prolonged operation above 1/2throttle.Rev the engine freely through thegears, but do not use full throttle atany time.500–1000 km (300–600 mi)Avoid prolonged operation above 3/4throttle.

ECA10370

CAUTIONAfter 1000 km (600 mi) of operation,the transmission oil must be chan-ged.

1000 km (600 mi) and beyondAvoid prolonged full-throttle opera-tion. Vary the engine speed occasio-nally.

ECA10270

CAUTIONIf any engine trouble should occurduring the engine break-in period,immediately have a Yamaha dealercheck the vehicle.

EAU17180

ParkingWhen parking, stop the engine, remo-ve the key from the main switch, andthen turn the fuel cock lever to “OFF”.

EWA10310

ss WARNING● Since the engine and exhaust

system can become very hot,park in a place where pedes-trians or children are not likelyto touch them.

● Do not park on a slope or onsoft ground, otherwise thevehicle may overturn.

ECA10380

CAUTIONNever park in an area where thereare fire hazards such as grass orother flammable materials.

5


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EAU17240

Safety is an obligation of the owner.Periodic inspection, adjustment andlubrication will keep your vehicle inthe safest and most efficient condi-tion possible. The most importantpoints of inspection, adjustment, andlubrication are explained on the follo-wing pages.The intervals given in the periodicmaintenance and lubrication chartshould be simply considered as ageneral guide under normal ridingconditions. However, DEPENDINGON THE WEATHER, TERRAIN, GEO-GRAPHICAL LOCATION, AND INDIVI-DUAL USE, THE MAINTENANCEINTERVALS MAY NEED TO BESHORTENED.

EWA10320

ss WARNINGIf you are not familiar with mainte-nance work, have a Yamaha dealerdo it for you.

EAU17320

Owner’s tool kit

1. Tool kit

The service information included inthis manual and the tools provided inthe owner’s tool kit are intended toassist you in the performance of pre-ventive maintenance and minorrepairs. However, additional toolssuch as a torque wrench may benecessary to perform certain mainte-nance work correctly.

NOTE:If you do not have the tools or expe-rience required for a particular job,have a Yamaha dealer perform it foryou.

EWA10350

ss WARNINGModifications not approved byYamaha may cause loss of perfor-mance and render the vehicleunsafe for use. Consult a Yamahadealer before attempting any chan-ges.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

6-1

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1D0-F8199-E2.qxd 20/9/04 11:32 Página 32

EAU17710

Periodic maintenance and lubrication chart

NOTE:● The annual checks must be performed every year, except if a kilometer-based maintenance is performed

instead.● From 30000 km, repeat the maintenance intervals starting from 6000 km.● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and

technical skills.


6-2

6

ODOMETER READING (x 1000 Km) ANNUALCHECK

No ITEM CHECK OR MAINTENANCE JOB 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 Clutch• Check operation.• Adjust.

√ √ √ √ √

5 * Front brake• Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √• Replace brake pads. Whenever worn to the limit

6 * Rear brake• Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √• Replace brake pads. Whenever worn to the limit

7 * Brake hoses• Check for cracks or damage. √ √ √ √ √• Replace. Every 4 years

8 * Wheels • Check runout, spoke tightness and for damage.• Tighten spokes if necessary. √ √ √ √

1D0-F8199-E2.qxd 20/9/04 11:32 Página 33



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. √ √ √ √

11 * Swingarm• Check operation and for excessive play. √ √ √ √• Lubricate with lithium-soap-based grease. Every 24000 km

• Check chain slack, alignment and condition.12 Drive chain • Adjust and lubricate chain with a special O-ring chain

Every 500 km and after washing the

lubricant thoroughly.motorcycle or riding in the rain

13 * Steering bearings• Check bearing play and steering for roughness. √ √ √ √ √• Lubricate with lithium-soap-based grease. Every 50000 km

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

15 Sidestand• Check operation.• Lubricate.

√ √ √ √ √

16 * Sidestand switch • Check operation. √ √ √ √ √ √

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

18 * Shock absorber assembly •Check operation and shock absorber for oil leakage. √ √ √ √

Rear suspension relay • Check operation. √ √ √ √19 * arm and connecting arm • Lubricate with lithium-soap-based grease. √ √pivoting points

20 * Carburetor• Check starter (choke) operation.• Adjust engine idling speed.

√ √ √ √ √ √

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

√ √ √ √


6-3

6

1D0-F8199-E2.qxd 20/9/04 11:32 Página 34



22 Transmission oil• Check oil level. √ √ √ √ √ √• Change. √ √

23 * Cooling system• Check coolant level and vehicle for coolant leakage. √ √ √ √ √• Change. Every 3 years

24 *Front and rear

• Check operation. √ √ √ √ √ √brake switches

25 Moving parts and cables • Lubricate. √ √ √ √ √

Throttle grip • Check operation and free play.26 * •Adjust the throttle cable free play if necessary. √ √ √ √ √

housing and cable • Lubricate the throttle grip housing and cable.

27 * Muffler and exhaust pipe • Check the screw clamp for looseness. √ √ √ √ √

28 *Lights, signals • Check operation.and switches • Adjust headlight beam.

√ √ √ √ √ √


6-4

6

EAU18670

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

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

ke fluid.• Replace the brake hoses every four years and if cracked or damaged.

1D0-F8199-E2.qxd 20/9/04 11:32 Página 35

EAU18711

Removing and installingcowlings and panels

1. Cowling A2. Cowling B3. Panel D

1. Cowling C2. Panel E

The cowlings and panels shown needto be removed to perform some of themaintenance jobs described in thischapter. Refer to this section eachtime a cowling or panel needs to beremoved and installed.

EAU18890

Cowling A

1. Screws (x 3)

To remove the cowlingRemove the cowling screws, and thenpull the cowling off as shown.To install the cowlingPlace the cowling in the original posi-tion, and then install the screws.

EAU18980

Cowlings B and CTo remove one of the cowlingsRemove the cowling screws, and thenpull the cowling off as shown.

1. Screws (x3)

To install the cowlingPlace the cowling in the original posi-tion, and then install the screws.

1. Screws (x3)

6


6-5

3 21

1 2 1

1

1

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EAU19292

Panels D and E

1. Screw

To remove one of the panelsRemove the screw, and then pull thepanel off as shown.To install the panelPlace the panel in the original posi-tion, and then install the screw.

EAU19620

Checking the spark plug

1. Spark plug inspection

The spark plug is an important enginecomponent, which should be chec-ked periodically, preferably by aYamaha dealer. Since heat and depo-sits will cause any spark plug toslowly erode, it should be removedand checked in accordance with theperiodic maintenance and lubricationchart. In addition, the condition of thespark plug can reveal the condition ofthe engine.

The porcelain insulator around thecenter electrode of the spark plugshould be a medium-to-light tan (theideal color when the vehicle is riddennormally). If the spark plug shows adistinctly different color, the enginecould be defective. Do not attempt todiagnose such problems yourself.Instead, have a Yamaha dealer checkthe vehicle.If the spark plug shows signs of elec-trode erosion and excessive carbonor other deposits, it should be repla-ced.

Specified spark plug:BR8ES (NGK)

Before installing a spark plug, thespark plug gap should be measuredwith a wire thickness gauge and, ifnecessary, adjusted to specification.

Spark plug gap:0,7-0,8 mm (0,0276-0,0315 in)

Clean the surface of the spark pluggasket and its mating surface, andthen wipe off any grime from thespark plug threads.

6


6-6

11

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Tightening torque:Spark plug:

20 Nm (2 m•kgf)

NOTE:If a torque wrench is not availablewhen installing a spark plug, a goodestimate of the correct torque is1/4–1/2 turn past finger tight. Howe-ver, the spark plug should be tighte-ned to the specified torque as soonas possible.

EAU19950

Transmission oil

1. Oil level window2. Maximum level mark3. Minimum level mark

The transmission oil level should bechecked before each ride. In addition,the transmission oil must be changedat the intervals specified in the perio-dic maintenance and lubricationchart.To check the transmission oil level

1. Place the vehicle on a level surfa-ce and hold it in an upright posi-tion.

NOTE:Make sure that the vehicle is positio-ned straight up when checking the oillevel. A slight tilt to the side can resultin a false reading.

1. Plug to fill with oil

2. Start the engine, warm it up forseveral minutes, and then turn itoff.

3. Wait a few minutes until the oilsettles, and then check the oillevel through the check windowlocated at the right side of thecrankcase.

NOTE:The transmission oil should be at orabove the minimum level mark.

4. If the oil is below the minimumlevel mark, remove the oil fillercap, add sufficient oil of therecommended type to raise it tothe correct level, and then installand tighten the cap.

To change the transmission oil

1. Drain bolt

6


6-7

2

3 1

1

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1D0-F8199-E2.qxd 20/9/04 11:32 Página 38

1. Start the engine, warm it up forseveral minutes, and then turn itoff.

2. Place an oil pan under the trans-mission to collect the used oil.

3. Remove the oil filler cap anddrain bolt to drain the oil from thetransmission.

4. Install the transmission oil drainbolt, and then tighten it to thespecified torque.

Tightening torque:Transmission oil drain bolt:

15 Nm (1,5 m•kgf)

5. Add the specified amount of therecommended transmission oil,and then install and tighten the oilfiller cap.

Recommended transmission oil:See page 8-1.

Oil change quantity:0,8 L (0,85 US qt)

ECA10450

CAUTION● In order to prevent clutch slip-

page (since the transmissionoil also lubricates the clutch),do not mix any chemical additi-ves with the oil.

● Make sure that no foreignmaterial enters the transmis-sion.

6. Start the engine, and then let itidle for several minutes whilechecking the transmission for oilleakage. If oil is leaking, imme-diately turn off the engine andcheck for the cause.

EAU20070

Coolant

The coolant level should be checkedbefore each ride. In addition, the coo-lant must be changed at the intervalsspecified in the periodic maintenanceand lubrication chart.

EAU20170

To check the coolant level

1. Place the vehicle on a level surfa-ce and hold it in an upright posi-tion.

NOTE:● The coolant level must be chec-

ked on a cold engine since thelevel varies with engine tempera-ture.

● Make sure that the vehicle ispositioned straight up whenchecking the coolant level. Aslight tilt to the side can result ina false reading.

2. Remove panel D. (See page 6-6.)3. Check the coolant level in the

coolant reservoir.

FULL

LOW

6


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1D0-F8199-E2.qxd 20/9/04 11:32 Página 39

NOTE:The coolant should be between theminimum and maximum level marks.

4. If the coolant is at or below theminimum level mark, open thereservoir cap, add coolant to themaximum level mark, and thenclose the reservoir cap.

Coolant reservoir capacity:0,3 L (0,32 US qt)

ECA10470

CAUTION● If coolant is not available, use

distilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto the engine.

● If water has been used insteadof coolant, replace it with coo-lant as soon as possible, other-wise the engine may not besufficiently cooled and the coo-ling system will not be protec-ted against frost and corrosion.

● If water has been added to thecoolant, have a Yamaha dealercheck the antifreeze content ofthe coolant as soon as possi-ble, otherwise the effective-ness of the coolant will bereduced.

EWA10380

ss WARNINGNever attempt to remove the radia-tor cap when the engine is hot.

5. Install the panel.

NOTE:If the engine overheats, see page 6-31 for further instructions.

EAU20370

To change the coolant

1. Radiator cap bolt2. Radiador cap

1. Put the vehicle on a level place.2. Remove cowling C and panel D.

(See page 6-5 ~ 6-6.)3. Remove the radiator cap stopper

bolt and the radiator cap.

1. Drain bolt

4. Place a container under the engi-ne and remove the coolant drainbolt.

5. Disconnect the coolant reservoirhose on the reservoir side anddrain the coolant from the reser-voir.

6. After draining the coolant, tho-roughly flush the cooling systemwith clean tap water.

7. Replace the coolant drain boltwasher if it is damaged, and thentighten the coolant drain bolt tothe specified torque.

6


6-9

2

1

1

1D0-F8199-E2.qxd 20/9/04 11:32 Página 40

Tightening torque:Coolant drain bolt:

10 Nm (1,0 m•kgf)

8. Connect the coolant reservoirhose.

9. Pour the recommended coolantinto the radiator until it is full.

Recommended antifreeze:High quality ethylene glycol antifree-ze containing corrosion inhibitors foraluminum engines

Antifreeze/water mixing ratio:1:1

Coolant quantity:Radiator capacity (including all rou-tes):

0,92 L (0,97 US qt)Coolant reservoir capacity:

0,3 L (0,32 US qt)

ECA10470

CAUTION● If coolant is not available, use

distilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto the engine.

● If water has been used insteadof coolant, replace it with coo-lant as soon as possible, other-wise the engine may not besufficiently cooled and the coo-ling system will not be protec-ted against frost and corrosion.

● If water has been added to thecoolant, have a Yamaha dealercheck the antifreeze content ofthe coolant as soon as possi-ble, otherwise the effective-ness of the coolant will bereduced.

10. Install the radiator cap.11. Run the engine several minutes.

Stop the engine and recheck thecoolant level in the radiator. If it islow, add more coolant until it rea-ches the top of the radiator.

12. Install the radiator cap stopperbolt.

13. Fill the coolant reservoir withcoolant up to maximum level.

14. Install the coolant reservoir capand check for coolant leakage.

NOTE:If any leakage is found, ask a Yamahadealer to inspect the cooling system.

15. Install the cowling and the panel.

EAU20831

Cleaning the air filterelement and check hoseThe air filter element should be clea-ned at the intervals specified in theperiodic maintenance and lubricationchart. Clean the air filter element morefrequently if you are riding in unu-sually wet or dusty areas. In addition,the air filter check hose must be fre-quently checked and cleaned ifnecessary.

1. Screws (x3)

6


6-10

1

1D0-F8199-E2.qxd 20/9/04 11:32 Página 41

To clean the air filter element1. Remove panel E. (See page 6-6.)2. Remove the air filter case cover

by removing the screws.

3. Pull the air filter element out.

1. Guide2. Filter

4. Remove the sponge materialfrom the air filter element frame,clean it with solvent, and thensqueeze the remaining solventout.

5. Apply oil of the recommendedtype to the entire surface of thesponge material, and then sque-eze the excess oil out.

NOTE:The sponge material should be wetbut not dripping.

Recommended oil:Foam air filter oil

6. Pull the sponge material over theair filter element frame.

7. Insert the element into the air fil-ter case.

ECA10480

CAUTION● Make sure that the air filter ele-

ment is properly seated in theair filter case.

● The engine should never beoperated without the air filterelement installed, otherwisethe piston(s) and/or cylinder(s)may become excessively worn.

8. Install the air filter case cover byinstalling the screws.

9. Install the panel.

To clean the air filter check hose1. Check the hose at the bottom of

the air filter case for accumulateddirt or water.

2. If dirt or water is visible, removethe hose, clean it, and then installit.

EAU21280

Adjusting the carburetorThe carburetor is an important part ofthe engine and requires very sophisti-cated adjustment. Therefore, mostcarburetor adjustments should be leftto a Yamaha dealer, who has thenecessary professional knowledgeand experience. The adjustment des-cribed in the following section, howe-ver, may be serviced by the owner aspart of routine maintenance.

ECA10550

CAUTIONThe carburetor has been set andextensively tested at the Yamahafactory. Changing these settingswithout sufficient technical know-ledge may result in poor perfor-mance of or damage to the engine.

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EAU21340

Adjusting the engine idlingspeed

1. Idle adjusting bolt

The engine idling speed must bechecked and, if necessary, adjustedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart.The engine should be warm beforemaking this adjustment.

NOTE:● The engine is warm when it

quickly responds to the throttle.● A diagnostic tachometer is nee-

ded to make this adjustment.

1. Attach the tachometer to thespark plug lead.

2. Check the engine idling speedand, if necessary, adjust it to spe-cification by turning the throttlestop screw. To increase the engi-ne idling speed, turn the screw indirection (a). To decrease theengine idling speed, turn thescrew in direction (b).

Engine idling speed:1250-1450 r/min

NOTE:If the specified idling speed cannot beobtained as described above, have aYamaha dealer make the adjustment.

EAU21370

Adjusting the throttle cablefree play

(a) Free play

The throttle cable free play shouldmeasure 3-5 mm (0,11-0,19 in) at thethrottle grip. Periodically check thethrottle cable free play and, if neces-sary, adjust it as follows.

NOTE:The engine idling speed must becorrectly adjusted before checkingand adjusting the throttle cable freeplay.

1. Lock nut2. Adjusting nut

1. Loosen the locknut.2. To increase the throttle cable free

play, turn the adjusting nut indirection (a). To decrease thethrottle cable free play, turn theadjusting nut in direction (b).

3. Tighten the locknut.

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EAU21590

TiresTo maximize the performance, durabi-lity, and safe operation of yourmotorcycle, note the following pointsregarding the specified tires.Tire air pressureThe tire air pressure should be chec-ked and, if necessary, adjusted befo-re each ride.

EWA10500

ss WARNING● The tire air pressure must be

checked and adjusted on coldtires (i.e., when the temperatu-re of the tires equals theambient temperature).

● The tire air pressure must beadjusted in accordance withthe riding speed and with thetotal weight of rider, passenger,cargo, and accessories appro-ved for this model.

Tire air pressure (measured on coldtires):

DT125RUp to 90 kg (198 lb):

Front:150 kPa (21,8 psi) (1,5 kgf/cm2)

Rear:175 kPa (25,4 psi) (1,75 kgf/cm2)

90 kg (198 lb) to maximum load:Front:

175 kPa (25,4 psi) (1,75 kgf/cm2)Rear:

200 kPa (28,9 psi) (2 kgf/cm2)Maximum load*:

178 kg (392 lb)DT125XUp to 90 kg (198 lb):

Front:180 kPa (26,1 psi) (1,8 kgf/cm2)

Rear:200 kPa (28,9 psi) (2 kgf/cm2)

90 kg (198 lb) to maximum load:Front:

180 kPa (26,1 psi) (1,8 kgf/cm2)Rear:

200 kPa (28,9 psi) (2 kgf/cm2)Maximum load*:

180 kg (396 lb)* Total weight of rider, passenger, car-

go and accessories

EWA11200

ss WARNINGBecause loading has an enormousimpact on the handling, braking,performance and safety characte-ristics of your vehicle, you shouldkeep the following precautions inmind.

● NEVER OVERLOAD THE VEHI-CLE! Operation of an overloa-ded motorcycle may result intire damage, loss of control, orsevere injury. Make sure thatthe total weight of rider, pas-senger, cargo, and accessoriesdoes not exceed the specifiedmaximum load for the vehicle.

● Do not carry along loosely pac-ked items, which can shiftduring a ride.

● Securely pack the heaviestitems close to the center of thevehicle and distribute theweight evenly on both sides.

● Adjust the tire air pressure withregard to the load.

● Check the tire condition and airpressure before each ride.

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Tire inspection

1.Wear limit2. Side wall

The tires must be checked beforeeach ride. If the center tread depthreaches the specified limit, if the tirehas a nail or glass fragments in it, or ifthe sidewall is cracked, have a Yama-ha dealer replace the tire immediately.

Minimum tire tread depth (front andrear):

1.6 mm (0.06 in)

NOTE:The tire tread depth limits may differfrom country to country. Alwayscomply with the local regulations.

Tire informationThis motorcycle is equipped with tubetires.

EWA10460

ss WARNING● The front and rear tires should

be of the same make anddesign, otherwise the handlingcharacteristics of the vehiclecannot be guaranteed.

● After extensive tests, only thetires listed below have beenapproved for this model byYamaha Motor España, S.A.

DT125RFront tire:

Size:80/90-21 48P

Manufacturer/model:MICHELIN / T63

Rear tire:Size:

110/80-18 58PManufacturer/model:

MICHELIN / T63

DT125XFront tire:

Size:120/70-17 58H

Manufacturer/model:Pirelli/Sport Demon

Rear tire:Size:

140/70-17 66HManufacturer/model:

Pirelli/Sport Demon

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EWA10570

ss WARNING● Have a Yamaha dealer replace

excessively worn tires. Besidesbeing illegal, operating themotorcycle with excessivelyworn tires decreases ridingstability and can lead to loss ofcontrol.

● The replacement of all wheel-and brake-related parts, inclu-ding the tires, should be left toa Yamaha dealer, who has thenecessary professional know-ledge and experience.

● It is not recommended to patcha punctured tube. If unavoida-ble, however, patch the tubevery carefully and replace it assoon as possible with a high-quality product.

EAU21940

Spoke wheelsTo maximize the performance, durabi-lity, and safe operation of yourmotorcycle, note the following pointsregarding the specified wheels.

● The wheel rims should be chec-ked for cracks, bends or warpa-ge, and the spokes for loosenessor damage before each ride. Ifany damage is found, have aYamaha dealer replace the whe-el. Do not attempt even the sma-llest repair to the wheel. A defor-med or cracked wheel must bereplaced.

● The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced.An unbalanced wheel can resultin poor performance, adversehandling characteristics, and ashortened tire life.

● Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” forit to develop its optimal characte-ristics.

EAU22041

Adjusting the clutch leverfree play

1. Lock nut2. Adjusting bolt3. Free play

The clutch lever free play should mea-sure 10-15 mm (0,34-0,59 in) asshown. Periodically check the clutchlever free play and, if necessary,adjust it as follows.

1. Loosen the locknut at the clutchlever.

2. To increase the clutch lever freeplay, turn the adjusting bolt indirection (a). To decrease theclutch lever free play, turn theadjusting bolt in direction (b).

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NOTE:If the specified clutch lever free playcould be obtained as described abo-ve, tighten the locknut and skip therest of the procedure, otherwise pro-ceed as follows.

3. Fully turn the adjusting bolt at theclutch lever in direction (a) to loo-sen the clutch cable.

1. Lock nut2. Adjusting nut

4. Loosen the locknut at the crank-case.

5. To increase the clutch lever freeplay, turn the adjusting nut indirection (a). To decrease theclutch lever free play, turn theadjusting nut in direction (b).

6. Tighten the locknut at the clutchlever and the crankcase.

EAU22092

Adjusting the brake leverfree play

1. Lock nut2. Adjusting bolt3. Free play

The brake lever free play should mea-sure 2-5 mm (0,07 ~ 0,19 in) asshown. Periodically check the brakelever free play and, if necessary,adjust it as follows.

1. Loosen the locknut at the brakelever.

2. To increase the brake lever freeplay, turn the adjusting screw indirection (a). To decrease the bra-ke lever free play, turn the adjus-ting screw in direction (b).

3. Tighten the locknut.EWA10630

ss WARNING● After adjusting the brake lever

free play, check the free playand make sure that the brake isworking properly.

● A soft or spongy feeling in thebrake lever can indicate thepresence of air in the hydraulicsystem. If there is air in thehydraulic system, have aYamaha dealer bleed the sys-tem before operating themotorcycle. Air in the hydraulicsystem will diminish the bra-king performance, which mayresult in loss of control and anaccident.

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EAU22192

Adjusting the brake pedalposition and free play

1. Footrest(a) Brake pedal position

EWA10670

ss WARNINGIt is advisable to have a Yamahadealer make these adjustments.

Brake pedal positionThe top of the brake pedal should bepositioned approximately 12-15 mm(0,47-0,49 in) below the top of thefootrest. Periodically check the brakepedal position and, if necessary,adjust it as follows.

1. Loosen the locknut at the brakepedal.

2. To raise the brake pedal, turn theadjusting bolt in direction (a). Tolower the brake pedal, turn theadjusting bolt in direction (b).

3. Tighten the locknut.EWA11230

ss WARNINGAfter adjusting the brake pedalposition, the brake pedal free playmust be adjusted.

Brake pedal free playThe brake pedal free play shouldmeasure 10-15 mm (0,34-0,59 in) asshown. Periodically check the brakepedal free play and, if necessary,adjust it as follows.To increase the brake pedal free play,turn the adjusting nut at the brake rodin direction (a). To decrease the brakepedal free play, turn the adjusting nutin direction (b).

EWA10680

ss WARNING● After adjusting the drive chain

slack or removing and installingthe rear wheel, always checkthe brake pedal free play.

● If proper adjustment cannot beobtained as described, have aYamaha dealer make thisadjustment.

● After adjusting the brake pedalfree play, check the operationof the brake light.

EAU22270

Adjusting the rear brake lightswitch

1. Brake light swicht2. Adjusting nut

The rear brake light switch, which isactivated by the brake pedal, is pro-perly adjusted when the brake lightcomes on just before braking takeseffect. If necessary, adjust the brakelight switch as follows.

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Turn the adjusting nut while holdingthe rear brake light switch in place. Tomake the brake light come on earlier,turn the adjusting nut in direction (a).To make the brake light come on later,turn the adjusting nut in direction (b).

EAU22340

Checking the front and rearbrake pads

1. Wear limit indicator

The front and rear brake pads mustbe checked for wear at the intervalsspecified in the periodic maintenanceand lubrication chart. To check thebrake pad wear, measure the liningthickness. If the lining thickness isless than 0,8 mm (0,03 in), have aYamaha dealer replace the brakepads as a set.

EWA10250

ss WARNINGIf a malfunction is noted, have aYamaha dealer check the systembefore riding.

1. Wear indicator

EAU22580

Checking the brake fluid level

1. Minimum level mark

Insufficient brake fluid may allow airto enter the brake system, possiblycausing it to become ineffective.

Before riding, check that the brakefluid is above the minimum level markand replenish if necessary. A low bra-ke fluid level may indicate worn brakepads and/or brake system leakage. Ifthe brake fluid level is low, be sure tocheck the brake pads for wear andthe brake system for leakage.Observe these precautions:

● When checking the fluid level,make sure that the top of thebrake fluid reservoir is level.

1. Minimum level mark

● Use only the recommended qua-lity brake fluid, otherwise the rub-ber seals may deteriorate, cau-sing leakage and poor brakingperformance.

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REAR

FRONT

REAR

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Recommended brake fluid:DOT 4

● Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking performan-ce.

● Be careful that water does notenter the brake fluid reservoirwhen refilling. Water will signifi-cantly lower the boiling point ofthe fluid and may result in vaporlock.

● Brake fluid may deteriorate pain-ted surfaces or plastic parts.Always clean up spilled fluidimmediately.

● As the brake pads wear, it is nor-mal for the brake fluid level togradually go down. However, ifthe brake fluid level goes downsuddenly, have a Yamaha dealercheck the cause.

EAU22730

Changing the brake fluidHave a Yamaha dealer change thebrake fluid at the intervals specified inthe NOTE after the periodic mainte-nance and lubrication chart. In addi-tion, have the oil seals of the mastercylinders and calipers as well as thebrake hoses replaced at the intervalslisted below or whenever they aredamaged or leaking.

● Oil seals: Replace every twoyears.

● Brake hoses: Replace every fouryears.

EAU22770

To check the drive chain slack

(a) Chain tension

1. Place the motorcycle on a levelsurface and hold it in an uprightposition.

NOTE:When checking and adjusting the dri-ve chain slack, the motorcycle shouldbe positioned straight up and thereshould be no weight on it.

2. Shift the transmission into theneutral position.

3. Move the rear wheel by pushingthe motorcycle to locate the tigh-test portion of the drive chain,and then measure the drive chainslack as shown.

Drive chain slack:45-55 mm (1,76-2,15 in)

4. If the drive chain slack is inco-rrect, adjust it as follows.

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EAU22960

To adjust the drive chain slack

1. Axle nut2. Chain tensioner

1. Loosen the axle nut.2. To tighten the drive chain, turn

the adjusting plate on each sideof the swingarm in direction (a).To loosen the drive chain, turnthe adjusting plate on each sideof the swingarm in direction (b),and then push the rear wheel for-ward.

NOTE:Make sure that both adjusting platesare in the same position for properwheel alignment.

ECA10570

CAUTIONImproper drive chain slack willoverload the engine as well asother vital parts of the motorcycleand can lead to chain slippage orbreakage. To prevent this fromoccurring, keep the drive chainslack within the specified limits.

3. Tighten the axle nut to the speci-fied torque.

Tightening torque:Axle nut:

90 Nm (9,0 m•kgf)

EAU23021

Lubricating the drive chainThe drive chain must be cleaned andlubricated at the intervals specified inthe periodic maintenance and lubrica-tion chart, otherwise it will quicklywear out, especially when riding industy or wet areas. Service the drivechain as follows.

ECA10581

CAUTIONThe drive chain must be lubricatedafter washing the motorcycle andriding in the rain.

1. Clean the drive chain with kero-sene and a small soft brush.

ECA11120

CAUTIONTo prevent damaging the O-rings,do not clean the drive chain withsteam cleaners, high-pressurewashers or inappropriate solvents.

2. Wipe the drive chain dry.3. Thoroughly lubricate the drive

chain with a special O-ring chainlubricant.

ECA11110

CAUTIONDo not use engine oil or any otherlubricants for the drive chain, asthey may contain substances thatcould damage the O-rings.

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EAU23100

Checking and lubricating thecablesThe operation of all control cablesand the condition of the cablesshould be checked before each ride,and the cables and cable ends shouldbe lubricated if necessary. If a cable isdamaged or does not move smoothly,have a Yamaha dealer check or repla-ce it.

Recommended lubricant:Engine oil

EWA10720

ss WARNINGDamage to the outer sheath mayinterfere with proper cable opera-tion and will cause the inner cableto rust. Replace a damaged cableas soon as possible to preventunsafe conditions.

EAU23110

Checking and lubricating thethrottle grip and cableThe operation of the throttle gripshould be checked before each ride.In addition, the cable should be lubri-cated or replaced at the intervals spe-cified in the periodic maintenancechart.

EAU23120

Adjusting the Autolube pumpThe Autolube pump is a vital and sop-histicated component of the engine,which must be adjusted by a Yamahadealer at the intervals specified in theperiodic maintenance and lubricationchart.

EAU23131

Checking and lubricating thebrake and shift pedalsThe operation of the brake and shiftpedals should be checked beforeeach ride, and the pedal pivotsshould be lubricated if necessary.

Recommended lubricant:Lithium-soap-based grease (all-pur-pose grease)

EAU23140

Checking and lubricating thebrake and clutch leversThe operation of the brake and clutchlevers should be checked before eachride, and the lever pivots should belubricated if necessary.


EAU23200

Checking and lubricating thesidestandThe operation of the sidestand shouldbe checked before each ride, and thesidestand pivot and metal-to-metalcontact surfaces should be lubricatedif necessary.

EWA10730

ss WARNINGIf the sidestand does not move upand down smoothly, have a Yama-ha dealer check or repair it.

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EAU23271

Checking the front forkThe condition and operation of thefront fork must be checked as followsat the intervals specified in the perio-dic maintenance and lubricationchart.To check the condition

EWA10750

ss WARNINGSecurely support the motorcycle sothat there is no danger of it fallingover.

Check the inner tubes for scratches,damage and excessive oil leakage.

To check the operation

1. Place the motorcycle on a levelsurface and hold it in an uprightposition.

2. While applying the front brake,push down hard on the handle-bars several times to check if thefront fork compresses andrebounds smoothly.

ECA10590

CAUTIONIf any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check orrepair it.

EAU23280

Checking the steering

Worn or loose steering bearings maycause danger. Therefore, the opera-tion of the steering must be checkedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart.

1. Place a stand under the engine toraise the front wheel off theground.

EWA10750

ss WARNINGSecurely support the motorcycle sothat there is no danger of it fallingover.

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2. Hold the lower ends of the frontfork legs and try to move themforward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the stee-ring.

EAU23290

Checking the wheel bearingsThe front and rear wheel bearingsmust be checked at the intervals spe-cified in the periodic maintenance andlubrication chart. If there is play in thewheel hub or if the wheel does notturn smoothly, have a Yamaha dealercheck the wheel bearings.

EAU23380

Battery

1. Battery2. Battery ventilation pipe

The battery is located behind panel D.(See page 6-6.)This model is equipped with a sealed-type (MF) battery, which does notrequire any maintenance. There is noneed to check the electrolyte or toadd distilled water.

ECA10620

CAUTIONNever attempt to remove the bat-tery cell seals, as this would per-manently damage the battery.

EWA10760

ss WARNING● Electrolyte is poisonous and

dangerous since it containssulfuric acid, which causessevere burns. Avoid any con-tact with skin, eyes or clothingand always shield your eyeswhen working near batteries.In case of contact, administerthe following FIRST AID.• EXTERNAL: Flush with plenty

of water.• INTERNAL: Drink large quan-

tities of water or milk andimmediately call a physician.

• EYES: Flush with water for 15minutes and seek promptmedical attention.

• Batteries produce explosivehydrogen gas. Therefore,keep sparks, flames, cigaret-tes, etc., away from the bat-tery and provide sufficientventilation when charging itin an enclosed space.

● KEEP THIS AND ALL BATTE-RIES OUT OF THE REACH OFCHILDREN.

To charge the batteryHave a Yamaha dealer charge thebattery as soon as possible if it seemsto have discharged. Keep in mind thatthe battery tends to discharge morequickly if the vehicle is equipped withoptional electrical accessories.To store the battery

1. If the vehicle will not be used formore than one month, removethe battery, fully charge it, andthen place it in a cool, dry place.

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2. If the battery will be stored formore than two months, check itat least once a month and fullycharge it if necessary.

3. Fully charge the battery beforeinstallation.

4. After installation, make sure thatthe battery leads are properlyconnected to the battery termi-nals.

ECA10630

CAUTION● Always keep the battery char-

ged. Storing a discharged bat-tery can cause permanent bat-tery damage.

● To charge a sealed-type (MF)battery, a special (constant-voltage) battery charger isrequired. Using a conventionalbattery charger will damagethe battery. If you do not haveaccess to a sealed-type (MF)battery charger, have a Yamahadealer charge your battery.

EAUS1180

Replacing the fuse

1. Fuse2. Reserve fuse

The fuse holder is located beside thebattery case.If the fuse is blown, replace it asfollows.

1. Turn the key to “OFF” and turn offall electrical circuits.

2. Remove the blown fuse, and theninstall a new fuse of the specifiedamperage.

Specified fuse:15 A

ECA10640

CAUTIONDo not use a fuse of a higher ampe-rage rating than recommended toavoid causing extensive damage tothe electrical system and possibly afire.

3. Turn the key to “ON” and turn onthe electrical circuits to check ifthe devices operate.

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

EAU23910

Replacing a headlight bulb

1. Couplers

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This model is equipped with quartzbulb headlights. If a headlight bulbburns out, replace it as follows.

1. Remove cowling A. (See page 6-5.)

2. Disconnect the headlight coupler,and then remove the headlightbulb cover.

3. Remove the headlight bulb hol-der according to the followingillustration, and then remove thedefective bulb.

NOTE:The removal procedure depends onthe type of bulb holder installed onyour vehicle.

EWA10790

ss WARNINGHeadlight bulbs get very hot. The-refore, keep flammable productsaway from a lit headlight bulb, anddo not touch the bulb until it hascooled down.

4. Place a new bulb into position,and then secure it with the bulbholder.

ECA10660

CAUTIONDo not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of thebulb, and the bulb life will be adver-sely affected. Thoroughly clean offany dirt and fingerprints on theheadlight bulb using a cloth mois-tened with alcohol or thinner.

5. Install the bulb cover, and thenconnect the coupler.

6. Install the cowling.7. Have a Yamaha dealer adjust the

headlight beam if necessary.

EAU24131

Replacing the tail/brake lightbulb

1. Screw (x2)2. Lens

1. Remove the tail/brake light lensby removing the screws.

2. Remove the defective bulb bypushing it in and turning it coun-terclockwise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrews.

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ECA10680

CAUTIONDo not overtighten the screws,otherwise the lens may break.

EAU24201

Replacing a turn signal lightbulb

1. Screw2. Lens3. Bulb

1. Remove the turn signal light lensby removing the screw.

2. Remove the defective bulb bypushing it in and turning it coun-terclockwise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrew.

ECA11190

CAUTIONDo not overtighten the screw,otherwise the lens may break.

EAU24350

Supporting the motorcycleSince this model is not equipped witha centerstand, follow these precau-tions when removing the front andrear wheel or performing other main-tenance requiring the motorcycle tostand upright. Check that themotorcycle is in a stable and levelposition before starting any mainte-nance. A strong wooden box can beplaced under the engine for addedstability.To service the front wheel

1. Stabilize the rear of the motorcy-cle by using a motorcycle standor, if an additional motorcyclestand is not available, by placinga jack under the frame in front ofthe rear wheel.

2. Raise the front wheel off theground by using a motorcyclestand.

To service the rear wheelRaise the rear wheel off the ground byusing a motorcycle stand or, if amotorcycle stand is not available, byplacing a jack either under each sideof the frame in front of the rear wheelor under each side of the swingarm.

EAU24360

Front wheel

EAU24640

To remove the front wheel

1. Speedometer cable2. Axle retainer nut (x4)3. Wheel axle

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EWA10820

ss WARNING● It is advisable to have a Yama-

ha dealer service the wheel.● Securely support the motorcy-

cle so that there is no danger ofit falling over.

1. Disconnect the speedometercable from the front wheel.

2. Loosen the wheel axle holdernuts, then the wheel axle.

3. Lift the front wheel off the groundaccording to the procedure onpage 6-26.

4. Pull the wheel axle out, and thenremove the wheel.

ECA11070

CAUTIONDo not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

EAU24950

To install the front wheel

1. Install the speedometer gear unitinto the wheel hub so that theprojections mesh with the slots.

2. Lift the wheel up between thefork legs.

NOTE:Make sure that there is enough spacebetween the brake pads before inser-ting the brake disc and that the slot inthe speedometer gear unit fits overthe retainer on the fork leg.

3. Insert the wheel axle.4. Lower the front wheel so that it is

on the ground.5. Tighten the wheel axle to the

specified torque.

Tightening torque:Wheel axle:

55 Nm (5,5 m•kgf)

6. Tighten the axle holder nuts tothe specified tightening torque. Tigh-ten the upper nuts first and then lowerones. When tightened in this sequen-ce, there should be a gap formed atthe bottom of the axle holder.

Tightening torque:Axle holder nut:

10 Nm (1,0 m•kgf)

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1. Gap

7. After tightening the axle holdernuts, push down hard on thehandlebars several times whileapplying the front brake to checkif the front fork compresses andrebounds smoothly.

8. Connect the speedometer cable.

EAU25080

Rear wheel

EAU25230

To remove the rear wheel

1. Axle retainer bolt

EWA10820

ss WARNING● It is advisable to have a Yama-

ha dealer service the wheel.● Securely support the motorcy-

cle so that there is no danger ofit falling over.

1. Loosen the axle nut.2. Lift the rear wheel off the ground

according to the procedure onpage 6-26.

1. Axle nut2. Chain tensioner

3. Remove the swingarm end bolts.4. Turn the drive chain adjusting

plate on each side of the swin-garm fully in direction (a).

5. Push the wheel forward, and thenremove the drive chain from therear sprocket.

NOTE:The drive chain does not need to bedisassembled in order to remove andinstall the rear wheel.

6. Pull the wheel axle out from theleft-hand side, and then removethe wheel by pulling it back.

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ECA11070

CAUTIONDo not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

EAU25530

To install the rear wheel1. Install the drive chain onto the

rear sprocket, and then insert thewheel axle from the left-handside.

NOTE:Make sure that there is enough spacebetween the brake pads before inser-ting the brake disc between the brakepads.

2. Install the drive chain adjustingplates.

NOTE:Make sure that the drive chain adjus-ting plates are installed with the pun-ched side facing to the outside.

3. Install the swingarm end bolts.

4. Adjust the drive chain slack. (Seepage 6-19.)

5. Tighten the axle nut and theswingarm end bolts to the speci-fied torques, and then install thecotter pin.

EWA10700

ss WARNINGAlways use a new cotter pin for theaxle nut.

Tightening torque:Axle nut:

90 Nm (9,0 m•kgf)Swingarm end bolt:

3 Nm (0,3 m•kgf)

EAU25850

TroubleshootingAlthough Yamaha motorcycles recei-ve a thorough inspection before ship-ment from the factory, trouble mayoccur during operation. Any problemin the fuel, compression, or ignitionsystems, for example, can cause poorstarting and loss of power.

The following troubleshooting chartrepresents a quick and easy procedu-re for checking these vital systemsyourself. However, should yourmotorcycle require any repair, take itto a Yamaha dealer, whose skilledtechnicians have the necessary tools,experience, and know-how to servicethe motorcycle properly.Use only genuine Yamaha replace-ment parts. Imitation parts may looklike Yamaha parts, but they are ofteninferior, have a shorter service life andcan lead to expensive repair bills.

6


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EAU25921

Troubleshooting chartsStarting problems or poor engine performance

EWA10840

ss WARNINGKeep away open flames and do not smoke while checking or working on the fuel system.


6-30

6

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

Operate the electric starter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

Remove the spark plugand check the electrodes.

3. Ignition Wipe off with a dry cloth and correct thespark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

The engine does not start.Have a Yamaha dealercheck the vehicle.

The engine does not start.Check the battery.

Operate the electric starter.

4. BatteryThe engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections,and charge the battery if necessary.

Dry

WetOpen the throttle halfway and operatethe electric starter.

1D0-F8199-E2.qxd 20/9/04 11:32 Página 61

NOTE:If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommendedcoolant as soon as possible.


6-31

6Wait until the engine has cooled.

Check the coolant level in the reservoir and radiator.

The coolant level is OK.

The coolant level is low.Check the cooling systemfor leakage.

Have a Yamaha dealer checkand repair the cooling system.

Add coolant. (See NOTE.)

Start the engine. If the engine overheats again, have a Yamaha dealer check and repair the cooling system.

There isleakage.

There is no leakage.

Engine overheatingEWA10400

ss WARNING● 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. Be sure to wait until the engine has cooled.● After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then

slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his-sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.

1D0-F8199-E2.qxd 20/9/04 11:32 Página 62

EAU26000

CareWhile the open design of a motorcy-cle reveals the attractiveness of thetechnology, it also makes it more vul-nerable. Rust and corrosion candevelop even if high-quality compo-nents are used. A rusty exhaust pipemay go unnoticed on a car, however,it detracts from the overall appearan-ce of a motorcycle. Frequent and pro-per care does not only comply withthe terms of the warranty, but it willalso keep your motorcycle lookinggood, extend its life and optimize itsperformance.Before cleaning

1. Cover the muffler outlet with aplastic bag after the engine hascooled down.

2. Make sure that all caps andcovers as well as all electricalcouplers and connectors, inclu-ding the spark plug cap, aretightly installed.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such pro-ducts onto seals, gaskets, sproc-kets, the drive chain and wheelaxles. Always rinse the dirt anddegreaser off with water.

CleaningECA10770

CAUTION● Avoid using strong acidic whe-

el cleaners, especially on spo-ked wheels. If such productsare used on hard-to-removedirt, do not leave the cleaner onthe affected area any longerthan instructed. Also, tho-roughly rinse the area off withwater, immediately dry it, andthen apply a corrosion protec-tion spray.

● Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Useonly a soft, clean cloth or spon-ge with mild detergent andwater to clean plastic.

● Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasivecleaning products, solvent orthinner, fuel (gasoline), rustremovers or inhibitors, brakefluid, antifreeze or electrolyte.

● Do not use high-pressure was-hers or steam-jet cleaners sin-ce they cause water seepageand deterioration in the follo-wing areas: seals (of wheel andswingarm bearings, fork andbrakes), electric components(couplers, connectors, instru-ments, switches and lights),breather hoses and vents.

● For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling or scrat-ching. Some cleaning com-pounds for plastic may leavescratches on the windshield.Test the product on a small hid-den part of the windshield tomake sure that it does not lea-

7

MOTORCYCLE CARE AND STORAGE

7-1

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ve any marks. If the windshieldis scratched, use a qualityplastic polishing compoundafter washing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottle-brush for hard-to-reach areas. Stub-born dirt and insects will come offmore easily if the area is covered witha wet cloth for a few minutes beforecleaning.After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed onroads during winter are extremelycorrosive in combination with water,carry out the following steps aftereach ride in the rain, near the sea oron salt-sprayed roads.

NOTE:Salt sprayed on roads in the wintermay remain well into spring.

1. Clean the motorcycle with coldwater and a mild detergent, afterthe engine has cooled down.

ECA10790

CAUTIONDo not use warm water since itincreases the corrosive action ofthe salt.

2. Apply a corrosion protectionspray on all metal, includingchrome- and nickel-plated, surfa-ces to prevent corrosion.

After cleaning1. Dry the motorcycle with a cha-

mois or an absorbing cloth.2. Immediately dry the drive chain

and lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally indu-ced discoloring of stainless-steelexhaust systems can be removedthrough polishing.)

4. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal, inclu-ding chrome- and nickel-plated,surfaces.

5. Use spray oil as a universal clea-ner to remove any remaining dirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.8. Let the motorcycle dry comple-

tely before storing or covering it.EWA10930

ss WARNING● Make sure that there is no oil or

wax on the brakes or tires. Ifnecessary, clean the brakediscs and brake linings with aregular brake disc cleaner oracetone, and wash the tireswith warm water and a milddetergent.

● Before operating the motorcy-cle test its braking performan-ce and cornering behavior.

7


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ECA10800

CAUTION● Apply spray oil and wax spa-

ringly and make sure to wipeoff any excess.

● Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.

● Avoid using abrasive polishingcompounds as they will wearaway the paint.

NOTE:Consult a Yamaha dealer for adviceon what products to use.

EAU26150

StorageShort-termAlways store your motorcycle in acool, dry place and, if necessary, pro-tect it against dust with a porouscover.

ECA10810

CAUTION● Storing the motorcycle in a

poorly ventilated room or cove-ring it with a tarp, while it is stillwet, will allow water and humi-dity to seep in and cause rust.

● To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

Long-termBefore storing your motorcycle forseveral months:

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

2. For motorcycles equipped with afuel cock that has an “OFF” posi-tion: Turn the fuel cock lever to“OFF”.

3. Drain the carburetor float cham-ber by loosening the drain bolt;this will prevent fuel depositsfrom building up. Pour the drai-ned fuel into the fuel tank.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

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

a. Remove the spark plug cap andspark plug.

b. Pour a teaspoonful of engine oilinto the spark plug bore.

c. Install the spark plug cap ontothe spark plug, and then placethe spark plug on the cylinderhead so that the electrodes aregrounded. (This will limit sparkingduring the next step.)

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder wall with oil.)

e. Remove the spark plug cap fromthe spark plug, and then installthe spark plug and the spark plugcap.

7


7-3

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EWA10950

ss WARNINGTo prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turningthe engine over.

6. Lubricate all control cables andthe pivoting points of all leversand pedals as well as of thesidestand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alter-natively, turn the wheels a littleevery month in order to preventthe tires from becoming degra-ded in one spot.

8. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.

9. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once amonth. Do not store the battery inan excessively cold or warm pla-ce [less than 0 °C (30 °F) or morethan 30 °C (90 °F)]. For moreinformation on storing the bat-tery, see page 6-23.

NOTE:Make any necessary repairs beforestoring the motorcycle.

7


7-4

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DimensionsOverall length

DT125RE 2210 mmDT125X 2139 mm

Overall width795 mm

Overall heightDT125RE 1200 mmDT125X 1121 mm

Seat heightDT125RE 900 mmDT125X 886 mm

WheelbaseDT125RE 1415 mmDT125X 1396 mm

Ground clearanceDT125RE 300 mmDT125X 271 mm

Minimum turning radiusDT125RE 2100 mmDT125X 2016 mm

WeightWith oil and fuel

DT125RE 126.0 kgDT125X 134.0 kg

EngineEngine type

Liquid cooled 2-strokeCylinder arrangement

Forward-inclined single cylinderDisplacement

124.0 cm3

Bore x stroke56.0 x 50.7 mm

Compression ratio6.70 :1

Starting systemElectric starter

Lubrication systemSeparate lubrication (Yamaha autolube)

TypeYAMALUBE 2-cycle oil or 2-stroke engineoil (JASO FC g

Engine oil quantityQuantity

1.3 LTransmission oil

TypeSAE10W30 type SE motor oil

Oil change quantity0.75 L

Cooling systemCoolant reservoir capacity (up to the maxi-mum leve

0.30 LRadiator capacity (including all routes)

0.92 LAir filter

Air filter elementWet element

FuelRecommended fuel

Regular unleaded gasoline onlyFuel tank capacity

10.7 LFuel reserve amount

1.8 L

CarburetorManufacturer

MIKUNIType x quantity

TM28-92 x1Spark plug(s)

Manufacturer/modelNGK/BR8ES

Spark plug gap0.7-0.8 mm

Clutch typeWet, multiple-disc

TransmissionPrimary reduction system

Helical gearPrimary reduction ratio

71/22 (3.227)Secondary reduction system

Chain driveSecondary reduction ratio

57/16 (3.563)Transmission type

Constant mesh 6-speedOperation

Left foot operationGear ratio

1st34/12 (2.833)

2nd30/16 (1.875)

3rd24/17 (1.412)

4th24/21 (1.143)

8

SPECIFICATIONS

8-1

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5th22/23 (0.957)

6th18/22 (0.818)

ChassisFrame type

Semi double cradleCaster angle

DT125RE 27.00 degreeDT125X 24.50 degree

TrailDT125RE 107.0 mmDT125X 73.1 mm

Front tireType

With tubeSize

DT125RE 80/90-21 48PDT125X 120/70-17 58H

Manufacturer/modelDT125RE MICHELIN/T63DT125X PIRELLI/Sport Demon

Rear tireType

With tubeSize

DT125RE 110/80-18 58PDT125X 140/70-17 66H

Manufacturer/modelDT125RE MICHELIN/T63DT125X PIRELLI/Sport Demon

Maximum loadDT125RE 178 kgDT125X 180 kg

Tire air pressure (measured on coldtires)

Loading condition0-90 kg

FrontDT125RE 150 kPaDT125X 180 kPa

RearDT125RE 175 kPaDT125X 200 kPa

Loading condition90-178 kg

FrontDT125RE 175 kPaDT125X 180 kPa

Rear200 kPa

Off-road ridingFront

DT125RE 150 kPaRear

DT125RE 175 kPaFront wheel

Wheel typeSpoke wheel

Rim sizeDT125RE 21x1.60DT125X 17x3.00

Rear wheelWheel type

Spoke wheelRim size

DT125RE 18x1.85DT125X 17x3.50

Front brakeType

Single disc brakeOperation

Right hand operationRecommended fluid

DOT 4Rear brake

TypeSingle disc brake

OperationRight foot operation

Recommended fluidDOT 4

Front suspensionType

Telescopic forkSpring/shock absorber type

Coil spring/oil damperWheel travel

DT125RE 270.0 mmDT125X 200.0 mm

Rear suspensionType

Swingarm (link suspension)Spring/shock absorber type

Coil spring/gas-oil damperWheel travel

DT125RE 260.0 mmDT125X 230.0 mm

Electrical systemIgnition system

CDI

8

SPECIFICATIONS

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Charging systemAC magneto

BatteryModel

GT6B-3Voltage, capacity

12 V, 6.0 AhHeadlight

Bulb typeHalogen bulb

Bulb voltage, wattage x quantityHeadlight

12 V, 600 W/55.0 W x 1Tail/brake light

12 V, 21.0 W/5.0 W x 1Front turn signal light

12 V, 10.0 W x 2Rear turn signal light

12 V, 10.0 W x 2Auxiliary light

12 V, 5.0 W x 1Meter lighting

LEDNeutral indicator light

12 V, 3.0 W x 1High beam indicator light

12 V, 3.0 W x 1Oil level warning light

12 V, 3.0 W x 1Turn signal indicator light

12 V, 3.0 W x 1Fuses

Main fuse15.0 A

8

SPECIFICATIONS

8-3

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EAU26351

Identification numbersRecord the key identification number,vehicle identification number andmodel label information in the spacesprovided below for assistance whenordering spare parts from a Yamahadealer or for reference in case thevehicle is stolen.KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EAU26381

Key identification number

1. Key identification number

The key identification number isstamped into the key tag.Record thisnumber in the space provided anduse it for reference when ordering anew key.

EAU26400

Vehicle identification number

1. Frame number

The vehicle identification number isstamped into the steering headpipe.Record this number in the spaceprovided.

NOTE:The vehicle identification number isused to identify your motorcycle andmay be used to register yourmotorcycle with the licensing autho-rity in your area.

9

CONSUMER INFORMATION

9-1

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EAU26440

Engine serial number

1. Engine serial number

The engine serial number is stampedinto the crankcase.

EAU26480

Model label

1. Model label

The model label is affixed to the frameunder the seat. (See page 3-8.)Record the information on this label inthe space provided. This informationwill be needed when ordering spareparts from a Yamaha dealer.

9

CONSUMER INFORMATION

9-2

1

1

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AAdjusting the autolube pump ..................6-21Adjusting the brake lever free play ..........6-16Adjusting the brake pedal position and

free play .................................................6-17Adjusting the clutch lever free play .........6-15Adjusting the drive chain slack................6-20Adjusting the engine idling speed ...........6-12Adjusting the rear brake light switch .......6-17Ajusting the carburetor ............................6-11Ajusting the throttle cable free play .........6-12

BBrake lever .................................................3-5Brake pedal................................................3-5

CCare............................................................7-1Catalytic converter .....................................3-6Changing the brake fluid..........................6-19Checking and lubricating the brake and

shift pedals ............................................6-21Checking and lubricating the breake and

clutch levers...........................................6-21Checking and lubricating the cables .......6-21Checking and lubricating the sidestand ..6-21Checking and lubricating the throttle grip

and cable ...............................................6-21Checking the drive chain slack................6-19Checking the front and rear brake

pads.......................................................6-18Checking the front fork ............................6-22Checking the spark plug............................6-6Checking the steering..............................6-22Checking the wheel bearings ..................6-23

Cleaning the air filter element and check hose .......................................................6-10

Clutch lever ................................................3-4Controls and instruments ..........................2-3Coolant.......................................................6-8

D2-stroke engine oil .....................................3-7

EEngine break-in ..........................................5-2

FFront wheel ..............................................6-26Fuel cock....................................................3-7Fuel tank cap .............................................3-5

HHandlebar switches ...................................3-3

IIdentification numbers ...............................9-1Ignition circuit cut-off system ..................3-10Indicator and warning lights ......................3-2

LLeft view.....................................................2-1Lubricating the drive chain ......................6-20

MMain switch/steering lock ..........................3-1

OOwner’s tool kit ..........................................6-1

PParking .......................................................5-3Periodic maintenance and lubrication

chart.........................................................6-2Pre-operation check list.............................4-2

RRear wheel ...............................................6-28

Removing and installing cowlings and panels ......................................................6-5

Replacing the fuse ...................................6-24Replacing the headlight bulb ...................6-24Replacing the tail/brake light bulb...........6-25Replacing the turn signal light bulb .........6-26Right view ..................................................2-2

SSeat............................................................3-8Shift pedal..................................................3-4Shifting .......................................................5-2Shock absorber..........................................3-9Sidestand .................................................3-10Specifications.............................................8-1Speedometer unit ......................................3-3Spoke wheels...........................................6-15Starter (choke) lever...................................3-8Starting a cold engine................................5-1Starting a warm engine..............................5-2Storage.......................................................7-3Supporting the motorcycle ......................6-26

TTires .........................................................6-13Transmission oil .........................................6-7Troubleshooting .......................................6-29

YYEIS handling precautions.........................3-9YPVS ..........................................................3-9

INDEX

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1D0-F8199-E2.qxd 20/9/04 11:32 Página 73

YAMAHA MOTOR ESPAÑA, S.A.PRINTED IN SPAIN

2004-07-Bengar Gràfiques, S.L.(E)

1D0-F8199-E2.qxd 20/9/04 11:32 Página 74

Documents

OWNER’S MANUAL - dt125.cz - web o motocyklu Yamaha · PDF filemanual does not only instruct you in how to operate, inspect and maintain your motorcycle, ... OWNER’S MANUAL ©2004