2000 YAMAHA DT125R clutch

EAU00009
TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9 GIVE SAFETY THE RIGHT OF WAY..................1-1
DESCRIPTION....................................................2-1
Left view............................................................2-1
Right view.........................................................2-2
Controls/Instruments.........................................2-3
INSTRUMENT AND CONTROL FUNCTIONS....3-1
Main switch.......................................................3-1
Indicator lights...................................................3-1
Oil level indicator circuit check..........................3-2
Speedometer....................................................3-3
Tachometer.......................................................3-3
Engine temperature gauge...............................3-4
Handlebar switches..........................................3-4
Clutch lever.......................................................3-5
Shift pedal.........................................................3-5
Front brake lever...............................................3-6
Rear brake pedal..............................................3-6
Fuel tank cap....................................................3-6
Fuel (except for Switzerland and Austria).........3-7
Fuel (for Switzerland and Austria)....................3-7
Catalyzer (for Switzerland and Austria)............3-8
Two-stroke engine oil........................................3-9
Fuel cock..........................................................3-9
Starter (choke) Ò
1Ó.........................................3-10Kick starter......................................................3-11
Steering lock...................................................3-11
Seat................................................................3-12
Helmet holder.................................................3-12
Rear shock absorber adjustment....................3-13
Rear carrier.....................................................3-14
Note on handling of the Yamaha Energy
Induction System (Y.E.I.S.).............................3-14
Y.P.V.S.
(Yamaha Power Valve System)......................3-15
Sidestand........................................................3-15
Sidestand switch operation check..................3-16
PRE-OPERATION CHECKS...............................4-1
Pre-operation check list....................................4-1
OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting the engine............................................5-1
Starting a warm engine.....................................5-3
Shifting..............................................................5-4
Recommended shift points
(for Switzerland only)........................................5-4
Tips for reducing fuel consumption...................5-5
Engine break-in.................................................5-5
Parking..............................................................5-6
123
45
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PERIODIC MAINTENANCE AND MINOR
REPAIR................................................................6-1
Tool kit..............................................................6-1
Periodic maintenance and lubrication chart......6-3
Cowling removal and installation......................6-6
Cowling A..........................................................6-6
Cowling B..........................................................6-7
Cowling C.........................................................6-8
Panel removal and installation..........................6-8
Panel D.............................................................6-9
Panel E.............................................................6-9
Spark plug.......................................................6-10
Transmission oil..............................................6-11
Cooling system...............................................6-12
Changing the coolant......................................6-13
Air filter............................................................6-15
Carburetor adjustment....................................6-16
Idle speed adjustment.....................................6-17
Throttle cable free play adjustment.................6-17
Tires................................................................6-18
Wheels............................................................6-20
Clutch lever free play adjustment...................6-21
Front brake lever free play adjustment...........6-21
Rear brake pedal height adjustment...............6-22
Brake light switch adjustment.........................6-23
Checking the front and rear brake pads.........6-23Inspecting the brake fluid level.......................6-24
Brake fluid replacement..................................6-25
Drive chain slack check..................................6-25
Drive chain slack adjustment..........................6-26
Drive chain lubrication....................................6-26
Cable inspection and lubrication.....................6-27
Throttle cable and grip lubrication...................6-27
Autolube pump adjustment.............................6-28
Brake and shift pedal lubrication.....................6-28
Brake and clutch lever lubrication...................6-28
Sidestand lubrication......................................6-29
Front fork inspection.......................................6-29
Steering inspection.........................................6-30
Wheel bearings...............................................6-30
Battery............................................................6-31
Fuse replacement...........................................6-33
Headlight bulb replacement............................6-33
Turn signal light bulb replacement..................6-35
Tail/brake light bulb replacement....................6-35
Supporting the motorcycle..............................6-36
Front wheel removal.......................................6-36
Front wheel installation...................................6-37
Rear wheel removal........................................6-38
Rear wheel installation....................................6-39
Troubleshooting..............................................6-39
Troubleshooting chart.....................................6-40
TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9
6
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12
3
4
5
6
7
8
9
DESCRIPTION
2-3
16.Clutch lever (page 3-5, 6-21)
17.Left handlebar switches (page 3-4)
18.Speedometer (page 3-3)
19.Coolant temperature gauge (page 3-4)
20.Tachometer (page 3-3)21.Right handlebar switches (page 3-5)
22.Front brake lever (page 3-6, 6-27)
23.Throttle grip (page 6-17, 6-27)
24.Fuel tank cap (page 3-6)
25.Main switch (page 3-1)
16171819202122
23 24 25
Controls/Instruments
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3-5
INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
9
1
1.Engine stop switch
EAU00138
Engine stop switch
The engine stop switch is a safety
device for use in an emergency such
as when the motorcycle overturns or
if trouble occurs in the throttle sys-
tem. Turn the switch to Ò#Ó to start
the engine. In case of emergency,
turn the switch to Ò$Ó to stop the
engine.
EAU00155
Clutch leverThe clutch lever is located on the left
handlebar. Pull the clutch lever to the
handlebar to disengage the clutch,
and release the lever to engage the
clutch. The lever should be pulled
rapidly and released slowly for
smooth clutch operation.
6
5
4
3
2
1 N
1
EAU00157
Shift pedalThis motorcycle is equipped with a
constant-mesh 6-speed transmission.
The shift pedal is located on the left
side of the engine and is used in
combination with the clutch when
shifting.1.Shift pedal
N.Neutral
1
1.Clutch lever
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3-11
INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
9
1
EAU00212
Kick starterRotate the kick starter away from the
engine. Push the starter down lightly
with your foot until the gears engage,
then kick smoothly and forcefully to
start the engine. This model has a
primary-coupled kick starter so the
engine can be started in any gear if
the clutch is disengaged. However,
shifting to neutral before starting is
recommended.1.Kick starter
EAU02934
Steering lockTo lock the steering
Turn the handlebars all the way to
the right and open the steering lock
cover.
Insert the key and turn it 1/8 turn
counterclockwise. Then, push the key
in while turning the handlebars slight-
ly to the left and turn the key 1/8 turn
clockwise.
Check that the steering is locked,
remove the key and close the lock
cover.
1
1.Steering lock
To unlock the steering
Insert the key, push it in and turn it
1/8 turn counterclockwise so that it
moves out. Then, release and
remove the key.
3MB-9-E7 12/27/00 2:52 PM Page 23

EW000045
wIf improper operation is noted,
consult a Yamaha dealer immedi-
ately.
3-16
INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
9
ENGINE WILL STALL.SIDESTAND SWITCH IS OK.
EAU00333
Sidestand switch operation
checkCheck the operation of the sidestand
switch against the information below.TURN THE MAIN SWITCH TO ÒONÓ AND
THE ENGINE STOP SWITCH TO Ò#Ó.TRANSMISSION IS IN NEUTRAL AND
SIDESTAND IS DOWN.PULL IN THE CLUTCH LEVER AND
PUT TRANSMISSION IN GEAR.ENGINE WILL START.KICK THE KICK STARTER.
EW000044
wThis motorcycle must not be oper-
ated with the sidestand in the
down position. If the stand is not
properly retracted, it could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control. Yamaha has designed into
this motorcycle a lockout system
to assist the operator in fulfilling
the responsibility of retracting the
sidestand. Please check carefully
the operating instructions listed
below and if there is any indication
of a malfunction, return the motor-
cycle to a Yamaha dealer immedi-
ately for repair.
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4-1
EAU01114
PRE-OPERATION CHECKS
1
2
34
5
6
7
8
9 Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid
leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thor-
ough visual inspection, you check the following points before each ride.
EAU00340
PRE-OPERATION CHECK LIST
ITEMCHECKSPAGE
Front brake9Check operation, free play, fluid level and vehicle for fluid leakage.
9Fill with DOT 4 (or DOT 3) brake fluid if necessary.
3-6, 6-21 ~ 6-25
Rear brake9Check operation, free play, fluid level and vehicle for fluid leakage.
9Fill with DOT 4 (or DOT 3) brake fluid if necessary.
Clutch9Check operation, condition and free play.
3-5, 6-21
9Adjust if necessary.
9Check for smooth operation.
Throttle grip and housing9Lubricate.6-17, 6-27
9Adjust throttle cable free play if necessary.
Engine oil9Check oil level.
3-9
9Fill with oil if necessary.
Transmission oil9Check oil level.
6-11 ~ 6-12
9Fill with oil if necessary.
Coolant9Check coolant level.
6-12
9Fill with coolant if necessary.
Drive chain9Check chain slack and condition.
6-26 ~ 6-27
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage and spoke tightness.
6-18 ~ 6-20
9Tighten spokes if necessary.
Control and meter cable9Check for smooth operation.
6-27
9Lubricate if necessary.
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4-2
PRE-OPERATION CHECKS
1
2
34
5
6
7
8
9
ITEMCHECKSPAGE
Brake and shift pedal shafts9Check for smooth operation.
6-28 9Lubricate if necessary.
Brake and clutch lever pivots9Check for smooth operation.
9Lubricate if necessary.
Sidestand pivot9Check for smooth operation.
6-29
9Lubricate if necessary.
Chassis fasteners9Make sure that all nuts, bolts and screws are properly tightened.
Ñ
9Tighten if necessary.
Fuel tank9Check fuel level.
3-6 ~ 3-8
9Fill with fuel if necessary.
Lights, signals and
9Check for proper operation.6-33 ~ 6-35
switches
Battery9Check fluid level.
6-31 ~ 6-32
9Fill with distilled water if necessary.
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a
very short time; and the added safety it assures is more than worth the time involved.wIf any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating
the motorcycle.
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