2000 YAMAHA DT125R brake

6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.21
*Carburetor¥Check starter (choke) operation.
¥Adjust engine idling speed.ÖÖÖÖÖÖ
22*Autolube pump¥Check operation.
¥Bleed if necessary.ÖÖÖÖ
23Transmission oil¥Check oil level.ÖÖÖÖÖÖ
¥Change.ÖÖ
24*Cooling system¥Check coolant level and vehicle for coolant leakage.ÖÖÖÖÖ
¥Change.Every 3 years
25*Front and rear brake
switches¥Check operation.ÖÖÖÖÖÖ
26Moving parts and cables¥Lubricate.ÖÖÖÖÖ
27*Lights, signals and
switches¥Check operation.
¥Adjust headlight beam.ÖÖÖÖÖÖ NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
16121824
3MB-9-E7 12/27/00 2:52 PM Page 41

6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00685
WheelsTo ensure maximum performance,
long service, and safe operation, note
the following:
8Always inspect the wheels
before a ride. Check for cracks,
bends or warpage of the wheel.
Be sure the spokes are tight and
undamaged. If any abnormal
condition exists in a wheel, con-
sult a Yamaha dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.
8Tires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can
result in poor performance,
adverse handling characteristics,
and shortened tire life.
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it
to develop its optimal character-
istics.
EAU00681
w8 8
Operating the motorcycle with
excessively worn tires
decrease riding stability and
can lead to loss of control.
Have excessively worn tires
replaced by a Yamaha dealer
immediately. Brakes, tires, and
related wheel parts replace-
ment should be left to a
Yamaha Service Technician.
8 8
Patching a punctured tube is
not recommended. If it is
absolutely necessary to do so,
use great care and replace the
tube as soon as possible with
a good quality replacement.
NOTE:
These limits may be different by regu-
lation from country to country. If so,
conform to the limits specified by the
regulations of your own country.
3MB-9-E7 12/27/00 2:52 PM Page 56

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
3
12b
a
EAU00694
Clutch lever free play
adjustmentThe clutch lever free play should be
adjusted to 10 ~ 15 mm.
1.Loosen the locknut at the clutch
lever.
2.Turn the adjusting bolt at the
clutch lever in direction ato
increase free play or in direction
bto decrease free play.
3.Tighten the locknut at the clutch
lever.
If the specified free play cannot be
obtained, proceed with the following
steps.1.Locknut
2.Adjusting bolt
3.Free play
ab 12
4.Loosen the locknut at the clutch
lever.
5.Turn the adjusting bolt at the
clutch lever in direction ato
loosen the cable.
6.Loosen the locknut at the
crankcase side.
7.Turn the adjusting nut at the
crankcase in direction ato
increase free play or in direction
bto decrease free play.
8.Tighten the locknut at the
crankcase and the clutch lever.1.Locknut
2.Adjusting nut
3
2
1b
a
EAU00696
Front brake lever free play
adjustmentThe free play at the front brake lever
should be 2 ~ 5 mm.
1.Loosen the locknut.
2.Turn the adjusting bolt in direc-
tion ato increase free play or in
direction bto decrease free
play.
3.After adjusting, tighten the lock-
nut.1.Locknut
2.Adjusting bolt
3.Free play
3MB-9-E7 12/27/00 2:52 PM Page 57

6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EW000099
w8 8
Check the brake lever free
play. Be sure the brake is
working properly.
8 8
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake
system. This air must be
removed by bleeding the brake
system before the motorcycle
is operated. Air in the system
will cause greatly diminished
braking capability and can
result in loss of control and an
accident. Have a Yamaha deal-
er inspect and bleed the sys-
tem if necessary.
a
1
EAU00712
Rear brake pedal height
adjustmentThe top of the brake pedal should be
positioned 15 mm below the top of
the footrest. If not, ask a Yamaha
dealer to adjust it.1.Footrest
a.Pedal height
EW000109
wA soft or spongy feeling in the
brake pedal can indicate the pres-
ence of air in the brake system.
This air must be removed by
bleeding the brake system before
the motorcycle is operated. Air in
the system will cause greatly
diminished braking capability and
can result in loss of control and an
accident. Have a Yamaha dealer
inspect and bleed the system if
necessary.
3MB-9-E7 12/27/00 2:52 PM Page 58

6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00713
Brake light switch
adjustmentThe rear brake light switch is activat-
ed by the brake pedal and is properly
adjusted when the brake light comes
on just before braking takes effect.
To adjust the rear brake light switch,
hold the switch body so it does not
rotate while turning the adjusting nut.
Turn the adjusting nut in direction a
to make the brake light come on earli-
er.
Turn the adjusting nut in direction b
to make the brake light come on
later.
b
a 1
2
1.Brake light switch
2.Adjusting nut
EAU00717
Checking the front and rear
brake padsCheck the brake pads for damage
and wear. If the thickness is less than
the specified value, have a Yamaha
dealer replace the pads.
1
1.Wear limit: 0.8 mm FRONT
1
1.Wear limit: 0.8 mmREAR
3MB-9-E7 12/27/00 2:52 PM Page 59

6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
98Use only the designated quality
brake fluid. Otherwise, the rub-
ber seals may deteriorate, caus-
ing leakage and poor brake per-
formance.
NOTE:
If DOT 4 is not available, DOT 3 can
be used.
EAU00732
Inspecting the brake fluid
levelInsufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef-
fective.
Before riding, check that the brake
fluid is above the minimum level and
fill when necessary.
Observe these precautions:
8When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.
1
1.Minimum level mark FRONT
1
1.Minimum level markREARRecommended brake fluid:
DOT 4
8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
8Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8Have a Yamaha dealer check
the cause if the brake fluid level
goes down.
3MB-9-E7 12/27/00 2:52 PM Page 60

6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00742
Brake fluid replacementThe brake fluid should be replaced
only by trained Yamaha service per-
sonnel. Have the Yamaha dealer
replace the following components
during periodic maintenance or when
they are damaged or leaking:
8oil seals (every two years)
8brake hoses (every four years)
EAU00744*
Drive chain slack checkNOTE:
Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while itÕs in this tightest position.
a
a.Chain slack
To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and with-
out rider. Check the slack at the posi-
tion shown in the illustration. Normal
slack is approximately 25 ~ 40 mm. If
the slack exceeds 40 mm, adjust it.
3MB-9-E7 12/27/00 2:52 PM Page 61

6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00774
Autolube pump adjustmentThe autolube pump is a vital part of
the engine and requires very sophisti-
cated adjustment.
Adjusting should be left to a Yamaha
dealer who has the professional
knowledge and experience to do so.
EAU02984
Brake and shift pedal
lubricationLubricate the pivoting parts.
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
3MB-9-E7 12/27/00 2:52 PM Page 64