2000 YAMAHA DT125R maintenance

6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU01071
BatteryCheck the level of the battery elec-
trolyte and make sure that the termi-
nals are tight.
Fill with distilled water if the elec-
trolyte level is low.1.Battery
2.Battery breather hose
EC000099
cCWhen inspecting the battery, be
sure the breather hose is routed
correctly. If the breather hose is
positioned in such a way as to
cause battery electrolyte or gas to
exit onto the frame, structural and
cosmetic damage to the motorcy-
cle can occur.
12
EW000116
wBattery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes
or clothing.
ANTIDOTE:
8 8
EXTERNAL: Flush with water.
8 8
INTERNAL: Drink large quanti-
ties of water or milk. Follow
with milk of magnesia, beaten
egg, or vegetable oil. Call a
physician immediately.
8 8
EYES: Flush with water for 15
minutes and get prompt med-
ical attention.
Batteries produce explosive
gases. Keep sparks, flame, ciga-
rettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
3MB-9-E7 12/27/00 2:52 PM Page 67

6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9Replenishing the battery fluid
A poorly maintained battery will cor-
rode and discharge quickly. The bat-
tery fluid should be checked at least
once a month. The level should be
between the minimum level and max-
imum level marks. Use only distilled
water if refilling is necessary.
EC000100
cCNormal tap water contains miner-
als which are harmful to a battery;
therefore, refill only with distilled
water.
EW000117
wTake care not to spill battery fluid
on the chain.
Battery fluid may weaken the chain
causing shorter chain life and pos-
sibly result in an accident.
1.Maximum level mark
2.Minimum level mark
1
2
Battery storage
8When the motorcycle will not be
used for a month or longer,
remove the battery, fully charge
it and store it in a cool, dry place.
Completely recharge the battery
before reinstallation.
8If the battery will be stored for
longer than two months, check
the specific gravity of the fluid at
least once a month and fully
recharge the battery when it is
too low.
8Always make sure the connec-
tions are correct when putting
the battery back in the motorcy-
cle. Make sure the breather hose
is properly connected and is not
damaged or obstructed.
3MB-9-E7 12/27/00 2:52 PM Page 68

6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00804
Fuse replacementIf the fuse is blown, turn off the main
switch and the switch of the circuit in
question. Install a new fuse of speci-
fied amperage. Turn on the switches
and see if the electrical device oper-
ates. If the fuse immediately blows
again, consult a Yamaha dealer.1.Fuse
EC000103
cCDo not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause exten-
sive electrical system damage and
possibly a fire.
Specified fuse:
10 A
1
1
1.Bolt (´2)
EAU01158
Headlight bulb replacementIf the headlight bulb burns out,
replace the bulb as follows:
1.Remove cowling A. (See page
6-6 ~ 6-7 for removal and instal-
lation procedures.)
2.Remove the headlight unit by
removing the bolts.
3MB-9-E7 12/27/00 2:52 PM Page 69

6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
93.Remove the headlight connector
and the bulb holder cover.4.Turn the bulb holder counter-
clockwise to remove it and then
remove the defective bulb.
EW000119
wKeep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.5.Put a new bulb into position and
secure it in place with the bulb
holder.
12
1.Bulb holder cover
2.Connector
1
1.Bulb holder
6.Install the bulb holder cover, con-
nector and headlight unit.
7.Install the cowling.
8.If the headlight beam adjustment
is necessary, ask a Yamaha
dealer to make that adjustment.
3MB-9-E7 12/27/00 2:52 PM Page 70

6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1
2
3
1
2
3
1.Screw (´2)
2.Lens
3.Bulb 1.Screw
2.Lens
3.Bulb
EAU01095
Turn signal light bulb
replacement1.Remove the screw and the lens.
2.Remove the defective bulb by
pushing it inward and turning it
counterclockwise.
3.Install a new bulb by pushing it
inward and turning it clockwise.
4.Install the lens and tighten the
screw.
EAU01623*
Tail/brake light bulb
replacement1.Remove the screws and the
lens.
2.Remove the defective bulb by
pushing it inward and turning it
counterclockwise.
3.Install a new bulb by pushing it
inward and turning it clockwise.
4.Install the lens and tighten the
screws.
EC000108
cCDo not over-tighten the screws as
the lens may break.
3MB-9-E7 12/27/00 2:52 PM Page 71

6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
122
1.Disc cover
2.Screw (´2)
EAU00898
Front wheel removal
EW000122
w8
8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.1.Remove the disc cover.
2.Remove the speedometer cable
from the front wheel side.
EAU01579
Supporting the motorcycleSince the Yamaha DT125R has no
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
Front wheel service
To stabilize the rear of the motorcy-
cle, either use a motorcycle stand or
place a motorcycle jack under the
frame in front of the rear wheel to
prevent it from moving from side to
side. Then use a motorcycle stand to
elevate the front wheel off of the
ground.Rear wheel service
Use a motorcycle stand or motorcycle
jack to elevate the motorcycle so the
rear wheel is off the ground.
Alternatively, two jacks can be placed
under the frame or swingarm.
3MB-9-E7 12/27/00 2:52 PM Page 72

6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
3
2 1
3.Elevate the front wheel by plac-
ing a suitable stand under the
engine.
4.Loosen the wheel axle holder
nuts.
5.Remove the wheel axle and the
front wheel. Make sure the
motorcycle is properly supported.NOTE:
Do not depress the brake lever when
the disc and caliper are separated.
EAU03104
Front wheel installation1.Install the speedometer gear unit
housing into the wheel hub.
Make sure the speedometer gear
unit housing is installed with the
projections meshed into the
slots.
2.Lift up the wheel between the
front fork legs and guide the
brake disc between the brake
pads. Make sure there is enough
gap between the brake pads
before inserting the brake disc.
1.Speedometer cable
2.Axle holder nut (´4)
3.Wheel axle
3.Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork
outer tube.
4.Install the wheel axle and let the
motorcycle down.
5.Tighten the wheel axle the speci-
fied torque.
Tightening torque:
Wheel axle:
58 Nm (5.8 m
0kg)
3MB-9-E7 12/27/00 2:52 PM Page 73

6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1
1
1.Swingarm end bolt (´2)
EAU03105
Rear wheel removal
EW000122
w8
8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.1.Loosen the rear axle nut.
2.Elevate the rear wheel by placing
a suitable stand under the
engine.
3.Remove the swingarm end bolts.4.Remove the axle nut.
5.Push the wheel forward and
remove the drive chain.
6.Pull out the rear axle and remove
the wheel assembly by pulling
backward.
NOTE:
8Do not depress the brake pedal
when the disc and caliper are
separated.
8You do not have to disassemble
the chain in order to remove or
install the rear wheel.
2
1
1.Axle nut
2.Chain adjusting plate
6.Tighten the axle holder nuts to
the specified tightening torque.
Tighten the upper nuts first and
then lower ones. When tightened
in this sequence, there should be
a gap formed at the bottom of
the axle holder.
7.After tightening the holder nuts,
push down on the handlebars
several times and check if the
fork rebounds smoothly. Tightening torque:
Axle holder nut:
10 Nm (1.0 m
0kg)1
1.Gap
3MB-9-E7 12/27/00 2:52 PM Page 74