2000 YAMAHA DT125R cooling

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
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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
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EAU01808
Cooling system1.Remove panel D. (See page 6-9
for panel removal and installation
procedures.)
2.Check the coolant level in the
reservoir tank when the engine is
cold as the coolant level will vary
with engine temperature. The
coolant level should be between
the maximum and minimum
marks.
3.If the level is low, add coolant or
distilled water to raise it to the
specified level.4.Install the panel.
EC000080
cCHard water or salt water is harmful
to the engine. You may use dis-
tilled water if you canÕt get soft
water.NOTE:
If water is added, have a Yamaha
dealer check the antifreeze content of
the coolant as soon as possible.If your motorcycle overheats, see
page 6-41 for details.
2
1
1.Maximum level mark
2.Minimum level mark
EAU03101
Changing the coolant1.Put the motorcycle on a level
place.
2.Remove cowling C and panel D.
(See page 6-8 ~ 6-9 for cowling
and panel removal and installa-
tion procedures.)
3.Remove the radiator cap stopper
bolt and the radiator cap.
12
1.Stopper bolt
2.Radiator cap
Reservoir tank capacity:
0.35 L
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98.Install the reservoir tank hose.
9.Pour the recommended coolant
into the radiator until it is full.
Recommended antifreeze:
High quality ethylene glycol
antifreeze containing
corrosion inhibitors for
aluminum engines.
Antifreeze and water mixing ratio:
1:1
Total amount:
1.05 L
Reservoir tank capacity:
0.35 L
4.Place a container under the
engine and remove the coolant
drain bolt.5.Disconnect the reservoir tank
hose on the reservoir tank side
and drain the coolant from the
reservoir tank.
6.After draining the coolant, thor-
oughly flush the cooling system
with clean tap water.
7.Replace the coolant drain bolt
washer if it is damaged and tight-
en the coolant drain bolt to the
specified torque.
1
13
2
1.Drain bolt1.Reservoir tank hose
2.Maximum level mark
3.Minimum level mark
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m
0kg)
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EC000080
cCHard water or salt water is harmful
to the engine. You may use dis-
tilled water if you canÕt get soft
water.10.Install the radiator cap.
11.Run the engine several minutes.
Stop the engine and recheck the
coolant level in the radiator. If it
is low, add more coolant until it
reaches the top of the radiator.
12.Install the radiator cap stopper
bolt.
13.Fill the reservoir tank with
coolant up to maximum level.
14.Install the reservoir tank cap and
check for coolant leakage.NOTE:
If any leakage is found, ask a
Yamaha dealer to inspect the cooling
system.15.Install the cowling and the panel.
1
EAU03107
Air filterThe air filter should be cleaned at the
specified intervals. It should be
cleaned more frequently when riding
in unusually wet or dusty areas.
1.Remove panel D. (See page 6-9
for panel removal and installation
procedures.)
2.Remove the air filter case by
removing the screws.1.Screw (´3)
3.Remove the air filter from the
case.
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4. Engine overheating
EW000070
wDo 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. Open the radiator cap as follows. Wait until the
engine has cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over
the radiator cap and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual
pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclock-
wise and remove it.Wait until the
Check the coolant level in the
Level is OK.Level is low, check the
NoLeakage.
Ask a Yamaha dealer to inspectAdd coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
engine has cooled.reservoir tank and/or radiator.cooling system for leakage.
Yamaha dealer to inspect and repair the cooling system. leakage.
and repair the cooling system.
NOTE:
If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the rec-
ommended coolant as soon as possible.
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