2002 YAMAHA DT125R check oil

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TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY ............... 1-1
DESCRIPTION .................................................. 2-1
Left view ......................................................... 2-1
Right view ....................................................... 2-2
Controls and instruments ............................... 2-3
INSTRUMENT AND CONTROL FUNCTIONS .. 3-1
Main switch ..................................................... 3-1
Indicator and warning lights ............................ 3-1
Speedometer unit .......................................... 3-2
Tachometer .................................................... 3-2
Coolant temperature gauge ............................ 3-3
Handlebar switches ........................................ 3-3
Clutch lever .................................................... 3-4
Shift pedal ...................................................... 3-4
Brake lever ..................................................... 3-5
Brake pedal .................................................... 3-5
Fuel tank cap .................................................. 3-5
Fuel (except for Switzerland and Austria) ...... 3-6
Fuel (for Switzerland and Austria) ................. 3-6
Catalytic converter
(for Switzerland and Austria) ....................... 3-7
2-stroke engine oil .......................................... 3-8
Fuel cock ........................................................ 3-9
Starter (choke) lever ..................................... 3-10Kickstarter .................................................... 3-10
Steering lock ................................................. 3-10
Seat .............................................................. 3-11
Helmet holder ............................................... 3-12
Adjusting the shock absorber assembly ....... 3-12
Carrier .......................................................... 3-14
YEIS handling precautions .......................... 3-14
YPVS ............................................................ 3-14
Sidestand ..................................................... 3-15
Ignition circuit cut-off system ........................ 3-16
PRE-OPERATION CHECKS ............................. 4-1
Pre-operation check list .................................. 4-1
OPERATION AND IMPORTANT
RIDING POINTS ............................................... 5-1
Starting a cold engine .................................... 5-1
Starting a warm engine .................................. 5-2
Shifting ........................................................... 5-2
Recommended shift points
(for Switzerland only) .................................. 5-3
Tips for reducing fuel consumption ................ 5-3
Engine break-in .............................................. 5-4
Parking ........................................................... 5-5
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45
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PERIODIC MAINTENANCE AND
MINOR REPAIR ................................................ 6-1
Owner’s tool kit ............................................... 6-1
Periodic maintenance and lubrication chart ... 6-2
Removing and installing cowlings .................. 6-5
Removing and installing panels ...................... 6-7
Checking the spark plug ................................. 6-9
Transmission oil ........................................... 6-10
Coolant ......................................................... 6-12
Changing the coolant ................................... 6-14
Cleaning the air filter element........................ 6-16
Adjusting the carburetor ............................... 6-17
Adjusting the engine idling speed ................ 6-17
Adjusting the throttle cable free play ............ 6-18
Tires ............................................................. 6-19
Spoke wheels ............................................... 6-21
Adjusting the clutch lever free play ............... 6-22
Adjusting the brake lever free play ............... 6-23
Adjusting the brake pedal position ............... 6-23
Adjusting the rear brake light switch ............. 6-24
Checking the front and rear brake pads ....... 6-24
Checking the brake fluid level ...................... 6-25
Changing the brake fluid .............................. 6-26
Drive chain slack .......................................... 6-27
Lubricating the drive chain ........................... 6-28
Checking and lubricating the cables ............. 6-29Checking and lubricating the
throttle grip and cable ................................ 6-29
Adjusting the Autolube pump ....................... 6-30
Checking and lubricating the brake and
shift pedals ................................................ 6-30
Checking and lubricating the brake and
clutch levers .............................................. 6-30
Checking and lubricating the sidestand ....... 6-31
Checking the front fork ................................. 6-31
Checking the steering ................................... 6-32
Checking the wheel bearings ....................... 6-32
Battery .......................................................... 6-33
Replacing the fuse ....................................... 6-35
Replacing the headlight bulb ........................ 6-36
Replacing a turn signal light bulb ................. 6-37
Replacing the tail/brake light bulb ................ 6-38
Supporting the motorcycle ............................ 6-39
Front wheel ................................................... 6-39
Rear wheel ................................................... 6-42
Troubleshooting ............................................ 6-43
Troubleshooting charts ................................. 6-44
MOTORCYCLE CARE AND STORAGE ........... 7-1
Care ................................................................ 7-1
Storage ........................................................... 7-4
TABLE OF CONTENTS6
7
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3-1
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INSTRUMENT AND CONTROL FUNCTIONS
3
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Main switchThe main switch controls the ignition
and lighting systems. The various
main switch positions are described
below.
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ON
All electrical systems are supplied
with power, and the engine can be
started. The key cannot be removed.
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OFF
All electrical systems are off. The key
can be removed.
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Neutral indicator light “N”
This indicator light comes on when
the transmission is in the neutral
position.
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2-stroke engine oil level warning
light “
7
”
This warning light comes on when
the 2-stroke engine oil level is low.
The electrical circuit of the warning
light can be checked according to the
following procedure.
1. Turn the key to “ON”.
2. Shift the transmission into the
neutral position.
3. If the warning light does not
come on, have a Yamaha dealer
check the electrical circuit.
NOTE:
Even if the 2-stroke engine oil level is
sufficient, the warning light may flick-
er when riding on a slope or during
sudden acceleration or deceleration,
but this is not a malfunction.
ON
OFF
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Indicator and warning lights
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Turn signal indicator light “5”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
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High beam indicator light “&”
This indicator light comes on when
the high beam of the headlight is
switched on.
1
2
3
4
1. Turn signal indicator light “5”
2. High beam indicator light “&”
3. Neutral indicator light “N”
4. 2-stroke engine oil level warning
light “
7
”
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4-1
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PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
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Pre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-5–3-7
2-stroke engine oil•Check oil level in oil tank.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.3-8
Transmission oil•Check oil level in transmission case.
•If necessary, add recommended oil to specified level.6-10–6-12
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-12–6-15
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check lever free play.
•Adjust if necessary.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-5, 6-23, 6-24–6-26
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-5, 6-23–6-26
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5-4
OPERATION AND IMPORTANT RIDING POINTS
5
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Engine break-inThere is never a more important peri-
od in the life of your engine than the
period between 0 and 1,000 km. For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do
not put an excessive load on it for the
first 1,000 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheat-
ing must be avoided.
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0–500 km
8Avoid prolonged operation above
6,000 r/min.
8After every hour of operation,
stop the engine, and then let it
cool for five to ten minutes.
8Vary the engine speed from time
to time. Do not operate the
engine at one set throttle posi-
tion.
500–1,000 km
8Avoid prolonged operation above
7,000 r/min.
8Rev the engine freely through
the gears, but do not use full
throttle at any time.
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cCAfter 1,000 km of operation, the
transmission oil must be changed.
1,000 km and beyond
The vehicle can now be operated
normally.
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cC8Keep the engine speed out of
the tachometer red zone.
8If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
9
*Wheels•Check runout, spoke tightness and for damage.
•Tighten spokes if necessary.√√√√
10*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11*Wheel bearings•Check bearing for looseness or damage.√√√√
12*Swingarm•Check operation and for excessive play.√√√√
13 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 500 km and after washing
the motorcycle or riding in the rain.
14*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 24,000 km
15*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand•Check operation.
•Lubricate.√√√√ √
17*Sidestand switch•Check operation.√√√√√ √
18*Front fork•Check operation and for oil leakage.√√√√
19*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting arm
pivoting points•Check operation.√√√√
•Lubricate with lithium-soap-based grease.√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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.√√√√√ √
22*Autolube pump•Check operation.
•Bleed if necessary.√√√√
23 Transmission oil•Check oil level.√√√√√ √
•Change.√√
24*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
25*Front and rear brake
switches•Check operation.√√√√√ √
26 Moving parts and cables•Lubricate.√√√√ √
27*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
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6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
a
a. Spark plug gap
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Transmission oilThe transmission oil level should be
checked before each ride. In addition,
the transmission oil must be changed
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the transmission oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.2. Start the engine, warm it up for
several minutes, and then turn it
off.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4–1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.4. Install the spark plug cap.
Spark plug gap:
0.7–0.8 mmTightening torque:
Spark plug:
20 Nm (2.0 m0kgf)
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