2002 YAMAHA DT125R torque

3-13
INSTRUMENT AND CONTROL FUNCTIONS
3 3. Tighten the locknut to the speci-
fied torque.
EC000018
cCAlways tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
EAU00315
wThis shock absorber contains
highly pressurized nitrogen gas.
For proper handling, read and
understand the following informa-
tion before handling the shock
absorber. The manufacturer can-
not be held responsible for proper-
ty damage or personal injury that
may result from improper han-
dling.
8Do not tamper with or attempt
to open the gas cylinder.
8Do not subject the shock
absorber to an open flame or
other high heat sources, other-
wise it may explode due to
excessive gas pressure.
8Do not deform or damage the
gas cylinder in any way, as
this will result in poor damp-
ing performance.
8Always have a Yamaha dealer
service the shock absorber.
NOTE:
The spring preload setting is deter-
mined by measuring distance A,
shown in the illustration. The shorter
distance A is, the lower the spring
preload; the longer distance A is, the
higher the spring preload.
A
Spring preload:
Minimum (soft):
Distance A = 235 mm
Standard:
Distance A = 230 mm
Maximum (hard):
Distance A = 220 mm
Tightening torque:
Locknut:
55 Nm (5.5 m0kgf)
3MB-9-E8 6/13/01 10:55 AM Page 25

6-1
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO
BE SHORTENED.
EW000060
wIf you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you.
EAU01175
Owner’s tool kitThe owner’s tool kit is located behind
panel B. (See page 6-8 for panel
removal and installation procedures.)
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be nec-
essary to perform certain mainte-
nance work correctly.
1
1. Owner’s tool kit
NOTE:
If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.
EW000063
wModifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any
changes.
3MB-9-E8 6/13/01 10:55 AM Page 38

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
EAU04272
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)
3MB-9-E8 6/13/01 10:55 AM Page 47

6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
63. Wait a few minutes until the oil
settles, and then check the oil
level through the check window
located at the right side of the
crankcase.
NOTE:
The transmission oil should be at or
above the minimum level mark.4. If the oil is below the minimum
level mark, remove the oil filler
cap, add sufficient oil of the rec-
ommended type to raise it to the
correct level, and then install and
tighten the cap.
1
2
1. Transmission oil level check window
2. Minimum level mark
4. Install the transmission oil drain
bolt, and then tighten it to the
specified torque.
5. Add the specified amount of the
recommended transmission oil,
and then install and tighten the
oil filler cap.
1
1. Transmission oil drain bolt
To change the transmission oil
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the trans-
mission to collect the used oil.
3. Remove the oil filler cap and
drain bolt to drain the oil from the
transmission.
1
1. Oil filler cap
Tightening torque:
Transmission oil drain bolt:
15 Nm (1.5 m0kgf)
3MB-9-E8 6/13/01 10:55 AM Page 48

6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03101
Changing the coolant1. Put the motorcycle on a level
place.
2. Remove cowling B and panel A.
(See page 6-6–6-8 for cowling
and panel removal and installa-
tion procedures.)
3. Remove the radiator cap stopper
bolt and the radiator cap.
12
1. Radiator stopper bolt
2. Radiator cap
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
1. Reservoir tank hose
4. Place a container under the
engine and remove the coolant
drain bolt.
1
1. Coolant drain bolt
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m0kgf)
3MB-9-E8 6/13/01 10:55 AM Page 51

6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
Make sure that both adjusting plates
are in the same position for proper
wheel alignment.
EC000096
cCImproper drive chain slack will
overload the engine as well as
other vital parts of the motorcycle
and can lead to chain slippage or
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.3. Tighten the axle nut to the speci-
fied torque.2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
cCDo not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
EAU03006
Lubricating the drive chainThe drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
EC000097
cCThe drive chain must be lubricated
after washing the motorcycle or
riding in the rain.1. Clean the drive chain with
kerosene and a small soft brush.
ECA00053
cCTo prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.
Tightening torque:
Axle nut:
90 Nm (9.0 m0kgf)
3MB-9-E8 6/13/01 10:55 AM Page 65

6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
67. After tightening the holder nuts,
while applying the front brake,
push down on the handlebars
several times to check if the front
fork compress and rebounds
smoothly.
8. Connect the speedometer cable.
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.
NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc and
that the slot in the speedometer gear
unit fits over the retainer on the fork
leg.3. Install the wheel axle.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle to the
specified torque.
1
1. Retainer
Tightening torque:
Wheel axle:
58 Nm (5.8 m0kgf)Tightening torque:
Axle holder nut:
10 Nm (1.0 m0kgf)
a
a. Gap
3MB-9-E8 6/13/01 10:55 AM Page 78

6-43
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03087
TroubleshootingAlthough Yamaha motorcycles
receive a thorough inspection before
shipment from the factory, trouble
may occur during operation. Any
problem in the fuel, compression, or
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcy-
cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
EAU01806
To install the rear wheel
1. Install the drive chain onto the
rear sprocket, and then insert the
wheel axle from the left side.NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc
between the pads.2. Install the swingarm end bolts,
and then lower the rear wheel so
that it is on the ground.
3. Adjust the drive chain slack.
(See page 6-27 for drive chain
slack adjustment procedures.)
4. Tighten the axle nut and
swingarm end bolts to the speci-
fied torques.
Tightening torques:
Axle nut:
90 Nm (9.0 m0kgf)
Swingarm end bolts:
3 Nm (0.3 m0kgf)
3MB-9-E8 6/13/01 10:55 AM Page 80