2002 YAMAHA DT125R clutch

5-3
OPERATION AND IMPORTANT RIDING POINTS
5
EC000048
cC8Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running.
Inadequate lubrication may
damage the transmission.
8Always use the clutch while
changing gears to avoid dam-
aging the engine, transmis-
sion, and drive train, which are
not designed to withstand the
shock of forced shifting.
EAU02937
Recommended shift points
(for Switzerland only)The recommended shift points during
acceleration are shown in the table
below.NOTE:
When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h when shifting
from 5th to 3rd gear).
EAU00424
Tips for reducing fuel
consumptionFuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
8Thoroughly warm up the engine.
8Turn the starter (choke) off as
soon as possible.
8Shift up swiftly, and avoid high
engine speeds during accelera-
tion.
8Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the
engine.
8Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cross-
ings).
Shift point
(km/h)
1st→2nd
2nd→3rd
3rd→4th
4th→5th
5th→6th20
30
40
50
60
3MB-9-E8 6/13/01 10:55 AM Page 35

6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1
*Fuel line•Check fuel hoses for cracks or damage.√√√√ √
2 Spark plug•Replace.√√√√ √
3 Air filter element•Clean.√√
•Replace.√√
4*Battery•Check electrolyte level and specific gravity.
•Make sure that the breather hose is properly routed.√√√√ √
5 Clutch•Check operation.
•Adjust.√√√√√
6*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
7*Rear brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
8*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-4.)Every 4 years
EAU03686
Periodic maintenance and lubrication chart
NOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
3MB-9-E8 6/13/01 10:55 AM Page 39

6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000077
cC8In order to prevent clutch slip-
page (since the transmission
oil also lubricates the clutch),
do not mix any chemical addi-
tives with the oil.
8Make sure that no foreign
material enters the transmis-
sion.6. Start the engine, and then let it
idle for several minutes while
checking the transmission for oil
leakage. If oil is leaking, immedi-
ately turn off the engine and
check for the cause.
EAU01808
CoolantTo check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Remove panel A. (See page 6-8
for panel removal and installation
procedures.)
3. Check the coolant level in the
coolant reservoir.NOTE:
The coolant should be between the
minimum and maximum level marks.
2
1
1. Maximum level mark
2. Minimum level mark
Recommended transmission oil:
See page 8-1.
Oil quantity:
Periodic oil change:
0.75 L
Total amount (dry transmission):
0.8 L
3MB-9-E8 6/13/01 10:55 AM Page 49

6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00694
Adjusting the clutch lever
free playThe clutch lever free play should
measure 10–15 mm as shown.
Periodically check the clutch lever
free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in
direction a. To decrease the
clutch lever free play, turn the
adjusting bolt in direction b.
12b
a c
1. Locknut (Clutch lever)
2. Adjusting bolt
c. Free play
5. Loosen the locknut at the
crankcase.
6. To increase the clutch lever free
play, turn the adjusting nut in
direction a. To decrease the
clutch lever free play, turn the
adjusting nut in direction b.
7. Tighten the locknut at the clutch
lever and the crankcase.
a
21
b
1. Locknut (Crankcase)
2. Adjusting nut
3. If the specified clutch lever free
play could be obtained as
described above, tighten the
locknut and skip the rest of the
procedure, otherwise proceed as
follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction ato
loosen the clutch cable.
3MB-9-E8 6/13/01 10:55 AM Page 59

6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00774
Adjusting the Autolube
pumpThe Autolube pump is a vital and
sophisticated component of the
engine, which must be adjusted by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
EAU03370
Checking and lubricating the
brake and shift pedalsThe operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch leversThe operation of the brake and clutch
levers should be checked before
each ride, and the lever pivots should
be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
3MB-9-E8 6/13/01 10:55 AM Page 67

8-2
SPECIFICATIONS
8
Carburetor
Manufacturer MIKUNI
Model × quantity TM28SS × 1
Spark plug
Manufacturer/model NGK / BR9ES
NGK / BR8ES (CH, A only)
Spark plug gap 0.7–0.8 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Helical gear
Primary reduction ratio 71/22 (3.227)
Secondary reduction system Chain drive
Secondary reduction ratio 3.563
Number of drive chain
sprocket teeth (rear/front) 57/16
Transmission type Constant mesh 6-speed
Operation Left foot operation
Gear ratio 1st 2.833
2nd 1.875
3rd 1.412
4th 1.143
5th 0.957
6th 0.818Chassis
Frame type Semi double cradle
Caster angle 27°30’
Trail 113 mm
Tire
Front
Type With tube
Size 2.75-21 45P
Manufacturer/ BRIDGESTONE / TW25
model
Rear
Type With tube
Size 4.10-18 59P
Manufacturer/ BRIDGESTONE / TW44
model
Maximum load* 180 kg
178 kg (CH, A only)
Air pressure (cold tire)
up to 90 kg load*
Front125 kPa (1.25 kgf/cm
2, 1.25 bar)
Rear150 kPa (1.50 kgf/cm2, 1.50 bar)
3MB-9-E8 6/13/01 10:55 AM Page 89